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Dover Markem-Imaje 5200, Service Manual

The Dover Markem-Imaje 5200 is a highly efficient and reliable industrial printer, perfect for labeling and coding needs. Ensure optimal performance and smooth operation by referring to the comprehensive Instruction Manual. Download this valuable resource for free from our website and experience hassle-free printing with your Dover Markem-Imaje 5200.

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TABLE OF CONTENTS

0855855eng 6/08

xi

10 Replacing the Control Board  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-22

10.1 What You Will Need  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-22
10.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-22
10.3 Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-22
10.4 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-22
10.5 Final Steps  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-23

11 Replacing the Printhead Volt Board   . . . . . . . . . . . . . . . . . . . . . . . . . .  6-24

11.1 What You Will Need  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-24
11.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-24
11.3 Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-24
11.4 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-26
11.5 Final Steps  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-26

12 Replacing the I/O Panel Assembly   . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-27

12.1 What You Will Need  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-27
12.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-27
12.3 Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-27
12.4 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-30
12.5 Final Steps  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-30

13 Replacing the Transformer(s)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-31

13.1 What You Will Need  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-31
13.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-31
13.3 Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-31
13.4 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-32
13.5 Final Steps  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-32

14 Replacing the Soft Start Board   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-33

14.1 What You Will Need  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-33
14.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-33
14.3 Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-33
14.4 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-34
14.5 Final Steps  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-34

15 Replacing the Vacuum/Ground Line  . . . . . . . . . . . . . . . . . . . . . . . . . .  6-35

15.1 What You Will Need  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-35
15.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-35
15.3 Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-35
15.4 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-35
15.5 Final Steps  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-35

16 Replacing the Printhead Data Cable  . . . . . . . . . . . . . . . . . . . . . . . . . .  6-36

16.1 What You Will Need  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-36
16.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-36
16.3 Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-36
16.4 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-36
16.5 Final Steps  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-36

Summary of Contents for Markem-Imaje 5200

Page 1: ...s e r v i c e g u i d e ...

Page 2: ......

Page 3: ...ht 2008 All rights reserved Reference List The information on your packing slips can be written below for reference When contacting Markem Imaje please give your Model Number Serial Number and Customer Account Number Model 5200 5400____________ Serial Number_______________ Date Installed______________ Customer Account Number ________________________________________________________ Name of Markem I...

Page 4: ...iv 0855855eng 6 08 ...

Page 5: ... Foreseen Use 1 9 4 6 Misuse 1 9 4 7 Training Programs 1 9 5 Label and Symbol Identification 1 10 6 Removal from Service 1 13 SECTION 2 Basic Operation 1 Basic Components 2 1 2 The Power Switch 2 3 2 1 Powering On the Coder 2 3 2 2 Powering Off the Coder 2 4 3 The User Interface Module 2 5 3 1 LED Indicators 2 6 3 2 Navigation 2 7 3 2 1 Menu Functions 2 7 3 2 2 Function Keys 2 8 3 2 3 ENTER and EX...

Page 6: ...Indicators on the Print Station 4 1 1 3 Signal Tower Lights 4 2 1 4 LED Indicator on the Printhead 4 3 1 5 LED Indicator on the Control Board 4 4 1 6 Switch Pack SW2 Settings on the Control Board 4 4 2 Machine Diagnostics Menu 4 5 2 1 Access Level 4 6 2 2 Version Information Menu 4 6 2 3 Ink System 4 7 2 3 1 Melt Temperature 4 8 2 3 2 Hold Temperature 4 8 2 3 3 Upper Float Sensor 4 8 2 3 4 Lower F...

Page 7: ...ery Module 4 15 2 5 1 State 4 15 2 5 2 Bottle Sensor 4 15 2 5 3 Melt Thermal State 4 15 2 5 4 Melt Thermistor 4 16 2 5 5 Melt Heater 4 16 2 5 6 Fan 4 16 2 5 7 Hold Thermal State 4 16 2 5 8 Hold Thermistor 4 17 2 5 9 Hold Heater 4 17 2 5 10 Upper Float 4 17 2 5 11 Lower Float 4 17 2 5 12 Pump Motor 4 18 2 5 13 Pump Cycle Time 4 18 2 5 14 Pump Home Switch 4 18 2 5 15 Current Pump Count 4 18 2 5 16 F...

Page 8: ...Beeper 4 24 2 8 3 Status Lights 4 24 2 8 4 Ink Lights 4 24 2 8 5 Fault Lights 4 24 2 8 6 Key Pressed 4 24 2 9 OCU 4 25 2 9 1 Reject Relay 4 25 2 9 2 Reader Sensor 1 and 2 4 26 2 9 3 Reader Scan Enable 1 and 2 4 26 2 9 4 Reader Data 1 and 2 4 26 2 9 5 Product ID Sensor 4 27 2 9 6 Product ID Scan Enable 4 27 2 9 7 Product ID Data 4 27 2 10 Ink Usage 4 28 2 10 1 Job Prints Per Bottle 4 28 2 10 2 Prin...

Page 9: ...Purge Printhead 5 5 Cannot Jet Test Printhead 5 6 Jets Fire Continuously 5 6 Image Prints Continuously in Print Mode 5 6 Printhead Will Not Heat 5 7 Printhead Stuck in Standby 5 7 Enclosure Ink Leak 5 7 Ink Delivery Module IDM Will Not Heat 5 8 Cannot Read Display 5 8 Machine Will Not Power Up 5 9 Machine Resets 5 10 Machine Locks Up 5 10 Communications Are Lost 5 10 Job Not Found 5 11 SECTION 6 F...

Page 10: ...acement 6 9 5 5 Final Steps 6 9 6 Replacing the Ink Level Sensor ILS in the IDM 6 10 6 1 What You Will Need 6 10 6 2 Preparation 6 10 6 3 Removal 6 10 6 4 Replacement 6 12 6 5 Final Steps 6 13 7 Replacing the Ink Pump Motor and Ink Pump Piston 6 14 7 1 What You Will Need 6 14 7 2 Preparation 6 14 7 3 Removal 6 14 7 4 Replacement 6 17 7 5 Final Steps 6 17 8 Replacing the IDM Filter 6 18 8 1 What Yo...

Page 11: ...12 4 Replacement 6 30 12 5 Final Steps 6 30 13 Replacing the Transformer s 6 31 13 1 What You Will Need 6 31 13 2 Preparation 6 31 13 3 Removal 6 31 13 4 Replacement 6 32 13 5 Final Steps 6 32 14 Replacing the Soft Start Board 6 33 14 1 What You Will Need 6 33 14 2 Preparation 6 33 14 3 Removal 6 33 14 4 Replacement 6 34 14 5 Final Steps 6 34 15 Replacing the Vacuum Ground Line 6 35 15 1 What You ...

