Videojet 1510 Service Manual P/N 361869-21 Revision: AA, July 2008 Copyright July 2008, Videojet Technologies Inc. (herein referred to as Videojet). All rights reserved. This document is the property of Videojet Technologies Inc. and contains confidential and proprietary information owned by Videojet. Any unauthorized copying, use or disclosure of it without the prior written permission of Videojet is strictly prohibited. Videojet Technologies Inc. 1500 Mittel Boulevard Wood Dale, IL 60191-1073 USA www.videojet.com Phone: 1-800-843-3610 Fax: 1-800-582-1343 Int’l Fax: 630-616-3629 Offices - USA: Atlanta, Chicago, Los Angeles, Philadelphia INT’L: Canada, France, Germany, Ireland, Japan, Spain, Singapore, The Netherlands, The United Kingdom Distributors Worldwide Compliance Information For Customers in the European Union This equipment displays the CE mark to indicate conformance to the following legislation. • BS EN61000-6-4 2007 Generic Emissions Standard for industrial environments • BS EN55022 Class A 2006 Emissions Standard for industrial environments • BS EN61000-3-2 2006 Harmonic Current Fluctuations • BS EN61000-3-3 1995 Voltage Fluctuation and Flicker • BS EN61000-6-2 2005 Generic Immunity Standard for industrial environments • BS EN61000-4-2 1995 ESD Requirements • BS EN61000-4-3 2006 Radiated Susceptibility • BS EN61000-4-4 2004 Electrical Fast Transient Burst Requirement • BS EN61000-4-5 2006 Surges Requirements • BS EN61000-4-6 1996 Conducted Susceptibility • BS EN61000-4-11 2004 Voltage Dips and Interruptions Following the provisions of EU EMC Directive 2004/108/EC For Customers in the U.S.A. This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: 1) this device may not cause harmful interference, and 2) this device must accept any interference received, including interference that may cause undesired operation. Warning Changes or modifications to this unit not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment. This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference, when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio Rev AA i Videojet 1510 Service Manual frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. Shielded cables must be used with this unit to ensure compliance with Class A FCC limits. The user may find the following booklet prepared by the Federal Communications Commission helpful: How to Identify and Resolve Radio-TV Interference Problems. This booklet is available from the U.S. Government Printing Office, Washington, DC 20402, Stock No. 004-0000345-4. This equipment has been tested and certified for compliance with U.S. regulations regarding safety and electrical emissions by: Electromagnetic Testing Services Limited Pratts Fields Lubberhedges Lane Stebbing, Dunmow Essex, CM6 3BT England, U K For Customers in Canada This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications. This equipment has been tested and certified for compliance with Canadian regulations regarding safety and electrical emissions by: Electromagnetic Testing Services Limited Pratts Fields Lubberhedges Lane Stebbing, Dunmow Essex, CM6 3BT England, U K ii Rev AA Videojet 1510 Service Manual Pour la clientèle du Canada Le present appareil numerique n’emet pas de bruits radioelectriques depassant les limites applicales aux appareils numerique de las class A prescrites dans le Reglement sur le brouillage radioelectrique edicte par le ministere des Communications du Canada. Cet équipement est certifié CSA. Rev AA iii Support and Training Contact Information If you have any questions or need assistance, please contact at 1-800-8433610 (for all customers within the United States). Outside the U.S., customers should contact their distributor or subsidiary for assistance. Videojet Technologies Inc. 1500 Mittel Boulevard Wood Dale, IL 60191-1073 U.S.A. Phone: 1-800-843-3610 Fax: 1-800-582-1343 International Fax: 630-616-3629 Web: www.videojet.com Service Program About Total Source® Commitment Tot al Source® TOTAL SERVICE PLUS RELIABILITY, is the commitment to provide you - our customer - the complete service you deserve. The Total Source Commitment The Total Source® Service Program is an integral part of our business in providing marks, codes, and images where, when, and how often customers specify for packages, products, or printed materials. Our commitment includes: • Applications support • Installation services • Maintenance training • Customer response center • Technical support • Field service • Extended hours phone assistance • Parts and supplies • Repair service Rev AA iv Videojet 1510 Service Manual Customer Training If you wish to perform your own service and maintenance on the printer, Videojet highly recommends you to complete a Customer Training Course on the printer. Note: The manuals are intended to be supplements to (and not replacements for) customer training. For more information on Customer Training Courses, call 1-800-843-3610 (within the United States only). Outside the US, customer should contact a subsidiary office or their local distributor for further information. Rev AA v Table of Contents For Customers in the European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . i For Customers in the U.S.A.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i For Customers in Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii Pour la clientèle du Canada. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Support and Training Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Service Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Customer Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Chapter 1 — Introduction Videojet 1510 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 About the Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 Related Publications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 Language Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 Content Presentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 The Word ‘Printer’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 Positional References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 Additional Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 User Interface Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 Chapters in the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 Chapter 2 — Safety Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 General Safety Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 Electrical Safety Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2 Electrical Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2 Electrical Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3 Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3 Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5 Fluid Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5 Ink and Make-up Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6 Cleaning Agent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7 Compressed Air Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8 UI Related Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8 Other Important Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9 Rev AA i Videojet 1510 Service Manual Chapter 3 — Main Parts Printer Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4 Main Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4 Electronics Compartment Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4 Ink Compartment Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6 Umbilical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6 Connector Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6 Back Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10 Electronics Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11 Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11 Control System Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13 Electronics Compartment Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16 Positive Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16 Printer Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17 EHT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–18 Ink Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–18 Ink Core Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–20 Ink Core Module Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–21 Smart Cartridges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23 Positive Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23 Ink Compartment Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23 Gutter Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–24 Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25 Printhead Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25 Printhead Valve Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25 Print Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25 Printhead Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–27 Umbilical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–31 The Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–31 Chapter 4 — Installation Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 Tools and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2 Typical Production Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2 Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4 Commission the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4 Inspect the Ink System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4 Log into UI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7 Install Ink and Make-up Cartridges . . . . . . . . . . . . . . . . . . . . . . . . 4–8 Configure the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10 Prime the Ink Core Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12 ii Rev AA Videojet 1510 Service Manual Perform Umbilical Purge and System Flush Purge . . . . . . . . . . 4–14 Perform Viscosity Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–16 Clean Stop and Clean Start the Printer . . . . . . . . . . . . . . . . . . . . . 4–17 Perform Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–17 Set the Password Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–19 Install the Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–20 Internal Encoding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–20 External Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–22 Install the Product Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–24 Install the Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–24 Align the Ink Stream . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–26 Perform Calibration and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–30 Calibrate EHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–30 Calibrate Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–32 Chapter 5 — Printer Operation Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 Reset Run Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 Restore Calibration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Perform Full System Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 Perform Full System Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 Chapter 6 — User Interface Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 Chapter 7 — Replacement Instructions Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2 Common Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3 How to Open the Electronics Compartment Door . . . . . . . . . . . . 7–3 How to Close the Electronics Compartment Door . . . . . . . . . . . . 7–5 How to Open the Ink Compartment Door. . . . . . . . . . . . . . . . . . . 7–5 How to Close the Ink Compartment Door. . . . . . . . . . . . . . . . . . . 7–7 Control System Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7 How to Remove the Old Control System Board . . . . . . . . . . . . . . 7–7 How to Install the New Control System Board . . . . . . . . . . . . . . . 7–8 Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9 How to Remove the Old Power Supply Unit . . . . . . . . . . . . . . . . 7–9 How to Install the New Power Supply Unit . . . . . . . . . . . . . . . . 7–11 Rev AA iii Videojet 1510 Service Manual LCD and FIB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13 How to Remove the Old LCD and FIB Assembly . . . . . . . . . . . . 7–13 How to Install the New LCD and FIB Assembly. . . . . . . . . . . . . 7–16 Keyboard/Electronics Compartment Door . . . . . . . . . . . . . . . . . . . . 7–16 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–16 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–17 How to Remove the Old Electronics Compartment Door . . . . . 7–17 How to Install the New Electronics Compartment Door . . . . . . 7–20 Ink Core Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–21 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–21 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–22 How to Remove the Old Ink Core Module. . . . . . . . . . . . . . . . . . 7–22 How to Install the New Ink Core Module . . . . . . . . . . . . . . . . . . 7–30 Ink Core Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–35 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–35 How to Remove the Old Ink Core Pump . . . . . . . . . . . . . . . . . . . 7–36 How to Install the New Ink Core Pump . . . . . . . . . . . . . . . . . . . . 7–39 Print Engine Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41 How to Remove the Old Print Engine Assembly . . . . . . . . . . . . 7–41 How to Install the New Print Engine Assembly . . . . . . . . . . . . . 7–43 Printhead Valve Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–44 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–44 How to Remove the Old Printhead Valve Module . . . . . . . . . . . 7–44 How to Install the New Printhead Valve Module. . . . . . . . . . . . 7–46 Umbilical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–49 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–49 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–50 Umbilical Assembly (with Printhead) Replacement . . . . . . . . . . . . . 7–51 How to Remove the Umbilical Assembly (with Printhead) . . . 7–51 How to Install the Umbilical Assembly (with Printhead) . . . . . 7–60 Umbilical Assembly (with Printhead Chassis) Replacement . . . . . . 7–68 How to Remove the Umbilical Assembly (with Printhead Chassis)7– 68 How to Install the Umbilical Assembly (with Printhead Chassis)7–70 Printer Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–73 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–73 How to Remove the Old Printer Interface Board . . . . . . . . . . . . 7–73 How to Install the New Printer Interface Board . . . . . . . . . . . . . 7–75 Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–76 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–76 How to Remove the Old Power Switch . . . . . . . . . . . . . . . . . . . . 7–76 iv Rev AA Videojet 1510 Service Manual How to Install the New Power Switch . . . . . . . . . . . . . . . . . . . . . 7–79 Septum Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–81 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–81 How to Remove the Old Ink and Make-up Septa. . . . . . . . . . . . 7–82 How to Install the New Ink and Make-up Septa . . . . . . . . . . . . 7–84 Electronics Compartment Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–85 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–85 How to Remove the Old Electronics Compartment Fan . . . . . . 7–85 How to Install the New Electronics Compartment Fan . . . . . . . 7–86 Ethernet Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–87 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–87 How to Remove the Old Ethernet Connector . . . . . . . . . . . . . . . 7–87 How to Install the New Ethernet Connector . . . . . . . . . . . . . . . . 7–88 Positive Air Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–89 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–89 How to Remove the Old Positive Air Kit . . . . . . . . . . . . . . . . . . . 7–90 How to Install the New Positive Air Kit. . . . . . . . . . . . . . . . . . . . 7–92 Gutter Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–93 Tools and Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–93 How to Remove the Old Gutter Pump . . . . . . . . . . . . . . . . . . . . . 7–94 How to Install the New Gutter Pump. . . . . . . . . . . . . . . . . . . . . . 7–97 Ink Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–98 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–98 How to Remove the Old Ink Door . . . . . . . . . . . . . . . . . . . . . . . . 7–99 How to Install the New Ink Door . . . . . . . . . . . . . . . . . . . . . . . . 7–101 Ink System Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–103 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–103 How to Remove the Ink System Fan. . . . . . . . . . . . . . . . . . . . . . 7–103 How to Install the New Ink System Fan. . . . . . . . . . . . . . . . . . . 7–105 EHT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–105 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–105 How to Remove the Old EHT Module . . . . . . . . . . . . . . . . . . . . 7–105 How to Install the New EHT Module. . . . . . . . . . . . . . . . . . . . . 7–107 USB Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–108 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–108 How to Remove the Old USB Connector . . . . . . . . . . . . . . . . . . 7–108 How to Install the New USB Connector. . . . . . . . . . . . . . . . . . . 7–109 Plug and Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–109 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–109 How to Remove the Old Power Cable . . . . . . . . . . . . . . . . . . . . 7–110 How to Install the New Power Cable . . . . . . . . . . . . . . . . . . . . . 7–112 CSB Lithium Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–115 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–115 Rev AA v Videojet 1510 Service Manual How to Remove the Old CSB Lithium Battery . . . . . . . . . . . . . 7–115 How to Install the New CSB Lithium Battery . . . . . . . . . . . . . . 7–117 PCB 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–117 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–117 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–117 How to Remove the PCB 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–117 How to Install the New PCB 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . 7–119 Chapter 8 — Maintenance Prime the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2 Umbilical Purge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 System Flush Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6 Nozzle Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–11 Replacement of Ink System Fan Filter for IP65. . . . . . . . . . . . . . . . . . 8–12 How to Remove the Old Ink System Fan Filter for IP65 . . . . . . 8–12 How to Install the New Ink System Fan Filter . . . . . . . . . . . . . . . 8–12 Replacement of Ink System Fan Filter for IP55. . . . . . . . . . . . . . . . . . 8–13 How to Remove the Old Ink System Fan Filter for IP55 . . . . . . 8–13 How to Install the New Ink System Fan Filter for IP55 . . . . . . . 8–13 Replacement of Floor Filter for IP65. . . . . . . . . . . . . . . . . . . . . . . . . . . 8–14 How to Remove the Old Floor Filter IP65 . . . . . . . . . . . . . . . . . . 8–14 How to Install the New Floor Filter IP65 . . . . . . . . . . . . . . . . . . . 8–14 Replacement of Floor Filter for IP55. . . . . . . . . . . . . . . . . . . . . . . . . . . 8–15 How to Remove the Old Floor Filter IP55 . . . . . . . . . . . . . . . . . . 8–15 How to Install the New Floor Filter for IP55 . . . . . . . . . . . . . . . . 8–16 Windows CE Upgrade Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–16 Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–16 System Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–16 Hardware Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–17 USB Download through Serial Commands . . . . . . . . . . . . . . . . . 8–18 USB Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–20 Chapter 9 — Troubleshooting Read the Operator Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1 Important Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1 Startup Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2 Printer Fails to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2 Display Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3 Backlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3 LCD Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4 vi Rev AA Videojet 1510 Service Manual Keypad Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5 Display Icons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6 Alarm Light Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6 Printer Status Icons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6 Indicator Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–7 Fault Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–7 Warning Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–14 Voltage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–34 Jet Start and Stop Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–34 Quick Start Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–35 Clean Start Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–36 Clean Stop Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–38 CSB Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–39 Installing DNW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–58 ADC/DAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–58 Ancillary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–58 Charge Amplifier Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–59 Charge Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–59 SRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–60 EHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–60 Levels/Pressure/Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–60 Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–61 Phase Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–61 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–61 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–61 DIN Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–61 Manual Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–62 Chapter 10 — Illustrated Parts List How to Read the IPL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1 Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1 Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–4 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–4 Videojet 1510 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–5 Electronics Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–6 Control System Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–7 Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–7 Electronics Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–8 Power Supply Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–9 Printer Interface Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . 10–10 Electronics Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–11 Positive Air Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–11 EHT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–12 Rev AA vii Videojet 1510 Service Manual Connector Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–12 PCB 2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–13 PCB 1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–13 Ink Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–16 Make-up Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–17 Ink Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–17 Septum Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–18 Ink Core Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–19 Ink Core Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–20 Gutter Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–21 Ink System Filter Assembly - IP65 . . . . . . . . . . . . . . . . . . . . . . . . 10–22 Ink System Filter Assembly - IP55 . . . . . . . . . . . . . . . . . . . . . . . . 10–22 Floor Filter IP65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–23 Floor Filter IP55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–24 Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–28 Printhead Valve Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–28 Print Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–29 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–30 Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–31 Beacon Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–31 Static Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–33 Mobile Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–34 Printhead Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–35 Printer Wall Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–36 Tools Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–39 Chapter 11 — Tools and Spare Part Kits Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1 Basic Start Up Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1 Service Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1 Other Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–2 Spare parts kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3 Comprehensive Spare Parts Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3 Appendix A — Clean/Quick Start and Stop Description Clean Start/Stop Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii A–1 A–2 A–2 A–2 A–3 A–4 Rev AA Videojet 1510 Service Manual Appendix B — Encoder Information Internal Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–1 When to Use Internal Encoding. . . . . . . . . . . . . . . . . . . . . . . . . . . . B–1 External (Reduce Or Direct) Encoding . . . . . . . . . . . . . . . . . . . . . . . . . B–2 When to Use External Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . B–3 Auto Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–5 When to Use Auto Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–5 Rev AA ix 1 Introduction Videojet 1510 Printer The Videojet 1510 is a continuous ink jet printer capable of printing fixed and variable codes at elevated line speeds upon consumer and industrial products. The printer is designed to deliver superior uptime, print quality, and ease of use to its users. About the Manual The Videojet 1510 Service Manual is written for the service technician of the printer. The service manual contains the procedures to install, service, and troubleshoot the printer. Related Publications The Videojet 1510 Operator Manual (Part Number: 361868) is available for reference. Language Codes When you order for these manuals, make sure to add the 2-digit language code at the end of the part number. For example, the part number of the Spanish version of the Operator Manual is 361868-04. Table 1-1 on page 12 provides the list of language codes that are used to identify the translated versions of the manual. Note: Availability of the Operator Manual is indicated by an asterisk (*). Availability of the Service Manual is indicated by a plus sign (+). Availability of the Illustrated Parts List is indicated by the number sign (#). For more information, contact the Videojet distributor or subsidiary. Rev AA Videojet 1510 Printer 1-1 Videojet 1510 Service Manual Code Language Availability (see note) 01 English (US) * 02 French * 03 German * 04 Spanish * 05 Portuguese (Brazilian) * 06 Japanese * 07 Russian * 08 Italian * 09 Dutch * 10 Chinese (Simplified) * 11 Arabic * 12 Korean * 13 Thai * 15 Norwegian * 16 Finnish * 17 Swedish * 18 Danish * 19 Greek * 20 Hebrew * 21 English (UK) * 23 Polish * 24 Turkish * 25 Czech * 26 Hungarian * 33 Vietnamese * 34 Bulgarian * 35 Portuguese * 36 Chinese (Traditional) * + # + # Table 1-1: List of Language Codes - 1510 1-2 Related Publications Rev AA Videojet 1510 Service Manual Content Presentation This manual contains different types of information like safety guidelines, additional notes, User Interface (UI) terminology and so on. To help you identify the different types of information, different writing styles are used. This section describes these writing styles. The Word ‘Printer’ The word ‘printer’ indicates the Videojet 1510 printer, from this point onwards, in this manual. Positional References Unless stated to the contrary, positions and directions such as left, right, front, rear, to the right and to the left are given with respect to the printer when viewed from the front. Units of Measurement This manual uses metric units of measurement. The equivalent English measures are included in parenthesis. For example, 240 mm (9.44 inches) Safety Information The safety information includes warning and caution statements. Warning The warning statements indicate hazards or unsafe practices that can result in personal injury or death. For example: Warning The cleaning agent is poisonous if taken internally. Do not drink. Seek medical attention immediately if ingested. Caution The caution statements indicate hazards or unsafe practices that can result in damage to the equipment. For example: Rev AA Content Presentation 1-3 Videojet 1510 Service Manual Caution Do not fit or remove any connector on the printer when the power is on, otherwise the printer may get damaged. Additional Notes Notes provide additional information about a particular topic. For example: Note: You can set the password protection for some functions to prevent any unauthorized access. User Interface Terminology The user interface (UI) elements are shown in italics. For example, Messages (see Figure 1-1). Figure 1-1. Menu Screen Keys Key Style Used Left arrow key Table 1-2: Content Presentation Style for Keys 1-4 Content Presentation Rev AA Videojet 1510 Service Manual Key Style Used Right arrow key Up arrow key Down arrow key Enter key Esc key F1 key F2 key F3 key F4 key Alt key Ctrl key Shift key Table 1-2: Content Presentation Style for Keys Rev AA Content Presentation 1-5 Videojet 1510 Service Manual Abbreviations and Acronyms Abbreviation Expansion AC Alternating Current CSB Control System Board DC Direct Current DMM Digital Multi Meter DVM Digital Volt Meter EHT Extra High Tension FPGA Field Programmable Gate Array IEC International Electrotechnical Commission LED Light Emitting Diode LCD Liquid Crystal Display MOD Modulation MS Microsoft PC Personal Computer PCB Printed Circuit Board PIB Printer Interface Board PSU Power Supply Unit QVGA Quarter Video Graphics Array SoC System on Chip SRAM Static Random Access Memory USB Universal Serial Bus VDC Volts of Direct Current WYSIWYG What You See Is What You Get FIB Front Panel Interface Board Table 1-3: Abbreviations and Acronyms 1-6 Abbreviations and Acronyms Rev AA Videojet 1510 Service Manual Chapters in the Manual Chapter No. Chapter Name Description 1. Introduction Contains the information about this manual, the related publications, and writing styles used in this manual 2. Safety Contains the safety and hazard information 3. Main Parts Describes the main parts of the printer 4. Installation Explains the installation procedures of different parts of the printer 5. Printer Operation Contains the information on how to use the UI to setup and operate the printer 6. User Interface Explains how to use the UI to create and store messages 7. Replacement Instructions Explains the procedures to remove and replace the parts of the printer 8. Maintenance Provides the maintenance and cleaning procedures of the printer. 9. Troubleshooting Contains diagnostic and troubleshooting procedures 10. IPL Contains the illustrated parts list of orderable parts 11. Tools and Spare Parts Kits Contains information on tools, spare parts and accessories and their part numbers 12. Important Information Contains additional information 13. Encoder Information Contains encoder setup information Table 1-4: List of Chapters Rev AA Chapters in the Manual 1-7 2 Safety Introduction The policy of Videojet Technologies Inc. is to manufacture non-contact printing/coding systems and ink supplies that meet high standards of performance and reliability. We enforce strict quality control techniques to eliminate the potential for defects and hazards in our products. The intended use of the Videojet 1510 printer is to print information directly onto a product. Use of this equipment in any other fashion may lead to serious personal injury. The safety guidelines provided in this chapter are intended to educate the technicians on all safety issues, so that the printer is serviced and operated in a safe manner. General Safety Guidelines • Always refer to the correct service manuals as per the specific Videojet printer model. • Only Videojet-trained personnel must carry out installation and maintenance work. Any such work undertaken by unauthorized personnel may damage the printer and will invalidate the warranty. • To avoid damage to the printer components, use only soft brushes and lint free cloths for cleaning. Do not use high pressure air, cotton waste, or abrasive materials. • The printhead must be completely dry before attempting to start the printer, otherwise the printhead may get damaged. • To prevent nozzle clogs, always wear rubber gloves whenever the nozzle tubing manifold is to be disconnected from the printhead valve module. Rev AA Introduction 2-1 Videojet 1510 Service Manual Electrical Safety Guidelines This section explains the safety guidelines related to electrical power supply and electrical cables. Electrical Power Supply Warning Make sure that the main electrical supply is within the range indicated by the label next to the main inlet of the printer. If the voltage ratings are different, do not use the printer and contact your local supplier. Warning Lethal voltages are present within this equipment when it is connected to the mains electrical supply. Only trained and authorized personnel must carry out the maintenance work. Observe all statutory electrical safety codes and practices. Unless it is necessary to run the printer, disconnect the printer from the mains electrical supply before removing the covers or attempting any service or repair activity. Non-adherence to this warning can result in death or personal injury. Warning A high AC voltage is present at the inverter and backlight. Extreme caution is required when diagnosing failure in these areas. 2-2 Electrical Safety Guidelines Rev AA Videojet 1510 Service Manual Electrical Cables Warning Use only the main power cable supplied with the printer. The end of this cable must have an approved, three-pole, main plug that has a protective ground conductor. The electrical power cables, sockets and plugs must be kept clean and dry. For pluggable equipment, the socket-outlet must be installed near the equipment and must be easily accessible. Warning Always inspect the cables for damage, wear, corrosion, and deterioration. Make all grounding/bonding connections void of areas of paint, ink build-up, and corrosion. Grounding Warning The printer must be connected only to an AC power supply that has a protective ground conductor and must be according to IEC requirements or applicable local regulations. Warning Do not use the printer if there is any interruption in the protective ground conductor or if the protective ground conductor is disconnected. The failure to follow this warning can cause an electrical shock. Rev AA Electrical Safety Guidelines 2-3 Videojet 1510 Service Manual Warning Always ground conductive equipment to an earthing electrode or to the building grounding system with approved cables as per NEC standards in order to drain all potential static discharge. For example, a metal service tray to earth ground. Warning A resistance reading from the grounded service tray to the equipment chassis or mounting bracket should be 0 to less than 1 ohm. A resistance check should be made using a safe and reliable ohmmeter and should be done on a frequent basis Warning To ensure safe grounding, the resistance between the mains lead earth wire and the test points must be less than 1Ω. Warning The PCBs contain static sensitive devices. A suitably grounded, antistatic wrist strap must be worn when working on or handling PCBs. Bonding Warning Always prevent static discharge from occurring. Use proper Grounding and Bonding methods. Only use Videojet approved metallic service trays and ground cables. 2-4 Electrical Safety Guidelines Rev AA Videojet 1510 Service Manual Warning Always bond conductive equipment together with approved cables to maintain them at the same potential and minimize static discharge. For example, printhead to metal service tray. Caution Always empty the service trays frequently. Some inks and cleaning solutions are flammable. Make sure that the waste fluids are disposed according to HAZMAT. Fuses Warning To ensure continued protection against fire hazards, replace fuses only with the specified type and rating. Fluid Safety Guidelines This section describes the hazards that may occur while handling ink, make-up fluid, and cleaning solutions, and the safety precautions that a user must take to prevent the hazards. Rev AA Fluid Safety Guidelines 2-5 Videojet 1510 Service Manual Ink and Make-up Fluid Warning The ink and make-up fluid are irritating to the eyes and respiratory system. To prevent personal injury when handling these substances: Always wear protective clothing and rubber gloves. Always wear goggles with side-shields or a face mask. It is also advisable to wear safety glasses when carrying out maintenance. Apply barrier hand cream before handling ink. If ink or make-up fluid contaminates the skin, wash immediately with soap water. DO NOT use washdown or solvent to clean ink stains from the skin. Warning The ink and make-up fluid are volatile and flammable. They must be stored and handled in accordance with local regulations. Do not smoke or use a naked flame in the vicinity of these substances. Immediately after use, remove any tissue or cloth that becomes saturated with these substances. Dispose all such items in accordance with the local regulations. In the event that any ink or make-up fluid container is not completely empty after use, it should be resealed. Only full bottles are recommended for use when replenishing ink or make-up fluid; partially filled bottles must be disposed in accordance with the local regulations. Warning When setting up the nozzle, direct the ink stream into a beaker or suitable container. To avoid the contamination of the ink, do not reuse any ink collected in this way. Dispose all waste ink in accordance with the local regulations. 