Page is loading ...
Service Manual
HITACHI Printer
Model PXR
Revision December 2008
Version C
[ Revision of PXR service manual ]
Revision Chapter Revised Page
A
(Apr. 2006)
- First edition -
1.2 Addition of “1.2 PXR-P usage precautions” 1-8
1.2.5 Addition of “Note: Meaning of orifice plate lot number” 1-12
1.3.2
1.3.3
Addition of Step 14 (Back up) to the installation procedure
(PXR-D,PXR-H and PXR-P)
1-16
1-17
2.1
2.5
2.12
3.2.1
3.3.1
Addition of the caution “
Be sure to use the system data
memory card stored the latest version software”
2-3
2-19
2-31
3-3
3-9
2.1 Addition of “4. Software option setup” to the function list
required the system memory card.
2-3
2.2
6.2
8.6
Addition of Ink type JP-K65 to the list of 40
µm 2-5
6-5
8-15
2.5
2.12
Addition of caution “Download timing” 2-20
2-32
2.8 Modification of 3.
From “download” to “system reset”
2.26
2.9 Addition of the backup data capacity and limitation 2-27
2.14 Addition of “Software option setup” 2-35
2-36
3.2.1 Modification of EZJ104 board replacement procedure 3-3 to
3-5
3.3.1 Modification of EZJ93 board replacement procedure 3-9 to
3-11
3.3.9 Modification of the caution
From “toward the filter covert” to “toward the exhaust
cover”
3-27
B
(Jun. 2006)
7.1
7.5.9
7.6.5
7.6.6
7.6.7
Addition of following troubleshooting
“7.5.9 Freeze of display”
“7.6.5 Failure of adjustment of excitaiton voltage”
“7.6.6 & 7.6.7 System error (xxx)”
7-2
7-49
7-54
7-55
Contents
1. Introduction·················································································································1-1
1.1 Safety precautions ······························································································· 1-1
1.2 PXR-P usage precautions ··················································································· 1-8
1.3 Structure of each part in the main body ······························································· 1-9
1.3.1 External views (PXR-D, PXR-H)····································································· 1-9
1.3.2 Main body internal (PXR-D, PXR-H)······························································· 1-10
1.3.3 External views (PXR-P) ·················································································· 1-11
1.3.4 Main body internal (PXR-P) ············································································ 1-12
1.3.5 Print head ····································································································· 1-13
1.4 Installation ··········································································································· 1-14
1.4.1 Wiring of power supply ·················································································· 1-14
1.4.2 Installation procedure (PXR-D, PXR-H)·························································· 1-17
1.4.3 Installation procedure (PXR-P) ······································································· 1-18
1.4.3-1 Installation procedure ············································································ 1-18
1.4.3-2 Air Connection and air pressure adjustment
(at the time of installation) ································· 1-19
1.4.3-3 Disposition of makeup ink inside main ink tank
(at the time of installation) ·································· 1-21
1.4.3-4 Ink replenishment (at the time of installation) ········································ 1-21
2. Maintenance work······································································································· 2-1
2.1 Setting of maintenance mode by service personnel·············································· 2-1
2.2 System environment setup···················································································· 2-4
2.3 Adjustment/operational checkout ·········································································· 2-7
2.3.1 Excitation adjustment······················································································ 2-7
2.3.2 Charging voltage confirmation ······································································ 2-9
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 ················································································ 2-18
2.5 Download ············································································································ 2-19
2.6 Calibration of viscometer ····················································································· 2-21
2.6.1 Calibration of viscometer ·············································································· 2-21
2.6.2 Confirmation of the ink viscosity coefficient ·················································· 2-23
2.6.3 Operation test of viscometer ········································································· 2-24
2.7 Ink concentration control ···················································································· 2-25
2.8 System reset ······································································································ 2-26
2.9 Back up ·············································································································· 2-27
2.10 Unit information ································································································ 2-29
2.11 Handling of the warning ”Product Speed Matching Error” ································· 2-30
2.12 Language registration ······················································································ 2-31
2.13 Fault / Warning log management code ····························································· 2-33
2.14 Software option set up ····················································································· 2-35
3. Maintenance of controlling part··················································································· 3-1
3.1 Construction of controlling part ··········································································· 3-1
3.2 Controller part ······································································································ 3-3