Page 12: ...hamber Cartridge Heater with Thermostat 400W 6 39 17 4 2 Melt Chamber Cartridge Heater with Thermostat 200W 6 40 17 5 Limit Switch 6 40 17 5 1 Replacing the Ink Door Lock Limit Switch 6 40 17 5 2 Replacing the Pump Stroke Counter Limit Switch 6 41 17 6 Reflective Tape on Bottle Guide 6 41 17 7 Fuse Kit 6 42 17 7 1 Fuses on Backplane Board 6 42 17 7 2 Fuses on Printhead Volt Board 6 43 17 7 3 Fuse ...

Page 13: ...Model 5200 5400 Service Guide SECTION 1 General Information ...

Page 14: ......

Page 15: ...for printing images on your product or package The coder can be connected to a dedicated computer or networked with a host computer for connection to multiple Markem Imaje coders Operation is controlled through a user interface module which is mounted to the top of the enclosure Some operations may also be controlled through networking 1 1 What s in this Guide Coder Description and Specifications ...

Page 16: ...lish 10020356 Model 5200 5400 Service Guide 0855855 Model 5200 5400 Operator Quick Reference Card 0855856 Model 5200 5400 Fault Messages 10019996 Model 5200 5400 Preventive Maintenance Instructions 0840813 Model 5200 5400 Printhead Soak Kit Instructions 0840546 Model 5200 5400 Customer Setup Parameters 0855903 Model 5000 5200 5400 Printhead Slide Assembly 10028084 1 3 Glossary A glossary of terms ...

Page 17: ...z single phase Model 5400 2530W maximum 200 208 230V 50 60Hz single phase Environmental Temperature range Standard 5200 5400 0 40 C 32 104 F Stainless 5200 5400 0 25 C 32 77 F Relative humidity 90 non condensing IP Protection Enclosure IP45 with doors latched Printhead Not rated Carton Sensor IP65 Encoder IP65 Print Area 65mm x 1200mm 2 56 x 47 Print Speed 55m min 180 ft min at Density 2 recommend...

Page 18: ...SECTION 1 General Information 1 4 0855855eng 6 08 3 Dimensional Drawing A B C D E F G H I INCHES 4 4 4 8 6 2 43 6 19 25 5 57 8 21 7 21 7 CM 11 2 12 2 15 8 111 48 3 64 8 146 85 55 1 55 1 ...

Page 19: ...n personal injury 4 1 Certification The Model 5200 5400 has been designed to meet the following standards and specifications CE Marked 98 37 EC Machinery Directive 73 23 EEC Low Voltage Directive Laws for electrical equipment within certain voltage limits 89 336 EEC EMC Directive Laws relating to electrical magnetic compatibility EN 60204 1 Electrical Safety EN 61000 6 4 Generic Emission EN 61000 ...

Page 20: ...200 5400 has NOT been properly connected the packaging machine can begin cycling when the condition is cleared Failure to observe this may result in personal injury ACTION There are various ways for an installer to use the Model 5200 5400 Fault Relay to control a packaging machine Only someone familiar with the packaging machine can determine the best way to signal it with an external device like ...

Page 21: ...ir Electronic troubleshooting must be performed by personnel trained to troubleshoot electrical circuits Hot Surfaces To prevent injury from burns be careful not to touch the jet array surface or hot ink directly Wear protective eyeglasses when working with hot ink Protective Earth This label identifies a protective earth point Earth This label identifies an earth point 4 4 Location of Safety Labe...

Page 22: ...SECTION 1 General Information 1 8 0855855eng 6 08 FRONT REAR ...

Page 23: ...ncluding the use and disposal of related chemicals Operating an unserviceable incomplete or modified coder Not observing safety messages and labels Permitting an unqualified person to operate or repair this coder See Markem Imaje Training Programs Combining or interfacing other equipment with this coder for anything other than the intended use Using supplies or materials that are not recommended f...

Page 24: ... configuration of your coder changes affix the appropriate voltage configuration label to the Serial I D Rating label on the rear panel of the enclosure so it covers the old voltage configuration rating Earth Label for Printheads This label is located above the I O panel and indicates the earth points for the four printheads Consult Installation Instructions This label advises the installer in bot...

Page 25: ...ymbol is located near the INK LED on the user interface module and indicates whether or not the ink supply is sufficient Start This symbol is located on the START key on the keypad and is used to start printing Stop This symbol is located on the STOP key on the keypad and is used to stop printing Enter This symbol is located on the ENTER key on the keypad and is used to open the selected menu or a...

Page 26: ...ection The printheads are abbreviated as PH1 PH2 PH3 and PH4 Keyboard This symbol indicates the keyboard port Encoder This symbol indicates the external encoder port Product Sensor This symbol indicates the product or carton sensor port Signal Tower This symbol indicates the signal tower port Use Only MARKEM Touch Dry Ink This label is located both on the top of the printhead and near the ink cham...

Page 27: ...rinthead wait approximately two hours for the printhead to cool and the Shut down message to appear 2 Disconnect the AC power cord from the electrical source 3 Disconnect cables and connections accessed from the I O door 4 Disconnect the umbilical lines from the printhead and the enclosure 5 Remove the signal tower carton sensor and encoder if applicable 6 Remove each printhead from its mounting a...

Page 28: ...SECTION 1 General Information 1 14 0855855eng 6 08 ...

Page 29: ...Model 5200 5400 Service Guide SECTION 2 Basic Operation ...

Page 30: ......

Page 31: ... The print station consists of the user interface module 4 Figure 2 1 and enclosure 5 Figure 2 1 The enclosure is the cabinet that houses the electrical components vacuum pressure controller and ink delivery module Mounted to the top of the enclosure is the user interface module consisting of a keypad and display which are used to operate program and monitor the coder Figure 2 1 1 2 3 4 5 ...

Page 32: ...m line and electrical line connects each printhead to the print station The operator inserts an ink bottle or an ink block through the ink door 2 Figure 2 2 The ink is melted and transported to the printhead through the ink line The printhead ejects droplets of ink onto your product or package Figure 2 2 2 1 ...

Page 33: ...alizes the coder The green STATUS LED will blink The Version menu will appear briefly The Top Level menu will appear The status message will say Warming up or Shut Down If the status message indicates the coder is shut down the start up process can be initiated by pressing F3 Start Up A prompt will ask you to confirm that you want to start up Select YES The amber LED on the printhead will begin to...

Page 34: ...To stop printing press STOP 2 From the Top Level menu press F3 Shutdown A message on the display will ask for confirmation 3 Press Fl Yes to confirm that you want to shut down Press F2 No to cancel the shutdown 4 Wait for the coder to cool and the Shutdown Done message to appear which may take three or four hours NOTE This time can be reduced by removing the front cover 5 Turn the power switch to ...

