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1000 Line Service Manual.book

1. 1 o m iji mil 1 O Le L Fill prerniJe i Milo Q T a 1 Cooling Fan 2 EHT Module Figure 3 31 Cooling Fan and EHT Module 3 26 Electronics Compartment Rev AA Rev AA Videojet 1610 Excel Service Manual 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 N ye d amp D UR gt 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 32 Ink Compartment Ink Compartment 3 27 Videojet 1610 Excel Service Manual Ink Core Module The ink core module maintains the pressure and viscosity of the ink in the printer 2 Ink Core Pump Figure 3 33 Ink Core Module 1 Ink Core Rev AA Ink Compartment 3 28 Videojet 1610 Excel Service Manual The ink core module contains the following subsystems Ink core pump e nk core Ink Core Module Connections There are three input three output and one vent hydraulic
2. Figure 10 4 Electronics Compartment 10 6 Electronics Compartment Rev AA Videojet 1610 Excel Service Manual Control System Board CSB with Back Plate Figure 10 5 Control System Board Assembly with Back Plate Power Switch mi ili 2B TRUM z di MT E 2A l RENE E I Figure 10 6 Power Switch Rev AA Electronics Compartment 10 7 Videojet 1610 Excel Service Manual Electronics Door Assembly e Figure 10 7 Electronics Door Assembly Display Door S SS NN Q Figure 10 8 Display Door 10 8 Electronics Compartment Rev AA Videojet 1610 Excel Service Manual LCD and FIB Assembly 14 Figure 10 9 LCD and FIB Power Supply Unit Assembly 19 Figure 10 10 Power Supply Unit Assembly Rev AA Electronics Compartment 10 9 Videojet 1610 Excel Service Manual Printer Interface Board Assembly PIB 8 Ne r em EZ Bo e Figure 10 11 Printer Interface Board Assembly Rev AA 10 10 Electronics Compartment Videojet 1610 Excel Service Manual Electroni
3. 7 2 bonding during SETVICINE dd ai det b bu e eu ees 7 4 Chapter 8 Maintenance Replacement of Ink System Fan Filter for IP65 8 1 How to Remove the Old Ink System Fan Filter for IP65 8 1 How to Install the New Ink System Fan Filter 8 2 Replacement of Floor Filter for IP65 8 2 How to Remove the Old Floor Filter IP65 8 2 How to Install the New Floor Filter IP65 8 4 Chapter 9 Troubleshooting Read the Operator Manual or RES 9 1 Important Guidelines s edv lis EE rep E ere 9 1 Startup P FODIems so vus ves EM Ne oboe Massa 9 2 Printer Pasto Stahl 25242 suo dedi oda ACE Mi ele pO terat 9 2 Display EQUES outre du hr e te OR er dei OH oct 9 3 Back A iad anteee s dbeeee at Seas emai 9 3 BCD Pats ias Bore a ease eee 9 4 Keypad Pauls bate uat ee Eau mm a ieee M aaah dae 9 5 Beacon MACON ESS dee ae Ne tata NE Oo at bte et petet 9 5 Printer Stotus Icons ria ea et peines ha Te Rs inda etna febr Re 9 7 nareator ICONS ES HEU D 9 7 A eh aaeeset neon cae ae esta eee manners gaat 9 8 VV ANS ICONS oot isc UE Ea a e ee Se VE ae eS NP 9 14 Voltage Checks os cielos px uote exe dw nae ede a bed be edt 9 35 Jet Start and Stop DIaPTOSLGS ss ness baaa bc ces 9 36 Quick Start Dino OS o aides verde ess ue 9 36 Clean Start DIABNOSMES Lie pe bete ibi Shea i 9 37 Clean Stop DI3PnoSble secre tacos a Peter e oe 9 39 COD JESTI OM 39 Cet
4. Restrictions in the nozzle Table 9 8 Warning Icons Rev AA Printer Status Icons 9 15 Videojet 1610 Excel Service Manual Warning Reason Causes Action Gutter Fault Operator has Printer is in Exit from service mode Shutdown disabled service mode Disabled machine shutdown on gutter fault Warning appears immediately Printhead Lid switch circuit The printhead 1 Install the printhead cover Cover is open coverisremoved 2 Make sure the printhead cover is Removed or not seated completely seated on the printhead correctly slide the printhead completely into the sleeve Missing Magnet Make sure the magnet is there in front of the printhead sleeve Defective lid 1 Stop the inkjet and turn off the printer switch 2 Remove the printhead engine and inspect the lid switch 3 Measure the resistance between the copper pads on the underside of the printhead engine and compare readings to the expected values 4 Check umbilical wires for continuity Open circuit Inspect the cabling from the umbilical to the PIB and from the PIB to the CSB Defective CSB Check measurement at TP56 on the CSB Table 9 8 Warning Icons 9 16 Printer Status Icons Rev AA Videojet 1610 Excel Service Manual Warning Reason Causes Action Phase The printer is The printhead is Clean and dry the printhead Threshold unable to dirty Error acquire a phase I I profile with the The ink stream is 1 Perform a nozzle backflush
5. 399504 25 way I O PCB 4 Cable LN tems are not shown in the figure 10 46 Optional Accessories Rev AA Videojet 1610 Excel Service Manual Power Cord Part Number Description Table 10 9 Power Cord Miscellaneous Accessories Connectivity Part Number Description 399186 Extension Cables 3 m RS485 399062 Extension Cables 6 m RS232 399279 Lampstack Extension Cable Beacon 6m 223213 External Ethernet Connector Cable 5 m SP399083 Ethernet Connector Kit Spares SP399084 USB Connector Kit Spares Table 10 10 Connectivity Rev AA Miscellaneous Accessories 10 47 Videojet 1610 Excel Service Manual Hydraulics Part Number Description 399472 Ink Door Spare 399171 Gutter Pump Spare 399072 Tubing kit Spare Table 10 11 Hydraulics Printhead and Umbilical Part Number Description 399506 Printhead and Umbilical Complete 3 m 60 micron Standard for Videojet 1610 Excel 399507 Printhead and Umbilical Complete 6 m 60 micron Optional for Videojet 1610 Excel 399508 Printhead Chassis and Umbilical 3 m Standard for Videojet 1610 Excel 399509 Printhead Chassis and Umbilical 6 m Optional for Videojet 1610 Excel SP399355 Printhead Sleeve and Screw 223277 Printhead Screw Only Table 10 12 Printhead and Umbilical Tools Kit There are several tools in the tool kit for normal maintenance of printer The Service Tool Kit TL399250 Table 10 13 lists the tool kit items and their part
6. Two cartridges of ink Two cartridges of make up fluid Wash bottle Wash solution Gloves e Tissue 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 stack light item 8 is fitted to the printer 4 2 Introduction Rev AA Videojet 1610 Excel Service Manual 1 Printhead 6 Printer 2 Shaft Encoder 7 Printer Stand 3 Shaft Encoder Cable 8 Stack light 4 Photo Cell 9 Printhead Stand 5 Photo Cell Cable Figure 4 1 Typical Production Line Installation Rev AA Introduction 4 3 Videojet 1610 Excel Service Manual Unpack and Inspect the Printer 1 Open the shipping box and make sure that all the parts listed 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 Putthe printer on a stand or table Note The printer can b
7. Videojet 1610 Excel Service Manual 209 ONS 1 Control Panel 5 Handle 2 Mains Power Switch 6 Umbilical 3 Electronics Compartment Door 7 Connector Panel 4 Ink Compartment Door 8 Back Filter The component is not shown in the figure Note Availability of the connectors depends on the printer model you choose Figure 3 3 Printer Cabinet Rev AA Cabinet 3 3 Videojet 1610 Excel Service Manual Control Panel The control panel Figure 3 4 provides the user interface to the printer Refer to Chapter 3 in the Videojet 1610 Excel Operator Manual for more information SVIDEOJE z o 1 Status LEDs 4 Function Keys 2 Arrow Keys 5 Contrast Key Brightness Control 3 Keypad 6 Display Figure 3 4 Control Panel Mains Power Switch The mains 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 mains power switch on the right side of the printer Note The handles item 2 are provided for easy movement of the unit 1 Mains Power Switch 2 Handle Figure 3 5 Mains Power Switch Electronics Compartment Door The electronics compartment door item 3 Figure 3 3 on page 3 3 is mounted on two hinges The door has a seal that is water resistant and prevents entry of any dust into the cabinet 3 4 Cabinet Rev AA Rev AA Videojet 1610 Excel Service Manual Note The seal depends on th
8. phase threshold misaligned 2 Restart the inkjet set to the 3 If the ink stream is still misaligned minimum value perform ink stream alignment refer to Nozzle Adjustment on page 4 37 No break off Perform a visual inspection to verify break off If break off does not exist check electrical connections on the printhead engine and in the electronics compartment Attempt to set the modulation manually to obtain break off If break off cannot be obtained check the modulation signal on the CSB If the modulation signal does not exist refer to CSB failed on page 9 18 If the modulation signal is present on the CSB check for the modulation signal in the printhead Remove the printhead engine and check its electrical connections Replace the printhead engine Phase Charge Check the Phase Charge setting incorrectly set Adjust the Phase Charge setting to recover the phase profile Electrical 1 Check the electrical connections malfunction in between the CSB and the PIB and TOF circuit between the PIB and the umbilical 2 Remove the printhead engine and check the electrical connections 3 Check the resistance between the copper pads on the underside of the printhead engine and compare the readings 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 1610 Excel Service Manual Warning Causes A
9. Clean Start Diagnostic Flowchart 9 38 Jet Start and Stop Diagnostics Go to sheet 1 Rev AA Videojet 1610 Excel Service Manual Clean Stop Diagnostic Start Ensure that the jet is in the correct position in the gutter v Place a piece of paper under the printhead Initiate the clean stop Does the ink remain in the gutter during the transition from ink to make up Is the break up of the jet symmetrical Backflush the nozzle to remove debris Is air visible in the flushing circuit Prime the flushing gt circuit Can Is the flush No solvent be seen pump working and exiting from the pumping solvent jewel Yes Flush the nozzle valve gt Yes Is mark on the paper within the acceptance Can all the line modes be printed over the entire EHT Move the jet position further back into the Change the criteria gutter ange PH valve module Yes 4 Yes Clean stop pass Figure 9 5 Clean Stop Diagnostics Rev AA Jet Start and Stop Diagnostics 9 39 Videojet 1610 Excel Service Manual CSB Test Points Figure 9 6 Test Point 105 The CSB test points are described in Table 9 10 Test Name Test Equipment Measurement Point Required TP105 Valve Control Voltmet
10. Country 399106 Display door with keypad Katakana Excel 399107 Display door with keypad US Excel English US Chinese Simplified English UK and Ireland Indian English Philippines English 290109 isply door win keypad Russian el Russian somo Display dor win keypad Greh BET Joe oris Display door win kopa Arabe Ben Lame ass isply door win keypad Hebrew en Wes Table 10 4 Display Door with Keypad Excel 10 16 Electronics Compartment Rev AA Videojet 1610 Excel Service Manual Ink Compartment Figure 10 17 Ink System Ink Cartridge Figure 10 18 Ink Cartridge Rev AA Ink Compartment 10 17 Videojet 1610 Excel Service Manual Make up Cartridge up Cartridge 19 Make Figure 10 Ink Door Assembly Figure 10 20 Ink Door Assembly Rev AA Ink Compartment 10 18 Videojet 1610 Excel Service Manual Septum Assembly Figure 10 21 Septum Assembly Rev AA Ink Compartment 10 19 JS S H DEN S ACN RR AS Lh S a VV CO Y LO VA E m Via f X E c N E V D Rev AA Videojet 1610 Excel Service Manual Ink Core Module Assembly Figure 10 22 Core Module Ink Core Pump Figure 10 23 In
11. EHT Module 3 Positive Air Pump 7 Connector Panel Boards 4 Control System Board CSB Figure 3 22 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 23 The AC electrical power is supplied through three core cables 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 TB1 Figure 3 23 Mains Input Circuit 3 20 Electronics Compartment Rev AA Rev AA Videojet 1610 Excel Service Manual TB2 Connector N TB1 Connector Figure 3 24 Power Supply Unit The PSU features are as follows The PSU provides four DC voltage levels 24 VDC 15 VDC 5 VDC and 15 VDC to the CSB The input power to the PSU ranges from 100 to 240 VAC 50 60 Hz Electronics Compartment 3 21 Videojet 1610 Excel Service Manual Control System Board uikta ie umet lcm ow UM d T Er ET E A Ue eg isl m kr i nji i j a 2 err i E UND j E 3 L 1 ej i F Tn s i 1 14 athe om q z s id LES z ENT AS a MONTE E i ETT Lisa UT Pu do i i g i LEN i m k Bi JM 1 Li y 2 4 1 Connectors CN1 CN2 and CN3 5 JTAG 2 Charge Tunnel and Modulation Signal 6 USB 2 Host Device Connector 7 User Interface Connector 3 Input Power
12. 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 N 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 N 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 A Warning Airborne particles and substances are a health hazard Do not use high pressure compressed air for cleaning purposes Rev AA Compressed Air Safety Guidelines 2 7 Videojet 1610 Excel Service Manual Ul Related Safety Guidelines A Caution To prevent unauthorized access to the software ensure that Clear Password is executed when exiting from a higher level password A 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 A Caution The Delete User Field option does not ask for confirmation to delete a us
13. Videojet 1610 Excel Service Manual 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 Nozzle Flush A 4 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 automatically times 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 turn off the feed valve V6 to stop the flow of ink to the nozzle Rev AA Encoder Information Internal Encoding Internal encoding is used when product speed is constant An internal clock sets the stroke rate to a constant pace Internal encoding 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 Operator Manual To use internal encoding it is necessary to determine the product speed This section describes four methods that can be used to determine the product speed Metho
14. setpoint with head heater enabled Requested raster table not loaded into the system Warning appears immediately Table 9 8 Warning Icons 9 14 Printer Status Icons Causes The printhead is temporarily overheated The ambient temperature is too high Defective power supply Defective temperature control circuit short 1 Corruption of data 2 Invalid use of file names Action Allow the inkjet to run The printhead temperature should correct itself If print quality or performance issues are noted consider operating the printer in a cooler environment Check the voltages from the mains power supply that is being supplied to the CSB Replace the mains power supply Inspect the electrical connections between the CSB and the PIB and between the PIB and the umbilical Remove the printhead valve module Inspect the electrical connections between the printhead valve module and the deck Measure the resistance between the copper pads on the underside of the printhead valve module and compare these values to the expected values Check the umbilical wires for continuity Delete custom files 2 Check file names and reload raster Rev AA Videojet 1610 Excel Service Manual Warning Reason Causes Action Printhead The printhead The printhead Allow the inkjet to continue to run The Temperature temperature is has not yet printhead t
15. 2 option is available with the optional PCB3 connector Rev AA Install the Product Detector 4 31 Videojet 1610 Excel Service Manual Do the following tasks to install a product detector 1 The photocells may be either NPN or PNP devices The default signal input is NPN Set Jumper JB1 on the CSB to match the device type see Figure 4 36 NPN Figure 4 38 Product Detector Configuration 4 32 Install the Product Detector Rev AA Videojet 1610 Excel Service Manual Table 4 5 lists the settings for the type of product detector Print trigger Device type Jumper1 Pins Jumper2 Pins Table 4 5 Jumper Settings 2 Turn on the printer 3 Select the product detector Access lt 07 Print Product Detector gt 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Printer Set Up gt 01 Print gt 02 Print gt 03 Print gt 04 Print gt 05 Print gt 06 Print gt 07 Print Set the relevant photocell level s to Active high or Active low based on the device type 4 Access 07 Print Active Level 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Printer Set Up gt 01 Print gt 02 Print gt 03 Print gt 04 Print gt 05 Print gt 06 Print gt 07 Print M Product Delay I Product Detector Figure 4 39 Product Delay Printhead Product Rev AA Install the Product Detector 4 33 Videojet 1610 Excel Service Manual Install the Stack light 1 Red lamp negative supply 4
16. 800 843 3610 Fax 1 800 582 1343 International Fax 630 616 3629 Web www videojet com Service Program About Total Source amp Commitment Total Source 8 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 Videojet 1610 Excel Service Manual Customer Training If you wish to perform your own service and maintenance on the printer Videojet Technologies Inc highly recommends you complete a Customer Training Course on the printer Note The manuals are intended to be supplements to and not replacements for Videojet Technologies Inc Customer Training For more information on Videojet Technologies Inc Customer Training Courses call 1 800 843 3610 within the United States only Outside the U S customer should contact a Videojet subsidiary office or the local Videojet distributor for further information Rev AA V Table of Contents Rev AA For Customers in the European UNION iusso rS RR ERI is 1 For Cus
17. Compartment Fan The ink compartment fan item 1 Figure 3 35 on page 3 31 cools the ink compartment Gutter Pump The gutter pump item 2 Figure 3 35 on page 3 31 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 3 80 Ink Compartment Rev AA Videojet 1610 Excel Service Manual 1 Ink Compartment Fan 2 Gutter Pump Figure 3 35 Fan and Gutter Pump Rev AA Ink Compartment 3 31 Videojet 1610 Excel Service Manual Condenser Assembly The condenser assembly converts the solvent air vapour created in the mixer tank into recoverable solvent Figure 3 36 Condenser Assembly Printhead The printhead contains the following parts Printhead cover Printhead engine e Printhead valve module 3 32 Printhead Rev AA Videojet 1610 Excel Service Manual S 1 Printhead Cover 3 Printhead Screw 2 Printhead Engine 4 Printhead Valve Module Figure 3 37 Printhead Printhead Cover The printhead cover item 1 Figure 3 37 is attach
18. Connector 8 Ethernet Connector 4 LEDs Figure 3 25 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 25 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 Charge 1 MOD Connector Pin Function Table 3 13 Pin Functions for Charge 1 MOD Connector 3 22 Electronics Compartment Rev AA Rev AA Videojet 1610 Excel Service Manual Function Table 3 13 Pin Functions for Charge 1 MOD Connector Continued Input Power Connector You can check the voltages at input power connector item 3 Figure 3 25 on page 3 22 to make sure that the power supply from the mains power supply is of the correct value Table 3 14 Pin Connections Input Power Connector LEDs 4 3 2 1 1 Power LED 3 SoC to FPGA LED 2 Printhead Engine LED 4 Ethernet LED Figure 3 26 Status LEDs Description Indicates the status of 3 3 VDC Printhead Flashes when printing is in progress Engine SoC to FPGA Indicates the status of communications between the processor and the FPGA Ethernet Indicates the status of Ethernet communications Table 3 15 Status LEDs El
19. Description 6 5 Videojet 1610 Excel Service Manual 04 Edit Menus Description Network Settings Provides network settings like Use DHCP IP Address Subnet Mask Default Gateway Build Graphic Enables to build and edit graphic of different sizes Shift Set Up Enables to set the shift information Set DayRoll Allows you to define the time the day rolls over to the new day other than the standard time midnight Daylight Settings Enables to set the daylight settings Status Screens Provides the status of various screens like diagnostic screens alarm screen etc Locale Setup Provides data about Editor Font Group keyboard languages display units and alternate zero Password Set up Enables setting up of passwords for levels A and B You can turn ON OFF the password option Display Language Enables you to select the display language System Info Provides system information Table 6 4 04 Edit Menu Description Diagnostic Screens Diagnostics Screen One Menu Commands Function Target Pressure Empirically and theoretically Feb PUBL determined pressures required Actual Pressure to match the actual velocity to Velocity Set Pt e the set point Actual velocity i Head Temp 0 000 22 900 Drop Frequency Nozzle Drive Voltage Printing Phase Phase Threshold Phase Profile Table 6 5 Diagnostics Screen One Menu and Commands 6 6 Frames and Menu Description Rev AA Videojet 1610 Excel Service Manual Diagnostics Screen One M
20. ET Washer Make gt q G c Q o o Q O Item Number Table 10 5 Ink Compartment Rev AA Ink Compartment 10 24 Videojet 1610 Excel Service Manual enter PN EC 399340 Ink Core with Pump EE Lx i o EN Z NA ON MU oorniis ie CR NER D E oe e A ee AAA o AAA E LUN OI coc ic A HU LAN 399171 Gutter Pump Assembly m Lu 399080 Ink System Fan Assembly mE DENN c NN ER mme NN LN a re NUN 00m IE 0 Table 10 5 Ink Compartment Rev AA Ink Compartment 10 25 Videojet 1610 Excel Service Manual A A 05 ER oJ ee gom 1610E Filter Kit Spares M Note This kit has 8 filters P N 234502 Lm ww II CA AA E E LS D LU je e LU AA AA AA NM EE AA MIMO Table 10 5 Ink Compartment Items are not shown in the figure Printhead D Figure 10 30 Printhead 10 26 Printhead Rev AA Videojet 1610 Excel Service Manual Printhead Valve Module Figure 10 31 Printhead Valve Module 10 27 Printhead Rev AA Videojet 1610 Excel Service Manual Printhead Engine F C 60 12 Figure 10 32 Printhead Engine CAC seinen Jw E 399181 Printhead Valve Module BE 1 M2 x 6 Cap head Screw PL NN NN rite PV otoke NN NN a NEN o jee Pon ote TO 7 3 Way Manifold Assembly Rear Tubing Manifold Table 10 6 Printhead Assembly 10 28 Printhead Rev AA Videojet 1610 Excel Service Manual PN Description LEN
21. Empty Flush Umbilical Core Core Prime Prime Figure 4 25 Umbilical Prime 46 Remove the nozzle bypass manifold and the 2 way manifold gasket 47 Fit the front tubing manifold to the printhead valve module using M2 x 6 socket head cap screw Make sure to fit the gasket under the manifold Rev AA Commission the Printer 4 19 Videojet 1610 Excel Service Manual Perform Ink Stream Alignment and Viscosity Calibration 48 Remove the make up cartridge from the make up stall 49 Turn the ink ON in the service mode access 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Service Printer gt 01 Service gt 02 Service OFF Hiah Test Fault Oz Voltage Print Reset Service Figure 4 26 Ink On You can see the ink stream toggling at the start because of air bubbles that remain in the system If the nozzle is clogged refer to How to Clear a Clogged Nozzle on page 9 52 50 Check the position of the ink stream into the gutter e If the ink stream is aligned into the gutter go to Step 51 Else do mechanical adjustments to the nozzle refer to Nozzle Adjustment on page 4 37 Note Inspect the nozzle orifice and charge electrode to make sure that the stream travels through the center of the electrode and runs parallel to the walls of the electrode charge tunnel If adjustments are at either end of the ranges there can be a nozzle partial clog even though the ink stream is not severely misaligned While in some cases an ink
