ALE Z-series Printer Service Manual UK
Contents
1. Fig 31 place the new print engine Fig 32 re screw the M2 5 screw Z series Service Manual Service procedures 19 ALE Design Print Trace 04 08 09 Connect the ink tubes coming from the print engines to the ink circuit Re connect the print engines electronic connectors Fig 32 a a i e VN ig 33 re plug the electronic connectors reassemble the rest of the print head by following the steps given in 2 8 2 Open the Z34 print head in reverse order Z series Service Manual Service procedures 20 ALE Design Print Trace 04 08 09 2 5 Adjusting the ink low detection Ink low detection has been specifically adjusted in ALE factory according to ink type and should not be changed there is a risk of running the printer dry or to have a too frequent ink low signal on the printer Proceed as follows if you still wish to adjust ink low detection e Switch the printer OFF e Use along and thin cross head screwdriver to reach the potentiometer on the ink low PCB Fig 34 Fig 34 Ink low adjusting o e Switch the printer ON e Adjust the potentiometer as necessary Don t forget that ink low detections have a latency ink takes a bit of time to drip from the detection tubes 2 6 Separating the print head from the ink system Empty the ink circuit remove the ink bottle use the jet function of the purge menu to empty the ink circuit Switch the printer off Extract the hydra2. Z series Service Manual Maintenance 34 ALE Design Print Trace 04 08 09 3 Empty the circuit of solvent Remove the solvent bottle from the reservoir Fig 58 and again use Jet and Norm functions to remove all fluid from the circuit 4 Flush the circuit with air Fig 58 remove the solvent bottle 18 and 34mm print heads can be further cleaned by using the syringe connection at the back of the print head to expel as much flushing fluid as possible Proceed as follows e Switch the system off e For 18 and 34mm print heads remove the print head from its bracket This will close the automatic valve and ensures that the air that will be sent will only go through the print engines Use an ink collection tray Fig 59 e Remove the syringe connector cap Fig 60 Fig 59 Fig 60 Z series Service Manual Maintenance 35 ALE Design Print Trace 04 08 09 e Either with a syringe filled with air Fig 61 or a low pressure air hose lt 0 8bar expel the rest of the solvent from the print engines Fig 61 he pressure is superior to this given value there is a risk of tearing off the le plate which would destroy the print engine 5 Close the ink circuit On the reservoir refit the cap and the transport pin attached to the ink system with a wire Fig 62 On 18 and 34mm print heads refit the print head front plate protection cap Z series Service Manual Maintenance 36 Ale
3. ALE DESIGN PRINT TRACE Z SERIES E O A SERVICE MANUAL Ale Design Print Trace 04 08 09 Disclaimer This manual contains instructions for service operations on the ALE Z series print heads and ink systems Read it carefully before performing any manipulation on these All service operations should be undertaken by qualified personnel only Contact us if you need training for our equipment All information written in this Service Manual was correct at the time indicated in the version table below However the continual enhancement of our products may result in some differences existing between the information contained in this document and your equipment Copyright 2009 ALE sarl all rights reserved Reproducing this manual in whole or part without permission is expressly prohibited RiX and TraceX are registered trademarks of ALE sarl All trademarks in this document belong to their respective owners Version history Date Revision Modifications Author 18 10 2007 0 Initial release AF 11 06 09 V Reservoir w DP driver board AF 03 08 09 V1 1 Electronics cleaning AF Z series Service Manual i Ale Design Print Trace 04 08 09 Contents Disclaimer Contents li Notes Iv 1 The Z printer architecture 1 1 Ink circuit 1 1 1 Z18 ink circuit 2 1 1 2 Z34 ink circuit 3 1 2 Pump function 4 1 3 Electronic components 4 1 3 1 Z18 and Z34 e