2-6 Fluid Safety Guidelines Rev AA Videojet 1510 Service Manual Warning Prolonged breathing of make-up fluid or cleaning fluid vapor may cause drowsiness and/or effects similar to alcoholic intoxication. Use only in open, well-ventilated areas. Cleaning Agent Warning The cleaning agent is poisonous if taken internally. Do not drink. Seek medical attention immediately if ingested. Warning The cleaning agent is irritating to the eyes and respiratory system. To prevent personal injury when handling this substance: Always wear protective rubber gloves and clothing. Always wear goggles with side-shields or a face mask. It is also advisable to wear safety glasses when carrying out maintenance. Apply barrier hand cream before handling the cleaning agent. If cleaning agent contaminates the skin, rinse off with running water for at least 15 minutes. Warning The cleaning agent is volatile and flammable. It must be stored and handled in accordance with local regulations. Do not smoke or use a naked flame in the vicinity of the cleaning agent. Immediately after use, remove any tissue or cloth that becomes saturated with cleaning agent. Dispose all such items in accordance with local regulations. Rev AA Fluid Safety Guidelines 2-7 Videojet 1510 Service Manual Caution Make sure that the cleaning agent is compatible with the ink used before carrying out printhead cleaning otherwise the printhead may get damaged. Compressed Air Safety Guidelines Warning Airborne particles and substances are a health hazard. Do not use high pressure compressed air for cleaning purposes. UI Related Safety Guidelines Caution To prevent unauthorized access to the software, ensure that Clear Password is executed when exiting from a higher level password. Caution Ensure that the correct message name is selected for message deletion as no message selection confirmation prompt is given. All messages apart from the TEST MESSAGE will be deleted. Caution The Delete User Field option does not ask for confirmation to delete a user field. 2-8 Compressed Air Safety Guidelines Rev AA Videojet 1510 Service Manual Other Important Guidelines 1 DEGRADED PERFORMANCE. Machine functions that only Videojettrained personnel can access are set at Password Level 3 (MASTER password), these functions must not be given as customer options. 2 EXCESSIVE USE OF MAKE-UP FLUID. As solvent is used during the stop cycle, repeatedly stopping and starting the printer can lead to excessive use of make-up fluid or solvent and can lead to a Ink Core Level High error. 3 QUICK STOP. After a quick stop, the machine must not be left in the same state for any length of time as drying ink may make restarting difficult. 4 PRINTER OVERHEATING. Report all overheating incidents to a maintenance engineer. 5 DAMAGE TO GUTTER. Never attempt to bend the gutter. Its position is fixed. 6 DAMAGE TO CHARGE ELECTRODE. The charge electrode is not adjustable so, do not attempt any mechanical adjustments. 7 EQUIPMENT DAMAGE. Adhere to prescribed circuit limitations when using any external input or output devices with the printer. 8 EQUIPMENT DAMAGE. The DIN connector for the lamp stack must not have any inductive load placed on it as it may cause damage to the PCB. 9 EQUIPMENT DAMAGE. Do not fit or remove any connector on the printer when the power is on, otherwise the printer may get damaged. 10 RISK OF EXPLOSION. If the battery is replaced by an incorrect type, it will lead to an explosion. Always dispose the used batteries according to the instructions and local regulations. 11 HEATER. In a fault condition, heater can reach 70 oC. Do not touch the plate on which the heater is mounted. The failure to follow this warning can cause personal injury. Rev AA Other Important Guidelines 2-9 3 Main Parts Printer Overview 1 5 2 4 3 1. Electronics Compartment Door 2. Ink Compartment 3. Printhead 4. Umbilical 5. Connector Panel 6. Electronics Compartment* 7. Main Power Switch* 8. Back Filter* * The components are not shown in the picture. Figure 3-1: Main Parts of the Printer Rev AA Printer Overview 3-1 Videojet 1510 Service Manual Figure 3-2 shows the schematic diagram of Videojet 1510 printer. PSU LCD FIB 0V 5V +15 V CSB 34 way -15 V Keypad 24 V 50 way Printhead 50 way 50 way Interface Connectors PIB Core Module Ink and Make-up Cartridges Figure 3-2: System Overview Cabinet The cabinet of Videojet 1510 printer is constructed of stainless steel with an inner fibre lining. The cabinet includes the following parts: • Control panel • Electronics compartment door • Main power switch • Ink compartment door • Connector panel • Umbilical Refer to Figure 3-3 on page 3-3 to see the parts of the cabinet. 3-2 Cabinet Rev AA Videojet 1510 Service Manual 1 7 2 3 6 4 5 1. Control Panel 2. Main Power Switch 3. Electronics Compartment Door 4. Ink Compartment Door 5. Handle 6. Umbilical 7. Connector Panel 8. Back Filter* *The component is not shown in the figure. Figure 3-3: Printer Cabinet Rev AA Cabinet 3-3 Videojet 1510 Service Manual Control Panel The control panel (Figure 3-4) provides the user interface to the printer. Refer to Chapter 3 in the Videojet 1510 Operator Manual for more information. 1 2 7 6 ! 2 Q 5 £ " 1 W A E R X ^ 5 D S Z % $ 4 3 T F C & 7 6 Y G V 8 J N B ) 9 I U H ( * 0 P O K L 3 M 4 5. Display 6. Contrast Key (Brightness Control) 7. Function Keys 1. Status LEDs 2. Arrow Keys 3. Keypad 4. Information Key Figure 3-4: Control Panel Main Power Switch The main power switch (item 1, Figure 3-5) is a green push button to turn on or turn off the power supply to the printer. You can find the main power switch on the right side of the printer. Note: The handles (item 2) are provided for easy movement of the unit. 2 1 1. Main Power Switch 2. Handle Figure 3-5: Main Power Switch Electronics Compartment Door The electronics compartment door (item 3, Figure 3-3 on page 3-3) is mounted on two hinges and its seal is water resistant when closed. The 3-4 Cabinet Rev AA Videojet 1510 Service Manual door is closed using two M4 x 30 socket head screws. The door contains control panel (refer to “Control Panel” on page 3-4) and front panel interface board. See “Electronics Compartment” on page 3-11 for more information on the electronics compartment. LCD and Front Panel Interface Board The front panel interface board (FIB), provides the interface between the CSB and the LCD and keyboard. This assembly is located inside the electronics compartment door. LCD Figure 3-6: LCD Rev AA Cabinet 3-5 Videojet 1510 Service Manual 1. Keypad Right 2. Touch Panel (Future Option) 3. Program (Only Used In Production) 4. 34-way Ribbon to CSB 5. Keypad Left 6. Mono LCD Figure 3-7: FIB Note: A TORX screwdriver is required to separate the FIB from the LCD. Ink Compartment Door The ink compartment door (item 4) is mounted on two hinges and its seal is water resistant when closed. See “Ink Compartment” on page 3-18 for more information on the contents of this compartment. Umbilical The umbilical (item 6) that connects the printer cabinet to the printhead is attached to the cabinet through a threaded fitting, secured with nuts and washers. Connector Panel The connector panel (item 7, Figure 3-3 on page 3-3) provides inputs for several types of external devices. 3-6 Cabinet Rev AA Videojet 1510 Service Manual 1 11 2 3 10 4 9 5 6 8 7 Cat 5e 1. BCD Message Select Input A 2. Reverse Print Input 3. Stacklight 4. Shaft Encoder 5. Fault Relay 6. Product Detector 1 7. USB 8. Ethernet 9. RS485 10. RS232 11. BCD Message Select Input B Figure 3-8: Connector Panel Stacklight Connector The printer provides an output for a set of status lights through the lamp stack connector (item 3, Figure 3-8). This is a 6 way DIN connector. The pin allocation is shown in Table 3-1: Pin Function DIN Pin 1 Red lamp negative supply. DIN Pin 2 Amber lamp negative supply. DIN Pin 3 Green lamp negative supply. DIN Pin 4 +24VDC supply to the strobe/siren. Maximum Rating = 900 mA DIN Pin 5 Strobe/siren negative supply DIN Pin 6 +24V DC common to the traffic lights Table 3-1: Lamp Stack Connector Pinouts Rev AA Cabinet 3-7 Videojet 1510 Service Manual Shaft Encoder Connector The printer provides a 12 V (200 mA DC total) output for use by a shaft encoder with a maximum frequency of 100 kHz. The shaft encoder connector (item 4) is a 4 way DIN connector. The pin allocation is shown in Table 3-2. Pin Function DIN Pin 1 +15 VDC supply to shaft encoder DIN Pin 2 Shaft encoder input ‘A’ DIN Pin 3 Shaft encoder input ‘B’ Din Pin 4 0 VDC common Table 3-2: Shaft Encoder Connector Pinouts Note: The shaft encoder output must be of the PUSH/PULL type. Fault Relay The fault relays connector (item 5) is a 7 way DIN connector. This connector supports the following relays: • Relay ‘A’ duplicates the functionality of the green LED on the keyboard, and you can use the relay to provide a ‘Print Ready’ output. • Relay ‘B’ duplicates the functionality of the yellow LED on the keyboard, and you can use the relay to provide a ‘warning’ output. Electrical Rating: 1A 30V DC 0.3A @ 125V AC Maximum Switch Cap Pin Function DIN Pin 1 Relay A - Normally open contact DIN Pin 2 Relay A - Normally closed contact DIN Pin 3 Relay A - Common contact DIN Pin 4 Relay B - Normally open contact DIN Pin 5 Relay B - Normally closed contact DIN Pin 6 Relay B - Common contact DIN Pin 7 Not used Table 3-3: Fault Relays Connector Pinouts 3-8 Cabinet Rev AA Videojet 1510 Service Manual Product Detector Connector The printer provides a 12V, 200mA, DC total output for use by a photoelectric cell (PEC), inductive proximity detector or micro switch. The product detector connector (item 6, Figure 3-8 on page 3-7) is a 3 way DIN connector. The pin functions are shown in Table 3-4. Pin Function DIN Pin 1 +15 VDC supply to sensor DIN Pin 2 Sensor output DIN Pin 3 0 VDC common Table 3-4: Print Trigger Connector Pinouts USB Connector The USB Connector allows for data to be transferred to and from a connected USB flash drive (item 7, Figure 3-8 on page 3-7). Ethernet Connector The ethernet connector (item 8) is used to connect the printer to a remote computer or network to import data or control the printer remotely. RS 485 Connector The RS 485 connector (item 9) is a 5 way DIN connector. Use this to connect the printer to an RS 485 network to import data or control the printer remotely. Pin Function DIN Pin 1 Line A DIN Pin 2 Line B DIN Pin 3 0 VDC Common DIN Pin 4 - DIN Pin 5 - Table 3-5: RS 485 Connector Pinouts Rev AA Cabinet 3-9 Videojet 1510 Service Manual RS 232 Connector The printer has an RS 232 communication port linked to the COMM1 connector. The RS 232 connector (item 10, Figure 3-8 on page 3-7) is a 5 way DIN connector. The pin allocation is shown in Table 3-6. Pin Function DIN Pin 1 0VDC common DIN Pin 2 Transmit data out from the printer. DIN Pin 3 Received data into the printer. Din Pin 4 DTR output from the printer. Din Pin 5 DCD input to the printer. Table 3-6: RS 232 Connector Pinouts Back Filter The ink compartment draws the air from the outside atmosphere to keep the compartment cool. The back filter removes the dust from the air that goes inside the ink compartment (see Figure 3-9). The IP65 version back filter is optional (see Figure 3-10 on page 3-11). Back Filter Figure 3-9: Back Filter (IP55 Version) 3-10 Cabinet Rev AA Videojet 1510 Service Manual Figure 3-10: Back Filter (IP65 Version) Electronics Compartment 1 7 2 6 3 5 4 1. Electronics Compartment Fan 2. Power Supply Unit (PSU) 3. Positive Air Pump 4. Control System Board (CSB) 5. Printer Interface Board (PIB) 6. EHT Module 7. Connector Panel Boards Figure 3-11: Electronics Compartment Power Supply Unit The Power Supply Unit (PSU) is the main source of power to the printer.The mains input circuit is shown in the Figure 3-12 on page 3-12. Rev AA Electronics Compartment 3-11 Videojet 1510 Service Manual The AC electrical power is supplied through three core cables to the mains filter. The line and neutral are fed to the On/Off switch. After the On/Off switch the line and neutral are fed to TB1 connector on the PSU. Mains Switch PSU L L N N E TB1 Figure 3-12: Mains Input Circuit TB 1 Connector Figure 3-13: Power Supply Unit The PSU features are as follows: • The mains fuse (T3A 110-240 V) is located in the PSU. • The PSU provides four DC voltage levels (+24 V DC, +15 V DC, +5 V DC, and -15 V DC) to the CSB. • Two fuses are soldered to the PSU board. These two fuses cannot be reset or replaced. • The input power to the PSU ranges from 84 to 264 VAC, 50 – 60 Hz. 3-12 Electronics Compartment Rev AA Videojet 1510 Service Manual Control System Board 1. Connectors CN1, CN2 and CN3 2. Charge Tunnel and Modulation Signal Connector 3. Input Power Connector 4. LEDs 5. JTAG 6. CPU JTAG 7. USB 2 Host Device 8. User Interface Connector 9. Ethernet Connector Figure 3-14: Control System Board Connectors 1, 2, and 3 The ribbon cables from the PIB connect to the CSB through the connectors 1, 2 and 3 (item 1, Figure 3-14) and relay the data that reaches PIB from different parts of the printer to the CSB. Charge Tunnel and Modulation Signal Connector The charge tunnel and modulation signals are generated on the CSB. These signals are sent directly to the printhead through the umbilical. All other input or output signals are sent through the PIB. Rev AA Electronics Compartment 3-13 Videojet 1510 Service Manual Charge 1 MOD Connector Pin Function DIN Pin 1 Charge DIN Pin 2 GND DIN Pin 3 GND DIN Pin 4 MOD Table 3-7: Pin Functions for Charge 1 MOD Connector Input Power Connector You can check the voltages at input power connector (item 3) to make sure that the power supply from the mains power supply is of the correct value. Pin Signal 1 +15 V 2 0V 3 +5 V 4 -15 V 5 +5 V 6 +24 V 7 0V 8 N/C Table 3-8: Pin Connections - Input Power Connector 3-14 Electronics Compartment Rev AA Videojet 1510 Service Manual LEDs 1. Power LED 2. Print Engine LED 3. SoC to FPGA LED 4. Ethernet LED Figure 3-15: Status LEDs LED Description Power Indicates the status of 3.3 VDC Print Engine flashes when printing is in progress SoC to FPGA Indicates the status of communications between the processor and the FPGA Ethernet Indicates the status of Ethernet communications Table 3-9: Status LEDs Rev AA Electronics Compartment 3-15 Videojet 1510 Service Manual Electronics Compartment Fan A cooling fan circulates the air inside the electronics compartment. The heat is dissipated outside by the fins that are fixed on top of the printer. Figure 3-16: Cooling Fan Positive Air Pump The positive air pump is a standard part for the 1510. The positive air pump provides dust free air to the printhead and thus prevents the accumulation of dust in the printhead. Positive Air Pump Figure 3-17: Positive Air Pump Positive Air Filter The positive air filter is located in the ink compartment. It filters the positive air pump discharge before it reaches the printhead. 3-16 Electronics Compartment Rev AA Videojet 1510 Service Manual Printer Interface Board 7 8 9 10 1 2 3 4 5 6 1. 10-way Printhead Connector 2. 12-way Printhead Connector 3. EHT Cable Connector 4. Positive Air Pump Connector 5. Electronics Compartment Fan Connector 6. CSB Ribbon Cable Connectors (x3) 7. USB Connector 8. PCB1 Connector 9. PCB 2 Connector 10. PCB 3 Connector Figure 3-18: Printer Interface Board (PIB) - Electronics Compartment Side 4 3 2 1 1. Ribbon Cable Connector from Ink Door 2. Ink Compartment Fan Connector 3. 16-way Ink Core Module Ribbon Cable Connector 4. 20-way Ink Core Module Ribbon Cable Connector Figure 3-19: Printer Interface Board (PIB) - Ink Compartment Side The description of different connectors on the PIB is provided in the Table 3-10. Connector Description 10-way Printhead Connector 12-way Printhead Connector Connection to valves, phase detector, strobe LED, heater and thermistor, and gutter detect EHT Cable Connector Input to EHT module Positive Air Pump Connector Input to positive air pump Table 3-10: PIB Connectors Rev AA Electronics Compartment 3-17 Videojet 1510 Service Manual Connector Description Fan Connector Input to electronics compartment fan CSB Connectors (x3) Input to CSB USB Connector External USB (not the USB connection on CSB) PCB1 Connector PCB 2 Connector PCB 3 Connector RS-232, Ethernet, Photocell, Shaft Encoder, Beacon, I/ O Ink System Ink pump, valves, sensors, level detectors, smart chip supplies validation system Table 3-10: PIB Connectors EHT Module The extra high tension (EHT) module (item 2, Figure 3-20) generates the high tension voltage (0 to 8000 VDC) that is supplied to the deflector plate in the printhead. 1 2 1. Cooling Fan 2. EHT Module Figure 3-20: Cooling Fan and EHT Module Ink Compartment The ink system provides a continuous supply of ink to the printhead at the correct pressure, temperature and viscosity. The ink system is housed in the printer cabinet and the different components of the system are interconnected by PTFE tubing. 3-18 Ink Compartment Rev AA Videojet 1510 Service Manual 1 2 3 1. Smart Cartridges 2. Ink Compartment Door 3. Ink Core Module 4. Ink Compartment Fan* *The component is not shown in the picture Figure 3-21: Ink Compartment Rev AA Ink Compartment 3-19 Videojet 1510 Service Manual Ink Core Module The ink core module maintains the pressure and viscosity of the ink in the printer. 1 2 1. Ink Core 2. Ink Core Pump Figure 3-22: Ink Core Module The ink core module contains the following subsystems: • Ink core pump • Ink core • Mixer tank • Venturi (for fluid addition) • Three Pico valves (fluid addition, flush pump control) • Filtration systems for the ink and the flush • Pressure damper • Instrumentation (pressure and temperature sensing) 3-20 Ink Compartment Rev AA Videojet 1510 Service Manual Ink Core Module Connections There are three input, three output, and one vent hydraulic connections to the ink core module. Connections Type of Tube Input Hydraulic Connections • Ink addition tube (black-striped tube) • Gutter pump discharge (blue-striped tube) • Make-up addition tube (green-striped tube) Output Hydraulic Connections • Flush supply tube (red-striped tube) • Ink supply tube (clear tube) • Ink Commissioning Tube (clear tube) Vent Vent or breather tube (Clear tube) Table 3-11: Ink Core Module Connections Two ribbon cables provide the electrical interface between the ink core module and the electronic system. The cables connect directly from the ink core module to the PIB and allow for the transfer of the following signals: • Ink pump motor control signal • Pressure sensing signals (2 sensors) • Ink temperature signal • Valve control signals • Mixer tank level detecting signals • Ink system smart chip information (refer to “Smart Cartridges” on page 3-23 for additional information). Ink Core Pump The ink core pump is a positive displacement gear pump driven by a 24 VDC brushless motor. The pump provides stable ink pressure to the nozzle during printing and also provides a flow of ink to other components inside the ink core module. Ink Core Module Functions The phasing and velocity fly-by sensors and supporting circuitry contribute directly or indirectly to the performance of six critical control functions during steady-state operation: • Phasing • Modulation control • TOF measurement Rev AA Ink Compartment 3-21 Videojet 1510 Service Manual • Pump speed control • Target pressure control • Viscosity control The functions of the ink core module are shown in Table 3-12. Name Function Frequency Phasing Between prints, charge transfer to test drops is measured by the LEAD fly-by sensor (phase detector) in order to synchronize drop charging to drop break-off, thereby optimizing print quality. Performed approximately 25 times per second Modulation Control Between prints, modulation amplitude is validated by performing an abbreviated auto-modulation test using the LEAD fly-by sensor (phase detector). The amplitude is changed in small increments whilst measuring the rate of change of the phase angle in order to verify that the amplitude setting remains at or near the “appropriate setting”. Performed continuously TOF Measurement Between prints, drop velocity is monitored by measuring the TIME OF FLIGHT of the test drops from the LEAD (phase) sensor to the TRAILING (velocity) sensor. The measured result is referred to as the “actual velocity”. Performed every TENTH phasing test Pump Speed Control A pressure transducer inside of the Core measures “actual pressure”. This pressure is compared to the “target pressure”. The resultant error is used to increase or decrease the pump speed. Performed once per second Target Pressure Control The “target pressure” represents the nominal pressure the printer determines that it must operate at in order for the actual velocity to be equal to the “velocity set point”. The printer makes modifications to the target pressure by reviewing the “history” of the velocity error parameter (“PID” control). “Velocity error” refers to the difference between the actual velocity and the set point. Occur every 10 seconds Viscosity Control Once the printer has determined its “target pressure”, it has the means to perform viscosity adjustments. Determination concerning viscosity is made by comparing the empiricallydetermined “target pressure” to a reference pressure known as the “temperature-compensated target pressure”. This value is acquired indirectly from data encoded on the ink cartridge Smart Chip. This reference pressure is mathematically determined and represents the pressure required to acquire the correct “actual velocity” under ideal viscosity conditions. If the target pressure deviates from the reference pressure, the printer attributes this to viscosity variation and responds accordingly. Occurs every 5 minutes (if necessary) Table 3-12: Ink Core Module Functions 3-22 Ink Compartment Rev AA Videojet 1510 Service Manual Smart Cartridges Two types of cartridges are used in the printer. • Ink cartridge - This contains the ink. • Make-up cartridge - This contains the make-up fluid. Functions The cartridge is based on smart chip technology that helps you to: • Find the accurate level of ink and make-up fluid • Use correct type of ink or make-up fluid • Know the expiry date of the ink 1 2 1. Smart Chip 2. Septum Figure 3-23: Smart Cartridges Positive Air Filter The positive air filter (item 1, Figure 3-24 on page 3-24) is fitted inside the ink compartment. The filter filters the air from the discharge of the positive air pump before the air enters the printhead. Ink Compartment Fan This ink compartment fan (item 2) cools the ink compartment. Rev AA Ink Compartment 3-23 Videojet 1510 Service Manual Gutter Pump The gutter pump (item 3) is fitted to the rear of the cabinet inside the ink compartment. The functions of the gutter pump are as follows: • Vacuum generation for gutter suction • Vacuum generation to assist in nozzle back flushing • Ink delivery to the ink core module during printer installation 1 2 3 1. Positive Air Filter 2. Fan 3. Gutter Pump Figure 3-24: Positive Air Filter, Fan and Gutter Pump 3-24 Ink Compartment Rev AA Videojet 1510 Service Manual Printhead The printhead contains the following parts: • Printhead cover • Print engine • Printhead valve module 1 4 3 1. Printhead cover 2. Print Engine 2 3. Knurled Screw 4. Printhead Valve Module Figure 3-25: Printhead Printhead Cover The printhead cover (item 1, Figure 3-25) is attached to the printhead with a knurled screw (item 3). The cover protects the printhead components. Removal of the cover is sensed by the printer through the cover switch. When the cover is removed the voltage to the deflector electrodes is turned off. Printhead Valve Module The printhead valve module (item 4) consists of the bleed/gutter valve, feed valve, feed line, and the head heater. Print Engine The print engine (item 2) consists of the nozzle, charge electrodes, time of flight sensors, deflection plate, and gutter tube. Rev AA Printhead 3-25 Videojet 1510 Service Manual Nozzle The nozzle (item 8, Figure 3-26 on page 3-27) creates the ink droplets. Charge Electrode The charge electrode (item 9) applies an electrical charge to each ink droplet. The charge applied to the droplet is variable and affects the position of the droplet on the substrate. Phase Detectors The phase detectors (item 12) measure the ink drop velocity and perform phasing. Gutter Tube The gutter tube (item 11) is the return path for the uncharged ink droplets that are not used for printing. The gutter delivers the ink back into the ink core. The gutter detect senses when ink is present in the gutter. The ink feed tubes are metallic and a signal is fed to one of them. A signal return lead is connected to the other. When ink (which is conductive) is present, the signal passes through it to the return lead. The gutter detect signal is then fed, via the umbilical, to the CSB in the electronics system. Deflection Plate The deflection plate (item 10) is supplied with a fixed positive DC voltage (0 - 8000 VDC) from the EHT Module. This voltage deflects the charged drops over the top of the gutter, through the printhead slot, and onto the substrate. 3-26 Printhead Rev AA Videojet 1510 Service Manual 16 1 2 3 4 15 5 6 14 13 7 8 9 12 10 11 1. Solvent Flush Line 2. Bleed/Gutter Line 3. Bleed/Gutter Valve 4. Feed Valve 5. Front Manifold 6. Ink Pipe 7. Ground 8. Nozzle 9. Charge Electrode 10. Deflection Plate 11. Gutter Tube 12. Phase Detectors (electrodes) 13. Nozzle Cradle 14. Nozzle Holder 15. Bleed Pipe 16. Feed Line Figure 3-26: Printhead Components Printhead Operation The flush supply and ink supply lines merge at Pico valve V1. The ink is heated as it flows through the manifold assembly to the nozzle. The nozzle is outfitted with both the feed and the bleed ports. The nozzle bleed port provides a source of vacuum, used during manual irrigation/ backflushing. Rev AA Printhead 3-27 Videojet 1510 Service Manual Ink Supply Make-up Supply Under Vacuum V1 V2 5 4 3 2 1 1. Gutter Tube 2. High Voltage/EHT Plate 3. Charge Electrode 4. Nozzle 5. Heater Figure 3-27: Printhead Operation The flow of ink is as follows: 1 The ink and solvent mixture flows through the feed line (item 16, Figure 3-26 on page 3-27) into the printhead. 2 The ink and solvent mixture enter the feed valve (item 4). 3 The valves open or close as per the print requirements. Note: The bleed valve opens and closes as needed during flushing the nozzle and suppling ink to the nozzle. 4 The ink and the solvent mixture flow into the nozzle. To adjust the nozzle refer to“Align the Ink Stream” on page 4-26. 5 The piezoelectric crystal vibrate the nozzle at a frequency of around 75 KHz nominal value in the longitudinal direction. This vibration enables the nozzle to breakup the stream of ink into droplets. 6 The ink drops enter the charge electrode (item 9) where they are charged at different voltage levels based on the character to be generated. 7 The charged ink drops then pass through the EHT/ High Voltage Field (item 2, Figure 3-27) and over the phase detectors. 3-28 Printhead Rev AA Videojet 1510 Service Manual 8 The High Voltage/EHT plate deflects the charged drops of ink at various angles depending on the charge placed on the drop at the moment of breakoff. 9 An electrically conductive ink is supplied under pressure by the ink core to the nozzle assembly (item 6, Figure 3-28) through the ink feed pipe (item 1). 10 An ink stream is formed as the ink is forced out of the nozzle jet orifice (item 5). A modulation signal is applied to a ceramic transducer which is clamped to the nozzle assembly. The transducer crystals (item 3 and item 4) causes the nozzle assembly to vibrate longitudinally, breaking up the ink stream into droplets, a small distance away (the break up point) from the nozzle jet orifice. The frequency of modulation is 76.8 kHz (nominal value). The ink droplets are produced at the same rate as the modulation frequency and are uniform in size and separated by equal distances. The nozzle orifice diameter is 70 microns. 1 6 5 2 4 1. Ink Feed Pipe 2. Damping Mass 3. Crystal Transducer 3 4. Crystal Transducer 5. Nozzle Jet Orifice 6. Nozzle Assembly Figure 3-28: Ink Jet Formation Droplet Charging 11 The charge electrode (item 2 in Figure 3-29) is positioned at the break up point of the ink stream and extends for several drops either side of it. Note: This allows a tolerance for break up position and shields the ink stream from the influence of the other electrostatic fields. The distance between the nozzle assembly (item 1) and the charge electrode is 2 mm. Rev AA Printhead 3-29 Videojet 1510 Service Manual 1 2 1. Nozzle assembly 2. Charge electrode Figure 3-29: Charge Electrode The ink stream and the charge electrode can be considered as the two electrodes of a capacitor. By raising the charge electrode to a specific positive voltage (with a charge pulse) the section of the ink system within the charge electrode will have a negative charge induced on it. When a drop of ink then breaks from the jet it will have trapped on it a charge directly proportional to that on the charge electrode. If the positive voltage is then removed from the charge electrode, the negative charge on the jet will discharge through the ink jet and nozzle assembly to ground. However, the drop of ink which has become detached from the jet cannot discharge as it no longer has a conductive path to ground. Droplet Deflection 12 The droplet stream passes through an electrostatic field maintained by the deflector electrodes that are connected to a high tension supply (typically 6 kV). 13 The negatively charged droplets are deflected by the field towards the high voltage deflector electrode. The distance a drop is deflected is proportional to the charge carried, which is in turn proportional to the voltage applied to the charge electrode when the drop became detached from the ink jet. The charged droplets once deflected leave the printhead to form characters in a dot matrix format on the substrate. Droplets which are not required for printing are not charged and are therefore not deflected. 3-30 Printhead Rev AA Videojet 1510 Service Manual 4 3 1 2 1. Deflected Droplet Path 2. Substrate 3. Gutter 4. Droplet Path to Gutter 5. Phase Detectors (Electrodes)* * The part is not shown in the figure Figure 3-30: Droplet Deflection Umbilical The umbilical has the electrical wiring and ink system tubing from the printer to the printhead. The Hydraulic System This section describes the combined operation of the ink system, printhead and umbilical to print on a substrate. The Figure 3-31 on page 332 shows the hydraulic system of the printer. The hydraulic system of the printer consists of the following components: • Ink cartridge • Make-up cartridge • Ink core module • Umbilical • Printhead Rev AA Umbilical 3-31 Videojet 1510 Service Manual • Gutter pump 9 8 1 2 3 4 7 5 6 1. Make-up fluid Addition Tube 2. Gutter Pump 3. Ink Addition Tube 4. Ink Cartridge 5. Make-up fluid Cartridge 6. Core Module 7. Printhead 8. Ink Supply Tube 9. Make-up Tube Figure 3-31: Hydraulic System Components 3-32 The Hydraulic System Rev AA 4 Installation Introduction This chapter describes the procedures to install 1510 printer. Caution Only Videojet trained personnel must carry out the installation and maintenance work. Any such work undertaken by unauthorized personnel can damage the printer and invalidate the warranty. Warning Make sure that the mains electrical supply is within the range indicated by the label adjacent to the mains inlet of the printer. If the voltage ratings differ, do not use the printer until you have consulted your local supplier. Use only the mains power cable supplied with the printer. This cable must terminate in an approved, three-pole, mains plug which has a protective ground conductor. Keep electrical power cables, sockets and plugs clean and dry at all times. Warning The printer must be connected to an AC power supply, which has a protective ground conductor in accordance with IEC requirements or applicable local regulations. Any interruption of the protective ground conductor or disconnection of the protective ground terminal may render the apparatus dangerous. Rev AA Introduction 4-1 Videojet 1510 Service Manual Warning Lethal voltages are present within this equipment when it is connected to the mains electrical supply. Observe all statutory electrical safety codes and practices. Unless it is necessary to run the printer, disconnect the printer from the mains electrical supply before removing the covers or attempting any service or repair activity, otherwise death or personal injury can occur. Tools and Supplies Refer to the service tool kit listed in Chapter 11, “Tools and Spare Part Kits” for the tools and supplies required to install the printer. Typical Production Line A typical printer installation is shown in Figure 4-1 on page 4-3, where the printer (item 6) is mounted on a printer stand (item 7). The printhead (item 1) is configured to print vertically with the help of a clamp and bracket assembly. A beacon (item 8) is fitted to the printer. 4-2 Introduction Rev AA Videojet 1510 Service Manual 9 1 2 8 4 3 5 MESSA B INPUTGE MESSA A INPUTGE COMM RS S 232 PRINT TRIGG ER STATU OUTPUS T COMM RS S 485 2 SHAFT ENCOD ER RELAY SWITC HES ETHER NET PRINT TRIGG ER 1 USB 6 7 1. Printhead 2. Shaft Encoder 3. Shaft Encoder Cable 4. Photo Cell 5. Photo Cell Cable 6. Printer 7. Printer Stand 8. Beacon 9. Printhead Stand Figure 4-1: Typical Production Line Installation Rev AA Introduction 4-3 Videojet 1510 Service Manual Unpack and Inspect the Printer 1 Open the shipping box, and make sure that all the parts in the packing list are present in the box. If any part is missing, contact Videojet Technologies Inc. • Refer to Chapter , “Support and Training” for Videojet contact information. • Refer to Chapter 10, “Illustrated Parts List” for part numbers. 2 Make sure that there are no damaged parts. If you find any damaged part, contact Videojet Technologies Inc. to order a new part. Commission the Printer This section describes the tasks that a user must perform to commission the printer. Inspect the Ink System 1 Turn the knob and open the ink compartment door (see Figure 4-2). Figure 4-2: Turn the Knob 2 Push the plate (item 2, Figure 4-3 on page 4-5) in the direction shown to open the ink compartment door (item 1) completely. 4-4 Unpack and Inspect the Printer Rev AA Videojet 1510 Service Manual 1. Ink Compartment Door 2. Plate Figure 4-3: Ink Compartment Door 3 Pull the ink core module out of the ink compartment (see Figure 4-4). 1. Ink Compartment Door 2. Ink Core Module Figure 4-4: Pull Ink Core Module Rev AA Commission the Printer 4-5 Videojet 1510 Service Manual 4 Make sure that the ink core manifold is connected to the ink core module correctly (see Figure 4-5). Ink Core Manifold Figure 4-5: Ink Core Manifold 5 Make sure that all the tubes are connected to the ink core manifold (see Figure 4-6). 1. Clear Tube (5/32 inch) 2. Red Stripe Tube (1/8 inch) 3. Green Stripe Ink Tube (1/8 inch) 4. Air Vent 5. Blue Stripe Tube (1/8 inch) 6. Black Stripe Make-up Tube (1/8 inch) 7. Clear Tube (1/8 inch) Figure 4-6: Tubes to Ink Core Manifold 4-6 Commission the Printer Rev AA Videojet 1510 Service Manual 6 Connect the air vent tube (item 4, Figure 4-6 on page 4-6) to the fitting at the bottom rear of the cabinet (if it is not already connected). 7 Push the ink core module into the ink compartment. 8 Close the ink compartment door. 9 Put the printer on a stand or table. The printer can be mounted on three types of stands: mobile printer stand, static printer stand, or the wall mounting assembly. Refer to the respective installation instructions to install the printer on a stand. Log into UI 10 Connect the printer to the AC power supply and turn on the printer. The menu screen appears on the display (see Figure 4-7). Figure 4-7: Menu Screen 11 If you cannot see the display, adjust the contrast using the contrast adjustment button . 12 Log into the user interface (UI) at level 3 password. On the Password menu, select Enter Password. The Enter Password dialog box appears. Rev AA Commission the Printer 4-7 Videojet 1510 Service Manual Use the password generated by the DailyPassword application. The daily top level password is provided to trained personnel only. Note: The printer may display a "No Ink Parameters" warning and an "Ink Core Change" alarm. These are normal indications that the ink core is new and not programmed. Install Ink and Make-up Cartridges 13 Open the ink compartment door (refer to Step 1 and Step 2 on page 44). Warning The ink, solvent and make-up fluid are irritating to the eyes and respiratory system. To prevent personal injury when handling these substances follow the guidelines given below: Always wear protective clothing and rubber gloves. Always wear goggles with side-shields or a face mask. It is also advisable to wear safety glasses when carrying out maintenance. Apply barrier hand cream before handling ink. If ink or make-up fluid contaminates the skin, wash immediately with soapy water. DO NOT use washdown or solvent to clean ink stains from the skin. 14 Install one new cartridge of ink and one new cartridge of make-up fluid in the printer. The printer displays the parameters from the smart chip on the ink cartridge. Press the Enter key to accept the parameters and program the ink core module. After the cartridges are installed, the following events occur: a. The No Ink Cartridge and No Makeup Cartridge icons disappear. Note: If the No Ink Cartridge icon or No Makeup Cartridge icon does not disappear, pull the cartridge out of the ink compartment and insert again. 4-8 Commission the Printer Rev AA Videojet 1510 Service Manual b. The Wrong Ink icon and Wrong Makeup icon appear until the smart chip data is read by the printer. Once, the printer reads the smart chip data, the screen displays the parameters from the ink cartridge smart chip. Press the Enter key to accept these parameters and program the ink core module c. The icons that show the level of the ink and make-up in the cartridges appear. 15 Make sure that the part number on the ink cartridge matches with the part number displayed on the screen. See Figure 4-8. Figure 4-8: Ink Part Number 16 Verify the ink type and expiration date. Access Calibrate > View Ink Smart Chip Data menu (see Figure 4-9 and Figure 4-10). Rev AA Commission the Printer 4-9 Videojet 1510 Service Manual Make sure that the ink type matches with the ink type displayed on the menu screen (see Figure 4-8 and Figure 4-10 on page 4-10). Figure 4-9: View Ink Smart Chip Data Figure 4-10: Ink Smart Chip Data Configure the Printer 17 Calibrate the EHT. Refer to “Calibrate EHT” on page 4-30. 18 Set date and time. Access Configure > Set Time/Date (see Figure 4-11 on page 4-11). 