Page 35: ... 3 are used to operate program and monitor the coder Various menus will appear on the display The Top Level menu is shown below 1 2 3 25 Mar 2008 15 17 49 Status Machine Ready PH1 On State Printing PH2 On Ink OK Counts Batch 999 Total 53796 Press ENTER to preview image Job Chocolate Job Select Reg Main Menu Shutdown ...

Page 36: ... condition The green STATUS LED indicates whether conditions are met for printing Off Power is off On Online Blinking Warming up cooling down fast blinking or Ready slow blinking The blue INK LED indicates when the coder needs ink Off Bottle of ink is present On Add ink bottle Blinking Add ink bottle immediately The amber FAULT LED indicates when the coder needs attention Off No error or warning O...

Page 37: ...will appear on the display The symbols are intended to inform the user that additional options are listed above or below When Page Up and Page Down buttons appear on the display the corresponding function key will display previous or next menu or list The Modify button appears on the display when the selected parameter has a value that can be changed A box will open that will allow the user to ent...

Page 38: ... Function keys often open new menus 3 2 3 ENTER and EXIT Keys The ENTER key 1 is used to open the selected menu Changes that were made to the current menu will be saved when the ENTER key is pressed The EXIT key 2 is used to return to the previous menu 15 Feb 2008 15 17 49 Status Machine Ready PH1 On State Printing PH2 On Ink OK Counts Batch 999 Total 53796 Press ENTER to preview image Job Chocola...

Page 39: ...xt 3 2 6 Select Characters Dialog Box When asked to enter text a Select Character dialog box will appear The keypad is used to select one character at a time Each character selected will be inserted at the insertion point 1 Use the arrow keys or F3 Back and F4 Forward to highlight a character When the desired character is highlighted press F1 Select Character The selected character will appear at ...

Page 40: ...spective F1 F2 F3 and F4 keys on the keypad The Esc key on the keyboard is equivalent to the EXIT key on the keypad The Enter key on the keyboard is equivalent to the ENTER key on the keypad The Backspace key on the keyboard deletes the character to the left of the insertion point and is equivalent to the Delete button on the Select Character dialog box on the display The directional arrow keys on...

Page 41: ... jets Hold the button for continuous operation The Purge button 6 is located next to the purge symbol on the rear of the printhead It is used to force trapped air and hot ink through the jet array for a few seconds Each press of the button initiates one shot action The amber LED 7 on the rear of the printhead is used to monitor the status of the printhead The Top Level menu on the display also rep...

Page 42: ...SECTION 2 Basic Operation 2 12 0855855eng 6 08 ...

Page 43: ...Model 5200 5400 Service Guide SECTION 3 Care and Cleaning ...

Page 44: ......

Page 45: ...ce Status Lights Ink Lights Fault Lights Inspect encoder bracket 6 weeks Once per month As needed Inspect tension Inspect ink lines and the inside of the enclosure 6 weeks Once per month As needed Visually inspect for electrical and mechanical integrity Inspect ink pump and ink line adapter 4 months Quarterly 2 months Inspect for ink leaks Clean carton sensor lens 4 months Quarterly 2 months Ensur...

Page 46: ... startup If the coder has been idle for more than 4 hours If the jets are not printing properly NOTE Use only Markem Imaje Printhead Wipes PN0712075 to remove ink from the jet array surface These Printhead Wipes were specially designed and tested for use with the coder and prevent lint particles from getting into the jet array surface Use of non Markem Imaje Printhead Wipes will cause jet array bl...

Page 47: ...d release the Purge button once 3 After purging is complete remove the ink drip tray if it is not kept in the tray bracket 4 If the drip tray is kept in the tray bracket remove it periodically to empty and clean it 2 1 1 Purging Printheads in the Down Jetting Position In the down jetting position an alternative purge procedure is required 1 Fold three Printhead Wipes together and hold them on the ...

Page 48: ...m Jobs created using the upper jets will therefore recover sooner NOTE Do not use the Auto Purge feature with the down jetting position The distance required between prints should be calculated so the purge cycle does not interfere with printing Missing or partial prints can occur when insufficient time is allowed after an auto purge Table 3 1 provides guidelines for determining minimum distances ...

Page 49: ...eyeglasses when working with hot ink 1 Press and hold the Jet Test button while moving a piece of paper approximately 6mm 1 4 from the front of the jet array 2 Examine the test pattern to confirm proper jet operation Table 3 2 Spacing Guideline Purge Duration Purge Cycle Time 0 2 Sec 2 75 Sec 0 3 Sec 3 625 Sec 0 4 Sec 3 75 Sec 0 5 Sec 3 875 Sec 0 6 Sec 4 0 Sec 0 7 Sec 4 125 Sec 0 8 Sec 4 25 Sec ...

Page 50: ...t array surface or hot ink directly Wear protective eyeglasses when working with hot ink The jet array should be wiped ONLY If several attempts at purging are unsuccessful in recovering jets Or in the down jetting position after each purge 1 Using a Markem Imaje Printhead Wipe wipe the jet array from the center out DO NOT scrub the jet array DO NOT drag contaminants across the jet array Wipe outwa...

Page 51: ... dust water or other debris collects on the printhead failure can result 1 Allow the printhead to cool down 20 30 minutes NOTE DO NOT SPRAY a hot printhead with water or air A hot printhead is sensitive to severe temperature changes Directly spraying the printhead may destroy it 2 Remove any excess supplies and Printhead Wipes from the areas to be cleaned 3 Use mild soap and water to wipe dust dir...

Page 52: ...ly when the INK LED is on or blinking The ink door will remain locked until the coder is ready to accept another bottle of ink Figure 3 1 1 Open the ink door 2 Remove the empty bottle from the chamber CAUTION Hot Surfaces The aluminum surface at the bottom of the bottle guide can be hot To prevent injury from burns use a protective glove when cleaning the sensor and reflective tape 3 Wear a protec...

Page 53: ... let the next melt cycle complete the melting of the ink To temporarily unlock the ink load door go to the Diagnostics Menu Print Station Ink Door Solenoid If the partially melted bottle of ink is deformed it should be discarded as it may not be able to slide down the melt tube If the bottle looks good it can be inserted again NOTE If the bottle of ink cannot be removed it may be necessary to heat...

Page 54: ...SECTION 3 Care and Cleaning 3 10 0855855eng 6 08 ...

Page 55: ...Model 5200 5400 Service Guide SECTION 4 Diagnostic Tools ...

Page 56: ......

Page 57: ...ngered when they exceed the limitations of their training NOTE Industry standard procedures must be followed to protect the electronics and associated components from damage by Electrostatic Discharge ESD as well as to protect the service person from injury 1 1 Signal Lights LED indicators on the print station and on each printhead are used to monitor the coder The Top Level menu provides addition...

