Dover Imaje 9020 Troubleshooting Manual Download Page 39 | Manualshive

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Troubleshooting

SECTION 06 Troubleshooting

39/54

Replacing the CPU board

■ Tools:

2.5 mm Allen wrenches.

CAUTION:

If possible, save the messages to a PCMCIA card.

Unplug the printer from its AC outlet.

■ Disassembly:

□ Open the printer's left side door. Remove the two screws then disconnect the
industrial interface board from the CPU board without removing the wires connected to
it.

□ Disconnect all the connectors from the CPU board:

-

Head

-

Ink circuit

-

Tacho, cell, alarms

-

EHV controls

-

Power supply

-

Fan

-

Motor

-

Keyboard ribbon

□ Remove the four screws from the CPU board.

□ Open the right side door. Loosen the three CPU board retaining screws.

□ Remove the CPU board by releasing the screws on the right side and sliding it gently
to the left.

□ Remove the display (see the "Replacing the display" sheet)

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Summary of Contents for Imaje 9020

Page 1: ...Troubleshooting SECTION 06 Troubleshooting 1 54 Troubleshooting ...

Page 2: ...g order and type of each alarm or fault A alarm printing may continue D fault printing disabled The third column lists checks causes remedies and solutions by order of probability There is generally only one cause of a fault Maintenance procedures for solving several faults are described in detail on the pages following the table These procedures are Solenoid valve test Releasing solenoid valve 0 ...

Page 3: ... did not install properly Consequences Unreliable printer operation The printer may crash 1 PCMCIA CompactFlash card reader defective Reinstall the software 2 PCMCIA CompactFlash card Insert another card 3 Upgrade file Check the files on the card Load another file 8 D CRC Flash memory error Algorithm The CRC calculated when the printer is switched on is different than the CRC stored Consequences T...

Page 4: ...RC stored Contents of PCMCIA CompactFlas h card incorrectly written to the printer Consequences Inconsistent data Reload the HEM files on the PCMCIA CompactFlash card into the printer Check the data in the View Algos menu Check the HEM file loaded 18 D Font used in message not available The message selected or sent over the serial link contains a font number not available in the printer Consequenc...

Page 5: ...e printer cannot print Replace the CPU 26 D CRC message library incorrect The CRC calculated when the printer is switched on is different than the CRC stored Consequences The messages in the library are lost 1 Reprogram the messages 2 Check the position of the battery jumper on the CPU 3 Check the voltage of the CPU battery 4 Replace the CPU 27 A Timeout speed meassurement 20sec If the object trav...

Page 6: ...is reset The HIJRI timestamp values are incongruous Consequences The printer cannot print the timestamp Reprogram with consistent values 33 A Incompatible software versions The versions of the ink and printing software are incompatible after the printer is switched on for the first time Consequences Unreliable printer operation 1 Check the versions of the software 2 Install the correct versions 34...

Page 7: ...onsequences Excessively wide marking but printing remains possible Change the tachometer division or select algorithms best suited to the application The alarm may be disabled if the speed is rarely exceeded and the print quality remains acceptable 45 A Message contains non valid option The message selected contains an option not supported by the printer or the option requested via the V24 RS 232 ...

Page 8: ...the needle with clean additive or replace the tip holder 4 CPU 51 A LOW ADDITIVE Prepare new cartridge The level of additive in the cartridge is calculated by the software using the negative pressure value and the number of times the cartridge has been pumped Warning The indication given by pictogram F7 may be distorted if the cartridge has not been correctly replaced full cartridge cartridge with...

Page 9: ...rtridge is too high during draining or rinsing The cartridge is indicated as being full Consequences Draining stops 1 Cartridge Full or filled with air Hollow needle blocked by unperforated tip O ring 2 Ink solenoid valve 0 locked closed Test Replace the IMM 3 Clogged or bent hollow needle Remove the tip holder and clean or replace it 4 CPU board connector 5 CPU 60 A U0 Ink Valve malfunction The p...