4. O DS e oa m a fl ti lt i s C SY TETEE ONTT wey iHi ia z Let HH i a jo mt i 1 3a aT f it AN Im umbilical BARB25 OD4xID2 valve tube gt 18R hydraulic components SOLVENT BARBL25F BARBL25M6F TUBE4X25C L Te rit LU inline st cninciom ln tT ay To LT 1 IEI LI tan S188 namm See T_T CC 1m umbilical BARB4X25 OD6xID4 valve tube fA Fig 8 18R print head tubes and fittings 1 4 2 Z34 hydraulic architecture Below are graphics describing the ink circuit in the ink system Fig 9 and the print head Fig 10 Note that depending on the version Oil or Solvent the valve tube is not the same Always replace tubes and fittings with those supplied by ALE BARBL25F BARB4RA BARB4X25RA BARB4T 40mm TUBE6X4C 2x BARB4RA 20mm TUBE6X4C TUBE4X25C 22mm TUBE6X4C BARB4X25 BARB4RA TUBE6X4C 34R ONLY Fig 9 Z34 ink system tubes and fittings Z series Service Manual The Z printer architecture Ale Design Print Trace 04 08 09 BARB3PF220 BARBL2S5M6F aa BARBCAP SSS Se een L_L Litt ED E Fi F mal ia p m E p E A ite aj a 141 JE woh jij CES lt lt f E a TUBE4X25C BARBL25M BARB4X25RA OD4xID2 valve tube BARB25RA i 1 HE 34R hydraulic components OIL BARB4RAT25 BARB3PF230 BARBL25M6F BAR
5. Fig 56 Fig 56 ink collection configuration e Use the pump in jet mode see controller user manual for details as many times as necessary to empty the system from ink e When ink is out replace the air cap and the shipping cap on the reservoir e Flush the print head Z18 34 with air see 2 7 Flushing a Z18 34 print head with a syringe to expel the remaining ink 3 2 2 Pack the printer e Pack with care Make sure the nozzle plate cannot be damaged during transport Refit the protection cap delivered with every Z18 34 Z series Service Manual Maintenance 33 ALE Design Print Trace 04 08 09 3 3 Procedure for long term storage of solvent based printers If the printer is not to be used for a period longer than one fortnight 15 days this procedure must be followed to store the printer Not following this procedure will invalidate the warranty of the printer 1 Empty the circuit of ink e Puta collection tray under the print head to catch the ink Fig 56 e Check that the ink valve is opened see Z series operator manual e Remove the ink bottle e Switch the system on e Using the Jet function of the controller purge menu empty the circuit of ink as much as possible 2 Flush the circuit with solvent With the same configuration as in step 1 fit a flush bottle on the reservoir Fig 57 and use either Jet or Norm functions to get a completely transparent flow of e8 flush from the print head
6. Print Trace 04 08 09 Printing mode the print engines take ink from the reservoir through the direct prime module through the 6X4 tube the valves and the filter The ink is ejected by the print engines nozzles Ce ee ee a RESERVOIR PRIMING MODE PUMP ACTIVE PRINTING MODE PUMP IDLE Fig 4 Direct prime 1 2 Pump function The pump only function is to prime the ink circuit It is not used to refill the reservoir this is done automatically by gravity The pump can operate at two pressure rates e Norm normal power priming used to remove small air bubbles from the circuit or to clean the nozzles plate The pump is only activated for a few seconds at atime e Jet high power priming used to fill an empty ink circuit The pump is connected to the electronics and is activated by using a Pulse Width Modulated PWM signal 1 3 Electronic components The Z18 and Z34 electronics are almost identical as they are printing with 18mm print engines 1 for the Z18 2 for the Z34 1 3 1 218 and Z34 electronics The electronics of the Z series printers is made of 2 linked boards ZCON connector board and J15D21 CPU board ZCON has all the connections keyboard etc plus ink low detection and pump control J15D21 is in charge of the printing itself Both are located in the electronics compartment of the printer Z series Service Manual The Z printer architecture 4 Ale Design Print Trace 04 08 0
7. is damaged perhaps due to incorrect use of internal photocell option gt Replace FPGA chip e Pump wire is shorted somewhere gt Inspect and repair Z series Service Manual Maintenance 42