Page 58: ... printing FAULT LED amber Off No present faults On Warning Blinking Error If the coder detects a warning condition a warning message will appear on the display but the coder will continue printing If the coder detects an error condition printing will typically stop 1 3 Signal Tower Lights If your coder is equipped with the optional signal tower the lights on the signal tower correspond to the LED ...

Page 59: ...on the rear of the printhead provides a quick status check of the printhead Figure 4 1 On Printhead is enabled ready to print and there are no fault conditions Off Printhead power is disconnected or Printhead is disabled or Printhead is purging Blinking Printhead is not ready Printhead is warming up or cooling down 1 ...

Page 60: ...ary switch that resets the microprocessor without cycling the power supplies in the machine Figure 4 2 1 6 Switch Pack SW2 Settings on the Control Board Switch pack SW2 3 Figure 4 2 has the following functions SW2 1 Flash Enable 4 Figure 4 2 Open for normal operation Closed for flashing new firmware to the control board SW2 2 Clear Memory 5 Figure 4 2 Open for normal operation Closed to clear para...

Page 61: ...cs menu will appear Not all the diagnostic fields can be displayed at one time Use F3 Page Down and F4 Page Up to display the remaining items 4 To display a particular diagnostic menu use the Down Arrow or Up Arrow key until the pointer is beside the desired field Access Level Version Information Ink System Printhead 1 Printhead 2 Printhead 3 Printhead 4 Ink Delivery Module Print Station VPC 1 2 M...

Page 62: ...rm all Level 1 functions plus modify some Machine Setup parameters Level 3 Can perform all Level 1 and 2 functions modify many Machine Setup parameters and has access to Machine Diagnostics Level 4 Can perform all Level 1 2 and 3 functions plus functions that can be performed only by Markem Imaje service personnel Access levels can be enabled disabled and configured using the Password Settings par...

Page 63: ...ng 6 08 4 7 2 3 Ink System The Ink System menus display the set point actual value and state of the ink system components Ink system values can be read with Level 3 access Set points can only be changed by Markem Imaje service personnel ...

Page 64: ... C default 110 in 0 5 increments Access Level Read 3 Write 4 The Hold Temp parameter is used to set the temperature of the ink holding chamber and can only be changed by Markem Imaje service personnel 2 3 3 Upper Float Parameter Options In Ink Out of Ink Access Level Read 3 In Ink indicates the ink holding chamber is full Add ink Out of Ink indicates the ink holding chamber needs ink within 30 min...

Page 65: ...sed to set the temperature of the specific printhead reservoir and can only be changed by Markem Imaje service personnel 2 3 7 Printhead 1 4 Ink Level Parameter Options 0 15VDC default 4 0 in 0 01 increments Access Level Read 3 Write 4 The PH Ink Level parameter is a reference voltage used to determine if the printhead reservoir has ink in it and can only be changed by Markem Imaje service personn...

Page 66: ...ical 0 00 5 00 In H20 default 1 73 Horizontal 0 00 5 00 In H20 default 2 13 Down 0 00 5 00 In H20 default 3 00 Access Level Read 3 Write 4 The PH Low Vacuum menu is used to determine the low vacuum settings for each printhead position and can only be changed by Markem Imaje service personnel For information on custom vacuum settings refer to Installation and Setup Guide Section 3 Custom Vacuum ...

Page 67: ...evel Read 3 The Ink parameter indicates the level of ink in the printhead Unknown is displayed when the printhead is not up to operating temperature 2 4 3 Temperature Parameter Options OK Warming Up Shutting Down Access Level Read 3 The Temperature parameter indicates the present temperature of the printhead 2 4 4 Array Thermistor Parameter Options 35 140 C Access Level Read 3 The Array Thermistor...

Page 68: ...ter indicates the present state of the printhead array heater 2 4 7 Reservoir Heater Parameter Options On Off Access Level Read 3 Write 3 The Reservoir Heater parameter indicates the present state of the printhead reservoir heater 2 4 8 Ink Level Sense Parameter Options 1 12VDC Access Level Read 3 The Ink Level Sense parameter indicates the level of ink in the printhead The set point is 4 00VDC Vo...

Page 69: ...r circuit is complete so that current is flowing through it 2 4 11 Ink Line Status Parameter Options Idle Heating Access Level Read 3 The Ink Line Status parameter indicates whether the ink line heater is heating or not 2 4 12 Printhead Voltage Parameter Options 115 195 VDC Access Level Read 3 Write 4 The Printhead Voltage parameter indicates the power supply voltage that is required by the printh...

Page 70: ...Machine Setup 2 4 15 Purge Button Parameter Options On Off Access Level Read 3 Write 3 The Purge Button parameter indicates the current state of the printhead purge button and provides the ability to purge the printhead remotely 2 4 16 Purge Count Access Level Read 3 The Purge Count parameter counts the number of manual purges Note that printhead firmware 2403049E or later is needed to support thi...

Page 71: ...fter stages reach their temperature set points in order to stabilize the chambers and ensure ink has melted properly 2 5 2 Bottle Sensor Parameter Options Present Absent Access Level Read 3 Present An ink bottle or ink block is in front of the bottle sensor reflective tape or bottle sensor reflective tape is defective Absent An ink bottle or ink block is not in front of the bottle sensor reflectiv...

Page 72: ...3 Write 3 The Melt Heater parameter indicates whether the melt chamber heater is on or off 2 5 6 Fan Parameter Options On Off Access Level Read 3 Write 3 The Fan parameter indicates whether the fan is on or off It is used to regulate the melt chamber temperature when idle and cool the melt chamber to a safe point to allow the ink load door to be opened safely when adding ink 2 5 7 Hold Thermal Sta...

Page 73: ...ssary to regulate the hold chamber to the set point 2 5 10 Upper Float Parameter Options Unknown In Ink Out of Ink Access Level Read 3 Unknown is reported until the system is in the ready state In Ink indicates the hold chamber is satisfied and needs no ink Out of Ink indicates that ink should be added within 30 minutes 2 5 11 Lower Float Parameter Options Unknown In Ink Out of Ink Access Level Re...

Page 74: ... pump motor and indicates relative loading of the ink filter or any restriction cold spot in the ink delivery system The typical value is 3 5 seconds If the value is greater than 8 seconds an Ink Pump Stall error may result 2 5 14 Pump Home Switch Parameter Options Open Closed Access Level Read 3 The Pump Home Switch parameter cycles from closed to open per revolution of the pump motor 2 5 15 Curr...

