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Hitachi PXR Service Manual

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Service Manual

HITACHI
Model PXR
Printer
Revision
Version
December 2008
C

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Summary of Contents for Hitachi PXR

  • Page 1: Service Manual

    Service Manual HITACHI Printer Model PXR Revision December 2008 Version...
  • Page 2 [ Revision of PXR service manual ] Revision Chapter Revised Page First edition (Apr. 2006) Addition of “1.2 PXR-P usage precautions” 1.2.5 Addition of “Note: Meaning of orifice plate lot number” 1-12 1.3.2 Addition of Step 14 (Back up) to the installation procedure 1-16 1.3.3...
  • Page 3 2.3.3 Phase margin test ························································································· 2-10 2.3.4 Auto phase gain adjustment ·········································································· 2-12 2.3.5 Level sensor confirmation ············································································· 2-14 2.3.5-1 Model PXR-D and model PXR-P level sensor confirmation ························ 2-14 2.3.5-2 Model PXR-H level sensor confirmation ······················································ 2-15 2.3.6 Heating unit confirmation ·············································································· 2-17 2.4 Test of solenoid valve/pump ················································································...
  • Page 4 3.3.7 High voltage power supply ············································································ 3-23 3.3.8 Fan Replacement Procedure ········································································ 3-24 3.3.9 Exhaust Filter Replacement Procedure ························································ 3-26 4. Maintenance of Circulation System (PXR-D, PXR-H) ··············································· 4-1 4.1 General Structure of Circulation System ······························································· 4-1 4.2 Main Ink Tank Replacement Procedure································································· 4-4 4.3 Pressure Relief Valve Replacement Procedure ····················································...
  • Page 5 4.11 Troubleshooting Procedure for the Circulation System········································ 4-25 4.12 Repairing Method When the Circulation Route Is Dry or Sticks ·························· 4-30 5. Maintenance of Circulation System (PXR-P) ···························································· 5-1 5.1 General Structure of Circulation System ······························································· 5-1 5.2 Main Ink Tank and Ink Reservoir Replacement Procedure···································· 5-4 5.3 Pressure Relief Valve Replacement Procedure ····················································...
  • Page 6 7.6 Miscellaneous ······································································································· 7-51 8. Attached Drawing········································································································ 8-1 8.1 Circulation system diagram ················································································· 8-1 8.1.1 Circulation system diagram (PXR-D, PXR-H)················································· 8-1 8.1.2 Circulation system diagram (PXR-P) ······························································ 8-2 8.2 Air system diagram (PXR-P) ················································································· 8-3 8.3 Electrical Connection Diagram ············································································ 8-4 8.3.1 Electrical Connection Diagram (PXR-D) ·······················································...

