Hitachi PXR User manual

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

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Hitachi PXR User manual

Hitachi PXR User manual

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