Page 10: ...g operation Depending on the results the software makes the difference between SVs 2 and 3 Consequences The IMM stops and printing is disabled Test solenoid valve 2 If OK pressure sensor or blocked tube replace IMM If not OK IMM or CPU or IMM CPU connections 63 D U3 Accumulator valve malfunction Incorrect pressure levels measured when ink flowed from buffer tank to accumulator at start up or durin...

Page 11: ...itself If PRef PAcc There is too little additive in the ink Check the additive cartridge Let the printer adjust the concentration itself 3 Auto calibration 71 D Ambient pressure measurement failed The atmospheric pressure is measured by solenoid valve 4 and the condenser each time the printer is started If after 3 attempts the value measured is not 0 bar 300 mb the pressure sensor is defective Con...

Page 12: ... printer remains ready If the air pocket is too small the pressure fluctuates and the print quality varies and drops 1 Test solenoid valves 3 and 4 2 Condenser vent 3 Make sure the motor is running 4 Make sure there is no ink in the air pump Kapsto 6 75 A Air pocket management incorrect The difference in pressure in the accumulator is too high or too low during operation Consequences The print qua...

Page 13: ...ops and printing is disabled Partially drain the ink in the printer and measure the amount collected Reminder This will drain the buffer tank 1 If ink collected 200 cc The overflow is caused by a crack in the ink pump diaphragm Ink has flowed to the condenser via the air pump ink overflow Replace the IMM 2 If ink collected 200 cc The overflow is caused by too much additive in the ink Restart the p...

Page 14: ... printer cannot print 1 Cover magnet 2 IM Connections cut wire in conduit 3 CPU 85 D Recovery not detected Jet out of gutter The recovery detector did not detect the jet in the gutter or detected too weak recovery during jet start up or during operation Consequences The jet stops 1 Jet Presence Pressure pressure SV A head SV modulation assembly or jet obstructed Stability cleanliness of modulation...

Page 15: ...ad and the cover Clean the modulation assembly Jet tip SV intro Stab check 2 Ink quality Dust moisture use by date rinse refill with new ink 3 Electronics Break off point piezo piezo board IM CPU Charge signal IM CPU Detection signal ADP board IM CPU bonding between cover and CPU 90 A Head temperature out of range The temperature measured inside the head is outside the limits of 0 45 C 32 113 F Co...

Page 16: ...4 92 D Pressure servo control If the air pocket is too small during operation the pressure inside is disrupted when ink is added making jet speed control impossible Consequences The IMM stops Printing is disabled 1 Test solenoid valves 3 and 4 2 IMM ...

Page 17: ...e may splash out during the procedure Take precautions and wear gloves and safety glasses All the ink circuit and head solenoid valves are accessible via this function and can be individually controlled WARNING Some combinations are prohibited Example U3 and U1 open at the same time COMMENT The single control U9 actuating solenoid valves 5 and 6 in turn is no longer available COMMENT On a valve co...

Page 18: ...olenoid valve U0 Open the right side door Remove the ink and additive cartridges Remove the cartridge support plate Remove the ink tip holder and check the needle for any clogs Clean if necessary with additive Protect the inside of the console under the IMM with absorbent paper or a cloth Using the cleaning flask insert additive into the solenoid valve conduit while actuating it press and hold tes...

Page 19: ...4 Releasing solenoid valves 5 and 6 WARNING Ink or additive may splash out during the procedure Take precautions and wear gloves and safety glasses The IMM must first be removed from the console and laid on its side Control U9 is no longer available ...

Page 20: ... cartridge is necessary Follow the instructions that appear on the screen WARNING Follow the instructions carefully to avoid spilling any fluid Wear gloves and safety glasses Rinsing the ink circuit Rinse the ink circuit in the following cases before a protracted period of non use to correct certain faults before replacing the IMM where possible This procedure drains the printer completely then ri...