  • Page 7: Safety Precautions

    1. Introduction 1.1 Safety precautions Before starting the maintenance and inspection work of this printer, thoroughly read and understand the “safety precautions”. When explaining the product to customers at the time of the installation, fully explain the “safety precautions”.
  • Page 8 Safety Precautions Before using the printer, thoroughly read the following safety precautions for optimum printer use. You should observe the precautions set forth below in order to use the product properly and avoid endangering or causing damage to you or other persons. For the purpose of clarifying the severity of injury or damage and likelihood of occurrence, the precautions are classified into two categories, WARNING and CAUTION, which both describe the hazardous situations that may arise if you ignore the precautions and perform an incorrect handling or operating procedure.
  • Page 9 Safety Precautions (Continued) WARNING Ensure that there is no flame- or arc-generating device within 5 m of the printer. The ink and makeup ink are both flammable and may cause fire. Fire can be generated by matches, lighters, cigarettes, heaters, stoves, gas burners, welders, grinders and static electricity.
  • Page 10 Only use Hitachi-approved consumables and periodic replacement parts. Using products that are not designated by Hitachi may lead to malfunction or failure. Such malfunction or failure will not be covered by the warranty.
  • Page 11 Safety Precautions (Continued) WARNING When charging a refill of ink or makeup ink, exchanging ink, or otherwise handling ink or makeup ink, take enough care not to spill ink or makeup ink. If you spill any ink or makeup ink by mistake, wipe it off neatly and promptly with lint-free wipes or something similar.
  • Page 12 Safety Precautions (Continued) Caution Only persons who have completed an operator training course for Hitachi IJP can operate and service the printer. If the printer is operated or serviced incorrectly, it may malfunction or break down. Do not attempt to make repairs for any purpose other than operation or maintenance.
  • Page 13 Safety Precautions (Continued) Caution Ensure that all electrical wiring, connections and grounding comply with applicable codes. Properly connect the printer to its dedicated ground. Complete the above procedure to avoid electrical shock hazards. Ink and makeup ink must be stored as flammable liquids. Storage must comply with local regulatory requirements.
  • Page 14 1.2 PXR-P usage precautions Carefully explain the following contents to your customers: Pigmented ink is ink whose components are likely to be deposited. Take care with handling ink so that such problems as no ink ejection when operating the printer, or no recovery due to accretion of the ink inside the printer, do not occur.
  • Page 15 1.3 Structure of each part in the main body 1.3.1 External views (PXR-D, PXR-H) Status indicator lamps Handle Turn it by 90degrees to open Displays “READY”, “FAULT” and “WARNING”. and close it. Various signals intakes See "1.5 Connection of signals"...
  • Page 16 1.3.2 Main body internal (PXR-D, PXR-H) Makeup ink reservoir reservoir Maintenance door Electrical access door Various signals connecting portion 1-10...
  • Page 17 1.3.3 External views (PXR-P) Operating status indicator lamps Displays “READY”, “FAULT” and “WARNING”. Handle Turn it by 90 degrees to open and close it. Various signal intakes See “1.5 Connection of Power lamp signals” in the Instruction manual. Power switch...
  • Page 18 1.3.4 Main body internal (PXR-P) Ink reservoir Makeup ink reservoir Main ink tank Ink filter Maintenance door Electrical access door Various signals connecting portion 1-12...
  • Page 19 1.3.5 Print head Print head (PXR-H) Nozzle (55µm) Minus deflection electrode Plus deflection electrode Pipe gutter Note: Meaning of orifice plate lot number 6 A12345 Position of lot number Serial number Nozzle diameter 6: 65μm 4: 40μm 1:100μm 5: 55μm...
  • Page 20 1.4 Installation 1.4.1 Wiring of power supply Caution ・Be sure to use an appropriate plug and connect a protective ground. ・Place a wall socket in the vicinity of the unit so as to easily remove it. ・Use a power cable within the designated specifications. ・Do not bundle a signal level cable and a power cable together outside the unit so that the signals (signal terminal block, a connection signal to an external communication connector) are not affected by a noise from...
  • Page 21 (1) Remove the Inlet cover.(Fixing screw 4 locations) Inlet cover (4 fixed screws） (2) Insert the power cable to the Inlet. Power Cable 1-15...
  • Page 22 (3) Mount the inlet cover. Inlet Cover CAUTION Power cable Tape the seal around the outside of the cable and as in the drawing, and insert it into the holder as shown in above. 1-16...
  • Page 23 The viscometer calibration will not be performed correctly if the step 5 and 6 are skipped. (The step 7 is not required for the model PXR-H. The step 5 and 6 can be skipped however, the initial viscosity value will be lower. Keep ejection of the ink until the viscosity returns to 100 in this case.)
  • Page 24 1.4.3 Installation procedure (PXR-P) 1.4.3-1 Installation procedure After wiring of power supply is complete, perform the installation work following the procedure shown below. “ * ” shows the same procedure as PX-D type. Step Work Related page Air connection and air pressure 1.3.3-2 Confirming air...
  • Page 25 1.4.3-2 Air connection and air pressure adjustment (at the time of installation) Pigmented ink is ink whose components are likely to be deposited. With PXR-P type IJ printer, ink inside main ink tank and ink reservoir will be automatically stirred by stirrer.
  • Page 26 (3) Set rotors. Two rotors are packed together as accessories: Put one rotor each into ink reservoir and main ink tank before adjusting air pressure. Caution ！ If a rotor is not in the tank, stirrer will be rotating at high speed. (4) Input pressure adjustment Adjust so that scale of filter regulator is 0.1 (+0.01) MPa.
  • Page 27 1.4.3-3. Disposition of makeup ink inside main ink tank (at the time of installation) Ink stream alignment is performed when installing the unit. Makeup ink should be collected from gutter and returned to main ink tank at this time. If ink is replenished as is, ink will be too thinned.
  • Page 28 2. Maintenance work A screen for use in the maintenance work by a service personnel is described. 2.1 Setting of maintenance mode by service personnel For the maintenance work by a service personnel, restrictions on use of the following functions are removed. - System environment setup - Adjustment/operational checkout - Solenoid valve/pump test...
  • Page 29 Password protection 2011.07.07 12:45 Status:XXXXXXXXX When the password entry is accepted, you can change the Password protection setup. Password Edit message/Select message ] (0: access 1:protect） Save message [ 0 ] (0: access 1:protect) Print specifications [ 0 ] (0: access 1:protect）...
  • Page 30 Features of the service personnel maintenance mode Functions Contents Maintenance menu The second page of the maintenance menu can be displayed. User environment The excitation V-ref. warning can be displayed. setup screen Operation The cumulative operating time can be changed. management screen Operation...
  • Page 31 Back ment ment Note: The nozzle diameter of PXR-H is setting needlessness. (55 µm is set automatically.) When the ink type is set, an initial value is automatically set. With respect to the initial value, refer to the next page. With respect to full details about the excitation curve, refer to the attached figure 8.6.
  • Page 32 Conditions set by the ink type*1 Excitation Operating Operating Excitation Nozzle size Ink type frequency temperature temperature curve (kHz) upper limit ( lower limit ( JP - K67 68.9 JP - K69 68.9 JP - K26 68.9 JP - K27 68.9 JP - R27 68.9...
  • Page 33 (see the table below). If the excitation curve is set to a value other than the initial one, printing may be abnormal: After finishing maintenance work, reset the value to the original. PXR-D PXR-P TYPE Constant excitation voltage output values (set on the “Excitation V update” screen) Setting value...
  • Page 34 2.3 Adjustment/operational checkout 2.3.1 Excitation adjustment - Adjust the drive conditions of nozzles. - This adjustment is performed in a state other than the IJ printer “ready” state. - Be sure to perform this adjustment in the case of replacing the board (EZJ93, 94, 104), the nozzle (including the print head) or changing the ink type.
  • Page 35 “In progress”. The excitation voltage is gradually increased, and the adjustment is completed at 360 V plus or minus 20 Vp-p (280 V plus or minus 20Vp-p in case of PXR-H), and the processing state is cleared. The excitation adjustment is completed within 10 minutes.
  • Page 36 2.3.2 Charging voltage confirmation - This confirmation is performed in a “Stop“ state. - Confirm when performing the board exchange (EZJ93 and 94). 1 Press adjustment/operational checkout at the second page of the With respect to the service maintenance screen. password protection, When the previous menu and the next menu are not displayed in the refer to 2.1 setting of...
  • Page 37 2.3.3 Phase margin test - Perform the phase margin test of a nozzle. - This test is performed for checking that (1) whether or not the nozzle is in a printable state (whether or not clogging is present) and (2) whether or not ink is deteriorated. - After the setting of a “standby”...
  • Page 38 3 Select the print timing from Button input or Sensor and the print data from For test or Data to be displayed on the screen, respectively. ・When the “Button input” is selected, the following figure is displayed and the printing phase is sequentially printed from 0 phase to 15(f) phase every time Start printing is pressed.
  • Page 39 2.3.4 Auto phase gain adjustment - The gain of the auto phase detection voltage is automatically adjusted. - Perform this adjustment after confirmation that the periphery of a gutter part within the nozzle head is not made dirty with ink or the like and the printing head cover is correctly fixed.
  • Page 40 3 After the completion of the automatic adjustment, when the Back key is pressed, the auto phase detection voltage is output and therefore, confirm the waveform by an oscilloscope. With respect to positions of Using the oscilloscope, confirm that the voltage of TP1 (APH signal) on the EZJ94 the board and the test pin, board is from 8 to 10 V as the maximum voltage, 2 V or less as the minimum voltage, refer to "...
  • Page 41 2.3.5 Level sensor confirmation - The level sensors of the main ink tank for the PXR-D/PXR-P and PXR-H are different. (Refer to the next page for PXR-H) - The operation confirmation of level sensor in the main ink tank is performed.
  • Page 42 2.3.5-2 Model PXR-H level sensor confirmation The level sensor for the PXR-H is different from the one for the model PXR-D/PXR-,P. 1 Construction of level sensor Dedicated viscosity control is performed by selecting levels depending on ambient temperature with the model PXR-H.
  • Page 43 3 Operation management screen The operation management screen of the PXR-H is as follows. Operation management 2011.07.07 12:45 Status: XXXXXXXXXX Start Shut down Ink Operating time [0000] (hours) Comm Manual Ink alarm time [1200] (hours; standard value :1200) On/Off Cumulative op. time 000000 (hours)
  • Page 44 2.3.6 Heating unit confirmation - The operation confirmation of heating unit is performed. (1)Heating unit power ON/OFF. - A display of an ambient temperature and a heating unit temperature is performed. - Perform this operation confirmation in a state other than "ready" state. 1 Press adjustment/operational checkout at the second page of the service maintenance screen.
  • Page 45 (9) Shutoff valve (MV9) (10) Viscometer coil (MV10) (11) Air valve for main ink tank stirrer (MV11) ---[PXR-P only] (12) Air valve for ink reservoir stirrer (MV12) ---[PXR-P only] (13) Pump - Perform this test in a "stop" state. (In an operating state, only an operating state is displayed.)
  • Page 46 " 3.3.1 EZJ93 board" - When replacing the EZJ93 board and the EZJ104 board, be sure to perform the Initialization of the board for PXR by download. With notes in case of the EZJ104 (Please follow “notes in case of the EZJ93 board replacement”, and “notes in case of board replacement , the EZJ104 board replacement”.)
  • Page 47 The upgrade software and the display language data are included in the memory card used for download. PXR type IJ printer can register two languages, but if the memory card doesn’t include the languages registered in the IJ printer, the language is automatically changed to English when after downloading.
  • Page 48 2.6 Calibration of viscometer 2.6.1 Calibrating viscometer - Calibration of viscometer is required for the model PXR-D: it is not required for the model PXR-H, PXR-P. - The calibration of viscometer is to determine the “coefficient” inherent in the equipment.
  • Page 49 4 The measurement is completed in four minutes, and a coefficient (calculated value) will be displayed Viscometer calibration 2011.07.07 12:45 Status:XXXXXXXXX <the previous calibration> <the current calibration > Exec.time 2011.07.01 16:00 Exec.time 2011.07.07 12:45 Plunger falling time Plunger falling time No.1 X.
  • Page 50 - Viscosity coefficient is not necessary to be changed usually. - Be sure to perform the viscometer calibration after the viscometer is changed. (PXR-D) - Be sure to input the coefficient for new viscometer after the viscometer is changed (PXR-H, PXR-P).
  • Page 51 XXXX Cancel Ink viscosity It is not necessary to calibrate the viscometer for PXR-H and PXR-P, therefore “the previous calibration” is not displaed. Proc. status: Ended If the process status is “fault” and message “Check viscometer for any defect” appears, normal measurement has not been executed. Follow “4.9 Troubleshooting when fault occurs in viscometer”.

  • Page 52: Ink Concentration Control

    2.7 Ink concentration control - Select whether or not the ink concentration is controlled based on results of the viscosity measurement. - Select whether or not the Ink concentration confirmation message will be displayed when the power is turned on. - Perform these at “stop”...

  • Page 53: System Reset

    2.8 System reset - Set the default values on the “Printing data,” “User pattern” and “Maintenance” screens. - Perform this function when the EZJ104 board or the EZJ93 board is replaced in a state allowing no backup. - If this function is performed, perform setup and/or adjustment according to the contents described in “3.2.4 EZJ104 board”...
  • Page 54 - Only the print data and the user patterns that are backed up by the model PX can be copied to the model PXR. - The data backed up by the model PXR can not be copied to the model PX. Copy from a memory card onto an IJ printer 1 Turn on the power.
  • Page 55 4 Insert a memory card into a slot. 5 Press Mem. card Printer and select a direction of copy. 6 Press User data, Unit-specific data . Copy data 2011.07.07 12:45 Status:XXXXXXXXX Copy direction Printer Printer Mem.card Mem. card Folder to be copied [ PXR99999 ] Serial number PXR99999...