3.2.1 EZJ104 board (controller board)····································································· 3-3
3.2.2 Battery ············································································································ 3-7
3.2.3 Power supply for LCD backlight······································································ 3-7
3.2.4 Control panel ································································································ 3-8
3.3 Engine part············································································································ 3-9
3.3.1 EZJ93 board (MPU board)·············································································· 3-9
3.3.2 EZJ94 board (NH board) ················································································ 3-13
3.3.3 EZJ95 board (I/O board)················································································· 3-15
3.3.4 EZJ99 board (Optional board) ········································································ 3-18
3.3.5 EZJ105 board ······························································································· 3-22
3.3.6 Multiple Power Supply ················································································· 3-23
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 ···················································· 4-6
4.4 Joint Structure and Handling ················································································· 4-7
4.5 Pump Unit Replacement Procedure······································································ 4-9
4.6 Solenoid Valves Replacement Procedure ····························································· 4-11
4.7 Pressure Sensor Replacement Procedure ···························································· 4-13
4.8 Circulation Unit Replacement Procedure ······························································ 4-14
4.9 Troubleshooting when Fault Occurs in Viscometer ··············································· 4-17
4.10 Print Head Replacement Procedure···································································· 4-23
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 ···················································· 5-7
5.4 Joint Structure and Handling ················································································· 5-7
5.5 Pump Unit Replacement Procedure······································································ 5-9
5.6 Solenoid Valves Replacement Procedure ····························································· 5-9
5.7 Replacement procedure for pressure sensor and pressure switch for air ············ 5-11
5.8 Circulation Unit Replacement Procedure ······························································ 5-13
5.9 Troubleshooting when Fault Occurs in Viscometer ··············································· 5-15
5.10 Stirrer replacement procedure ··········································································· 5-16
5.11 Print Head Replacement Procedure ···································································· 5-18
5.12 Troubleshooting Procedure for the Circulation System ······································· 5-18
5.13 Repairing Method When the Circulation Route Is Dry or Sticks ·························· 5-18
5.14 Repairing method for each solenoid valve and pump using solenoid pump········ 5-19
6. Print head-related maintenance·················································································· 6-1
6.1 Outline structure of print head and how to remove each cover ····························· 6-1
6.2 Nozzles Replacement Procedure (appendix: nozzle drive conditions)·················· 6-2
6.3 Deflecting base Replacement Procedure ······························································ 6-6
6.4 Cover switch Replacement Procedure ·································································· 6-9
6.5 Sealing valve (MV9) Replacement Procedure······················································· 6-10
6.6 Heating unit Replacement Procedure ··································································· 6-12
6.7 Gutter base group Replacement Procedure·························································· 6-13
6.8 Head base Replacement Procedure ····································································· 6-14
6.9 Replacing EZJ98 Board (APH Sensor Board)······················································· 6-16
7. Troubleshooting ·········································································································· 7-1
7.1 Troubleshooting List ······························································································ 7-1
7.2 Faults - Ink-stop type ··························································································· 7-3
7.3 Faults - Print-stop type ·························································································· 7-22
7.4 Warning conditions (printing continuously performed)··········································· 7-32
7.5 Faults - No on-screen indications·········································································· 7-42
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) ······················································· 8-4
8.3.2 Electrical Connection Diagram (PXR-H) ······················································· 8-5
8.3.3 Electrical Connection Diagram (PXR-P) ······················································· 8-6
8.4 Circulation sequence····························································································· 8-7
8.5 Dimensions around charge electrode and deflection electrode····························· 8-10
8.6 Excitation curve ··································································································· 8-11
1-1
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”.
1-2
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. The precautions in these two categories are both
important and must therefore be observed without fail.