Page 21: ...rence calibrate using ink with the appropriate concentration When the jet reaches its rated speed the auto calibration validation positions the curve Pressure f Temperature Procedure Printer empty and stopped Connect a new ink cartridge at the same temperature as the printer Remove the additive cartridge Start the printer faults 51 and 53 appear Check or enter the head height difference and ink ty...

Page 22: ...or is at the theoretical value along the reference curve if the ink P f T Start the jet as if you were going to print Close the head cover The jet must be ready to print green Jet status LED lit steady COMMENT Acknowledge all faults and alarms before confirming auto calibration When the jet speed is at its nominal value confirm Auto calibration Yes Check that the reference pressure is the same as ...

Page 23: ...with equipped single jet Seals and hardware included A28592 Recovery assembly equipped twin jet Seals and hardware included Gutter adjustment tool A12230 Nozzle plate O ring EPT 4 0 6 A28155 Modulation assembly O ring EPT 2 3 0 6 A10403 ENM 5836 Tip holder O ring EPT 18 72 2 62 A15218 ENM7802 Teflon hose 2 7 4 A13429 Teflon hose 1 9 2 7 EN6540 ENM6540 Piezo wire Kit of 10 wires A28629 ADP board A2...

Page 24: ...ive maintenance it is not always possible to follow the recommended procedures in full e g it might not be possible to drain the ink circuit if a solenoid valve is blocked In such cases we recommend taking all possible precautions to avoid spilling or splashing ink or additive Whenever parts with gaskets are disassembled new gaskets must always be fitted even if the parts are not replaced ...

Page 25: ... cover Disconnect the resonator wires Unscrew the two screws holding the modulator assembly and remove it Take care with the seals two O rings Reassembly Clean the seal mating surface with additive remove the old O rings and fit two new O rings in their locations on the head Place the new modulator assembly in position then tighten the two mounting screws Reconnect the resonator power supply cord ...

Page 26: ...Disassemble the resonator wire protective cover Disconnect the resonator wires Unscrew and remove the resonator clamping sleeve Pull the resonator out of its housing Take care with the seal one O ring Reassembly Clean the inside of the modulation chamber with additive Remove the old O ring Fit the new O ring on the resonator before reassembling it Tighten the clamping sleeve Reconnect the resonato...

Page 27: ... care with the seals two O rings Unscrew the two screws from the nozzle plate and remove it Take care with the seal one O ring Reassembly Clean the nozzle plate seal mating surface with additive remove the old O ring and fit a new one Reassemble the nozzle plate on the modulator assembly Clean the modulator assembly seal mating surface with additive remove the old O rings and fit two new O rings i...

Page 28: ...lding the 4 solenoid valve block and remove the block Take care with seals one rectangular 3 hole gasket one square 4 hole gasket Reassembly Use solvent to clean the seal mating surface on the 4 solenoid valve block and the contact board Replace the seals 2 flat gaskets then replace the solenoid valve block Testing Restart the printer before closing the rear cover Check that there are no leaks CAU...

Page 29: ...very assembly and remove it Pay attention to the seals O rings around pins Clean the seal mating surface between the head and the recovery unit using additive Reassembly Replace the O ring on the recovery solenoid valve tip Fit new O rings around the pins 2 seals for a single jet head 3 seals for a twin jet and fit the new recovery assembly taking care not to damage the fragile recovery pins Tight...

Page 30: ...re screw on the same side as the gutter to be replaced by half a turn Use the gutter adjustment tool to extract the gutter to be replaced Use additive to clean the port on the recovery unit Reassembly Insert the new gutter in the orifice on the recovery assembly unit and push it fully in Testing and adjustment Set the jet to adjustment mode Use the adjustment tool to adjust the gutter jet in cente...

Page 31: ...d screw from the body of the recovery solenoid valve Disconnect the solenoid valve rinsing hose To avoid damaging the recovery assembly loosen the four screws in the corners of the assembly by one full turn do not loosen the central screw detach the recovery assembly remove the four screws and gently remove the recovery assembly by pulling it free in line with the head axis Pay attention to the se...