4-10 Commission the Printer Rev AA Videojet 1510 Service Manual Figure 4-11: Set Time/Date 19 Set the nozzle type and the conduit length. Access Configure > System Settings. The System Settings dialog box appears (see Figure 4-12). • Make sure that the nozzle type is set correctly for the current configuration (70 micron). • Make sure that the conduit length is set correctly for the current configuration (2m, 3m or 6m). Figure 4-12: System Settings 20 Make sure that the current printhead elevation is zero. Access Calibrate > Printhead Elevation. The Printhead Elevation dialog box appears (see Figure 4-13 on page 4-12). Rev AA Commission the Printer 4-11 Videojet 1510 Service Manual Note: Keep the printhead at the same height as the point where the umbilical is attached to the cabinet. Figure 4-13: Printhead Elevation Prime the Ink Core Module 21 Select System > Fill Ink Core to prime the printer with the ink (see Figure 4-14 on page 4-12) and record the time. Figure 4-14: Fill Ink Core Menu 4-12 Commission the Printer Rev AA Videojet 1510 Service Manual 22 Make sure that the fluid flows in the black-striped tube (item 1, Figure 4-15) and the blue-striped tubes (item 2). 1. Black Striped Tube 2. Blue Striped Tube Figure 4-15: Prime Core 23 Monitor the Diagnostics Screen Two to track the Ink Core Level from Empty to Low to Middle. Select Calibrate > Diagnostics Screen 2. The Diagnostics Screen 2 appears (see Figure 4-16). Figure 4-16: Diagnostics Screen 2 24 Replace the ink cartridge with a new cartridge when the printer warning appears. Continue with Fill Ink Core procedure until the middle level is achieved. Rev AA Commission the Printer 4-13 Videojet 1510 Service Manual Perform Umbilical Purge and System Flush Purge 25 Remove the printhead cover screw that fastens the printhead cover to the printhead chassis and remove the printhead cover (refer to Figure 4-17). 1. Umbilical 2. Printhead Cover 3. Print Engine 4. Printhead Cover Screw 5. Printhead Valve Module Figure 4-17: Printhead Cover Removed Caution Always wear a set of rubber gloves before disconnecting the nozzle tubing manifold. This helps to prevent nozzle clogs. 26 Remove the M2 x 6 socket-head-cap screw (item 1, Figure 4-18 on page 4-15) that attaches the front tubing manifold to the printhead valve module. 27 Remove the 2-way manifold gasket (item 5). 28 Put the 2-way manifold gasket provided in the bypass kit on the ports of the printhead valve module. 29 Fit the nozzle bypass manifold (that has the loop of tube) to the printhead valve module using the M2 x 6 socket-head screw. 4-14 Commission the Printer Rev AA Videojet 1510 Service Manual 1 2 3 5 3 4 1. M2 x 6 Socket-head Screw 2. Nozzle Bypass Manifold 3. Tubing 4. Quick Disconnect 5. 2 Way Manifold Gasket Figure 4-18: Bypass Manifold 30 Open the quick disconnect (item 4, Figure 4-18) in the middle of the loop and direct the supply side into a receptacle. 31 Start System Flush Purge (select System > System Flush Purge). Refer to “System Flush Purge” on page 8-5 to perform system flush purge. 32 Observe if the fluid is going through the flush supply line (red stripe) and eventually exiting the loop. Make sure that the fluid being ejected is clear (make-up, not ink). 33 Perform umbilical purge (refer to “Umbilical Purge” on page 8-3). This procedure will not time-out automatically, so perform a quick stop to stop the umbilical purge process after a few seconds. Rev AA Commission the Printer 4-15 Videojet 1510 Service Manual Figure 4-19: Umbilical Purge 34 Remove the nozzle bypass manifold and the 2-way manifold gasket. 35 Fit the front tubing manifold to the printhead valve module using M2 x 6 socket-head-cap screw. Perform Viscosity Calibration 36 Remove the make-up cartridge from the make-up stall. 37 Start the jet using quick start. Figure 4-20: Quick Start Jet You may experience the ink stream toggling initially due to air bubbles remaining in the system. If the nozzle is clogged, perform 4-16 Commission the Printer Rev AA Videojet 1510 Service Manual nozzle backflush. (System > Nozzle Flush). Limit the number of backflushes to 40. 38 Check the position of the ink stream into the gutter: • If the ink stream is aligned into the gutter, go to the Step 39. Alignment can be fine-tuned later. • Otherwise, perform an ink stream alignment, if necessary (refer to “Align the Ink Stream” on page 4-26). Make sure that the adjustments are not at either end of the adjustment ranges - if they are, you may have a nozzle partial clog even if the ink stream is not severely misdirected. If necessary, do a nozzle backflush (System > Nozzle Flush). 39 Make sure that the jet startup is complete. The jet running icon on the home screen should be solid (not blinking) . 40 Make sure that the printer has reached steady state. Steady state means: actual velocity = velocity set point, + or - 0.1m/sec. 41 Perform viscosity calibration (refer to “Calibrate Viscosity” on page 432). 42 Check the ink stream alignment and fine-tune if necessary. Ink stream should be centered and no more than 2 to 3 stream widths from the top of the gutter. The top of the gutter is closest to the EHT plate. 43 Insert the make-up fluid cartridge. Clean Stop and Clean Start the Printer 44 Put a piece of paper under the printhead (to capture splatter) and press the F1 key to do a clean stop. During shutdown if ink splatters inside the printhead, check the ink stream alignment again and make sure that the flush pump is fully primed. 45 Put another piece of paper under the printhead and press the F1 key to do a clean start. Perform Final Checks 46 Install the printhead cover and make sure that the amber light extinguishes: Rev AA Commission the Printer 4-17 Videojet 1510 Service Manual • If the amber light is illuminated with the printhead cover fitted, check the Current Warnings screen and perform the required troubleshooting. 47 Use a flow meter and make sure that the positive air flow rate out of the printhead slot is 4 SCFH. 48 Close the ink compartment door. 49 Make sure that the electronics compartment door and the ink compartment door are closed correctly. Caution Do not perform Step 50 until the system is ready for production, as it affects the viscosity adjustments of the printer. 50 If production printing is desired, measure the vertical distance between the umbilical exit point on the side of the cabinet and the bottom of the printhead when it is fitted to the conveyor. This is the printhead elevation. Enter the value (in centimeters) in the UI. Figure 4-21: Printhead Elevation 51 Back up printer settings using a USB flash drive. Select Configure > Backup System Settings. 4-18 Commission the Printer Rev AA Videojet 1510 Service Manual Figure 4-22: Backup System Settings 52 Press the Enter key to backup the settings. 53 Validate machine parameters. Note: If the customer has ordered the positive air pump option, the pump should be installed now (before the power is switched on). Refer to “How to Install the New Positive Air Kit” on page 7-92 for information on installation of positive air pump. Set the Password Levels Notes: You must be at Password Level 3 to set the password levels. Do not divulge the master password to the customer. Consult the customer and find out which machine functions they want available to relevant personnel and which passwords they want to use. Set the passwords for Levels 1 and 2. You can also set the password levels for the menus. Use the DailyPassword application to generate the password to be used every day. Rev AA Set the Password Levels 4-19 Videojet 1510 Service Manual Figure 4-23: Password Menu Caution Machine functions that only trained personnel can access are set at Password Level 3 (master password), these functions must not be given as customer options. Install the Encoder When product speed is constant, the printer uses internal encoding. External encoding (that is shaft encoder) is used when the speed of the conveyor varies. Internal Encoding An internal clock sets the stroke-rate to a constant pace. Refer to “When to Use Internal Encoding” on page B-1, for more information on internal encoding. Do the following tasks to set encoding source to internal source: 1 Navigate to Configure> Shaft Encoder Source. The Print Control menu appears (see Figure 4-24 on page 4-21). 2 Set the Shaft Encoder Source to Internal. 4-20 Install the Encoder Rev AA Videojet 1510 Service Manual Figure 4-24: Internal Shaft Encoder Source Note: If the line speed varies, then an external shaft encoder must be fitted in order to maintain constant message width (refer to “External Encoding” on page 4-22). Note: A width of 1 will provide the fastest print that the printer can achieve in each font using the Internal Shaft Encoder option (refer to Figure 4-25). The message width is increased by approximately 3% for each increment. Figure 4-25: Message Width Refer to “Internal Encoding” on page B-1 for more information. Rev AA Install the Encoder 4-21 Videojet 1510 Service Manual External Encoding To install an external shaft encoder, do the following tasks: 1 Turn off the printer. 2 Connect the shaft encoder cable to the shaft encoder connector. See the following pictures for connections: • Figure 4-26 on page 4-22 - Shows the shaft encoder connector on the connector panel. • Figure 4-1 on page 4-3 - Shows the installed shaft encoder and the related connections. • Figure 4-27 on page 4-23 - Describes the shaft encoder connector socket pin layout. Note: The printer can be configured to accept two shaft encoder (quadrature) outputs. This allows the printer to compensate for changes in direction of the production line. Note: Using quadrature shaft encoders to determine changes of direction disables the width function (that is, the width must be set to 1). If width control is required, an external divider box must be provided. Shaft Encoder Connector Cat 5e Figure 4-26: Connector Panel 4-22 Install the Encoder Rev AA Videojet 1510 Service Manual 1 4 2 3 Figure 4-27: Encoder - Socket Pin Layout 3 Two LEDs show the operating status of the shaft encoder inputs. Use the LEDs to confirm a properly connected shaft encoder. 4 Set the Shaft Encoder Source to External. Navigate to Configure> Print Control in the 1510 UI (Figure 4-28). Figure 4-28: Print Control Menu 5 Make sure to set the physical parameters for external encoder. Rev AA Install the Encoder 4-23 Videojet 1510 Service Manual Install the Product Sensors Figure 4-1 on page 4-3 shows a photocell (item 4) connected through a cable (item 5) to product detector 1 connector on the connector panel. Note: Product detector 2 is for reverse print and is not a product detector trigger, but a change in state reverses the direction of print. It has an NPN and PNP connection. The product detector 2 option requires the use of non-standard system software. 1 The photocells may be either NPN or PNP devices. Set Jumper JB1 on the CSB to match the device type. 2 Turn on the printer. 3 Select the photocell source. Access Configure > Photocell Source. The Print Control menu appears. Set the relevant photocell level(s) to Active high or Active low dependant upon the device type. (NPN = Active high: PNP = Active low). Access Configure > Photocell Levels. The Photocell Levels menu appears. Printhead Product Delay Product Product Detector Figure 4-29: Product Delay Install the Beacon Do the following tasks to install a beacon: 1 Fit the beacon (item 1, Figure 4-30 on page 4-25) to the beacon mounting bracket (item 3) using three M4x10 socket-head cap screws (item 2). 2 Fit the beacon mounting bracket to the printer cabinet (item 1, Figure 4-31 on page 4-25), using three M4x10 socket-head cap screws (item 2) and three M4 plain nylon washers (item 3). 4-24 Install the Product Sensors Rev AA Videojet 1510 Service Manual 1 2 3 1. Beacon 2. M4x10 Socket-head cap Screws (x3) 3. Beacon Mounting Bracket Figure 4-30: Beacon 1 2 3 1. Printer Cabinet 2. M4x10 Socket-head cap Screws (x3) 3. M4 Plain Nylon Washers (x3) Figure 4-31: Beacon Installation 3 Insert the beacon connector into the status output connector on the connector panel (see Figure 4-32 on page 4-26). Rev AA Install the Beacon 4-25 Videojet 1510 Service Manual Status Output Connector Cat 5e Figure 4-32: Connector Panel The installation of the beacon is complete. Align the Ink Stream Two adjustments are required: nozzle vertical adjustment and nozzle horizontal adjustment. Warning The ink and make-up fluid are irritating to the eyes and respiratory system. To prevent personal injury when handling these substances: Always wear protective clothing and rubber gloves. Always wear goggles with side-shields or a face mask. It is also advisable to wear safety glasses when carrying out maintenance. Apply barrier hand cream before handling ink. If ink or make-up fluid contaminates the skin, wash immediately with soap water. DO NOT use washdown or solvent to clean ink stains from the skin. 4-26 Align the Ink Stream Rev AA Videojet 1510 Service Manual Do the following tasks to align the ink stream: 1 Loosen the knurled screw and remove the cover from the printhead. 2 Secure the printhead vertically in a suitable stand with the nozzle pointing downwards. Put a suitable container beneath the printhead to collect the ink. 3 Disable Gutter Detect and Charge Check, as follows: a. Press Alt + S. The System menu appears. Figure 4-33: System Menu b. Select Gutter Fault Shutdown Enable. The Gutter Fault Shutdown box appears. c. Toggle to set the value to Disable. d. Press the Enter key. Rev AA Align the Ink Stream 4-27 Videojet 1510 Service Manual Optimum jet position, 2 to 3 times diameter of jet Gutter center line First quarter of the gutter Figure 4-34: Ink Jet Gutter Position 4 Perform a quick start. When the ink jet has started, check that the ink jet is in the correct position in the gutter (Figure 4-34). Note: You must perform a quick start rather than a clean start when you are aligning the printhead during the commissioning process. However, if you are aligning the printhead of a printer that has already been in operation for some time, you may perform either a quick start or a clean start at this point. Caution EQUIPMENT DAMAGE. Never attempt to bend the gutter. Its position is fixed. 5 Adjust the ink jet position, if necessary using the horizontal adjustment screws (item 2, Figure 4-35 on page 4-29) and vertical adjustment screw (item 1). When the adjustment has been made make sure that the horizontal adjustment screws are tight and the ink jet position is correct. 4-28 Align the Ink Stream Rev AA Videojet 1510 Service Manual 1 4 3 2 1. Vertical Adjustment Screw 2. Horizontal Adjustment Screw 3. Horizontal Locking Screw 4. Vertical Locking Screw Figure 4-35: Printhead Adjustment Screw Location 6 When the ink jet position is correct in the gutter, check the ink jet is flowing through the centre of the charge electrode slot parallel to the sides of the slot (Figure 4-36). Equidistant Gap Figure 4-36: Ink Flow Through Charge Electrode Rev AA Align the Ink Stream 4-29 Videojet 1510 Service Manual Caution You must not tamper with the printhead charge electrode components. 7 To direct the ink jet flow through the charge electrode: a. Release the horizontal adjustment screw (item 2, Figure 4-35 on page 4-29). b. Move the block until the jet is in the correct position. Secure the adjustment screw and check the jet position again. Perform Calibration and Testing The system calibration and test procedures must be performed to commission the machine after the repairs are done to the printer. Note: If the customer has ordered the positive air pump option, the pump should be installed now (before the power is switched on). See “Positive Air Kit” on page 7-89 for information on installation of positive air pump. Calibrate EHT Do the following tasks to calibrate the EHT: 1 Loosen the knurled screw and remove the cover from the printhead. 2 Press Alt + l. The Calibrate menu appears. 4-30 Perform Calibration and Testing Rev AA Videojet 1510 Service Manual Figure 4-37: Calibrate Menu 3 Select Calibrate EHT. The EHT Calibration Messages appear based on the condition. Figure 4-38: EHT Calibration Messages 4 Press Enter. EHT Calibration Sweep occurs.Refer to Figure 4-39. Figure 4-39: EHT Calibration Sweep Rev AA Perform Calibration and Testing 4-31 Videojet 1510 Service Manual Calibrate Viscosity Do the following tasks to perform viscosity calibration: Note: Perform this procedure immediately after completing the Fill Ink Core sequence, but before the jet has been started. 1 Keep the printhead at the same height as the point where the umbilical is attached to the cabinet. 2 Set the printhead elevation value to zero (0). See Figure 4-40. Figure 4-40: Printhead Elevation 3 Turn the knob and open the ink compartment door (see Figure 4-41). Figure 4-41: Unlock Ink Compartment Door 4-32 Perform Calibration and Testing Rev AA Videojet 1510 Service Manual 4 Remove the make-up cartridge (see Figure 4-42). Figure 4-42: Cartridge Removal 5 Perform a Quick Start. See Figure 4-43. Figure 4-43: Quick Start 6 Make sure that the jet startup is complete. The jet running icon on the home screen should be solid (not blinking) . 7 Make sure that the printer has reached steady state. Steady state means: Actual Velocity = Velocity Set Point + or -0.1 m/s For example, see Figure 4-44 on page 4-34. Rev AA Perform Calibration and Testing 4-33 Videojet 1510 Service Manual Figure 4-44: Steady State 8 Perform viscosity calibration. Follow the prompts provided by the printer, assuming that the ink is known perfect ink. See Figure 4-45. Note: Perfect ink is the ink that is pulled directly from an ink cartridge known to be within a specific viscosity range. Figure 4-45: Viscosity Calibration 9 Put the make-up cartridge into make-up cartridge slot. 10 Enter the correct printhead elevation in the UI. Refer to Figure 4-40 on page 4-32. 11 Put the printhead into the printhead bracket on the conveyor. 4-34 Perform Calibration and Testing Rev AA 5 Printer Operation Introduction Refer to the Operator Manual for the following information: • How to turn on the printer • How to Clean Start and Stop the Printer • How to login for the first time • How to set the passwords for menus and levels • How to access other password levels • How to clear the passwords • How to view version info • How to reset and hide the product counter • How to view and reset run hours • How to configure the serial port • How to connect to a remote device • How to enter service information • How to create a message • How to Print Messages Reset Run Hours If the Service icon is displayed, the time until the next service is due must be entered to remove it. Note: The contact information that is displayed on screen when this icon appears can be configured by selecting Enter Service Information in the Data Logging menu. Rev AA Introduction 5-1 Videojet 1510 Service Manual 1 Navigate to Data Logging > Reset Run Hours. Figure 5-1: Data Logging Menu 2 Press the Enter key. The Reset Run Hours menu appears. Figure 5-2: Reset Run Hours Menu 3 Select Set machine alarm hours. Enter the number of hours until the next ink core change is due. For more information refer to the Table 8-1 on page 8-1. 4 Set Reset machine run hours to Yes. 5 Configure Set machine alarm hours to the number of hours until the next air filter inspection is due. For the recommended interval, refer to Table 8-1 on page 8-1. 6 Set Reset machine run hours to Yes. 7 Press the Enter key to save the settings. Restore Calibration Parameters The following procedure may be performed in order to recover previously backed-up job and printer configuration information from a USB flash drive: 1 Insert the USB flash drive into the external USB port of the printer. 5-2 Restore Calibration Parameters Rev AA Videojet 1510 Service Manual 2 Select Configure >Restore System Settings. Figure 5-3: Calibrate Menu 3 Press the Enter key to restore the settings. Perform Full System Backup Do the following tasks to perform a complete back-up of all programmable printer files, including job and printer configuration information: 1 Press the F1 key to stop the ink jet. 2 Insert a USB flash drive into the external USB port of the printer. 3 Select Configure > Full System Backup. Figure 5-4: Full System Backup Rev AA Perform Full System Backup 5-3 Videojet 1510 Service Manual 3) Follow the printer prompts and complete the backup. Perform Full System Restore Do the following tasks to recover previously backed-up information from the USB flash drive: 1 Press the F1 key to stop the ink jet. 2 Insert a USB flash drive into the external USB port of the printer. 3 Select Configure > Full System Restore. Figure 5-5: Full System Restore 4 Use the Right or Left arrow keys to scroll through the available options to restore. Figure 5-6: Restore Options 5 Press the Enter key to restore the selected option. 5-4 Perform Full System Restore Rev AA 6 User Interface Introduction Refer to Videojet 1510 Operator Manual for information on how to: navigate in the UI, create the messages, edit the messages, save the messages, and create the user fields. Rev AA Introduction 6-1 7 Replacement Instructions Introduction This section contains complete instructions for the replacement of the components listed below. Description Page No. Replace the Control System Board 7-7 Replace the Power Supply Unit 7-9 Replace the Liquid Crystal Display (LCD) or the Front Panel Interface Board (FIB) 7-13 Replace the Keyboard/Electronics Compartment Door 7-16 Replace the Ink Core Module 7-21 Replace the Ink Pump 7-35 Replace the Print Engine Assembly 7-41 Replace the Printhead Valve 7-44 Replace the Umbilical Assembly 7-49 Replace the Printer Interface Board (PIB) 7-73 Replace the Electronics Fan 7-85 Replace the Septum Assembly 7-81 Replace the Gutter Pump 7-93 Replace the Power Switch 7-76 Replace the Ethernet Connector 7-87 Replace the Positive Air Filter 7-89 Replace the Ink Door Assembly 7-98 Replace the Ink System Fan 7-103 Replace the EHT Module 7-105 Replace the USB Connector 7-108 Replace the Plug and Power Cable 7-109 Table 7-1:Location of the Instructions Rev AA Introduction 7-1 Videojet 1510 Service Manual Description Page No. Replace the CSB Lithium Battery 7-115 Replace the PCB 1, 2 and 3 7-117 Table 7-1:Location of the Instructions Safety Information Caution PERSONAL INJURY. Before you begin any maintenance work, make sure that the printer is turned off and disconnected from the AC power supply. Warning LETHAL VOLTAGES. Lethal voltages are present within this equipment when it is connected to the mains electrical supply. Only trained and authorized personnel can carry out maintenance work. Observe all statutory electrical safety codes and practices. Unless it is necessary to run the printer, disconnect the printer from the mains electrical supply before removing the covers or attempting any service or repair activity, otherwise death or personal injury may result. Caution ELECTROSTATIC SENSITIVE DEVICES. The printed circuit boards contain static sensitive devices. A suitably grounded, antistatic wrist strap must be worn when working on or handling printed circuit boards. 7-2 Safety Information Rev AA Videojet 1510 Service Manual Caution PERSONAL INJURY. Only trained service or maintenance personnel must perform these installation procedures. Qualified personnel have successfully completed the training courses, have sufficient experience with this printer, and are aware of the potential hazards to which they will be exposed. Common Procedures How to Open the Electronics Compartment Door Do the following tasks to open the electronics compartment: 1 Turn off the main power switch of the printer. 2 Turn off the AC power supply to the printer. 3 Disconnect the mains power cord from the outlet. Warning Before you open the electronics compartment door, wear anti-static wrist straps and ground yourself to the chassis of the cabinet. Failure to follow this warning can cause both personal injury and damage to the printer. 4 Use the 3 mm allen wrench to remove the two M4 screws (Figure 7-1 on page 7-4) that attach the electronics compartment door to the printer cabinet. Rev AA Common Procedures 7-3 Videojet 1510 Service Manual Figure 7-1: Electronics Compartment Door 5 Open the electronics compartment door (Figure 7-2). Figure 7-2: Electronics Compartment Door Opened 7-4 Common Procedures Rev AA Videojet 1510 Service Manual 6 Push the latch (item 2, Figure 7-3) downwards to open the control system board (CSB) (item 1). 1 2 3 4 1. CSB 2. Latch 3. M4 x 8 Cap-head Screws (x2) 4. Retainer Figure 7-3: Latch How to Close the Electronics Compartment Door Do the following tasks to close the electronics compartment door: 1 Close the CSB (item 1, Figure 7-3). 2 Push the latch (item 2) up and close the CSB. 3 Close the electronics compartment door with the two M4 screws (see Figure 7-1 on page 7-4). 4 Connect the mains power cord to the electrical outlet and turn on the power. How to Open the Ink Compartment Door Do the following tasks to open the ink compartment door: 1 Stop the production and remove the printer from the print mode. 2 Log into the Videojet 1510 user interface (UI) as level B or level C user. 3 Press the F1 key to stop the ink jet. Rev AA Common Procedures 7-5 Videojet 1510 Service Manual 4 Turn the knob and open the ink compartment door (see Figure 7-4). Figure 7-4: Unlock Ink Compartment Door 5 Push the plate (item 2) in the direction shown to open the ink compartment door (item 1, Figure 7-5) completely. 1. Ink Compartment Door 2. Plate Figure 7-5: Ink Compartment Door Opened 7-6 Common Procedures Rev AA Videojet 1510 Service Manual How to Close the Ink Compartment Door Do the following tasks to close the ink door: 1 Close the ink compartment door and turn the knob to lock the door (see Figure 7-4 on page 7-6). 2 Connect the mains power cord to the electrical outlet. 3 Turn on the main power switch of the printer. Control System Board Tools and Supplies Required Tool or Supply Quantity 3 mm Allen Wrench 1 Table 7-2:Tools and Supplies Warning Read the “Safety Information” on page 7-2 before you perform the below tasks. How to Remove the Old Control System Board Do the following tasks to remove the old control system board (CSB): 1 Open the electronics compartment door. Refer to “How to Open the Electronics Compartment Door” on page 7-3. 2 Remove the hinge bracket that holds the CSB. 3 Remember all the cable connections to the CSB (Figure 7-6 on page 78). 4 Disconnect all the cable connectors from the CSB. Rev AA Control System Board 7-7 Videojet 1510 Service Manual Figure 7-6: CSB 5 Discard the CSB according to the local regulations. The removal of the old CSB is complete. How to Install the New Control System Board Do the following tasks to install the new CSB: 1 Put the new CSB in the electronics compartment, so that the pins on the mounting plate fit in the hinge bracket. 2 Connect all the cable connectors to the CSB. 3 Push the latch up and close the CSB. 4 Put the retainer over the hinge pins of the CSB mounting plate. 5 Fit the retainer using the two M4 x 8 cap-head screws (item 3, Figure 7-3 on page 7-5). 6 Close the electronics compartment door. Refer to “How to Close the Electronics Compartment Door” on page 7-5. The installation of the new CSB is complete. 7-8 Control System Board Rev AA Videojet 1510 Service Manual Power Supply Unit Tools and Supplies Required Tool or Supply Quantity 3 mm Allen Wrench 1 7 mm Nut Runner 1 Table 7-3:Tools and Supplies Warning Read the “Safety Information” on page 7-2 before you perform the below tasks. How to Remove the Old Power Supply Unit Do the following tasks to remove the old power supply unit (PSU): 1 Open the electronics compartment door. Refer to “How to Open the Electronics Compartment Door” on page 7-3. 2 Swing open the control system board (CSB) (item 2, Figure 7-7 on page 7-10). Rev AA Power Supply Unit 7-9 Videojet 1510 Service Manual 1. PSU 2. CSB Figure 7-7: Control System Board 7-10 Power Supply Unit Rev AA Videojet 1510 Service Manual 3 Remove the two M4 nyloc nuts (item 3, Figure 7-8) from the stud (item 2) inside the cabinet. 1. PSU 2. Stud 3. M4 Nyloc Nut Figure 7-8: PSU Assembly 4 Disconnect the following cables from the PSU (item 1, Figure 7-7 on page 7-10). • PSU cable to the 8-way connector on the CSB • Cable to the 3-way mains connector on the power switch 5 Discard the old PSU according to local regulations. The removal of the old PSU is complete. How to Install the New Power Supply Unit Do the following tasks to install the new PSU: 1 Connect the following cables to the PSU: • PSU cable from the 8-way connector on the CSB • 3-way mains connector from the power switch 2 Put the PSU assembly into the lug (see Figure 7-9 on page 7-12) in the rear of the electronics compartment and then on the two studs. Rev AA Power Supply Unit 7-11 Videojet 1510 Service Manual 3 Use the two M4 nyloc nuts to fit the PSU assembly into the lug inside the cabinet. Figure 7-9: Lug 4 Close the CSB. 5 Close the electronics compartment door. Refer to “How to Close the Electronics Compartment Door” on page 7-5. The installation of the new PSU is complete. 7-12 Power Supply Unit Rev AA Videojet 1510 Service Manual LCD and FIB Assembly Introduction The LCD and FIB are part of one assembly. Replace the FIB and LCD together. Tools and Supplies Required Tool or Supply Quantity T20 Torx Screwdriver 1 Table 7-4:Tools and Supplies Warning Read the “Safety Information” on page 7-2 before you perform the below tasks. How to Remove the Old LCD and FIB Assembly Do the following tasks to remove the old LCD and FIB assembly: 1 Open the electronics compartment door. Refer to “How to Open the Electronics Compartment Door” on page 7-3. Rev AA LCD and FIB Assembly 7-13 Videojet 1510 Service Manual 1. Electronics Compartment Door 2. K40 x 10 Torx Screws (x4) 3. Inner Display Cover 4. FIB Cable 5. Ground Wire Figure 7-10: Open Electronics Compartment Door 2 Disconnect the front panel interface board (FIB) ribbon cable (item 4, Figure 7-10) from the FIB. 3 Remove the four K40 x 10 Torx screws (item 2) at the corners of the inner display cover (item 3) on the underside of the electronics compartment door. 4 Disconnect the ground wire from the FIB (item 2, Figure 7-11 on page 7-15) that is connected to the keypad tag (item 3). 7-14 LCD and FIB Assembly Rev AA Videojet 1510 Service Manual 1. Screw 2. Ground Wire 3. Keypad Tags (x2) Figure 7-11: Ground Wire on Keypad Tag 5 Disconnect the two keyboard-to-FIB ribbon cables (item 1, Figure 712) from connectors X7 and X8 on the periphery of the FIB (item 3). 1. Keyboard-to-FIB Ribbon Cable (x2) 2. K40x10 Torx Screws (x4) 3. FIB Figure 7-12: Remove the FIB 6 Use T20 Torx driver to unscrew the four K40x10 Torx screws (item 2, Figure 7-12) from the four corners of the FIB. 7 Remove the old LCD and FIB assembly and discard according to the local regulations. The removal of the old LCD and FIB assembly is complete. Rev AA LCD and FIB Assembly 7-15 Videojet 1510 Service Manual How to Install the New LCD and FIB Assembly Do the following tasks to install the new LCD and FIB assembly: 1 Before you install the new LCD and FIB assembly, peel the protective film from the new LCD (see Figure 7-13). 2 Fit the new LCD and FIB assembly to the old electronics compartment door using four K4x10 Torx screws (refer to Figure 7-12 on page 7-15). . Figure 7-13: Peel the Protective Film 3 Connect the two keyboard to FIB ribbon cables to connectors X7 and X8 on the periphery of the FIB (see Figure 7-12 on page 7-15). 4 Connect the ground wire to the FIB (refer to Figure 7-11 on page 7-15). 5 Fit the inner display cover and tighten the four K40 x 10 Torx screws. Make sure that the cover fits into the gasket all the way round. 6 Connect the FIB ribbon cable to the FIB. 7 Close the electronics compartment door. Refer to “How to Close the Electronics Compartment Door” on page 7-5. The installation of the new LCD and FIB assembly is complete. Keyboard/Electronics Compartment Door Introduction The spare electronics compartment door comes with the relevant keyboard overlay (in language required), gasket and fixings screws. However it does not contain liquid crystal display and front panel 7-16 Keyboard/Electronics Compartment Door Rev AA Videojet 1510 Service Manual interface board (LCD and FIB) assembly, cover, and leads. Hence, the replacement instructions are same for both the keyboard and electronics compartment door. Tools and Supplies Required Tools or Supplies Quantity 3 mm Allen Wrench 1 T20 Torx Screwdriver 1 7 mm Nut Spinner 1 Table 7-5:Tools and Supplies Required Warning Read the “Safety Information” on page 7-2 before you perform the below tasks. How to Remove the Old Electronics Compartment Door Do the following tasks to remove the old electronics compartment door: 1 Open the electronics compartment door. Refer to “How to Open the Electronics Compartment Door” on page 7-3. Note: There is no need to open the Control System Board (CSB). Rev AA Keyboard/Electronics Compartment Door 7-17 Videojet 1510 Service Manual 1. Electronics Compartment Door 2. K40 x 10 Torx Screws (x4) 3. Inner Display Cover 4. FIB Ribbon Cable 5. Ground Wire Figure 7-14: Open Electronics Compartment Door 2 Disconnect the front panel interface board (FIB) ribbon cable (item 4, Figure 7-14) from the FIB. 3 Use a T20 Torx screwdriver to remove the four K40 x 10 Torx screws (item 2, Figure 7-14) at the corners of the inner display cover (item 3) on the underside of the electronics compartment door. 4 Use a T20 Torx screwdriver to remove the six K50 x 12 Torx screws (item 1, Figure 7-15 on page 7-19) that hold the electronics compartment door (item 3) to the hinge bracket (item 2). 7-18 Keyboard/Electronics Compartment Door Rev AA Videojet 1510 Service Manual 1. K50 x 12 Torx Screws (x6) 2. Hinge Bracket 3. Electronics Compartment Door Figure 7-15: Remove the Electronics Compartment Door 5 Remove the electronics compartment door from the printer. 6 Disconnect the ground wire from the FIB (item 2, Figure 7-16) that is connected to the keypad tag (item 3). 1. Screw 2. Ground Wire 3. Keypad Tags (x2) Figure 7-16: Ground Wire on Keypad Tag Rev AA Keyboard/Electronics Compartment Door 7-19 Videojet 1510 Service Manual 7 Disconnect the two keyboard-to-FIB ribbon cables (item 1, Figure 717) from connectors X7 and X8 on the periphery of the FIB (item 3). 1. Keyboard-to-FIB Ribbon Cable (x2) 2. K40x10 Torx Screws (x4) 3. FIB Figure 7-17: Remove the FIB 8 Use T20 Torx driver to unscrew the four K40 x 10 Torx screws (item 2) from the four corners of the FIB. 9 Remove the FIB and LCD assembly from the electronics compartment door. 10 Keep the FIB and LCD assembly on an antistatic bubble sheet. 11 Discard the electronics compartment door according to the local regulations. The removal of the old electronics compartment door is complete. How to Install the New Electronics Compartment Door Do the following tasks to install the new electronics compartment door: 1 To attach the old FIB and LCD assembly to the new electronics compartment door, do the following tasks: a. Fit the old FIB and LCD assembly to the new electronics compartment door using four K4 x 10 Torx screws (see Figure 7-17). b. Connect the ground wire to the FIB (see Figure 7-16 on page 7-19). c. Connect the two keyboard to FIB ribbon cables to connectors X7 and X8 on the periphery of the FIB (see Figure 7-17). 7-20 Keyboard/Electronics Compartment Door Rev AA Videojet 1510 Service Manual 2 Fit the electronics compartment door to the hinge bracket using the six K50 x 12 screws (item 1, Figure 7-15 on page 7-19). 3 Fit the inner display cover and tighten the four K40 x 10 screws. Make sure that the cover fits into the gasket all the way round. 4 Connect the FIB ribbon cable to the FIB. 5 Close the electronics compartment door. Refer to “How to Close the Electronics Compartment Door” on page 7-5. The installation of the new electronics compartment door is complete. Ink Core Module Introduction The ink core module comes as a single unit. The only part that you can replace is ink core pump. This instruction sheet describes how to replace the ink core module with and without the pump. 1 2 1. Ink Core Pump 2. Ink Module Figure 7-18: Ink Core Module Rev AA Ink Core Module 7-21 Videojet 1510 Service Manual Tools and Supplies Required Tool or Supply Quantity 2.5 mm Allen Wrench 1 3 mm Allen Wrench 1 T10 Torx Screwdriver 1 7 mm Nut Spinner 1 Side Cutters 1 Table 7-6:Tools and Supplies Required How to Remove the Old Ink Core Module Do the following tasks to remove the old ink core module: 1 Stop the production and remove the printer from the print mode. 2 Log into the Videojet 1510 UI as level 2 or level 3 user. 3 Press the F1 key for Videojet 1510. 4 Turn the knob and open the ink compartment door (see Figure 7-19). Figure 7-19: Unlock Ink Compartment Door 7-22 Ink Core Module Rev AA Videojet 1510 Service Manual 5 Remove the ink and the make-up cartridges from their slots in the module (see Figure 7-20). Figure 7-20: Cartridge Removal 6 Insert an empty solvent cartridge or a special cartridge into the ink cartridge slot. Note: A special cartridge is an empty cartridge used for draining. Note: Do not remove the special cartridge until the Empty Ink Core routine is completed. The smart chip on the cartridge is programmed to allow for one time insertion only. 7 Select Empty Ink Core option for 1510 (see Figure 7-21 on page 7-24). The contents of the ink core will be pumped into the special cartridge. Note: The Empty Ink Core process can take up to 10 minutes and may require two special cartridges. Rev AA Ink Core Module 7-23 Videojet 1510 Service Manual Figure 7-21: Empty Ink Core Note: Do not remove the special cartridge until the routine is completed as a leak can occur. 8 After the Empty Ink Core routine is complete, discard the special cartridge according to hazardous materials (HAZMAT). 9 Turn off the main power switch of the printer. 10 Disconnect the mains power cord from the electrical outlet. 11 Push the plate in the direction shown to open the ink compartment door completely (see Figure 7-22). Figure 7-22: Plate 7-24 Ink Core Module Rev AA Videojet 1510 Service Manual 12 Pull the ink core module out of the ink compartment (see Figure 7-23). Figure 7-23: Pull Ink Core Module 13 Disconnect the ink core module ribbon cable (item 1, Figure 7-24) from the printer interface board (PIB) (see Figure 7-25 on page 7-26). 1. Ink Core Module Ribbon Cable 2. Ground Wire Figure 7-24: Ink Core Module Manifold Rev AA Ink Core Module 7-25 Videojet 1510 Service Manual 14 Disconnect the ground wire (item 2, Figure 7-24 on page 7-25) from the printer cabinet (see Figure 7-25). 1. Ribbon Cable Connection to PIB 2. Spiral Wrap 3. Ring Terminal 4. Ground Wire Connection Figure 7-25: Ground Wire to the Printer Cabinet 15 Cut the ring terminal (item 3, Figure 7-25) from the ground wire and remove the wire from the spiral wrap (item 2). 16 Loosen and remove the two M3 screws (item 1, Figure 7-26 on page 727) that fasten the ink core manifold (item 2) to ink core module using 2.5 mm allen wrench. 