WARNING is used to indicate the presence of a hazard which may cause severe
personal injury or death if the warning against performing an incorrect handling
procedure is ignored.
CAUTION is used to indicate the presence of a hazard which may cause
personal injury or property damage if the warning against performing an
incorrect handling procedure is ignored.
If the warning in the CAUTION category is ignored, serious results may occur depending on the
situation.
After the manual has been read, it must be stored in such a location that all printer operation
personnel can refer to it at all times.
All the instructions set forth in this manual are important and must therefore be observed without
fail.
Pictograph Examples
The symbols are used to indicate precautions (including those related to potential hazards
and warnings) to be observed. Detailed information is furnished by a picture within the
symbol outline (a shock hazard is indicated by the example shown at left).
The symbols are used to describe prohibited actions. The details of a prohibited action are
given by a picture within or near the symbol outline (the example shown at left dictates that you
must keep flames away).
The symbols are used to describe required actions. Detailed instructions are given by a
picture within the symbol outline (the example shown at left dictates that a ground connection
must be made).
Safety Precautions
WARNING
CAUTION
1-3
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. Arcs may be generated from open-type
relays, switches, and brush motors. Before handling the ink and makeup ink,
remove electricity from your body, peripheral equipment, and so on. In the interest
of safety, position a dry-chemical fire extinguisher near the printer.
Since the ink and makeup ink contain organic solvents, install the
printer at an adequately ventilated location.
(1) Never install the printer in an enclosed space.
(2) Connect exhaust equipment to the printer in order to prevent it from filling
with organic solvent vapor.
Do not insert tweezers, a screwdriver, or any other metal article into the
ink ejection hole in the end of the print head.
When the printer is ready to print, a high voltage (approximately 6 kV) is applied
to the deflection electrode section in the print head.
Exercise caution to avoid electric shock, injury, and fire.
Before opening the outer covering (excluding the maintenance door),
be sure to shut off the power supply.
A high voltage is applied to some sections of the printer.
Exercise caution to avoid electric shock and injury.
Use an AC voltage of 100 to120 V or 200 to 240 V(*) ±10% only and
a power frequency of 50 or 60 Hz only.
If the above requirements are not met, the electric parts may overheat and burn,
creating a risk of fire or electric shock.
Use the power cable that is designated in this manual.
Wire the power supply in accordance with this manual.
Never drain the ink or makeup ink waste solution into a public sewer
system.
Waste disposal must comply with all appropriate regulations. Consult the
appropriate regulatory agency for further information.
Safety Precautions (Continued)
WARNING
1-4
Exercise caution to avoid inadvertently disconnecting, forcibly pulling,
or bending piping tubes.
Since the ink and makeup ink in some portions of piping tubes are pressurized,
they may splash into your eyes or mouth or onto your hands or clothing.
If any ink or makeup ink enters your eyes or mouth, immediately flush with warm
or cold water and consult a physician.
While the printer is operating, do not look into the ink ejection hole in
the end of the print head.
Ink or makeup ink may enter your eyes or mouth or soil your hands or clothing.
If any ink or makeup ink enters your eyes or mouth, immediately flush with warm
or cold water and consult a physician.
Ensure that no welding operations are performed within 5 m of the printer.
The welding current may flow to the control section in the printer and cause a circuit
board or printer malfunction. Also, the flame generated by welding may cause a fire.
Before servicing the printer, be sure to stop the ink ejection.
Because ink or makeup ink may splash into your eyes or mouth or onto
your hands or clothing. If any ink or makeup ink enters your eyes or mouth,
immediately flush with warm or cold water and consult a physician.
If an earthquake, fire, or other emergency occurs while the printer
is engaged in printing or just turned on, press the ON/OFF power
switch to turn off the power.
The printer must be managed in compliance with all appropriate
regulations.
Read and understand the appropriate Material Safety Data Sheet (MSDS)
before using any ink or makeup ink.
Properly connect the power cable to the correct input terminal inside
the printer.