22. M 40 0us A Chl f 7 20V 9Jul 2009 ii 9 800 11 26 49 HEADT Printhead Voltmeter Use the voltmeter to measure the signal at TP39 Temperature TP53 This represents the analog output of the printhead temperature sensor 0 055 VDC 1 Celsius INKT Ink temperature Voltmeter Use the voltmeter to measure the signal at TP42 TP54 This represents the analog output of the core temperature sensor 0 055 VDC 1 Celsius TP41 41Strobe 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 Probe 10 1 Table 9 14 CSB Test Points Continued 9 46 CSB Test Points Rev AA Videojet 1610 Excel Service Manual Test Equipment Measurement Reguired Printhead cover Voltmeter Use the voltmeter to measure the signal at TP56 e f the printhead cover is removed the measured voltage should be 3 3 VDC e f the printhead cover is fitted the measured voltage should be 0 5 VDC PHA Phasing Oscilloscope Use the oscilloscope to measure the signal TP89 at TP57 This represents the analog signal being detected by the first TOF sensor in the printhead A good signal will look as follows 1 2 AUTO RTS d U Table 9 14 CSB Test Points Continued Test Name Test Equipment Measurement Point Reguired 3V3 3 3 VDC Voltmeter Used to verify the output of the 3 3 VDC TP71 voltage regulator chip U54 on the C
23. Message Check the line speed setting to make sure stretched that the printer is printing at the problem speed Encoder Check the shaft encoder and settings to Problem make sure that the messages are printed completely and that the code is not stretched over several products Print Print starts Check Product Check the setup and sensing of the Overlap before end of Detector detector for double triggering problems current print Message Check the line speed setting to make sure stretched that the printer is printing at the problem speed Encoder Check the shaft encoder and settings to Problem make sure that the messages are printed completely and that the code is not stretched over several products No Time to Less than 6 The line speedis Increase the line speed if possible Phase milliseconds too slow from the end of 4 one print to the The distance Increase the distance between adjacent CO beginning of the between products if possible next adjacent products is too short The message is Reduce the message length if possible too long The selected Enter the message again using a smaller font is too big font if possible Table 9 8 Warning Icons 9 30 Printer Status Icons Rev AA Videojet 1610 Excel Service Manual Warning Reason Causes Action No Time for The printer is No phase profile Observe Diagnostics Screen One Note TOF unable to the Phase Profile acquire an If phase profile is not
24. NL c NR LIC RE a RS ON ne lt lt lt CE RA A UA MO O OR NN A A A SE in m 15 2 Way Manifold Assembly Front Tubing Manifold MA po LN it SO ee eese LE CL NNNM S CS rs 00 e Table 10 6 Printhead Assembly tems are not shown in the figure Rev AA Printhead 10 29 Videojet 1610 Excel Service Manual Cables A Figure 10 33 Cables PIN Description 2 EE LE Ribbon Cable Ribbon Cable Assembly Display Display Ribbon Cable Assembly Smart Chip and Pump 14 Way Table 10 7 Cables 10 30 Cables Rev AA Videojet 1610 Excel Service Manual Optional Accessories Beacon Kit Figure 10 34 Beacon Kit Rev AA Optional Accessories 10 31 Videojet 1610 Excel Service Manual Dry Air Kit Assembly Figure 10 35 Dry Air Kit Assembly 10 32 Optional Accessories Rev AA Videojet 1610 Excel Service Manual Static Stand Figure 10 36 Static Stand Note You can use the adaptor plates with the existing printer stands Rev AA Optional Accessories 10 33 Videojet 1610 Excel Service Manual Mobile Stand Fieure 10 37 Mobile Stand Note You can use the adaptor plates with the existing printer stands Rev AA 10 34 Optional Accessories Videojet 1610 Excel Service Manual Printhead Stand Figure 10 38 Printhead
25. Nebi er beue eb 4 24 Sel the Throw DISTANCE a meu ani een aa Re utere et 4 25 Mistal the ENCORE a ad o tma eina die du cba 4 25 Internal BNC OGG u iier e drob Hdi sida 4 25 External Encoding is wits i sema PEL IRURE nid e pedis 4 26 AO ENCON ie 4h trade asc ae eod de Red E de ae tee 4 28 Set the Speed compensa hoM s ioa ee Ed eR EI ERE NE ERE es 4 30 Install the Product Detector i sva gx REESE E RARE 4 30 Install the Stack WE DE men boned ire pdd en 4 34 Nozzle MA ist ERE esci td eur obiter adea te 4 37 Perform Calibration and Testing 4 40 Calibrate Fit leech sna iona SEES SERENE SP SE SKEDE TERESE ico bios 4 40 Calibrate VISCOSITY ous pana troba 4 4 Chapter 5 Printer Operation aura a bd debe Ph E de ebat ebat dede nir 5 1 Reser BU EOU S o a an rai MU Ace ONE AE ut edidere dt iat ee 5 1 Perform System Backups adeo Set epa Fe te RR pd 9 2 Perform Full System Restore 3 3 Perform pmbilical PERI 2 4x 92 4 42 5 5 ie doe RE Reto es 5 3 Chapter 6 User Interface TOG bie HO a PCT 6 1 Frames and Menu Description 6 1 OLEU O a ROA JE TNI ENE A EO ETA 6 1 OPER PP no ee ee abe os PODA evi db epi eae 6 2 USE ces ooo ER OE Ed A 6 3 PP dise d db ate a drench hg stan en tees 6 3 Dra No UC Cree OS eta ion 6 6 Videojet 1610 Excel Service Manual Chapter 7 Replacement Instructions Printhead Bonding during Printing
26. Service Department at 1 800 843 3610 United States only or contact the local Videojet Technologies Inc representative e Access Service gt Videojet Password Generator tab on www videojet com 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 21 Open the ink compartment door refer to Step 2 and Step 3 on page 4 4 N 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 4 10 Commission the Printer Rev AA Rev AA Videojet 1610 Excel Service Manual A Warning 22 23 24 25 Read and understand the Material Safety Data Sheet MSDS before using any ink make up fluid or cleaning solution An MSDS exists for each type of ink make up fluid and cleaning solution For more information visit www videojet com and navigate to Documentation gt Material Safety Data
27. Sheets Access 04 System System Info gt 01 Info Version Info to view the version information Record the following e SW Version e PE Firmware Version e CE Image Version Confirm that the CSB Ink Core utilization are set at High High for 1610 Excel Perform a hardware test Access 04 Edit gt Service Printer Service 1 gt Service 2 gt Service 3 gt Service 4 gt Service 5 gt Service 6 gt HARDWAR TEST Press the F1 Key Figure 4 11 O lt 26 possible open On current low 0 lt 26 possible open v1 on current low 0 lt 26 possible open v on current low 0 26 possible open fo ARDW R USB Data Gutter Act Debug 15 TEST Logging Pump Sed Logging Service Figure 4 11 Hardware Self test Install one new cartridge of ink and one new cartridge of make up fluid in the printer Figure 4 12 on page 4 12 Make sure that the ink out and make up out icons disappear Commission the Printer 4 11 Videojet 1610 Excel Service Manual gt 1 Ink Receptacle 2 Make up Receptacle Figure 4 12 Ink and Makeup Cartridge Holder 26 If unknown ink and unknown make up icons are displayed perform the Update Ink Core Parameters Note Make sure that the ink and make up cartridges are inserted into the correct slots To update the parameters do the following tasks a Select 01 Edit 02
28. Stand Printhead Holder TD i9 Ve Figure 10 39 Printhead Photocell Holder 8 mm Rev AA Optional Accessories 10 35 Videojet 1610 Excel Service Manual c Nd Figure 10 40 Printhead Photocell Holder 18 mm Mounts to Printhead Holder e gt E uere p 8 A Figure 10 41 Mounts to Printhead Photocell Holder 8 Ee r al Figure 10 42 Mounts to Printhead Photocell Holder 18mm 10 36 Optional Accessories Rev AA Videojet 1610 Excel Service Manual Wash Station Assembly AUS os LT 99 Figure 10 43 Wash Station Assembly Shaft Encoder Figure 10 44 Shaft Encoder Rev AA Optional Accessories 10 37 Videojet 1610 Excel Service Manual Shaft Encoder Accessories 61 Figure 10 47 Spring Bracket Product Detectors Figure 10 48 Detector EZ 10 38 Optional Accessories Rev AA Videojet 1610 Excel Service Manual Figure 10 50 Detector Label Eye Power Accessories Figure 10 51 Power Conditioner Rev AA Optional Accessories 10 39 Videojet 1610 Excel Service Manual Figure 10 52 Uninterrupted Power Supply Power Cord Figure 10 53 Power Cord 10 40 Optional Accessories Rev AA Videojet 1610 Excel Service Manual Din Plugs Figure 10 55 7 Way DIN Plug Rev AA Optional Accessories 10 41 Videojet 1610 Excel Service Manual CO Umm 000 mm
29. Subassemblies and Parts gt lt TA How to Read the IPL 10 3 Videojet 1610 Excel Service Manual Tables Figure 10 2 describes the styles used to show the explosion of the main assemblies in parts lists Pomeni on CN Main Assembly Subassembly 1 oubassembly 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 1610 Excel Service Manual Videojet 1610 Excel Printer Z7 S O K 905 V SVS O ge O gt S UT S ZL D JO SF 8 S38 IS SSI ni ST S S N SX E e EM LE lt SX Figure 10 3 Main Parts of the Printer Table 10 2 shows the sub assemblies of the printer Mem Dems 7000000000 A Electronics Compartment LN Ink Compartment CS AAA D Printhead Table 10 2 Videojet 1610 Excel Printer Assemblies Rev AA Videojet 1610 Excel Printer 10 5 Videojet 1610 Excel Service Manual Electronics Compartment
30. VIDEOJET Videojet 1610 Excel Service Manual P N 462134 21 Revision AA August 2009 Copyright August 2009 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 Phone 1 800 843 3610 Offices USA Atlanta Chicago Los Angeles Philadelphia Wood Dale IL Fax 1 800 582 1343 INT L Canada France Germany Ireland Japan Spain 60191 1073 USA Intl Fax 630 616 3629 singapore The Netherlands The United Kingdom www videojet com 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 2001 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 B5 EN61000 4 3 2006 Radiated Susceptibility BS EN61000 4 4 2004 Electrical Fast Transient Burst Requirement BS EN61000 4 5 2006 Surges Requ
31. at Password Level B The password level of functions set at Password Level C cannot be changed at any password level Contact the Videojet representative or access Service gt Videojet Password Generator tab on www videojet com to obtain the password Enalish Locale Password Display System 04 Setup Set up lt Language Info System 1111 zele Password Password Password Di A Entry B Entry Feature Password Figure 4 29 Password Menu A Caution Machine functions that only trained personnel can access are set at password level C master password Contact the Videojet representative or access Service gt Videojet Password Generator tab on www videojet com to obtain the password 4 24 Set the Password Levels Rev AA Videojet 1610 Excel Service Manual Set the Throw Distance Install the Set the throw distance from 5 mm to 15 mm The optimum printhead distance for the 1610 Excel printer is 12 mm Encoder The printer has two options to adjust print pitch The first is external encoding shaft encoder This is when the product is transported on a conveyor or transport Make sure that the shaft encoder is directly related to the movement of the conveyor for the external encoder to work properly The second varying speed option is to use the auto encoder option This option is used when a shaft encoder cannot be used since there is no way of tracking the production line movement The auto encode option uses a very accurate dete
32. control Viscosity control Function 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 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 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 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 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 Table 3 18 Ink Core Module Functions 3 36 Printhead The functions of the ink
33. core module are shown in Table 3 18 Frequency Performed approximately 25 times per second Performed continuously Performed every TENTH phasing test Performed once per second Occur every 10 seconds Rev AA Viscosity Control Videojet 1610 Excel Service Manual Function Frequency Once the printer has determined its target pressure it has Pressure is the means to perform viscosity adjustments Determination constantly concerning viscosity is made by comparing the empirically measured determined target pressure to a reference pressure known The printer as the temperature compensated target pressure This value adds make up is acquired indirectly from data encoded on the ink cartridge if the pressure Smart Chip This reference pressure is mathematically goes outside determined and represents the pressure required to acquire the given the correct actual velocity under ideal viscosity conditions If range for a set the target pressure deviates from the reference pressure the time period printer attributes this to viscosity variation and responds accordingly Table 3 18 Ink Core Module Functions Printhead Operation Rev AA 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 duri
34. en oen Sr mewnr Leman cime LT orrs EIN rs opaco rna for pans a a m smsmmeme TO m omsnancae ER 378985 Encoder Adapter Cable Kit To convert from older style Conxall excel connectors to new DIN connectors 64 234211 Detector EZ Pro Proximity Fiber LN 234212 Detector EZ Pro Through Beam fiber a 234215 Detector Retro Smart Clear Materials IS 234213 Detector Label Eye Web Printing 3 234214 Detector Mark Eye Web Registration Mark um 67 378981 Product Detector Adapter Cable To convert from older style Conxall excel connectors to new DIN connectors 356841 02 120 V Power Conditioner NEM 234597 240 V Power Conditioner LEN A 80000008 Uninterrupted Power Supply 120 V Version BEEN Cord EE to Table 10 9 on page 10 47 EMEN 0036 578 3 Way DIN Plug Photo Cell For product detector and reverse printing input 500 0036 583 7 Way DIN Plug Relays For Print Ready output and warnings 500 0036 577 6 Way DIN Plug Alert Beacon m 500 0036 581 4 Way DIN Plug Shaft Encoder m 500 0036 584 8 Way DIN Plug Message Select A B HE 500 0076 141 DIN Plug Dust Cap LN 399133 CA Refer item 48 Anti Vibration Kit Stand m Table 10 8 Accessories Continued Rev AA Optional Accessories 10 45 Videojet 1610 Excel Service Manual SP378810 Alarm cable 7 way DIN connector with 6ft cable SP378982 Encoder Adapter Cable 399475 25 way I O PCB 4 Cable Kit Table 10 8 Accessories Continued Femmes
35. forced through the filter to the printhead mixing solvent into the ink stream in the heater manifold Approximately one second after the solvent starts to mix with the ink the feed valve V6 in the cabinet turns off removing ink pressure from the printhead Ink ceases to flow into the heater manifold and the solvent flushes ink from the nozzle body Five seconds later the bleed valve turns off and then turns on again introducing solvent into the jet valve which inhibits the formation of ink residues when the printer is turned off The jet valve on the heater manifold turns off ensuring that no ink diffuses into the solvent At this point no ink should be present in the nozzle body The gutter valve switches off increasing the suction on the bleed system After a short pause the bleed valve turns off After another short pause the gutter valve turns on to clear any fluid from the gutter Once the gutter valve turns off the main ink pump also turns off Note This sequence is used to manually stop the jet for a short period or to automatically stop the jet during instances like EHT trip and charge error 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 dry ink in the jet orifice may make restarting difficult This procedure is primarily intended Clean Stop A 3
36. may be present if the printhead engine module is showing signs of a misaligned ink stream loss of ink stream Perform a Nozzle Flush Do the following tasks to perform a nozzle flush 1 Remove the printhead cover screw that fastens the printhead cover to the printhead chassis and remove the printhead cover see Figure 4 22 on page 4 17 2 Support the printhead in a suitable stand and place a container underneath to collect any extra solvent Make sure the container is connected to the electrical ground 4 Initiate Nozzle Flush 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Service Printer gt 01 Service gt 02 Service gt 03 Service Auto Prime gt 01 Prime gt 02 Prime 9 52 How to Clear a Clogged Nozzle Rev AA Videojet 1610 Excel Service Manual Auto Ink Nozzle Fault 13 Prime Pressure Setting Reset Service Y ON Prime Empty Flush Umbilical 01 Core Core Prime Prime Prime Calibrate Update Calibrate OZ N Flush v iecacit Core Hi Prime Figure 9 8 Nozzle Flush 5 Press the Enter key The nozzle orifice must be washed with washdown to clear any blockages while nozzle flush is running 6 Ifthe problem is not resolved even after five nozzle flushes perform a clean start refer to Perform a Clean Start on page 9 53 Perform a Clean Start For information on how to perform a clean start refer to Clean Stop and Clean Start the Printer on page 4 21 A clean start will clean the nozzle with a higher operatin
37. numbers Part Number Description 234639 Allen Hex Key 0 035 inch Set of 5 234638 M4 Nut Spinner 7mm Table 10 13 TL399250 Tool Kit Parts List 10 48 Tools Kit Rev AA Videojet 1610 Excel Service Manual Part Number Description Tool Bag Table 10 13 TL399250 Tool Kit Parts List Continued Rev AA Tools Kit 10 49 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 stop Typical dirty start stop Minimum standard required Figure A 1 Clean Start Stop Test Illustrations Rev AA Clean Start Stop Standards A 1 Videojet 1610 Excel Service Manual Clean Start The Clean Start sequence is as follows 1 10 11 12 Quick Start The solvent from the filter is forced through the umbilical connection into the printhead At the printhead the solvent enters the heater manifold and passes into the main fluid path between the jet valve and the nozzle The jet starts when the nozzle becomes pressurized by the solvent flow 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 Fluid in the jet is caught by the gutter and dire
38. oo Scent Red rs ER NENA 10 47 Miscellaneous Accessories 10 47 CODBeg VB oaa be DP e NEU da 10 47 TY AUS uode tei avertis Blas ae Stk node 10 48 Printhead and Umbilical 10 48 TOOLS S sa ee aa dm ea es 10 48 Appendix Clean Quick Start and Stop Description Clean Start Stop Standards Clean ola A A DISP QUA EI REN OFFER SLOPE semet ke ace ste Ur aet ao Aita os de Sa Clean SlOD nani jo MA Lowest bees Co BEDES MOSES SEERE SN sooo PER Nozzle Bl sblos sus Eb E ERR ERU ER A Ae Od eed n dos eos e Appendix B Encoder Information Material ENCODE ass ei ene ba Ni E SERE EU eee dune External EROS ouis sober KERIN NA ido r AUTO ET COMING 6 co iir Senin se eta iaa eae dad Rev AA Introduction Videojet 1610 Excel Printer The Videojet 1610 Excel is a continuous ink jet printer that can print fixed and variable codes at high line speeds on consumer and industrial products The printer delivers superior uptime print quality and ease of use to the operators About the Manual The Videojet 1610 Excel Service Manual is written for the service technician of the printer The Service Manual contains the installation service and troubleshooting procedures Related Publications The Videojet 1610 Excel Operator Manual Part Number 462133 is available for reference Language Codes When you order these manuals make sure to add the 2 d
39. present all actual velocity zeroes allow the printer to adjust the and thus cannot phase threshold to attempt and acquire perform TOF a phase profile velocity control 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 Observe Diagnostics Screen One Note unable to set the the Phase Profile modulation If the phase profile is erratic 1 s and 0 s automatically present but randomly the modulation value acquired automatically by the printer may be erroneous Perform a visual inspection of the printhead to confirm incorrect modulation value Attempt to manually set the modulation to restore break off monitor diagnostics screen to assess status of automated controls If modulation cannot be restored manually see causes and actions under Phase Threshold Error on page 9 17 Table 9 8 Warning Icons Rev AA Printer Status Icons 9 31 Videojet 1610 Excel Service Manual Warning Overspeed BELT HE Maximum Print Rate Exceeded No Valid Ink Parameters Possible Ink Coefficient Update USB Connection Is Over Current Reason The message cannot be printed at the required width Current print go received less than one millisecond from last print go Ink core module not programmed or invalid values in smart chip Ink cartridge coe
40. quoc re ug stt see daa ANA 9 40 How to Clear a Clogged Nozzle 9 52 Performa Nozzle Mushze i 25 soie eate qu 9 52 Perform a Clean Sarl eos ue Pe deb de eb vee areas 9 53 Perform System Flush Purge with Nozzle Attached 9 53 Clean the Nozzle with a Syringe and Cleaning Liquid 9 54 How to Correct Loss of Modulation 9 55 Chapter 10 Illustrated Parts List Howtohead INO PL uas ak ied bu hada eens A NERIS S dure 10 1 4 Rev AA Videojet 1610 Excel Service Manual TS MON sea aha cient ata Gan fee A op rot woe ande 10 1 Dee e E ketones E a UAE S IP O eres 10 4 io CR 10 4 Videojet 1610 Excel Panel ani sente demie lune 10 5 Electronics Compartment 10 6 Control System Board CSB with Back Plate 10 7 PON T SMILE She Ru nur nina 10 7 Electronics Door Assembly ss unes at Ein 10 8 Power Supply Unit Assembly sue sara eames soute 10 9 Printer Interface Board Assembly PIB 10 10 Electronics Fan ASSEM DIY s ow ije sedute ar eda 10 11 Positive Air Pump Assembly 23325 ere sr eme 10 11 ERE Modules ctas A ee aje ea ton ea 10 12 Connector Ane redier at ins Pia pbi bed 10 12 PCB ASSerbLies 3 2 e pui erui yd a ou MU eem Rd 10 13 Display Door with Keypad in Different Languages 10 15 Ink Compartinent 2s dao sn LA CLE IER NE Lx Kebe ae 10 17 Ink Cartridge oscar da veut bd ac Sabe pde o RE RA aes
41. significant digit or nibble 2 4 Yd TT Leo ST 3 ESAS Figure 3 18 Message A Input Connector 3 16 Cabinet Rev AA Videojet 1610 Excel Service Manual Message Selection Bit DIN Pin 1 0 Least significant bit 15V DC supply DIN Pin 2 0 Least significant bit input DIN Pin 3 1 Second bit 15V DC supply 1 Second bit input 2 Third bit 15V DC supply Din Pin6 2 Third bit input Din Pin 7 3 Most significant bit 15V DC supply 3 Most significant bit input Table 3 9 Message A Input Connector Pinouts x 4 1 Ot lt lt oT NES e T Figure 3 19 Message B Input Connector E Pin Function DIN Pin 1 Least significant bit 15V DC supply Third bit input NII a A com vo vo AS mM RS om Din Pin 7 Most significant bit 15V DC supply Din Pin 8 T mme Most significant bit input Table 3 10 Message B Input Connector Pinouts An Example Rev AA Cabinet 3 17 Videojet 1610 Excel Service Manual Message Selection Bits PA Je jaz ja dim os hrs COACALCO rms nist Table 3 11 Message Selection Bits An Example Print Trigger 2 Connector The printer provides 15VDC 100mA output for use by a photoelectric cell PEC inductive proximity detector or micro switch The print trigger 2 connector item 2 is a3 way DIN connector The pin functions are shown in Table 3 12 on page 3 18 This connector is also used in cross print applications Note T
42. 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 Note The default date display format is US month day year for the Videojet 1610 Excel UI 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 N 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 Content Presentation 1 3 Videojet 1610 Excel Service Manual A 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 frames and menus of the UI are shown between two angle brackets For example 01 Edit I x ot Printing OQ 0 0 Ink P