Page 32: ... oriented correctly then retighten the nut Connect the rinsing hose Screw the two ground lugs back on Use solvent to clean the seal mating surface on the recovery assembly then replace the seals O rings around pins and replace it Use solvent to clean the seal mating surface on the 4 solenoid valve block then replace the seals two gaskets and replace it Testing Restart the head before closing the r...

Page 33: ...uple the multi way hydraulic connector and fit the stopper on the conduit side CAUTION Residual ink may pour out take appropriate precautions Open the left side door Disconnect the head connector from the CPU board and unscrew the conduit ground wire lug Underneath the printer unscrew the four conduit mounting screws and withdraw the wires and hoses Take care with the seal one O ring Reassembly Fi...

Page 34: ...ide door and remove the ink and additive cartridges Unscrew the two cartridge guide rods Remove the cartridge support plate two screws Position the print head lower than the ink circuit Remove the hydraulic connector from the console without uncoupling it and place it above a retention tray Uncouple the hydraulic connector Place a stopper in the conduit side of the half connector CAUTION If the dr...

Page 35: ... function Wait until the pressure in the accumulator is released close U11 then disconnect the printer from the electrical supply Open the left side door Disconnect the motor control connector from the CPU board and move the wires clear Loosen but do not remove the two screws holding the ink management module Via the hydraulic compartment lift the ink management module to release the two screws an...

Page 36: ... mounts in their brackets Tighten the two mounting screws Clean the seal mating surface on the multi way hydraulic connector remove the old O rings and fit five new O rings Tighten the three screws Place the connector in the console CAUTION the hoses must not obstruct the fan Pass the motor control wires back through the grommet and reconnect the connector to the CPU board Reassemble the cartridge...

Page 37: ...trol connector Open the right side door and remove the ink and additive cartridges Unscrew the two cartridge guide rods Unscrew the top screw remove the bottom screw from the cartridge support plate and remove the plate Unscrew the two screws from the EHV block and remove it Reassembly Position the two screws on the new EHV block Bring up the EHV block and tighten the screws Reassemble the cartrid...

Page 38: ...e door Disconnect all the wires connected to the industrial interface board terminal blocks cell tachometer etc CAUTION Identify the wires before removing them Remove the 2 attachment screws and disconnect the industrial interface board from the CPU board Reassembly Fit the new industrial interface board on the connector on the CPU board and reassemble the two mounting screws Reconnect all the wir...

Page 39: ...dustrial interface board from the CPU board without removing the wires connected to it Disconnect all the connectors from the CPU board Head Ink circuit Tacho cell alarms EHV controls Power supply Fan Motor Keyboard ribbon Remove the four screws from the CPU board Open the right side door Loosen the three CPU board retaining screws Remove the CPU board by releasing the screws on the right side and...

Page 40: ...board into its slot engage the three screws on the right side then insert the four attachment screws on the left side and tighten them moderately Adjust the position of the PCMCIA card reader Tighten the three screws on the right side Reconnect all the connectors Reconnect the industrial interface board and put the screws back in Tighten moderately Close the left side door Plug the printer into it...

Page 41: ...ve the CPU board see the Replacing the CPU board sheet There is no need to store the messages Remove the four attachment screws Disconnect the display Reassembly Connect the new display Replace the four screws Tighten moderately Replace the CPU board see the Replacing the CPU board sheet There is no need to reload the messages Adjust the display contrast keys ...

Page 42: ...pen the left side door From the outside of the printer unscrew the three screws which hold the power supply board to the heatsink Withdraw the board Disconnect the two connectors from the board Reassembly Bring up the new power supply board Connect the two connectors Position the board on the heatsink and replace the three attachment screws Tighten moderately ...

Page 43: ... and withdraw it from its housing Disconnect the multi pin connector Unsolder the three mounting points from the shielding cover Unsolder the electrical wires from the board Reassembly CAUTION Before reassembly check that all items are clean and wipe off any traces of ink or additive Solder the wires to the new board Relocate the shielding cover and solder the three mounting pins Plug the connecto...