  • Page 56: Unit Information

    3 Press the Unit information on the second page of the Service maintenance screen. Unit information 2011.07.07 12:45 Status:XXXXXXXXX TYPE-FORM PXR- D460 Ink type JP- K67 Serial number PXR [ 9 9 9 9 9 9 9 ] Ink viscosity coefficient...
  • Page 57 2.11 Handling of the warning “Product Speed Matching Error” - The warning “Product Speed Matching Error” can be set to “Enable” or “Disable”. Enable: The warning message is displayed when the conditions are met. Disable: The warning is not displayed even is the conditions are met. - The screen for the setting is displayed at the “Service personnel maintenance mode”, and it is not displayed at the “User maintenance mode”.
  • Page 58 2.12 Language registration -This function is to register screen languages. (Only English is registered when shipped.) - Register the languages to the IJP from the memory card. - If the customer is using password to protect the functions for maintenance work, release the protection on functions and after setting this function is finished, reset the protection on functions.
  • Page 59 4 Point the cursor to the Language 1 and press Prev. Language or Next Language, and select a desirable language. 5 Move the cursor to the Input mode and select the keyboard type. Special characters Accent characters, Greek and Russian Kana and Dedicated characters Katakana and dedicated characters for date - Special character can not be selected when the language of screen is Japanese or...
  • Page 60 2.13 Fault / Warning log management code - This function displayed code number in the Fault/Warning log screen. Fault/Warning Log Code Table Code Code Message name Message name Ink Low Fault Improper Sensor Position Main Ink Tank Too Full Target Sensor Fault Deflection Voltage Fault Target Spacing Too Close Print Data Changeover In Progress S...
  • Page 61 Code Code Message name Message name External Communication Error 005 Replenishment Timeout --(Ink) External Communication Error 006 Ink Heating Current Fault ---(02) External Communication Error 007 External Communication Error 008 External Communication Error 009 External Communication Error 010 External Communication Error 011 Viscometer not calibrated External Communication Error 012 External Communication Error 013...
  • Page 62 2.14 Software option setup - Use this function when setting up software options to IJ printer. - In order to set up options, EZJ99 board and a memory card (IJP system-data is stored) are required. - Perform this function when the IJ printer is in a “Stop” state. - There are some combinations that cannot be set up simultaneously with other options.
  • Page 63 5 Change the option to set up to “1: Enable”. Option Setup 2011.07.07 12:45 Status:XXXXXXXXX 02-1 Addition of printing columns [ 0 ] (0: Disable 1: Enable ) 1Addition of registers [ 0 ] (0: Disable 1: Enable ) 1Special communication A [ 0 ] (0: Disable 1: Enable )
  • Page 64 3. Maintenance of controlling part 3.1 Construction of controlling part The controlling part is mainly composed of a controller part of performing the display and the data management, and an engine part of performing the printing control and the circulation system control. Caution against electric shock When opening the cover of the controller part and the engine part, be sure to cut off the power supply.
  • Page 65 Cover fixing screws (Two locations) Cover fixing screws (Two locations) Controller part [Controller part (cover-opening state)] Touch panel (operation side) (Backside of panel) EZJ104 board EZJ97 board LCD backlight power supply Battery...
  • Page 66 3.2 Controller part - With regard to the electric parts/control board of the controller part, the functional outline, the setting of the switch, the list of the check point and the note at the replacement are described. 3.2.1 EZJ104 board (controller board) [Function] - Preparation/management of print data is performed.
  • Page 67 (6) It is displayed, "Wait for a minute", and progresses the indicator bar. When the specific data stored on EZJ104 board are different from the data stored on the EZJ93 board, following message screen “Board Replacement Procedure” is displayed. Select “EZJ104” on the message. (When the specific data stored on EZJ104 board and on EZJ93 board are same, this message is not displayed.) ＝＝＝＝＝...
  • Page 68 In the case where the EZJ104 board is replaced in a state allowing NO backup, follow the procedure below. [ Replacement procedure of EZJ104 board in a state allowing NO back up] (1) Turn off the power. (2) Replace the EZJ104 board.(Do not replace the EZJ93 board simultaneously.) (3) Before turning on the power, insert the system data memory card into the slot of EZJ104 board.
  • Page 69 [ EZJ104 board external views ] Connector for touch panel Fixing screw Fixing screw (4 locations) (4 locations) Memory card slot REG1 Connector for LCD harness Connector for inverter board Connector for EZJ97 board Fixing screw (4 locations) Fixing screw (4 locations) Connector for Connector for...
  • Page 70 3.2.2 Battery [Function] - The back up battery for the RTC (Calendar IC) on the EZJ104 board [Note at the replacement] - Before replacing the battery, be sure to turn off the power. With respect to the setting - Be sure to insert it into CN4. of date and time, refer to - After replacing the battery, set the date and time.