7-26 Ink Core Module Rev AA Videojet 1510 Service Manual 1. M3 Screws (x2) 2. Ink Core Manifold 3. Gasket Figure 7-26: Ink Core Module Manifold Note: You must fit the old ink core manifold to the new ink core module immediately. 17 Remove the plate on the ink core manifold of the new ink core module. 18 Fit the old ink core manifold to the new ink core module using the two M3 screws and new gasket immediately (see Figure 7-26). Note: Keep the ink core manifold clean. 19 If you need to replace the ink core module along with the pump, there is no need to remove the pump, discard the ink core module along with the pump, according to hazardous materials (HAZMAT). The removal of the ink core module along with the ink core pump is complete. 20 If you need to replace the ink core module without the pump, you need to first remove and store the pump, and then replace only the ink core module. Refer to “How to Remove the Ink Core Pump” on page 7-28. Rev AA Ink Core Module 7-27 Videojet 1510 Service Manual How to Remove the Ink Core Pump Do the following tasks to remove the ink core pump: 21 Use a T10 Torx screwdriver to remove the two K30 x 12 Torx screws (item 3, Figure 7-27) that fasten the ink core pump cover (item 1) to the ink core module (item 2). 3 1 2 1. Ink Core Pump Cover 2. Ink Core Module 3. K30 x 12 Torx Screws (x2) Figure 7-27: Ink Core Pump Cover 22 Slide the pump cover down the ribbon cable and remove the cover. 23 Discard the pump cover according to the local regulations. 24 Remember the method of routing the pump wire harness inside the ink core module. 25 Disconnect the pump wire harness from JP1 connector on the ink core module interface board. 26 Use the 3 mm allen wrench to remove the two M4 x 35 socket-headcap screws (item 1, Figure 7-28 on page 7-29) that hold the pump saddle clamp (item 2) to the ink core module (item 7). 27 Remove the pump saddle clamp and keep the clamp in a safe location. 7-28 Ink Core Module Rev AA Videojet 1510 Service Manual 28 Disconnect the ground wire from the ink pump earth tag (item 3). See Figure 7-29 on page 7-30 for reference. 1 2 3 4 5 6 7 1. M4 x 35 Socket-head-cap Screw (x2) 2. Pump Saddle Clamp 3. Earth tag 4. Ink Core Pump 5. O-rings 6. Ports on the Ink Core Module 7. Ink Core Module Figure 7-28: Ink Core Module Rev AA Ink Core Module 7-29 Videojet 1510 Service Manual Ground Wire Figure 7-29: Ground Wire Note: Use tissues to absorb the spills from the pump. 29 Gently lift the ink core pump out of the ink core module. 30 Remember the location of the two O-rings (item 5, Figure 7-28 on page 7-29) that seal the pump inlet and outlet ports and discard the Orings. 31 Keep the ink core pump in a safe location to use again. 32 Discard the ink core module (without the pump) according to hazardous materials (HAZMAT). The removal of ink core module without the ink core pump is complete. How to Install the New Ink Core Module Do the following tasks to install the new ink core module: • If you have removed the ink core pump from the old ink core module, you need to fit the old ink core pump to the new ink core module. Refer to “How to Install the Old Ink Core Pump” to install the old ink core pump into the new ink core module. • If you have not removed the ink core pump from the old ink core module, go to “How to Install the New Ink Core Module” on page 731. How to Install the Old Ink Core Pump Do the following tasks to install the old ink core pump into the new ink core module: 1 Remove the two K30 x 12 Torx screws (item 3, Figure 7-27 on page 728) that fasten the ink core pump cover (item 1) to the ink core module (item 2). 2 Slide the pump cover down the ribbon cables. 7-30 Ink Core Module Rev AA Videojet 1510 Service Manual 3 Remove the protective plate on the pump mounting block. 4 Discard the screws, plates, and O-rings. 5 Insert the new O-rings on the ports of the pump before you install the old ink pump. 6 Install the old ink pump over the ports of the new ink core module. Make sure that the two pins go into the two holes of the ink core pump correctly (see Figure 7-30). Pin Figure 7-30: Pins 7 Connect the ground wire to the pump earth tag (see Figure 7-29 on page 7-30). 8 Fit the pump saddle clamp over the old ink core pump using M4 x 35 socket-head-cap screws (item 1, Figure 7-28 on page 7-29). 9 Connect the pump wire harness to the JP1 connector on the ink core module interface board. 10 Feed the ink core ribbon cable and the ground wire towards the back of the cabinet and slide the cover until it is in the correct position. 11 Fasten the ink core pump cover to the ink core module using the K30x12 Torx screws. 12 Go to Step 13 to continue with the installation of the ink core module. How to Install the New Ink Core Module 13 Wind the ground wire around the spiral wrap twice to retain and reconnect to the earth point in the back. 14 Connect the ground wire to the printer cabinet (see Figure 7-25 on page 7-26). 15 Connect the ink core module ribbon cable (item 1, Figure 7-24 on page 7-25) to the PIB. Rev AA Ink Core Module 7-31 Videojet 1510 Service Manual 16 Push the ink core module back into the printer cabinet. 17 Install the smart cartridges. Make sure that the correct fluid types are used. 18 Close the ink compartment door and turn the knob to lock the door. 19 Connect the mains power cord to the electrical outlet. 20 Turn on the main power switch of the printer. 21 Select level 2 or level 3 password as the user level to log into the UI. 22 Check the ink system run hours. The system must display 0 hours. Figure 7-31: View Run Hours 23 Fill the ink core. Note: The process takes approximately 20 minutes to complete the cycle. Figure 7-32: Fill Ink Core Option 7-32 Ink Core Module Rev AA Videojet 1510 Service Manual 24 Remove the printhead cover screw that fastens the printhead cover to the printhead chassis and remove the printhead cover (see Figure 733). 1. Umbilical 2. Printhead Cover 3. Print Engine 4. Printhead Cover Screw 5. Printhead Valve Module Figure 7-33: Printhead Cover Removed Caution To prevent nozzle clogs, always wear rubber gloves whenever the front tubing manifold is disconnected from the printhead valve module. 25 Remove the M2 x 6 socket-head-cap screw that attaches the front tubing manifold to the printhead valve module. 26 Fit the nozzle bypass manifold that has the loop of tube to the printhead valve module using the M2 x 6 socket-head screw (see Figure 7-34 on page 7-34). Rev AA Ink Core Module 7-33 Videojet 1510 Service Manual 1 2 3 5 3 4 1. M2 x 6 Socket-head Screw 2. Bypass Manifold 3. Tube 4. Quick Disconnect 5. 2 Way Manifold Gasket Figure 7-34: Bypass Manifold 27 Perform Umbilical Purge for 10 to 15 minutes (refer to the “Umbilical Purge” on page 8-3 for procedure). 28 Remove the nozzle bypass manifold and the 2 way manifold gasket. 29 Loosely connect the front tubing manifold along with a new gasket (do not tighten). 30 Put a full make-up fluid cartridge in the ink compartment. 31 Put a receptacle under the printhead to catch the make-up fluid during flushing. 32 Perform a System Flush Purge. Refer to the “System Flush Purge” on page 8-5 for procedure. Make-up fluid will flow from the two way manifold into the receptacle. Flushing will automatically stop when the purge cycle is complete. 33 Tighten the 2 way front tubing manifold to printhead valve module. 34 Perform the quick start (see Figure 7-35 on page 7-35). 7-34 Ink Core Module Rev AA Videojet 1510 Service Manual Figure 7-35: Quick Start 35 Check the ink stream alignment and adjust if necessary (refer to the “Align the Ink Stream” on page 4-26 for procedure). 36 Perform a clean stop, and then a clean start to check the performance. Press the F1 key to perform clean start or clean stop. Note: Put a paper towel below the printhead when you perform a clean start and stop. The installation of the new ink core module is complete. Ink Core Pump Tools and Supplies Required Tools or Supplies Quantity T10 Torx Screwdriver 1 3 mm Allen Wrench 1 Table 7-7:Tools and Supplies Rev AA Ink Core Pump 7-35 Videojet 1510 Service Manual Warning Read the “Safety Information” on page 7-2 before you perform the below tasks. How to Remove the Old Ink Core Pump Do the following tasks to remove the old ink core pump: 1 Pull the ink core module out of the ink compartment (see Figure 7-36). Figure 7-36: Ink Core Module Figure 7-37 shows how the ink core module ribbon cable, and the ground wire are routed through the ink pump cover. 1. Ink Core Module Ribbon Cable 2. Ground Wire Figure 7-37: Ink Core Module Ribbon Cable 7-36 Ink Core Pump Rev AA Videojet 1510 Service Manual 2 Use a T10 Torx screwdriver to remove the two K30 x 12 Torx screws (item 3, Figure 7-38) that fasten the ink pump cover (item 2) to the ink core module. 3 2 1 1. Ink Core Pump 2. Ink Core Pump Cover 3. K30 x 12 Torx Screws (x2) Figure 7-38: Ink Core Pump Cover 3 Lift the ink pump cover and gently slide it towards the back of the cabinet, exposing the pump. 4 Feed the ink core module ribbon cable and the ground wire through the pump cover to allow it to be repositioned. 5 Remember the method of routing the pump wire harness inside the ink core module. 6 Disconnect the pump wire harness from JP1 connector on the ink core module interface board. 7 Use the 3 mm allen wrench to remove the two M4 x 35 socket-headcap screws (item 1, Figure 7-40 on page 7-39) that hold the pump saddle clamp (item 2) to the ink core module (item 7). 8 Remove the pump saddle clamp. 9 Disconnect the ground wire from the ink core pump earth tag (item 3). See Figure 7-39 on page 7-38 for reference. Rev AA Ink Core Pump 7-37 Videojet 1510 Service Manual Ground Wire Figure 7-39: Ground Wire Note: Use tissues to absorb the spills from the pump. 10 Gently lift the ink core pump out of the ink core module. 11 Remember the location of the two O-rings (item 5) that seal the pump inlet and outlet ports and discard the O-rings. 7-38 Ink Core Pump Rev AA Videojet 1510 Service Manual 1 2 3 4 5 6 7 1. M4 x 35 Socket-head-cap Screws 2. Pump Saddle Clamp 3. Earth Tag 4. Ink Core Pump 5. O-rings 6. Ports on the Ink Core Module 7. Ink Core Module Figure 7-40: Ink Core Module 12 Dispose the ink core pump as per local regulations. The removal of the old ink core pump is complete. How to Install the New Ink Core Pump Do the following tasks to install the new ink core pump: 1 Insert the new O-rings (item 5, Figure 7-40) on the ports of the pump before you install the new pump. 2 Install the new ink pump onto the mounting block. Rev AA Ink Core Pump 7-39 Videojet 1510 Service Manual Make sure that the two pins go into the two holes of the ink core pump correctly (see Figure 7-41). Pin Figure 7-41: Pins 3 Connect the ground wire to the pump earth tag (see Figure 7-39 on page 7-38). 4 Fit the pump saddle clamp over the new ink core pump using M4 x 35 socket-head-cap screws (item 1, Figure 7-40 on page 7-39). 5 Connect the pump wire harness to the JP1 connector on the ink core module interface board. 6 Put the ink core pump cover over the ink core module in correct position. 7 Feed the core ribbon cable and the ground wire towards the back of the cabinet and slide the cover until it is in the correct position. 8 Fasten the ink core pump cover to the ink core module using the K30x12 Torx screws. 9 Push the core module back into the printer cabinet. 10 Close the ink compartment door. Refer to “How to Close the Ink Compartment Door” on page 7-7. The installation of the new ink core pump is complete. 7-40 Ink Core Pump Rev AA Videojet 1510 Service Manual Print Engine Assembly Tools and Supplies Required Tool or Supplies Quantity 1.5 mm Allen Wrench 1 Table 7-8: Tools and Supplies How to Remove the Old Print Engine Assembly 1 2 3 4 11 10 5 9 6 7 8 1. M2 x 6 Socket-head-cap Long Screw (x6) 2. Nozzle Assembly 3. Charge Electrode 4. Deflector Plate 5. Print Engine Deck 6. Gutter Tube 7. Print Engine Gasket 8. M2 Spring Washer 9. Printhead Valve Module 10. Front Tubing Manifold Gasket 11. Front Tubing Manifold Figure 7-42: Print Engine Rev AA Print Engine Assembly 7-41 Videojet 1510 Service Manual Do the following tasks to remove the old print engine assembly: 1 Turn off the mains power switch of the printer. 2 Disconnect the mains power cord from the electrical outlet. 3 Remove the printhead cover screw that fastens the printhead cover to the printhead chassis and remove the printhead cover (see Figure 743). 1. Umbilical 2. Printhead Cover 3. Print Engine 4. Printhead Cover Screw 5. Printhead Valve Module Figure 7-43: Printhead Cover Removed 4 Remove the six M2 x 6 socket-head-cap screws (item 1, Figure 7-42 on page 7-41) that are used to fasten the print engine to the chassis. Caution To prevent nozzle clogs, always wear rubber gloves whenever the front tubing manifold is disconnected from the printhead valve module. 5 Remove the M2 x 6 socket-head-cap screw that fastens the front tubing manifold (item 11) to the printhead valve module (item 9). 6 Tilt the print engine to one side carefully to access the undercarriage. 7 Remove the M2 x 6 socket-head-cap screw and M2 spring washer (item 8) that attach the EHT/HV wire (red wire) to the undercarriage of the print engine. 8 Apply pressure vertical to the print engine deck as the gutter slides into the chassis. 9 Discard the old print engine, print engine gasket, and the front tubing manifold gasket according to local regulations. 7-42 Print Engine Assembly Rev AA Videojet 1510 Service Manual The removal of the old print engine assembly is complete. How to Install the New Print Engine Assembly Do the following tasks to install the new print engine assembly: 1 Take the new print engine assembly and fit the new print engine gasket (item 7, Figure 7-42 on page 7-41) to the print engine. 2 Put the front tubing manifold gasket (item 10) into the manifold. 3 Attach the EHT/HV wire (red wire) to the undercarriage of the print engine using one M2 x 6 socket-head-cap screw and one M2 spring washer (item 8). 4 Carefully fit the print engine to the chassis and make sure to align the gutter tube with its opening in the chassis. Note: Make sure that the gutter is installed correctly or gutter can be pushed out of place. 5 Visually inspect that the print engine gasket is seated properly before securing the print engine to the chassis. 6 Fit the print engine to the chassis using the six M2 x 6 socket-head-cap screws (item 1). 7 Connect the mains power cord to the electrical outlet. 8 Turn on the main power switch of the printer. 9 Log into user interface (UI) using Level 3 password. 10 Perform a system flush purge (refer to the “System Flush Purge” on page 8-5 for procedure). 11 Fit the front tubing manifold (item 11, Figure 7-42 on page 7-41) to the printhead valve module (item 9) using one M2 x 6 socket-head-cap screw. 12 Run the printer for approximately 15 minutes to let the printer stabilize. 13 Perform viscosity calibration (refer to Service Manual for procedure). 14 Turn on the inkjet and check the ink stream alignment. If required, align the ink stream (refer to Service Manual for procedure). 15 Fit the printhead cover to the printhead chassis using the printhead cover screw. 16 Perform EHT calibration (refer to Service Manual for procedure). The installation of the new print engine assembly is complete. Rev AA Print Engine Assembly 7-43 Videojet 1510 Service Manual Printhead Valve Module Tools and Supplies Required Tool or Supply Quantity 1.5 mm Allen Wrench 1 Table 7-9:Tools and Supplies How to Remove the Old Printhead Valve Module Do the following tasks to remove the old printhead valve module: Note: Make sure that the printhead is above the level of the ink core module when performing this procedure. Otherwise, the ink in the ink core module may flow through the umbilical and leak through the tubing manifold once it is removed. 1 Turn off the main power switch of the printer. 2 Disconnect the mains power cord from the electrical outlet. 3 Remove the printhead cover screw that fastens the printhead cover to the printhead chassis and remove the printhead cover (see Figure 744). 1. Umbilical 2. Printhead Cover 3. Print Engine 4. Printhead Cover Screw 5. Printhead Valve Module Figure 7-44: Printhead Cover Removed 7-44 Printhead Valve Module Rev AA Videojet 1510 Service Manual Caution To prevent nozzle clogs, always wear rubber gloves whenever the front tubing manifold is disconnected from the printhead valve module. 4 Remove the M2 x 6 socket-head-cap screw (item 4, Figure 7-45) that attaches the front tubing manifold (item 5) to the printhead valve module (item 2). 1 9 2 8 3 7 4 6 1. M2 x 6 Socket-head-cap Screw (x6) 2. Printhead Valve Module 3. Printhead Valve Module Gasket 4. M2 x 6 Socket-head-cap Screw 5. 2 Way Manifold Assembly (Front Tubing Manifold) 5 6. Front Tubing Manifold Gasket 7. Rear Tubing Manifold Gasket 8. 3 Way Manifold Assembly (Rear Tubing Manifold) 9. M2 x 6 Socket-head Cap Screw (x2) Figure 7-45: Printhead Valve Module 5 Remove the two M2 x 6 socket-head-cap screws (item 9, Figure 7-45) that attach the rear tubing manifold (item 8) to the printhead valve module. 6 Remove the six M2 x 6 socket-head-cap screws (item 1) that attach the printhead valve module to the chassis. 7 Lift the front and rear tubing manifolds away from the printhead valve module. Note: Prevent the bending of the tubing to avoid the damage to the tubing. Rev AA Printhead Valve Module 7-45 Videojet 1510 Service Manual 8 Carefully lift and remove the printhead valve module from the chassis. 9 When the printhead valve module is removed from the chassis, carefully rotate the printhead valve module to one side to access the undercarriage. 10 Detach the gutter tube from the gutter return pipe (item 2, Figure 746) carefully. Note: Replace the gutter tube if found damaged. 11 Discard the old printhead valve module gasket (item 3, Figure 7-45 on page 7-45), front tubing manifold gasket (item 6) and rear tubing manifold gasket (item 7) according to the local regulations. The removal of the old printhead valve module is complete. 1. Printhead Valve Module 2. Gutter Return Pipe Figure 7-46: Gutter Return Pipe How to Install the New Printhead Valve Module Do the following tasks to install the new printhead valve module: 1 Fit the new rectangular printhead valve module gasket onto the chassis. Note: Make sure that the tab on gasket is aligned to the notch on chassis. 2 Tilt the new printhead valve module to one side and insert the gutter tube into the gutter return pipe. 3 Press the printhead valve module into the chassis. Note: Make sure that the printhead valve module gasket is seated correctly. 7-46 Printhead Valve Module Rev AA Videojet 1510 Service Manual 4 Fit the printhead valve module using M2 x 6 socket-head-cap screws in the order given below: a. Fit the first screw, facing the module with the printhead pointing to the right (see Figure 7-47). Figure 7-47: Order of Placing Screws - First Screw b. Fit the second screw (see Figure 7-48). . Figure 7-48: Order of Placing Screws - Second Screw 5 Fit the remaining four screws in any order. 6 Fit the rear tubing manifold to the printhead valve module using the two M2 x 6 socket-head screws and the new rear tubing manifold gasket. 7 Put the 2 way manifold gasket provided in the bypass kit on the ports of the printhead valve module. 8 Fit the nozzle bypass manifold (that has the loop of tube) to the printhead valve module using the M2 x 6 socket-head screw (see Figure 7-49 on page 7-48). Rev AA Printhead Valve Module 7-47 Videojet 1510 Service Manual 1 2 3 5 3 4 1. M2 x 6 Socket-head Screw 2. Nozzle Bypass Manifold 3. Tube 4. Quick Disconnect 5. 2 way Manifold Gasket Figure 7-49: Bypass Manifold 9 Connect the mains power cord to the electrical outlet. 10 Turn on the main power switch of the printer. 11 Log into the User Interface (UI). 12 Perform umbilical purge (refer to the “Umbilical Purge” on page 8-3). 13 Perform system flush purge (refer to the“System Flush Purge” on page 8-5). 14 Remove the nozzle bypass manifold and the 2-way manifold gasket. 15 Put the new front tubing manifold gasket on the ports. 16 Fit the front tubing manifold to the printhead valve module using a M2 x 6 socket-head screw. 17 Fit the printhead cover to the printhead chassis using the printhead cover screw. The installation of the new printhead valve module is complete. 7-48 Printhead Valve Module Rev AA Videojet 1510 Service Manual Umbilical Assembly Introduction The umbilical assembly with printhead (see Figure 7-50) contains new print engine and new printhead valve module attached to a new printhead chassis. Refer to “Umbilical Assembly (with Printhead) Replacement” on page 7-51. Figure 7-50: Umbilical with Printhead The umbilical assembly with printhead chassis (see Figure 7-51 on page 750) comes without the print engine and printhead valve module attached. So, remove the old print engine and printhead valve module from the old printhead chassis and attach the modules to the new printhead chassis. Refer to “Umbilical Assembly (with Printhead Chassis) Replacement” on page 7-68. Rev AA Umbilical Assembly 7-49 Videojet 1510 Service Manual Figure 7-51: Umbilical with Printhead Chassis Tools and Supplies Required Tools or Supplies Quantity 7 mm Nut Driver 1 T10 TORX Screwdriver 1 #2 Phillips Screwdriver 1 Side Cutters 1 1.5 mm Allen Wrench (for print engine and printhead valve module replacement) 1 2.5 mm Allen Wrench 1 3 mm Allen Wrench 1 Crimp Pliers 1 Sharp Knife 1 Bypass Kit (Part Number 399247) 1 Table 7-10:Tools and Supplies 7-50 Umbilical Assembly Rev AA Videojet 1510 Service Manual Umbilical Assembly (with Printhead) Replacement How to Remove the Umbilical Assembly (with Printhead) Do the following tasks to remove the umbilical assembly along with printhead: 1 Turn off the main power switch of the printer. 2 Disconnect the mains power cord from the electrical outlet. 3 Turn the knob and open the ink compartment door (see Figure 7-52 and Figure 7-53 on page 7-52). Figure 7-52: Unlock Ink Compartment Door 4 Push the plate (item 2, Figure 7-53 on page 7-52) in the direction shown to open the ink compartment door (item 1) completely. Rev AA Umbilical Assembly (with Printhead) Replacement 7-51 Videojet 1510 Service Manual 5 Pull the ink core module out of the ink compartment. 1. Ink Compartment Door 2. Plate Figure 7-53: Open Ink Compartment Door 6 Loosen and remove the two M3 screws that fasten the ink core manifold to the ink core module using the 2.5 mm allen wrench (see Figure 7-55 on page 7-53). 1. Ink Core Module Ribbon Cable 2. Ground Wire Figure 7-54: Ink Core Module Manifold 7-52 Umbilical Assembly (with Printhead) Replacement Rev AA Videojet 1510 Service Manual 1. M3 Screws (x2) 2. Ink Core Manifold 3. Gasket Figure 7-55: Ink Core Manifold 7 Remove the p-clip in the back of the cabinet that holds all the tubes. 8 Remove the spiral wrap that holds the tubes that connect to the ink core manifold (see Figure 7-54 on page 7-52). 9 Cut the tubes shown in Figure 7-56 on page 7-54 with a sharp knife 16 mm away from the face of the ink core manifold. Caution Do not remove the ground wire (item 5, Figure 7-54 on page 7-52) that is connected to ink core. Note: Keep the tubes to use again during the installation. Note: Use tissues to absorb the spills. Rev AA Umbilical Assembly (with Printhead) Replacement 7-53 Videojet 1510 Service Manual 1. Clear Tube (5/32”) 2. Green Stripe Ink Tube (1/8”) 3. Air Vent 4. Blue Stripe Tube (1/8”) 5. Black Stripe Make-up Tube (1/8”) Figure 7-56: Cut Tubes 10 Cut the 5/32 inch tube from the gutter pump manifold with a sharp knife, 16 mm away from the face of the gutter pump manifold. 11 Pull the tubes out of the p-clips and make sure that the blue and brown sleeved tubes kept. 12 Cut the tube left on the gutter pump manifold barb vertically down with a knife and remove the tube. Warning Before you open the electronics compartment door, wear anti-static wrist straps and ground yourself to the chassis of the cabinet. Failure to follow this warning can cause both personal injury and damage to the printer. 13 Use the 3 mm allen wrench to remove the two M4 screws (see Figure 7-57 on page 7-55) that fasten the electronics compartment door to the printer cabinet. 7-54 Umbilical Assembly (with Printhead) Replacement Rev AA Videojet 1510 Service Manual Figure 7-57: Electronics Compartment Door 14 Open the electronics compartment door (see Figure 7-58). Figure 7-58: Electronics Compartment Opened 15 Push the latch down to open the control system board (CSB). See Figure 7-59 on page 7-56. Rev AA Umbilical Assembly (with Printhead) Replacement 7-55 Videojet 1510 Service Manual 1 2 1. CSB 3. Latch Figure 7-59: Latch 16 If the positive air kit is fitted, then do the following steps, else go to Step 17 on page 7-56. a. Disconnect the silicon tubes that are connected to the inlet and outlet of the positive air pump. b. Disconnect the yellow striped tube (routed through the tube interface) from the positive air filter. c. Pull the yellow striped tube out of the p-clips. 17 Remove the four K30 x 10 pan-head torx screw (item 2, Figure 7-60 on page 7-57) that attach the tube interface (item 1) on the dividing floor (item 3) inside the electronics compartment. 7-56 Umbilical Assembly (with Printhead) Replacement Rev AA Videojet 1510 Service Manual 1. Tube Interface 2. K30 x 10 Pan-head Torx Screw (x4) 3. Dividing Floor Figure 7-60: Remove Tube Interface 18 Release the p-clips that hold the following cables: • 21 core (connects to the PHEAD1 and PHEAD2 connectors) and other cables • Red EHT plug, the EHT cable and the fan cable • PSU cable and other cables Note: Remember the connections to connect the cables again during the installation. 19 Disconnect the connectors PHEAD1 and PHEAD2 connectors from the printer interface board (PIB). Note: The RF clamp holds the 21 core cable. 20 Remove and keep the two nuts that attach RF clamp to the cabinet (see Figure 7-61 on page 7-58). 21 Disconnect the red EHT plug from the EHT. Rev AA Umbilical Assembly (with Printhead) Replacement 7-57 Videojet 1510 Service Manual RF Clamp Figure 7-61: RF Clamp 22 Cut the ty-raps that hold the charge tunnel cable along with the PSU cable. 23 Disconnect the 4-way charge tunnel wire connector from the control system board (CSB). 24 Disconnect the printhead ground wires that are connected inside the electronics compartment. 25 Remove the four M4 x 8 counter-sunk screws (item 1, Figure 7-62 on page 7-59) that attach the conduit assembly (item 2) to the printer cabinet. 7-58 Umbilical Assembly (with Printhead) Replacement Rev AA Videojet 1510 Service Manual 1. M4 x 8 Counter-sunk Screw (x4) 2. Conduit Assembly 3. Elbow Gasket Figure 7-62: Remove Conduit 26 Pull the wires and tubes along with the ink core manifold and tube interface out of the opening on the side of the cabinet. 27 Discard the old umbilical assembly along with the printhead according to local regulations. The removal of the umbilical assembly with the complete printhead is complete. Rev AA Umbilical Assembly (with Printhead) Replacement 7-59 Videojet 1510 Service Manual How to Install the Umbilical Assembly (with Printhead) Do the following tasks to install the umbilical assembly along with the printhead: 1 Route the tubes and cables of the new umbilical through the opening on the side of the cabinet along with the ink core manifold and the tube interface into the electronics compartment. 2 Route the ink core manifold and the yellow striped tube through the hole in the dividing floor. 3 Put the elbow gasket in the correct position on the opening on the side of the cabinet. 4 Tighten the four M4 x 8 counter-sunk screws to fasten the conduit assembly to the printer cabinet (see Figure 7-62 on page 7-59). 5 Connect the printhead ground wires inside the electronics compartment. 6 Reconnect the PHEAD1 and PHEAD2 connectors to the printer interface board (PIB). 7 Group the following cables into the p-clips: • 21 core (connects to the PHEAD1 and PHEAD2 connectors) and other cables • Red EHT plug, the EHT cable and the fan cable • PSU cable and other cables 8 Refit all the p-clips to the cabinet. 9 Wrap the three ty-raps around the charge tunnel cable along with the PSU cable. 10 Connect the red EHT plug to EHT. 11 Reconnect the 4-way charge tunnel wire connector to the CSB. 12 Fit RF cable clamp over the 21 core cable in area where braid is exposed. Caution Make sure that the RF clamp is seated over the exposed braid so that the braid is grounded to the cabinet. 13 Fit the RF clamp using the two nuts (see Figure 7-61 on page 7-58). 7-60 Umbilical Assembly (with Printhead) Replacement Rev AA Videojet 1510 Service Manual 14 Tighten the four K30 x 10 pan-head torx screws to fasten the tube interface on the dividing floor inside the electronics compartment (see Figure 7-60 on page 7-57). 15 If the positive air pump is fitted then, do the following tasks: a. Connect the silicon tube to the yellow striped tube that is routed from the umbilical. Crimp the silicon tube and the yellow striped tube with the O-clip. b. Connect the silicon tube to the outlet of the positive air pump. Figure 7-63: Route Yellow Striped Tube c. Remove the sealing cap from the end of the yellow striped tube. d. Route the yellow striped tube through the hole in the tube interface (see Figure 7-63) and through the p-clips inside the ink compartment. e. Connect the yellow striped tube to the outlet of the positive air filter. f. Remove the sealing cap from the other end of the yellow striped tube in the electronics compartment. g. Fit the silicon tube to the yellow striped tube. h. Connect the silicon tube to the inlet of the positive air pump. 16 Close the CSB. 17 Fasten the electronics compartment door to the printer cabinet using the four M4 screws. Rev AA Umbilical Assembly (with Printhead) Replacement 7-61 Videojet 1510 Service Manual 18 Route the 5/32 inch tube through the p-clip and connect the tube to the barb on the gutter pump manifold. 19 Group the following tubes using the spiral wrap: • Black stripe tube • Green stripe tube • Blue stripe tube • 5/32 inch clear tube • 1/8 inch clear tube and red stripe tube from the new printhead 20 Connect all the tubes to the correct ports on the ink core manifold (see Figure 7-64). 1. Clear Tube (5/32 inch) 2. Red Stripe Tube (1/8 inch) 3. Green Strip Ink Tube (1/8 inch) 4. Air Vent 5. Blue Stripe Tube (1/8 inch) 6. Black Stripe Make-up Tube (1/8 inch) 7. Clear Tube (1/8 inch) Figure 7-64: Tubes to Ink Core Manifold 21 Use the two M3 screws to fasten the ink core manifold to ink core module (see Figure 7-55 on page 7-53). 22 Take all the tubes but the vent tube and the ground wire to the ink core and wrap the spiral wrap. 23 Fit the p-clip at the rear of the cabinet to hold the tubes. 24 Push the ink core module into the ink compartment. 25 Close the ink compartment door. 7-62 Umbilical Assembly (with Printhead) Replacement Rev AA Videojet 1510 Service Manual 26 Remove the printhead cover screw that fastens the printhead cover to the printhead chassis and remove the printhead cover (see Figure 765). 1. Umbilical 2. Printhead Cover 3. Print Engine 4. Printhead Cover Screw 5. Printhead Valve Module Figure 7-65: Printhead Cover Removed Caution To prevent nozzle clogs, always wear rubber gloves whenever the front tubing manifold is disconnected from the printhead valve module. 27 Remove the M2 x 6 socket-head-cap screw that fastens the front tubing manifold (item 11, Figure 7-66 on page 7-64) to the printhead valve module (item 9). Rev AA Umbilical Assembly (with Printhead) Replacement 7-63 Videojet 1510 Service Manual 1 2 3 4 11 10 5 9 6 7 8 1. M2 x 6 Socket-head-cap Screw (x6) 2. Nozzle Assembly 3. Charge Electrode 4. Deflector Plate 5. Print Engine Deck 6. Gutter Tube 7. Print Engine Gasket 8. M2 Spring Washer 9. Printhead Valve Module 10. Front Tubing Manifold Gasket 11. Front Tubing Manifold Figure 7-66: Print Engine 28 Remove the front tubing manifold gasket (item 10, Figure 7-66) and keep it in a safe location to use again. 29 Put the 2-way manifold gasket provided in the bypass kit on the ports of the printhead valve module. 30 Fit the nozzle bypass manifold (that has the loop of tube) to the printhead valve module using the M2 x 6 socket-head screw (see Figure 7-67 on page 7-65). 31 Reconnect the mains power cord from the electrical outlet. 7-64 Umbilical Assembly (with Printhead) Replacement Rev AA Videojet 1510 Service Manual 32 Turn on the main power switch of the printer. 1 2 3 5 3 4 1. M2 x 6 Socket-head Screw 2. Bypass Manifold 3. Tubing 4. Quick Disconnect 5. 2 Way Manifold Gasket Figure 7-67: Bypass Manifold 33 Log into the User Interface (UI). 34 Put a receptacle under the printhead to catch the make-up fluid during flushing. 35 Perform an umbilical purge to prime the ink supply system (see Figure 7-68 on page 7-66). Refer to the Service Manual for the umbilical purge procedure. Rev AA Umbilical Assembly (with Printhead) Replacement 7-65 Videojet 1510 Service Manual Figure 7-68: Umbilical Purge 36 Perform a system flush purge (see Figure 7-69 on page 7-66). Refer to the Service Manual for the detailed system flush purge procedure. Make-up fluid will flow from the two way manifold into the receptacle. Flushing will automatically stop when the purge cycle is complete. 37 Remove the nozzle bypass manifold and the 2-way manifold gasket. 38 Put the new front tubing manifold gasket on the ports. 39 Fit the front tubing manifold to the printhead valve module using a M2 x 6 socket-head screw. Figure 7-69: System Flush Purge 7-66 Umbilical Assembly (with Printhead) Replacement Rev AA Videojet 1510 Service Manual 40 Perform EHT calibration (see Figure 7-70). Refer to the Service Manual for the detailed procedure. Figure 7-70: Calibrate EHT 41 Run the printer for approximately 15 minutes to let the printer stabilize. 42 Perform viscosity calibration (refer to Figure 7-71). Refer to the Service Manual for the detailed procedure. Figure 7-71: Viscosity Calibration 43 Turn on the inkjet and check the ink stream alignment. Refer to the Service Manual for the detailed procedure of ink stream alignment. 44 Fit the printhead cover to the printhead chassis using the printhead cover screw. The installation of umbilical assembly with complete printhead is complete. Rev AA Umbilical Assembly (with Printhead) Replacement 7-67 Videojet 1510 Service Manual Umbilical Assembly (with Printhead Chassis) Replacement How to Remove the Umbilical Assembly (with Printhead Chassis) Do the following tasks to remove the umbilical assembly (with printhead chassis): How to Remove the Print Engine from Old Printhead Do the following tasks to remove the print engine: 1 Turn off the main power switch of the printer. 2 Disconnect the mains power cord from the electrical outlet. 3 Remove the printhead cover screw that fastens the printhead cover to the printhead chassis and remove the printhead cover (see Figure 7-65 on page 7-63). 4 Remove the six M2 x 6 socket-head-cap screws (item 1, Figure 7-66 on page 7-64) that are used to fasten the print engine to the chassis. Caution To prevent nozzle clogs, always wear rubber gloves whenever the front tubing manifold is disconnected from the printhead valve module. 5 Remove the M2 x 6 socket-head-cap screw that fastens the front tubing manifold (item 11) to the printhead valve module (item 9). 6 Apply pressure vertical to the print engine deck as the gutter slides into the chassis. 7 Tilt the print engine to one side carefully to access the undercarriage. 8 Remove the M2 x 6 socket-head-cap screw and M2 spring washer (item 8) that attach the EHT/HV wire (red wire) to the undercarriage of the print engine. 9 Discard the print engine gasket, and the front tubing manifold gasket according to the local regulations. The print engine removal is complete. 7-68 Umbilical Assembly (with Printhead Chassis) Replacement Rev AA Videojet 1510 Service Manual How to Remove the Printhead Valve Module from Old Printhead Do the following tasks to remove the printhead valve module: Note: Make sure that the printhead is above the level of the ink core module when you do this procedure. Else, the ink in the ink core module can flow through the umbilical and leak through the tubing manifold after it is removed. 1 9 2 8 3 7 4 6 1. M2 x 6 Socket-head-cap Screw (x6) 2. Printhead Valve Module 3. Printhead Valve Module Gasket 4. M2 x 6 Socket-head-cap Screw 5. 2 Way Manifold Assembly (Front Tubing Manifold) 5 6. Front Tubing Manifold Gasket 7. Rear Tubing Manifold Gasket 8. 3 Way Manifold Assembly (Rear Tubing Manifold) 9. M2 x 6 Socket-head Cap Screws (x2) Figure 7-72: Printhead Valve Module 10 Remove the two M2 x 6 socket-head-cap screws (item 9, Figure 7-72) that attach the rear tubing manifold (item 8) to the printhead valve module. 11 Keep the rear tubing manifold in the old printhead chassis. 12 Remove the six M2 x 6 socket-head-cap screws (item 1) that attach the printhead valve module to the chassis. 13 Lift the front and rear tubing manifold away from the printhead valve module. Note: Prevent the bending of the tubing, because the tubing can get damaged. 14 Carefully lift the printhead valve module from the chassis. Rev AA Umbilical Assembly (with Printhead Chassis) Replacement 7-69 Videojet 1510 Service Manual 15 When the printhead valve module is removed from the chassis, carefully rotate the printhead valve module to one side to access the undercarriage. 16 Detach the gutter tube from the gutter return pipe (item 2, Figure 773) carefully. 17 Discard the old printhead valve module gasket (item 3, Figure 7-72 on page 7-69), and rear manifold tubing gasket (item 7) according to the local regulations. 1. Printhead Valve Module 2. Gutter Return Pipe Figure 7-73: Gutter Return Pipe The printhead valve module removal is complete. 18 Follow Step 3 on page 7-51 till Step 26 on page 7-59 under “How to Remove the Umbilical Assembly (with Printhead)” on page 7-51. 19 Discard the old umbilical assembly and the printhead chassis according to the local regulations. The removal of the umbilical assembly with printhead chassis is complete. How to Install the Umbilical Assembly (with Printhead Chassis) Do the following tasks to install the umbilical assembly: 1 Follow Step 1 on page 7-60 till Step 25 on page 7-62 under “How to Install the Umbilical Assembly (with Printhead)” on page 7-60. 7-70 Umbilical Assembly (with Printhead Chassis) Replacement Rev AA Videojet 1510 Service Manual How to Install the Printhead Valve Module Do the following tasks to install the printhead valve module: 2 Fit the new rectangular printhead valve module gasket onto the chassis. Note: Make sure that the tab on gasket is aligned to the notch on chassis. 3 Tilt the printhead valve module to one side and insert the gutter tube into the gutter return pipe. Note: Replace the gutter return tube if the tube is damaged. 