Page 44: ...emble the rear head cover Disassemble the 4 solenoid valve block Take care with seals one rectangular 3 hole gasket one square 4 hole gasket Unscrew the two screws from the ADP board and withdraw it from its housing without disconnecting it Unscrew the two screws from the contacts board of the 4 solenoid valve block and withdraw it without disconnecting it Unscrew the two screws from the 4 solenoi...

Page 45: ...ecovery assembly remove the four screws and gently remove the recovery assembly by pulling it free in line with the head axis CAUTION O rings are located around the pins CAUTION The recovery detection pins and contacts are very fragile Unscrew the nut 7 mm across flats from the recovery solenoid valve and withdraw it from its housing without unsoldering the electrical wires and without disconnecti...

Page 46: ...olenoid valve and the recovery assembly then put them back in place Replace the seals and put the the solenoid valve block bracket back in place Put the contacts board back on the solenoid valve block Put the ADP board back in place Replace the seals and put the solenoid valve block back in place Testing Start the printer before closing the rear head cover Check that there are no leaks Start the j...

Page 47: ...precautions Disassembly Disassemble the rear head cover Disassemble the 4 solenoid valve block Take care with the seals one rectangular 3 hole gasket one square 4 hole gasket Unscrew the two screws from the ADP board and withdraw it from its housing without disconnecting it Unscrew the two screws from the contacts board of the 4 solenoid valve block and withdraw it without disconnecting it Unscrew...

Page 48: ...assembly remove the four screws and gently remove the recovery assembly by pulling it free in line with the head axis CAUTION O rings are located around the pins CAUTION The recovery detection pins and contacts are very fragile Unscrew the nut 7 mm across flats from the recovery solenoid valve and withdraw it from its housing without unsoldering the electrical wires and without disconnecting the r...

Page 49: ...noid valve and the recovery assembly then put them back in place Replace the seals and put the solenoid valve block bracket back in place Put the contacts board back on the solenoid valve block Put the ADP board back in place Replace the seals and put the solenoid valve block back in place Testing Start the printer before closing the rear head cover Check that there are no leaks Start the jet and ...

Page 50: ...conditioner assembly Push the filter housing down slightly and turn it counterclockwise by one eighth of a turn as far as it will go and pull out Unscrew the filter cartridge and the grid Use a small flat screwdriver to prise the O ring out of its groove Reassembly Clean the grid and the inside of the tank with cleaning solution Install the new O ring Install the new cartridge and grid tighten mod...

Page 51: ... by pulling from an angle Clean the console surface with alcohol or acetone to eliminate traces of adhesive Reassembly Remove the protective film from under the new keyboard in the central zone in order to reveal the screen and ribbon cable cut out Pass the ribbon cable through the slit in the console and center the keyboard Remove the protective film from the sides and finish sticking the keyboar...

Page 52: ...er etc Adjustment To adjust the break off point look at the jet opposite the charge electrode stroboscopic LED through the eyepiece see Figure 2 Start by turning the potentiometer to the left until it stops The jet is not modulated Slowly turn to the right until the jet break off point is in the center of the charge electrode The shape should be similar to the one illustrated in Figure 2 Correct a...

Page 53: ...meter 2 Magnifying glass eyepiece 3 Potentiometer direction 4 Charge electrode 5 Satellite drops 6 Break off point 7 CORRECT ADJUSTMENT Inspection and tests Close the head cover Cancel any faults that appear Run printing tests and readjust if necessary 3 4 7 1 2 7 6 4 5 ...

Page 54: ...duction Maint Jet maintenance Adjust jet function Remove the head cover Adjustment Loosen the gutter retaining screw on the side under the head one on either side on twin jet heads Hold the gutter with the gutter adjustment tool Adjust the position of the gutter by moving it back and forth or right and left until the jet centered in the gutter Retighten the screw moderately Clean the head Exit the...

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