Page 75: ...his number would increase until a warning is given 2 6 Print Station The Print Station menu is used to monitor functioning and diagnose problems with the print station 2 6 1 Ink Door Switch Parameter Options Door Open Door Closed Access Level Read 3 The Ink Door Switch parameter indicates whether the ink load door is open or closed 2 6 2 Ink Door Solenoid Parameter Options Locked Unlocked Access L...

Page 76: ... 3 The Remote Purge parameter displays the status of the remote purge input The remote purge input uses the product sensor 4 input for its connection The Remote Purge feature must be enabled on the Machine Setup Print Station Settings menu for this diagnostic to function When active all printheads that are ready will perform a purge 2 6 7 Encoder 1 and 2 Access Level Read 3 This Encoder parameter ...

Page 77: ...tions In Hg Access Level Read 3 This value indicates the high vacuum level reaching the printhead and should be above 16 5 In Hg NOTE On early model VPCs the parameter options are Present or Absent Present High Vacuum sensor is satisfied closed Absent High Vacuum sensor is not satisfied open and the high vacuum pump will stay on longer in an attempt to maintain the required vacuum 2 7 3 High Vacuu...

Page 78: ...20 Access Level Read 3 The Low Vacuum parameter reports the value in inches of water of low vacuum to printhead 1 VPC 1 2 or printhead 3 VPC 3 4 and depends on printhead orientation Refer to Installation and Setup Guide Section 3 Printhead Vacuum Settings for parameter options 2 7 6 Low Vacuum Duty Cycle 1 and 3 Parameter Options 0 100 Access Level Read 3 The Low Vac Duty Cycle parameter reports t...

Page 79: ...low vacuum pump 2 VPC 1 2 or low vacuum pump 4 VPC 3 4 is turned on 2 7 10 Purge Solenoid 2 and 4 Parameter Options On Off Access Level Read 3 Write 3 The Purge Solenoid parameter indicates whether pressure is provided to printhead 2 VPC 1 2 or printhead 4 VPC 3 4 to purge ink through the orifices 2 8 User Interface The User Interface menu is used to determine the current status of the various sys...

Page 80: ...tus Lights parameter indicates whether a status light is on or off 2 8 4 Ink Lights Parameter Options On Off Access Level Read 3 Write 3 The Ink Lights parameter indicates whether an ink light is on or off 2 8 5 Fault Lights Parameter Options On Off Access Level Read 3 Write 3 The Fault Lights parameter indicates whether a fault light is on or off 2 8 6 Key Pressed Access Level Read 3 Write 3 The ...

Page 81: ... reject relay located inside the OCU assembly is currently energized This relay is energized by the scanner when a bad read has occurred The On Time of the OCU reject relay is adjustable and must be set by the user through Machine Setup Print Station Settings OCU Settings Reject Relay On Time The Reject Relay is available to control external devices The user must hardwire to the reject relay termi...

Page 82: ...er 1 or 2 scanner will be triggered to read The user must set it to Off and back On again to get the Reader 1 or 2 scanner to retrigger and read a second time The bar code data that is read will be displayed inside the Reader 1 or 2 Data field also shown on the Machine Diagnostics OCU menu 2 9 4 Reader Data 1 and 2 Parameter Options On Off Access Level Read 3 The Reader ID Data parameter displays ...

Page 83: ...e Product ID scanner will be triggered to read The user must set it to Off and back On again to get the Product ID scanner to retrigger and read a second time The bar code data that is read will be displayed inside the Product ID Data field also on the Machine Diagnostics OCU menu 2 9 7 Product ID Data Parameter Options On Off Access Level Read 3 The Product ID Data parameter displays inside squar...

Page 84: ... Number of Pixels parameter reports the number of jets that will be fired for this printhead for the specified job with a density of one 2 10 3 Printhead 1 4 Image Density The Printhead Image Density parameter is used to determine the amount of ink being jetted It is limited by the speed of the product being printed Refer to Installation and Setup Guide Section 3 Image Density for parameter option...

Page 85: ...ormat and data files are created The time includes the following the time to render the slant images if Slant mode is enabled the time to clear each rendering buffer s area as defined by Composer the time to process any job parameter file the time to delete any volatile label files if in Host Database Mode the time to save any bar code data from the bar codes in the images Time ends when the Rende...

Page 86: ...ffers The time includes the time to re render all the slant images which were affected if Slant mode is enabled 2 11 6 Incremental Fields Access Level Read 3 When Activate Timing is On the Incremental Fields parameter reports the time it takes to re render all the incremental fields in the Render buffers The time includes the time to update all the slant images which were affected if Slant mode is...

Page 87: ...ost port this includes the time to reply with a Status response message For a new job selected at the user interface module the total time to select it includes Label Rendering and Swap Image Buffer times The time to print a label is reflected by the Printing PH x times Since the printheads print asynchronous to each other the total print time cannot be determined by simply adding up the printing ...

Page 88: ...ful only to the engineering team to diagnose system issues 2 14 MCU Logger Access Level Read 3 The MCU Logger screen captures a maximum of 50 specific instances of software malfunction such as illegal operations and non maskable interrupts This information is very critical and is used by the engineering team to improve product performance 2 15 Statistics Access Level Read 3 The Statistics screen r...

Page 89: ...Model 5200 5400 Service Guide SECTION 5 Troubleshooting ...

Page 90: ......

Page 91: ...d the rear of the printhead Use the Machine Diagnostics menu to troubleshoot various coder problems and to observe set points actual values and state of the ink system components Check test points for VAC and VDC 2 Error and Warning Messages If the coder detects a warning condition a warning message will appear on the display but the coder will continue printing If the coder detects an error condi...

Page 92: ...eference to the appropriate procedure in the 5200 5400 documentation set References 2 character abbreviation of document section number paragraph title Example OP 3 Selecting a Job Operation Guide Section 3 Selecting a Job Documents OP Operation Guide 0855849 IN Installation and Setup Guide 0855848 SE Service Guide 0855855 Fault Messages 10019996 Printhead Soak Kit Instructions 0840546 ...

Page 93: ...mage Density Throw distance too far IN 2 Mounting the Printhead Printhead voltage setting SE 4 Printhead Voltage Missing prints Incorrect print registration OP 3 Setting the Registration IN 3 Registration Spacing Incorrect product sensor location IN 2 Installing a Product Sensor Gap between cartons too small Check for small gaps may need different setting Intermittent encoder problem IN 2 Installi...

Page 94: ...k droplets blurring the printed image Encoder line speed mismatch IN 5 Encoder Line Speed SE 4 Print Station Encoder Print is stretched condensed or tilted Encoder line speed mismatch Model 5200 5400SC with tilted printhead IN 5 Encoder Line Speed Use external encoder Missing jets jets drop out Contamination SE 3 Daily Cleaning of the Printhead Incorrect low vacuum IN 2 Connecting Umbilical Lines ...