4 Press the printhead valve module into the chassis. Note: Make sure that the printhead valve module gasket is seated correctly. 5 Attach the printhead valve module using M2 x 6 socket-head-cap screws in the order given below: a. Fit the first screw, facing the module with the printhead pointing to the right (see Figure 7-74). Figure 7-74: Order of Placing Screws- First Screw b. Fit the second screw (see Figure 7-75) . Figure 7-75: Order of Placing Screws- Second Screw 6 Fit the remaining four screws in any order. 7 Remove the cap attached to the rear manifold on the new chassis. The gasket comes out. 8 Put the rear manifold gasket on the ports of the old printhead valve. Rev AA Umbilical Assembly (with Printhead Chassis) Replacement 7-71 Videojet 1510 Service Manual 9 Fit the old rear tubing manifold to the printhead valve module using the two M2 x 6 socket-head screws. The printhead valve module installation is complete. How to Install the Old Print Engine Do the following tasks to install the old print engine: 10 Take the old print engine assembly and fit the new print engine gasket (item 7, Figure 7-66 on page 7-64) to the print engine. 11 Attach the EHT wire (red wire) to the undercarriage of the print engine using one M2 x 6 socket-head-cap screw and one M2 spring washer (item 7). 12 Fit the new print engine gasket. 13 Carefully fit the print engine to the chassis and make sure to align the gutter tube with its opening in the chassis. Note: Make sure that the gutter is installed correctly or gutter can be pushed out of place. 14 Visually inspect that the print engine gasket is seated properly before securing the print engine to the chassis. 15 Fit the print engine to the chassis using the six M2 x 6 socket-head-cap screws (item 1). The print engine installation is complete. 16 Follow the steps from Step 29 on page 7-64 to Step 38 on page 7-66. 17 Fit the front tubing manifold to the printhead valve module using a M2 x 6 socket-head screw. 18 Follow the steps from Step 40 on page 7-67 to Step 44 on page 7-67. The installation of the umbilical assembly with printhead chassis is complete. 7-72 Umbilical Assembly (with Printhead Chassis) Replacement Rev AA Videojet 1510 Service Manual Printer Interface Board Tools and Supplies Required Tool or Supply Quantity 3 mm Allen Wrench 1 Table 7-11:Tools and Supplies Warning Read the “Safety Information” on page 7-2 before you perform the below tasks. How to Remove the Old Printer Interface Board Do the following tasks to remove the old printer interface board (PIB): 1 Open the electronics compartment door (refer to “How to Open the Electronics Compartment Door” on page 7-3). Note: Before removal, remember the connectors connected to the PIB. 2 Disconnect all the connectors from the PIB (see Figure 7-76 on page 774). 3 Open the ink compartment door (refer to “How to Open the Ink Compartment Door” on page 7-5) and pull the ink core module out to access the PIB connectors. 4 Disconnect all the connectors from the PIB (see Figure 7-77 on page 774). Rev AA Printer Interface Board 7-73 Videojet 1510 Service Manual 7 8 9 10 1 2 3 4 5 6 1. 10-way Printhead Connector 2. 12-way Printhead Connector 3. EHT Cable Connector 4. Positive Air Pump Connector 5. Electronics Compartment Fan Connector 6. CSB Ribbon Cable Connectors (x3) 7. USB Connector 8. PCB1 Connector 9. PCB 2 Connector 10. PCB 3 Connector Figure 7-76: PIB Connectors - Electronics Compartment Side 4 3 2 1 1. Ribbon Cable Connector from Ink Door 2. Ink Compartment Fan Connector 3. 16-way Ink Core Module Ribbon Cable Connector 4. 20-way Ink Core Module Ribbon Cable Connector Figure 7-77: PIB Connectors - Ink Compartment Side 5 Remove the six M4 screws (item 1, Figure 7-78 on page 7-75) and M4 ET washers (item 2) to detach the PIB (item 3) from inside the cabinet. 6 Remove the gasket (item 4). 7 Discard the PIB, M4 screws, washers and gasket according to the local regulations. 7-74 Printer Interface Board Rev AA Videojet 1510 Service Manual 1 2 3 4 1. M4 Screws (x6) 2. ET Washers (x6) 3. Printer Interface Board 4. Gasket Figure 7-78: PIB Inside the Cabinet The removal of the old PIB is complete. How to Install the New Printer Interface Board Do the following tasks to install the new PIB: 1 Put the gasket on the dividing floor over the six upstanding threaded bushes in the electronics compartment. 2 Put the new PIB on the gasket. 3 Fit the new PIB to the cabinet with M4 screws and M4 ET washers. 4 Reconnect all the cables and connectors above and below the new PIB. 5 Close the CSB. 6 Close the electronics compartment door. Refer to “How to Close the Electronics Compartment Door” on page 7-5. 7 Close the ink compartment door. Refer to “How to Close the Ink Compartment Door” on page 7-7. The installation of the new PIB is complete. Rev AA Printer Interface Board 7-75 Videojet 1510 Service Manual Power Switch Tools and Supplies Required Tool or Supply Quantity Screwdriver 1 Nr.1 Posidrive 1 3 mm Allen Wrench 1 7 mm Nut Spinner 1 Adjustable Pipe Pliers (to hold and tighten the ring nut on switch) 1 Table 7-12:Tools and Supplies Warning Read the “Safety Information” on page 7-2 before you perform the below tasks. How to Remove the Old Power Switch Do the following tasks to remove the old power switch: 1 Open the electronics compartment door (refer to “How to Open the Electronics Compartment Door” on page 7-3). 2 Do the following tasks to detach the power supply unit (PSU) (item 1, Figure 7-79 on page 7-77) assembly from the electronics compartment: a. Disconnect the following cables from the PSU: • Cable to the 8-way connector on the CSB • Cable to the 3-way mains connector on the power switch. b. Release the PSU cable from the p-clips. c. Remove the two M4 nyloc nuts (item 3) from the studs (item 2) inside the electronics compartment. d. Keep the PSU in a safe location. 7-76 Power Switch Rev AA Videojet 1510 Service Manual 1. PSU 2. Studs 3. M4 Nyloc Nut Figure 7-79: PSU Assembly 3 Pull the contact block (item 3, Figure 7-80 on page 7-78) covered by the sleeve (item 4) upwards to disconnect the claws. Or, use a screwdriver to release the claws. 4 Push the sleeve backwards away from the contact block. Caution Do not unbend the terminals, the terminals can break. Note: Remember the positions of the terminals. 5 Loosen the four screws (item 1) and remove the terminals (item 2) using Nr.1 posidrive. 6 Disconnect the terminals from the contact block. Rev AA Power Switch 7-77 Videojet 1510 Service Manual 4 3 2 1 1. Screws 2. Terminals 3. Contact Block 4. Sleeve Figure 7-80: Remove Terminals 7 Use a large pair of mole grips or adjustable pipe pliers to grip the contact block holder (item 3, Figure 7-81) and twist backwards. The contact block holder comes out or breaks. The lock ring (item 2) is released. Note: Apply considerable force to separate the two portions of the power switch. 8 Extract the actuator body (item 1) of the switch out of the handle. 3 2 1 1. Actuator Body 2. Lock Ring 3. Contact Block Holder Figure 7-81: Power Switch Disassembled 7-78 Power Switch Rev AA Videojet 1510 Service Manual 9 Discard all the parts of the power switch according to the local regulations. The removal of old power switch is complete. How to Install the New Power Switch Do the following tasks to install a new power switch: 1 Remove the lock ring from the actuator of the new power switch. 2 Do not remove the rubber gasket. 3 Insert the actuator body into the printer handle. The key on actuator body must align with the key in the handle. 4 Fit the lock ring from inside the electronics compartment. 5 Align and fix the contact block holder to the switch actuator. Note: The black legs on the actuator align with the rectangular hole in the contact block holder and this can be fitted in two different orientations. 6 Connect the terminals to the rear of the new contact block. 7 Cover the terminals with the sleeve. 8 Do the following tasks to fit the PSU: a. Connect the contact block to the contact block holder of the power switch. b. Put the PSU assembly into the lug (see Figure 7-82 on page 7-80) in the rear of the electronics compartment and then on the two studs. c. Use the two M4 nyloc nuts to fit the PSU assembly to the studs. Rev AA Power Switch 7-79 Videojet 1510 Service Manual Figure 7-82: Lug d. Connect the 3-way connector from the switch to the PSU. Figure 7-83: Power Switch Installed 9 Close the CSB. 10 Close the electronics compartment door. Refer to “How to Close the Electronics Compartment Door” on page 7-5. The installation of the new power switch is complete. 7-80 Power Switch Rev AA Videojet 1510 Service Manual Power Switch Wiring Information The Figure 7-84 shows the power switch connections for both US and Europe. Refer to Table 7-13 for more information. Figure 7-84: Power Switch Connection Europe USA 1A Mains Cable Live (brown) Mains Cable Live (black) 1B Wire to 3-way Connector (brown) Wire to 3-way Connector (brown) 2B Mains Cable Neutral (blue) Mains Cable Neutral (white) 2A Wire to 3-way Connector (blue) Wire to 3-way Connector (blue) Table 7-13:Power Switch Wiring Information Septum Assembly Tools and Supplies Required Tool or Supply Quantity T10 Torx Screwdriver 1 Side Cutters 1 3 mm Allen Wrench 1 7 mm Nut Spinner 1 2.5 diameter x 100 mm pin 1 Light Hammer 1 Sharp Knife 1 Table 7-14:Tools and Supplies Rev AA Septum Assembly 7-81 Videojet 1510 Service Manual Warning Read the “Safety Information” on page 7-2 before you perform the below tasks. How to Remove the Old Ink and Make-up Septa Do the following tasks to remove the old ink and make-up septa: 1 Open the ink compartment door (refer to “How to Open the Ink Compartment Door” on page 7-5). 2 Remove the smart cartridges, so that the ink and make-up septa are seen (see Figure 7-85). 2 1 1. Ink Septum 2. Make-up Septum Figure 7-85: Ink and Make-up Septa 3 Use the 2.5 mm pin and hammer to knock out the hinge pin (item 2, Figure 7-86 on page 7-83) from the right hand side hole of the door. The pin comes out of the hole on the left side of the door. 4 Pull the hinge completely, so that the door is released. 7-82 Septum Assembly Rev AA Videojet 1510 Service Manual Note: Take care not to bend the hinge pin. Keep the hinge pin to use again. 2 1 1. Lug 2. Hinge Pin Figure 7-86: Hinge Pin 5 Cut the ink tube (item 1, Figure 7-88 on page 7-84) and the make-up tube (item 6) 16 mm from the face of the ink and make-up septa (item 4) using a sharp knife. 6 Remove the two K30 x 12 screws (item 2) to release the clamp (item 5). 7 Is the length of the ink and make-up tubes enough to use again during the installation of new septa? • If Yes, proceed to Step 8. • If No, disconnect the other end of the ink and make-up tubes from the ink core manifold (see Figure 7-87). Discard the pipes according to the local regulations. 1 2 1. Ink Tube (Black Stripe) 2. Make-up Tube (Green Stripe) Figure 7-87: Ink Core Manifold Rev AA Septum Assembly 7-83 Videojet 1510 Service Manual 8 Remove the three K30 x 8 screws (item 3) on each septum to remove the two septa. 9 Discard the septa according to the local regulations. 6 1 2 3 4 5 1. Ink Tube (Green Stripe) 2. K30 x 12 Screw (x2) 3. K30 x 8 Screw (x6) 4. Ink/Make-up Septum (x2) 5. Clamp 6. Make-up Tube (Black Stripe) Figure 7-88: Cartridge Stall Rear Side The removal of the old ink and make-up septa is complete. How to Install the New Ink and Make-up Septa Do the following tasks to install the new ink and make-up septa: 1 Fit the ink and make-up septa to the smart cartridge stalls using the six K30 x 8 screws (item 3, Figure 7-88). 2 If you have discarded the ink and make-up tubes during the removal procedure, connect one end of the ink and make-up tubes to the ink core manifold (see Figure 7-87 on page 7-83). 3 Put the clamp in the position shown in Figure 7-88. 4 Guide the ink tube, make-up tube, ribbon cable, gutter pump cable, and the valve cable through the clamp, and fit the clamp to the ink and make-up septa using the two K30 x 12 screws. 5 Connect the other end of the ink and make-up tubes to the ink and make-up septa. 7-84 Septum Assembly Rev AA Videojet 1510 Service Manual 6 Fit the smart cartridges. 7 To fit the ink compartment door into the hinge, do the following tasks: a. Reinsert the hinge pin to the left side of the door with the lug on the left side of the hinge pin. b. The hinge pin is hammered with the 2.5 mm pin until resistance is felt. The hinge pin is locked. Note: Make sure that the pipes and cables move freely when the door is opened and closed. Adjust the clamp if necessary. 8 Close the ink compartment door. Refer to “How to Close the Ink Compartment Door” on page 7-7. The installation of the new ink and make-up septa is complete. Electronics Compartment Fan Tools and Supplies Required Tool or Supply Quantity 3 mm Allen Wrench 1 Nr.2 Posidrive 1 7 mm Spanner 1 7 mm Nut Spinner 1 Table 7-15:Tools and Supplies Warning Read the “Safety Information” on page 7-2 before you perform the below tasks. How to Remove the Old Electronics Compartment Fan Do the following tasks to remove the old electronics compartment fan: 1 Open the electronics compartment door. Refer to “How to Open the Electronics Compartment Door” on page 7-3. Rev AA Electronics Compartment Fan 7-85 Videojet 1510 Service Manual 2 Before you continue to remove the fan, remember the location where the fan cable is connected on the printer interface board (PIB). 3 Disconnect the fan connector (item 7, Figure 7-89) from the PIB. 4 Release the P-clips. The fan wiring drops down through the P-clips. 5 Use Nr.2 posidrive and 7 mm spanner to remove the two M4 x 16 counter-sunk screws (item 6, Figure 7-89) and two M4 nyloc nuts (item 5) and remove the finger guard (item 4). 6 Use the 3 mm allen wrench to remove the four M4 x 10 cap-head screws (item 3) and four M4 ET washers (item 2) that hold the fan (item 1) to the printer cabinet. 7 Discard the fan according to the local regulations. The removal of the old electronics compartment fan is complete. . 7 1 2 3 4 5 6 1. Fan 2. M4 ET Washer (x4) 3. M4 x 10 Cap-head Screw (x4) 4. Finger Guard 5. M4 Nyloc Nut (x2) 6. M4 x 16 Counter-sunk Screw (x2) Figure 7-89: Remove Fan How to Install the New Electronics Compartment Fan Do the following tasks to install the new electronics compartment fan: 1 Fit the new fan to the printer cabinet using the four M4 x 10 cap-head screws and four M4 ET washers. 7-86 Electronics Compartment Fan Rev AA Videojet 1510 Service Manual 2 Fit the finger guard using the two M4 x 16 counter-sunk screws and two M4 nyloc nuts. 3 Guide the fan connector through the P-clips and connect to the PIB. 4 Close the electronics compartment door. Refer to “How to Close the Electronics Compartment Door” on page 7-5. The installation of the new electronics compartment fan is complete. Ethernet Connector Tools and Supplies Required Tool or Supply Quantity 3 mm Allen Wrench 1 Adjustable spanner or pipe pliers to give minimum 33A/F 1 Table 7-16:Tools and Supplies Warning Read the “Safety Information” on page 7-2 before you perform the below tasks. How to Remove the Old Ethernet Connector Do the following tasks to remove the old ethernet connector: 1 Open the electronics compartment door (refer to “How to Open the Electronics Compartment Door” on page 7-3). 2 Disconnect the Ethernet cable (a special 90 degrees cable) between the Ethernet connector (item 8, Figure 7-90 on page 7-88) and the CSB Ethernet connection. Rev AA Ethernet Connector 7-87 Videojet 1510 Service Manual 1 2 3 4 8 7 6 1. Stud 2. Ring Terminal 3. M4 ET washer 4. M4 Nyloc Nut 5 5. Ground Cable 6. Lock Nut 7. Rubber Washer 8. Ethernet Connector Figure 7-90: Ethernet Connector 3 Remove the M4 nyloc nut (item 4) and M4 ET washer (item 3) on the M4 ring terminal (item 2) attached to the stud (item 1) on the printer cabinet. 4 Disconnect the ground cable (item 5). 5 Loosen and remove the lock nut (item 6). 6 Detach the old ethernet connector from the printer cabinet. 7 Remove the rubber washer (item 7). 8 Discard the old connector, locknut and the rubber washer. The removal of the old ethernet connector is complete. How to Install the New Ethernet Connector Do the following tasks to install the new Ethernet connector: 1 Make sure that the rubber washer is on the ethernet connector. 2 Align the key feature in the washer with the key feature on the connector body. 3 Insert the ethernet connector into the hole in the printer cabinet. Make sure that the key on the ethernet connector aligns with the key in the cabinet hole. 4 Fit the ethernet connector with the lock nut inside the printer cabinet. 7-88 Ethernet Connector Rev AA Videojet 1510 Service Manual 5 Connect one end of the ground cable to the ethernet connector. 6 Connect the M4 ring terminal end of the ground cable to the stud using the M4 nyloc nut and M4 ET washer. 7 Connect the ethernet cable between the Ethernet connector and the CSB ethernet connection. The 90 degree end must be fitted to the connector on the side panel. 8 Close the electronics compartment door. Refer to “How to Close the Electronics Compartment Door” on page 7-5. 9 Fit the dust cap to the connector. The strap on the dust cap has a small hole at the free end. Push it over the pin at the side of the connector body. The installation of the new ethernet connector is complete. Positive Air Kit Tools and Supplies Required Tool or Supply Quantity 3 mm Allen Wrench 1 7 mm Nut Driver 1 Crimp Pliers 1 Table 7-17:Tools and Supplies Warning Read the “Safety Information” on page 7-2 before you perform the below tasks. Rev AA Positive Air Kit 7-89 Videojet 1510 Service Manual How to Remove the Old Positive Air Kit Note: This kit includes the positive air pump and positive air filter. Do the following tasks to remove the old positive air kit: 1 Open the electronics compartment door. Refer to “How to Open the Ink Compartment Door” on page 7-5. 2 Disconnect the printhead tube (yellow stripe tube, silicon tube and the O-clip) (item 2, Figure 7-91). 3 Disconnect the filter tube (yellow stripe tube and the silicon tube) (item 3) that is connected to the inlet of the positive air pump (item 1). Note: The other end of the filter tube is connected to the outlet of the positive air filter that is fitted inside the ink compartment. 3 2 1 1. Positive Air Pump 2. Printhead Tube 3. Filter Tube Figure 7-91: Positive Air Pump 4 Remove the M4 nyloc nut (item 3, Figure 7-92 on page 7-91) that attaches the P-clip (item 2) to the rear of the printer cabinet. Keep the P-clip to use again. 5 Release the 5-way connector cable from the P-clip. 6 Use a nut driver to remove the other M4 nyloc nut (item 4) from the pump mount. 7-90 Positive Air Kit Rev AA Videojet 1510 Service Manual 4 1. Air Pump Bracket 2. P-clip 3 2 1 3. M4 Nyloc Nut 4. M4 Nyloc Nut Figure 7-92: Remove Positive Air Pump 7 Disconnect the 5-way connector cable (item 1, Figure 7-93) from the printer interface board (PIB). 2 1 1. 5-way Connector Cable 2. Positive Air Pump Cables Figure 7-93: Positive Air Pump Cable 8 Discard the positive air pump according to the local regulations. Rev AA Positive Air Kit 7-91 Videojet 1510 Service Manual 9 Open the ink compartment door. Refer to “How to Open the Ink Compartment Door” on page 7-5. 10 Disconnect the filter tube (item 1, Figure 7-94) from the outlet of the positive air filter (item 2). 11 Pull the filter tube from the interface board and discard the tube according to the local regulations. 12 Pull the positive air filter from the terry clip (item 3) and discard the filter according to the local regulations. 1 2 3 1. Filter Tube (yellow striped) 2. Positive Air Filter 3. Terry Clip Figure 7-94: Positive Air Filter The removal of the old positive air kit is complete. How to Install the New Positive Air Kit Do the following tasks to install the new positive air kit: 1 Put the new positive air pump assembly on the studs inside the electronics compartment. 2 Put the P-clip on the top stud. 3 Fit the P-clip with M4 nyloc nut using 7 mm nut driver. 4 Route the 5-way connector cable through the P-clip. 5 Tighten the other M4 nyloc nut using the 7 mm nut driver. 7-92 Positive Air Kit Rev AA Videojet 1510 Service Manual 6 Connect the 5-way connector cable to the connection labeled A_PUMP on the PIB. 7 Fit the silicon tube to the outlet of the positive air pump. 8 Slide the O-clip over the silicon tube. 9 Push the yellow stripe printhead tube into the silicon tube approximately 25 mm (0.98 inches). 10 Crimp the O-clip in position to retain the silicon tube and the printhead tube. 11 Fit the silicon tube to the inlet of the positive air pump. 12 Push the yellow stripe filter tube into the silicon tube approximately 25 mm (0.98 inches). 13 Push the other end of the filter tube into the ink compartment through the interface board. 14 Close the electronics compartment door. Refer to “How to Close the Electronics Compartment Door” on page 7-5. 15 Push the new positive air filter into the terry clip. Note: The direction of the flow on the positive air filter must point upwards. 16 Connect the filter tube to the outlet of the positive air filter. 17 Close the ink compartment door. Refer to “How to Close the Ink Compartment Door” on page 7-7. The installation of the new positive air kit is complete. Gutter Pump Tools and Supplies Tools or Supplies Quantity 7 mm Nut Spinner 1 2.5 mm Allen Wrench 1 T10 Torx Driver 1 Light Hammer 1 Table 7-18:Tools and Supplies Rev AA Gutter Pump 7-93 Videojet 1510 Service Manual Tools or Supplies Quantity Sharp Knife 1 Side Cutter 1 2.5 D x 100 mm Long Pin (to knock the hinge pin out) 1 Table 7-18:Tools and Supplies How to Remove the Old Gutter Pump Do the following tasks to remove the old gutter pump: 1 Open the ink compartment door. Refer to “How to Open the Ink Compartment Door” on page 7-5. 2 Use the 2.5 mm pin and hammer to knock out the hinge pin (item 2, Figure 7-95) from the right hand side hole of the door. The pin comes out of the hole on the left side of the door. 3 Pull the hinge completely, so that the door is released. 2 1 1. Lug 2. Hinge Pin Figure 7-95: Hinge Pin 4 Pull the ink core module from inside the ink compartment. 5 Disconnect the ground wire that is connected to the ink compartment door from the stud inside the ink compartment. 6 Disconnect the 4-way gutter pump connector (item 5, Figure 7-96 on page 7-95) and 2-way valve connector (item 1) from the PCBs on the cartridge holder. Both components connect to connectors labeled J2. 7-94 Gutter Pump Rev AA Videojet 1510 Service Manual The gutter pump connector has four colored wires. The valve connector has two black wires. 1 5 2 4 3 1. 2-way valve Connector 2. K30 x 12 Pan-head Torx Screw (2) 3. Cable Clamp 4. Cartridge Holder 5. 4-way Gutter Pump Connector Figure 7-96: Cartridge Holders 7 Use the T10 torx driver to remove the K30 x 12 pan-head screws (item 2, Figure 7-96) and release the cable clamp (item 3) that holds the gutter pump cables, valve cables, green stripe ink tube, black stripe make-up tube, and the ribbon cables. 8 Use the 7 mm nut spinner to remove the two nuts that attach the Pclips (item 6, Figure 7-97 on page 7-96) to the floor of the ink compartment. 9 Detach the black cable from the cable bundle (this cable contains the wires for the gutter pump and the valve). 10 Push the blue and brown sleeves up the pipes on the gutter pump manifold to access the tubes. Note: Use tissues to retain spill from the tubes. 11 Cut the following tubes approximately 16 mm (0.63 inch) away from the face of the gutter pump manifold with a sharp knife. a. Clear tube connected to the front right port b. Clear tube connected to the front left port c. Blue striped tube connected to the rear port Rev AA Gutter Pump 7-95 Videojet 1510 Service Manual 12 Using the 7 mm nut spinner, remove the two M4 nyloc nuts (item 3, Figure 7-97) that attach the gutter pump bracket (item 4) to the rear wall of the ink compartment. 1 2 3 4 5 7 1. Blue Stripe Pipe with Blue Sleeve 2. Clear Pipe with Brown Sleeve 3. M4 Nyloc Nuts (x2) 4. Gutter Pump Bracket 6 5. Clear Pipe 6. P-clip 7. Commissioning Valve Figure 7-97: Gutter Pump Assembly 13 Remove the gutter pump assembly from the ink compartment. The removal of the old gutter pump is complete. 7-96 Gutter Pump Rev AA Videojet 1510 Service Manual How to Install the New Gutter Pump Do the following tasks to install the new gutter pump: 1 Put the new gutter pump in the ink compartment. Fit the three tubes to the pump manifold according to the following instructions: • Clear tube (item 2, Figure 7-98) to the front right port • Clear tube (item 3) with brown sleeve to the front left port • Blue striped tube (item 1) with blue sleeve to the rear port 3 1 2 1. Blue Stripe Tube with Blue Sleeve 2. Clear Tube 3. Clear Tube with Brown Sleeve Figure 7-98: Gutter Pump Tubes 2 Using the 7 mm nut spinner, fit the two M4 nyloc nuts that attach the gutter pump assembly to the rear wall of the ink compartment (see Figure 7-97 on page 7-96). 3 Add the two black cables to the cable bundle and route the bundle through the P-clips. 4 Using the 7 mm nut spinner, secure the P-clips to the floor of the ink compartment. 5 Route the cable bundle, green stripe ink tube, black stripe make-up tube, and the ribbon cable through the cable clamp (see Figure 7-96 on page 7-95). 6 Connect the 2-way valve connector and 4-way gutter pump connector to the PCBs. • The connector with the two black wires (2-way) plugs into J2 on the PCB on make-up cartridge holder. • The connector with the four colored wires (4-way) plugs into J2 on the PCB on the ink cartridge holder. Rev AA Gutter Pump 7-97 Videojet 1510 Service Manual 7 To fit the ink compartment door into the hinge, do the following tasks: a. Reinsert the hinge pin to the left side of the door with the lug on the left side of the hinge pin. b. The hinge pin is hammered with the 2.5 mm pin until resistance is felt. The hinge pin is locked. 8 Connect the ground wire to the stud inside the ink compartment. Use the 7 mm nut spinner. Note: When the door is fitted, check that the cables and tubes can move freely when the door is closed and opened. The cables and tubes must not be strained. 9 Close the ink compartment door. Refer to “How to Close the Ink Compartment Door” on page 7-7. The installation of the new gutter pump is complete. Ink Door Assembly Tools and Supplies Required Tool or Supply Quantity 2.5 D x 100 mm Long Pin (to knock the hinge pin out) 1 Light Hammer 1 7 mm Nut Spinner 1 10 mm Spanner 1 T10 Torx Driver 1 Sharp Knife (to cut tubes) 1 Table 7-19:Tools and Supplies 7-98 Ink Door Assembly Rev AA Videojet 1510 Service Manual How to Remove the Old Ink Door Do the following tasks to remove the old ink door: 1 Open the ink compartment door. Refer to “How to Open the Ink Compartment Door” on page 7-5. 2 Use the 2.5 mm pin and hammer to knock out the hinge pin (item 2, Figure 7-99) from the right hand side hole of the ink door assembly. 2 1 1. Lug 2. Hinge Pin Figure 7-99: Hinge Pin 3 The pin comes out of the hole on the left side of the door. 4 Pull the hinge completely, so that the door is released. 5 Use the 7 mm nut spinner to disconnect the ground wire that is connected to the ink compartment door from the stud inside the ink compartment. 6 Disconnect the 4-way gutter pump connector (item 7, Figure 7-100 on page 7-100) and 2-way valve connector (item 1) from the PCBs on the cartridge holder (item 5). Both components connect to connectors labeled J2. Rev AA Ink Door Assembly 7-99 Videojet 1510 Service Manual 1 7 2 6 3 5 4 1. 2-way valve Connector 2. Ink Tube (Green Stripe) 3. K30 x 12 Pan-head Torx Screw (2) 4. Cable Clamp 5. Cartridge Holder 6. Make-up Tube (Black Stripe) 7. 4-way Gutter Pump Connector Figure 7-100: Cartridge Holder 7 Use the T10 torx driver to remove the K30 x 12 pan-head screws (item 3, Figure 7-100) and release the cable clamp (item 4) that holds the gutter pump and valve cables, the 14 way ribbon cable, the black (item 6) and green stripe pipes (item 2). 8 If you want to keep the old 14-way ribbon cable, disconnect the 14way headers from the PCBs on the ink door. Else, go to step 9. 9 If the ribbon cable must be replaced, do the following: a. Release the P-clips that retain the 14-way ribbon cable in the ink system. b. Disconnect the 14-way ribbon cable from the underside of the printer interface board (PIB). c. Remove and discard the 14-way ribbon cable. 10 If you must reuse the black and green stripe tubes then do the following tasks. Else, go to step 11. a. Pull out the ink core module from the ink compartment. b. Disconnect the ink core manifold. 7-100 Ink Door Assembly Rev AA Videojet 1510 Service Manual c. Cut the green striped tube and black stripe tube (item 1 and item 2, Figure 7-101) with a sharp knife 16 mm from the face of manifold. d. Cut the tubes left on the barb fittings vertically downwards and remove tubes. e. The black and green stripe tubes is pulled back through the spiral wrap and the P-clips. 1 2 1. Ink Tube (Green Stripe) 2. Make-up Tube (Black Stripe) Figure 7-101: Ink Core Manifold 11 If the pipes are not short on the existing door, then pull the tubes off or cut with a sharp knife from the septum tubes. 12 Discard the old door according to local regulations. The removal of the old ink door assembly is complete. How to Install the New Ink Door Do the following tasks to install the new ink door assembly: 1 Align the new ink door assembly carefully. 2 Reinsert the hinge pin to the left side of the ink door assembly with the lug (item 1, Figure 7-99 on page 7-99) on the left side of the hinge pin. 3 The hinge pin is hammered with the 2.5 mm pin until resistance is felt. The hinge pin is locked. 4 If the old door tubes are used, insert the tubes into the septum connections. If new pipes are used then, do the following tasks: a. Route the new black and green stripe tubes through all the p-clips and the spiral wrap. Rev AA Ink Door Assembly 7-101 Videojet 1510 Service Manual b. Connect the pipes to the ink core manifold. c. Push the ink core module into the ink compartment. 5 If the old 14-way cable is used then, reconnect the 14-way headers to the relevant PCBs. If you want to install a new 14-way cable, do the following tasks: a. Route the ribbon cable through all the P-clips b. Connect the ribbon cable to the PIB. 6 Connect the 4-way gutter pump connector and 2-way valve connector to the PCBs on the cartridge holder. Both the connectors connect to J2 connectors on the PCB. Refer to Figure 7-102. 7 Use the T10 torx driver to attach the cable clamp with the K30 x 12 pan-head screws that holds the gutter pump cables, valve cables, green stripe ink tube, black stripe make-up tube and the 14-way ribbon cable. Refer to Figure 7-102. Figure 7-102: Septum Connections 8 Tighten all the p-clips. 9 Connect the ground wire that is connected to the ink compartment door from the stud inside the ink compartment. Note: After the door is fitted, check that the cables and tubes can move freely when the door is closed and opened. The cables and tubes must not be strained. 7-102 Ink Door Assembly Rev AA Videojet 1510 Service Manual 10 Adjust the two M6 nuts (item 5, Figure 7-103) and two M6 washers (item 4) on the stud (item 2) to give the required compression to the door gasket (item 1). 1 2 3 4 5 4. M6 Washer (x2) 5. M6 Nut (x2) 1. Door Gasket 2. Stud 3. Latch Figure 7-103: Latch 11 Close the ink compartment door. Refer to “How to Close the Ink Compartment Door” on page 7-7. The installation of the new ink door assembly is complete. Ink System Fan Tools and Supplies Required Tool or Supply Quantity 3 mm Allen Wrench 1 Table 7-20: Tools and Supplies How to Remove the Ink System Fan Do the following to remove the ink system fan: 1 Open the ink compartment door. Refer to “How to Open the Ink Compartment Door” on page 7-5. Rev AA Ink System Fan 7-103 Videojet 1510 Service Manual 2 Pull the ink core module (item 3, Figure 7-104) out of the ink compartment. 1. Cartridges 2. Ink Compartment Door 3. Ink Core Module Figure 7-104: Pull Ink Core Module 3 Detach the fan guard (item 4, Figure 7-105) from the fan housing (item 2). 1 2 4 1. M4 ET Washer (x4) 2. Fan Housing 3 3. M4 x 10 Cap Head Screw (x4) 4. Fan Guard Figure 7-105: Ink Fan Assembly 4 Disconnect the fan cable from the printer interface board (PIB). 5 Remove the four M4 x 10 cap-head screws (item 3) and four M4 ET washers (item 1) to detach the fan housing from the raised mounting box located at the back of the ink compartment. Keep the four M4 x 10 cap-head screws and the four M4 ET washers to use again. 7-104 Ink System Fan Rev AA Videojet 1510 Service Manual 6 Discard the ink system fan as per the local regulations. The removal of the old ink system fan is complete. How to Install the New Ink System Fan Do the following tasks to install the new ink system fan: 1 Attach the new fan housing to the raised mounting box located at the back of the ink compartment using the four M4 x 10 cap-head screws and four M4 ET washers. 2 Connect the fan cable to the PIB. 3 Attach the fan guard to the fan housing. 4 Push the ink core module into the ink compartment. 5 Close the ink compartment door. Refer to “How to Close the Ink Compartment Door” on page 7-7. The installation of the new ink system fan is complete. EHT Module Tools and Supplies Required Tool or Supply Quantity 3 mm Allen Wrench 1 7 mm Nut Driver 1 Table 7-21:Tools and Supplies How to Remove the Old EHT Module Do the following tasks to remove the old EHT Module: 1 Open the electronics compartment door. Refer to “How to Open the Electronics Compartment Door” on page 7-3. 2 Disconnect the EHT cable (item 3, Figure 7-106 on page 7-106) from the PIB. 3 Disconnect the EHT plug (item 1) from the EHT module. Rev AA EHT Module 7-105 Videojet 1510 Service Manual 1 2 3 1. EHT Plug 2. P-Clip 3. EHT Cable Figure 7-106: EHT Plug and Cable 4 Release p-clips (item 2) that hold the EHT cable. 5 Use the 7 mm nut driver to remove the two M4 Nyloc nuts (item 2, Figure 7-107) that attach the EHT Module (item 1) to the cabinet. 6 Dispose the old EHT Module according to the local regulations. 1 2 1. EHT Module 2. M4 Nyloc Nuts (x2) Figure 7-107: Removal of EHT Module The removal of old EHT Module is complete. 7-106 EHT Module Rev AA Videojet 1510 Service Manual How to Install the New EHT Module Do the following tasks to install the new EHT Module: 1 Place the new EHT Module on the cabinet. 2 Use the 7 mm nut driver to tighten the two M4 nyloc nuts to attach the EHT Module to the cabinet. 3 Connect the EHT cable from the new EHT Module to the PIB. 4 Reconnect the EHT plug. 5 Position the new EHT cable in the p-clips and refit. 6 Close the CSB assembly. 7 Close the electronics compartment door. Refer to “How to Close the Electronics Compartment Door” on page 7-5. 8 Perform EHT Calibration (see Figure 7-108). Figure 7-108: Calibrate EHT The installation of the new EHT Module is complete. Rev AA EHT Module 7-107 Videojet 1510 Service Manual USB Connector Tools and Supplies Required Tool or Supply Quantity 3 mm Allen Wrench 1 Adjustable spanner or pipe pliers to give minimum 33A/F 1 Table 7-22:Tools and Supplies How to Remove the Old USB Connector Do the following tasks to remove the old USB connector: 1 Open the electronics compartment door. Refer to “How to Open the Electronics Compartment Door” on page 7-3. 2 Disconnect the USB cable (item 2, Figure 7-109) from the USB 2 on the printer interface board (PIB). 4 3 1 2 1. Lock Nut 2. USB Cable 3. Rubber Washer 4. USB Connector Figure 7-109: USB Connector 3 Loosen and remove the locknut (item 1, Figure 7-109). 4 Detach the old USB connector (item 4) from the printer cabinet. 7-108 USB Connector Rev AA Videojet 1510 Service Manual 5 Remove the rubber washer (item 3). 6 Discard the old connector, locknut and the rubber washer. The removal of the old USB connector is complete. How to Install the New USB Connector Do the following tasks to install the new USB connector: 1 Make sure rubber washer is on connector body. Align the key feature in the washer with the key feature on the connector body. 2 Insert the USB connector into the hole in the printer cabinet. Make sure that the key on the connector body aligns with the key in the cabinet hole. 3 Fit the lock nut (with the USB cable) inside the printer cabinet. 4 Connect the other end of the USB cable to USB 2 on the PIB. 5 Close the CSB. 6 Fit the dust cap to the connector. The strap on the dust cap has a small hole at the free end. Push it over the pin at the side of the connector body. 7 Close the electronics compartment door. Refer to “How to Close the Electronics Compartment Door” on page 7-5. The installation of the new USB connector is complete. Plug and Power Cable Tools and Supplies Required Tool or Supply Quantity Nr.1 Posidrive 1 3 mm Allen Wrench 1 24mm Spanner 1 Table 7-23: Tools and Supplies Rev AA Plug and Power Cable 7-109 Videojet 1510 Service Manual How to Remove the Old Power Cable Do the following tasks to remove the old power cable: 1 Open the electronics compartment door (refer to “How to Open the Electronics Compartment Door” on page 7-3). 2 Do the following tasks to detach the power supply unit (PSU) assembly from the electronics compartment: a. Remove the two M4 nyloc nuts (item 3, Figure 7-110 on page 7-110) from the studs (item 2) inside the electronics compartment. b. Disconnect the following cables from the PSU: • PSU cable from the 8-way connector on the CSB. • 3-way mains connector from the power switch. c. Disconnect the ty-raps securing the charge/modulation cable to the PSU cable. 1. PSU 2. Studs 3. M4 Nyloc Nut Figure 7-110: PSU Assembly d. Keep the PSU in a safe location. 3 Pull the contact block (item 3, Figure 7-111 on page 7-111) covered by the sleeve (item 4) upwards to disconnect the claws, or use a screwdriver to release the claws. 4 Push the sleeve backwards off the contact block. 7-110 Plug and Power Cable Rev AA Videojet 1510 Service Manual Caution Do not unbend the terminals, the terminals can break. Note: Remember the positions of the terminals. 5 Loosen the four screws (item 1) and remove the terminals (item 2) using Nr.1 posidrive. 6 Disconnect the terminals from the contact block. 4 3 2 1 1. Screws 2. Terminals 3. Contact Block 4. Sleeve Figure 7-111: Remove Terminals 7 Remove the M4 nyloc nut (item 3, Figure 7-112) and M4 ET washer (item 1) and disconnect the ground wire from the ground stud (item 5). 8 Remove the M20 x 1.5p lock nut (item 2). Rev AA Plug and Power Cable 7-111 Videojet 1510 Service Manual 1. M4 ET Washer 2. M20 x 1.5p Nut 3. M4 Nyloc Nut 4. Cable Gland 5. Ground Stud Figure 7-112: Remove Cable Gland 9 Disconnect the plug from power cable. 10 Release the cable-strain-relief-clamp nut on the cable gland. 11 Open the cable gland by inserting a screwdriver on either side. 12 Hinge open the gland and slide the gland from the cable. 