8. speed variable The longer the photocell delay the more chance for slippage gt Minimise photocell delay Photocell detection unreliable gt Inspect photocell Determine a method of verification Photocell detection inverted Use I O monitor gt Rectify Z series Service Manual Maintenance 4 Ale Design Print Trace 04 08 09 e Conveyor speed exceeding maximum print speed causing print stretch Max speed is approx 40m min at 100 print width 20m min at 50 and 80m min at 200 gt Change width setting or encoder wheel Z34 print head half of the message is inverted e Incorrect head configuration selected This is common if CodexX files are used that were originally connected to other printer models gt Open all CodexX files change the head configuration to 1x34mm etc save and close Fig 64 Horizontal print errors due to depriming Fig 65 Vertical print errors due to eion problem or interference Leak from lowest print engine e Bottle is almost empty together with large temperature changes gt Use smaller bottles or fit shipping cap e Reservoir level too high gt Alter level Pump will not prime the sound of the pump is too high e Air leak in tubes or fittings gt If leak is not obvious return for repair e Kinked tube gt Inspect for kinks in pump tube e Direct prime module is blocked gt Return for repair Pump runs continuously e FPGA
9. 9 In case any component FPGA for example has to be replaced or upgraded please contact ALE for a step by step operations procedure Er a J15D21 ZCON Fig 5 Z series electronics Z series Service Manual The Z printer architecture 5 ALE Design Print Trace 04 08 09 1 4 Hydraulic architecture 1 4 1 2Z18 hydraulic architecture Below are graphics describing the ink circuit in the ink system Fig 7 and the print head Fig 8 The shut off valve is made of a flexible tube clamped by a switch and a spring Fig 6 Fig 6 Oil version clamp valve Note that depending on the version Oil or Solvent the valve tube is not the same Always replace tubes and fittings with those supplied by ALE BARB4RA BARB4X25RA BARB4T 40mm TUBE6X4C 2x BARB4RA 20mm TUBE6X4C H Tt fg t IAN G I A i f 1 4 inzan oe ad al w anc COAR e HH gt i m z 14 i nr S z 3 4 i iA Sims BARBL4M AL OWA PR esos 2 i a TUBE4X25C 22mm TUBE6X4C BARB4X25 BARB4RA TUBE6X4C Fig 7 Z18 ink system tubes and fittings Z series Service Manual The Z printer architecture 6 ALE Design Print Trace 04 08 09 18R hydraulic components OIL SABREDER BARB25Y BARBL25M6F HA TUBE4X25C jh i a GEEEEEEEGEEEEEEGGEEEEEEEEEEEEEEEEEREGGGRRGEEE g Ss s ao i Sew j j in frana a R ISA H HE noA HE 7
10. BCAP F BARBLAF E ce iig EST l le l 1 4 ae sf TUBE4X25C BARBL25M ja BARB4X 5 BARB4RA OD6xID4 valve tube BARB4X25RA iE E CCO j Fig 10 34R print head tubes and fittings Z series Service Manual The Z printer architecture Ale Design Print Trace 04 08 09 1 5 Colour codes and ink compatibility WARNING Never change the ink type in a printer and use only ALE supplied fluids Mixing different inks causes catastrophic damage Components of the hydraulic circuit can be damaged by inappropriate ink or solvent The ink reservoirs and pumps are coded with colour tie wraps The pumps are coded with a tie wrap around the gear head Ink reservoir and pump colour codes e RED means compatible with ALE supplied solvent based inks e YELLOW means compatible with ALE supplied oil based inks e NONE means compatible with ALE supplied oil based inks Other ink types please contact ALE for further compatibility information Z series Service Manual The Z printer architecture 9 ALE Design Print Trace 04 08 09 2 Service procedures 2 1 Access to the ink reservoir Access to the contents of the ink reservoir is needed for replacing the filter at the bottom of the reservoir e Remove the ink bottle and the air cap if still present e Unscrew the top plate 4 M4 button head screws through the ink tray Remove the plate Be careful that a small o ring from the reservoir lid doesn t sti