Page 95: ...ead enclosure purged ink is leaking out SE 3 Daily Cleaning of the Printhead Wiping Auto Purge is enabled IN 3 Auto Purge Frequency Cannot Purge Printhead Printhead not enabled SE 4 LED Indicator on the Printhead IN 3 PH Enable SE 4 Printhead 1 4 State Printhead not ready SE 4 LED Indicator on the Printhead SE 4 Printhead 1 4 State Printhead low on ink SE 4 Ink System Printhead Ink Level VPC low v...

Page 96: ...Panel IN 3 Printhead Vacuum Settings Defective jet test switch SE 4 Printhead 1 4 Jet Test Button Printhead not functioning Defective Head Interface Board SE 6 Replacing the Printhead Defective printhead SE 6 Replacing the Printhead Jets Fire Continuously Incorrect printhead settings IN 3 Print Trigger Jet test button pressed SE 4 Printhead 1 4 Jet Test Button Corrupted job file Recreate the job i...

Page 97: ...ostat in the printhead protects the printhead from runaway heat The thermostat will take over as a heat control but not at the ideal operating temperatures Check machine parameters for proper settings SE 4 Ink System Printhead Array Temperature SE 4 Ink System Printhead Reservoir Temperature IN 3 Array Temperature IN 3 Reservoir Temperature Printhead failure Array Reservoir thermistor SE 6 Replaci...

Page 98: ...ately 100k ohms at 25 C SE 4 Ink Delivery Module Melt Thermistor SE 4 Ink Delivery Module Hold Thermistor Failed hold heater device should read 36 ohms SE 4 Ink Delivery Module Hold Heater Failed melt heater device should read 72 ohms SE 4 Ink Delivery Module Melt Heater Electrical connection 5200 5400 Block Diagram Failed I O Panel assembly backplane SE 6 Replacing the I O Panel Assembly Incorrec...

Page 99: ...tion 5200 5400 Block Diagram Test for properly seated electrical connections test for proper DC voltage levels Control board is locked up SE 4 LED Indicator on Control Board Failed Backplane or Control Board SE 6 Replacing the I O Panel Assembly SE 6 Replacing the Control Board Machine Will Not Power Up No AC input power IN 2 Connecting the AC Power Incorrect voltage configuration IN 2 Changing th...

Page 100: ...ostatic Discharge ESD IN 2 Electrical IN 5 Not Printing Corrupted job file Recreate the job in Composer and download it to the machine before trying again Select job OP 3 Selecting a Job IN 4 The Database Management Menu Improperly grounded Verify grounding Machine Locks Up Possible failure in machine initialization routines Cycle power Corrupted RAM If cycling power does not resolve the problem r...

Page 101: ...ase Management Menu Incomplete download Download job file again Select job OP 3 Selecting a Job IN 4 The Database Management Menu Job file not in local database Verify that the job file exists on local system Verify that the job name was entered correctly Select job OP 3 Selecting a Job IN 4 The Database Management Menu Corrupted job file Recreate the job in Composer and download it to the machine...

Page 102: ...SECTION 5 Troubleshooting 5 12 0855855eng 6 08 ...

Page 103: ...Model 5200 5400 Service Guide SECTION 6 Field Replaceable Parts ...

Page 104: ......

Page 105: ...the VPC Module 2 1 What You Will Need 3mm metric ball end Allen wrench Large flathead screwdriver Pliers 2 2 Preparation 1 Power off the Model 5200 5400 and disconnect the power cable 2 Remove the front cover by loosening the five large captive screws NOTE The ground wire may need to be disconnected from the print station 2 3 Removal 1 Disconnect the electrical connector 1 Figure 6 1 2 Disconnect ...

Page 106: ... three standoffs on the wall and fasten it with the three screws using the ball end Allen wrench with the pliers for leverage if needed 4 Connect the two remaining translucent silicone tubes 5 Connect the electrical connector 1 Figure 6 1 2 5 Final Steps When paragraphs 1 2 through 1 4 are complete 1 Install the front cover NOTE The ground wire may need to be connected to the print station first 2...

Page 107: ...2 Disconnect the ribbon connector located at the top middle of the backplane board 2 Figure 6 2 3 Locate the access hole 3 Figure 6 2 through which the Ethernet cable passes It is located above the backplane board and near the rear wall of the inside of the print station 4 From the IO panel at the rear of the print station locate the access hole through which the Ethernet cable passes 4 Figure 6 2...

Page 108: ...not pinch the cables below the user interface module 2 Align the edges of the user interface to the edges of the control box 3 Only engage the front captive screw about one turn to allow for the back one to start easier One still may have to push down to compress the gasket to get the thread engagement to start Tighten both screws 1 2 3 5 4 ...

Page 109: ...eng 6 08 6 5 Figure 6 3 3 5 Final Steps When paragraphs 2 2 through 2 4 are complete 1 Install the front cover NOTE The ground wire may need to be connected to the print station first 2 Connect the power cable and power on the Model 5200 5400 ...

Page 110: ...To prevent damage to the O ring be sure to press the release on the quick disconnect when disconnecting or connecting vacuum lines 3 Disconnect the data cable 3 Figure 6 4 4 Disconnect the ink line 4 Figure 6 4 5 Loosen the printhead mounting clamp and remove the printhead 5 Figure 6 4 4 4 Replacement 1 Connect the printhead reversing the steps in Removal paragraph 3 3 NOTES Be sure not to confuse...

Page 111: ... the Model 5200 5400 2 The cold printhead requires 15 minutes to heat 3 When the printhead is nearly ready tighten the ink line fitting 4 When the printhead is ready perform a purge and jet test 5 Position the printhead for proper jetting distance 6mm or 0 25in Figure 6 4 NOTE Model 5000 printheads are NOT interchangeable with Model 5200 5400 printheads ...

Page 112: ... Removal 1 Loosen the screw for the ink bottle guide Lower the guide and retighten the screw 1 Figure 6 5 2 Use two wrenches to disconnect the ink lines from the IDM 2 Figure 6 5 Bend them forward to be out of the way 3 Wear an antistatic wrist strap connected to the earth point that connects the green and yellow ground wire from the user interface 1 Figure 6 18 Remove the control board 2 Figure 6...

Page 113: ...ctors into the backplane board They can be incorrectly inserted and be one or more pitches off NOTE When sliding the ink bottle guide up into place be sure the necked down area of the guide is completely inserted in its mating hole until its shoulder is in contact with the ceiling 8 Figure 6 5 5 5 Final Steps When paragraphs 4 2 through 4 4 are complete 1 Install the front cover NOTE The ground wi...