  • Page 71: Control Panel

    3.2.4 Control panel [Function] - A LCD, a power supply for the backlight, a touch panel and an EZJ97 board (LED board) are included in the control panel. With respect to the setting [Note at the replacement] the calibrating touch - Before the replacement, be sure to turn off the power.
  • Page 72 3.3 Engine part - With regard to the electric parts/control board of the engine part, the functional outline, the setting of the switch, the list of the check point/LED and the note at the replacement are described. 3.3.1 EZJ93 board (MPU board) [Function] - Performs printing control, circulation system control and nozzle control (charge voltage, excitation voltage, auto phase and so on).
  • Page 73 (6) It is displayed, "Wait for a minute", and progresses the indicator bar. When the specific data stored on EZJ93 board are different from the data stored on the EZJ104 board, following message screen “Board Replacement Procedure” is displayed. Select “EZJ93” on the message. (When the specific data stored on EZJ93 board and on EZJ104 board are same, this message is not displayed.) ＝＝＝＝＝...
  • Page 74 In the case where the EZJ93 board is replaced in a state allowing NO backup, follow the procedure below. [ Replacement procedure of EZJ93 board in a state allowing NO back up] (1) Turn off the power. (2) Replace the EZJ93 board. (Do not replace the EZJ104 board simultaneously.) (3) Before turning on the power, insert the system data memory card into the slot of EZJ104 board.
  • Page 75 [ EZJ93 board external views ] Five studs for fixing Five studs for fixing EZJ94 EZJ94 Five studs for fixing EZJ94 One setscrew Five studs for fixing Five studs for fixing EZJ94 EZJ94 3-12...
  • Page 76 - Control of nozzle (charging voltage control, excitation voltage, APH detection, PTC control and the like) is performed. - The EZJ94 board is used for the model PXR-D/P, and the EZJ94DH is used for the model PXR-H. (The red check mark and the blue label are put on the EZJ94DH board for identification.)
  • Page 77 [Difference between the EZJ94 board and the EZJ94DH board] - The red check mark and the blue label are put on the EZJ94DH board for identification. - The EZJ94 board and the EZJ94DH board are different in resistance of the R125. How to identify the EZJ94 board and the EZJ94DH board The red check mark and the blue External view of R125...
  • Page 78 3.3.3 EZJ95 board (I/O board) [Function] With respect to the wiring, - The I/F signal with the conveyer is connected. refer to Instruction manual “1.5 Connection of Output signal: ready, fault, warning, printing-in-progress/printing-completed, on-line signals”. Input signal: print target detector, printing stop, reverse direction printing, encoder (for product speed matching) [Setting of switch/check point/LED display and the like] - Setting of switch...
  • Page 79 - When using the external dedicated power supply: Irrespective of the output form of the rotary encoder, set as shown in the following table depending on the power supply voltage. Power supply voltage SW2 - 1 SW2 - 2 SW2 - 3 SW2 - 4 DC12V DC24V...
  • Page 80 [Circuit diagram of EZJ95] 3-17...
  • Page 81 3.3.4 EZJ99 board (Optional board) [Function] Serves as an optional signal interface for the host equipment. [Note at the setting] - Confirm the included parts, and set it in accordance with setting procedure. [Included parts] Hexagonal spacer Resin spacer (2 pieces) (2 pieces) Ferrite core Screw...
  • Page 82 (4) Set the two hexagonal spacers to board base, and the two plastic spacers to EZJ95 board. Board base Hexagonal spacer Plastic spacer EZJ95 board (5) Plug the EZJ99 board into connector CN1 on the EZJ93 board, and then attach the screws to the two hexagonal screws and tighten them.
  • Page 83 (8) Turn the power on. (9) Before software options are added and the EZJ99 board is attached to the IJP, set the As for the software software option. option setup, see “2.14 Software option setup”. *) This procedure is not necessary when the software options have been installed and only the EZJ99 is replaced.
  • Page 84 [Setting of switch] ・Setting of switch [SW1] Standard Description setting Bit 1 Sets host communications (Set to ON) Bit 2 Sets host communications (Set to OFF) Bit 3 Reserve (Set to OFF) Bit 4 Reserve (Set to OFF) Bit 5 Sets the polarity of strobe signal transmitted from host.
  • Page 85 3.3.5 EZJ105 board [Function] - This is dedicated control board for the high speed model (model PXR-H) - Control of the liquid levels (change of the level 1, 2 and 3) is performed. [Note at the replacement] - Be sure to turn off the power before replacing the EZJ105 board.
  • Page 86 3.3.6 Multiple Power Supply DC output for [Function] CN9 of EZJ93 - AC input：AC100∼240V （50／60Hｚ） DC output：＋5V ＋12V ＋24V [Note at the replacement] - At the replacement, be sure to turn off the power. Fixing screw Fixing screw (4 locations) (4 locations) Fixing screw Fixing screw...
  • Page 87 3.3.8 Fan Replacement Procedure 1 Turn off the power supply. 2 Open the operation panel and remove the fixing screws (2 locations). Remove the electrical component cover. Fixing screw (2 locations) Electrical component cover Operation panel 3 Remove the fixing screw of the board base (2 locations) and the connector of the fan.
  • Page 88 5 Remove the nuts (4 positions) and then remove the filter cover, exhaust filter, fixing screws (4 positions) and the fan. [Configuration of the model PXR-D and the model PXR-H] Rear cover Exhaust filter Spacer Filter cover Exhaust cover Fan guard...
  • Page 89 2 Remove the exhaust cover. Exhaust cover Fixing screw (4 locations) 3 Remove the fixing nuts (4 locations), the filter cover and the exhaust filter. [Configuration of the model PXR-D and the model PXR-H] Exhaust Filter Filter cover *Red mark...
  • Page 90 [Configuration of the model PXR-P] Exhaust Filter Filter cover Fixing screw Wire mesh filter (4 pieces) * Red mark Exhaust cover Rear cover 4 Install a new Exhaust Filter by reversing the above procedure. (The red mark side is the filter cover side.) Caution There are a front side and a backside of the exhaust filter.
  • Page 91 4. Maintenance of Circulation System (PXR-D, PXR-H) 4.1 General Structure of Circulation System 4.1.1 The general structure of the circulation system is shown in the following figure. Using an open/close type door (unit door) as a partition, the system is roughly divided into an ink circulating area (the front side of the equipment) and a driving part area (the rear side of the equipment).
  • Page 92 4.1.2 Approach to the parts on the front side of the equipment 1 Move the ink reservoir and the makeup ink reservoir to a safe place after removing the connection tube block. Connection tube block Connection tube block Ink reservoir Makeup ink Holder reservoir...
  • Page 93 4.1.3 Approach to the parts on the rear side of the equipment 1 Perform the operations of 1 to 3 in “4.1.2 Approach to the parts on the front side of the equipment”. 2 Remove the fixing screws (2 pieces) of the unit door and open the unit door.
  • Page 94 Exhaust tube White Black (short) Recovery tube Black (long) *) The wire connecting part of the liquid level sensor for the PXR-H is different from PXR-D. There are five positions of the wire connecting part screws. Bind White Overflow White...
  • Page 95 5 Remove the fixing screws (4 positions) of the main ink tank and take out the main tank. "Caution" Put wiping paper under the main ink tank to provide for an ink drip. Main ink tank Fixing screws Fixing screws 6 Clean the portion stained with ink and then install the main ink tank by reversing the above procedure.
  • Page 96 4.3 Pressure Relief Valve Replacement Procedure 1 Perform “Pressure relief”. 2 Perform “4.1.2 Approach to the parts on the front side of the equipment”. 3 Remove the fixing screws (2 positions) of the pressure relief valve and the tube joint. The pressure relief valve can be removed. "Caution"...
  • Page 97 4.4 Joint Structure and Handling 4.4.1 “ICU joint” structure and handling When removing the tube during the maintenance work, loosen the tube lock beforehand. The ICU joint should be removed only at occurrence of damage. ICU joint Procedure for installing the tube Tube lock 1 Pass the tube through the tube lock.
  • Page 98 4.4.2 “Filter joint” structure and handling Usually, for disconnecting the tube, loosen the filter joint nut and remove the whole without disassembling the filter. Disassembling should be performed only at occurrence of damage. Disassembling the filter joint 1 Loosen the filter joint nut and remove the whole from the mounting part. 2 Fix the end of the filter joint and loosen the tube block.
  • Page 99 4.5 Pump Unit Replacement Procedure 1 Perform “Ink drainage” to “Pressure relief”. 2 Turn off the power supply. 3 Perform “4.1.3 Approach to the parts on the rear side of the equipment”. 4 Remove the wires from the clamps (5 positions) that fix them. Connector for the motor 5 Remove the connector that connects the motor.
  • Page 100 Insert the screwdriver from this slit. Unit door *) This figure is for the Fixing screw PXR-D. The main ink tank (8 positions) is not attached for the PXR-P. Hold this portion. 8 Clean the portion stained with ink and make sure that the O-rings (4 positions) are securely mounted in the concave parts of the lower-side circulation unit.
  • Page 101 4.6 Solenoid Valves Replacement Procedure "Caution " : MV8 (Cleaning valve) is deferent from other valves. Check the color of seal below. MV8 (Cleaning valve) Other valves Orange (Serial No.) White (Serial No.) 1 Perform the following pre-replacement operation for each solenoid valve that you are to replace.
  • Page 102 5 Remove the fixing screws (2 positions) of the solenoid valve. "Caution": Put wiping paper under the solenoid valve to provide for an ink drip. Fixing screw 6 Clean the portion stained with ink and then install a solenoid valve by reversing the above procedure.
  • Page 103 4.7 Pressure Sensor Replacement Procedure 1 Perform “Nozzle Backwash”. (At the end of automatic stop without pouring the makeup ink to the gutter) 2 Turn off the power supply. 3 Perform “4.1.3 Approach to the parts on the rear side of the equipment”. (The reason is that the connector is provided on the rear side of the equipment.) 4 Remove the connector of the pressure sensor.
  • Page 104 Exhaust tube White Black (short) Black (long) Main ink tank *) The wire connecting part of the liquid level sensor for the PXR-H is different from PXR-D. There are five positions of the wire connecting part screws. Bind White Overflow...
  • Page 105 5 Remove the plumbing tubes (11 positions) that are connected to the circulation unit. "Caution" Take care about an ink drip. 6 Remove the clamps (5 positions) that fix the wires. 7 Remove the connectors of the electric parts (motor, solenoid valves, pressure sensor, level sensor and viscometer) 4-15...
  • Page 106 8 Remove the fixing screws at 4 positions that fix the circulation unit. The circulation unit can be removed. Fixing screw Fixing screw 9 Clean the portion stained with ink and then install the main ink tank by reversing the above procedure. 10 Perform “Makeup ink refill”...
  • Page 107 4.9 Troubleshooting when Fault Occurs in Viscometer Perform the following when abnormality occurs in the viscometer: Note: If abnormality occurred when “Viscometer Calibration” was executed during installation, no “coefficient” can be determined. If “coefficient” has not been determined, the IJP will automatically switch to the dot count system and operate.
  • Page 108 (D) Pull out the viscometer IN-side tube (mark G) from viscometer. (The ink in tube will slightly drip: Fit wiping paper to the end of tube. No reverse flow of ink will occur inside the viscometer.) (E) Immediately lift the end of removed tube higher than the level of liquid in main container, and then continue this for at least 10 seconds (to return the ink in tube to the main container).
  • Page 109 Attention to the model PXR-H There is a check mark on the label of the model PXR-H. When replacing PXR-H viscometer, be sure to use the viscometer with label on which check mark is applied to the corresponding coefficient. And once replaced, corresponding coefficient must be input from the screen.
  • Page 110 4.9.2 Disassembling and washing viscometer (A) Remove the three setscrews from viscometer cover, and then remove the cover. (B) Place the viscometer upside down while fitting wiping paper to the plunger, and then remove the plunger. (Let all of the ink remaining in viscometer seep out to the wiping paper.) (C) Make sure that no ink remains in viscometer, and then pull out the cylinder.
  • Page 111 4.9.3 Viscometer assembly procedure (A) Replace the cylinder, and then insert the plunger. Handle the plunger with tweezers making sure that no dust adheres to the surface of plunger. (B) Set the collar to cylinder, taking care with its orientation (with the convex up). (C) Make sure that an O-ring is set in the viscometer cover, and then assemble the cover into the viscometer case.
  • Page 112 4.9.5 Proximity sensor replacement procedure Replace the single proximity sensor when it is faulty. Caution: Perform replacement only after turning power off. Do not spill the intensifier over the proximity sensor: Doing so could cause a fault. (A) Remove the viscometer from circulation unit, referring to item 4.9.1. (B) Remove the cover setscrew, and then take out the proximity sensor.
  • Page 113 4.10 Print Head Replacement Procedure 1 Turn off the power supply. 2 Open the operation panel and remove the fixing screws (2 positions). Remove the board cover. Fixing screw Board cover Operation panel 3 Remove the print head and the connectors (6 positions). Excitation signal wire High-voltage wire EZJ94 board: CN5...
  • Page 114 5 Remove the removed tube from the fixing clamp. 6 Perform “4.1.3 Approach to the parts on the rear side of the equipment” and open the unit door. 7 Remove the wires removed in 3 from the fixing clamps. 8 Pull out the tube removed in 4 from the rear side of the equipment. 9 Remove the fixing screws (4 positions) of the print head on the rear side of the equipment.