If you inadvertently connect the power cable to the wrong input terminal,
the electrical parts may break, overheat, and burn, creating a risk of fire
or electric shock.
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.
Safety Precautions (Continued)
WARNING
1-5
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. Do not close the
maintenance door until you make sure that the portion you have
just wiped is completely dry.
You must pay particular attention when you have spilled ink or makeup
ink inside the printer and it is not completely dry. Why? Because vapors
of ink or makeup ink will stay inside the printer and may catch on or cause
a fire.
If you find it hard to wipe the printer when energized, stop it with the maintenance
door open. Power it down, then wipe it off again.
If you wish to clean the casing of the printer with lint-free wipes impregnated
with makeup ink, be sure to do so with the power down.
Attempting to clean it when energized will cause makeup ink or vapors of makeup
ink to enter the printer, possibly catching on or causing a fire.
When the cleaning is over, open the maintenance door and make sure that no
makeup ink has entered and no vapors stay inside.
Should you find a leak of ink or makeup ink inside the printer while the
printer is running or being maintained, wipe it off promptly with
lint-free wipes or something similar. Then, with the maintenance door
open, stop the printer, power it down, and repair the leak.
A continued run with a leak of ink or makeup ink will cause an anomaly,
resulting in abnormal printing.
Ink and makeup ink are flammable. They may therefore catch on or cause
a fire.
If you wish to receive ink drops in a beaker, for a printing test for
example, use an electrically conductive beaker and connect the beaker
securely to the ground.
Do not let the tip of the printing head enter the beaker.
Ink drops used for printing are electrically charged. An ungrounded beaker
has a gradually rising charge, possibly catching on or causing a fire.
Safety Precautions (Continued)
WARNING
1-6
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.
Since the ink and makeup ink contain organic solvents, observe the
following handling precautions.
(1) Secure adequate space for the ink/makeup ink handling area and printer
installation site. At least 200 m
3
must be provided per print head.
Ensure that adequate ventilation is provided.
(2) When handling the ink or makeup ink, wear protective gloves and safety
goggles to avoid direct skin contact. If the ink or makeup ink comes into
contact with skin, wash thoroughly with soap and warm or cold water.
(3) When transferring the ink or makeup ink to or from a bottle, exercise
caution to prevent it coming into contact with the printer or surrounding
articles.
If there is any spillage, immediately wipe it clean using a cloth moistened
with ethyl alcohol.
Safety Precautions (Continued)
Caution
1-7
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. Consult the
appropriate regulatory agency for further information.
If extraneous noise enters the printer, it may malfunction or break down.
For maximum noise immunity, observe the following installation and
wiring precautions.
(1) Ensure that 100 to 120 VAC or 200 to 240 VAC power cables are not
bundled with other power supply cables.
(2) Insulate the printer main body and print head so that they do not come
into direct contact with the conveyor or other devices.
(3) If the employed printing target detector is housed in a metal case, use a
plastic mounting brace for the purpose of insulating the detector from the
conveyor and other devices.
(4) Be sure that the printing target detector wiring is not bundled together with
other power supply cables.
When replaced with an incorrect type of battery, the battery is in
danger of exploding. Be sure to replace the battery with the one
specified by parts list.
When disposing of the battery (lithium battery), you must comply with local
regulatory requirements. Consult the appropriate regulatory agency for further
information.
When handling PCB or electrical parts, take enough care the electrostatic
Electrical devices are mounted on the printed circuit boards and electrical parts
that are sensitive to the electrostatic.
Be sure to eliminate the electricity by using a grounding wrist band or others when
handling them.
Caution
Safety Precautions (Continued)
1-8
1.2 PXR-P usage precautions
Carefully explain the following contents to your customers:
(1) If the printer is in shutdown status for a long time, ink will tend to accrete.
Read “1.2.2 IJ printer long-term shutdown and “7.15 Long-term shutdown” in the instruction manual.
(2) If orifice plate is soiled with ink, ink beam may bend: Wash and clean orifice plate before operating printer.