Page 114: ...m Allen wrench Large flathead screwdriver 5 8 inch open end wrench 9 16 inch open end wrench Wire cutters 6 2 Preparation 1 Power off the Model 5200 5400 and disconnect the power cable 2 Remove the front cover by loosening the five large captive screws NOTE The ground wire may need to be disconnected from the print station 6 3 Removal 1 Remove the wire harness from the wire duct under the transfor...

Page 115: ... the bottle guide into place 6 Remove the two Allen screws holding the melt chamber to the heat shield Lift out the bottle guide and melt chamber together CAUTION Hot Surfaces To prevent injury from burns use care not to touch hot surfaces or hot ink directly Wear protective eyeglasses when working with hot ink 7 Remove the ink level sensor Figure 6 8 by loosening the two nuts with the 5 8 inch op...

Page 116: ...e 6 1 for guidance Figure 6 9 Table 6 1 IDM Connector Pins Pin Function 1 RED MELT THERMISTOR 1 Figure 6 9 2 RED MELT THERMISTOR 3 RED HOLDING THERMISTOR 4 RED HOLDING THERMISTOR 5 WHITE PUMP SWITCH MIDDLE NO 6 WHITE PUMP SWITCH COM 7 WHITE PHOTO SENSOR 8 BROWN PHOTO SENSOR 9 BLUE PHOTO SENSOR 10 RED INK LEVEL SENSOR 11 WHITE INK LEVEL SENSOR 12 BLACK INK LEVEL SENSOR 1 ...

Page 117: ... two Allen screws and tighten Ensure that there are no pinched wires between the melt chamber assembly and the heat shield See Figure 6 10 5 Loosen the bottle guide and slide it up on the melt chamber Tighten the bottle guide into place 6 Install new wire ties to the wire harness Figure 6 10 6 5 Final Steps When paragraphs 5 2 through 5 4 are complete 1 Install the front cover NOTE The ground wire...

Page 118: ...r off the Model 5200 5400 and disconnect the power cable 2 Remove the front cover by loosening the five large captive screws NOTE The ground wire may need to be disconnected from the print station 7 3 Removal 1 Using the 2mm Allen wrench remove the motor eccentric by removing the setscrew Figure 6 11 Carefully remove the eccentric from the motor shaft being careful not to damage the lever arm of t...

Page 119: ...SECTION 6 Field Replaceable Parts 0855855eng 6 08 6 15 Figure 6 12 3 Carefully cut the wire ties from the wire harness leading to the connector and remove the motor FIgure 6 13 Figure 6 13 ...

Page 120: ...ess from the wire duct under the transformer 1 Figure 6 14 Figure 6 14 5 Disconnect the green connector J from the back panel circuit board 1 Figure 6 15 Figure 6 15 6 Remove the two ink pump motor wire leads from the connector noting which wire color goes to which terminal 1 1 ...

Page 121: ...perly seated on the eccentric 4 Ensure that the switch lever is not damaged and is properly located to the eccentric 5 Tighten the setscrew when the eccentric is flush to the end of the motor shaft Ensure that the setscrew engages the dimple on the shaft 6 Install new wire ties to the wire harness 7 5 Final Steps When paragraphs 6 2 through 6 4 are complete 1 Install the front cover NOTE The groun...

Page 122: ...nect the power cable 2 Remove the front cover by loosening the five large captive screws NOTE The ground wire may need to be disconnected from the print station 8 3 Removal 1 Using the 2 5mm Allen wrench remove the two screws holding the filter Figure 6 16 Set one of the screws aside for use with the new filter 2 Place the other screw into one of the threaded holes on the filter top and tighten th...

Page 123: ...pushing in the center of the filter top 2 Install the two screws previously removed 8 5 Final Steps When paragraphs 7 2 through 7 4 are complete 1 Install the front cover NOTE The ground wire may need to be connected to the print station first 2 Connect the power cable and power on the Model 5200 5400 3 The pump count must be reset from the Machine Setup menu Note that Level 3 access is required F...

Page 124: ...eplacing the Ink Delivery Module IDM This may require two wrenches to make sure the ink adapter fitting does not loosen from the ink delivery module 5 Remove the plastic nut on the ink line strain relief and slide the assembly from the bottom of the enclosure 9 4 Replacement 1 Slide the new ink line assembly through the bottom of the enclosure securing the strain relief with the plastic nut provid...

Page 125: ... High voltage is present in the print station enclosure 2 When the printhead is warm retighten the printhead connection 3 Purge enough ink from the printhead to cause an ink low condition in the printhead 4 Observe the ink delivery path for ink leaks 5 Power off the Model 5200 5400 if the ink line fittings need tightening at the ink delivery module 6 Install the enclosure front cover ...

Page 126: ...OTE The cover ground wire may need to be disconnected from the print station 10 3 Removal 1 Wear an antistatic wrist strap connected to the earth point that connects the green and yellow ground wire from the user interface 1 Figure 6 18 2 Remove the control board 2 Figure 6 18 3 Place the control board in the static shielding bag and close the bag 10 4 Replacement 1 Wear an antistatic wrist strap ...

Page 127: ... 6 08 6 23 Figure 6 18 10 5 Final Steps When paragraphs 9 2 through 9 4 are complete 1 Install the front cover NOTE The ground wire may need to be connected to the print station first 2 Connect the power cable and power on the Model 5200 5400 1 2 ...

Page 128: ...moval 1 Wear an antistatic wrist strap connected to the earth point that connects the green and yellow ground wire from the user interface 1 Figure 6 18 2 Remove the control board 1 Figure 6 19 3 Place the control board in the static shielding bag and close the bag 4 Unplug the transformer connector from the printhead volt board 2 Figure 6 19 5 Unplug the ink line connector s from the printhead vo...

Page 129: ... are folded behind the printhead volt board to be able to repeat the same folding when installing the new printhead volt board An example of a folded ribbon cable for the left hand side is shown below Figure 6 20 Figure 6 20 7 Slide the volt board forward and off the six keyhole standoffs 8 Disconnect the two ribbon connectors from the backplane board ...

Page 130: ...ps in Removal paragraph 10 3 to install the new printhead volt board 11 5 Final Steps When paragraphs 10 2 through 10 4 are complete 1 Install the front cover NOTE The ground wire may need to be connected to the print station first 2 Connect the power cable and power on the Model 5200 5400 ...

Page 131: ... 2 Preparation 1 Power off the Model 5200 5400 and disconnect the power cable 2 Remove the front cover by loosening the five large captive screws NOTE The cover ground wire may need to be disconnected from the print station 12 3 Removal 1 Wear an antistatic wrist strap connected to the earth point that connects the green and yellow ground wire from the user interface 1 Figure 6 18 2 Remove the con...