13 Pull the disconnected power cable through the hole in the electronics compartment. 14 Discard the power cable with the plug according to local regulations. The removal of the old power cable is complete. How to Install the New Power Cable Do the following tasks to install the new power cable: 1 Slide the M20 x 1.5p lock nut over the free end of the new power cable (see Figure 7-113 on page 7-113). 7-112 Plug and Power Cable Rev AA Videojet 1510 Service Manual Figure 7-113: Power Cable 2 Insert this free end of the power cable through the hole in the cabinet from inside the electronics compartment. 3 Connect the power cable to the switch contact block at the correct terminals with the four screws using Nr.1 posidrive (see Figure 7-114 and Table 7-24 on page 7-113). Figure 7-114: Power Switch - US and Europe Table 7-24 shows the wiring details of the power switch. Connection Europe USA 1A Mains Cable Live (brown) Mains Cable Live (black) 1B Wire to 3-way connector (brown) Wire to 3-way connector (brown) 2B Mains Cable Neutral (blue) Mains Cable Neutral (white) 2A Wire to 3-way Connector (blue) Wire to 3-way Connector (blue) Table 7-24:Wiring Information 4 Pull the sleeve back on the contact block. 5 Connect the contact block to the mains switch assembly. 6 Reconnect the ground wire to the ground stud with the M4 nyloc nut and M4 ET washer. 7 Slide the new cable gland over the free end of the power cable towards the hole in the cabinet from outside. Rev AA Plug and Power Cable 7-113 Videojet 1510 Service Manual Do not close the cable gland at this stage. 8 Push any excess cable in the electronics compartments out through the hole. 9 Locate the gland in the hole and on the support bracket below this hole. Close the cable gland near the hole. 10 Tighten the M20 x 1.5p lock nut. 11 Tighten the cable strain relief nut on the cable gland to retain the cable. 12 Do the following tasks to fit the PSU: a. Connect the below cables: • Connect the 8-way cable to the CSB. • Connect the 3-way connector from the switch to the PSU. b. Put the PSU assembly into the lug (see Figure 7-115 on page 7-114) in the rear of the electronics compartment and then on the two studs. c. Use the two M4 nyloc nuts to fit the PSU assembly to the studs. Figure 7-115: Lug d. Ty-rap the charge/modulation cable to the PSU cable. 13 Connect the new plug to the power cable. 14 Close the CSB. 15 Close the electronics compartment door. Refer to “How to Close the Electronics Compartment Door” on page 7-5. The installation of the new power cable is complete. 7-114 Plug and Power Cable Rev AA Videojet 1510 Service Manual CSB Lithium Battery Tools and Supplies Required Tool or Supply Quantity 3 mm Allen Wrench 1 Table 7-25:Tools and Supplies How to Remove the Old CSB Lithium Battery Do the following tasks to remove the old CSB lithium battery: 1 Open the electronics compartment door. Refer to “How to Open the Electronics Compartment Door” on page 7-3. 2 Use the 3 mm allen wrench to remove the two M4 x 8 cap-head screws (item 3, Figure 7-116) that holds the retainer (item 4). 3 Push the latch (item 1) down to open the control system board (CSB) (item 2). 1 2 3 4 1. Latch 2. Control System Board 3. M4 x 8 Cap-head Screws (x2) 4. Retainer Figure 7-116: Latch 4 Locate the CSB lithium battery (Figure 7-117). 5 Lift the battery clamp and remove the old CSB lithium battery. Rev AA CSB Lithium Battery 7-115 Videojet 1510 Service Manual 1 2 1. Battery Clamp 2. Lithium Battery Figure 7-117: Control System Board 6 Dispose the old CSB lithium battery according to local regulations. The removal of the old CSB lithium battery is complete. 7-116 CSB Lithium Battery Rev AA Videojet 1510 Service Manual How to Install the New CSB Lithium Battery Do the following tasks to install the new CSB lithium battery: 1 Push the new CSB lithium battery under the battery clamp. 2 Swing the CSB assembly into the closed position. 3 Attach the retainer with the two M4 x 8 cap-head screws. Use the 3 mm allen wrench. 4 Close the electronics compartment door. Refer to “How to Close the Electronics Compartment Door” on page 7-5. The installation of the new CSB lithium battery is complete. PCB 1, 2 and 3 Introduction The printer is provided with PCB 1 and PCB 2 on the connector panel. There are three standard connectors on each PCB. PCB 3 is optional. The instructions given below are for PCB 2 only. You must follow the same instructions for PCB 0, PCB 1 and PCB 3. Tools and Supplies Required Tool or Supply Quantity 3 mm Allen Wrench 1 7mm Nut Spinner 1 Special Din Spanner (P/N 234657) 1 Table 7-26:Tools and Supplies How to Remove the PCB 2 Do the following tasks to remove the old PCB 2: 1 Open the electronics compartment door. Refer to “How to Close the Electronics Compartment Door” on page 7-5. 2 Remove and keep the connector plugs that are fitted to the connectors on PCB 2. Rev AA PCB 1, 2 and 3 7-117 Videojet 1510 Service Manual 3 Push the latch and open the control system board. 4 Disconnect the 14-way ribbon cable from PCB 2 from the printer interface board (PIB). 5 If you must replace PCB 1 and PCB 3 then, disconnect the following ribbon cables form the PIB: • 20-way ribbon cable connected to the PCB 1 • 16-way ribbon cable connected to the PCB 3 5 4 3 1. PCB 2 2. M4 Nyloc Nut 3. M4 ET Washer 2 1 4. Earthing Tab 5. PCB 1 Figure 7-118: PCB 2 6 Remove and discard the M4 nyloc screw (item 2, Figure 7-118) and M4 ET washer (item 3) that attach the earthing tab (item 4) to the cabinet. 7 Use the special din spanner to detach the lock nut (item 4, Figure 7-119 on page 7-119) from the connectors on the PCBs. 8 Remove and discard PCB 2 (item 1, Figure 7-118) according to local regulations. 7-118 PCB 1, 2 and 3 Rev AA Videojet 1510 Service Manual 1 2 3 4 1. PCB 3 2. PCB 2 3. PCB 1 4. Lock Nut Figure 7-119: Connector Panel 9 Discard the PCBs as per local regulations. The removal of the old PCBs is complete. How to Install the New PCB 1, 2 and 3 Do the following tasks to install the new PCB 2: 1 Insert the new PCB 2 into their correct positions from inside the electronics compartment. 2 Fit the PCBs with the lock nuts from outside. 3 Fit the earthing tabs to the cabinet with the M4 nyloc screw and M4 ET washer. 4 Tighten the M4 nyloc screws and M4 ET washers that attach the earthing tabs to the cabinet. 5 Connect the 14-way ribbon cable from PCB 2 to the PIB. 6 Close the control system board. 7 Fit the dust caps to all the connectors. 8 Close the electronics compartment door. Refer to “How to Close the Electronics Compartment Door” on page 7-5. The installation of the new PCBs is complete. Rev AA PCB 1, 2 and 3 7-119 8 Maintenance The preventative maintenance schedules mentioned in this chapter must be carried out by a suitably trained maintenance technician. Actual intervals depend on machine running hours. The figures below are based on eight hours usage per day. If the actual usage is higher, the intervals should be reduced. Task Medium Clean the Printhead Weekly Replace the Core Module 9,000 hours Replace the Ink pump 18,000 hours (for every other ink core) Replace the Fan Filter (IP55) 2,000 hours Replace the Floor Filter (IP55) Will be replaced with the Ink Core Module Replace the Fan Filter (IP65) 2,000 hours Replace the Floor Filter (IP65) Will be replaced with the Ink Core Module Replace the Positive Air Filter 2,000 hours Replace the Dry Air Kit Filter 2,000 hours Table 8-1: Preventative Maintenance Schedule Warning It is possible that in a fault condition the heater can reach 70 °C. Do not touch the plate on which heater is mounted. The failure to follow this warning can cause personal injury. Rev AA 8-1 Videojet 1510 Service Manual Prime the Printer Warning HANDLING CLEANING AGENT. The cleaning agent is irritating to the eyes and respiratory system. To prevent personal injury when handling this substance: Always wear protective rubber gloves and clothing. Always wear goggles with side-shields or a face mask. It is also advisable to wear safety glasses when carrying out maintenance. Apply barrier hand cream before handling ink. If cleaning agent contaminates the skin, rinse off with running water for at least 15 minutes. 1 Select System > Fill Ink Core. This process primes the printer with ink. Record the prime time. Figure 8-1. Fill Ink Core Command 2 Observe if the ink is going through the black-striped and blue-striped tubes. During this process, it should take approximately 22 minutes for the ink core to change status from empty to middle. Note: Make sure that there are no leaks in tubing and fittings. 3 Check the ink cartridge. If empty, replace with a new cartridge. 8-2 Prime the Printer Rev AA Videojet 1510 Service Manual Umbilical Purge The umbilical purge option is used to flush the ink core module before fitting the nozzle. Caution Do not fit the nozzle before you perform this procedure. Perform umbilical purge in the following conditions: • To prevent debris from blocking the nozzle if the printer has not been used for a long time • If contamination of the umbilical is suspected • If a new umbilical has been fitted • If the ink color or type is to be changed Do the following tasks to perform umbilical purge: 1 Turn off the main power switch of the printer. 2 Disconnect the mains power cord from the electrical outlet. 3 Remove the printhead cover screw that fastens the printhead cover to the printhead chassis and remove the printhead cover (see Figure 8-2). . 1. Printhead Cover 2. Print Engine 3. Printhead Cover Screw 4. Printhead Valve Module 5. Umbilical Figure 8-2. Printhead Cover Removed Rev AA Umbilical Purge 8-3 Videojet 1510 Service Manual Caution To prevent nozzle clogs, always wear rubber gloves whenever the nozzle tubing manifold is to be disconnected from the printhead valve module deck. 4 Remove the M2 x 6 socket-head-cap screw that attaches the front tubing manifold to the printhead valve module. 5 Put the 2-way manifold gasket provided in the bypass kit on the ports of the printhead valve module. 6 Fit the nozzle bypass manifold that has the loop of tube to the printhead valve module using the M2 x 6 socket-head screw (see Figure 8-3). 1 2 3 5 3 4 1. M2 x 6 Socket-head Screw 2. Bypass Manifold 3. Tube Loop 4. Quick Disconnect 5. 2-way Manifold Gasket Figure 8-3. Nozzle Bypass Manifold 7 Connect the mains power cord to the electrical outlet. 8 Turn on the main power switch of the printer. 8-4 Umbilical Purge Rev AA Videojet 1510 Service Manual 9 Log into the User Interface (UI). 10 Select umbilical purge option (see Figure 8-4). Note: Make sure that there are no leaks in tubing and fittings. Figure 8-4. Umbilical Purge Command 11 The purge option runs for 15 minutes. 12 Remove the nozzle bypass manifold and the 2-way manifold gasket. 13 Put the new front tubing manifold gasket on the ports. 14 Fit the front tubing manifold to the printhead valve module using a M2 x 6 socket-head screw. 15 Fit the printhead cover to the printhead chassis using the printhead cover screw. System Flush Purge The system flush purge procedure is usually performed during the commissioning of the printer. Tools and Supplies Required Tool or Supply Quantity Nozzle bypass manifold 1 Table 8-2: Tools and Supplies Required Rev AA System Flush Purge 8-5 Videojet 1510 Service Manual Tool or Supply Quantity Cartridges of clear solvent (appropriate to ink base) 5 Ink cartridge case with a smart chip programmed for ink 1 Empty container for recovered ink Minimum 1 liter capacity 1.5 mm ball driver 1 Syringe or Wash Bottle 1 Clean solvent 1 liter Safety glasses 1 Table 8-2: Tools and Supplies Required Procedure Do the following tasks to perform system flush purge: 1 Turn off the main power switch of the printer. 2 Disconnect the mains power cord from the electrical outlet. 3 Make sure that the printhead is installed on a correct mounting bracket and is directed into a suitable container. 4 Turn the knob and open the ink compartment door. 5 Remove the ink and the make-up fluid cartridges from the cartridge holders. 6 Remove the printhead cover screw that fastens the printhead cover to the printhead chassis, and remove the printhead cover (see Figure 8-2 on page 8-3). Caution To prevent nozzle clogs, always wear rubber gloves whenever the nozzle tubing manifold is to be disconnected from the printhead valve module. 7 Remove the M2 x 6 socket-head-cap screw that attaches the front tubing manifold to the printhead valve module. 8 Manually flush the nozzle assembly with a clean solvent. Use a syringe or wash bottle to do this task. 8-6 System Flush Purge Rev AA Videojet 1510 Service Manual 9 Fit the nozzle bypass manifold and the 2 way manifold gasket to the printhead valve module (refer to Figure 8-3 on page 8-4). 10 Open the quick disconnect (item 4, Figure 8-3 on page 8-4). 11 Put the container for recovered ink under the nozzle bypass manifold. 12 Connect the mains power cord to the electrical outlet. 13 Turn on the main power switch of the printer. The menu screen appears on the display. 14 Navigate to Password menu. The menu shown in Figure 8-5 appears. Figure 8-5. Password Menu 15 Select Enter Password submenu. The Enter Password dialog box appears (see Figure 8-6). Figure 8-6. Enter Password Dialog Box 16 Enter the Level 3 password and press the Enter key. The system allows you now to access all the menus in the UI. 17 Navigate to System menu and disable the Gutter Fault Shutdown. Rev AA System Flush Purge 8-7 Videojet 1510 Service Manual Figure 8-7. Gutter Fault Shutdown Command 18 Select System > Quick Start Jet. Figure 8-8. Quick Start Jet Command The ink flows from the nozzle bypass manifold until the ink core empty level is reached. 19 When the ink flows from the nozzle bypass manifold, introduce solvent into the gutter for 30 seconds. 20 Put the recovered ink aside for re-use if required (it is not required again during this procedure). 21 Close the quick disconnect in the nozzle bypass manifold. 8-8 System Flush Purge Rev AA Videojet 1510 Service Manual 22 Fit one of the solvent cartridges into the ink cartridge stall (with the smart chip programmed for ink) and fit this into the ink bottle holder (the right-hand holder) of the door. 23 Select System > Fill Ink Core. The ink core pump should stop when the middle level is reached. Figure 8-9. Fill Ink Core Command 24 If the pump does not stop within 4 minutes, do the following tasks: This condition occurs when the fluid is not conductive because of dilution in ink. a. Remove the cartridge from the stall and check if the cartridge is empty. b. If the cartridge is empty, proceed to Step 25. c. If there is still some fluid in the cartridge, return it to the stall and allow the pump to run for a further minute, before checking again. 25 Select System > Umbilical Purge and allow the printer to purge the umbilical with solvent for a minimum of 5 minutes (refer to “Umbilical Purge” on page 8-3). 26 After 5 minutes, stop the umbilical purge using Quick Stop. 27 Select System > System Flush Purge. Record the time. Rev AA System Flush Purge 8-9 Videojet 1510 Service Manual Figure 8-10. System Flush Purge Command 28 Observe if fluid is going through the red-striped tube (flush supply line). This process will take about 44 cycles. Note: Make sure that there are no leaks in tubing and fittings. 29 Press the Enter key. 30 Press Y to confirm, or N to cancel the operation. • Make sure that a receptacle is placed beneath the printhead to collect the used make-up fluid. • The make-up fluid must be removed from the printhead to complete the procedure. • If make-up fluid is not visible, repeat the procedure. • If air is visible in the effluent, repeat the procedure.The procedure will take approximately 10 - 15 minutes 31 The printer takes between 3 and 4 minutes to empty the ink core. At about this time, listen for the sound of the pump changing, as it begins to race when the level of fluid in the ink core drops below the pick-up tube. At this point, stop the printer by switching it off at the mains. 32 Repeat instructions for the remaining solvent cartridges (Step 22 to Step 31). 33 Remove the final empty solvent cartridge and the nozzle bypass manifold. 34 Refit the front tubing manifold of the nozzle. 35 Disconnect the 3-way manifold from the printhead valve module and disconnect the 3 printhead tubes from the ink system in the cabinet (clear tube, red-striped tube and larger gutter tube). 8-10 System Flush Purge Rev AA Videojet 1510 Service Manual 36 Expel fluid from the printhead tubes with clean air. 37 Reconnect the printhead tubes to the ink system tubes and refit the 3way manifold to the heater manifold. 38 Close the ink compartment door. 39 Fit the printhead cover to the printhead. Nozzle Flush Perform the nozzle flush in the following conditions: • If a nozzle has been clogged with dried ink • If the jet break up is asymmetric. Do the following tasks to perform nozzle flush: 1 Remove the printhead cover screw that fastens the printhead cover to the printhead chassis and remove the printhead cover (see Figure 8-2 on page 8-3). 2 Support the printhead in a suitable stand and place a container underneath to catch any extra solvent. 3 If the nozzle is clogged, initiate System > Nozzle Flush. Figure 8-11. Nozzle Flush Option If nozzle does not clear, seek assistance to have nozzle inspected by engineering. 4 Press the Enter key. The nozzle orifice should be irrigated with washdown to clear any blockages. Rev AA Nozzle Flush 8-11 Videojet 1510 Service Manual 5 The nozzle flush remains active for 2 minutes, but can be stopped at any time by pressing the F1 key. Replacement of Ink System Fan Filter for IP65 How to Remove the Old Ink System Fan Filter for IP65 Do the following tasks to remove the old ink system fan filter: 1 Turn the knob and open the ink system fan filter cover (item 2, Figure 8-12). 2 Remove the fan filter element (item 1) from the fan filter cover. 1 2 1. Fan Filter Element 2. Fan Filter Cover Figure 8-12. Ink System Fan Filter - IP65 3 Discard the fan filter element according to the local regulations. The removal of ink system fan filter for IP65 is complete. How to Install the New Ink System Fan Filter Do the following tasks to install the new ink system fan filter: 1 Insert the new ink system fan filter element inside the fan filter cover. 2 Close the ink system fan filter cover carefully. The installation of ink system fan filter for IP65 is complete. 8-12 Replacement of Ink System Fan Filter for IP65 Rev AA Videojet 1510 Service Manual Replacement of Ink System Fan Filter for IP55 How to Remove the Old Ink System Fan Filter for IP55 Do the following tasks to remove the old ink system fan filter: 1 Turn the knob and open the ink system fan filter cover (item 2, Figure 8-13). 2 Remove the fan filter element (item 1) from the fan filter cover. 1 2 1. Fan Filter Element IP55 2. Fan Filter Cover Figure 8-13. Ink System Fan Filter - IP55 3 Discard the old fan filter according to the local regulations. The removal of old ink system fan filter for IP55 is complete. How to Install the New Ink System Fan Filter for IP55 Do the following tasks to install the new ink system fan filter: 1 Insert the new ink system fan filter element inside the fan filter cover. 2 Close the ink system fan filter cover carefully. The installation of new ink system fan filter for IP55 is complete. Rev AA Replacement of Ink System Fan Filter for IP55 8-13 Videojet 1510 Service Manual Replacement of Floor Filter for IP65 How to Remove the Old Floor Filter IP65 Do the following tasks to remove the old floor filter: 1 Loosen the four M4 x 40 cap-head screws (item 1, Figure 8-14) and remove the screws. 2 Detach the ink core support channel (item 2). 3 Remove the filter element (item 3) from the filter tray (item 6). 1 2 3 4 5 6 1. M4 x 40 Cap-head Screw (x4) 2. Ink Core Support Channel 3. Filter Element 4. Filter Clamp 5. M4 x 8 Cap-head Screw (x6) 6. Filter Tray Figure 8-14. Floor Filter - IP65 4 Discard the old floor filter element according to the local regulation. The removal of old floor filter for IP65 is complete. How to Install the New Floor Filter IP65 Do the following tasks to install the new floor filter: 1 Insert the new floor filter element on the filter tray. 2 Attach the ink core support channel. 8-14 Replacement of Floor Filter for IP65 Rev AA Videojet 1510 Service Manual 3 Tighten the M4 x 40 cap-head screws. The installation of new floor filter for IP65 is complete. Replacement of Floor Filter for IP55 How to Remove the Old Floor Filter IP55 Do the following tasks to remove the old floor filter: 1 Loosen the four M4 x 40 cap-head screws (item 1, Figure 8-15) and remove the screws. 2 Detach the ink core support channel (item 2). 3 Detach the ink side filter top (item 3) and ink side filter base (item 4). 4 Remove the floor filter element (item 5) from the cabinet base. 1 2 3 4 5 1. M4 x 40 Cap-head Screw (x4) 2. Ink Core Support Channel 3. Ink Side Filter Top 4. Ink Side Filter Base 5. Floor Filter Element Figure 8-15. Floor Filter - IP55 5 Discard the old floor filter element according to the local regulations. The removal of old floor filter for IP55 is complete. Rev AA Replacement of Floor Filter for IP55 8-15 Videojet 1510 Service Manual How to Install the New Floor Filter for IP55 Do the following tasks to install the new floor filter: 1 Insert the new floor filter element on the cabinet base. 2 Attach the ink side filter base and ink side filter top above the floor filter element. 3 Attach the ink core support channel. 4 Tighten the M4 x 40 cap-head screws. The installation of new floor filter for IP55 is complete. Windows CE Upgrade Procedure Tools and Supplies Required Equipment Quantity “A to A” USB Cable 1 Serial Cable (MS1227 or 80200258) 1 Laptop 1 CSB Pack (bundled software files) 1 Table 8-3: Tools and Supplies Required System Backup You must perform a full system backup in order to safeguard the existing data of the customers, as the subsequent steps that you will be performing will erase all existing data. Refer to “Perform Full System Backup” on page 5-3. 8-16 Windows CE Upgrade Procedure Rev AA Videojet 1510 Service Manual Hardware Connections Do the following tasks to establish hardware connections: 1 Turn off the power supply to the printer. Warning Before you open the electronics compartment door, wear anti-static wrist straps and ground yourself to the chassis of the cabinet. Failure to follow this warning can cause both personal injury and damage to the printer. 2 Open the electronics compartment. 3 Connect the "A to A" USB cable from the USB connection of the laptop to the USB connection on the left side of the CSB. 4 Configure SW2 as follows: 1 OFF 2 OFF 3 OFF 4 ON 5 ON 6 OFF This ensures that the CSB is set to the USB device mode. 5 Connect the serial cable from the DB-9 port on the laptop to the 5-pin DIN connector on the side of the printer. 6 Turn on the printer. WINDOWS XP Laptop should establish USB connection with the printer, and prompt for a new hardware device and look for a suitable driver. Guide it to the secbulk.sys and secbulk.inf files in the USB directory of the CSB Pack bundle. WINDOWS 2000 7 Do the following tasks to install the driver for windows 2000: a. Navigate to Start> Settings> Control Panel. b. Select Add/Remove Hardware. Rev AA Windows CE Upgrade Procedure 8-17 Videojet 1510 Service Manual c. Navigate through the associated Wizard and Troubleshooter. When prompted to identify the needed driver, select the secbulk.sys and secbulk.inf files in the USB directory of the CSB Pack bundle. 8 Turn off the printer. USB Download through Serial Commands Do the following tasks to initiate USB download through serial commands: 1 Configure Hyper terminal on the laptop with the following specifications: • 115,200 baud • 8 data bits • No parity • 1 Stop Bit • No flow control 2 Turn on the printer. 3 Monitor the terminal software display. You must press the space bar on the laptop within 5 seconds. The code that appears on the terminal display is shown in Figure 8-16. Figure 8-16.Terminal Display You can see a countdown to Initiating image launch. 8-18 Windows CE Upgrade Procedure Rev AA Videojet 1510 Service Manual You have 5 seconds from power-up in which to press the space bar. If you miss it, turn off the printer and try again. 4 The "EBoot menu" should be provided through Hyper terminal (see Figure 8-17). Figure 8-17.Eboot Menu 5 Go through the following sequence of steps to prepare for USB (or Ethernet) download on the laptop, and to ensure that the downloaded image is programmed to NAND (thereby making the board standalone bootable). Note: The first four steps can be modified as necessary. a. Press '4' to show (Reset to factory default configuration) b. Press '8' until Kernel Debugger shows DISABLED c. Press '5' until Startup Image: shows LAUNCH EXISTING d. Press '6' until Program disk image into SmartMedia card shows ENABLED e. Press 'T' (Clear the sector info for steploader and Eboot) f. Press 'S' (Protect the StepLoader) g. Press '9' (Format Boot Media for BinFS) h. Press 'W' (Write Configuration Right Now) i. Finally, press 'U' to initiate USB Download Rev AA Windows CE Upgrade Procedure 8-19 Videojet 1510 Service Manual USB Download Do the following tasks for USB download: 1 Run dnw.exe software. This application is located in the USB folder of the CSB Pack bundle. 2 Make sure that USB:OK is displayed (see Figure 8-18). Figure 8-18.USB: OK 3 Select USB Port > UBOOT(WINCE500) > UBOOT and the screen shown in Figure 8-19 appears. Figure 8-19.USB Port Menu 8-20 Windows CE Upgrade Procedure Rev AA Videojet 1510 Service Manual 4 Navigate to the required location and select the appropriate.bin file. Click the Open button (see Figure 8-20). Figure 8-20..bin File 5 The USB download gets initiated. Rev AA Windows CE Upgrade Procedure 8-21 Videojet 1510 Service Manual 6 Once the download is complete you should see the image (see Figure 8-21) appear in the Hyper terminal display and this is the image being committed to NAND Flash. Figure 8-21.Terminal Window Display 7 The following code should appear in Hyper terminal (and WinCE and then the UI will start on the printer) (see Figure 8-22). Figure 8-22.Terminal Window Display 8 The printer will prompt the user to load the 43s interface. Make the appropriate selection. 8-22 Windows CE Upgrade Procedure Rev AA Videojet 1510 Service Manual 9 Once the printer has booted, it will automatically go into the EHT Calibration procedure. Note: These settings (EHT Calibration) were erased during the upgrade. 10 Enter the Level 3 password. 11 The printer will have loaded a software version and a firmware version as part of the CE upgrade process. 12 You can check the version information under Data Logging. 13 Additional changes to the software and firmware versions may be accomplished by using the normal process and the USB flash drive. Rev AA Windows CE Upgrade Procedure 8-23 9 Troubleshooting Read the Operator Manual The Videojet 1510 Operator Manual (Part Number 361868) contains the troubleshooting procedures that an operator is allowed to perform. Refer to the operator manual for these procedures. This chapter contains the troubleshooting procedures that only a service technician is allowed to perform. Warning It is possible that in a fault condition the heater can reach 70 °C. Do not touch the plate on which heater is installed. The failure to follow this warning can cause the personal injury. Important Guidelines • Before you perform fault diagnosis or do any repairs described in this section, Videojet recommends you to move the printer from the production line to a clean environment. • When a fault condition occurs, the first step in locating the reason for the fault must be to check the following: • The fault and status icons displayed on the display. • The status LEDs on the CSB. • Table 9-6 on page 9-7 through Table 9-8 on page 9-14 list the possible printer status icons. These tables contain either remedial action or a reference to more detailed fault finding information. Rev AA Read the Operator Manual 9-1 Videojet 1510 Service Manual Startup Problems Printer Fails to Start Possible Cause Remedial Action No main power supply Make sure that the main power supply is turned on. To turn on the printer, press the green push button. Main power supply input cable disconnected or defective 1. Make sure that the cable that provides the main power supply is connected. 2. Check the continuity of the cable. If the cable is defective, repair or replace the cable. Printer main power supply fuse failed Check the F1 fuse in the PSU. Replace the fuse if necessary. Faulty mains switch Check mains power switch. Replace the switch if the switch is faulty. Cable between mains switch and PSU is disconnected or faulty 1. Check the cable connections. Reconnect if necessary. 2. Check the cable for continuity. Replace if faulty. PSU output not reaching the CSB Check LEDs 1, 2, 3, 4 and 5 on CSB (see Figure 9-1 on page 9-3). Cable between PSU and CSB is faulty or disconnected 1. Check if the cable between PSU and CSB is connected. Reconnect if necessary. 2. Check the cable for continuity, replace if faulty. PSU fuse failed Check the fuse, replace if necessary. PSU faulty Replace PSU (see “Power Supply Unit” on page 7-9). CSB failed 1. Make sure that LEDs 1, 2, 3, 4 or 5 on CSB are illuminated.See Figure 9-1 on page 9-3. 2. Change CSB (see “Control System Board” on page 7-7). Table 9-1: Printer Startup Problem and Remedies 9-2 Startup Problems Rev AA Videojet 1510 Service Manual 1 5 4 3 2 1. CSB 2. Power LED 3. Print Engine LED 4. SoC to FPGA LED 5. Ethernet LED Figure 9-1: Status LEDs Display Faults Backlight Warning LETHAL VOLTAGES. A high AC voltage is present at the inverter and backlight. Extreme caution is required when diagnosing failure in these areas. Rev AA Display Faults 9-3 Videojet 1510 Service Manual Note: Some DVMs may not show the 1000 V AC correctly. Use an oscilloscope fitted with a high voltage probe to measure the voltage. Possible Cause Remedial Action Backlight inverter faulty 1. Check for 24 V DC at 3 way input connector on backlight converter (Pins 1 and 2 on I/O board B/LIGHT connector). 2. Check for 1000 V AC at output leads from backlight inverter (Pins 3 and 5). 3. If 24 V DC is present but 1000 V AC is missing, change the LCD/ backlight assembly (see “LCD and FIB Assembly” on page 7-13). Cable from CSB to backlight is disconnected or faulty 1. If 24 V DC is not present at backlight inverter but is present at Pins 1 and 3 of B/LIGHT connector on I/O board, make sure that the cable is connected between the CSB and the backlight. 2. Check the cable for continuity, replace if faulty. Backlight faulty If 1000 V AC is present at output of backlight inverter but backlight is not illuminated, change the LCD/Backlight assembly (see “LCD and FIB Assembly” on page 7-13). CSB door board faulty Check for 24 V DC on pins 1 and 3 of B/LIGHT connector on I/O board. If 24 V DC is not present, change CSB (see “Control System Board” on page 7-7). Table 9-2: Display Backlight Failure LCD Faults Possible Cause Remedial Action LCD contrast not set correctly Press to set the contrast. Ribbon cable between CSB and LCD is faulty Check the cable for continuity. Replace if faulty. CSB faulty Change the CSB (see “Control System Board” on page 7-7). LCD faulty Change the LCD assembly. Table 9-3: LCD Failure 9-4 Display Faults Rev AA Videojet 1510 Service Manual Keypad Faults Possible Cause Remedial Action Ribbon cable between CSB and keypad is disconnected or faulty 1. Make sure that the ribbon cable between CSB and the keypad is connected. 2. Check the cable for continuity, replace if faulty. CSB faulty Change the CSB (see “Control System Board” on page 7-7). Keyboard faulty Change the keyboard. (see “Keyboard/Electronics Compartment Door” on page 716). Table 9-4: Keypad Failure Rev AA Display Faults 9-5 Videojet 1510 Service Manual Display Icons Alarm Light Conditions Alarm Light Color Description Red Jet Off, No warnings. All Relays off Amber Jet On, Warning present, Print not enabled and Relay 2 set. Green Print Enabled, No Warnings and Relay 1 set Green and Amber Print Enabled, Warning Present, Relay 1 and 2 set Red and Amber Jet off, Warning Present and Relay 2 set No Lights Jet Running, No Warnings, and Print disabled. All Relays are off in this mode Table 9-5: Alarm Light Conditions Printer Status Icons The printer status icons are divided into three groups: • The indicator icons. The indicator icons show the status of the ink jet. • The fault icons. When a fault condition occurs, the printer stops printing. • The warning icons. When a warning condition occurs, the printer continues to print until the warning condition becomes a fault condition. 9-6 Display Icons Rev AA Videojet 1510 Service Manual Indicator Icons Icon Name Description Jet Running The ink jet is running and the machine is ready to print. When the machine starts, the icon flashes. Jet Stopped Indicates that the ink jet is stopped. When the machine stops, the icon flashes. Table 9-6: Indicator Icons Fault Icons Fault Reason Causes Action Charge Error The charge amplifier is over temperature OR invalid charge data. Excessive electronics compartment temperature. 1. Check electronics compartment temperature on diagnostics screen. 2. Check to ensure that electronics compartment fan is turning. 3. Keep electronics compartment door open and see if compartment temperature drops; attempt restart. 4. If fault returns, lower print rate and monitor electronics compartment temperature. Defective CSB 1. Check test points related to charge amplifier: TP50, TP72, CHG. 2. Replace the CSB (see “Control System Board” on page 7-7). Table 9-7: Fault Icons Rev AA Printer Status Icons 9-7 Videojet 1510 Service Manual Fault Reason Causes Action EHT Trip Excessive current in the EHT circuit as measured by the CSB. The printhead is dirty or wet 1. Clean and dry the printhead. 2. Restart the inkjet; monitor for ink build-up on the printhead during printing operations if possible. The EHT circuit is not calibrated 1. Stop the ink jet. 2. Perform "Calibrate EHT". 3. Restart the inkjet; monitor system performance. Short in umbilical or EHT resistor 1. Stop the inkjet and de-energize the printer. 2. Unplug the EHT wire from the EHT power supply. 3. Measure the resistance between the EHT wire and the EHT plate. 4. f open or short circuit exists, remove the Printhead Engine and inspect the EHT resistor. 5. Replace the umbilical. Defective EHT power supply Replace the EHT power supply. Defective CSB Replace the CSB. Table 9-7: Fault Icons 9-8 Printer Status Icons Rev AA Videojet 1510 Service Manual Fault Reason Causes Action Gutter Fault Jet is on, ink stream is not detected in the gutter for more than 5 seconds Nozzle is clogged 1. Perform a nozzle back flush. 2. Restart the inkjet and make sure that the ink stream is entering the gutter. Inadequate ink pressure 1. Check for the presence of pump fault 2. Check the actual pressure using diagnostics screens. Ink stream is misaligned 1. Perform a nozzle flush. 2. Restart the inkjet and confirm that the ink stream is entering the gutter. 3. Perform an ink stream alignment. No vacuum 1. Clean the printhead. 2. Perform a nozzle flush and check for flow in the return line to confirm the proper operation of the vacuum system. 3. Remove the Print Engine and inspect the length of tubing between the gutter and the Printhead Valve Module for clogs. 4. Loosen Valve V2 (VP and VG) and clean. The gutter sense chamber is defective 1. Remove the Print Engine and inspect the gutter sense chamber. 2. Check CSB test point 45 for the gutter sense signal 3. Check umbilical wires related to the gutter sense signal. 4. Replace the umbilical. New installation. Perform "Fill Ink Core" procedure to establish correct level in ink core module. "Ink Core Low" and printer is unable to add ink. Refer to “Ink Core Level Low” on page 9-26. Ink Core Empty The "low" level sensor in the ink core module is uncovered. Table 9-7: Fault Icons Rev AA Printer Status Icons 9-9 Videojet 1510 Service Manual Fault Reason Causes Action Pump Fault The pump speed is >98% of the maximum value and the actual pressure is >0.2 bar below the target pressure. Leak 1. Inspect ink compartment, electronics compartment, and umbilical for leaks. 2. Repair if possible. Erroneous pressure indication 1. Inspect the electrical connections between the ink core module and the PIB, and between the PIB and the CSB. 2. Check and compare the voltage readings at the test points related to pump and pressure: TP20, TP21, TP22, and TP47. Also, remove the top cover of the ink core module and measure the voltage between points + Press and - Press. Defective pump. 1. Inspect the electrical connections between the ink core module and the PIB, and between the PIB and the CSB. 2. Open the pump compartment, and inspect the pump. 3. Replace the pump. Ink too thin. 1. Check the diagnostics screen. 2. Compare the "target pressure" with the temperature-compensated target pressure. 3. If the "target pressure" is significantly less than (1 bar) than the temperaturecompensated target pressure, the ink is too thin. 4. Recover the viscosity by allowing the jet to run continuously, or by draining and re-priming the system. Erroneous velocity indication 1. Clean the printhead. 2. Check the diagnostics screen. 3. Compare the "actual velocity" with the "velocity set point". 4. Remove the printhead engine and measure the resistances between the copper pads on the underside of the Printhead Engine; compare to the expected values. 5. With an oscilloscope, check the waveforms at the CSB test points related to velocity: "PHA", TP69, TP58, TP59, TP60, TP61. Table 9-7: Fault Icons 9-10 Printer Status Icons Rev AA Videojet 1510 Service Manual Fault Reason Causes Action Cabinet Too Hot The cabinet temperature measured by the CSB is above 80° Celsius The electronics compartment is overheated. 1. Open the electronics compartment. 2. Inspect the electronics compartment components for any damage or overheating. 3. If possible, operate the printer with the electronics compartment door open and monitor the "Electronics Temperature" via the diagnostics screen. The ambient temperature is too high. 1. Move the printer to a location where the ambient temperature is lower, or attempt to lower the temperature at the current location. 2. Monitor the "Electronics Temperature" via the diagnostics screen. The heat sink is insulated or obstructed. Remove the insulation/obstruction from the vicinity of the heat sink. The mains power supply is defective. 