Read “1.2.3 Print head cleaning” and “2.1 Startup” in the instruction manual.
(3) If deposition of ink in the tank accumulates, automatic stirring during operation may be impossible.
Confirm the rotation of rotor, referring to “1.2.7 air supply for stirrer and operation ” in the instruction
manual.
(4) Stir the ink inside tank using the stirring rod provided.
Refer to “2.1 Startup” in the instruction manual.
(5) For new ink before replenishment, note that ink components will settle inside ink bottle during storage:
Be sure to stir ink using stirring rod before replenishment.
(6) Depending on change of ink viscosity, warning of “ Excitation V-ref. Review “ may be displayed.
If this warning is displayed, perform nozzle property test and update excitation setting.
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.
1-9
1.3 Structure of each part in the main body
1.3.1 External views (PXR-D, PXR-H)
Status indicator lamps
Dis
p
la
y
s “READY”
,
“FAULT” and “WARNING”.
Maintenance doo
r
Opened/closed for ink
replacement and other
maintenance purposes.
Power lamp
Handle
Turn it by 90degrees to open
and close it.
Various signals intakes
See "1.5 Connection of signals"
in the instruction manual.
Power switch
Push ON-push OFF
alternative.
Connection tube (4m)
Print head
This section performs printing
Handle
Air-purge connection port
See section "1.2.6, Print
head air purge" in the
instruction manual.
Exhaust duct connection port
1-10
1.3.2 Main body internal (PXR-D, PXR-H)
Maintenance doo
r
Makeup ink
reservoir
Ink
reservoir
Electrical access doo
r
Various signals connecting portion
1-11
1.3.3 External views (PXR-P)
Connection tube (4m)
Power switch
Push ON-push OFF
alternative.
Print head
This section performs printing.
Various signal intakes
See “1.5 Connection o
f
signals” in the Instruction
manual.
Handle
Turn it b
y
90 de
g
rees to o
p
en and close it.
Handle
Turn it by 90 degrees to open
and close it.
Operating status indicator lamps
Displays “READY”, “FAULT” and “WARNING”.
Power lam
p
M
a
in
te
n
a
n
ce
co
v
er
Opened / closed for ink
replacement and othe
r
maintenance purposes.
Filter regulator
Stirrer air connection port
Exhaust duct connection port
A
i
r
-purge connection port
See Section “1.2.6 Print
head air purge” in the
instruction manual.
1-12
1.3.4 Main body internal (PXR-P)
Ink reservoir
Main ink tank
Makeup ink
reservoir
Ink filter
Electrical access doo
r
Various signals connecting portion
Maintenance doo
r
1-13
1.3.5 Print head
Note: Meaning of orifice plate lot number
6 A12345
Serial number
Nozzle diameter
6: 65 m
4:
40 m
1:100m
5:
55 m
Print head
(
PXR-H
)
Pipe
g
utte
r
Plus deflection electrode
Nozzle
(
55µm
)
Minus deflection electrode
Position of
lot numbe
r
Orifice plate
1-14
1.4 Installation
1.4.1 Wiring of power supply
[The usable power cable]
The power cable must conform to following conditions.
Connector specification : IEC inlet connector (3 pin L type)
Use the connector of following form and sizes
indicated below.
Cable outer diameter
: 7-10mm
Conductor size : 0.75mm
2
or more
Cable length : Less than 5m (Please shorten as much as possible.)
Other specifications
: Use the cable according to the safety standard in
each country.
[Notes about UL]
When the IJ printer is used in North America, the power cable must conform to
following conditions besides the above-mentioned conditions.
Standard : UL and CUL recognition parts
Rating : 125V,More than 7A
Plug : NEMA5-15P
Cable : Type SJT,18AWG,More than 60 degrees C.
Cable length : 1.5 to 4.5 m
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
a power cable.
Caution
!
min18
7 to 10
38.5 - 44.5
Max25
Max60
Max30
Pay attention to the direction
of the cable.
Unit: mm
/