Page 132: ...ables are folded behind the printhead volt board in order to be able to repeat the same folding when installing the new printhead volt board An example of a folded ribbon cable for the left hand side is shown below Figure 6 22 Figure 6 22 7 Slide the volt board forward and off the six keyhole standoffs 8 Disconnect the two ribbon connectors from the backplane board 9 Disconnect all the connectors ...

Page 133: ...SECTION 6 Field Replaceable Parts 0855855eng 6 08 6 29 Figure 6 23 Figure 6 24 1 1 ...

Page 134: ...eps in Removal paragraph 11 3 to install the new I O panel assembly 12 5 Final Steps When paragraphs 11 2 through 11 4 are complete 1 Install the front cover NOTE The ground wire may need to be connected to the print station first 2 Connect the power cable and power on the Model 5200 5400 ...

Page 135: ...re may need to be disconnected from the print station 3 It may be necessary to remove the control board if there are two voltage supply boards See Section 6 0 Replacing the Control Board Removal 13 3 Removal 1 Disconnect the three transformer plugs from the soft start board 1 Figure 6 25 the voltage supply board 2 Figure 6 25 and the backplane board 3 Figure 6 25 2 Loosen the two hex cap screws 4 ...

Page 136: ...the fan 5 Figure 6 25 3 If the control board was removed reinstall it NOTE Make sure none of the wires will interfere with the operation of the fan blades NOTE Push the wires back and down into the wall cutout 6 Figure 6 25 13 5 Final Steps When paragraphs 12 2 through 12 4 are complete 1 Install the front cover NOTE The ground wire may need to be connected to the print station first 2 Connect the...

Page 137: ...er plug s from the soft start board 1 Figure 6 26 2 Loosen the screw securing the left wire attached to the terminal block 2 Figure 6 26 Note the position voltage at which this wire connects This determines the voltage configuration of the machine and must match the incoming voltage Refer to the Installation and Setup Guide Section 2 Changing the Voltage Configuration 3 Remove the screw securing t...

Page 138: ...m the transformer if in the bottom position route up behind the fan 5 Figure 6 26 NOTE Make sure none of the wires will interfere with the operation of the fan blades 14 5 Final Steps When paragraphs 13 2 through 13 4 are complete 1 Install the front cover NOTE The ground wire may need to be connected to the print station first 2 Connect the power cable and power on the Model 5200 5400 1 2 3 4 5 ...

Page 139: ...rom the foam gasket slide the gasket out from the access compartment for easy removal 5 Disconnect the quick connect air fittings from the back of the enclosure Be sure to note where the red and gray tubing match the port with the red or gray dot 6 Disconnect the ground wire from the back of the enclosure 15 4 Replacement 1 Reverse the steps in Removal paragraph 14 3 to install a new air line Be s...

Page 140: ... 2 Open the access door on the back of the print station enclosure 3 Follow the identified data cable back to the enclosure and pull it from the foam gasket slide the gasket from the back of the enclosure for easy removal 4 Disconnect the data cable from the I O panel 16 4 Replacement 1 To replace the printhead data cable reverse the steps in Removal paragraph 15 3 16 5 Final Steps When paragraphs...

Page 141: ...nstructions included in the Spare Parts Kit 17 2 M4 Pan Head Phillips Screws These are spare screws for securing the ground line at the printhead or print station See Section 6 Replacing the Vacuum Ground Line 17 3 Thermistor The thermistor may need to be replaced in two places located in the ink delivery module See Section 6 Replacing the Ink Delivery Module Holding Chamber 1 Figure 6 27 Melt Cha...

Page 142: ...by removing the two screws 3 Remove the screw 1 split washer 2 flat washer 3 and thermostat 4 trapping the melt chamber thermistor 5 and cartridge heater 6 and slide the thermistor out 4 Disconnect the thermistor wires from positions 1 and 2 of the green 12 position plug Refer to Figure 6 9 and Table 6 1 5 To replace the thermistor reverse steps 1 through 4 above retaining the stacking order of th...

Page 143: ... Remove the screw 1 split washer 2 and flat washer 3 holding the thermostat 4 1 Figure 6 28 on the backside of holding chamber located below the motor Figure 6 28 3 Remove the screw trapping the thermistor and cartridge heater and slide the cartridge heater out 1 Figure 6 27 There is an access hole at the bottom to push the cartridge out if necessary 4 Disconnect the cartridge heater with thermost...

Page 144: ...h thermostat reverse steps 1 through 4 above retaining the stacking order of the screws and washers Make sure there are no wires pinched between the melt chamber assembly and the heat shield 3 Figure 6 27 NOTE Be careful plugging the connector into the backplane as it is possible to plug one pitch position off 17 5 Limit Switch The limit switch may need to be replaced in two places Ink Door Lock P...

Page 145: ... same position on the new switch 4 Mount the new limit switch onto the motor bracket using the two screws two split lock washers and two hex nuts 5 Adjust the switch fully toward the eccentric rotate clockwise and tighten 17 6 Reflective Tape on Bottle Guide 1 Remove damaged reflective tape from the rectangular slot inside of the bottle guide 2 Clean the rectangular slot with mineral spirits on a ...

Page 146: ...er supply against accidental short or over current This fuse is not replaceable Fuse F3 PTC RXE185 1 33Amp 50C F3 is self resetting and is used to protect the 24VDC 24VDC power supply against accidental short or over current This fuse is not replaceable Fuses F4 F5 GDC 500mA Time Delay 5 x 20mm F4 is a time delay fuse placed in series with the 26VAC power line that feeds the optional OCU scanner e...

Page 147: ...y 100 Watt heaters against accidental short or over current F3 is a time delay fuse used to protect the attached printhead 1 and 3 reservoir and array 100 Watt heaters against accidental short or over current Fuses F4 F5 S505 10 0Amp Time Delay 5 x 20mm F4 is a time delay fuse used to protect 26VAC power to printhead ink line 1 ink line 3 in 5400 on second Printhead Volt Board F5 is a time delay f...

Page 148: ...r current 17 8 Replacing the Low Vacuum Diaphragm Pump 1 Remove the VPC module See Section 6 Replacing the VPC Module 2 Puncture the rubber insulator strips on the bottom of each new pump 0695036 to facilitate mounting screw insertions 3 Mount the pump bracket 1 Figure 6 30 to the base plate reusing the two existing M4 x 16mm 0 63 screws 2 Figure 6 30 Figure 6 30 4 Mount the low vacuum diaphragm p...

Page 149: ...d to make field repairs to a printhead that has ink in the low vacuum line Ink can enter the low vacuum line when the printhead is moved while ink inside the printhead is in a liquid state If ink enters the low vacuum line the purge function will be disabled and ink will likely weep from the printhead array 1 To confirm whether or not ink has migrated into the low vacuum line remove the printhead ...

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