1. Check the voltages from the mains power supply being supplied to the CSB. 2. Replace the mains power supply The CSB is defective. Replace the CSB Ink System Service Overdue Ink core module is in use for more than 8000 hours Table 9-7: Fault Icons Rev AA Printer Status Icons 9-11 Videojet 1510 Service Manual Fault Reason Causes Action Unable to Control Viscosity The printer has been unable to perform automatic viscosity control for an interval of 30 minutes or greater. Ink core level is "high" and target pressure has been >.1 bar above temperaturecompensated target pressure for 1 hour. Refer to “Ink Core Level High” on page 9-25. No make-up cartridge, or invalid makeup cartridge, and target pressure has been >.1 bar above temperaturecompensated target pressure for 1 hour. Refer to “No Make-up Cartridge” on page 9-23 Printer is unable to obtain a phase profile for ½ hour. Refer to “Phase Threshold Error” on page 9-17 Printer is unable to measure velocity for ½ hour. Refer to “No Time for TOF” on page 9-30. Mod Driver Chip Over Temperatu re Mod amplifier hardware has shutdown. Rasters Memory Overflow Detected Not enough memory to store all requested raster tables Amplifier over temperature Table 9-7: Fault Icons 9-12 Printer Status Icons Rev AA Videojet 1510 Service Manual Fault Reason Valve Error - Contact the Service Department Hardware error in valve hit / hold drive circuit Bad Phasing Unable to obtain phase data during startup Modulation Readback Failed Hardware error, ADC readback invalid Causes Action Table 9-7: Fault Icons Rev AA Printer Status Icons 9-13 Videojet 1510 Service Manual Warning Icons Warning Reason Causes Action Printhead Temperature Too High The printhead temperature is 3° Celsius greater than setpoint, with head heater enabled. The printhead has (temporarily) overheated. Allow the inkjet to run - the printhead temperature should correct itself. The ambient temperature is too high. If print quality or performance issues are noted, consider operating the printer in a cooler environment if possible. Defective power supply. 1. Check the voltages from the mains power supply being supplied to the CSB. 2. Replace the mains power supply. Defective temperature control circuit (short) 1. Inspect the electrical connections between the CSB and the PIB, and between the PIB and the umbilical 2. Remove the Printhead Valve Module. Inspect the electrical connections between the Printhead Valve Module and the deck. 3. Measure the resistances between the copper pads on the underside of the Printhead Valve Module and compare these to the expected values. 4. Check the umbilical wires for continuity. Incorrect Raster or Raster Family Name Requested raster table not loaded into the system.Warnin g appears immediately Table 9-8: Warning Icons 9-14 Printer Status Icons Rev AA Videojet 1510 Service Manual Warning Reason Causes Action Printhead Temperature Too Low The measured printhead temperature is more than 3° Celsius below the target temperature. Error duration before warning is 30 seconds The printhead has not yet reached operational temperature. Allow the inkjet to continue to run - the printhead temperature should correct itself. The ambient temperature is too low. If print quality or performance issues are noted, consider operating the printer in a cooler environment if possible. Defective power supply. 1. Check the voltages from the mains power supply being supplied to the CSB. 2. Replace the mains power supply. Defective temperature control circuit (open) 1. Inspect the electrical connections between the CSB and the PIB, and between the PIB and the umbilical. 2. Remove the Printhead Valve Module. 3. Inspect the electrical connections between the Printhead Valve Module and the deck. 4. Reset the Printhead Valve Module, start the printer and monitor printhead temperature 5. If problem persists, Measure the resistances between the copper pads on the underside of the Printhead Valve Module and compare these to the expected values. 6. Check the umbilical wires for continuity TOF Too High Measured jet velocity is more than 10% above target figure. Warning appears immediately Table 9-8: Warning Icons Rev AA Printer Status Icons 9-15 Videojet 1510 Service Manual Warning Reason TOF Too Low Measured jet velocity is more than 10% below target figure. Warning appears immediately Charge Error Shutdown Disabled Operator has disabled machine shutdown on charge error. Warning appears immediately Gutter Fault Shutdown Disabled Operator has disabled machine shutdown on gutter fault. Warning appears immediately Printhead Cover Removed Lid switch circuit is open Causes Action The printhead cover is removed Replace the printhead cover Open circuit Inspect the cabling from the umbilical to the PIB and from the PIB to the CSB Defective lid switch 1. Stop the inkjet and de-energize the printer. 2. Remove the Print Engine and inspect the lid switch. 3. Measure the resistances between the copper pads on the underside of the Printhead Engine and compare readings to the expected values. 4. Check umbilical wires for continuity. Defective CSB Check measurement at TP56 on the CSB. Table 9-8: Warning Icons 9-16 Printer Status Icons Rev AA Videojet 1510 Service Manual Warning Reason Causes Action Phase Threshold Error The printer is unable to acquire a phase profile with the phase threshold set to the minimum value. The printhead is dirty Clean and dry the printhead. The ink stream is misaligned. 1. Perform a nozzle backflush. 2. Restart the inkjet. 3. If the ink stream is still misaligned, perform the ink stream alignment procedure. No break-off. 1. Perform a visual inspection to verify breakoff. 2. If break-off does not exist, perform a cursory check of electrical connections on the Print Engine and in the electronics compartment. 3. Attempt to set the modulation manually to obtain break-off. 4. If break-off cannot be obtained, check the modulation signal on the CSB. If the modulation signal does not exist, see below (“CSB failed"). 5. If the modulation signal is present on the CSB, check for the modulation signal in the printhead. 6. Remove the Print Engine and check its electrical connections. 7. Replace the Print Engine. "Phase Charge" incorrectly set. 1. Check the "Phase Charge" setting. 2. Adjust the "Phase Charge" setting to recover the phase profile. Electrical malfunction in TOF circuit. 1. Check the electrical connections between the CSB and the PIB, and between the PIB and the umbilical. 2. Remove the Print Engine and check its electrical connections. 3. Check the resistances between the copper pads on the underside of the Printhead Engine, and compare results with the expected values. 4. Check for continuity in the umbilical wires. Table 9-8: Warning Icons Rev AA Printer Status Icons 9-17 Videojet 1510 Service Manual Warning Reason Causes Action No charge pulses. 1. With the ink jet running but the printer not printing, check for the presence of charge pulses at the charge tunnel. 2. If no pulses are present, check for the presence of charge pulses at TP "CHG" on the CSB 3. Check for continuity in the umbilical wires. CSB failed With test equipment, check for presence of all related signals on CSB: TP38, CHG, PHA. Table 9-8: Warning Icons 9-18 Printer Status Icons Rev AA Videojet 1510 Service Manual Warning Reason Causes Action Ink Viscosity Too High The target pressure is >.1 bar above the temperaturecompensated target pressure The ink is too thick. The printer should add make-up fluid to correct its viscosity. Monitor the progress of make-up additions using "Diagnostics Screen Three". If the printer does not appear to be attempting to add make-up (allow at least five minutes for a make-up addition to be attempted), see causes below. If make-up addition capability is confirmed but printer operations are impaired by thick ink, consider flushing the system. The make-up cartridge is removed or seated improperly. 1. Install or reset the make-up cartridge. 2. Verify that the "no make-up" icon extinguishes. The make-up cartridge is of the wrong type. 1. Install a cartridge of the correct make-up type. 2. Verify that the "wrong make-up" icon extinguishes The make-up add line is disconnected or leaks. 1. Open the ink compartment door and gently slide the ink core module forward. 2. Locate the GREEN-striped tube behind the ink core module. 3. Make sure that the quick disconnect in this line is secure and that the line is not leaking. The ink core module level is "high". 1. Confirm condition by checking icons on home screen. 2. To clear the condition, perform these steps: • Direct the printhead into a service tray. • Disable the "gutter fault". • Raise the ink stream above the catcher. 3. Allow the ink stream to jet into the service tray until the ink core module level is restored to normal. The ink core module level is defective Replace the ink core module Table 9-8: Warning Icons Rev AA Printer Status Icons 9-19 Videojet 1510 Service Manual Warning Reason Causes Action Ink Viscosity Too low The target pressure is >.1 bar below the temperaturecompensated target pressure. The ink is too thin. 1. Allow the inkjet to run so that the excess make-up fluid evaporates. The following actions will help to recover the viscosity: • Avoid nozzle backflushing and improper printhead cleaning (with the vacuum applied). • Exercise the "Quick Start" and "Quick Stop" options whenever possible. • Run Gutter Pump at maximum speed. • Check for flow in the GREEN-striped tube, to make sure that make-up is not being inadvertently added. 2. If printer operations are impaired by thin ink, consider flushing the system. Or, complete the following steps: • Direct the printhead into a service tray. • Disable the "gutter fault". • Raise the ink stream above the catcher. • Allow the ink stream to jet into the service tray until the viscosity is restored (the printer will add fresh ink to compensate for system losses). Pressure too High The actual pressure is more than 0.2 bar above the target pressure. Printer transient Printer will correct itself Erroneous pressure indication. 1. Inspect electrical connections between the ink core module and the PIB, and between the PIB and the CSB. 2. Replace the ink core module. Check and compare the voltage readings at the test points related to pump and pressure: TP20, TP21, TP22, and TP47. Also, remove the top cover of the ink core module and measure the voltage between points + Press and - Press. Table 9-8: Warning Icons 9-20 Printer Status Icons Rev AA Videojet 1510 Service Manual Warning Reason Causes Action Pressure Too Low The actual pressure is more than 0.2 bar below the target pressure. Printer transient. Printer will correct itself. Leak 1. Inspect the ink compartment, electronics compartment, and umbilical for leaks. 2. Repair if possible. Erroneous pressure indication. 1. Inspect the electrical connections between the ink core module and the PIB, and between the PIB and the CSB. 2. Check and compare the voltage readings at the test points related to pump and pressure: TP20, TP21, TP22, and TP47. Also, remove the top cover of the ink core module and measure the voltage between points + Press and - Press. Defective pump 1. Inspect electrical connections between the ink core module and the PIB, and between the PIB and the CSB. 2. Open the pump compartment, and inspect the pump. 3. Replace the pump. No ink cartridge is present Insert an ink cartridge into the proper cartridge holder. The ink cartridge is empty Remove the empty cartridge and insert a new ink cartridge. The printer is unable to read the ink cartridge Smart Chip 1. Ensure that the ink cartridge is seated correctly in its receptacle. 2. Remove the ink cartridge. Check that the smart chip is present and is clean. 3. If another ink cartridge is available, insert it into the printer and see if the printer can read its smart chip. 4. Check that the smart chip reader (inside the receptacle) is positioned correctly and is clean. 5. Check the electrical connections between the smart chip reader and the PIB board, and between the PIB board and the CSB. No Ink Cartridge No ink available for addition to the Core Table 9-8: Warning Icons Rev AA Printer Status Icons 9-21 Videojet 1510 Service Manual Warning Reason Causes Action Wrong Ink Cartridge Ink type in cartridge incompatible with ink core module. Fluid Ref and fluid Type must match ink core module. A cartridge containing the wrong ink type has been inserted into the printer 1. Remove the ink cartridge. 2. Check the label on the ink cartridge to confirm the ink type. 3. Insert a cartridge of the correct ink type into the printer A make-up cartridge was accidentally inserted into the ink cartridge holder 1. Remove the cartridge. 2. Check the label on the cartridge to confirm fluid type. 3. Insert a cartridge of the correct ink type into the printer. The smart chip on the ink cartridge is programmed incorrectly or does not match the label. 1. Remove the cartridge. 2. Check the label on the cartridge to confirm fluid type. 3. Insert a cartridge of the correct ink type into the printer. Ink used for printing Insert a new ink cartridge into the proper cartridge holder after ink out. Ink Cartridge Expired Ink past expiry date Ink Cartridge Low Less than 5% of the ink in the ink cartridge remains. Ink Cartridge Empty Ink cartridge smart chip data 0% Ink Insertions Exceeded This ink cartridge inserted more than TEN times Table 9-8: Warning Icons 9-22 Printer Status Icons Rev AA Videojet 1510 Service Manual Warning Reason Causes Action No Make-up Cartridge No make-up available for addition to the Core No make-up cartridge is present Insert a make-up cartridge into the proper cartridge holder. The make-up cartridge is empty Remove the empty cartridge and insert a new make-up cartridge The printer is unable to read the make-up cartridge Smart Chip. 1. Ensure that the make-up cartridge is seated correctly in its receptacle. 2. Remove the make-up cartridge. Check that the smart chip is present and is clean. 3. If another make-up cartridge is available, insert it into the printer and see if the printer can read its smart chip. 4. Check that the smart chip reader (inside the receptacle) is positioned correctly and is clean. 5. Check the electrical connections between the smart chip reader and the PIB board, and between the PIB board and the CSB. A cartridge containing the wrong make-up type has been inserted into the printer 1. Remove the make-up cartridge 2. Check the label on the make-up cartridge to confirm the make-up type. 3. Insert a cartridge of the correct make-up type into the printer. An ink cartridge was accidentally inserted into the make-up cartridge holder. 1. Remove the cartridge 2. Check the label on the cartridge to confirm fluid type. 3. Insert a cartridge of the correct make-up type into the printer. The Smart Chip on the make-up cartridge is programmed incorrectly or does not match the label. 1. Remove the make-up cartridge 2. Check the label on the make-up cartridge to confirm the make-up type. 3. Insert a cartridge of the correct make-up type into the printer. Wrong Makeup Cartridge The cartridge inserted into the make-up cartridge holder contains the wrong makeup type. Table 9-8: Warning Icons Rev AA Printer Status Icons 9-23 Videojet 1510 Service Manual Warning Reason Causes Action Makeup Cartridge Low Less than 5% of the make-up in the make-up cartridge remains. Make-up evaporation used during "jet on" operations. Make preparations to insert a fresh make-up cartridge into the proper cartridge holder. Replace the cartridge following "make-up out". Clean Start / Stop Inhibited Viscosity is too low, so clean start / stop inhibited to prevent solvent addition Makeup Insertions Exceeded This makeup cartridge inserted more than TEN times Table 9-8: Warning Icons 9-24 Printer Status Icons Rev AA Videojet 1510 Service Manual Warning Reason Causes Action Ink Core Level High The "high" level sensor in the ink core module is covered Excessive starts and stops. 1. Use "Quick Start" and "Quick Stop" options until ink core module level is restored 2. Keep jet running to burn off excess makeup. 3. If printer operation is impaired by high ink core module level ("unable to control viscosity"), raise the ink stream above the catcher to restore the ink core module level to normal. Excessive nozzle backflushing. 1. Use "Quick Start" and "Quick Stop" options until ink core module level is restored. 2. Keep jet running to burn off excess makeup. 3. If printer operation is impaired by high ink core module level ("unable to control viscosity"), raise the ink stream above the catcher to restore the ink core module level to normal. Improper printhead cleaning 1. Use "Quick Start" and "Quick Stop" options until ink core module level is restored. 2. Keep jet running to burn off excess makeup. 3. If printer operation is impaired by high ink core module level ("unable to control viscosity"), raise the ink stream above the catcher to restore the ink core module level to normal. Leak 1. Check for flow in the black or green striped tubing (ink and make-up add line). 2. If flow is present continuously, disconnect the line and check for presence of vacuum. 3. Replace the Core Module. Table 9-8: Warning Icons Rev AA Printer Status Icons 9-25 Videojet 1510 Service Manual Warning Reason Causes Action Ink Core Level Low The "middle" level sensor in the mixer tank is uncovered. Ink usage during printing. The printer should add ink to restore ink core module level to "middle". However, if the printer is attempting to add ink, but the level is not restored, perform the following: 1. Confirm that the printer is attempting to add ink by monitoring the "ink add valve" on the diagnostics screen. The screen should indicate that the valve is opening. 2. If the printer is not attempting to add ink, check to make sure that a valid cartridge of the correct ink type is inserted into the ink cartridge receptacle. 3. If the printer is attempting to add ink, but the level is not restoring, troubleshoot the ink addition system as follows: 1. Ensure that the ink cartridge is not actually empty 2. Stop the jet and perform a "valve test". Verify that the ink add valve is operational. If it is not operational, remove and clean the valve. 3. Inspect the black-striped tubing and the ink receptacle septum needle for obstruction 4. Troubleshoot the venturi system - use the temporary gauge manifold to check the venturi vacuum. 5. Replace the Core. Table 9-8: Warning Icons 9-26 Printer Status Icons Rev AA Videojet 1510 Service Manual Warning Reason Causes Action Cabinet Hot The cabinet temperature measured by the CSB is greater than 70º Celsius The electronics compartment is overheating. 1. Open the electronics compartment. 2. Inspect the electronics compartment components for damage or overheating. 3. If possible, operate the printer with the electronics compartment door open and monitor the "Electronics Temperature" via the diagnostics screen The ambient temperature is too high. 1. Move the printer to a location where the ambient temperature is lower, or attempt to lower the temperature at the current location. 2. Monitor the "Electronics Temperature" via the diagnostics screen. The heat sink is insulated or obstructed. Remove the insulation / obstruction from the vicinity of the heat sink. The mains power supply is defective. 1. Check the voltages from the mains power supply being supplied to the CSB. 2. Replace the mains power supply if found faulty The CSB is defective. The CSB is defective. Ink Core Insertions Exceeded The ink core module has been disconnected / reconnected more than TEN times Table 9-8: Warning Icons Rev AA Printer Status Icons 9-27 Videojet 1510 Service Manual Warning Reason Causes Action Pump RPM Near Max The pump speed is >98% of the maximum value. Leak 1. Inspect the ink compartment, electronics compartment, and umbilical for leaks. 2. Repair if possible Defective pump 1. Inspect electrical connections betwixt the Core and the PIB, and between the PIB and the CSB. 2. Open the pump cover, and inspect the pump. 3. Replace the pump. Ink too thin. 1. Check the diagnostics screen. 2. Compare the "target pressure" with the temperature-compensated target pressure. 3. If the "target pressure" is significantly less than (1 bar) than the temperature-compensated target pressure, the ink is too thin. 4. Recover the viscosity by allowing the jet to run continuously, or by flushing and repriming the system. Defective pump 1. Inspect electrical connections between the Core Module and the PIB, and between the PIB and the CSB. 2. Open the pump cover, and inspect the pump. 3. Replace the pump. Erroneous velocity indication. 1. Clean the printhead. 2. Check the diagnostics screen. 3. Compare the "actual velocity" with the "velocity set point". 4. Change the Print Engine. Ink Core Empty Ink core module low probe is uncovered tank close to empty or empty Pump Fault Pump near max RPM & pressure low No Ink Core No data from ink core smart chip - ink core not plugged in Table 9-8: Warning Icons 9-28 Printer Status Icons Rev AA Videojet 1510 Service Manual Warning Reason Causes Action Ink Core Service Soon (0.5% Left). Ink core module very near end of service life 40 hours remaining on the Core Smart Chip Make preparations to change the Core. Ink Core Service Soon (2% Left) Ink core module nearing end of service life 160 hours remaining on the Core Smart Chip. Make preparations to change the Core. Ink Core Service Soon (5% Left) Ink core module nearing end of service life 400 hours remaining on the Core Smart Chip Make preparations to change the Core. Product Delay Too Short Compile time greater than product delay. Inter-print Gap Too Short Insufficient time to compile between prints. Print Queue Too Deep Too many products between PEC and printhead. Print Overlap Print starts before end of current print. Table 9-8: Warning Icons Rev AA Printer Status Icons 9-29 Videojet 1510 Service Manual Warning Reason Causes Action No Time to Phase Less than 10 milliseconds from the end of one print to the beginning of the next. The line speed is too fast Reduce the line speed, if possible The distance between adjacent products is too short. Increase the distance between adjacent products, if possible. The message is too long. Reduce the message length, if possible. The selected font is too big. Reenter the message using a smaller font, if possible. No phase profile. 1. Observe "Diagnostics Screen One". Note the Phase Profile. 2. If phase profile is not present (all zeroes), allow the printer to adjust the phase threshold to attempt to acquire a phase profile. 3. If the phase threshold is reduced to the minimum value and a phase profile still has not been acquired, see causes and perform actions under “Phase Threshold Error” on page 9-17". The printer is unable to set the modulation automatically. 1. Observe "Diagnostics Screen One". Note the Phase Profile. 2. If the phase profile is erratic (1's and 0's present, but randomly), the modulation value acquired automatically by the printer may be erroneous. 3. Perform a visual inspection in the printhead to confirm incorrect modulation value. 4. Attempt to manually set the modulation to restore break-off; monitor diagnostics screen to assess status of automated controls. 5. If modulation cannot be restored manually, see causes and actions under “Phase Threshold Error” on page 9-17. No Time for TOF The printer is unable to acquire an "actual velocity" and thus cannot perform TOF velocity control. Table 9-8: Warning Icons 9-30 Printer Status Icons Rev AA Videojet 1510 Service Manual Warning Reason Causes Action Overspeed The message cannot be printed at the required width The current line speed is too fast. 1. Reduce the line speed. 2. If "Shaft Encoder Source" is Internal, adjust the width to obtain the desired characters per inch. The current width setting is too low. 1. Increase the width setting. 2. Test the print to see if the warning condition gets cleared. The "max printed dots" parameter is too high 1. Edit the current message; examine the "max printed dots" parameter. 2. Reduce the "max printed dots" to the minimum allowable value. The selected font is too large. Create a new message - use a smaller font if this is feasible. Ensure that the "max printed dots" is set to the minimum allowable value. Defective, or improper, USB flash drive. Use a different USB flash drive Maximum Print Rate Exceeded Print go received less than one millisecond from last print go No Valid Ink Parameters Ink core module not programmed or invalid values in smart chip Possible Ink Coefficient Update Ink cartridge coefficients do not match ink core module coefficients USB Connection Is Over Current External USB device drawing excessive current Suspected Head Heater Failure Heater set to 100% for over one minute to achieve set temperature Table 9-8: Warning Icons Rev AA Printer Status Icons 9-31 Videojet 1510 Service Manual Warning Reason Creating Raster Catalog Software busy. Raster being replaced. Cannot print. Bad Nozzle!!! Please Replace Or Repair Nozzle taking excessive current possible short Tank Not Filling Ink Core still LOW after FIVE attempts to add ink to increase level DAC Overflow Charge DAC not operating correctly CSB hardware fault DAC Comms Error Charge DAC not operating correctly CSB hardware fault Tuning Required Nozzle tuning is required and the "Auto Tuning" function is disabled. Causes Action Modulation voltage about to adjust itself outside of the control range (0 - 200 VAC) Enable "Auto tuning". Table 9-8: Warning Icons 9-32 Printer Status Icons Rev AA Videojet 1510 Service Manual Warning Reason Causes Action TOF Warning The "actual velocity" deviates from the "velocity set point" by +/ - 1%. Erroneous TOF measurement. Clean and dry the printhead. Nozzle partially obstructed. Perform a nozzle backflush. Improper modulation setting. See actions above for "the printer is unable to set the modulation automatically". Pump or pressure problem. See causes and actions above under "Pressure Too Low". The life of ink core module is over Replace the Core. Valve error 1. Run a " Valve Test " and a " Hardware Self Test " to try to determine which valve is problematic. 2. If valve or valves are not functioning, check electrical connections. Attempt to clear any clogged valves. 3. If all the valves are functioning, check CSB test points related to valves to identify potential electrical issues. They are: TP 1 through TP16, TP30, TP68. Service Due Printer requires servicing. Table 9-8: Warning Icons Rev AA Printer Status Icons 9-33 Videojet 1510 Service Manual Voltage Checks The Table 9-9 is a representation of the POWER connector with the voltages shown for each pin. Use Pin 2 as the 0 V reference. Power Connector Figure 9-2: CSB Power Connectors Note: Allow ± 5% tolerance on all voltages except -24V which is allowed at ±10%. The power connector must be connected to the CSB to carry out this check. PIN 4 -15V PIN 8 -24V PIN 3 +5 V PIN 7 0V PIN 2 0V PIN 6 +24 V PIN 1 +15 V PIN 5 +5 V Table 9-9: CSB POWER Connector Voltage Check Jet Start and Stop Diagnostics Use the following flow charts to diagnose problems because of dirty inkjet starts and stops. 9-34 Voltage Checks Rev AA Videojet 1510 Service Manual Quick Start Diagnostics Visually inspect nozzle alignment print engine and ink Figure 9-3: Quick Start Diagnostics Flowchart Rev AA Jet Start and Stop Diagnostics 9-35 Videojet 1510 Service Manual Clean Start Diagnostics make-up Clean the make-up valve in the PH Replace the PH valve module Back flush the nozzle System flush prime Refer to........ Sheet 1 9-36 Jet Start and Stop Diagnostics Rev AA Videojet 1510 Service Manual print engine No Back flush the nozzle Is the ink drawn into the gutter Is Break-up Symmetrical Yes Go to sheet 1 No Yes print engine Sheet 2 Figure 9-4: Clean Start Diagnostic Flowchart Rev AA Jet Start and Stop Diagnostics 9-37 Videojet 1510 Service Manual Clean Stop Diagnostic make-up? Flush the nozzle valve PH valve module Figure 9-5: Clean Stop Diagnostics 9-38 Jet Start and Stop Diagnostics Rev AA Videojet 1510 Service Manual CSB Test Points Figure 9-6: Test Points 1 to 16 Rev AA CSB Test Points 9-39 Videojet 1510 Service Manual The CSB test points are described in Table 9-10. Test Point Name Test Equipment Required Measurement TP1 Valve Control Common Voltmeter Measure the voltage at TP1. The voltmeter must read approximately 5VDC. TP3 Valve 0 (Makeup fluid add valve monitor) Voltmeter Measure the voltage at TP3. • A reading > 4 VDC indicates that the valve is currently de-energized (shut). • A reading < 1 VDC indicates that the valve is currently energized (open). TP4 Valve 1 (Gutterto-jet pump #2 valve monitor) Voltmeter Measure the voltage at TP4. • A reading > 4 VDC indicates that the valve is currently de-energized (shut). • A reading < 1 VDC indicates that the valve is currently energized (open). TP5 Valve 2 (Gutterto-jet pump #1 valve monitor) Voltmeter Measure the voltage at TP5. • A reading > 4 VDC indicates that the valve is currently de-energized (shut). • A reading < 1 VDC indicates that the valve is currently energized (open). TP6 Valve 3 (Flush Pump Vacuum Valve Monitor) Voltmeter Measure the voltage at TP6. • A reading > 4 VDC indicates that the valve is currently de-energized (shut). • A reading < 1 VDC indicates that the valve is currently energized (open). TP7 Valve 4 (Flush pump pressure valve monitor) Voltmeter Measure the voltage at TP7. • A reading > 4 VDC indicates that the valve is currently de-energized (shut). • A reading < 1 VDC indicates that the valve is currently energized (open). TP8 Valve 5 (drain valve monitor) Voltmeter Measure the voltage at TP8. • A reading > 4 VDC indicates that the valve is currently de-energized (shut). • A reading < 1 VDC indicates that the valve is currently energized (open). TP9 Valve 6 (Head feed valve monitor) Voltmeter Measure the voltage at TP9. • A reading > 4 VDC indicates that the valve is currently de-energized (shut). • A reading < 1 VDC indicates that the valve is currently energized (open). TP10 Valve 7(Head flush valve monitor) Voltmeter Measure the voltage at TP10. • A reading > 4 VDC indicates that the valve is currently de-energized (shut). • A reading < 1 VDC indicates that the valve is currently energized (open). Table 9-10: CSB Test Points 9-40 CSB Test Points Rev AA Videojet 1510 Service Manual Test Point Name Test Equipment Required Measurement TP11 Valve 8 (Head gutter valve monitor) Voltmeter Measure the voltage at TP11. • A reading > 4 VDC indicates that the valve is currently de-energized (shut). • A reading < 1 VDC indicates that the valve is currently energized (open). TP12 Valve 9 (Head purge valve monitor) Voltmeter Measure the voltage at TP12. • A reading > 4 VDC indicates that the valve is currently de-energized (shut). • A reading < 1 VDC indicates that the valve is currently energized (open). TP13 Valve 10 - Not used TP14 Valve 11 - Not used TP15 Valve 12 - Not used TP16 Valve 13 - Not used Table 9-10: CSB Test Points (Continued) Figure 9-7: Test Point 17, 18, 19, and 63 Rev AA CSB Test Points 9-41 Videojet 1510 Service Manual Test Point Name Test Equipment Required Measurement TP17 Photocell one Voltmeter Used to determine "Active state" of photocell. Block the photocell with a product and measure the voltage at TP17. • A reading > 3VDC indicates that the photocell is ACTIVE HIGH. • A reading <.5VDC indicates that the photocell is ACTIVE LOW. TP18 Shaft encoder one Oscilloscope Used to verify if the shaft encoder is supplying pulses to the printer. 1. Make sure that the encoder is connected to the printer and start the conveyor. 2. Measure the signal at TP18. The following output is considered to be good. Table 9-11: CSB Test Points 9-42 CSB Test Points Rev AA Videojet 1510 Service Manual Test Point Name Test Equipment Required Measurement TP19 Shaft encoder two Oscilloscope Used to verify if the shaft encoder is supplying pulses to the printer. 1. Make sure that the encoder is connected to the printer and start the conveyor. 2. Measure the signal at TP19. Note: A signal will be present only if a quadrature (two-phase) encoder is in use. Table 9-11: CSB Test Points (Continued) Figure 9-8: Test Point 20 and 21 Rev AA CSB Test Points 9-43 Videojet 1510 Service Manual Test Point Name Test Equipment Required Measurement TP20 Pump tacho Oscilloscope Used to verify if the ink pump is turning when the ink pump is energized. TP21 Pump set point Voltmeter Used to verify the analog signal provided by the FPGA to the pump driver circuit to set the TARGET PRESSURE. 1 bar =.28 VDC. TP22 Pump enable Voltmeter Measure the voltage at TP22 with a voltmeter. A reading of 3.3VDC indicates that the CSB is providing an ON signal to the pump motor driver. +5V (TP23) 5 VDC Voltmeter Used to verify if the filtered 5VDC level on the CSB. Measure the voltage at TP23. Measured voltage should be approximately +5VDC. V CORE (TP25) FPGA core voltage +12 ANAL (TP26) +12 VDC Voltmeter Used to verify regulated +12 VDC produced on the CSB. Measure the voltage at TP26. Measured voltage should be approximately +12VDC. -12V (TP27) -12 VDC Voltmeter Used to verify regulated -12 VDC produced on the CSB. Measure the voltage at TP27. Measured voltage should be approximately -12VDC. +24V (TP28) +24 VDC Voltmeter Used to verify unfiltered +24 VDC provided to the CSB from the mains power supply. Measure the voltage at TP28. Measured voltage should be approximately +24VDC. -24V (TP29) -24 VDC Voltmeter Used to verify unfiltered -24 VDC provided to the CSB from the Mains power supply. Measure the voltage at TP29. Measured voltage should be approximately -24VDC. Used to verify the FPGA Core voltage on the CSB. Measure the voltage at TP25. Measured voltage should be approximately +1.5VDC. Table 9-12: CSB Test Points 9-44 CSB Test Points Rev AA Videojet 1510 Service Manual Test Point Name Test Equipment Required Measurement +22V (TP31) 22V Pump Voltmeter Used to verify 22 VDC produced for the pump driver circuit. Measure the voltage at TP31. Measured voltage should be approximately 22VDC. TP38 MOD Modulation Oscilloscope Used to verify output modulation signal supplied by the CSB to the nozzle. With inkjet running, measure signal at TP38. The following picture shows a good signal. Table 9-12: CSB Test Points (Continued) Rev AA CSB Test Points 9-45 Videojet 1510 Service Manual Test Point Name Test Equipment Required Measurement TP41 Level probe common Voltmeter or Oscilloscope Used to verify the common electrical drive signal in the Core (ink core module) level detection circuit. • If a voltmeter is used, the voltage shall read 1.6 VDC. • If an oscilloscope is used, a good signal will look like the signal shown in the following figure. TP42 Level probe 0 (ink core High) Voltmeter or Oscilloscope Used to confirm whether the "high" sensor in the ink core module is covered or uncovered. • If a voltmeter is used and the sensor is covered, a voltage of 1.6 VDC indicates that the sensor is uncovered. • A voltage <.7 VDC indicates that the sensor is covered. • If an oscilloscope is used, the following signal indicates that the sensor is uncovered. Table 9-13: CSB Test Points 9-46 CSB Test Points Rev AA Videojet 1510 Service Manual Test Point Name Test Equipment Required Measurement TP43 Level probe 1 (ink core Middle) Voltmeter or Oscilloscope Used to confirm whether the middle sensor in the ink core module is covered or uncovered. • If a voltmeter is used and the sensor is covered, a voltage of 1.6 VDC indicates that the sensor is uncovered. • A voltage <.7 VDC indicates that the sensor is covered. • If an oscilloscope is used, the following signal indicates that the sensor is uncovered. TP44 Level probe 2 (ink core Low) Voltmeter or Oscilloscope Used to confirm whether the low sensor in the ink core module is covered or uncovered. • If a voltmeter is used and the sensor is covered, a voltage of 1.6 VDC indicates that the sensor is uncovered. • A voltage < 0.7 VDC indicates that the sensor is covered. • If an oscilloscope is used, the following signal indicates that the sensor is uncovered. Table 9-13: CSB Test Points (Continued) Rev AA CSB Test Points 9-47 Videojet 1510 Service Manual Test Point Name Test Equipment Required Measurement TP45 Gutter sense Voltmeter or Oscilloscope Used to confirm the status of the gutter detect circuit. • If a voltmeter is used and ink is present in the gutter, voltage should read < 0.7 VDC. • A voltage of 1.6 VDC indicates that the gutter detect chamber is empty. • If an oscilloscope is used, the following signal is expected if the gutter detect chamber is empty. TP47 Ink pressure Voltmeter Used to verify the electrical output of the pressure transducer that monitors the ink pump output in the Core. 1 bar = 0.8 VDC. TP48 Vacuum Voltmeter Used to verify the electrical output of the pressure transducer that monitors the vacuum in the makeup fluid addition system in the Core Module. Table 9-13: CSB Test Points (Continued) 9-48 CSB Test Points Rev AA Videojet 1510 Service Manual Test Point Name Test Equipment Required Measurement CHG (TP51) Charge Amplifier Oscilloscope Use the oscilloscope to measure the signal at TP51. When the ink stream is ON, and the printer is not printing, ability to acquire the following signal indicates that the charge amplifier circuit is functioning properly. HEADT (TP53) Printhead Temperature Voltmeter Use the voltmeter to measure the signal at TP53. This represents the analog output of the printhead temperature sensor. 0.055 VDC = 1° Celsius. INKT (TP54) Ink temperature Voltmeter Use the voltmeter to measure the signal at TP54. This represents the analog output of the core temperature sensor. 