11. Design Print Trace 04 08 09 Z series Service Manual Maintenance 37 ALE Design Print Trace 04 08 09 6 Storage instructions Store the printer in a clean environment in its original packaging away from extremes of heat and cold Z series Service Manual Maintenance 38 Ale Design Print Trace 04 08 09 3 4 Managing effects of large temperature changes Inks are sensitive to the temperature of the environment The temperature range that is acceptable will depend on the type of ink used and the application It is important to establish that the inks in use will be appropriate for all seasons of the year e f the factory is very hot in summer and very cold in winter the ink may give different print results e Do not install the system near a window where direct sunlight can affect it Almost empty ink bottles are sensitive to significant temperature variations in a short period of time for example between day and night The air in an empty bottle will expand and contract with temperature and cause the reservoir level to move up and down Depending on the ink types large daily expansion and contraction of air in an almost empty bottle may affect print quality and or dripping from the print engine nozzle due to there being too high a level of ink in the reservoir at certain times during the day e In factories with large daily temperature fluctuations be prepared to only allow bottles to become half em
12. M5 shoulder screws 3mm Allen key Fig 50 and the M3 grub screw 2mm Allen key Fig 51 from the tube Z series Service Manual Service procedures 28 ALE Design Print Trace 04 08 09 Fig 50 unscrew the two M5 shoulder screws Fig 51 unscrew the M3 grub screw Z series Service Manual Service procedures 29 ALE Design Print Trace 04 08 09 e With a tool push the valve switch inside the tube and rotate the tube with respect to the back plate to hold the switch inside Fig 52 push the valve switch inside the tube e Pull the tube backwards and remove it from the print head Fig 53 and Fig 54 Fig 54 remove the tube from the print head Fig 53 pull the tube backwards Z series Service Manual Service procedures 30 Ale Design Print Trace 04 08 09 3 Maintenance 3 1 Periodic service You can contact Ale for a service kit containing all the necessary filters o rings and tubes matching the ink used in your printer The following actions should be taken during the periodic service 3 1 1 print head e Open the print head by following the instructions given in 2 8 1 Open the Z18 print head and 2 8 20pen the Z34 print head Inspect tubes and fittings for leaks Inspect ribbon cables for possible damage clean interior and exterior surfaces e Inspect the clamp valve tube for leaks or damage cracks Replace if needed by a new tube of the same material supplied in the servic
13. ck to it Fig 11 remove M4 screws from the top plate e Remove the lid of the reservoir You now have access to the contents of the reservolr ane SS eee lt A Cae be o a a ee _ 6 em i i i ye Dy y FR Q tes i j 7 5 4 4 x Se eee df AF EAN iL L i g f Fig 13 remove the lid of the reservoir Z series Service Manual Service procedures 10 ALE Design Print Trace 04 08 09 2 2 Remove the hydraulic drawer e Unscrew the M3 countersunk screw 2mm Allen key and the 5 5mm nut that hold the drawer inside the ink system Fig 14 Remove M3 screw and 5 5mmnut e Pull the drawer and rotate it to the left Fig 15 andFig 16 AWA j Se ydraulic drawer Fig 16 rotated h 4 r 4 S g d SIF P 2 ff SS j 4 Eia Fig 15 pull and rotate the drawer to the left e Disconnect the 25 ways connector from the bulkhead at the back of the hydraulic compartment Z series Service Manual Service procedures 11 ALE Design Print Trace 04 08 09 Fig 17 remove the 25 ways connector e The hydraulic drawer is now completely removed 2 3 Open the electronics compartment Here are the steps to follow to open the electronics compartment of a Z1 8 34 e Remove power lead e Remove the counter sunk screw at the bottom of the back plate Fig 18 witha 2mm Allen key m E Fig 19 remove the 2 counter s
14. e kit e Prime the engine and print a black pad test in the prime menu of the controller see controller manual for details to make sure all dots are printing 3 1 2 Ink system The following actions should be taken during the periodic service e Open the pump compartment as in 2 2 Remove the hydraulic drawer e Open the reservoir see 2 1 Access to the ink reservoir and empty it with a syringe Do not turn the ink system upside down Inspect tubes and fittings for leaks Inspect circuit board for cleanliness e Clean interior and exterior surfaces Replace the filter ref FILTGAUZE at the bottom of the reservoir remove the clip holding the filter replace the