  • Page 115 4.11 Troubleshooting Procedure for the Circulation System Perform “(1) Fault locating and repairing method” for each trouble symptom. For the items marked * in “Probable Cause”, perform “(2) Locating method for the control system/circulation system” to make sure that the control system is normal, and then perform the repair work.
  • Page 116 Check method Symptom Probable cause Repairing method The supply pump The same as “Ink does not jet". malfunctions. When “Open” is Replace or repair the executed on the solenoid valve Solenoid (MV1). Refer to * MV1 Valve/Pump Test “4.12 Repairing malfunctions.
  • Page 117 Symptom Probable cause Check method Repairing method The collection pump The same as “The supply pump malfunctions ". malfunctions. When “Open” is Replace or repair the executed on the solenoid valve (MV3). The solenoid * MV3 Solenoid Refer to “4.12 valve Valve/Pump Test Repairing method...
  • Page 118 Symptom Probable cause Check method Repairing method The supply pump The same as “Ink does not jet. malfunctions. When “Open” is Replace or repair the executed on the solenoid valve The solenoid Solenoid (MV6). Refer to Charging or * MV6 valve Valve/Pump Test “4.12 Repairing...
  • Page 119 (2) Fault locating method for the control system/circulation system (a) When the pump motor and all the solenoid valves are not operated, the multi- power supply (24 V system) is abnormal. (b) If the electric parts (pump motor, solenoid valves, and pressure sensor) are not operated in any case other than the above, make the following checks first.
  • Page 120 4.12 Repairing Method When the Circulation Route Is Dry or Sticks 4.12.1 Cleaning method for the solenoid valve 1 Remove the sticking solenoid valve. (Refer to “4.6 Solenoid Valves Replacement Procedure) 2 Connect the connector of the target solenoid valve. 3 Inject the makeup ink with the flush bottle from the holes shown in the following figure until it overflows and leave for about 10 minutes.
  • Page 121 4.12.3 Repairing method for the makeup ink pump 1 Remove the tube connecting block of the makeup ink reservoir and connect the cleaning bottle. (You can apply pressure more easily by putting a tube between the pipe and the cleaning bottle.) Cleaning bottle Pipe Pipe[N]...
  • Page 122 5 Maintenance of Circulation System (PXR-P) 5.1 General Structure of Circulation System 5.1.1 The general structure of the circulation system is shown in the following figure. Using an open/close type door (unit door) as a partition, the system is roughly divided into an ink circulating area (the front side of the equipment) and a driving part area (the rear side of the equipment).
  • Page 123 5.1.2 Approach to the parts on the front side of the equipment 1 Remove the ink reservoir, makeup ink reservoir, main ink tank and ink filter from each holder and put them in safe place. Makeup ink reservoir reservoir Ink filter Main ink tank 2 Remove the two knurled screws fixing reservoir holder, the tube from tube clamp, and then remove the reservoir holder.
  • Page 124 5.1.3 Approach to the parts on the rear side of the equipment 1 Perform the operations of 1 to 3 in “5.1.2 Approach to the parts on the front side of the equipment”. 2 Remove the fixing screws (2 pieces) of the unit door and open the unit door.
  • Page 125 5.2 Main Ink Tank and Ink Reservoir Replacement Procedure 5.2.1 Main Ink Tank Replacement Procedure 1 Turn the power off. 2 Remove the main ink tank from the holder. 3 Remove the three wire connecting part screws of the liquid level sensor on the connection block.
  • Page 126 7 Attach the new main ink tank by the reverse procedure to above. <Note> (1) For rotor removed in step 6, carefully wipe off ink and clean using paper wiper soaked in solvent, etc. Be sure to replace in the tank. (2) After setting rotor, securely tighten the cap.
  • Page 127 5.2.2 Ink reservoir replacement procedure 1 Turn the power off. 2 Remove the ink reservoir from the holder. 3 Remove the cap and dispose of ink. Note: Since there is a rotor inside the reservoir, pick up rotor using stirring rod provided before disposing of ink.
  • Page 128 5.3 Pressure Relief Valve Replacement Procedure The procedure is the same as for the model PXR-D. See the “4.3 Pressure Relief Valve Replacement Procedure”. 5.4 Joint Structure and Handling 5.4.1 “ICU joint” structure and handling The procedure is the same as for the model PXR-D.
  • Page 129 5.4.3 Air joint structure and handling - Structure diagram of joint Lock claw Joint Open ring Guide ring Flexible sleeve - Tube connection method * Shut off primary side air before starting work. Insert the air tube until it reaches the end. Note: (1) If the tube is not inserted completely, air leakage may result.
  • Page 130 5.5 Pump Unit Replacement Procedure Pump unit is the same as for PXR-D type. See the “4.5 Pump Unit Replacement Procedure”. 5.6 Solenoid Valves Replacement Procedure 5.6.1. Solenoid valve for circulation unit Circulation unit is the same as for PXR-D type.
  • Page 131 6 Remove the solenoid valve from the solenoid valve fixing plate. O-ring4.7 Fixing screw (M4x16) O-ringS16 Solenoid valve (MV11) Harness Harness Solenoid valve (MV12) Fixing screw (M4x16) Solenoid valve fixing plate 7 Install the new solenoid valve by the reverse procedure to above. Note: (1) Securely attach the O-ring to the groove of the solenoid valve: Carefully attach so that O-ring does not come off or get caught when...
  • Page 132 5.7 Replacement procedures for pressure sensor and pressure switch for air 5.7.1 Replacement procedures for pressure Pressure sensor is the same as for PX-D type. See the “4.7 Pressure Sensor Replacement procedure”. 5.7.2 Replacement procedure for pressure switch for air 1 Turn the power off and shut off primary side air before starting work.
  • Page 133 6 Install the new pressure switch by the reverse procedure to above. Pressure switch Adjustment screw Note: (1) When handling the switch, be careful not to drop it or allow any impact: It could be broken. (2) Do not touch the adjustment screw of pressure switch. (It was adjusted to the set pressure when shipped from factory.) 5-12...
  • Page 134 5.8 Circulation Unit Replacement Procedure 1 Perform “Ink drainage” and then “Pressure relief”. 2 Turn off the power supply. 3 Perform “5.1.3 Approach to the parts on the rear side of the equipment”. 4 Remove the wire connecting part screws (13 positions) of the liquid level sensor in the main ink tank and the exhaust tube.
  • Page 135 Remove the connectors of the electric parts (motor, solenoid valves, pressure sensor, and viscometer) Connector of pressure sensor and viscometer Connector of motor Connector of solenoid valves Remove the fixing screws at 4 positions that fix the circulation unit. The circulation unit can be removed Fixing screw Fixing screw Clean the portion stained with ink and then install the main ink tank by...
  • Page 136 With check mark for the model PXR-P Non Choke pin in PXＲ-P The viscometer for PXR-P is the same as for PXR-D except the check mark of label and non choke pin. When replacing PXR-P viscometer, be sure to use the viscometer with label on which check mark is applied to the corresponding coefficient.
  • Page 137 5.10 Stirrer replacement procedure 1 Turn the power off and shut off primary side air before starting work. 2 Perform the procedure of “5.1.2 Approach to the parts on the front side of the equipment”. 3 Remove all air tubes connected to stirrer. Refer to “5.4.3 Air joint structure and handling”...
  • Page 138 6 Install a new stirrer by the reverse procedure to above. 7 Turn the power on and supply air to primary side, and confirm that stirrer rotates. See the “7.18 Confirming rotation of Rotor” in the instruction manual of PXR-P. 5-17...
  • Page 139 5.11 Print Head Replacement Procedure Print head replacement procedure is almost the same as for model PXR-D. See the “4.10 Print head replacement procedure”. Different points from the model PXR-D Note that position of pipe connection to print head is different from PX-D type.
  • Page 140 5.14 Repairing method for each solenoid valve and pump using solvent pump Use the solvent pump, after connecting ink tube “RR” to each joint, and turn ON each solenoid valve and pump using “Solenoid valve/pump test” screen. By doing so, sticking of ink inside each path can be cleared.
  • Page 141 Print head-related maintenance 6.1 Outline structure of print head and how to remove each cover 1. Outline structure of print head (1) The outline structure of the print head is shown in the following figure. Two kinds of bases (head base and gutter base) are joined to the head cable by screws. The sealing valve, the heating unit and the deflecting base are disposed on the head base.
  • Page 142 6.2 Nozzles Replacement Procedure (appendix: nozzle drive conditions) (1) Depressurize the printer. (2) Unscrew the video signal wire setscrews and the charged electrode setscrews, and remove the charged electrode. (3) Remove the nozzle setscrew (2 locations), the nozzle IN joint presser foot (sealing valve side) and the excitation connector.
  • Page 143 (6) Attach a new nozzle and fix the nozzle setscrew, (2 locations), the nozzle IN joint presser foot (sealing valve side), the nozzle OUT joint and the excitation connector. “Caution” (A) Confirm that a filter is present in the terminal area (inside the sealing valve) of the nozzle IN joint.
  • Page 144 Appendix: nozzle drive conditions This table shows the nozzle drive conditions for each ink of the PXR type IJP together. When performing the reset or the like of the kinds of ink, be careful because the excitation frequency and the standard pressure vary depending on the ink.
  • Page 145 0.105 28.1 0 - 35 0.105 28.1 0 - 35 0.105 28.1 0 - 35 0.105 28.1 0 - 35 (4) 55 µm nozzle (PXR-H) Standard pressure Excitation Temperature Remarks (MPa) frequency range (ºC) (kHz) 0.290 95.2 0 - 40 0.270...
  • Page 146 6.3 Deflecting base Replacement Procedure When the LED protection glass is damaged or when the deflection base is extremely dirty and cannot be rid of the abnormality even after cleaning, it is necessary to replace the deflection base. Perform it by using the following procedure. (1) Depressurize the printer.
  • Page 147 (6) Perform the assembly in inverse procedure. Caution (A) When mounting the rear cover and the deflection base, pay attention to pinching of the lead and gasket. (B) here are two kinds of length of the M2 screw. It may cause a failure if mistakenly mounted .
  • Page 148 b) Fill it up with the silicone sufficiently as shown below. The metallic portion of the Silicone Filling Portion high-voltage line terminal portion (Hatching Portion) should be completely hidden. Rib of the base plate Fill it up to approximately the same height as the rib of the base plate so that the screw head will not be out.
  • Page 149 Knack of infusing the silicone When infusing the silicone into the dispenser, perform it as shown below (to purge air). Cylinder Put the silicone in Metallic needle Place the needle on the upside Cylinder Wait until the silicone comes down to the piston Downside is NG Piston...
  • Page 150 6.5 Sealing valve (MV9) Replacement Procedure (1) Depressurize the printer. (2) Remove the head cover and the heater cover. (3) Remove the head base rear cover and disassemble the connector of the sealing valve. (4) Unloosen the nozzle IN joint presser foot and the sealing valve presser foot. (A) A filter is put in the terminal area (inside the sealing valve) of the nozzle IN joint.
  • Page 151 (6) Prepare a new sealing valve and put O-rings into the respective holes of the joint part. φ (A) Put the O-ring P2.2 (hole diameter: about 2.1) into the hole on the heating unit φ side and put the O-ring P1.7 (hole diameter: about 1.6) into the hole on the makeup ink IN side.
  • Page 152 6.6 Heating unit Replacement Procedure When “Ink Heating Too High”, “Heating Unit Sensor Fault” and “Ink Heating Current Fault” occur, the heating unit must be replaced. (1) Perform depressure. (2) Remove all of the covers. (3) Remove the connector (4P, white) of the heating unit. Heating unit connector (4) Remove the sealing valve.
  • Page 153 (9) Connect the ink-furnishing tube(E) and fasten it by the heating unit joint presser foot. “Caution” (A) Engage the slit of the heating unit joint presser foot as shown in the following figure. (B) After dipping the O-ring in makeup ink, connect the ink-furnishing tube. (Damage prevention of O-ring) Sealing valve IN joint Sealing valve packing...
  • Page 154 6.8 Head base Replacement Procedure When damaging the head base, the head base must be replaced. Perform it by the following procedure. (1) Remove all of the covers described in the item 6.1. (2) Remove the nozzle described in the item 6.2. (3) Remove the deflecting base described in the item 6.3.
  • Page 155 (12) Attach the heater, the heater spacer, the deflecting base, the heater spacer packing, the heater packing and the deflecting base packing. Heater Heater spacer Deflecting base Heater Heater spacer packing Heater packing Deflecting base packing (13) Dispose the APH tube part group on the head base and connect it to the recovery tube.
  • Page 156 16) Screw the video signal wire and the high voltage wire. After screwing the high voltage wire, coat it with silicon. With respect to the coating method, refer to the item 6.3. (17) Assemble each connector and close the base rear cover. (18) Attach the gutter base, the sealing valve and the nozzle.
  • Page 157 (3) Remove the four setscrews and unplug connector CN1 of lead wires. Screw (for APH sensor) Screws (for securing) Screw (for APH sensor) EZJ98 board Connector CN1 Among the four setscrews (M2x5), two are for securing the EZJ98 board, the other two, for securing the APH sensor and EZJ98 board.
  • Page 158 Viscosity Readings Out of Range 7.4.10 High Ink Concentration 7.4.11 Low Ink Concentration 7.4.12 Excitation V-ref. Review 7.4.13 High Air Pressure (PXR-P only) Faults – No on-screen indications 7.5.1 Chipped print (lower dots) 7.5.2 Chipped print (upper dots) 7.5.3 Varying character height 7.5.4 Increased character distortion 7.5.5...
  • Page 159 Faults – No on-screen indications 7.5.1 Chipped print (lower dots) 7.5.2 Chipped print (upper dots) 7.5.3 Varying character height 7.5.4 Increased character distortion 7.5.5 Disordered characters 7.5.6 Ink leakage/blowout 7.5.7 Printing initiation failure in ready state 7.5.8 No ink ejection from nozzle 7.5.9 Freeze of display Miscellaneous...