0.055 VDC = 1° Celsius. TP55 Strobe Oscilloscope Use the oscilloscope to measure the signal at TP55. This represents the digital signal used to drive the printhead strobe LED. A good signal will look as follows. Table 9-14: CSB Test Points Rev AA CSB Test Points 9-49 Videojet 1510 Service Manual Test Point Name Test Equipment Required Measurement TP56 Printhead cover Voltmeter Use the voltmeter to measure the signal at TP56. • If the printhead cover is removed, the measured voltage should be 3.3 VDC. • If the printhead cover is fitted, the measured voltage should be < 0.5 VDC. PHA (TP57) Phasing Oscilloscope Use the oscilloscope to measure the signal at TP57. This represents the analog signal being detected by the first TOF sensor in the printhead. A good signal will look as follows. Table 9-14: CSB Test Points (Continued) Test Point Name Test Equipment Required Measurement 3V3 (TP62) 3.3 VDC Voltmeter Used to verify the output of the 3.3 VDC voltage regulator (chip U44) on the CSB. Measure the voltage at TP62. Measured voltage should be approximately 3.3 VDC. TP63 Photocell two Voltmeter Used to determine "Active state" of photocell #2 ("Reverse Print Input"). Block the photocell with a product and measure the voltage at TP17. • A reading > 3VDC indicates that the photocell is ACTIVE HIGH. • A reading <.5VDC indicates that the photocell is ACTIVE LOW. TP68 Valve common monitor Voltmeter Monitor during start-up sequence or valve test procedure to verify application of "hit" voltage by valve driver circuit. Table 9-15: CSB Test Points 9-50 CSB Test Points Rev AA Videojet 1510 Service Manual Test Point Name Test Equipment Required Measurement TP69 VEL Velocity Oscilloscope Use the oscilloscope to measure the signal at TP69. This represents the analog signal being detected by the second TOF sensor in the printhead. A "good" signal will look as follows. Table 9-15: CSB Test Points (Continued) Test Point Name Test Equipment Required Measurement +15V +15 VDC Voltmeter Used to verify unfiltered +15 VDC provided to the CSB from the Mains power supply. Measure the voltage at "+15V". Measured voltage should be approximately +15VDC. -15V -15 VDC Voltmeter Used to verify unfiltered -15 VDC provided to the CSB from the Mains power supply. Measure the voltage at "-15V". Measured voltage should be approximately -15VDC. TP30 V HOLD Valve drive hold voltage Voltmeter Used to verify the onboard voltage generated and used to hold solenoid valves open following actuation. Measure the voltage at TP30. Measured voltage should be approximately +6 VDC. TP72 Charge supply negative Voltmeter Used to verify the negative output voltage supplied by the Charge Amplifier Supply to the Charge Amplifier. Measure the voltage at TP72. Measured voltage should be approximately -24 VDC. Table 9-16: CSB Test Points Rev AA CSB Test Points 9-51 Videojet 1510 Service Manual Test Point Name Test Equipment Required Measurement TP2 Hit drive Voltmeter Used to verify that the valve drive circuit is being supplied with the correct electronic signal to enable the application of "hit" voltage when solenoid valves are actuated. Measure the voltage at TP2. • If the measured voltage is +3.3 VDC, the "hit" circuit is turned off (this is the steady-state condition). • If measured voltage is 0 VDC, the "hit" circuit is turned on (indicating that valves are being opened). TP76 VREFP Voltage Reference Positive Voltmeter Used to measure the positive reference voltage provided to the DAC on the CSB. Measure the voltage at TP76. Measured voltage should be approximately +4.08 VDC. TP77 DAC OUTPUT 6 Voltmeter TP39 Modulation first stage Oscilloscope This test point allows for the measuring of the first-stage modulation signal at the output of chip U45. Measure the signal at TP39 using an oscilloscope. A good signal will look as follows. VREFN Voltage reference negative Voltmeter Used to measure the negative reference voltage provided to the DAC on the CSB. Measure the voltage at "VREFN". Measured voltage should be approximately -4.08 VDC. TP71 DAC OUTPUT 7 Voltmeter Table 9-16: CSB Test Points (Continued) 9-52 CSB Test Points Rev AA Videojet 1510 Service Manual Test Point Name Test Equipment Required Measurement MODV Modulation voltage monitor Voltmeter The Modulation Voltage Monitor is an output of the modulation circuit used by the CSB to track modulation voltage. Measure the voltage at "MODV". Measured voltage should be less than 2 VDC, and will change as the automodulation routine is performed. TP67 Modulation Power Amplifier Transformer Primary Oscilloscope TP67 allows for the measuring of the modulation sine wave on the primary side of the modulation power amplifier transformer. Measure the signal at TP67 with an oscilloscope. A good signal will look as follows. TP37 Modulation Power Amplifier Transformer Primary Oscilloscope Same as TP67, except TP37 is located on the opposite side of the transformer. Measure the signal at TP37 with an oscilloscope. A good signal will look as follows. Table 9-16: CSB Test Points (Continued) Rev AA CSB Test Points 9-53 Videojet 1510 Service Manual Test Point Name Test Equipment Required Measurement TP24 EHT Setpoint Voltmeter Allows for the measurement of the signal being provided to the EHT circuit to establish the EHT voltage. Measure the voltage at TP24. 1. A voltage between 0 and +24 VDC will be measured, depending upon the current “Character height”. 2. Vary the “Character height” and check to make sure that the voltage at TP24 varies accordingly. TP 40 MODI Modulation Current Monitor Voltmeter The Modulation Current Monitor is an output of the modulation circuit used by the CSB to track modulation current. Measure the voltage at TP40. Measured voltage should be less than 1 VDC, and will change as the automodulation routine is performed. TP65 Modulation Data Oscilloscope TP65 allows for the monitoring of the data signal supplied by the FPGA to the modulation circuit. Measure the signal at TP65 with an oscilloscope. A good signal will look like this. Table 9-16: CSB Test Points (Continued) 9-54 CSB Test Points Rev AA Videojet 1510 Service Manual Test Point Name Test Equipment Required Measurement TP66 Modulation Clock Oscilloscope TP66 allows for the monitoring of the clock signal supplied by the FPGA to the modulation control circuit. Measure the signal at TP66 with an oscilloscope. A good signal will look like the following figure. TP58 Phasing Signal Amplified Oscilloscope This test point allows for the monitoring of the processed phasing signal downstream of chip U14 on the CSB. Measure the signal at TP58 with an oscilloscope. A good signal will look like the following figure. Table 9-16: CSB Test Points (Continued) Rev AA CSB Test Points 9-55 Videojet 1510 Service Manual Test Point Name Test Equipment Required Measurement TP59 Velocity Signal Amplified Oscilloscope This test point allows for the monitoring of the processed velocity signal downstream of chip U15 on the CSB. Measure the signal at TP59 with an oscilloscope. A good signal will look like the signal shown in the following figure. TP60 Phasing trigger 'A' Oscilloscope This test point allows for the monitoring of the trigger signal supplied by chip U16 to the FPGA. Measure the signal at TP60 with an oscilloscope. A "good" signal will look like this: Table 9-16: CSB Test Points (Continued) 9-56 CSB Test Points Rev AA Videojet 1510 Service Manual Test Point Name Test Equipment Required Measurement TP61 Phasing trigger 'B' Oscilloscope This test point allows for the monitoring of the trigger signal supplied by chip U16 to the FPGA. Measure the signal at TP61 with an oscilloscope. A good signal will look like this. TP50 HV Charge Supply Positive Voltmeter Used to verify the positive output voltage supplied by the Charge Amplifier Supply to the Charge Amplifier. Measure the voltage at TP50. Measured voltage should be approximately +312 VDC. Table 9-16: CSB Test Points (Continued) Rev AA CSB Test Points 9-57 Videojet 1510 Service Manual Installing DNW 1 When the CSB device is connected to a PC for the first time you will be prompted to install drivers. Choose C:\500051\Installers\USB Driver\secbulk.inf. 2 To configure the software, select Options under the Configuration menu: Figure 9-9: Configure Menu 3 Change the download address to 0x3020000. Figure 9-10: 4 Click OK button. ADC/DAC This test checks that the ADC device can be accessed and the cabinet temperature is less than 60 ºC. Ancillary This test does the following checks: 9-58 CSB Test Points Rev AA Videojet 1510 Service Manual • Checks a standing current through the beacon current input is in range. • Checks the current drawn when switching dummy loads with the ancillary switch (head heater, cabinet fan, and air pump outputs). • Checks for fixed voltages on the head temperature [2.47, 2.90] and ink temperature [1.93, 2.34] sensors. • Turns the LED strobe off and checks the gutter is dry (square wave present). • Turns the LED strobe on and checks the gutter is wet (square wave not always present). • Turns VALVEDRIVE_5 off and checks the cover switch is open (input high). • Turns VALVEDRIVE_5 on and checks the cover switch is closed (input low). • Checks the ink bottle smart chip memory starts with the string “INK”. • Checks the solvent bottle smart chip memory starts with the string “SOL”. • Checks the ink core module smart chip memory starts with the string “MIX”. • Checks the CSB smart chip is present. Charge Amplifier Supply This test does the following checks: • Checks that the charge amplifier supply (test point HV+) is initially about 20V and the switching FET (Q8) is inactive. • Turns on the charge amplifier supply (sets a charge scale not equal to zero) and checks the supply is now about 310V and the switching FET is active. Charge Amplifier This test does the following checks: • Writes and reads all bits of the charge DAC to test the interface between it and the FPGA. • Sets the charge scale to full (0x3FF would give 409.6 V output, if the supply were that high). Rev AA CSB Test Points 9-59 Videojet 1510 Service Manual • Attempts to move the charge output up and down using the charge and phase offset registers (one bit of charge offset = 0.4 V positive, phase offset same but negative) until it is within the range ±1 V. • Checks that increasing the phase offset moves the output negative by 0.4 V. • Checks that increasing the charge offset moves the output positive by 0.4 V. • Halves the charge scale. • Re-establishes the charge output within the range ±1 V. • Checks that the output moves by 0.2 V when the charge offset is increased by one bit. SRAM This test checks writes sixteen random values to the SRAM at each single address bit transition (0, 16, 32, 64, 128...) then reads and checks all values are correct. EHT This test does the following checks: • Checks for a fixed voltage on EHTVMON [2.41, 3.04]. • Checks for a fixed voltage on EHTIMON [1.83, 2,61]. • Ramps the EHT setpoint into a fixed load and checks the measured current is correct. Levels/Pressure/Vacuum This test does the following checks: • Checks for a fixed voltage on the pressure signal [2.15, 2.63]. • Checks for a fixed voltage on the vacuum signal [2.68, 4.10]. • Switches on only VALVEDRIVE_6, 7 and 8 in turn and checks that only level sensor INK1, 2 then 3 is shorted respectively. 9-60 CSB Test Points Rev AA Videojet 1510 Service Manual Modulation This test ramps the modulation into a fixed load and checks the measured voltage and current are correct. Phase Detector This test does the following checks: • Checks for a fixed voltage on the phase detector input [2.75, 3.85]. • Checks for a fixed voltage on the velocity detector input [0.91, 2.15]. • Sweeps the phase and velocity thresholds from below to above these fixed voltages to check the comparators work. Pump This test runs the pump driver (using the RELAY4-6 outputs to emulate rotation on the Hall sensor inputs) into a dummy load and checks the current drawn is correct and the TACHO output matches the Hall sensor inputs. Valves Turns on VALVEDRIVE_9 to VALVEDRIVE_13 only in turn and checks the valve driver current is within range. DIN Interface This test does the following checks: • Checks for connections between the following beacon drive and PEC/ SENC signals. Rev AA Beacon Drive PEC/SENC Signals Green PEC1 Amber SENC2 Red SENC1 Strobe PEC2 CSB Test Points 9-61 Videojet 1510 Service Manual • Checks for connections between the following relays, valves and message select signals. VALVEDRIVE_0 MSEL0 VALVEDRIVE_1 MSEL1 VALVEDRIVE_2 MSEL2 VALVEDRIVE_3 MSEL3 VALVEDRIVE_4 MSEL4 RELAY1 MSEL5 RELAY2 MSEL6 RELAY3 MSEL7 • Checks for connections between the following signals. RELAY1 RELAY7 RELAY2 PELTEMP_D RELAY3 PELTEMP_C Manual Tests This test sets the modulation up as a 250Vpp 76.8kHz sine wave and a 300V high staircase waveform on the charge and asks the user to check them on the scope. The user is then asked to turn the board off and check the bleed valve holdup circuit works by checking the brightness of the BLEED LED on the test box. 9-62 CSB Test Points Rev AA Illustrated Parts List 10 The Illustrated Part List (IPL) contains the illustrations and the parts lists for the different assemblies in the printer. The parts lists give the part numbers, description and quantity of all the items and the modules in the printer. You can order the items and the modules for which the part numbers are given. How to Read the IPL This section describes how the higher assemblies are broken down to their related sub assemblies and other separate parts. Illustrations Table 10-1 on page 10-2 shows the symbols used to indicate the different levels of main assemblies in a printer, and the sub assemblies under the main assembly. Rev AA How to Read the IPL 10-1 Videojet 1510 Service Manual Assembly Symbol Main Assembly Sub Assembly 1 Sub Assembly 2 Sub Assembly 3 Sub Assembly 4 Table 10-1: Symbols Representation - Assemblies Indicates further explosion. Alphabets • An alphabet is assigned to the main assemblies of a printer and each sub assembly under the main assembly. See Figure 10-1 on page 10-3. For example: If A, B, C and D identify the main assemblies of a printer, then the alphabets E,F, and so on identify sub assemblies below each main assembly in a sequence. • The alphabets assigned to main assemblies are used only for one time. • The alphabets “I” and “O” are not used because they look like the numbers 1 and 0. 10-2 How to Read the IPL Rev AA Videojet 1510 Service Manual Numbers A natural number (1,2,3.....) is assigned to the stand alone parts (in ascending order) through out the breakdown of main assemblies. See Figure 10-1. Note: The numbers assigned to main assemblies can be used only for one time. Printer B A 3 E F H J 2 4 5 6 1 1 E F 2 3 D C G E F G 1 2 3 Figure 10-1: Graphical Representation of the Different Subassemblies and Parts Rev AA How to Read the IPL 10-3 Videojet 1510 Service Manual Tables Figure 10-2 describes the styles used to show the explosion of the main assemblies in parts lists. Main Assembly Subassembly 1 Subassembly 2 Parts under the Subassembly OR Stand-alone Part Figure 10-2: Representation of the different Subassemblies and parts in the Table Notes Notes provide useful information. Some examples for note are as follows: Note: To order this item, use part number of item 9 in this table. Note: This screw is a part of Core Module. Note: This item can be ordered separately. 10-4 How to Read the IPL Rev AA Videojet 1510 Service Manual Videojet 1510 Printer A B D C Figure 10-3: Main Parts of the Printer Table 10-2 shows the sub assemblies of the printer. Item Descriptions A Electronics Compartment B Ink Compartment C Umbilical D Printhead Table 10-2: Videojet 1510 Printer Assemblies Rev AA Videojet 1510 Printer 10-5 Videojet 1510 Service Manual Electronics Compartment E A 2 F View A 1 View A L H K J G Figure 10-4: Electronics Compartment 10-6 Electronics Compartment Rev AA Videojet 1510 Service Manual Control System Board 1 Figure 10-5: Control System Board Assembly Power Switch 2 Figure 10-6: Power Switch Rev AA Electronics Compartment 10-7 Videojet 1510 Service Manual Electronics Door Assembly E M N 6 3 4 5 7 8 9 Figure 10-7: Electronics Door Assembly Display Door 10 M 11 12 13 15 14 Figure 10-8: Display Door 10-8 Electronics Compartment Rev AA Videojet 1510 Service Manual LCD and FIB Assembly 16 N 17 Figure 10-9: LCD and FIB Power Supply Unit Assembly F 18 19 20 21 22 Figure 10-10: Power Supply Unit Assembly Rev AA Electronics Compartment 10-9 Videojet 1510 Service Manual Printer Interface Board Assembly G 23 24 25 26 Figure 10-11: Printer Interface Board Assembly 10-10 Electronics Compartment Rev AA Videojet 1510 Service Manual Electronics Fan Assembly H 27 28 29 30 31 32 Figure 10-12: Electronics Fan Assembly Positive Air Pump Assembly J 33 34 Figure 10-13: Positive Air Pump Assembly Rev AA 35 Electronics Compartment 10-11 Videojet 1510 Service Manual EHT Module K 36 37 Figure 10-14: EHT Module Connector Panel L 38 39 40 42 41 Figure 10-15: Connector Panel 10-12 Electronics Compartment Rev AA Videojet 1510 Service Manual PCB 2 Assembly 39 Figure 10-16: PCB 2 Assembly PCB 1 Assembly 40 Figure 10-17: PCB 1 Assembly Rev AA Electronics Compartment 10-13 Videojet 1510 Service Manual . Item Number P/N A Description Qty Electronics Compartment 1 500074 Control System Board (CSB) 1 2 219041 Power Switch 1 E Electronics Door Assembly 3 Membrane Ground Wire 1 4 M4 Nyloc Nut 1 5 M4 ET Washer 2 6 Display Ground Wire 1 7 Display Rear Cover 1 8 K40 x 10 Pan-head Torx Screw 4 9 M4 x 10 Cap-head Screw 1 M 399116 Display Door with Keypad (English) 10 Display Gasket 1 11 Display Front Moulding 1 12 Keypad Standard 1 13 VJC Membrane 1 14 M4 Washer 2 15 K40 x 10 Pan-head Torx Screw 2 N 399091 Liquid Crystal Display and Front Panel Interface Board Assembly 16 K40 x 10 Pan-head Torx Screw 4 17 LCD and FIB Assembly 1 F 399077 Power Supply Unit (PSU) 18 PSU 1 19 PSU Mounting Plate 1 20 M3 ET Washer 4 Table 10-3: Electronics Compartment 10-14 Electronics Compartment Rev AA Videojet 1510 Service Manual Item Number Description Qty 21 M3 x 5 Cap-head Screw 4 22 M4 Nyloc Nut 2 G P/N 399078 Printer Interface Board (PIB) Assembly 23 M4 x 8 Cap-head Screw 6 24 M4 ET Washer 6 25 PIB 1 26 PIB Gasket 1 H 399079 Electronics Fan Assembly 27 Fan, 60 mm 1 28 M4 ET Washer 2 29 M4 x 10 Cap-head Screw 2 30 Finger guard, 60 mm 1 31 M4 Nyloc Nut 2 32 M4 x 16 Counter Sunk Screw 2 J 500084 Positive Air Pump Assembly 33 Positive Air Pump 1 34 P-Clip 1 35 M4 Nyloc Nut 2 K 399081 EHT Module Assembly 36 M4 Nyloc Nut 2 37 EHT Module 1 L Connector Panel 38 500096 PCB 3 Assembly 1 39 500097 PCB 2 Assembly 1 40 500095 PCB 1 Assembly 1 41 399084 USB Connector 1 42 399083 Ethernet Connector 1 Table 10-3: Electronics Compartment (Continued) Rev AA Electronics Compartment 10-15 Videojet 1510 Service Manual Ink Compartment B 1 2 E F Figure 10-18: Ink System Ink Cartridge 1 Figure 10-19: Ink Cartridge 10-16 Ink Compartment Rev AA Videojet 1510 Service Manual Make-up Cartridge 2 Figure 10-20: Make-up Cartridge Ink Door Assembly E N 3 Figure 10-21: Ink Door Assembly Rev AA Ink Compartment 10-17 Videojet 1510 Service Manual Septum Assembly N 10 9 8 7 5 6 4 Figure 10-22: Septum Assembly 10-18 Ink Compartment Rev AA Videojet 1510 Service Manual Ink Core Module Assembly F 12 11 L M Figure 10-23: Core Module Rev AA Ink Compartment 10-19 Videojet 1510 Service Manual Ink Core Pump L 13 14 15 Figure 10-24: Ink Core Pump Assembly M 19 18 17 16 Figure 10-25: Ink Core Module Without Pump 10-20 Ink Compartment Rev AA Videojet 1510 Service Manual Gutter Pump Assembly G 20 21 Figure 10-26: Gutter Pump Assembly Ink System Fan H 22 23 24 25 Figure 10-27: Ink System Fan Assembly Rev AA Ink Compartment 10-21 Videojet 1510 Service Manual Ink System Filter Assembly - IP65 J 26 27 Figure 10-28: Ink System Filter Assembly - IP65 Ink System Filter Assembly - IP55 28 29 Figure 10-29: Ink System Filter Assembly - IP55 10-22 Ink Compartment Rev AA Videojet 1510 Service Manual Floor Filter IP65 K 30 31 32 33 34 35 Figure 10-30: Floor Filter IP65 Rev AA Ink Compartment 10-23 Videojet 1510 Service Manual Floor Filter IP55 36 37 38 39 40 Figure 10-31: Floor Filter IP55 10-24 Ink Compartment Rev AA Videojet 1510 Service Manual Air Filter 41 Figure 10-32: Air Filter Item Number Description Qty 1 Ink Cartridge 1 2 Make-up Cartridge 1 E P/N 399071 3 N Ink Door Assembly Hinge Pin 399073 1 Septum Assembly 4 K30 x 12 Pan-head Torx Screw 2 5 M3 ET Washer 2 6 Tube and Ribbon Cable Clamp 1 7 K30 x 8 Pan-head Torx Screw 6 8 Black Stripe Tube (Ink System) 1 9 Septum 2 10 Green Stripe Tube (Make-up System) 1 Table 10-4: Ink Compartment Rev AA Ink Compartment 10-25 Videojet 1510 Service Manual Item Number F P/N Description 399069 Ink Core with Pump Qty 11 Ink Core Pump Cover 1 12 K30 x 12 Pan-head Torx Screw 2 L 399076 Ink Core Pump 13 M4 x 35 Cap-head Screw 2 14 Saddle Clamp 1 15 Ink Core Pump 1 M 399070 Ink Core Module without Pump 16 M3 x 7 Manifold Screw 2 17 Ink Core Manifold (Male) 1 18 Ink Core Manifold Gasket 1 19 Ink Core Manifold (Female) 1 G 399171 Gutter Pump Assembly 20 M4 Nyloc Nut 2 21 Gutter Pump and Valve 1 H 399080 Ink System Fan Assembly 22 M4 ET Washer 4 23 M4 x 10 Cap-head Screw 4 24 Fan 1 25 Fan Guard 1 J Ink System Filter Assembly 399238 IP65 26 Filter Element 1 27 Filter Cover 1 399239 IP55 28 Filter Element 1 29 Filter Cover 1 Table 10-4: Ink Compartment 10-26 Ink Compartment Rev AA Videojet 1510 Service Manual Item Number P/N K Description Qty Floor Filter Assembly Refer to Ink System Filter Assembly - IP65 IP65 30 M4 x 40 Cap-head Screw 4 31 Ink Core Support Channel 1 32 Filter Element 1 33 Filter Clamp 1 34 M4 x 8 Cap-head Screw 4 35 Drip Tray 1 Refer to Ink System Filter Assembly - IP55 IP55 36 M4 x 40 Cap-head Screw 4 37 Ink Core Support Channel 1 38 Ink Side Filter Top 1 39 Ink Side Filter Base 1 40 Filter Element 1 Air Filter 1 41 Refer to Table 10-3 on page 10-14 - Positive Air Pump Assembly Table 10-4: Ink Compartment Rev AA Ink Compartment 10-27 Videojet 1510 Service Manual Printhead D E F Figure 10-33: Printhead Printhead Valve Module 1 E 2 3 4 7 6 5 Figure 10-34: Printhead Valve Module 10-28 Printhead Rev AA Videojet 1510 Service Manual Print Engine 8 F 9 10 11 15 14 12 13 Figure 10-35: Print Engine Item Number P/N D Qty Printhead E F Description 399181 Printhead Valve Module 1 1 M2 x 6 Cap-head Screw 9 2 Gutter Valve 1 3 Printhead Valve Module Deck 1 4 Printhead Valve Module Gasket 1 5 Feed Valve 1 6 Rear Manifold Gasket 1 7 3 Way Manifold Assembly (Rear Tubing Manifold) 1 399180 Print Engine Table 10-5: Printhead Assembly Rev AA Printhead 10-29 Videojet 1510 Service Manual Item Number P/N Description Qty 8 M2 x 6 Cap-head Screw 8 9 Nozzle Assembly 1 10 Charge Electrode 1 11 Deflector Plate 1 12 Print Engine Deck 1 13 Print Engine Gasket 1 14 Front Tubing Manifold Gasket 1 15 2 Way Manifold Assembly (Front Tubing Manifold) 1 Table 10-5: Printhead Assembly Cables 2 3 1 Figure 10-36: Cables Item Number P/N Description Qty 1 500072 Ribbon Cable Assembly Display 1 2 399052 Ribbon Cable Assembly Smart Chip and Pump 14 Way 1 3 500078 50 Way Ribbon Cables 3 Table 10-6: Cables 10-30 Cables Rev AA Videojet 1510 Service Manual Optional Accessories Beacon Assembly 1 2 3 Figure 10-37: Beacon Assembly Rev AA Optional Accessories 10-31 Videojet 1510 Service Manual Dry Air Kit Assembly 8 5 4 6 7 Figure 10-38: Dry Air Kit Assembly 10-32 Optional Accessories Rev AA Videojet 1510 Service Manual Static Stand 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Figure 10-39: Static Stand Rev AA Optional Accessories 10-33 Videojet 1510 Service Manual Mobile Stand 24 25 26 27 28 37 36 35 29 30 31 32 33 34 Figure 10-40: Mobile Stand 10-34 Optional Accessories Rev AA Videojet 1510 Service Manual Printhead Stand 38 39 49 40 41 43 44 48 47 42 45 46 Figure 10-41: Printhead Stand Rev AA Optional Accessories 10-35 Videojet 1510 Service Manual Printer Wall Mount 50 51 52 53 Figure 10-42: Printer Wall Mount Item Number P/N Description 399089 Beacon Assembly Qty 1 Beacon 1 2 M4x10 Socket-head Cap Screw 3 3 Beacon Mounting Bracket 1 399090 Stealth Air Dryer Assembly 4 Stealth Air Dryer Mounting Bracket 1 5 M4 Nylon Washers 2 6 M4 x 10 Socket-head Cap Screw 3 7 Stealth Air Dryer 1 8 1/4 inch-20 x 1 inch Socket-head Screw 2 Table 10-7: Printhead Assembly 10-36 Optional Accessories Rev AA Videojet 1510 Service Manual Item Number P/N Description 399099 Static Stand Qty 9 M6 x 16 Long Flat Socket-head Screw 4 10 Adapter Plate 1 11 M5 Flat Washers 4 12 M5 Spring Lock Washers 4 13 M5 x 20 Long Socket-head Screw for IP55 Printers (or) M5 x 30 Long Socket-head Screw for IP65 printers 4 14 Column Top Plate 1 15 M6 Flat Washer 4 16 M6 Spring Lock Washer 4 17 M6 Hex Nut 4 18 Column 1 19 Cap-head Hex Screw, 1/4” x 20 UNC x 0.625 4 20 Flat Washer 4 21 Column Bottom Plate 1 22 Floor Plate 1 23 3/8” - 16 Flat Point Socket-head, 1” Long 4 399100 Mobile Stand 24 M6 x 16 Long Flat Socket-head Screw 4 25 Adapter Plate 1 26 M5 Flat Washer 4 27 M5 Spring Lock Washer 4 28 M5 x 20 Long Socket-head Screw for IP55 Printers (or) M5 x 30 Long Socket-head Screw for IP65 Printers 4 29 Column 1 30 Acorn Hex Nut 2 31 Flat Washer 4 32 Castors 4 33 Legs 2 Table 10-7: Printhead Assembly Rev AA Optional Accessories 10-37 Videojet 1510 Service Manual Item Number P/N Description Qty 34 Hex-head Bolt 2 35 M6 Hex Nut 4 36 M6 Spring Lock Washer 4 37 M6 Plain Washer 4 399086 Printhead Stand 38 Clamp Assembly 1 39 Vertical Tube 1 40 Printhead Cross Tube 1 41 Printhead Mount Assembly 1 42 M6 x 8 Grub Screw 2 43 M10 Nut 8 44 M10 Washer 8 45 Stand Base Plate 1 46 M16 X 40 Hex Bolt 1 47 Adjustable Foot 4 Anti-vibration Mounting 4 Umbilical Clamp Assembly 1 48 399093 49 399201 Printer Wall Mount 50 Wall Mounting Stand 1 51 Stand Cups 4 52 Clamp Washer 4 53 M5 x 30 Socket-head Screw or M5 x 20 Socket-head Screw 4 Table 10-7: Printhead Assembly 10-38 Optional Accessories Rev AA Videojet 1510 Service Manual Tools Kit There are several tool and spare parts kits consisting of normal maintenance items for the Videojet 1510 printer. The Service Tool Kit Table 10-8 lists the service tool kit items and their part numbers. Description Qty 7 mm Nut Driver 1 T9 Torx Screwdriver 1 #2 Phillips Screwdriver 1 T10 Torx Screwdriver 1 Screwdriver 1 T20 Torx Screwdriver 1 Nr.2 posidrive 1 Nr.2 posidrive 1 Side Cutters 1 3/16” Allen Wrench 1 2.5 mm Allen Wrench 1 Open-ended Wrench 1 1.5 mm Allen Wrench 1 3 mm Allen Wrench 1 4 mm Allen Wrench 1 2.5 diameter x 100 mm pin 1 Light Hammer 1 Sharp Knife 1 Adjustable Pipe Pliers (to hold and tighten ring nut on switch) 1 Adjustable spanner or pipe pliers to give minimum 33A/F 1 Crimp Pliers 1 2.5 D x 100 mm Long Pin (to knock the hinge pin out) 1 Table 10-8: Service Tool Kit Parts List Rev AA Tools Kit 10-39 Videojet 1510 Service Manual Description Qty 7 mm Spanner 1 10 mm Spanner 1 9/16 inch Spanner 2 13 mm Spanner 1 17 mm Spanner 1 24 mm Spanner 1 1/2 inch Spanner 2 14 mm Masonry Drill 1 Flow Meter (P/N 356230) 1 Spirit Level 1 Table 10-8: Service Tool Kit Parts List 10-40 Tools Kit Rev AA 11 Tools and Spare Part Kits Tools Basic Start Up Kit The basic start up kit (P/N 378232) includes the following: Description Part Number Safety glasses 28000035 Squeeze bulb 21000170 Wash bottle, 250cc 202047 Latex gloves 209953 Hand cleaner SP212321 Cleaning pan, steel 217035 Magnifier loupe 355269 Service Tool Kit The Service tool kit (P/N 378228) consists of the following. Rev AA Description Part Number Pipe pliers 5260001115 Tube cutter 5260001112 Nut driver set 5260001118 Allen hex driver set 5260001119 Pozi drive screwdriver #1 5260001108 Pozi drive screwdriver #0 5260001116 Nozzle adjusting tool 1000370224 Manifold flush block 200-0466-247 Knife, retractable 217043 Tools 11-1 Videojet 1510 Service Manual Description Part Number Ultra sonic bath 5260001120 Reverse action tweezers 5260001107 Syringes, with slip tips 5000118001 Wrench, open end, 8mm x 10 mm 526-0001-124 Din socket wrench 526-0001-123 IC removal tool, mini-fit 526-0001-113 Pump priming adapter 2000466246 Filler cup wrench 100-043S-193 Electronics compartment key 500-0048-133 Printhead cleaning station 378337 Blow bulb 21000170 Serial download cable 80200258 EHT trip tool 100-0370-265 EHT printhead cover 100-0370-264 Tubing, 1/4 O.D. cobothane, 3.5 ft 251410 Magnifier, illuminated 3.5x 203023 Other Tools Additional tools that may be useful for service personnel include the following: • a laptop computer with Windows NT 4 or greater installed • standard field service tools, including a DVM and oscilloscope 11-2 Tools Rev AA Videojet 1510 Service Manual Spare parts kits Comprehensive Spare Parts Kit The comprehensive spare parts kit (P/N 378231) contains the following: Rev AA Description Part Number Basic spare parts kit 378230 CPU board 200-043S-166 PSU 200-0390-102 I/O board 200-0430-260 EHT Module 200-0390-239 Pressure transducer 378254 Pressure transducer O-ring, front 500-0031-164 Pressure transducer O-ring, back 500-0031-201 System manifold 100-0370-200 Phase detector assembly 200-3900-298 Charge electrode assembly 200-3900-135 22 Meg EHT resistor 522-0080-226 Ink Core sensor kit 378269 Spare parts kits 11-3 A Clean/Quick Start and Stop Description Clean Start/Stop Standards The following illustrations show the minimum acceptable standards for clean start and clean stop. Compare these to samples obtained by placing a sheet of blank paper directly under the printhead. (samples are shown actual size) Typical clean start-up/shutdown Typical dirty start-up/shutdown Minimum standard required Figure A-1: Clean Start/Stop Test Illustrations Rev AA Clean Start/Stop Standards A-1 Videojet 1510 Service Manual Clean Start This method starts on flush (pure solvent) in order to dissolve any ink residues in the jet orifice. It then bleeds on flush to remove air from the nozzle before switching to ink, eliminating ink splash and spray during start-up. The Clean Start Jet Sequence is as follows: 1 The solvent from the filter is forced through the umbilical connection into the printhead. 2 At the printhead, the solvent enters the heater manifold and passes into the main fluid path between the jet valve and the nozzle. 3 The jet starts when the nozzle becomes pressurized by the solvent flow. 4 If the previous stop was a clean stop, the jet will consist of almost pure solvent. The flow of solvent quickly removes any ink residues in the jet orifice. 5 Fluid in the jet is caught by the gutter and directed to the ink core. 6 Approximately ten seconds after the flush pump switches off, the bleed valve closes and ink continues to flow through the jet at 4 bar. 7 Modulation is switched on and the ink pressure changes to give the correct jet velocity. 8 Heater manifold temperature is allowed to reach the correct value before enabling the phasing checks on the jet. Quick Start This method starts without a flushing sequence, and uses the ink supply to bleed air from the nozzle. Clean Stop This method switches from ink to flush in order to purge the nozzle. This method allows time for the manifold, nozzle and jet orifice to be purged of ink before stopping the jet. The Clean Stop Jet Sequence is as follows: 1 Deflector plate voltages are switched off before beginning this sequence. A-2 Clean Start Rev AA Videojet 1510 Service Manual 2 The ink pressure is set to 4 bar and the modulation voltage switches off. 3 To increase the ink flow through the nozzle body, the bleed valve switches on. 4 The flush pump valve switches on applying solvent pressure to the printhead. 5 Pure solvent is forced through the filter to the printhead mixing solvent into the ink stream in the heater manifold. 6 Approximately one second after the solvent starts to mix with the ink, the feed valve (V6) in the cabinet switches off, removing ink pressure from the printhead. 7 Ink ceases to flow into the heater manifold and the solvent flushes ink from the nozzle body. 8 Five seconds later the bleed valve switches off and then switches on again, introducing solvent into the jet valve, which inhibits ink residues forming whilst the machine is switched off. 9 The jet valve (on the heater manifold) switches off, ensuring that no ink diffuses into the solvent. At this point, no ink should be present in the nozzle body. 10 The gutter valve switches off, increasing the suction on the bleed system. After a short pause, the bleed valve switches off. 11 After another short pause, the gutter valve switches on to clear any fluid from the gutter. 12 Once the gutter valve switches off, the main ink pump also switches off. Quick Stop Note: This sequence is used to manually stop the jet for a short period, or to automatically stop the jet during an EHT trip, charge error, etc. This method switches off the ink without flushing the nozzle or manifold. Hence the manifold and the nozzle are full of ink when the jet stops. The machine must not be left in this state for long periods, as drying ink in the jet orifice may make restarting difficult. This procedure is primarily intended for situations where the machine may be stopped and restarted several times in quick succession. Under these conditions, the use of solvent may become excessive and cause dilution of the ink. Rev AA Quick Stop A-3 Videojet 1510 Service Manual Nozzle Flush When Nozzle flush is selected, the vacuum from the venturi is applied to the return side of the nozzle, creating suction at the nozzle orifice. Solvent is applied to the nozzle orifice to clear any blockage. Nozzle flush will automatically time out after 2 minutes but can be stopped at any time before that by pressing F1 key Abort Flush. A nozzle flush can be started with the jet running or stopped. If the jet is running, selecting Nozzle flush will first of all de-energize feed valve V6 to stop the flow of ink to the nozzle. A-4 Nozzle Flush Rev AA Encoder Information B Internal Encoding This is used when product speed is constant. An internal clock sets the stroke-rate to a constant pace. Refer “When to Use Internal Encoding” on page B-1, for more information about internal encoding. When to Use Internal Encoding Internal coding is used when the product speed is constant. The internal clock of the printer is set to the speed of the product in feet per minute (FPM) or meters per minute (MPM) Note: Internal encoding is also used when test printing a sample message. For information on test printing a sample message, refer to... It is necessary to determine the product speed. Below are four methods that can be used to determine the product speed. Rev AA Internal Encoding B-1 Videojet 1510 Service Manual Method 1 Use a handheld tachometer that is calibrated to measure linear surface speed in FPM or measure the revolutions per minute of the pulley. Convert RPM to surface speed by using the following formula Surface speed (FPM) = [Πd x (RPM)]/12 where Π = 3.14 where d = pulley diameter in inches Method 2 Establish a reference mark on the conveyor belt and measure how many inches (one inch equals 25.4 mm) this mark moves in 5 seconds. This number is equal to the conveyor speed in FPM Method 3 If you know the number of products produced per minute on the line, the size of the product, and the gap between each product, you can calculate the product speed. For example: 1200 products per minute are produced on the line, each product is 2.5 inches wide, and there is a one inch gap between each product. Conveyor speed = [(products per minute) x (size + gap)]/12 where size and gap are in inches Method 4 It is also possible to use the printer’s product counter to determine the number of products per minute, and then calculate the line speed as shown in “Method 3”. External (Reduce Or Direct) Encoding A shaft encoder is used when the speed of the conveyor varies. Shaft encoders may either be direct coupled or divided-down: • A direct encoder maintains a 1:1 ratio between the encoder pulses and print strokes. • A divided-down encoder is used when the conveyor speed requires fewer pulses than the actual output of the shaft encoder. The following are the three methods to do encoding: This is used when product conveyor speed is not constant. A shaft encoder must be used with this selection. The shaft encoder monitors B-2 External (Reduce Or Direct) Encoding Rev AA Videojet 1510 Service Manual changes in conveyor speed and varies the stroke rate accordingly. Select REDUCE if the encoder rate input must be electrically divided down for use. Select DIRECT if the encoder input can be used without dividing. Refer “When to Use External Encoding” on page B-3, for more information about external encoding. When to Use External Encoding External coding is used when printing is required when the speed of the product and conveyor changes. In this case, a shaft encoder is required. The shaft encoder is coupled to the conveyor at a point where the selected conveyor shaft and the conveyor are turning together. The shaft encoder will provide either one pulse or many pulses (which are mathematically divided) for each vertical stroke of the message. d d = distance of conveyor (product) travel per revolution of shaft Figure B-1: Product Distance Required shaft encoder: Pulses per Revolution (PPR) = d x (strokes per inch) Where strokes per inch = (strokes per character) x (characters per inch) Example 1 Given information: d = 23 inches 5 x 7 matrix 10 characters per inch 6 strokes per character (five printed strokes from the 5 x 7 character, plus one “guard” stroke that leaves a space between the characters.) 23 inches per revolution x 60 strokes per inch = 1380 PPR Rev AA External (Reduce Or Direct) Encoding B-3 Videojet 1510 Service Manual Example 2 If the standard 1800 PPR shaft encoder is to be used as shown in Example 1, it will be necessary to provide some type of gearing to supply the required 60 pulses per inch as shown in Figure B-2. d Figure B-2: External Shaft Encoder To determine the required gearing, the following method is used. 1800 PPR/1380 PPR = 1.3 or 1:3:1 gear ratio 2 1 1. Pulley b 2. Pulley a Figure B-3: External Shaft Encoder - With Pulley If the diameter of “a” = 2.0 inches, then the diameter of “b” is 2.6 inches (2.0 inches x 1.3 = 2.6 inches). For one rotation of “a”, 1380 pulses are produced from the 1800 PPR shaft encoder. If that same 1800 PPR shaft encoder is connected directly to the shaft on the conveyor, the calculation would be as follows: (1800 pulses per revolution)/(23 inches per revolution) = 78 pulses per inch (78 pulses per inch) / (6 strokes per character) = 13 characters per inch Since the standard calls for 10 characters per inch (refer to Example 1), the message would be compressed on the product. B-4 External (Reduce Or Direct) Encoding Rev AA Videojet 1510 Service Manual Auto Encoding This is used when the product speed varies from that of the conveyor (product slippage). With this selection, the signal from the product detector is used to determine product speed. Refer “When to Use Auto Encoding” on page B-5, for more information about auto encoding. When to Use Auto Encoding Auto Encoding is used when the speed of the product is changing due to slippage on the conveyor or when the product is allowed to fall through guides from one level to another. When set for Auto Encoder, the printer will determine the speed of each individual product, and then code that product at a set stroke rate. The printer needs a product detector installed in order to work with auto encoding. In addition, the length of the detect area (the amount which the detector senses) must be known and entered into the printer. Product Motion Product Detect Jumper Set for Negative Edge Trigger Product { No Product Pulse Width = Product Speed Detector Signal Figure B-4: Auto Encoding Example 1 Given information: Detect area = 5 inches (127 mm) Pulse width of this product = 0.1 seconds Then, Product speed = 5 inches/0.1 seconds = 50 inches per seconds (127.0 mm/0.1 s = 1270.0 mm/s) Rev AA Auto Encoding B-5 Videojet 1510 Service Manual (50 inches per second x 60 seconds per minute)/(12 inches per feet) = 250 FPM (1270 mm/s x 60 s/minute)/1000 mm/m = 76.2 MPM B-6 Auto Encoding Rev AA