filter put back the clip A Do not let dirt fall into the circuit Z series Service Manual Maintenance 31 ALE Design Print Trace 04 08 09 a gt S a m E m o a i e FILTGAUZE Fig 55 Gauze filter replacement e Replace the o rings in the reservoir by new o rings supplied in the service kit e Reassemble the entire printer prime it and check print quality Z series Service Manual Maintenance 32 ALE Design Print Trace 04 08 09 3 2 Transport 3 2 1 Empty the ink circuit It is recommended to clean and empty the printer before transport To flush out the printer e Remove the ink bottle e Switch the printer ON e Put the print head in this configuration print down with a collecting bucket
15. h engines e Bottle valve is not opening properly or worn out due to the same bottle being re used gt Don t re use bottles Bottom of print missing on an engine e Needs priming gt Prime e Ink reservoir level too high causing an ink bubble on nozzles gt Adjust levels gt Reservoir level too high due to empty bottle together with large daily temperature changes gt Air leak in tubes or seals of reservoir pump or badly fitted bottle Top of print missing on an engine e Needs priming gt Prime Random dots missing e Nozzles blocked by a particle or by drying solvent version gt Purge the print head use the Jet position If the problem remains on a Z18 34 it is possible to flush the print head with a syringe see 2 7 Flushing a Z18 34 print head with a syringe If the nozzles remain blocked contact your distributor Z series Service Manual Maintenance 40 ALE Design Print Trace 04 08 09 Engine not printing or exactly half of engine not printing Loose connection check ribbon cables in print head gt Replace connector or use silicone paste as necessary No print photocell does not work Installation uses a shaft encoder and line is stationary gt Line must be moving for photocell to be detected when controller set in shaft encoder mode When using the I O monitor function on controller other functions menu the display POO changes to P10 during phot
16. h only the print engines and not the rest of the circuit To empty the print head for transportation use the syringe without any fluid The syringe will be used to expel the fluid from the print engines To recover a missing dot fill the syringe with ALE ODFLUSH solvent if the machine is for ALe BODNPM ink or with AZ SOB if the machine is for ALE BOB ink Disconnect the print head from its bracket and put it over a collecting tray To connect the syringe to the print head remove the syringe cap from the back of the print head and screw the syringe luer not too tightly the thread is conical and may be very hard to unscrew Fig 40 flushing the Z18 34 print head with a syringe GENTLY flush the print head as desired remove the syringe and plug the syringe cap back After flushing to recover missing dots it will be necessary to go again through the priming procedure to refill the print engines with ink Z series Service Manual Service procedures 24 ALE Design Print Trace 04 08 09 2 8 Opening the print head 2 8 1 Open the Z18 print head Completely empty the print head first Remove the ink bottle and purge the ink circuit until nothing comes out of the print engines see controller instruction for purging g i A L Pa A TE r _ amp 2 4 Fig 41 unscrew the grub screw from the tube Unscrew the M4 grub screw from the tube with a 2 mm Allen key Fig 41 Unscrew the two M5 shoulde
17. lectronics 4 1 4 Hydraulic architecture 6 1 4 1 Z18 hydraulic architecture 6 1 4 2 Z34 hydraulic architecture 7 1 5 Colour codes and ink compatibility 9 2 Service procedures 10 2 1 Access to the ink reservoir 10 2 2 Remove the hydraulic drawer 1 2 3 Open the electronics compartment 12 2 4 Changing a print engine 14 2 4 1 Changing the Z1 8 print engine 14 2 4 2 Changing a Z34 print engine 15 2 5 Adjusting the ink low detection 19 2 6 Separating the print head from the ink system 19 2 7 Flushing a Z18 34 print head with a syringe 22 2 8 Opening the print head 23 2 8 1 Open the Z18 print head 23 2 8 2 Open the Z34 print head 25 3 Maintenance 28 3 1 Periodic service 28 3 1 1 print head 28 3 1 2 Ink system 28 Z series Service Manual Ale Design Print Trace 04 08 09 3 