43. stream can be misaligned you can adjust the ink stream to flow correctly into the gutter But a misaligned ink stream leads to incorrect pressure setting as the printer needs more than normal pressure to get the correct velocity with a slightly clogged nozzle 51 Make sure that the jet startup is complete The jet running icon on the main screen must be solid must not flash 52 Make sure that the printer has reached steady state Steady state indicates actual velocity velocity set point 0 1m second check these parameters on Diagnostics Screen One 4 20 Commission the Printer Rev AA Videojet 1610 Excel Service Manual A Caution If the viscosity calibration is not done the viscosity high low warning will not disappear from the screen This calibration step is the most critical step in installing the printer 53 Perform viscosity calibration refer to Calibrate Viscosity on page 4 41 and record Target Pressure both the values To record the pressure access 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Service Printer gt 01 Service gt Diagnostic Screens gt Diagnos Screen gt Diagnos Screen 54 Check the ink stream alignment and make the fine adjustments if necessary The ink stream must be centered horizontally and vertically not more than 2 to 3 stream widths from the top of the gutter The top of the gutter is the arc opposite the EHT plate angled plate Refer to Figure 4 44 on page 4 38 for more
44. too thin Table 9 7 Fault Icons Continued 9 10 Printer Status Icons Inspect the ink compartment electronics Repair if possible Monitor the speed of the pump Action compartment and umbilical for leaks 1 Tip the core forward check if the speed increases 2 Bring the core back to the normal posi tion 3 Tip the core backward Check if the speed decreases This is a good test to check if the filter in the ink core is cracked or if there is a leak in the ink core If the speed of the pump changes on tipping the core replace the core Inspect the electrical connections between the ink core module and the PIB and between the PIB and the CSB Check and compare the voltage readings at the test points related to pump and pressure TP20 TP21 TP22 and TP47 refer to CSB Test Points on page 9 40 Also remove the top cover of the ink core module and measure the voltage between points Press and Press Inspect the electrical connections between the ink core module and the PIB and between the PIB and the CSB Open the pump compartment and inspect the pump Replace the pump if required Check the Diagnostics Screen One Compare the target pressure with the temperature compensated target pressure If the target pressure is significantly less than 1 bar the temperature compensated target pressure the ink is too thin Recover the viscosit
45. 10 17 Makeup Cartrides a cocotte do ede haut od aut beac 10 18 Ink Door Assemb uos eto as ee eee eas eos RU estu 10 18 Septum Assembly 26 259 iuo a etat ebd m dedo 10 19 Ink Gore Module Assembly carei ts Son ipod 10 20 MICO o ii ei A va ad ee art aont had 10 20 Gutter Pump Assem Oly na Seid rati PA ina 10 21 Ing oa Slot sea oe quide A te 10 22 Condenser Assembly cuiu ei ao ERR US MER e es 10 22 Ink System Filter Assembly soria ero PERRO EE 10 23 R TOT s l WCE 68 ud csi de uncus EM LOM MO 10 24 PARKER c PER Tr 10 26 Printhead Valve Module 10 27 Printhead Eno NE aud to reat a b eec t 10 28 Cables soe ues sive es a ioo eat Prts 10 30 Optional Accessories sau Boss expe Ov Bo brad etant ga 10 31 Beacon NI ae GM a nel i Se Da duoc Pubs dario ttn 10 31 Dry Ait Kit Assembly oat db tS eot dfe ahaa des 10 32 SOUCI Tati ood cose ed oo RG 10 33 Mobile Standes 05k siga ii dieu 10 34 Printhead Stand 4 deo secrete ebore dde TUE d EAS 10 35 Printhead Holder oie er bed RC EU ated ark Be ates Ses 10 35 Mounts to Printhead Holder 10 36 Wash Station Assembly uideo en hd aec iter 10 37 Snalt Encoder ue cda ove a t ve WIEN GA opt 10 37 Product Detectors codex v uo em ob CS e is e oet 10 38 Videojet 1610 Excel Service Manual Power ACCESSOTICS c god s Sa Qoae land Exi eee ees 10 39 Poet CON o e e OE aa hate 10 40 Din PI OS ne ir adero burden Ot das dtd aaa are 10 41 ROME CON AE ME een EP
46. 2 on page 4 17 N Caution Always wear a set of rubber gloves before disconnecting the nozzle tubing manifold This helps to prevent nozzle clogs 5 Remove the M2 x 6 socket head cap screw that attaches the front tubing manifold to the printhead valve module see Figure 4 23 on page 4 18 6 Use a syringe to flush the nozzle with 50 ml of cleaning liquid a Inject the solvent through the feed side of the manifold You must see a stream of cleaning liquid that flows out of the nozzle b Use an empty syringe to push air through the nozzle You can repeat the process any number of times as it does not add any fluid to the system 7 Ifthe ink stream is still misaligned contact Videojet Technologies Inc Refer to Chapter Support and Training for Videojet contact information Note When the nozzle misalignment clears after a clean start the ink stream goes out of alignment in the gutter and the system identifies a drop in target pressure that can result in the system erroneously detecting low viscosity fluid So it is critical that the nozzle orifice and charge electrode are inspected to verify that a slight misalignment is not present 9 54 How to Clear a Clogged Nozzle Rev AA Videojet 1610 Excel Service Manual How to Correct Loss of Modulation Do the following tasks if a printhead engine module indicates loss of modulation 1 Rev AA Perform the following procedures as a slightly misaligned ink stream or partial
47. 24 VDC supply to the strobe siren 2 Amber lamp negative supply Maximum Rating 900 mA 3 Green lamp negative supply 5 Strobe siren negative supply Figure 4 40 Status Output Connector Pin Diagram Do the following tasks to install a stack light 1 Fitthe stack light item 1 Figure 4 41 on page 4 35 to the stack light mounting bracket item 3 using three M4x10 socket head cap screws item 2 2 Fitthe stack light mounting bracket to the printer cabinet item 1 Figure 4 42 on page 4 35 using three M4x10 socket head cap screws item 2 and three M4 plain nylon washers item 3 Note The position of the M4 plain nylon washers is important to maintain the IP rating 4 34 Install the Stack light Rev AA Videojet 1610 Excel Service Manual 1 Stack light 2 M4x10 Socket head cap Screws x3 3 Stack light Mounting Bracket Figure 4 41 Stack light 1 Printer Cabinet 2 M4 x 10 Socket head cap Screws x3 3 M4 Plain Nylon Washers x3 Figure 4 42 Stack light Installation 3 Insert the stack light connector into the status output connector on the connector panel see Figure 4 43 on page 4 36 Rev AA Install the Stack light 4 35 Videojet 1610 Excel Service Manual 1 Reverse Print Input 2 Status Output Connector 3 Product Detect Input PEC1 Figure 4 43 Connector Panel The installation of the stack light is complete 4 36 Insta
48. 4 Commission the Printer 4 13 Videojet 1610 Excel Service Manual 018 0 413930435594 Makeup Ref Serial Ma OFOOACD 128 255 21 10 2008 Prod Fluid Cartridge FluidExp Batchcode Level Refit Cnt Date Ink Makeup Data Data Figure 4 15 Makeup Smart Chip Data 29 Verify and record the Time Ink On Access 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Service Printer gt 01 Service Printer Log gt 01 Log Run Times gt 01 Run Time see Figure 4 16 1 5353512 0 40 Drop Time Machine 01 Counter Ink On Run Time Run Time Figure 4 16 01 Run Time Configure the Printer 30 Please make sure printhead is clean and dry Calibrate the HV Refer to Calibrate EHT on page 4 40 31 Set date and time Access 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit System Set Up gt 01 System see Figure 4 17 12 37 03712708 OO il Set Set Set Set 1 Time Date HR AE WK YR System Figure 4 17 Set Time Date 32 Set the nozzle type and the conduit length e Access 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Service Printer gt 01 Service gt 02 Service gt 03 Service Nozzle Setting gt 01 Settings Nozzle Type see Figure 4 18 on page 4 15 Make sure that the nozzle type is set correctly for the current configuration 60 micron 4 14 Commission the Printer Rev AA Videojet 1610 Excel Service Manual SN 60 Micron MER bal 76 805 Nozzle Fluid Frequency Drop O1 N Type Type Divider Frequ
49. 5 Connector The RS 485 connector item 10 is a 5 way DIN 180 degree or stereo type connector Use this to connect the printer to an RS 485 network to import data or control the printer remotely at up to 1Mbps bi directional half duplex The pin allocation is shown in Table 3 7 Figure 3 16 RS 485 Connector Pin Function DIN Pin 3 0 VDC Common Table 3 7 RS 485 Connector Pinouts RS 232 Connector The printer has an RS 232 communication port at up to 250 kbps 1 8 1 no parity bi directional full duplex The RS 232 connector item 11 is a 5 way DIN connector The pin allocation is shown in Table 3 8 Cabinet 3 15 Videojet 1610 Excel Service Manual O Figure 3 17 RS 232 Connector Pin Function DIN Pin 1 0 VDC common DIN Pin 2 Transmit data out from the printer DIN Pin 3 Receive data into the printer DTR output from the printer DCD input to the printer Table 3 8 RS 232 Connector Pinouts Message A and B Input Connectors There are eight external message inputs provided on PCB3 with four inputs on each of two Message connectors as shown in Table 3 9 on page 3 17 and Table 3 10 on page 3 17 The user has to link adjacent pins to indicate a logic 1 value on that bit The link short circuits a resistive 15V DC supply to an opto isolated input The 1610 printers use the Message inputs to select message numbers coded in either BCD format 00 99 or binary format 0 255 with Message A as the least
50. 6 VDC e f an oscilloscope is used a good signal will look like the signal shown in the following figure Probe 10 1 TP88 Level probe Voltmeter or Used to confirm whether the high sensor in the O mixer Oscilloscope mixer tank module is covered or uncovered tank high e f a voltmeter is used and the sensor is covered a voltage of 1 6 VDC indicates that the sensor is uncovered A voltage lt 0 7 VDC indicates that the sensor is covered e f an oscilloscope is used the following signal indicates that the sensor is uncovered 5ms Trig AS Table 9 13 CSB Test Points Rev AA CSB Test Points 9 43 Videojet 1610 Excel Service Manual Test Test Equipment Measurement Point Required TP93 Level probe Voltmeter or Used to confirm whether the middle sensor in the 1 mixer Oscilloscope mixer tank module is covered or uncovered tank middle e 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 e f an oscilloscope is used the following signal indicates that the sensor is uncovered Probe 10 1 TP94 Level probe Voltmeter or Used to confirm whether the low sensor in the 2 mixer Oscilloscope mixer tank is covered or uncovered tank low e f 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 cov
51. 65 Figure 8 2 Floor Filter 4 Discard the old floor filter element according to the local regulation The removal of old floor filter for IP65 is complete Replacement of Floor Filter for IP65 8 3 Rev AA Videojet 1610 Excel Service Manual 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 drip tray 2 Attach the ink core support 3 Tighten the M4 x 16 cap head screws The installation of new floor filter for IP65 is complete 8 4 Replacement of Floor Filter for IP65 Rev AA Troubleshooting Read the Operator Manual The Videojet 1610 Excel Operator Manual Part Number 462133 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 trained personnel or a service technician is allowed to perform N Warning It is possible that in a fault condition the heater can reach 70 C 158 F temperature Do not touch the plate on which heater is installed The failure to follow this warning can cause personal injury Important Guidelines Before you perform fault diagnosis or do any repairs described in this section Videojet recommends to shift the printer from the production line to a clean environment When a fault condition occurs the first step to locate the cause must be to check t
52. 7 1 Available Instructions Printhead Bonding during Printing Do the following tasks to establish bonding for the printhead and receptacle 1 Make sure that the printhead cover item 6 Figure 7 1 on page 7 3 is attached Note The printhead is ground through the printhead screw item 3 and umbilical item 1 If there is no screw you must provide the printhead with the path to the electrical ground 7 2 Printhead Bonding during Printing Rev AA Videojet 1610 Excel Service Manual 1 Umbilical 5 Receptacle 2 Earth Bond Strap 6 Printhead Cover 3 Printhead Screw T Printhead 4 Crocodile Clip Figure 7 1 Printhead and Receptacle 2 Usea metal or other conducting receptacle item 5 Figure 7 1 to collect the printhead fluid 3 Connect one end of the earth bond strap item 2 using crocodile clip item 4 to the receptacle Make sure that the connection is rigid 4 Connect the other end of the earth bond strap to the printhead cover screw Make sure that the connection is rigid 5 Check the path from the electrical ground to the main printer cabinet using a multi meter or a similar device to make sure that the earth loop is closed 6 After the checks are completed continue the printing operation Rev AA Printhead Bonding during Printing 7 3 Videojet 1610 Excel Service Manual Bonding during Servicing N Warning 1 2 5 6 PERSONAL INJURY This operation must be carried out by a trained service tech
53. 9091 Liquid Crystal Display and Front Panel Interface Board Assembly K40 x 10 Pan head Torx Screw LCD and FIB Assembly 399077 Power Supply Unit PSU with Mount CS CS JJ e Pav oun Pit s B R 13 14 M3 ET Washer ANNE AAA I Eo DN UNA ki AA kli 399473 Printer Interface Board PIB Assembly ua LUN MN i x AAA AAA LEE O ned E A AA E AAA A AAA LA LOU ML A A OO EN REN A Table 10 3 Electronics Compartment Continued n Z lt 10 14 Electronics Compartment Rev AA Videojet 1610 Excel Service Manual enim pw ou aw Lio eem NE re NN CN ORNK JEAN gt NN 089 e TT Oa o CI DI EE 08 0 MARNE TT a ae DL emm ON N N LC NE HM MIEDO Iw 7 LM e OD A LO jw eos DEUM ps mew t Table 10 3 Electronics Compartment Continued Display Door with Keypad in Different Languages Part Number Display Door with Keypad EXCEL Country 399101 Display door with keypad European Excel French German Spanish Portuguese Brazilian Italian Dutch Norwegian Finnish Swedish Danish Portuguese Portugal Swiss German Swiss French Swiss Italian Spanish CALA 399102 Display door with keypad Turkish Excel 399103 Display door with keypad Korean Excel Korean 399105 Display door with keypad Polish Excel Polish Table 10 4 Display Door with Keypad Excel Rev AA Electronics Compartment 10 15 Videojet 1610 Excel Service Manual Part Number Display Door with Keypad EXCEL
54. B 3 Connector 6 16 way Connector 12 26 way Connector Figure 3 29 Printer Interface Board PIB Electronics Compartment Side 0000000000000000000000000 QO0000000000000000000000000 0C000000000000000000000000 O0000000000000000000000000 0000000000000000000000000 0000000000000000000000000 00000000 00000000 0000 00000 000 1 14 way Ink Door Ribbon Cable Connector 4 20 way Ink Core Module Ribbon Cable 2 Ink Compartment Fan Connector Connector 3 16 way Ink Core Module Ribbon Cable Connector Figure 3 30 Printer Interface Board PIB Ink Compartment Side Rev AA Electronics Compartment 3 25 Videojet 1610 Excel Service Manual The description of different connectors on the PIB is provided in the Table 3 16 Connector Description 10 way Printhead Connector Connection to valves phase detector strobe LED heater and 12 way Printhead Connector thermistor and gutter detect Ink System Ink pump valves sensors level detectors smart chip supplies validation system Table 3 16 PIB Connectors EHT Module The extra high tension EHT module item 2 Figure 3 31 on page 3 26 generates the high tension voltage 0 to 8000 VDC that is supplied to the deflector plate in the printhead
55. D backlight assembly Cable between CSB If 24 VDC is not present at backlight inverter but is present at Pins 1 and backlight is and 3 of B LIGHT connector on CSB make sure that the cable is disconnected or faulty connected between the CSB and the backlight 2 Check the cable for continuity replace if faulty Backlight faulty If 1000 VAC is present at output of backlight inverter but backlight is not illuminated replace the LCD Backlight assembly CSB faulty Check for 24 VDC on pins 1 and 3 of B LIGHT connector on CSB If 24 VDC is not present replace the CSB Table 9 2 Display Backlight Failure LCD Faults Possible Cause Remedial Action LCD contrast not set Brass b to set the contrast correctly Ribbon cable between CSB Check the cable for continuity Replace if faulty and LCD is faulty CSB faulty Replace the CSB LCD faulty Replace the LCD assembly Table 9 3 LCD Failure 9 4 Display Faults Rev AA Videojet 1610 Excel Service Manual Keypad Faults Possible Cause Remedial Action Ribbon cable between CSB and 1 Make sure that the ribbon cable between CSB and the keypad is disconnected or faulty keypad is connected 2 Replace the cable for continuity replace if faulty CSB faulty Replace the CSB Keyboard faulty Replace the keyboard Table 9 4 Keypad Failure Beacon Indication Beacon Color Description and Multi I O Information e Alarm present Jet off All relays are off Mu
56. Edit gt 03 Edit 04 Edit Service Printer gt 01 Service gt 02 Service gt 03 Service Auto Prime gt 01 Prime gt 02 Prime Update Core The ink data is displayed on the screen b Make sure that the part number on the ink cartridge matches with the part number displayed on the screen Record the part number oee Figure 4 13 on page 4 13 c Press the Enter key and wait for about 4 to 5 seconds The ink data displayed on the screen disappears and the new ink type information appears 4 12 Commission the Printer Rev AA Rev AA Videojet 1610 Excel Service Manual IN x ot Printing C C Ink Part Mo VSO1A D 0 0 Counter 0000000239 Store Recall ie Print 03 Message Message Store Message Edit Figure 4 13 Ink Data 27 Verify and record the ink type and expiration date Access 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Service Printer gt 01 Service Printer Log gt 01 Log Ink Data gt 01 Ink Ink Data see Figure 4 14 on page 4 13 20148 0 N 3634463 34 O 1152 72151 WSC V ISC VAS Serial Ma Coef 1 Coef 2 Caef 3 1 58 20 FluidExp Fluid Cartridge Ref BatchCode Date Level Petit Cnt Ink Makeup Data Data Figure 4 14 Ink Smart Chip Data 28 Verify and record the make up type and expiration date Access 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Service Printer gt 01 Service Printer Log gt 01 Log Ink Data gt 01 Ink Makeup Data see Figure 4 15 on page 4 1
57. Inc 5 Replace the umbilical Defective EHT Replace the EHT power supply power supply Defective CSB Replace the CSB Charge Error Hardware A short Make sure the charge tunnel charge electrode ER Fault circuited is clean and dry charge Clear the fault and restart the inkjet If the electrode problem continues call Videojet Technologies Faults in the Inc Customer Service Department at 1 800 CSB 843 3610 United States only or contact the local Videojet Technologies Inc representative e f the problem continues replace the CSB Table 9 7 Fault Icons 9 8 Printer Status Icons Rev AA Videojet 1610 Excel Service Manual Reason Causes Action Gutter Fault Ink jet is on Nozzle is Perform a nozzle back flush x but ink clogged Restart the inkjet and make sure that the ink stream is not stream is entering the gutter L detected in the gutter for Inadequate ink Check for the presence of pump fault refer more than 5 pressure to Pump Fault on page 9 10 seconds Check the actual pressure using diagnostics Note Gutter Screens Fault is disabled Ink stream is Perform a nozzle flush while in misaligned Restart the inkjet and make sure that the ink Service stream is entering the gutter Mode Perform an ink stream alignment refer to Nozzle Adjustment on page 4 37 No vacuum Clean the printhead Perform a nozzle flush and check for flow in the return line to make sure the prope
58. Manifold 8 Make sure that all the tubes are connected to the ink core manifold see Figure 4 7 on page 4 7 Refer to Table 4 1 on page 4 7 for the colour code of the sleeves Rev AA 4 6 Commission the Printer Videojet 1610 Excel Service Manual 9 Make sure that the air vent tube is connected to the condenser assembly inside the hydraulics compartment 1 Clear Tube 5 32 inch 5 Blue Stripe Tube 1 8 inch 2 Red Stripe Tube 1 8 inch 6 Black Stripe Make up Tube 1 8 inch 3 Green Stripe Ink Tube 1 8 inch 7 Clear Tube 1 8 inch 4 Air Vent Figure 4 7 Tubes to Ink Core Manifold Tube Colour code of the Number Sleeve E e pe NM T Yellow Table 4 1 Manifold Sleeves 10 Push the ink core module into the ink compartment 11 Close the ink compartment door Inspect the Electronics System 12 Open the electronics compartment and make sure that all the electrical cables are fitted and routed correctly Rev AA Commission the Printer 4 7 Videojet 1610 Excel Service Manual 13 Make sure that the pneumatic tube that connects to positive air pump is connected correctly ae HE lasi 1 i FT pr 3 ss EFI y y D zn ETT ve La LE Lm F 1 Cables 2 Pneumatic Tube Figure 4 8 Air Pump and Dampener Inspect the Printhead 14 Remove the printhead cover see Figure 4 9 on page 4 9 and inspect for damages like Loose tubing decks screws and manifolds Damage to printhe
59. SB Measure the voltage at TP62 Measured voltage should be 3 3 VDC TP62 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 e A reading gt 3 VDC indicates that the photocell is ACTIVE HIGH A reading lt 0 5VDC indicates that the photocell is ACTIVE LOW TP106 Valve common Voltmeter Monitor during start up sequence or valve monitor test procedure to verify application of hit voltage by valve driver circuit Table 9 15 CSB Test Points Rev AA CSB Test Points 9 47 Videojet 1610 Excel Service Manual Name Test Equipment Measurement Required Velocity Oscilloscope Use the oscilloscope to measure the signal at TP69 This represents the analog signal is being detected by the second TOF sensor in the printhead A good signal will look as follows Probe 10 1 Table 9 15 CSB Test Points Continued Test Name Test Equipment Measurement Point Required 15 V 15 VDC Voltmeter Used to verify if unfiltered 15 VDC is being provided to the CSB from the Mains power supply Measure the voltage at 15 V Measured voltage should be 15 VDC 15 V 15 VDC Voltmeter Used to verify if unfiltered 15 VDC is provided to the CSB from the Mains power supply Measure the voltage at 15V Measured voltage should be 15 VDC TP104 Hit drive Voltmeter Used to verify that the valve drive circuit is being supplied w
60. Safety GUIGCIINGS arre nC ICA nn fe ed 2 5 Read the Material Safety Data Sheets 2 5 Ink ond Makeup TIU EC os nn EEN 2 5 Cleaning AOE A dq S eee eM eee 2 6 Compressed Air Safety Guidelines 2 7 UI Related Safety Guidelines 2 8 Videojet 1610 Excel Service Manual Other Important Guidelines 524 po RU ebd rh dat e bed 2 8 Chapter 3 Main Parts Printer verviey sese E kej be tee 3 1 oni T U PO 3 2 Control Panel courbe sl DS VEU VEA d dE ou 3 4 Mains Prower SWIC s sibs cede how ia er doe Ss 3 4 Electronics Compartment Door 3 4 Ink Compartment DOB is vi Se a REESE RHENUS 3 6 EJ ae ei CET 3 6 Connector Pane line S oen thn cds Pe e Pro eb vi qo bes 3 6 Punt TInssen2 CODWeClOE es Lars RA ras em oe 3 18 sI 3 19 Electronics Comparhnent aeos re rra pate 3 19 Power Suppl UN uou dee e iaa tido rad Perd 3 20 Controrsystem Board siii eges Pumpe tra 3 22 Electronics Compartment Fan 3 24 l OSIUVO AE PUM oo reato aped A box SN boe 3 24 Printer Interface Board 3 25 EHT Modil siio ber a tuor mm 3 26 ME OR Dal NEM T PTT 3 27 Ink Core Module Es det RE Ea EX eI Ire ESAE AE 3 28 amar CANNES iced eau etate ir elis si Medea Mo esq ppt 3 29 Ink Compartiment Pati ua serrana Sis chad ndr td 3 30 CRE POMPES Sao dodi Re tena ea Ua noie 3 30 Condense