  • Page 160: Ink Low

    7.2 Faults – Ink-stop type 7.2.1 Ink Low Ink Low Open the maintenance cover. Uncap the ink reservoir and add ink. Is there ink in the ink reservoir? Is the fault cleared by pressing the Clear key? ・Turn OFF the power. ・Unscrew and pull out the sensor section.
  • Page 161 7.2.2 Main Ink Tank Too Full Main Ink Tank Too Fill Is the initial-level sensor Open the maintenance cover. Check the initial- Is the ink main tank full Has the Main Ink level sensor Tank Too Fill fault of ink? connection again and frequently occurred? correct it if necessary.
  • Page 162 7.2.3 Makeup Ink Low Makeup ink Open the maintenance cover. Is the makeup ink Reservoir charged with the makeup ink? Uncap the makeup ink reservoir and add the makeup ink. Turn OFF the power. Can the abnormality be cleared by pressing the Clear key? Is the sensor connector disconnected?
  • Page 163 7.2.4 Replenishment Time-out Replenishment Time-out Is the ink refilling function being executed? Press the Clear key to clear the fault and execute the ink Press the Reset key to clear the refilling function again. fault and restart the printer. Does the “Replenishment Time-out”...
  • Page 164 7.2.5 Ink Drop Charge Too Low Ink Drop Charge Too Low Is the nozzle clogged or the ink stream bent? Pour a cleaning solution over the orifice plate surface to clean it, then allow it to thoroughly dry. If the problem is Does the charge not fixed: electrode communicate...
  • Page 165 7.2.6 No Ink Drop Charge No Ink Drop Charge Is the ink stream See under “No ink being ejected from ejection from nozzle.” the nozzle? See under “Ink Drop Is the nozzle clogged or Charge Too Low”. the ink stream bent? See under “Ink Drop Is the gutter section Charge Too Low”.
  • Page 166 7.2.7 Noise Fault M/S Noise Fault M/S Is the IJ printer connected to its dedicated ground? Properly establish the ground connection. Are the nozzle head and IJ printer main body insulated from the other equipment? Ensure that the print head and printer main body are not in contact with the other equipment.
  • Page 167 7.2.8 Deflection Voltage Leakage Deflection Voltage Leakage Does the ink stream enter the center of the Is the ink or makeup ink gutter? deposited on the deflection electrodes and their surrounding sections? Adjust the ink stream position. Is any foreign matter deposited between the Thoroughly remove deflection electrodes?
  • Page 168 Does the IJ printer become ready when you start it by pressing the Startup key with the high-voltage power supply unit output connector disconnected? Replace the high-voltage power supply unit. Resume the Is the alarm issued? operation. Replace the EZJ94 board. Resume the Is the alarm issued? operation.
  • Page 169 7.2.9 Deflection Voltage Fault Deflection Voltage Fault Is the EZJ94 board CN6 connector or high-voltage power supply CN1 connector disconnected? Disconnect the connector and then Connect the connector. reconnect it. Does the printer become ready for printing? Replace the high-voltage power supply unit.
  • Page 170 7.2.10 DC Power Supply Fan Fault DC Power Supply Fan Fault Is the EZJ93 CN9 connector or Is the multiple power supply fan multiple power supply CN4 running? connector disconnected? Connect the connector. Replace the multiple power supply. Is the problem fixed? Replace the EZJ93 board.
  • Page 171 7.2.11 Charge Voltage Fault Charge Voltage Fault Remove the print head cover. Pour the makeup ink over the charge electrode area to clean it. ・Allow the print head surface to adequately dry. ・Clear the fault. ・Restart the IJ printer. Does the printer become ready? Replace the EZJ94 board.
  • Page 172 7.2.12 Internal Communication Error S Internal Communication Error S Does the fault recur upon power-on reset? Replace the EZJ93 board. Resume the operation. 7.2.13 F Memory Fault M/S/9 F Memory F Memory Fault M/S Fault 9 Does the fault recur Does the fault recur upon power-on reset? when the EZJ99 board...
  • Page 173 7.2.14 Hardware Error C Hardware Error C Is the CN2 connection on the EZJ104 board in poor contact? Normality is restored when the connector is disconnected Replace the EZJ104 board. and then reconnected. Resume the operation. 7-16...
  • Page 174 7.2.15 Ink Heating Too High Ink Heating Too High ・Clear the fault. ・Restart the IJ printer. See Section “6.5.8, No ink ejection Does the ink jet out? from nozzle.” Disconnect EZJ94 board CN7 connector and reconnect it. ・Clear the fault. ・From the maintenance screen, place the heating unit in the operating mode.
  • Page 175 7.2.16 Heating Unit Sensor Fault Heating Unit Sensor Fault Disconnect the EZJ94 board CN7 connector and reconnect it. Does the fault recur? Replace the heating unit. ・Clear the fault. ・ From the maintenance screen, place the heating unit in the operating mode.
  • Page 176 7.2.17 Ink Heating Current Fault Ink Heating Current Fault Is the PTC resistance measured (between the EZJ94 board TP3 and TP15) lower than 23 Ω? Replace the heating unit. ・Clear the fault. ・From the maintenance screen, place the heating unit in the operating mode. ・Restart the IJ printer.
  • Page 177 7.2.18 Ambient Temperature Sensor Fault Ambient Temperature Sensor Fault Disconnect the EZJ94 board CN7 connector and reconnect it. Does the fault recur? Replace the print head. Does the fault recur? Resume the Replace the EZJ93 board. operation. 7.2.19 Viscometer Temperature Sensor Fault Viscometer Temperature Sensor Fault Pull out and insert the...
  • Page 178 7.2.20 Pump Motor Fault Pump Motor Fault Pull out and insert the connector CN2 of the EZJ93 board and the pump motor connector. Does the fault recur? Replace the pump motor. Does the fault recur? Resume the Replace the EZJ93 board. operation 7.2.21 Cooling Fan Fault Cooling Fan Fault...
  • Page 179 7.3 Faults – Print-stop type 7.3.1 Print Overlap Fault Print Overlap Fault Is the next printing sequence timed before completion of the current one? Is the time interval between the end of a printing operation and the beginning of the next printing operation less than 10 Set the time interval between the end of a printing operation and...