2 Transport 30 3 2 1 Empty the ink circuit 30 3 2 2 Pack the printer 30 3 3 Procedure for long term storage of solvent based printers 31 1 Empty the circuit of ink 31 2 Flush the circuit with solvent 31 3 Empty the circuit of solvent 32 4 Flush the circuit with air 32 5 Close the ink circuit 33 6 Storage instructions 33 3 4 Managing effects of large temperature changes 34 3 5 Fault diagnosis 35 Z series Service Manual ili Ale Design Print Trace 04 08 09 Notes Z series Service Manual iV ALE Design Print Trace 04 08 09 1 The Z printer architecture The Z series printers are designed to be all in one printing systems Each Z p
18. ocell activation gt Photocell is OK problem with message I O monitor normally shows P10 and changes to POO when photocell is activated gt Detection is inverted change photocell or change the detection setting in the controller I O monitor always shows POO gt Fault in photocell connector or controller First try an alternative photocell to verify that controller is OK IO monitor always shows P10 gt Fault in photocell connector or controller First try an alternative photocell to verify that controller is OK No print shaft encoder does not work When using the I O monitor function on controller other functions menu the display A00 changes rapidly to A10 A11 A01 during conveyor movement gt Encoder working correctly problem with message The I O monitor shows one of the inputs not changing gt Faulty encoder Connect different encoder and spin the wheel by hand to see if inputs change Print start slipping image misalignment Poor contact between shaft encoder wheel and conveyor gt Rectify Encoder too far from print heads so that conveyor stretch causes problems gt Move encoder as close to print heads as possible Encoder mode not switched on gt Rectify Many conveyors vibrate when stationary causing false pulses to be sent by encoder Does this occur during photocell delay gt Minimise photocell delay Photocell delay quite long and system line
19. ollowing the instructions given in 2 8 2 Open the Z34 print head Disconnect the print engine electronic connectors Fig 23 i an aN Fig 23 unplug the electronic connectors Disconnect the ink tubes from the print engines Fig 24 and extract the print engines assembly Fig 25 assembly Fig 24 disconnect ink tubes Z series Service Manual Service procedures 16 ALE Design Print Trace 04 08 09 Remove the ink tubes left Fig 26 Fig 26 remove the old ink tubes Unscrew the flat head screw holding the defective print engine Fig 27 and remove the print engine Fig 28 Z series Service Manual Service procedures 17 04 08 09 Design Print Trace ALE Fig 28 remove deficient print engine Fig 27 unscrew M2 5 flat head screw Fit the replacement tube on the remaining print engine given with the replacement print engine Fig 29 MUU eee ete ke I 7 mm lt We f 5 _ _s er 7 set _ _ Ds sr C_i er n s Ar f a gt E 7 i Fig 29 fit replacement tube Put the new print engine in place Fig 30 Z series Service Manual Service procedures ALE Design Print Trace 04 08 09 Fig 30 put the new print engine Re screw the M2 5 flat head screw
20. print head with a syringe connection The shut off valve allows to close the ink circuit between the ink reservoir and the print engines Because the syringe connection is located between the valve and the print engine it is possible to use a syringe to flush the print engines only the valve is closed for that operation see 2 7 Flushing a Z18 34 print head with a syringe Priming mode the pump sucks ink from the reservoir and sends it towards the print engine through the umbilical If the shut off valve is closed nothing happens The ink is blocked If the shut off valve is open the ink will go through the print engine When the pump is active the ball in the direct prime module located in the reservoir blocks the way and the ink cannot go back to the reservoir When the pump is inactive the ball goes out of the way and the ink can pass through the direct prime see Fig 4 Printing mode the print engine takes ink from the reservoir through the direct prime module through the 6X4 tube and the valves The ink is ejected by the print engine nozzles Z series Service Manual The Z printer architecture 2 Ale Design Print Trace 04 08 09 1 1 2 234 ink circuit Z34 INK CIRCUIT RESERVOIR DIRECT PRIME 4X25 tube CLOSED OPEN Shut off valve j Luer for syringe connection 03 03 AF Fig 3 234 ink circuit Below is a schematic describing the Z34 ink circuit It includes a re