61. ad elevation value to zero see Figure 4 48 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Service Printer gt 01 Service gt 02 Service gt 03 Service Ink Pressure gt 01 Pressure 3 Mitra Do Conduit Print Head 01 Lenath Elevatian Pressure lt ___ Figure 4 48 Printhead Elevation 2 Turn the knob and open the ink compartment door see Figure 4 49 Figure 4 49 Unlock Ink Compartment Door Rev AA Perform Calibration and Testing 4 41 Videojet 1610 Excel Service Manual 3 Remove the make up fluid cartridge see Figure 4 50 Make up Fluid Cartridge EN Figure 4 50 Cartridge Removal 4 Perform a Quick Start See Figure 4 51 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Service Printer gt 01 Service gt 02 Service OFF High Test Fault 02 nk Voltage Print Reset Service Figure 4 51 On Ink 5 Make sure that the jet startup is complete The jet running icon on the home screen should be solid not blinking IM 6 Make sure that the printer has reached steady state Steady state means Actual Velocity Velocity Set Point or 0 1 m s 7 Perform viscosity calibration Follow the prompts provided by the printer assuming that the ink is known perfect ink see Figure 4 52 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Service Printer gt 01 Service gt 02 Service gt 03 Service Auto Prime gt 01 Prime gt 02 Prime Note Perfect ink is the ink that is
62. ad sleeve e Scratches to printhead assembly Loose fitting of the umbilical on the back of the printhead Cracks and abrasions on the black umbilical rubber jacket 15 Check the distance between the nozzle and the charge electrode Table 4 2 Microns Charge Electrode Distance Table 4 2 Charge Electrode Distance 16 Visually check the charge electrode gap Gap 0 575 0 675 mm 17 Replace the printhead cover 4 8 Commission the Printer Rev AA Videojet 1610 Excel Service Manual 1 Umbilical 4 Printhead Cover Screw 2 Printhead Cover 5 Printhead Valve Module 3 Printhead Engine Figure 4 9 Printhead Cover Removed Log into UI 18 Connect the printer to the AC power supply and turn on the printer The 01 Edit screen appears see Figure 4 10 on page 4 9 Ink Part Ma V5nD15 D Counter OODODODODE LEVEL O Loaln Loa Clear Mini Print Di Out Message Print Message Edit Figure 4 10 lt 01 Edit gt Screen 19 Ifyou cannot see the display adjust the contrast using the contrast adjustment button dep 20 Log into the user interface UI at level C password Press the F1 key The following message appears Rev AA Commission the Printer 4 9 Videojet 1610 Excel Service Manual Enter password B lt To set Level O Press Enter without any entry Use the password generated by the DailyPassword application To obtain the password do one of the following Call Videojet Technologies Inc Customer
63. al prime 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 Note If you change the type of ink then you must change the ink core module Refer to Perform System Flush Purge and Umbilical Purge on page 4 16 for information on how to perform umbilical prime Rev AA Perform Full System Restore 5 3 User Interface Introduction Refer to Videojet 1610 Excel 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 Frames and Menu Description For more information refer to the User Interface chapter in the operator manual 01 Edit 01 Edit Menus Description LEVEL C Login Log Clear KP jE Print O1 Cut Message Print Message Edit Table 6 1 01 Edit Menu Description Rev AA Introduction 6 1 Videojet 1610 Excel Service Manual 02 Edit 02 Edit Menus Description SINGLE Char Font Char 02 Size Setup Set Up Inserts Edit Can set the character size to single or double Font Setup Can set the print matrices and font type normal narrow or custom Raster substitution ON OFF This allows the printer to select the best raster for the set print speed Select raster This allows the operator to select a specific raster for printin
64. 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 A 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 re use any ink collected in this way Dispose all waste ink in accordance with the local regulations A 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 A Warning The cleaning agent is poisonous if taken internally Do not drink Seek medical attention immediately if ingested 2 6 Fluid Safety Guidelines Rev AA Videojet 1610 Excel Service Manual A 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
65. art Ma v5015 D Counter 0000000239 Clear View Print Di Message Print Message Edit Figure 1 1 Menu Screen 1 4 Content Presentation Rev AA Videojet 1610 Excel Service Manual Keys Style Used Left arrow key Right arrow key Up arrow key Enter key F1 key F2 key F3 key F4 key F5 key E B Ctrl key Table 1 2 Content Presentation Style for Keys Rev AA Content Presentation 1 5 Videojet 1610 Excel Service Manual Ke Style Used Shift key shift ER ni PRINT key PRINT CANCEL key DELETE key Table 1 2 Content Presentation Style for Keys Abbreviations and Acronyms Abbreviation Expansion AC Alternating Current Control System Board Direct Current l Digital Multi Meter Digital Volt Meter Extra High Tension Field Programmable Gate Array n RR E CN m International Electrotechnical Commission ITI U Light Emitting Diode Liguid Crystal Display Personal Computer Printed Circuit Boara Table 1 3 Abbreviations and Acronyms 1 6 Abbreviations and Acronyms Rev AA Videojet 1610 Excel Service Manual Abbreviation Expansion LENNNL OI CI N N NN Table 1 3 Abbreviations and Acronyms Chapters in the Manual Chapter Chapter Name Description 1 Introduction Contains the information about this manual the related publications and writing styles used in this manual Safety Contains the safety and hazard information Describes the main parts o
66. as follows A 500m Sus Trig AS Probe 10 1 TP38 EHT Setpoint Voltmeter Allows 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 Table 9 16 CSB Test Points Continued Rev AA CSB Test Points 9 49 Videojet 1610 Excel Service Manual Test Equipment Required Modulation Current Voltmeter MODI Monitor TP90 Phasing Signal Oscilloscope Amplified TP91 Velocity Signal Oscilloscope Amplified Table 9 16 CSB Test Points Continued 9 50 CSB Test Points Measurement 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 4 VDC and will change as the automodulation routine is performed This test point allows the monitoring of the processed phasing signal downstream of chip U63 on the CSB Measure the signal at TP58 with an oscilloscope A good signal will look like the following figure Probe 10 1 This test point allows the monitoring of the processed velocity signal downstream of chip U63 on the CSB Measure the signal at TP59 with an oscilloscope A good signal will look like the signal shown in the following fig
67. ational If it is not operational remove and clean the valve 4 Inspect the black striped tubing and the ink receptacle septum needle for obstruction 5 Troubleshoot the venturi system use the temporary gauge manifold to check the venturi vacuum 6 Replace the ink core if required Grounding is not Check the green ground wire and lug correct under the motor cover Table 9 8 Warning Icons 9 26 Printer Status Icons Rev AA Videojet 1610 Excel Service Manual Warning Reason Causes Action Cabinet Hot The cabinet The electronics 1 Open the electronics compartment temperature compartment is 2 Inspect the electronics compartment measured by overheating components for damage or the CSB is overheating greater than 70 3 If possible operate the printer with the C 158 F electronics compartment door open and monitor the Cabinet Temperature using the Diagnostics Screen Two The ambient Move the printer to a location where the temperature is ambient temperature is lower or too high attempt to lower the temperature at the current location Monitor the Cabinet Temperature using the Diagnostics Screen Two The heat sink is Remove the insulation obstruction from insulated or the vicinity of the heat sink obstructed The mains 1 Check the voltages from the mains power supply is power supply being supplied to the defective CSB 2 Replace the mains power supply if fou
68. cal Safety Guidelines Rev AA Videojet 1610 Excel Service Manual Fuses N 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 thata user must take to prevent the hazards Read the Material Safety Data Sheets Read and understand the Material Safety Data Sheet MSDS before using any ink make up fluid or cleaning solution An MSDS exists for each type of ink make up fluid and cleaning solution For more information visit www videojet com and navigate to Documentation gt Material Safety Data Sheets Ink and Make up Fluid A 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 Rev AA Fluid Safety Guidelines 2 5 Videojet 1610 Excel Service Manual A Warning The ink and make up fluid are volatile and flammable They must be stored
69. 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 Flush supply tube red striped tube Connections Ink supply tube clear tube Ink Commissioning Tube clear tube Vent or breather tube clear tube Table 3 17 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 ink core data 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 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 Store the information about the ink levels and make up fluid Use the correct type of ink or make up fluid Rev AA Ink Compartment 3 29 Videojet 1610 Excel Service Manual Know the expiry date of the ink 1 Smart Chip PCB 2 Septum Figure 3 34 Smart Cartridges Ink
70. cs Fan Assembly Figure 10 12 Electronics Fan Assembly Positive Air Pump Assembly Figure 10 13 Positive Air Pump Assembly Rev AA Electronics Compartment 10 11 Videojet 1610 Excel Service Manual EHT Module K Figure 10 14 EHT Module Connector Panel A As WF KY MY MESSAGE MESSAGE PRINT L gt B INPUT A INPUT TRIGGER 2 OOO COMMS Na S RS 232 OUTPUT ENCODER O O Os COMMS RELAY or RS 485 SWITCHES TRIGGER 1 36 ETHERNET Figure 10 15 Connector Panel 10 12 Electronics Compartment Rev AA Videojet 1610 Excel Service Manual PCB Assemblies di CAT UONI go 9 ITT Dou 4 i 37 35 cy e c a MC zl zla O D as N Q GO malla Figure 10 16 PCB 1 2 3 and 4 Assembly PN Description SP399394E Control System Board CSB with Back Plate 0 AA AA A DK 2 A E ici E see ARA AA AAA CO NA ANN AN O E di Le ENEELEENNNNNLLLLLJJNNNMG Table 10 3 Electronics Compartment Rev AA Electronics Compartment 10 13 Videojet 1610 Excel Service Manual P N Description Qty Display Door with Keypad See Table 10 4 on page 10 15 for part 10 12 numbers of different languages 39
71. cted to the ink core Once the solvent flows through the jet the jet valve opens merging ink with the solvent The bleed valve then opens to increase the fluid flow through the nozzle removing any trapped air bubbles from the nozzle body Once the bleed valve opens the flush pump valve V7 turns off preventing further solvent from being pumped into the nozzle The flush pump returns to its priming stroke and the non return valves in the pump prevent fluid from the printhead returning to the umbilical connection Approximately ten seconds after the flush pump turns off the bleed valve closes and ink continues to flow through the jet at 4 bar Modulation is switched on and the ink pressure changes to give the correct jet velocity Heater manifold temperature is allowed to reach the correct value before enabling the phasing checks on the jet This method starts without a flushing sequence and uses the ink supply to bleed the air from the nozzle A 2 Clean Start Rev AA Clean Stop The Clean Stop sequence is as follows 1 10 11 12 Quick Stop Rev AA Videojet 1610 Excel Service Manual Deflector plate voltages are switched off before beginning this sequence The ink pressure is set to 4 bar and the modulation voltage switches off To increase the ink flow through the nozzle body the bleed valve turns on The flush pump valve turns on applying solvent pressure to the printhead Pure solvent is
72. ction No charge 1 With the ink jet running but the printer pulses not printing check for the presence of charge pulses at the charge tunnel 2 If pulses are not 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 and PHA Table 9 8 Warning Icons 9 18 Printer Status Icons Rev AA Warning Ink Viscosity Too High Reason The target pressure is greater than 0 1 bar above the temperature compensated target pressure Table 9 8 Warning Icons Rev AA Causes The ink is too thick The make up cartridge is removed or seated improperly The make up cartridge is of the wrong type The make up add line is disconnected or leaks The ink core module level is high The ink core module level is defective Videojet 1610 Excel Service Manual Action 2 The printer should add make up fluid to correct the ink viscosity Monitor the progress of make up additions using Diagnostics Screen Two 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 Install or reset the make up cartridge Make sure
73. ctor to sense the leading and trail edge of each product and adjust the width of the code for every product When the product speed is constant the printer uses internal encoding Internal Encoding Rev AA An internal clock sets the stroke rate to a constant pace Refer to Internal Encoding on page B 1 for more information on internal encoding Do the following tasks to set encoding source to internal encoder 1 Navigate to 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Print Set Up gt 01 Print gt 02 Print gt 03 Print gt 04 Print Select Encoder see Figure 4 30 on page 4 25 2 Set Select Encoder to Int 1 OFF OFF OFF Multi Reverse Invert Reverse 03 Stroke Message Message All Ch Print eS Int Select Set Lip Set Lip Set Up 04 k Encoder Auto Internal External Print BRL A Figure 4 30 Internal Shaft Encoder Set the Throw Distance 4 25 Videojet 1610 Excel Service Manual 4 26 mm 75 Auto Message Print 1 Print Height Width Delay Print TL Note 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 31 The message width is increased by approximately 3 for each increment service Message System Frint 04 Printer Exp Imp Set Up Set Lip Edit Figure 4 31 Messages Width External Encoding If the conveyor speed varies an external shaft encoder
74. d 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 Ild x RPM 12 where II 3 14 and 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 Rev AA Internal Encoding B 1 Videojet 1610 Excel Service Manual 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 described in Method 3 on page B 2 External Encoding b 2 External encoding is used when the speed of the conveyor varies A shaft encoder measures the conveyor speed and transmits the data to the printer This data enables the printer to vary the stroke rate according to the variation in the speed of the conveyor You ca
75. de Frame Service 01 gt and automatically enabled upon leaving the Service mode Nozzle Adjustment 4 37 Videojet 1610 Excel Service Manual Optimum jet position 2 to 3 times diameter of jet Deflection Plate Phase Detectors Gutter Tcro peccet qe 1777 center line First quarter of the gutter Figure 4 44 Ink Stream Alignment 4 38 Nozzle Adjustment Rev AA Videojet 1610 Excel Service Manual 5 Perform a Quick Start When the ink jet has started check that the ink jet is in the correct position in the gutter see Figure 4 44 on page 4 38 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 N Caution EQUIPMENT DAMAGE Never attempt to bend the gutter Its position is fixed 6 Adjust the ink jet position if necessary using the horizontal adjustment screws item 2 Figure 4 45 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 Sa SSP 1 Vertical Adjustment Screw 3 Horizontal Locking Screw 2 Horizontal Adjustment Screw 4 Vertical Locking Screw Figure 4 45 Printhead Adjustment Screw Location Rev AA Nozzle Adjust
76. e When ink core is empty the red LED is illuminated Note Make sure to see that the ink is being pulled from the cartridge to the gutter pump and then sent to the ink core If the ink is not flowing the system shows the cartridge empty icon even though no fluid was pulled from it 36 The Prime Core procedure stops automatically when the ink core level reaches middle level If the ink level stalls above low but below middle replace the cartridge when prompted to allow the completion of the Prime Core procedure Note The printer indicates if another cartridge is required to complete the procedure Note Monitor the Diagnostics Screen Two to track the Ink Core Level from Empty to Low to Middle Perform System Flush Purge and Umbilical Purge 37 Remove the printhead cover screw that fastens the printhead cover to the printhead chassis and remove the printhead cover see Figure 4 22 4 16 Commission the Printer Rev AA Videojet 1610 Excel Service Manual rinthead Cover Screw rinthead Valve Module 1 Umbilical 4 2 Printhead Cover 5 3 Printhead Engine Figure 4 22 Printhead Cover Removed N Caution Always wear a set of rubber gloves before disconnecting the nozzle tubing manifold This helps to prevent nozzle clogs 38 Remove the M2 x 6 socket head cap screw item 1 Figure 4 23 that attaches the front tubing manifold to the printhead valve module 39 Remove the 2 way manifold gasket item 5 40 Pu
77. e Cabinet Temperature through the Diagnostics Screen Two The heat sink is Remove the insulation obstruction from the insulated or surroundings of the heat sink obstructed The mains 1 Check the voltage levels of the mains power power supply is supply being supplied to the CSB defective 2 Replace the mains power supply The CSB is Replace the CSB defective Replace the ink core Ink System Ink core Service module is in Overdue use for more than 12000 hours for 1610 Excel Table 9 7 Fault Icons Continued Rev AA Printer Status Icons 9 11 Videojet 1610 Excel Service Manual Reason Causes Action Unable to The printer Presence of Ink Refer to Ink Core Level High on page 9 25 Control has been Core Level High Viscosity unable to warning and perform target pressure automatic has been viscosity greater than O 1 control for 60 bar above minutes or temperature more compensated target pressure for 1 hour No make up Refer to No Make up Cartridge on page 9 23 cartridge empty make up cartridge or invalid make up cartridge and target pressure has been greater than O 1 bar above temperature compensated target pressure for 1 hour Faulty make up Check valve functionality valve Printer is unable Refer to Phase Threshold Error on page 9 17 to obtain a phase profile for 60 minutes Printer is unable Refer to No Time for TOF on page 9 31 to measure velocity for 60
78. e PCB Standard Optional Print Trigger1 PCB 1 Videojet 1610 Excel p MN eI _ m m RR Status Output PCB 2 Videojet 1610 Excel 3 L A Input PCB3 Videojet 1610 Excel Ge Print Trigger 2 Videojet 1610 Excel Bi directional input Message B Input PCB 3 Videojet 1610 Excel DN Ethernet CEN Videojet 1610 Excel LEE I O 25 Way PCB 4 Videojet 1610 Excel LONE Table 3 1 Connector Panel Ports Rev AA Cabinet 3 7 Videojet 1610 Excel Service Manual D TEM E 1 Message A Input 7 VO 25 Way 2 Print Trigger 2 Reverse Print 8 USB 3 Status Output Lampstack 9 Ethernet 4 Shaft Encoder 10 COMMS RS485 5 Relay Switches 11 COMMS RS232 6 Print Trigger 1 12 Message B Input Figure 3 8 Connector Panel Note All the connectors are sealed to provide the required protection from water and dust according to the IP65 standard Status Output Connector The printer provides an output for a set of status lights through the status output connector item 3 Figure 3 8 on page 3 8 This is a 6 way DIN connector The pin allocation is shown in Table 3 2 and Figure 3 9 3 8 Cabinet Rev AA Videojet 1610 Excel Service Manual Pin Function Red lamp negative supply Amber lamp negative supply Green lamp negative supply Table 3 2 Status Output Connector Pinouts a Maximum current rating is 900 mA for pins 4 and 6 combined Shaft Encoder Connector The printer p
79. e and printer are correct Check the ink core data If necessary replace the ink core Update the ink core data 2 Check the make up and ink cartridge parameters Check the ink core parameters Use a different USB flash drive Rev AA Warning Suspected Head Heater Failure Creating Raster Catalog Bad Nozzle Please Replace Or Repair Tank Not Filling DAC Overflow DAC Comms Error Tuning Required Reason Heater set to 100 for more than one minute to achieve set temperature Software busy Raster being replaced Cannot print Nozzle taking excessive current possible short circuit Ink core module still LOW after 5 attempts to add ink to increase the level Charge DAC not operating correctly CSB hardware fault Charge DAC not operating correctly CSB hardware fault Nozzle tuning is required and the Auto Tuning function is disabled Table 9 8 Warning Icons Rev AA Videojet 1610 Excel Service Manual Causes Action Printhead valve deck problems Check whether the valve deck e IS mounted correctly loose screws Wiring problems Check the wiring between the Umbilical and PIB 1 Replace the printhead engine 2 Check the connection of the printhead engine to the copper pads below the printhead engine 3 Check the nozzle drive signal on the CSB Modulation voltage about to adjust itself outside the con
80. e model of the printer Videojet 1610 is fitted with IP65 sealing The 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 19 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 Cabinet 3 5 Videojet 1610 Excel Service Manual 1 Keypad Right 4 34 way Ribbon to CSB 2 Touch Panel Future Option 5 Keypad Left 3 Program Only Used In Production 6 Mono LCD Figure 3 7 FIB Ink Compartment Door The ink compartment door item 4 Figure 3 3 on page 3 3 is mounted on a hinge pin The door has a seal that is water resistant and prevents entry of any dust into the cabinet Note Videojet 1610 Excel is fitted with IP65 sealing Umbilical The umbilical item 6 connects the printhead to the printer cabinet It sends the control signals and ink to the printhead Connector Panel The connector panel item 7 provides inputs for several types of external devices Table 3 1 provides the connectors available for the printer 3 6 Cabinet Rev AA Videojet 1610 Excel Service Manual Connector Typ
81. e 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 2 Turn the knob and open the ink compartment door see Figure 4 2 VIDEOJET Figure 4 2 Turn the Knob 3 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 Rev AA Videojet 1610 Excel Service Manual 1 Ink Compartment Door 2 Plate Figure 4 3 Ink Compartment Door Remove and discard the foam pads see Figure 4 4 on page 4 5 Foam Pads Figure 4 4 Foam Pads Removal Remove and discard the foam pads that are attached to the CSB in the electronics compartment Commission the Printer 4 5 Videojet 1610 Excel Service Manual 6 Pull the ink core module out of the ink compartment see Figure 4 5 on page 4 6 Inspect the ink core for shipping damages such as cracks v PA DE 4 Y sx LS JA 7 N ER 4 4 Ni QT HT 1 Ink Compartment Door 2 Ink Core Module 5 Pull Ink Core Module Figure 4 7 Make sure that the ink core manifold is connected to the ink core see Figure 4 6 module correctly Figure 4 6 Ink Core