  • Page 180: Cover Open

    7.3.2 Cover Open Cover Open Is the print head cover removed? Properly install the print head cover. Is the print head cover completely closed? Completely close the print head cover. Is the magnet at the end of the cover damaged or missing? Properly install the magnet.
  • Page 181 7.3.3 Improper Sensor Position Improper Sensor Position Is the repeat printing function required? Is there an excessive clearance between the print head and print target detector? Is the “Repeat count” is set to “0000” from the print Decrease the specifications screen? clearance between the print head and print target...
  • Page 182 7.3.4 Target Sensor Fault Target Sensor Fault Is the target sensor fault function required? From the printing specifications screen, select a “Target sensor timer” setting of “0000”. Is the “Sensor out timer” setting is greater than necessary for the sensor normal ON time? Select a setting that is greater than necessary.
  • Page 183 7.3.5 Target Spacing Too Close Target Spacing Too Close Are there more than four workpieces (print targets) between the sensor and print head? Decrease the clearance between the sensor and print head and reduce the number of workpieces between the sensor and print head to four or less.
  • Page 184 7.3.7 Blank Print Items Blank Print Items Does any print item consisting of Blank characters alone exist? Adjust the print contents so that print items consisting of Blank characters only no Does any item of the longer exist. EAN-13 format be inputted less than 10 characters? Input just 10 characters in the...
  • Page 185 7.3.9 Substitution Character Undefined Substitution Character Undefined Is character substitution setup performed for the calendar character Year ? Open the year substitution rule setup screen and enter a substitution character in an undefined field. Resume the operation. 7-28...
  • Page 186 7.3.10 Ink Drop Charge Too High Ink Drop Charge Too High Clean the gutter section and its surrounding area with a Is the gutter cleaning solution. When using carbon type ink like JP-K31A, section soiled? refer “Instruction manual 1.2.3 Print head cleaning (4). Does the IJ printer become ready for printing when you...
  • Page 187 Is any vibration or shock applied to the IJ printer, print head, or print head cable during operation or startup? Eliminate the cause of vibration or shock. Does the IJ printer become ready for printing when you eject ink and start the IJ printer with the high- voltage power supply unit high-voltage output...
  • Page 188 7.3.11 Internal Communication Error C / M Internal Communication Error C/M Is the EZJ93 board CN3 connector disconnected or in poor contact? Is the EZJ104 board CN2 connector disconnected or in poor contact? Normality is restored when the connector is disconnected and then reconnected.
  • Page 189 7.4 Warning conditions (printing continuously performed) 7.4.1 Ink Shelf Life Exceeded Ink Shelf Life Exceeded Has the “Ink alarm time” preselected from the operation management screen elapsed since last ink replacement? Was the “Ink operating time” set to 0 from the operation management screen when the ink was replaced last?
  • Page 190 7.4.2 Operating Temperature Too High / Too Low Operating temperature Too High / Too Low Properly set the operating Is the operating temperature upper-/lower-limit value temperature upper-/lower-limit erroneously set? value. Use an air-conditioner or the like Does the IJ printer to ensure that the IJ printer temperature indication agree ambient temperature is within...
  • Page 191 7.4.3 Ink Heating Too Low Ink Heating Too Low Disconnect the EZJ94 board CN7 connector and reconnect it. Is the warning issued again? Replace the heating unit. Is the warning issued again? Replace the EZJ94 board. Is the warning issued again? Resume the Replace the EZJ93 board.
  • Page 192 7.4.4 Battery Low Battery Low Is the EZJ104 board CN4 connector disconnected or in poor contact? Normality is restored when the connector is disconnected Replace the battery. and then reconnected. Resume the operation. 7.4.5 Product Speed Matching Error Product Speed Matching Error The frequency of the encoder signal is exceeding the printing capability of the IJ printer.
  • Page 193 7.4.6 Ink Pressure Low Ink Pressure Low Check the indicated value and standard value of the ink pressure on the Operation management screen. Is it below the lower limit? (Indicated value < standard value x 0.90) Can the pressure be adjusted by the pressure reducing valve?
  • Page 194 7.4.7 Ink Pressure High Ink Pressure High Check the indicated value and standard value of the ink pressure on the Operation management screen. Is it above the upper limit? (Indicated value > standard value x 1.10) Can the pressure be adjusted by the pressure reducing valve? Replace the pressure reducing...
  • Page 195 7.4.8 Viscosity Reading Instability Viscometer uneven abnormality during installation Viscosity Reading (calibration) Instability * Appears in processing status approx. 12 minutes after calibration starts Perform the viscometer operation test on the Re-execute viscometer Circulation system control calibration (2-3 times). screen. Does calibration finish normally? Is it normally measured?
  • Page 196 7.4.9 Viscosity Readings Out of Range Viscosity Reading Out of Range Perform the viscometer operation test on the Circulation system control screen.。 Is it normally measured? Replace the ink. Is it normally measured? Replace the proximity sensor. Is it normally measured? Disassemble and clean the viscometer.
  • Page 197 7.4.10 High Ink Concentration High Ink Concentration Check the printing quality. Is the printing quality normal? Replace the ink. Operate the printer for an hour or so, and check the ink viscosity. Has the viscosity increased? Replace the ink in the ink reservoir. Resume the operation.
  • Page 198 7.4.12 Excitation V-ref. Review Excitation V-ref. Review Readjust the excitation setup. Resume the operation. 7.4.13 High Air Pressure High Air Pressure Confirm pressure scale of filter regulator. Is it within adjustment Shut off pressure supply. range? (0.10 – 0.11MPa) Can alarm be reset? Adjust pressure.
  • Page 199 7.5 Faults - No on-screen indications 7.5.1 Chipped print (lower dots) Chipped print Direction of Is the ink stream deflection positioned at the center of the gutter? Adjust the ink stream Missing dots position so that the ink Is the ink pressure stream is centered with higher that the respect to the gutter.
  • Page 200 7.5.2 Chipped print (upper dots) Missing dots Chipped print Direction of deflection Is the ink stream positioned at the center of the gutter? Adjust the ink stream position so that the ink Is the ink pressure stream is centered with lower than the respect to the gutter.
  • Page 201 7.5.3 Varying character height Varying character height Is optimum clearance provided between the nozzle head end and print target? Optimize the clearance between the nozzle head end and print target. Was the character height setting changed? Adjust the character height setting. Is the ink pressure within the specified range?
  • Page 202 7.5.4 Increased character distortion Increased character distortion Is optimum clearance provided between the nozzle head end and print target? Optimize the clearance between the nozzle head Is the ink pressure end and print target. higher than the specified limit? Has the operating Can the ink pressure time exceeded the ink be adjusted?
  • Page 203 7.5.5 Disordered characters Disordered characters Are the upper or lower print dots lost? See under “Chipped print”. Is the upper end of the print blotted? Is the operating temperature with the specified limits? Ensure that the operating temperature is within the specified limits.
  • Page 204 7.5.6 Ink leakage/blowout Ink leakage/blowout Is the ink stream bent, dislocated from the gutter, or brought into contact with the gutter edge? Clean the orifice plate and the inside and outside of the nozzle head cover with the makeup ink, and then allow Clean the orifice place them to thoroughly dry.
  • Page 205 7.5.7 Printing initiation failure in ready-for-printing state (no prints) No prints Does the obtained Is the printer in Is the print start print consist of the “Ready” signal entered? spaces only? state? Is the “Profuct Check the print Enter characters speed matching”...
  • Page 206 7.5.8 No ink ejection from nozzle No ink ejection from nozzle Does the on-screen pressure reading represent the specified value? Execute the nozzle Is the supply backwash function. pump running? Is the EZJ93 board Is the problem CN2 connector, fixed? junction connector, Replace the ink filter or supply pump CN1...