21. pty it is the air in the bottle that expands not the ink e Alternatively remove the ink bottle when the system is not in use and fit the shipping cap This will prevent the reservoir level changing e When print re starts the excess ink will be taken from the reservoir first quickly restoring the correct level Z series Service Manual Maintenance 39 Ale Design Print Trace 04 08 09 3 5 Fault diagnosis Refer to the Z series operators manual for basic fault diagnosis of common printing and priming problems likely to be encountered during installation and use of the system Listed below is additional information After priming print is OK for a few minutes Then progressively de primes horizontal lines appear in the image or print is grey e Insufficient prime pressure to clear air from the tubes in new systems or in systems that have run dry gt Temporarily set the prime pressure to HIGH and prime e Print heads are being lifted by the customer during priming so air flows back in to the engines due to incorrect level gt Print heads should not be moved during priming e Shocks to umbilicals or print heads gt Isolate from source of vibration e Pump has failed gt Prime while checking for a good flow of ink from print engine s e Tubes kinked a kink occurs when a tube bends too much gt Prime while checking for a good flow of ink from print engine s With Z34 system check for the same flow from bot
22. r screws from the tube with a 3 mm Allen key Fig 42 i j Fig 42 unscrew the shoulder screws from the tube Z series Service Manual Service procedures 25 ALE Design Print Trace 04 08 09 Unscrew the two M4 dome nuts from the back of the print head with a 7mm key Fig 43 i i Fig 43 remove M4 dome nuts Push the valve switch inside the tube and rotate the tube with respect to the back plate to hold the switch inside Fig 44 Fig 44 push the switch inside the tube Move the tube backwards and remove it from the print head Fig 45 and Fig 46 next page Z series Service Manual Service procedures 26 ALE Design Print Trace 04 08 09 Fig 46 tube removed from the print head Fig 45 remove the tube 2 8 2 Open the Z34 print head Follow this procedure e Completely flush the print head first Remove the ink bottle and purge the ink circuit until nothing comes out of the print engines see controller instruction for purging Z series Service Manual Service procedures 27 ALE Design Print Trace 04 08 09 e Unscrew and remove the two M4 dome nuts from the back plate Fig 47 Fig 47 Unscrew the two M4 dome nuts e Remove the syringe plug Fig 48 and the back plate Fig 49 reeitill 7 R gt f 1A y r 2 a As NU Ie Fig 48 remove the syringe plug i Td Fig 49 remove the back plate e Unscrew the two
23. rinter consists of an ink system connected to a print head with a lm long umbilical The enclosure also includes the electronics to drive the print head a keypad and an LCD screen for the user Each Z printer contains hydraulics and electronics e Hydraulics allow the ink flow from the reservoir ink system to the print engine print head e Electronics are used to send the data to the print engine s to control the pump and to communicate with the external world RS232 USB Both the printer itself and the print head are enclosed in stainless steel at least 1 2mm thick 1 1 Ink circuit The Z series printers introduce a single reservoir design with automatic level control and pump assisted priming The bottle fitted on this reservoir is compatible with the entire range of ALE ink systems It contains a valve which is automatically sealed during bottle removal and fitting The reservoir is normally open to air via the air vent hole Fig 1 Fig 1 Reservoir air vent with cap Z series Service Manual The Z printer architecture 1 Ale Design Print Trace 04 08 09 1 1 1 218 ink circuit 6X4 tube RESERVOIR CLOSED OPEN Shut off valve XAAR 128mm PRINT ENGINE Luer for syringe connection 03 03 09 AF Fig 2 Z18 ink circuit Below is a schematic describing the Z18 ink circuit It includes a reservoir with a direct prime module a pump an ink tube and a shut off valve for the