82. e ones can also be wrapped around 1111110000000111 Ink Temperature Typically 10 C 35 C subject to the environmental temperature Higher and lower temperatures may be seen when running at environmental extremes of 5 C or 45 C Electronics Temperature Typically 15 C to 50 C This is subject to the environmental temperature Makeup Vacuum Variable Subject to the amount of make up fluid available in the cartridge Heater Power Variable Relative to the environmental temperature Zero above 35 C Gutter Detect Status In Gutter When Ink Jet is running normally Ink Core Level Mid level EHT Voltage 4 KV to 8 KV Table 4 4 Typical Diagnostics Screen Values Rev AA Commission the Printer 4 23 Videojet 1610 Excel Service Manual Machine Parameter Typical Value see Note above Traffic light Green Printing no warn ings or errors Green and Yellow Printing but with errors Yellow Not printing warnings or errors present Red Failure state Table 4 4 Typical Diagnostics Screen Values Continued Set the Password Levels Consult the customer and find out which machine functions must be available for different personnel and which passwords they want to use Set the passwords for levels A and B You can also set the password levels for the menus Use the DailyPassword application for the daily level C password Notes The password levels of functions set at password Level 0 A or B can be changed
83. ectronics Compartment 3 23 Videojet 1610 Excel Service Manual Electronics Compartment Fan A cooling fan circulates the air inside the electronics compartment The top cover casting of the printer dissipates the heat Figure 3 27 Cooling Fan Positive Air Pump The positive air pump with dampener assembly provides dust free air to the printhead and thus prevents the accumulation of dust in the printhead and contamination of the ink Figure 3 28 a v Le T a S i LEE e 1 Dampener 2 Positive Air Pump Figure 3 28 Positive Air Pump 3 24 Electronics Compartment Rev AA Videojet 1610 Excel Service Manual Note When a customer orders a Videojet 1610 Excel printer with an air dryer kit the positive air pump is not fitted to the printer The air dryer supplies positive air to the printhead from an external air source Air dryers are required when the printer is operated in an environment where the humidity is more than 80 Printer Interface Board 7 1 10 way Printhead Connector 7 CSB Ribbon Cable Connectors x3 2 12 way Printhead Connector 8 USB Connector 3 EHT Cable Connector 9 PCB1 Connector 4 Positive Air Pump Connector 10 PCB 2 Connector 5 Electronics Compartment Fan Connector 11 PC
84. ed to the printhead with a printhead 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 ink feed valve solvent feed valve and the head heater Printhead Engine The printhead engine item 2 consists of the nozzle charge electrodes time of flight sensors deflection plate and gutter tube Nozzle The nozzle item 8 Figure 3 38 on page 3 35 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 Rev AA Printhead 3 33 Videojet 1610 Excel Service Manual 3 34 Printhead 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 T
85. emperature should correct Too Low more than 3 C reached itself 37 F below operational the target temperature Error duration before warning is 30 seconds temperature The ambient If print quality or performance issues are temperature is noted consider operating the printer in a too low warmer environment Defective power Check the voltages from the mains supply power supply being supplied to the CSB Replace the mains power supply Defective Inspect the electrical connections temperature between the CSB and the PIB and control circuit between the PIB and the umbilical open Remove the printhead valve module Inspect the electrical connections between the printhead valve module and the deck Reset the printhead valve module start the printer and monitor printhead temperature If problem persists measure the resistance between the copper pads on the underside of the printhead valve module and compare these values to the expected values Check the umbilical wires for continuity TOF Too Measured jet Viscosity too Check the viscosity and pressure High velocity is more low values than 10 above Pressure too Perform ink purge and reload target velocity high Restrictions in the nozzle TOF Too Low Measured jet Viscosity too Check the viscosity and the pressure velocity is more High values than 10 below Pressure too Perform backflush and reload target velocity Low
86. ency Settings Figure 4 18 Nozzle Type Access 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Service Printer gt 01 Service gt 02 Service gt 03 Service Ink Pressure gt 01 Pressure Conduit Length see Figure 4 19 on page 4 15 Make sure that the conduit length is set correctly for the current configuration see Table 4 3 Note During the installation procedure keep the printhead at the same height as the point where the umbilical is attached to the cabinet Printer Conduit Length Videojet 1610 Excel 3 m standard 6m optional Table 4 3 Conduit Length 3 Mtrs D Conduit Print Head 01 Length levation Pressure Ne RR Figure 4 19 Conduit Length Prime the Ink Core Module 33 Start Prime Core 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Service Printer gt 01 Service gt 02 Service gt 03 Service Auto Prime gt 01 Prime see Figure 4 20 and record the time to prime Cif Flush Umbilical 1 Prime Prime Figure 4 20 Prime Core 34 Make sure that the fluid flows through the black striped tube item 1 Figure 4 21 and blue striped tube item 2 Rev AA Commission the Printer 4 15 Videojet 1610 Excel Service Manual 1 Black Striped Tube 2 Blue Striped Tube Figure 4 21 Prime Core 35 Monitor the flow of fluid as itis pulled toward the ink core As the ink core reaches a low level the red LED is turned off and is replaced with a Ink Core low icon Not
87. enu Commands Function Actual Pressure Pressure measured at the pressure transducer in the Core Velocity Set Point Required drop velocity Actual Velocity Drop speed measured in the printhead Head Temperature measured by the Temperature temperature sensor in the printhead Drop Frequency Current nozzle frequency Nozzle Drive Voltage Printing Phase Current phase selected for printing Phase Threshold Threshold value required to optimize the current phase profile obtain eight 1 s and eight 0 s Phase Profile Digital representation of the results of the current phasing test Table 6 5 Diagnostics Screen One Menu and Commands Rev AA Frames and Menu Description 6 7 Videojet 1610 Excel Service Manual Diagnostics Screen Two Menu Commands Function Ink Temperature Temperature measured by the temperature sensor in the Core Ink Temp O Cabinet Ternp Cabinet Pump EPI Temperature Makeup Wacuum Heater Power Gut Detect Status 0 pH Aa pups Core Level Empty B Aalen ane Trip Heater Power Percentage of current heater power with respect to the maximum allowable Gutter Detect Current state of gutter detect otatus circuitry in the printhead and on the CSB Ink Core level Shows the current level of fluid in the ink core module High Voltage Current EHT voltage High Trip Percentage of measured EHT leakage current with respect to the maximum allowable value Diagnostics Screen Three Menu Menu Op
88. er Measure the voltage at TP105 Common The voltmeter must read approximately 4 5 VDC Table 9 10 CSB Test Points Figure 9 7 Test Point 59 60 and 61 Test Name Test Equipment Measurement Point Required TP60 Photocell one Voltmeter Used to determine the active state of photocell Block the photocell with a product and measure the voltage at TP60 reading gt 3 VDC indicates that the photocell is ACTIVE HIGH A reading lt 0 5VDC indicates that the photocell is ACTIVE LOW Table 9 11 CSB Test Points 9 40 CSB Test Points Rev AA Test Equipment Required Shaft encoder one Oscilloscope TP59 Shaft encoder two Oscilloscope Table 9 11 CSB Test Points Continued Rev AA Videojet 1610 Excel Service Manual Measurement 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 TP61 The following output is considered to be good 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 TP59 Note A signal will be present only if a quadrature two phase encoder is in use Probe 10 1 CSB Test Points 9 41 Videojet 1610 Excel Service Manual Name Test Equipment Measurement Required Pump set Voltmeter point Used to veri
89. er field Other Important Guidelines 1 DEGRADED PERFORMANCE Machine functions that only Videojet trained personnel can access are set at password level 3 MASTER password To obtain the password do one of the following Call Videojet Technologies Inc Customer Service Department at 1 800 843 3610 United States only or contact the local Videojet Technologies Inc representative Access Service tab at www videojet com 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 This makes the viscosity go out of the range 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 2 8 UI Related Safety Guidelines Rev AA Rev AA 10 11 Videojet 1610 Excel Service Manual DAMAGE TO GUTTER Never attempt to bend the gutter Its position is fixed DAMAGE TO CHARGE ELECTRODE The charge electrode is not adjustable so do not attempt any mechanical adjustments EQUIPMENT DAMAGE Adhere to prescribed circuit limitations when using any external input or output devices with the printer EQUIPMENT DAMAGE The DIN connector for the lamp stack must not have any inductive load placed on it as i
90. ered e f an oscilloscope is used the following signal indicates that the sensor is uncovered 5ms Trig AI Probe 10 1 Table 9 13 CSB Test Points Continued 9 44 CSB Test Points Rev AA Videojet 1610 Excel Service Manual Test Name Test Eguipment Measurement Point Required TP97 Gutter Voltmeter or Used to confirm the status of the gutter detect sense Oscilloscope circuit e f 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 e f an oscilloscope is used the following signal is indicates that the gutter detect chamber is empty Probe 10 1 TP101 Ink Voltmeter Used to verify the electrical output of the pressure pressure transducer that monitors the ink pump output in the core 1 bar 0 8 VDC TP103 Vacuum Voltmeter Used to verify the electrical output of the pressure VPWR transducer that monitors the vacuum in the make up addition system in the core Table 9 13 CSB Test Points Continued Test Equipment Measurement Required Charge Amplifier Oscilloscope Use the oscilloscope to measure the signal at TP51 When the ink stream is ON and the printer is not printing the following signal indicates that the charge amplifier circuit is functioning properly Table 9 14 CSB Test Points Rev AA CSB Test Points 9 45 Videojet 1610 Excel Service Manual Test Equipment Measurement Required 10 0V
91. etting is a non quad configuration the channel uses both the edges so the PPI value is 78 PPI x 2 156 Example 3 1800 PPR Encoder connected to a production line d 23 inches per revolution PPR 1800 For two edges PPR 3600 Therefore 3600 PPR 23 156 PPI Reduction Factor 156 PPI 60 2 6 As you cannot get the value 2 6 you must use either 2 or 3 If you use the value 2 then 156 PPI 2 78 PPI or 13 CPI The value reduces the line speed for all matrices proportionally To get the reduction follow the example below If you want to print using 5 x 7 matrix that has a 800 feet minute line speed at 10 CPI then Line speed feet minute 800 feet minute 10 CPI 13 CPI 615 feet minute With 2 as the reduction factor the new line speed for a 5 x 7 single line has reduced to 615 feet minute If this speed is slow for the application set the reduction factor as 3 156 PPI 3 52 PPI or 8 6 CPI Therefore B 4 External Encoding Rev AA Rev AA Videojet 1610 Excel Service Manual Line speed feet minute 800 feet minute 10 CPI 8 6 CPI 930 feet minute Example 4 Given information d 23 inches 9 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 Example 5 If the standard 1800 PPR shaft encoder is to be
92. f the printer 4 Installation Explains the installation procedures of different parts of the printer Printer Operation Contains the information on how to use the UI to setup and operate the printer m User Interface Explains how to use the Ul to create and store messages Explains how to use the Ul to create and store messages to use the Ul to create and store messages Replacement Explains the procedures to remove and replace the parts Instructions of the printer ope Provides the maintenance and cleaning procedures of the printer LAN Troubleshooting Contains diagnostic and troubleshooting procedures UC AEN LL LL Contains the illustrated parts list of orderable parts the illustrated parts list of orderable parts Appendix A Describes clean start quick start clean stop and quick stop procedures Table 1 4 List of Chapters Rev AA Chapters in the Manual 1 7 Videojet 1610 Excel Service Manual Chapter Chapter Name Description No Appendix B Contains encoder setup information Table 1 4 List of Chapters 1 8 Chapters in the Manual Rev AA 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 1610 Excel printer is to print i
93. fficients do not match ink core module coefficients External USB device drawing excessive current Table 9 8 Warning Icons 9 32 Printer Status Icons Causes The current line speed is too fast The current width setting is too low The max printed dots parameter is too high The selected font is too large Continuous Print problems Print Matrix problems Product detector problems Shaft Encoder problems Ink core not inserted or not plugged properly Distorted data is transmitted Ink Core problems Defective or improper USB flash drive Action Reduce the line speed 2 f the encoder source is Internal adjust the width to obtain the desired characters per inch Increase the width setting 2 Test the print to see if the warning condition gets cleared Edit the current message examine the max printed dots parameter Reduce the max printed dots to the minimum allowable value 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 1 Increase the continuous print delay 2 Increase the print delay 3 Check the product detector for any noise or multiple detects Make sure that the print matrix is correct Check product detector for any noise or multiple detects Correct the parameters for character pitch Insert ink core 2 Make sure that the connections between the ink cor
94. for continuity Replace if faulty PSU output not reaching the Check LEDs 2 and 4 on CSB see Figure 9 1 on page 9 3 CSB LED 2 power must be ON and LED 4 board processor must be flashing Cable between PSU and CSB is 1 Check if the cable between PSU and CSB is connected faulty or disconnected Reconnect if necessary 2 Check the cable for continuity replace if faulty PSU faulty Replace the PSU CSB failed 1 Make sure that LEDs 2 3 4 and 5 on CSB are illuminated see Figure 9 1 on page 9 3 2 Change the CSB Table 9 1 Printer Startup Problem and Remedies 9 2 Startup Problems Rev AA Videojet 1610 Excel Service Manual 54 32 1 CSB 4 SoC to FPGA LED 2 Power LED 5 Ethernet LED 3 Printhead Engine LED Figure 9 1 Status LEDS Display Faults Backlight N 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 1610 Excel Service Manual Note Some DVMs may not show the 1000 VAC correctly Use an oscilloscope fitted with a high voltage probe to measure the voltage Possible Cause Remedial Action Backlight inverter faulty Check for 24 VDC at 3 way input connector on backlight converter Pins 1 and 2 on CSB B LIGHT connector Check for 1000 VAC at output leads from backlight inverter Pins 3 and 5 If 24 VDC is present but 1000 VAC is missing replace the LC
95. fy the analog signal provided by the FPGA to the pump driver circuit to set the target pressure 1 bar 0 28 VDC 5 V o VDC Voltmeter Used to verify if the filtered 5 VDC level on the TP78 CSB Measure the voltage at TP23 Measured voltage should be 5 VDC VCORE FPGA core Voltmeter Used to verify the FPGA core voltage on the TP80 voltage CSB Measure the voltage at TP25 Measured voltage should be 1 5 VDC 12 VDC Voltmeter Used to verify the regulated 12 VDC produced on the CSB Measure the voltage at TP26 Measured voltage should be 12 VDC 12 V 12 VDC Voltmeter Used to verify regulated 12 VDC produced on TP75 the CSB Measure the voltage at TP27 Measured voltage should be 12 VDC 24 V 24 VDC Voltmeter Used to verify unfiltered 24 VDC provided to TP77 the CSB from the mains power supply Measure the voltage at TP28 Measured voltage should be 24VDC TP46 Modulation Oscilloscope Used to verify output modulation signal supplied by the CSB to the nozzle With inkjet running measure the signal at TP38 The following picture shows a good signal Er o Probe 10 1 MOD Table 9 12 CSB Test Points 9 42 CSB Test Points Rev AA Videojet 1610 Excel Service Manual Test Equipment Measurement Required Level probe Voltmeter or Used to verify the common electrical drive signal in common Oscilloscope the CORE mixer tank level detection circuit e f a voltmeter is used the voltage should read 1
96. g The selected raster does not change if the printer speed changes Char Set Up Can create characters that are reversed inverted make the character bolder within a message and character spacing of an individual charac ter within a message Contains variable information that can be placed into a message Serializer Clock Date Timer Insert English Remote Bar Insert Insert IZ Data Cade Numbers Graphic Insert Serializer It is an alphanumeric value which is set in a message and the printer automatically starts from this value and repeats from the set count value Clock Can insert the clock information like the hour Minute HR WK and WK YR and alpha hour Can insert date information like the current dates and the expiry dates Timer Can insert and set the timer type format in which it must appear update interval Remote Data It is used to download fixed or variable information from a host per sonal computer PC into the message Inserts bar code into a message Insert Numbers Can change numeral inserts from English to Arabic numbers Table 6 2 02 Edit Menu Description 6 2 Frames and Menu Description Rev AA Videojet 1610 Excel Service Manual 02 Edit Menus Description Insert Graphic Inserts graphic which is stored in the system Table 6 2 02 Edit Menu Description 03 Edit 03 Edit Menus Description Store Recall View Print 03 Message Message Store Message Edit Table 6 3 03 Edit Menu Descripti
97. g pressure You can perform the Clean Start procedure for three times If the ink jet remains misaligned perform system flush purge refer to Perform System Flush Purge with Nozzle Attached on page 9 53 Perform System Flush Purge with Nozzle Attached Do the following tasks to perform a system flush purge with the nozzle attached 1 Start Flush Prime 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Service Printer gt 01 Service gt 02 Service gt 03 Service Auto Prime gt 01 Prime OB Frime Empty Flush Umbilical 11 Core Core Prime Prime Figure 9 9 System Flush Purge 2 Allow the system flush purge to run completely Do not stop the purge prematurely 3 After system flush purge is completed perform a clean start refer to Clean Stop and Clean Start the Printer on page 4 21 Rev AA How to Clear a Clogged Nozzle 9 53 Videojet 1610 Excel Service Manual 4 Ifthe ink stream is still misaligned clean the nozzle with a syringe and cleaning liquid refer to the next procedure Clean the Nozzle with a Syringe and Cleaning Liquid Do the following tasks to clean the nozzle with a syringe and cleaning liquid 1 Turn off the mains power switch of the printer Turn off the AC power supply to the printer 2 3 Disconnect the mains power cord from the electrical outlet 4 Remove the printhead cover screw that fastens the printhead cover to the printhead chassis and remove the printhead cover see Figure 4 2
98. haft encoder A A 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 1800 PPR Encoder connected to production line d 10 inches of product travel for one revolution If you want to print using 5x7 SL matrix and the required print pitch is 10 Characters Per Inch CPI then 1800 PPR 10 180 PPI as the printer can see both edges of incoming channel then 180 x 2 360 PPI If both A and B channel are in use then multiply the PPI value that you get by 2 for the second channel 360 x 2 lt 720 Note If you use both channels A and B from the encoder use the following calculation Encoder PPR Inches travelled for one revolution x 4 The printer PPI is 720 with a print pitch requirement of 10 CPI The number of strokes required for a 5x7 SL matrix at 10 CPI is 60 External Encoding B 3 Videojet 1610 Excel Service Manual Therefore 720 PPI 60 strokes 12 12 is the printer reduction factor or width divider setting This gives you a print output of 10 CPI of 5x7 SL matrix As the 5x7 SL matrix is based on 10 CPI you can get the top line speed on printer speed chart Example 2 1800 PPR Encoder connected to a production line d 23 inches per revolution PPI 1800 23 78 PPI But as the s
99. he following The fault and status icons displayed on the display refer to Printer Status Icons on page 9 7 e 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 When you need to replace a part for example CSB LCD and so on refer to the related replacement instructions For more information on how to obtain the related instructions refer to Chapter 7 Replacement Instructions Rev AA Read the Operator Manual 9 1 Videojet 1610 Excel Service Manual Startup Problems Printer Fails to Start Possible Cause Remedial Action Printer does not start Check the power cord and plug for damage No mains power supply Make sure that the mains power supply is turned on To turn on the printer press the green push button Mains power supply input cable 1 Make sure that the mains power supply cable is connected disconnected or defective 2 Check the continuity of the cable If the cable is defective repair or replace the cable Printer mains power circuit Reset the circuit breaker Turn off and turn on the circuit breaker has tripped breaker Mains switch is faulty Check mains switch Replace the switch if faulty Cable between mains switch and 1 Check the cable connections Reconnect if necessary PSU is disconnected or faulty 2 Check the cable
100. he 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 Rev AA y D Do Solvent Flush Line Bleed Gutter Line Bleed Gutter Valve Ink Solvent Feed Valve Front Manifold Ink Pipe Ground Nozzle 0 JO O1 o NN Videojet 1610 Excel Service Manual 9 Charge Electrode 10 Deflection Plate 11 Gutter Tube 12 Phase Detectors electrodes 13 Nozzle Cradle 14 Nozzle Holder 15 Bleed Pipe 16 Ink Feed Line Figure 3 38 Printhead Components Rev AA Printhead 3 35 Videojet 1610 Excel Service Manual Printhead 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 Modulation Control TOF Measurement Pump Speed Control Target Pressure Control e Phasing Modulation control e TOF measurement Pump speed control Target pressure
101. he maximum input signal is 60 mA and 24VDC 2 CN 1L a Figure 3 20 Print Trigger 2 Connector Function Pin DIN Pin 1 15V DC DIN Pin 2 Sensor Output Table 3 12 Print Trigger 2 Connector Pinouts 3 18 Cabinet Rev AA Videojet 1610 Excel Service Manual 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 21 The IP65 back filter is standard for Videojet 1610 Excel Figure 3 21 Back Filter Electronics Compartment Note When a customer orders a Videojet 1610 Excel printer with an air dryer kit the positive air pump is not fitted to the printer The air dryer supplies positive air to the printhead from an external air source Air dryers are required when the printer is operated in an environment where the humidity is more than 6076 Rev AA Electronics Compartment 3 19 Videojet 1610 Excel Service Manual diu AR gt ii ia UE D DA SA Ze D Y inns a Res kli dini m k 1 Electronics Compartment Fan 5 Printer Interface Board PIB 2 Power Supply Unit PSU 6