  • Page 207: Freeze Of Display"

    7.5.9 Freeze of display *) “Freeze of display” means that the touch screen does not operate without any error message when the screen is touched. Freeze of display Remove the panel protection sheet. Does the screen operate normally? Attach the panel protection sheet correctly.
  • Page 208 7.6 Miscellaneous 7.6.1 Problems due to inappropriate ink stream position in charged electrode If the ink stream does not pass through the charged electrode, the following > problems may occur: (1) The height of printed characters will be larger than standard (2) Since the ink drops are not charged normally: - The character quality will degrade (characters are distorted).
  • Page 209 7.6.2 Problems due to inappropriate ink stream position to gutter If the ink stream does not enter the center of gutter, the following problems may > occur: (1) The ink stream hits the inner wall of gutter inlet and “splash” occurs. This will dirty the gutter, causing either Ink Drop Charge Too High or No Ink Drop Charge.
  • Page 210 7.6.3 Increase of dot missing - “Dot missing” is a phenomenon in which some of the dots comprising a character are lost. Generally, missing of one per several thousand Deflecting missing direction dots is normal, but this may increase if the following abnormal status continues: Deflection direction Dot missing...
  • Page 211 7.6.4 Handling of the charge related faults - The model PXR and PX are changed from the model KX in terms of handling of the charge related faults as follows. Model KX Faults Ink ejection Conditions that the fault occur No electrical Ink is stopped.
  • Page 212 7.6.5 Failure of adjustment of excitation voltage Failure of adjustment of excitation voltage Disconnect and reconnect the Is the EZJ94 board CN5 Resume the EZJ94 board CN5 connector connector disconnected or operation. correctly. in poor contact? When the adjustment Is the DSW1 of Is the excitation fails, is the voltage of １...
  • Page 213 7.6.6 System Error （1-79） *) This alarm is displayed when download goes wrong. System Error (1-79) Insert the system-data memory card and turn on the power switch. Resume the Does the fault restore? operation Replace the EZJ104 board. 7.6.7 System Error ( 80 or more) *) This alarm is displayed when the data to download is not normal.
  • Page 217 8.3 Electrical Connection Diagram 8.3.1 Electrical Connection Diagram[PXR-D]...
  • Page 218 8.3.2 Electrical Connection Diagram [PXR-H]...
  • Page 219 8.3.3 Electrical connection diagram [PXR-P]...
  • Page 220 Sequence Name Eject Ink （Goes to Ready） [PXR-D] ＯＮ Operation [Start up] - [Eject ink] ＯＦＦ Remarks Start sequence Step − Interval Pre-heating Refresh ink Pressurize Suck Eject Eject ink Suck air in Detect bent Suck air in Interval for...
  • Page 221 Sequence Name Eject Ink （Goes to Standby） ［PXR-D、PXR-H］ Operation [Control] - [Eject ink] or [Circulation Control] - [Eject ink] Remarks Start sequence （For mentenance） Step − Interval Pre-heating Refresh ink Pressurize Suck Eject ink Suck air in Interval for Standby...
  • Page 222 Sequence Name Cleaning stop [PXR-D、PXR-H] Operation [Shut down]→[Shut down] or [Circulation Control] - [Cleaning stop] Remarks Suck the circulation / recovery path Step − High-voltage Interval Pressurize Eject makeup ink Check the Pressure- Pressure- Pressure- Outline the makeup MV8 OFF...
  • Page 223 8.5 Dimensions around charge electrode and deflection electrode 8-10...
  • Page 224 8.6 Excitation curve - Depending on the ambient temperature of IJ printer, the setting value is changed to the excitation voltage value suitable to form particles. - The curve No. varies depending on the ink type. (1) [Excitation curve (65 um nozzle)] JP-K26 Excitation voltage setting value Temperature...
  • Page 225 JP-K33 Excitation voltage setting value Temperature 10 11 12 13 14 15 16 17 18 19 0 - 20 51 57 63 69 75 81 87 93 99 105 111 117 123 129 135 141 147 154 160 166 34 38 42 46 50 54 58 62 66 70 74 78 82 86 90 94 98 102 106 110 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 JP-Y37...
  • Page 226 JP-R65 Excitation voltage setting value Temperature 10 11 12 13 14 15 16 17 18 19 0 - 20 73 82 91 100 108 117 126 135 144 152 161 170 179 188 196 205 214 223 231 240 56 62 69 76 82 89 96 102 109 116 122 129 136 142 149 156 162 169 176 182 38 42 47 51 56 61 65 70 74 79 83 88 92 97 101 106 110 115 120 124 38 42 47 51 56 61 65 70 74 79 83 88 92 97 101 106 110 115 120 124 JP-K67...
  • Page 227 JP-R76 Excitation voltage setting value Temperature 10 11 12 13 14 15 16 17 18 19 0 - 20 84 94 104 114 124 135 145 155 165 175 185 195 205 215 225 236 246 256 266 276 58 65 72 79 86 93 99 106 113 120 127 134 141 148 155 162 168 175 182 189 31 35 38 42 46 50 53 57 61 64 68 72 75 79 83 87 90 94 98 101 30 30 30 30 30 30 31 33 35 37 39 42 44 46 48 50 52 54 56 58 JP-W73...
  • Page 228 (2) [Excitation curve (40 um nozzle)] JP-K67 Excitation voltage setting value Temperature 10 11 12 13 14 15 16 17 18 19 0 - 20 79 89 98 108 117 127 136 146 155 165 174 184 193 203 212 222 231 241 250 260 75 83 92 101 110 119 128 137 146 155 164 172 181 190 199 208 217 226 235 244 72 81 90 98 107 116 124 133 142 151 159 168 177 185 194 203 211 220 229 238 70 78 87 95 104 112 120 129 137 146 154 162 171 179 188 196 204 213 221 230...
  • Page 229 JP-K68 Excitation voltage setting value Temperature 10 11 12 13 14 15 16 17 18 19 0 - 20 39 44 48 53 58 62 67 72 76 81 86 91 95 100 105 109 114 119 123 128 40 45 50 54 59 64 69 74 78 83 88 93 98 102 107 112 117 122 126 131 41 46 50 55 60 65 70 75 80 85 90 95 99 104 109 114 119 124 129 134 41 46 51 56 61 66 71 76 81 86 91 96 101 106 111 116 121 126 131 136 JP-K72...
  • Page 230 JP-K68 Excitation voltage setting value Temperature 10 11 12 13 14 15 16 17 18 19 0 - 20 146 163 180 198 215 233 250 268 285 303 320 338 355 360 360 360 360 360 360 360 129 144 160 175 190 206 221 237 252 268 283 298 314 329 345 360 360 360 360 360 120 135 149 163 178 192 207 221 236 250 264 279 293 308 322 337 351 360 360 360 112 125 139 152 165 179 192 206 219 232 246 259 273 286 300 313 326 340 353 360 JP-K26...
  • Page 231 JP-K33 Excitation voltage setting value Temperature 10 11 12 13 14 15 16 17 18 19 0 - 28 41 46 51 56 61 66 70 75 80 85 90 95 100 105 110 115 119 124 129 134 41 46 51 56 61 66 70 75 80 85 90 95 100 105 110 115 119 124 129 134 41 46 51 56 61 66 70 75 80 85 90 95 100 105 110 115 119 124 129 134 41 46 51 56 61 66 70 75 80 85 90 95 100 105 110 115 119 124 129 134 JP-K61...

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