24. servoir with a direct prime module a pump two ink tubes and a shut off valve for the print head with a syringe connection The shut off valve allows to close the ink circuit between the ink reservoir and the print engines Because the syringe connection is located between the valve and the print engines it is possible to use a syringe to flush the print engines only the valve is closed for that operation see 2 7 Flushing a Z18 34 print head with a syringe Priming mode the pump sucks ink from the reservoir and sends it towards the print engine through the umbilical If the shut off valve is closed all the ink flows back to the reservoir through the 4x25 tube This is particularly useful to get rid of air in the umbilical e g when the system is dry without losing ink the pump will force the air back into the reservoir where it can escape through the air vent hole When there is no air left in the umbilical only ink is sent back to the reservoir If the shut off valve is open most of the ink will go through the print engines A small part of the ink will still go back to the reservoir through the 4x25 tube When the pump is active the ball in the direct prime module located in the reservoir blocks the way and the ink cannot go back to the reservoir When the pump is inactive the ball goes out of the way and the ink can pass through the direct prime see Fig 4 Z series Service Manual The Z printer architecture 3 Ale Design
25. ulic drawer as shown in 2 2 Remove the hydraulic drawer Z series Service Manual Service procedures 21 ALE Design Print Trace 04 08 09 a r i j 4 amp gt g peme i f j i a q f r D gt i i rti no ye Pr als SS Wa we amp LA Aves MF Y oo y i 3 Hi Se gt act lt reuse a T Fig 35 unscrew M3 dome nuts Fig 36 unscrew M4 nyiock nuts Unscrew both M4 nylock nuts from the pump plate 7mm key see Fig 36 Unscrew the two M3 dome nuts 5 5mm key on the external plate of the drawer Fig 35 Separate carefully the umbilical plate from the reservoir assembly by 3 4cm Fig 37 next page Z series Service Manual Service procedures 22 ALE Design Print Trace 04 08 09 Fig 37 separate carefully reservoir assembly and umbilical plate 4cm max Unplug the electronic connector and the ink connector s Fig 38 Fig 38 unplug ink and electronic connectors Finish extracting the umbilical plate Fig 39 Close the tubes with caps to protect the ink circuit from the dust Fig 39 separated umbilica To reassemble the print head and the umbilical follow the same steps in reverse order Z series Service Manual Service procedures 23 ALE Design Print Trace 04 08 09 2 7 Flushing a Z1 8 34 print head with a syringe By connecting a syringe at the back of the print head it is possible to flus
26. unk screws 2mm Allen key Fig 18 remove the counter sunk screw 2mm Allen key e Remove the 2 counter sunk screws at the top of the back plate Fig 19 with a 2mm Allen key Z series Service Manual Service procedures 12 ALE Design Print Trace 04 08 09 e Extract the back plate carefully Fig 20 A Fig 20 start extracting the back plate e Remove the three connectors LCD LEDs and Printing from the connector board shown on Fig 20 Z series Service Manual Service procedures 13 ALE Design Print Trace 04 08 09 2 4 Changing a print engine 2 4 1 Changing the Z18 print engine To change the Z18 print engine follow these steps open the print head by following the instructions given in 2 8 1 Open the Z18 print head Disconnect the ink tube between the print engine and the valve Fig 21 x Fig 21 disconnect the ink tube Disconnect the print engine connector and extract the print engine assembly Fig 22 Z series Service Manual Service procedures 14 ALE Design Print Trace 04 08 09 Fig 22 disconnect and extract the print engine replace the print engine assembly and reassemble the print head by following the steps in reverse order Z series Service Manual Service procedures 15 ALE Design Print Trace 04 08 09 2 4 2 Changing a Z34 print engine To change the Z34 print engine follow these steps open the print head by f
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