102. ics compartment and the ink compartment doors are closed and locked N Caution Do not perform Step 64 until the system is ready for production as it affects the viscosity adjustments of the printer 63 Backup printer settings using a USB flash drive Select 05 Service System Backup 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Service Printer gt 01 Service gt 02 Service gt 03 Service gt 04 Service gt 05 Service Sequence HV Phase Fault 04 Control dlust Select Reset Service Figure 4 27 System Backup 64 If the production printing is necessary 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 3 Mrs Conduit Print Head 01 Length Elevation Pressure Figure 4 28 Printhead Elevation 65 Press the Enter key to backup the settings 66 Validate machine parameters refer to Table 4 4 4 22 Commission the Printer Rev AA Videojet 1610 Excel Service Manual Machine Parameter Typical Value see Note above Phasing Threshold 200 auto controls after setup 170 250 nominally Phase Profile Variable combinations of 1 and 0 For every 16 digits there should always be between 7 and 9 consecutive ones The rest of the digits should be zeros For example e 1111111110000000 e 0001111111000000 e 0000011111111100 Note Th
103. igit language code at the end of the part number For example the part number of the Spanish version of the Operator Manual is 462133 04 Use the list of language codes shown in Table 1 1 on page 1 4 to identify the translated versions of the manual Note Availability of the Operator Manual is indicated by an asterisk 7 Availability of the Service Manual is indicated by a plus sign Availability of the Illustrated Parts List is indicated by the number sign 1t Contact the Videojet distributor or subsidiary for more information Rev AA Videojet 1610 Excel Printer 1 1 Videojet 1610 Excel Service Manual Code Language Availability see note 01 English US 2 fren s femm O swn Porus fie ou EL NN RN 15 Norwegian i A CNE Po w NR w fom e fee ENCRES mme 7 owe 70 m eem Po m pem NR m names o a mew Table 1 1 List of Language Codes 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 1 2 Content Presentation Rev AA Rev AA Videojet 1610 Excel Service Manual The Word Printer The word printer indicates the Videojet 1610 Excel printer from this point onwards in this manual Positional References Unless
104. information 55 Insert a fresh make up fluid cartridge again Clean Stop and Clean Start the Printer 56 Puta piece of paper under the printhead to capture splatter and press the HEAD key to do a clean stop Note Exit the service mode with the ink and high voltage on then use the HEAD key to stop the jet During shutdown if ink splatters inside the printhead check the ink stream alignment again and make sure that the flush pump is fully primed Note The flush pump is a controlled diaphragm inside the ink core module 57 Put another piece of paper under the printhead and press the HEAD key to do a clean start During startup perform clean start if the ink splatters inside the printhead check the ink stream alignment again and make sure that the flush pump is fully primed Perform Final Checks 58 Make sure that auto modulation is enabled 04 Edit System Set up gt 03 System Status Screens gt 03 Screen Enables Screen 59 Install the printhead cover and verify that the amber light is turned off Rev AA Commission the Printer 4 21 Videojet 1610 Excel Service Manual If the amber light is turned on when with the printhead cover fitted check the Current Warnings screen and perform the required troubleshooting Access 04 Edit Service Printer gt 01 Service Diagnostic Screens gt 02 Diagnostic Warnings Screen 60 Take a sample print 61 Close the ink compartment door 62 Make sure that the electron
105. int trigger 1 connector item 6 is a 3 way DIN connector The pin functions are shown in Table 3 5 Note For 24 VDC the maximum current is 60 mA Rev AA Cabinet 3 11 Videojet 1610 Excel Service Manual 3 12 Cabinet Figure 3 12 Print Trigger 1 Connector Pin Diagram Function Pin DIN Pin 1 15 VDC supply to sensor DIN Pin 2 Sensor output DIN Pin 3 0 VDC common Table 3 5 Print Trigger 1 Connector Pinouts Rev AA Videojet 1610 Excel Service Manual I O 25 Way Connector The I O 25 way connector Bulgin Connector is available for Videojet 1610 Excel printer item 7 See Figure 3 13 Figure 3 13 I O 25 Way Pin Function ECN EEN re Semeur oo Table 3 6 I O 25 Way Pinouts Rev AA Cabinet 3 13 Videojet 1610 Excel Service Manual Pin Function E Warnings Open Collector Faults Open Collector Table 3 6 I O 25 Way Pinouts Continued Beacon Indicator Pins Pin Function LA Print Ready Output Warning Output Fault Output USB Connector The USB Connector item 8 allows for data to be transferred to and from a connected USB flash drive apap 0000 Figure 3 14 USB Connector Ethernet Connector The ethernet connector item 9 is used to connect the printer to a remote computer or network to import data or control the printer remotely 3 14 Cabinet Rev AA Rev AA Videojet 1610 Excel Service Manual e d Figure 3 15 Ethernet Connector RS 48
106. irements 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 EC Low Voltage Directive 2006 95 EEC Essential health and safety reguirements relating to electrical eguipment designed for use within certain voltage limits IEC 60950 1 2001 Safety reguirements for information technology eguipment including electrical business eguipment EN 60529 1992 Degrees of protection provided by enclosures IP code 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 Rev AA 1 Videojet 1610 Excel Service Manual A 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 frequency energy and if not installed and used in accordance with the instruction ma
107. ith Canadian regulations regarding safety and electrical emissions by Electromagnetic Testing Services Limited Pratts Fields Lubberhedges Lane Stebbing Dunmow Essex CM6 3BT England UK This equipment has been investigated by Underwriters Laboratories Incorporated in accordance with the standard for safety CAN CSA C22 2 No 60950 1 03 Safety of information technology equipment Subject 2178 marking and coding equipment electronics Report reference E252185 Pour la client le 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 quipement est certifi CSA This equipment has been investigated by Underwriters Laboratories Incorporated in accordance with the standard for safety CAN CSA C22 2 No 60950 1 03 Safety of information technology equipment Subject 2178 marking and coding equipment electronics Report reference E252185 Rev AA 111 Support and Training Rev AA Contact Information If you have any questions or need assistance please contact at 1 800 843 3610 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
108. ith the correct electronic signal to enable the application of hit voltage when solenoid valves are actuated Measure the voltage at TP2 e f the measured voltage is 3 3 VDC the hit circuit is turned off this is the steady state condition e f measured voltage is O VDC the hit circuit is turned on indicating that valves are being opened Table 9 16 CSB Test Points 9 48 CSB Test Points Rev AA Videojet 1610 Excel Service Manual Test Test Equipment Measurement Voltage Reference Positive Point Required Used to measure the positive reference voltage provided to the DAC on the CSB Measure the voltage at TP76 Measured TP36 Voltmeter VREFP voltage should be 4 08 VDC VREFNT Voltage reference Voltmeter Used to measure the negative reference P57 negative voltage provided to the DAC on the CSB Measure the voltage at VREFN Measured voltage should be 4 08 VDC MODVT Modulation voltage Voltmeter The modulation voltage monitor is an output P44 monitor of the modulation circuit used by the CSB to track modulation voltage Measure the voltage at MODV Measured voltage should be less than 4 VDC and should change as the automodulation routine is performed TP45 Modulation Power Oscilloscope TP45 allows the measuring of the Amplifier modulation sine wave and is located on the Transformer opposite side of the transformer Measure Primary the signal at TP45 with an oscilloscope A good signal will look
109. itted 60 hours remaining on the ink core smart chip 240 hours remaining on the ink core smart chip 600 hours remaining on the ink core smart chip 1200 hours remaining on the ink core smart chip Not enough time to build a message Not enough time to build a message Videojet 1610 Excel Service Manual Action 1 Insert ink core 2 Make sure that the connections between the ink core and the printer are correct 3 Check the ink core data If necessary replace the ink core Make preparations to replace the ink core module Make preparations to replace the ink core module Make preparations to replace the ink core module Make preparations to replace the ink core module Enable the double buffering option Increase the print delay Check the product detector for double triggering problems Enable the double buffering option Increase the print delay Check the product detector for double triggering problems If continuos print is active increase the distance between the prints Make sure the message does not have leading or trailing spaces Printer Status Icons 9 29 Videojet 1610 Excel Service Manual Warning Reason Causes Action Print Queue Too many Continuous Print Increase the distance between repeat Too Deep products delay set prints between PEC incorrectly and printhead Check Product Check the setup and sensing of the
110. k Core Pump Assembly Ink Compartment 10 20 Videojet 1610 Excel Service Manual Figure 10 24 Ink Core Module Without Pump Gutter Pump Assembly 20 21 DYI 22 Gutter Pump Assembly Figure 10 25 10 21 Ink Compartment Rev AA Videojet 1610 Excel Service Manual Ink System Fan Figure 10 26 Ink System Fan Assembly Condenser Assembly Figure 10 27 Condenser Assembly 10 22 Ink Compartment Rev AA Videojet 1610 Excel Service Manual Ink System Filter Assembly K Y AW NN AN W o Figure 10 28 Ink System Filter Assembly IP65 Rev AA Ink Compartment 10 23 Videojet 1610 Excel Service Manual Floor Filter Figure 10 29 Floor Filter IP65 up Cartridge K30 x 12 Pan head Torx Screw Ink Cartridge Ink Door Assembly Septum Assembly M3
111. l in the core 2 Let the printer idle to burn off excess make up fluid Replace make up cartridge Note Repeated insertions can lead to a viscosity too high condition as excessive punctures reduce the seal on the cartridge Rev AA Videojet 1610 Excel Service Manual Warning Reason Causes Action Ink Core The high level Excessive clean Use Quick Start and Quick Stop options Level High sensor in the ink start and stops until ink core module level is restored core module is Keep jet running to use excess make covered up If printer operation is impaired by high ink core module level presence of Unable to Control Viscosity warning raise the ink stream above the catcher to restore the ink core module level to normal Excessive Use Quick Start and Quick Stop options nozzle until ink core module level is restored backflushing Keep jet running to use excess make up If printer operation is impaired by high ink core module level presence of Unable to Control Viscosity warning raise the ink stream above the catcher to restore the ink core module level to normal Improper Use Quick Start and Quick Stop options printhead until ink core module level is restored cleaning Keep the jet running to use excess make up If printer operation is impaired by high ink core module level presence of Unable to Control Viscosity warning raise the ink stream above the catcher to restore the ink core m
112. ll the Stack light Rev AA Videojet 1610 Excel Service Manual Nozzle Adjustment Rev AA Two adjustments are required nozzle vertical adjustment and nozzle horizontal adjustment Note Make sure that the adjustments are not at either end of the adjustment ranges If adjustments are at either end of the ranges there can be a partial clog in the nozzle even though the ink stream is not severely misaligned to remove the blockage in the nozzle refer to How to Clear a Clogged Nozzle on page 9 52 A Warning The ink and make up fluid are irritating to the eyes and respiratory system Remember the following guidelines 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 Do the following tasks to align the ink stream 1 Loosen the printhead screw and remove the cover from the printhead 2 Secure the printhead vertically in a suitable stand with the nozzle pointing downwards see Figure 4 44 on page 4 38 3 Puta suitable container beneath the printhead to collect the ink 4 The Gutter Fault Shutdown is automatically disabled upon entering the Service mo
113. lti 1 0 Connector Information Fault output on PCB 4 Multi I O connector is ON Pin 19 Amber Jet on off e Warning present Print not enabled Relay 2 is set Multi 1 0 Connector Information Warning output on PCB 4 Multi I O connector is ON Pin 18 Green Print enabled No warnings Relay 1 is set Multi 1 0 Connector Information Print Ready output on PCB 4 Multi I O connector is ON Pin 17 Green and Print enabled Amber e Warning present Relay 1 and 2 is set Multi I O Connector Information e Warning output on PCB 4 Multi I O connector is ON Pin 18 e Print Ready output on PCB 4 Multi I O connector is ON Pin 17 Table 9 5 Alarm Light Conditions Rev AA Beacon Indication 9 5 Videojet 1610 Excel Service Manual Beacon Color Description and Multi I O Information Red and Amber e Alarm present e Warning present Jet off Relay 2 is set Multi I O Connector Information e Warning output on PCB 4 Multi I O connector is ON Pin 18 Fault output on PCB 4 Multi I O connector is ON Pin 19 No Lights Jet on or off No alarms No warnings Print disabled All relays are off Table 9 5 Alarm Light Conditions 9 6 Beacon Indication Rev AA Videojet 1610 Excel Service Manual Printer Status Icons The printer status icons are divided into three groups The indicator icons These icons show the status of the ink jet The fault icons These icons indicate a fault condition During a fault conditi
114. ly clogged orifice can cause bad drop formation that causes bad modulation a Perform a Nozzle Flush on page 9 52 b Perform a Clean Start on page 9 53 Use a magnifying loupe to inspect the ink stream for drop formation You must perform this task to make sure that the nozzle creates the droplets If the ink stream remains solid check the modulation wire small black wire on the printhead engine module to make sure that it is not damaged and is correctly connected If you see a broken modulation wire contact Videojet Technologies Inc to change the printhead engine module If the modulation wire is not broken use an oscilloscope to measure the MOD test point on the CSB to make sure that the on board power supplies the modulation voltage Another possible cause of a loss of modulation is a bad connection under the printhead engine module itself a Turn off the printer b Remove the printhead engine module and test for continuity between the CSB and the printhead circuit c If the continuity is good install again the printhead engine module d Restart the printer How to Correct Loss of Modulation 9 55 Illustrated Parts List 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
115. m E DION ES ICI A NN CN 8 L NNNM pome emm IC CE NUN CI A O D LC a m a CA EEN qe EE A MARNE NI A IR IM AAA A A A A UA ZN NA ON NON O A 1 O PE OR MA AAA AAA MO E e DOV AA A TU PU lt A MM DI Ni A A A EN EMEN M LLLI eM Table 10 8 Accessories 10 42 Optional Accessories Rev AA Videojet 1610 Excel Service Manual eme m oe C2 Lm ee 0 0m CO ORNK NI NIN sot obl LL NNNM Ooa RN LL O OO s p CI ORNK JAM Leone OC 1 1 CIM 00m Lee NIKI s mona IA O A i EE pe eme 0 NE JA NI NIKIH A NIKI ee ES pap eoe aes a E s meme a Oo JE RN NICI ar rare ENNNLONNL s 08 CS po akal MUN rience tte Table 10 8 Accessories Continued Rev AA Optional Accessories 10 43 Videojet 1610 Excel Service Manual CE E mier Z gt A SSA eo D jo og IZ 8 DL ee iT L9 D wei S O Re 1 pwee PRET LI 9 mes SC a a de aa ANN NEM CE pe pau 1 2 GE W 8 ee PO o JB a mni Ses t OO ra EE E HA A A reco 1 137885 A 1800 PPR kit encoder 25ft 1800 PPR kit encoder 25ft cable 40331750 2500 PPR kit SE mounting bracket wheel s 378821 3600 PPR kit 3600 PPR kit encoder 25ft cable 25ft cable 80200266 5000 PPR kit O EO oo mounting bracket wheel Table 10 8 Accessories Continued 10 44 Optional Accessories Rev AA Videojet 1610 Excel Service Manual Weser
116. ment 4 39 Videojet 1610 Excel Service Manual Perform Calibration and Testing The system calibration and test procedures must be performed when printhead engine module EHT supply CSB or umbilical is changed Calibrate EHT Do the following tasks to calibrate the EHT Note Please make sure printhead is clean and dry 1 Access Calibrate HV 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Service Printer gt 01 Service gt 02 Service gt 03 Service Auto Prime gt 01 Prime gt 02 Prime Nozzle Calibrate Update e Flush Vv iscacit Core HV A Figure 4 46 02 Prime 2 Press the F4 key to select Calibrate HV 3 Calibration sweep occurs Refer to Figure 4 47 Calibration Sweep Nozzle Calibrate Update Calibrate O2 Flush Viscocitv Core Hr Prime Figure 4 47 Calibration Sweep 4 40 Perform Calibration and Testing Rev AA Videojet 1610 Excel Service Manual Calibrate Viscosity Do the following tasks to perform viscosity calibration Note Perform this procedure every time the following are replaced e nk core module Printhead engine e CSB Note Perform the viscosity calibration if the viscosity is correct The viscosity is correct if target pressure and the temperature compensated target pressure were equal before the components were replaced 1 Keep the printhead at the same height as the umbilical during installation this height is later adjusted when moved to the production line Set the printhe
117. minutes Mod Driver Mod Mod amplifier 1 Check the fan at the top of the electronics Chip Over amplifier temperature is compartment Temperature hardware more than the 2 Make sure the heat sink does not have any has specified limit debris shutdown Table 9 7 Fault Icons Continued 9 12 Printer Status Icons Rev AA Rasters Memory Overflow Detected Valve Error Contact the Service Department d Bad Phasing Modulation Readback Failed Reason Causes Not enough memory to store all requested raster tables Hardware Faulty power error in valve supply or control hit hold system board drive circuit Unable to Loose obtain phase Connection data during startup Hardware CSB Failure error ADC not working or readback invalid Table 9 7 Fault Icons Continued Rev AA Videojet 1610 Excel Service Manual Action Remove the rasters that are not used Follow the procedure to delete rasters Contact the Videojet Technologies Inc Customer Service Department at 1 800 843 3610 United States only or contact the local Videojet Technologies Inc representative Check for any loose connections between the cabinet and printhead Replace CSB Printer Status Icons 9 13 Videojet 1610 Excel Service Manual Warning Icons Warning Printhead Temperature Too High Incorrect Raster or Raster Family Name Reason The printhead temperature is 3 C 37 4 F more than the
118. must be fitted in order to maintain constant message width If the product moves the encoder turns and if the product stops the encoder stops refer to External Encoding on page B 2 for more information Note Make sure that the movement of the product is directly related to the movement of the conveyor Do the following tasks to install an external shaft encoder 1 2 Install the Encoder Turn off the printer Connect the shaft encoder cable to the shaft encoder connector See the following pictures for connections e Figure 4 32 on page 4 27 shows the shaft encoder connector on the connector panel Figure 4 33 on page 4 27 describes the shaft encoder connector socket pin layout Note You can configure the printer to accept a two phased encoder input quadrature 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 Rev AA Videojet 1610 Excel Service Manual Ed ED EY CO PAIN FR Shi Encoder Connector E VI Y NW Y S IL be Figure 4 32 Connector Panel 2 LE S 3 1 TA pu 1 Pin 1 lt 15VDC Supply 2 Pin 2 Signal A Input 3 Pin 3 Signal B Input 4 Pin 4 OV Common Figure 4 33 Encoder Socket Pin Layout 3 Two LEDs on the boards show the operating status of the shaft encoder input
119. n use the following types of shaft encoding methods e A direct shaft encoder maintains a 1 1 ratio between the encoder pulses and print strokes Non quad Uses both the channels from encoder A and B The leading and trailing edges of the channels give four times the number of pulses delivered from the encoder For example if PPI from the encoder is 180 the pulses from the two edges x 2 of the channels A and B are 360 PPI each which totals to 720 PPI If the required strokes per inch is 60 the reduction factor or width is 720 60 12 Backlash protection printing If the product is placed on a line that can move or settle for example conveyor belt and it stops backlash protection makes sure that the printer prints on that product one time only In this feature either A leads B or B leads A This provides the printer with backlash protection The printer counts the number of encoder counter strokes as it prints If the line stops and moves backwards the printer will not restart printing until the counter stroke number has returned to the last known good position This feature makes sure that the printer prints one time in the standard External Encoding Rev AA Rev AA Videojet 1610 Excel Service Manual direction of line travel and not in the reverse direction of line travel The maximum stroke count is 64K A divided down shaft encoder is used when the conveyor speed requires fewer pulses than the actual output of the s
120. nd faulty The CSB is Replace the CSB defective Electronics Make sure the fan operates properly compartment fan is defective Filters are Make sure the filters are not clogged or defective dirty Replace the filters if required Ink Core The ink core Insertions module has Exceeded been disconnected reconnected more than 10 times Table 9 8 Warning Icons Rev AA Printer Status Icons 9 27 Videojet 1610 Excel Service Manual Warning Reason Causes Pump RPM The pump Ink too thin Near Max speed is greater than 98 of the maximum value Erroneous velocity indication Defective pump Ink Core Ink core module Motor grounding Empty low probe is uncovered tank close to Ri empty or empty The pump Refer to Pump speed is greater RPM Near Max than 98 of the maximum value Table 9 8 Warning Icons 9 28 Printer Status Icons Action Check the Diagnostics Screen One 2 Compare the Target Pressure with the temperature compensated target pressure If the Target Pressure is significantly less than 1 bar than the temperature compensated target pressure the ink is too thin Recover the viscosity by allowing the jet to run continuously or by flushing and priming the system Inspect the ink compartment electronics compartment and umbilical for leaks Repair if possible While monitoring the pump speed rpm from diagnostic screen 2 tip ink core back
121. new ink cartridge into the proper cartridge holder after ink cartridge becomes empty 1 Check if the current cartridge has fluid and is locked into position 2 Replace the empty cartridge with a new ink cartridge Replace ink Cartridge Rev AA Warning No Make up Cartridge Wrong Make up Cartridge Reason No make up fluid available for addition to the ink core module The cartridge inserted into the make up cartridge holder contains the wrong make up type Table 9 8 Warning Icons Rev AA Causes Make up cartridge is not present The make up cartridge is empty The printer is unable to read the make up cartridge smart Chip cartridge containing the wrong make up type has been inserted into the printer An ink cartridge was accidentally inserted into the make up cartridge holder The smart chip on the make up cartridge is programmed incorrectly or does not match the label Videojet 1610 Excel Service Manual Action Insert a make up cartridge into the proper cartridge holder Remove the empty cartridge and insert a new make up cartridge Ensure that the make up cartridge is seated correctly in its receptacle Remove the make up cartridge Make sure that the smart chip is present and is clean If another make up cartridge is available insert it into the printer and see if the printer can read its smart chip Check that the smart chip reader in
122. nformation 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 Toavoid 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 1610 Excel Service Manual Electrical Safety Guidelines This section explains the safety guidelines related to electrical power supply and electrical cables Electrical Power Supply A 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
123. ng manual irrigation backflushing Ink Supply lt Make up Supply Under Vacuum V1 V2 O 0 0 0 e 0 5 T 3 A E 4 sy 1 Gutter Tube 4 Nozzle 2 High Voltage EHT Plate 5 Heater 3 Charge Electrode Figure 3 39 Printhead Operation Printhead 3 37 Videojet 1610 Excel Service Manual 3 38 Printhead The flow of ink is as follows 1 10 The ink and solvent mixture flows through the feed line item 16 Figure 3 38 on page 3 35 into the printhead The ink enters the feed valve item 4 The valves open or close as per the print requirements Note The bleed valve opens and closes as needed during flushing the nozzle and supplying ink to the nozzle The ink flows into the nozzle To adjust the nozzle refer to Nozzle Adjustment on page 4 37 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 The ink drops enter the charge electrode item 9 where they are charged at different voltage levels based on the character to be generated The charged ink drops then pass through the EHT High Voltage Field item 2 Figure 3 39 and over the phase detectors The High Voltage EHT plate deflects the charged d
124. nician only Remove the printhead cover Figure 7 1 on page 7 3 Locate the printhead screw into the printhead Figure 7 2 and make sure that the screw is in contact with the earth wire in the umbilical Printhead Screw Figure 7 2 Printhead Screw Follow Step 2 to Step 5 under Printhead Bonding during Printing on page 7 2 Perform the required maintenance operation Refer to the Chapter 8 Maintenance for more information on maintenance procedures Remove the printhead screw Refit the printhead cover The printhead bonding instructions is complete 7 4 Bonding during Servicing Rev AA Maintenance The preventative maintenance schedules mentioned in this chapter must be carried out by a trained and authorized personnel 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 Frequency Replace the Core Module 12000 hours for 1610 Excel Replace the Ink pump 24000 hours Replace the Fan Filter 2 000 hours Replace the Floor Filter Must be replaced with the ink core module Replace the Air Dryer Filter if 2 000 hours fitted Table 8 1 Preventative Maintenance Schedule A 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 Replacemen
125. nter Status Icons 9 21 Videojet 1610 Excel Service Manual Warning Wrong Ink Cartridge Ink Cartridge Expired Ink Cartridge Low Ink Cartridge Empty Ink Insertions Exceeded Reason Ink type in cartridge incompatible with ink core module fluid reference and fluid type must match ink core module Ink past expiry date Less than 596 of the required ink remains in the ink cartridge Ink cartridge smart chip data shows 0 This ink cartridge is inserted more than 10 times Table 9 8 Warning Icons 9 22 Printer Status Icons Causes cartridge containing the wrong ink type has been inserted into the printer A make up cartridge has been accidentally inserted into the ink cartridge holder The smart chip on the ink cartridge is programmed incorrectly or does not match the label Ink used for printing Action Remove the ink cartridge 2 Check the label on the ink cartridge to confirm the ink type Insert a cartridge of the correct ink type into the printer Remove the cartridge 2 Check the label on the cartridge to confirm fluid type Insert a cartridge of the correct ink type into the printer Remove the cartridge 2 Check the label on the cartridge to confirm fluid type Insert a cartridge of the correct ink type into the printer Check the label on cartridge for expiration date Replace the old cartridge with new ink cartridge Insert a
126. nter the value 720 for the PPI option 12 Go to Message gt Message Parameters gt Width Divider Enter the value of 12 for the divider This divides the 720 PPI 12 60 This is the print pitch value the printer uses for printing Auto Encoding When auto encoding is selected the signal from the product detector is used to determine the product speed and code the product at a set stroke rate For more information refer to Auto Encoding on page B 6 and the Operator Manual Do the following tasks to set encoding source to internal encoder 4 28 Install the Encoder Rev AA Videojet 1610 Excel Service Manual 13 Navigate to 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Print Set Up gt 01 Print gt 02 Print gt 03 Print gt 04 Print Select Encoder see Figure 4 30 on page 4 25 Set Select Encoder to Int Rev AA Install the Encoder 4 29 Videojet 1610 Excel Service Manual Set the Speed compensation Speed compensation enables the printer to print a message in the same position on a product as the product speed changes This feature can be useful if the conveyor speed is very high and the product is relatively small The printer computes a variable stroke delay for each product As the product speed is reduced the variable stroke delay increases The correct print distance must be entered The nominal value is 11 mm and the range is 5 mm to 15 mm Note When speed compensation is ON the print delay i
127. nual 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 00 00345 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 UK This equipment has been investigated by Underwriters Laboratories Inc in accordance with the standard for safety UL 60950 1 Safety of information technology equipment first edition Subject 2178 marking and coding equipment electronics Report reference E252185 Rev AA Videojet 1610 Excel Service Manual For Customers in Canada This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications This equipment has been tested and certified for compliance w
128. odule level to normal Make sure the ink core is seated on a level surface in the cabinet Check for flow in the black or green striped tubing ink and make up add line If flow is present continuously disconnect the line and check for presence of vacuum Replace the ink core module if required Grounding is not Check the green ground wire and lug correct under the motor cover Table 9 8 Warning Icons Rev AA Printer Status Icons 9 25 Videojet 1610 Excel Service Manual Warning Reason Causes Action Ink Core The middle level Ink usage during The printer should add ink to restore ink Level Low sensor in the ink printing core module level to middle However if core module is the printer is attempting to add ink but the uncovered level is not restored perform the following ELT 1 Confirm that the printer is attempting to add ink by monitoring the ink add valve on the Valves Screen The screen should indicate that the valve is opening If the printer is not attempting to add ink check if a valid cartridge of the correct ink type is inserted into the ink cartridge receptacle If the printer is attempting to add ink but the level is not restoring troubleshoot the ink addition system as follows 1 Make sure the ink cartridge is not empty 2 Make sure the ink core is seated on a level surface in the cabinet 3 Stop the jet and perform a valve test Make sure that the ink add valve is oper
129. on 04 Edit 04 Edit Menus Description Service Message System Frint 04 Printer Exp Imp Set Up Set lip Edlit Service Printer Provides information on the status of the printer and enables the service technician to perform maintenance and troubleshooting operations Message Exp Imp Enables the transfer of message files to and from the USB Stick System Set Up Enables the service technician to set up time variables create graphics display language and so on Print Set Up Enables the service technician to set the printing parameters like mes sage height width type of encoding throw distance and so on Table 6 4 04 Edit Menu Description Rev AA Frames and Menu Description 6 3 Videojet 1610 Excel Service Manual 04 Edit Menus Description Service Printer Diagnostic X Printer Test Fault 1 Screens Lod Print Reset Service GIN OFF High Test Fault Oz Ink Voltage Print Reset Service Auto Ink Nozzle Fault 03 Prime Pressure lt Setting Reset Service Sequence HV Phase Fault 04 Control dlust Select Reset Service System System System System 5 Backup Restore Clone Upgrade Service fo ARDWAR USB Data Gutter Act Debug IG TEST Logging Fume Sed Logging Service Line Valve O Polarity Test Service Access the various diagnostic screens Provides ink data core data and run time data Prints a test message Resets a fault message Enables Quick start and quick stop High Voltage Can turn off or on the high vol
130. on the printer stops printing The warning icons These icons indicate a warning condition The printer continues to print until the warning condition becomes a fault condition Indicator Icons Description Jet Running The ink jet is running and the machine is ready to print When the machine starts this icon flashes Jet Stopped Indicates that the ink jet has stopped When the machine stops this icon flashes Table 9 6 Indicator Icons Rev AA Printer Status Icons 9 7 Videojet 1610 Excel Service Manual Fault Icons Fault Reason Causes Action EHT Trip Excessive The printhead is 1 Clean and dry the printhead currentin the dirty or wet 2 Restart the inkjet monitor for ink buildup on EHT circuit the printhead during the printing operations as measured if possible by the CSB The EHT circuit Stop the ink jet is not calibrated Calibrate EHT refer to Calibrate EHT on page 4 40 Restart the inkjet and monitor the system performance Short in Stop the inkjet and turn off the printer umbilical or EHT Unplug the EHT wire from the EHT power resistor supply Measure the resistance between the EHT wire and the EHT plate 44 mega ohms Note Not all meters can measure high resistance use parallel resistor to calculate resistance If open or short circuit exists remove the printhead engine and inspect the EHT resistor If you need any support please contact Videojet Technologies
131. ons are affected by thin ink flush the system Perform 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 flow into the service tray until the viscosity is restored the printer will add fresh ink to compensate for system losses Pressure too The actual Printer transient Printer will correct itself High pressure is more than 0 2 bar Erroneous 1 Inspect electrical connections between dr above the target pressure the ink core module and the PIB and pressure indication between the PIB and the CSB 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 refer to CSB Test Points on page 9 40 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 Warning Reason Pressure Too The actual Low pressure is gt 0 2 bar below the ln target pressure No Ink No ink available Cartridge for addition to the ink core x module Table 9 8 Warning Icons Rev AA Causes Leak in the ink compartment electronics compartment or umbilical Erroneous pressure indication Defective pump Action Printer transient Printer will correct itself 1 2 3 No ink cartridge In
132. ower Connectors Note Allow 5 tolerance on all voltages except 24V which is allowed at 10 tolerance The power connector must be connected to the CSB to carry out this check PIN 8 No connect Table 9 9 CSB Power Connector Voltage Check Rev AA Voltage Checks 9 35 Videojet 1610 Excel Service Manual Jet Start and Stop Diagnostics Use the following flow charts to diagnose problems that occur because of dirty inkjet starts and stops Quick Start Diagnostics Start Visually inspect nozzle alignment Carry out a quick start A Refit print engine and backflush before starting jet A Does the jet kick when the ink valve is opened Quick start good Is the break up of the jet symmetrical Is the break up of the jet symmetrical now Remove the nozzle and clean in an ultrasonic bath No Backflush the nozzle to remove debris Yes p Is the pump achieving the correct pressure Reset the pressure zero offset Clean out any restrictions in the print head and cabinet Figure 9 3 Quick Start Diagnostics Flowchart 9 36 Jet Start and Stop Diagnostics Rev AA Videojet 1610 Excel Service Manual Clean Start Diagnostics Start Ensure that the printer has been shut down with a clean stop Place a clean piece of paper
133. product detector The length of the detect area the amount which the detector senses This value must be entered into the printer The distance between the printhead and the product detector must be set such that both the leading and trailing edges of the product are sensed by the product detector before the printer starts printing the message Rev AA Rev AA Videojet 1610 Excel Service Manual Nod Product Motion A Product Detect Jumper Set for Negative Edge Trigger Product e No Product BEEN Unm Pulse Width Product Speed Detector Signal Figure B 4 Auto Encoding Example Given information Detect area 5 inches 127 mm Pulse width of this product 0 1 seconds Then Product speed 5 inches 0 1 second 50 inches per second 127 0 mm 0 1 s 1270 0 mm s 50 inches per second x 60 seconds per minute 12 inches per foot 250 FPM 1270 mm s x 60 s minute 1000 mm m 76 2 MPM Auto Encoding B 7
134. pulled directly from an ink cartridge known to be within a specific viscosity range LN LR Update Calibrate 02 Flush Viscocit Core Hv Prime p Figure 4 52 Viscosity Calibration 8 Putthe make up cartridge into make up cartridge slot 4 42 Perform Calibration and Testing Rev AA Videojet 1610 Excel Service Manual 9 Enter the correct printhead elevation in the UI Refer to Figure 4 48 on page 4 41 10 Putthe printhead into the printhead bracket on the conveyor Rev AA Perform Calibration and Testing 4 43 Printer Operation Introduction This chapter describes the procedures you can perform at level C For information on other tasks refer to the Operator Manual Reset Run Hours If the Service icon appears the time until the next service is due must be entered to remove it Navigate to Frame 01 Run Time 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Service Printer gt 01 Service Printer Log 01 Log Run Times 01 Run Time Rev AA Introduction 5 1 Videojet 1610 Excel Service Manual Service Message System Print 04 Printer Exp Imp Set Up Set Lip Edit Y Diagnostic Printer Test Fault 1 Screens LOG Print Reset Service O Run Ink Core System 01 Times Data Data Count Log lt 1 65512 0 40 Drop Time Machine Di Counter Ink On Run Time Run Time Figure 5 1 Data Logging Menu Perform System Backup Do the following tasks to perform a complete backup of all programmable printe
135. r operation of the vacuum system Remove the printhead engine and inspect the length of tubing between the gutter and the printhead valve module for clogs Loosen and clean valve V2 VP and VG The gutter Remove the printhead engine and inspect sense chamber the gutter sense chamber is defective Check CSB test point 45 for the gutter sense signal Check umbilical wires related to the gutter sense signal 4 Replace the umbilical if required Ink Core The low level New installation Perform Fill Ink Core procedure to maintain Empty sensor in the correct level in ink core module ink core module is not Ink Core Level 1 Make sure the ink core is seated on a level has occurred 2 Make sure the ink core and make up cartridge are installed 3 Check the ink core life For more information refer to Ink Core Level Low on page 9 26 and the printer is unable to add ink Grounding is not Check the green ground wire and lug under the correct motor cover Table 9 7 Fault Icons Continued Rev AA Printer Status Icons 9 9 Videojet 1610 Excel Service Manual Fault Reason Causes Presence of leaks in the ink compartment electronics compartment or umbilical Pump Fault The pump speed is greater than 98 of the maximum value and the actual pressure is greater than 0 2 bar below the target pressure Erroneous pressure indication Defective pump Ink
136. r Assembly ia 2i acie either dede ds 3 32 PRES EE ns ated dau ptit Nor bends uie le drej diee in etta 3 32 Pinhead COVGE os os sceau NE MER pdt 3 33 Printhead Valve Module si zau vani en stas tiepida PEORES 3 33 Printhead BO lii sese vous poc AE E dns USA eme 3 33 Printhead PUNCHONSes eg ani te EE d oni p ER 3 36 Pruithe ad Opera HON oe di d e PA Ned tian eee eden pu 3 37 Umm IE O O ea tu 3 41 Thelbydraule SYSTEME ia Ta 3 41 Chapter 4 Installation HA OO HOD ni od a O 4 1 To0ls ond ou ppHes aa sie robe rd dart eee bbb dobri 4 2 Typical Productor LINE s eue quema pra een 4 2 Unpack and Inspect the Printer 4 4 Commission The rier sues bes ox mas ata iia vere he 4 4 Inspeetdne Ink SYSTEM cis obi Ey AE eb des etu dc a 4 4 2 Rev AA Videojet 1610 Excel Service Manual Inspect the Electronics SySle liia iu vous ui dete esi ttc ed 4 7 Inspect the Printheads re sms ger be ae ws ee donc 4 8 LOS DIO O esent 20a fo dedos deb st ehe Dep Ga ebrio ETAPI ENEM 4 9 Install Ink and Make up Cartridges 4 10 Confreur the Printer cds a neo E nC Ed ea M Sd 4 14 Prime the Ink Core Module kada i e bod eet 4 15 Perform System Flush Purge and Umbilical Purge 4 16 Perform Ink Stream Alignment and Viscosity Calibration 4 20 Clean Stop and Clean Start the Printer 4 2 Pertorm Final C NECKS vos box e sale EU ed aba K CE 4 21 pet the Password Levels ets zr
137. r files including job and printer configuration information 1 Press the HEAD key to stop the ink jet 2 Insert a USB flash drive into the external USB port of the printer 3 Select System Backup at 05 Service 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Service Printer gt 01 Service gt 02 Service gt 03 Service gt 04 Service gt 05 Service FF RD System System System 05 Backup Restore Clone Uparade Service AQ gf Figure 5 2 System Backup 4 Follow the printer prompts and complete the backup 5 2 Perform System Backup Rev AA Videojet 1610 Excel Service Manual Perform Full System Restore Do the following tasks to recover previously backed up information from the USB flash drive 1 Press the HEAD key to stop the ink jet 2 Insert a USB flash drive into the external USB port of the printer 3 Select System Restore at 05 Service 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Service Printer gt 01 Service gt 02 Service gt 03 Service gt 04 Service gt 05 Service The Overwrite all option appears AOON System System System System 5 Backup Restore Clone lIparade Service O Figure 5 3 System Restore 4 Press Y Figure 5 4 and system restore is completed Overwrite all Y ye5 Make Sure USE stick is in the slot Completed Printer restart i nin the slot Please power cycle the printer Figure 5 4 System Message Perform Umbilical Prime You should perform umbilic
138. rops of ink at various angles depending on the charge placed on the drop at the moment of breakoff An electrically conductive ink is supplied under pressure by the ink core to the nozzle assembly item 6 Figure 3 40 through the ink feed pipe item 1 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 60 microns Rev AA Videojet 1610 Excel Service Manual DO ZE A gt sa gt Sy e ud v 1 Ink Feed Pipe 4 Crystal Transducer 2 Damping Mass 5 Nozzle Jet Orifice 3 Crystal Transducer 6 Nozzle Assembly Figure 3 40 Ink Jet Formation Droplet Charging 11 The charge electrode item 2 in Figure 3 41 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 no
139. rovides a nominal 15 VDC 100 mA 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 3 Note For 24 VDC the maximum current is 60 mA Rev AA Cabinet 3 9 Videojet 1610 Excel Service Manual if I z orn Lay Figure 3 10 Shaft Encoder Connector Pin Diagram Function Pin DIN Pin 1 15 VDC supply to shaft encoder DIN Pin 2 Shaft encoder input A DIN Pin 3 Shaft encoder input B 0 VDC common Table 3 3 Shaft Encoder Connector Pinouts Note The shaft encoder output must be of the PUSH PULL type Relay Switches The relay switches 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 Maximum Contact Loading 1A 30 VDC 0 3 A 2125 VAC 3 10 Cabinet Rev AA Videojet 1610 Excel Service Manual Figure 3 11 Relay Switches Connector Pin Diagram Function Pin Table 3 4 Relay Switches Connector Pinouts Print Trigger 1 Connector The printer provides a 15 VDC 100mA output for use by a photoelectric cell PEC inductive proximity detector or micro switch The pr
140. s Use the LEDs to confirm that a shaft encoder is connected correctly 4 Set the shaft encoder source to External Navigate to 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Print Set Up gt 01 Print gt 02 Print gt 03 Print gt 04 Print Select Encoder Rev AA Install the Encoder 4 27 Videojet 1610 Excel Service Manual Reduced Select Set Lip Set Lip Set Lip 04 Encoder Auto Internal External Print Figure 4 34 Select Encoder 5 Make sure to set the physical parameters for external encoder 6 Make sure the encoder movement is in direct relation to the movement of the product being printed on 7 Calculate the distance in inches mm the product moves per revolution of the shaft of the encoder 8 Divide the PPR of the encoder by the calculated distance inches For example 1800 PPR 12 inches calculated distance 180 pulses per inch PPI 9 Since the printer is setup in the non quad encoder mode the printer uses both edges of the A and B channels to calculate the PPI Therefore as per the example PPI of channel A and B 180 x 4 720 PPI 10 To determine the correct width factor divide the PPI value by 60 This give you the width factor to divide the incoming pulses For example 720 PPI 60 12 11 Set the correct width setting Navigate to Print gt Line Configuration gt Message Configuration Press the right cursor key to change setting to Divider Strokes Scroll down to Encoder Resolution and e
141. s increased by 60 strokes approximately one inch or 25 4 mm Therefore one inch must be subtracted from the existing delay in order for the printed code to remain in the same position on the product Turn on Speed Comp based on the method of encoding for example see Figure 4 35 Access 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Print Set Up gt 01 Print gt 02 Print gt 03 Print gt 04 Print Set Up External gt 01 Ext E FF Mon auacdr S40 E Speed Encoder Encoder Reduction Di Comp Setup Resolution Factor Ext E Figure 4 35 Speed Compensation Setting Example Enter the throw distance access 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Print Set Up gt 01 Print gt 02 Print gt 03 Print gt 04 Print gt 05 Print gt 06 Print Throw Distance 1 ON OFF Throw Reverse Sx SL Special 06 Distance Barcode Tower Print Mode Print Figure 4 36 Throw Distance Install the Product Detector Figure 4 1 on page 4 3 shows a photocell item 4 connected through a cable item 5 to print trigger 1 connector on the connector panel 4 80 Set the Speed compensation Rev AA Videojet 1610 Excel Service Manual 1 15 VDC Supply to Sensor 2 Sensor Output 3 0 VDC Common Figure 4 37 Print Trigger 1 Connector Pin Diagram Note Print Trigger 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 Print Trigger
142. sert an ink cartridge into the proper is present cartridge holder Videojet 1610 Excel Service Manual Inspect the ink compartment electronics compartment and umbilical for leaks Repair if possible Inspect the electrical connections between the ink core module and the PIB and between the PIB and the CSB Check and compare the voltage readings at the test points related to pump and pressure TP20 TP21 TP22 and TP47 refer to CSB Test Points on page 9 40 Also remove the top cover of the ink core module and measure the voltage between points Press and Press Inspect electrical connections between the ink core module and the PIB and between the PIB and the CSB Open the pump compartment and inspect the pump Replace the pump The ink cartridge Remove the empty cartridge and insert a is empty new ink cartridge The printer is unable to read the ink cartridge smart chip 1 Make sure that the ink cartridge is installed correctly and locked into the holder Remove the ink cartridge Check if the smart chip is present and is clean If another ink cartridge is available insert it into the printer and see if the printer can read its smart chip Check if the smart chip reader inside the receptacle is positioned correctly and is clean Check the electrical connections between the smart chip reader and the PIB board and between the PIB board and the CSB Pri
143. side the receptacle is positioned correctly and is clean Check the electrical connections between the smart chip reader and the PIB and between the PIB and the CSB Remove the make up cartridge Check the label on the make up cartridge to confirm the make up type Insert a cartridge of the correct make up type into the printer Remove the cartridge Check the label on the cartridge to confirm fluid type Insert a cartridge of the correct make up type into the printer Remove the make up cartridge Check the label on the make up cartridge to confirm the make up type Insert a cartridge of the correct make up type into the printer Printer Status Icons 9 23 Videojet 1610 Excel Service Manual Warning Makeup Cartridge Low Clean Start Stop Inhibited Makeup Insertions Exceeded Reason Less than 5 of the make up in the make up cartridge remains Viscosity is too low so clean start stop inhibited to prevent solvent addition This make up cartridge is inserted more than 10 times Table 9 8 Warning Icons 9 24 Printer Status Icons Causes Make up used during jet on operations Action Make preparations to insert a fresh make up cartridge into the proper cartridge holder Replace the cartridge following Make up Out indication 1 Start printer with the quick start procedure and allow the printer to print at a high duty cycle to lower the fluid leve
144. 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 N Warning A high AC voltage is present at the inverter and backlight Extreme caution is reguired when diagnosing failure in these areas Electrical Cables A Warning Use only the mains power cable supplied with the printer The end of this cable must have an approved three pole mains 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 2 2 Electrical Safety Guidelines Rev AA Rev AA Videojet 1610 Excel Service Manual A Warning Grounding 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 N Warning The printer must be connected only to an AC power supply that has a protective ground conductor and must be according to IEC reguirements or applicable local regulations N 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 follo
145. t may cause damage to the PCB EQUIPMENT DAMAGE Do not fit or remove any connector on the printer when the power is on otherwise the printer may get damaged 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 HEATER In a fault condition heater can reach 70 C Do not touch the plate on which the heater is mounted The failure to follow this warning can cause personal injury Other Important Guidelines 2 9 Main Parts Printer Overview 1 Electronics Compartment Door 5 Connector Panel 2 Ink Compartment 6 Electronics Compartment 3 Printhead 7 Mains Power Switch 4 Umbilical 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 1610 Excel Service Manual Figure 3 2 shows the schematic diagram of Videojet 1610 Excel printer as 64 way em He ey tou li LT J L Figure 3 2 System Overview Cabinet The cabinet of Videojet 1610 Excel printer is made of stainless steel The cabinet includes the following parts Control panel Electronics compartment door Mains 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
146. t 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 1 Rev AA Replacement of Ink System Fan Filter for IP65 8 1 Videojet 1610 Excel Service Manual 2 Remove the fan filter element item 1 from the fan filter cover 1 Fan Filter Element 2 Fan Filter Cover Figure 8 1 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 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 16 cap head screws item 1 Figure 8 2 on page 8 3 and remove the screws 2 Detach the ink core support channel item 2 3 Remove the filter element item 3 from the drip tray item 4 8 2 Replacement of Floor Filter for IP65 Rev AA Videojet 1610 Excel Service Manual 3 Filter Element 4 Drip Tray 1 M4 x 16 Cap head Screw x4 2 Ink Core Support IP
147. tage option Enables to prime the core empty core flush prime and umbilical prime Nozzle Setting Provides the nozzle setting data like nozzle type fluid type frequency divider and drop frequency Table 6 4 04 Edit Menu Description 6 4 Frames and Menu Description Rev AA Videojet 1610 Excel Service Manual 04 Edit Menus Description Sequence Control Enables to set run and edit sequence of operation for valve test nozzle flush and so on HV Adjust Enables to adjust the high voltage value Phase Select Enables to set the manual phase enable or disable phase test and phase charge voltage oystem Backup Saves the parameters set during the calibration process to the system memory overwriting any previously saved parameters oystem Restore Reads the previously saved parameters and settings are from memory undoing any recent changes oystem Clone Makes a copy of the entire system onto the USB stick oystem Upgrade Updates the software with the latest additions System Set Up 12 37 03 12 08 OO 11 Set Set Set Set 11 Time Date HE ANE WEAR System Serial Remate Network Build Oz Comm Protocols Settings Graphic System 00 00 Shift Set Daylight Status Set Lip DavRal Settings Screens Locale Password Display System 04 Setup Set up Language Info System Serial Comm Sets up the RS 232 and RS 485 baud rates that are configured for the required baud rate Table 6 4 04 Edit Menu Description Rev AA Frames and Menu
148. that the No Make up icon disappears Install a cartridge of the correct make up type Make sure that the Wrong Make up icon disappears Open the ink compartment door and gently pull the ink core module out Locate the green striped tube behind the ink core module Make sure that the quick disconnect in this line is secure and that the line is not leaking Confirm the condition by checking icons on display screen To clear the condition perform 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 flow into the service tray until the ink core module level is restored to normal Replace the ink core module Printer Status Icons 9 19 Videojet 1610 Excel Service Manual Warning Reason Causes Action Ink Viscosity The target The ink is too 1 Allow the inkjet to run so that the Too low pressure is thin excess make up fluid evaporates The lesser than 0 1 following actions will help to recover the bar below the viscosity temperature Avoid nozzle backflushing and improper compensated printhead cleaning with the vacuum target pressure applied Use the Quick Start and Quick Stop options whenever possible e Run Gutter Pump at maximum speed Check for flow in the green striped tube to make sure that make up is not being unnecessarily added 2 If printer operati
149. 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 1610 Excel Service Manual Assembly Table 10 1 Symbols Representation Assemblies p 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 Rev AA Videojet 1610 Excel 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 pogod JV AN AA E 1 E F G EF G 1 2 3 s ord EL 2 M x O Figure 10 1 Graphical Representation of the Different
150. tion Function InkSvstem Life 65512 Software Build 7556M Firmware Version 755 255 25 Gutter Pump Yes MakeupExp Date 21 10 2008 Inkbot Refit 255 Makeupbot Refit 25 Chrg Table Version Ink dd Pulses E Table 6 6 Diagnostics Screen Three Menu and Commands 6 8 Frames and Menu Description Rev AA Replacement Instructions When you order a spare part kit the replacement instructions of the respective spare part are provided along with the kit For more information contact Videojet Technologies Inc Refer to Chapter Support and Training for the contact information The replacement instructions are available for the parts included in the following table Spare Part Control System Board Power Supply Unit Liquid Crystal Display LCD or the Front Panel Interface Board FIB Keyboard Electronics Compartment Door Ink Core Module Ink Pump Printhead Engine Assembly Printhead Valve Module Assembly Umbilical Assembly Printer Interface Board PIB Electronics Compartment Fan oeptum Assembly Gutter Pump Power Switch Ethernet Connector Positive Air Kit Ink Door Assembly Ink System Fan Table 7 1 Available Instructions Rev AA 7 1 Videojet 1610 Excel Service Manual Spare Part EHT Module USB Connector Plug and Power Cable CSB Lithium Battery PCB 1 2 and 3 Pressure Vacuum Test Tool Printhead Bonding Encoder and Adaptor Cable Print Ready and Warning Output Cable Table
151. tomers mthe USS Discs srt part ooa d ce Doe a Dent ate ene ee en 1 FOr Customer CORO v oves SA OH SRE bin sida i Pour la clientele du Canada di lex eet XE D 111 Support and Training Contaci UOMA radiata UE da ui oaa iv A Oaertn Ob oderunt ne ed esc tds iv CUS POME KO NO RES Red A A atari MEM de V Chapter 1 Introduction Chapter 2 Safety Videojet 1610 Excel Printer suisse dile dee diet ro ens 1 1 ode ihe MANUAL zou darin teda o ERREUR Sato ved 1 1 Related PubliedtiODS us oa idus debba d dvds dr dara 1 1 Lanenase Coda b deii bau ED editor 1 1 Content PRESENT HON s cuo sida ee P e PE ae 1 2 he Word PANIER ve PU PIN Up tette 1 3 Positional RelerenceS a ses ox oa A stas MEUM ES 1 3 UnitsotVvleasutemefit sx oni Edo lastra UE e 1 3 Satety Mor maloe oe pU drsi Nera dob adi pts 1 3 Additional Notes SRE ei qiti E a dala fa sab pod 1 4 User Interface Terminology 1 4 INS O E ASE A O DE O A VE eye 1 5 Abbreviations and Acronyms 1 6 Chapters im th Manual nei ES eure ee a bete 1 7 ir OdUEHON xa xau a a i pedes MD een di as Ado 2 1 General Safety Guidelines 2 1 Electrical Safety Guidelines 2 2 Electrical Power Supply 22 ricas rro tas 2 2 Electrical Cables t54 cde os ded S a ated adhd ata yes RO Se 2 2 CHOU NCO DNE 2 3 DONGINE e vor usos teh NDS MM nu e be tU ed ped 2 4 PUSCS oli E EDS is ds 2 5 Elia
152. trol range 0 200 VAC Enable Auto tuning Printer Status Icons 9 33 Videojet 1610 Excel Service Manual Warning Reason Causes Action TOF Warning The Actual Erroneous TOF Clean and dry the printhead Velocity measurement deviates from l the Velocity Set Nozzle partially Perform a nozzle backflush Point by 1 obstructed Improper See actions above for The printer is modulation unable to set the modulation setting automatically on page 9 31 Pump or See causes and actions described in pressure Pressure Too Low on page 9 21 problem Service Due Printer requires The life of ink Replace the ink core module servicing core module is d over Valve error 1 Run a Valve Test and a Hardware Self Test to determine which valve is defective If a valve or valves is not functioning check electrical connections Attempt to clear any clogged valves 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 and TP68 refer to CSB Test Points on page 9 40 Table 9 8 Warning Icons Disable this warning if not required under System Set Up menu 9 34 Printer Status Icons Rev AA Videojet 1610 Excel Service Manual Voltage Checks 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 P
153. tthe 2 way manifold gasket provided in the bypass kit on the ports of the printhead valve module 41 Fitthe nozzle bypass manifold that has the loop of tube part Number 399247 to the printhead valve module using the M2 x 6 socket head screw Rev AA Commission the Printer 4 17 Videojet 1610 Excel Service Manual C e i AH e WZ 4 1 M2 x 6 Socket head Screw 4 Quick Disconnect 2 Nozzle Bypass Manifold 5 2 Way Manifold Gasket 3 Tubing Figure 4 23 Bypass Manifold 42 Open the quick disconnect item 4 in the middle of the loop and direct the supply side into a receptacle 43 Start Flush Prime 01 Edit gt 02 Edit gt 03 Edit gt 04 Edit Service Printer gt 01 Service gt 02 Service gt 03 Service Auto Prime gt 01 Prime Prime Empty Umbilical 01 Prime Figure 4 24 System Flush Purge 44 Observe if the fluid flows through the flush supply line red stripe and flows out of the loop in the end Make sure that the fluid that is ejected is clear make up not ink Note Allow the system flush procedure to stop automatically after completion The procedure takes 15 minutes 45 Connect the quick disconnect in the middle of the loop connector and perform umbilical prime This procedure will not finish automatically 4 18 Commission the Printer Rev AA Videojet 1610 Excel Service Manual so turn off the mains power switch to stop the umbilical prime process after a few seconds ON Prime
154. ty N 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 consult your Videojet 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 N Warning Rev AA The printer must be connected to an AC power supply which has a protective ground conductor in accordance with IEC reguirements or applicable local regulations Any interruption of the protective ground conductor or disconnection to the protective ground terminal may render the apparatus dangerous Introduction 4 1 Videojet 1610 Excel Service Manual A 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 The failure to follow this warning can cause death or personal injury Tools and Supplies Tools Refer to the service tool kit listed in Tools Kit on page 10 48 for information on tools and supplies required to install the printer Supplies
155. under the printhead Carry out a Clean start A From sheet 2 Is the Was initial jet the printer Carry out a make up colored shut down with a clean stop clean stop Clean the make up Replace the PH valve in the PH valve module Change the nozzle gt Is the 1 initial solvent NX eec tI E Is air visible in the Is the break up jet seta ou i flushing circuit symmetrical Back flush the nozzle gutter p Go to sheet 2 System flush prime Refer to Sheet 1 Rev AA Jet Start and Stop Diagnostics 9 37 Videojet 1610 Excel Service Manual Start from sheet 1 Does the ink remain in the gutter Is the breakup Yes symmetrical Change the during the transition 5 from ink to SAL Ename solvent no No Is Break up Yes Yes Back flush the nozzle Symmetrical Go to sheet 1 v RN th Work through quick a SENE start flow chart gutter Is the Can all the mark on the Move the jet position line modes be dem Change the paper within the further back into the printed over the entire zimi zm acceptance gutter criteria EHT range Clean start OK Sheet 2 Figure 9 4
156. ure Probe 10 1 Rev AA Videojet 1610 Excel Service Manual Test Equipment Measurement Required TP95 Oscilloscope This test point allows the monitoring of the trigger signal supplied by chip U61 to the FPGA Measure the signal at TP60 with an oscilloscope A good signal will look like the following figure ig Probe 10 1 TP96 Phasing trigger B Oscilloscope This test point allows the monitoring of the trigger signal supplied by chip U61 to the FPGA Measure the signal at TP96 with an oscilloscope A good signal looks like the following figure Phasing trigger A Probe 10 1 TP53 HV Charge Supply Voltmeter Used to verify the positive output voltage Positive supplied by the charge amplifier supply to the charge amplifier Measure the voltage at TP50 Measured voltage should be 300 VDC TP37 Power Supply for Voltmeter 28VDC EHT Driver Table 9 16 CSB Test Points Continued Rev AA CSB Test Points 9 51 Videojet 1610 Excel Service Manual Test Name Test Equipment Measurement Point Required TP32 3 3V to LCD Voltmeter Used to verify the voltage supplied to the LCD Measured voltage should be 3 3VDC TP33 VEE 28V to LCD Voltmeter Used to verify the voltage supplied to the LCD Measured voltage should be 28VDC Table 9 17 CPU Test Points How to Clear a Clogged Nozzle To clear the blockage in the nozzle you require to do the procedures described in this section A blockage in the nozzle
157. 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 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 1 Pulley b 2 Pulley a Figure B 3 External Shaft Encoder With Pulley External Encoding B 5 Videojet 1610 Excel Service Manual 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 Auto Encoding B 6 Auto Encoding Auto encoding is used when the product speed and the conveyor speed are different product slippage or when the product is allowed to fall through guides from one level to another When auto encoding is selected the signal from the product detector is used to determine the product speed and code the product at a set stroke rate The requirements for auto encoding are the following A
158. ve 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 Rev AA Umbilical Videojet 1610 Excel Service Manual 2 1 Deflected Droplet Path 4 Droplet Path to Gutter 2 Substrate 5 Phase Detectors Electrodes 3 Gutter The part is not shown in the figure Figure 3 42 Droplet Deflection The umbilical has the electrical wiring and ink system tubing from the printer to the printhead The Hydraulic System Rev AA This section describes the combined operation of the ink system printhead and umbilical to print on a substrate The Figure 3 43 on page 3 42 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 Umbilical 3 41 Videojet 1610 Excel Service Manual Gutter pump e Condenser Nozzle Flush Pump Printhead VJ VI VM Condensor Mixer Tank Ink Make up Figure 3 43 Hydraulic System Components 3 42 The Hydraulic System Rev AA Installation Introduction This chapter describes the procedures to install Videojet 1610 Excel printer N 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 warran
159. w this warning can cause an electrical shock N Warning Always ground conductive eguipment 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 N Warning A resistance reading from the grounded service tray to the eguipment chassis or mounting bracket should be 0 to less than1 ohm A resistance check should be made using a safe and reliable ohmmeter and should be done on a freguent basis Electrical Safety Guidelines 2 3 Videojet 1610 Excel Service Manual A Warning To ensure safe grounding the resistance between the mains lead earth wire and the test points must be less than 12 N Warning The PCBs contain static sensitive devices A suitably grounded antistatic wrist strap must be worn when working on or handling PCBs Bonding N Warning Always prevent static discharge from occurring Use proper Grounding and Bonding methods Only use Videojet approved metallic service trays and ground cables N Warning Always bond conductive eguipment together with approved cables to maintain them at the same potential and minimize static discharge For example printhead to metal service tray N Caution Always empty the service trays freguently Some inks and cleaning solutions are flammable Make sure that the waste fluids are disposed according to HAZMAT 2 4 Electri
160. wards If the speed decreases there is a damaged filter in the core Replace the core Clean the printhead 2 Check the Diagnostics Screen One Compare the Actual Velocity with the Velocity Set Point Replace the printhead engine Inspect electrical connections between the ink core module and the PIB and between the PIB and the CSB Open the pump cover and inspect the pump Replace the pump Check ink core connections 2 Check the replenishment cartridges ink add circuit and valves Check Grounding Check ink cartridge data expiration date type and so on Check make up cartridge data Check if printer must draw any vacuum Replace the ink core Refer to Pump RPM Near Max Rev AA Warning No Ink Core Ink Core Service Soon 0 5 Left Ink Core Service Soon 2 Left Ink Core Service Soon 5 Left Ink Core Service Soon 10 Left Product Delay Too Reason No data from ink core smart chip ink core not plugged in Ink core module is very near the end of service life Ink core module nearing the end of service life Ink core module nearing the end of service life Ink core module nearing the end of service life Compile time greater than product delay Insufficient time to compile between prints Table 9 8 Warning Icons Rev AA Causes Ink core not inserted or not plugged properly Distorted data is transm
161. y by allowing the jet to run continuously or by draining and re priming the system Rev AA Videojet 1610 Excel Service Manual Reason Causes Action Erroneous velocity indication Clean the printhead Check the Diagnostics Screen One 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 TP87 TP90 TP91 TP95 and TP96 refer to CSB Test Points on page 9 40 N gt Cabinet Too The cabinet Hot temperature measured by the CSB is above 80 C 178 F The electronics Open the electronics compartment compartment is Inspect the electronics compartment overheated components for any damage or overheating If possible operate the printer with the electronics compartment door open and monitor the Cabinet Temperature through the Diagnostics Screen Two Make sure that the fan inside the electronics compartment is working Check the filters at the bottom and behind the cabinet Make sure that they are not clogged else replace the filters The ambient Move the printer to a location where the temperature is ambient temperature is lower or attempt to too high lower the temperature at the current location Monitor th
162. zzle assembly item 1 and the charge electrode is 2 mm 1 Nozzle Assembly 2 Charge Electrode Figure 3 41 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 Rev AA Printhead 3 39 Videojet 1610 Excel Service Manual 3 40 Printhead 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 The charge carried is proportional to the voltage applied to the charge electrode when the drop became detached from the ink jet The charged droplets once deflected lea

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