Dover markem-image 9020 User manual

Bookforserviceengineers
internal useonly

A36163-C.doc
3/189
Contents

Contents
A36163-C.doc
4/189
Notes:

Contents
A36163-C.doc
5/189
CONTENTS 3
SAFETY 11
■ R EMINDER 13
■ S UPPLEMENT FOR M ARKEM -I MAJE SERVICE ENGINEERS 13
R ESPONSIBILITY 13
H EALTH AND SAFETY 13
F IRE PREVENTION 14
E NVIRONMENT 15
S YSTEM 15
H ANDLING 15
S ERVICING - TROUBLESHOOTING 15
C ONSUMABLES 16
S AFETY EQUIPMENT FOR M ARKEM -I MAJE SERVICE ENGINEERS 16
R ULES OF CONDUCT FOR M ARKEM -I MAJE SERVICE ENGINEERS WHEN VISITING
CUSTOMERS
16
PRINTER DESCRIPTION 17
■ I NTRODUCTION 19
■ C ABINET 20
■ O PERATOR I NTERFACE 23
■ P RINT -H EAD & U MBILICAL 25
■ E LECTRONIC COMPARTMENT 28
■ H YDRAULIC COMPARTMENT 30
■ I NDUSTRIAL I NTERFACE CONNECTION BOARD 31
■ G ENERAL SPECIFICATION 35
■ E NERGY 37
PRE-INSTALLATION INSTALLATION TRAINING 39
■ P OLICY 41
■ I NSTALLATION G UIDE 42
S TEP 1: C USTOMER PROJECT VALIDATION 44

Contents
A36163-C.doc
6/189
S TEP 2: I NSTALLATION PREPARATION 45
S TEP 3: I NSTALLATION 46
S TEP 4: B ASIC INSTRUCTION 47
S TEP 5: I NSTALLATION VALIDATION 47
N OTE : 47
■ F IRST PRINTER START - UP 48
■ O PERATOR I NFORMATION 49
D AILY START - UP 49
■ C USTOMER TRAINING 49
O BJECTIVES 49
H OW CUSTOMER TRAINING CAN HELP REACHING OBJECTIVES 49
C USTOMER TRAINING CONTENT 50
D ELIVERABLES 51
N OTE : 51
AFTER SALES SERVICE POLICY 53
■ ACCESS MAINTENANCE AGREEMENT 55
■ STANDARD MAINTENANCE AGREEMENT 61
MAINTENANCE 69
■ P REVENTIVE AND PROACTIVE MAINTENANCE TABLE 71
■ T HREE REASONS WHY 9020/30 PRINTERS REQUIRE MAINTENANCE 72
I NK CIRCUIT 72
I NK 72
I NK / MACHINE PAIR 72
■ T O SUM UP ... 73
■ P RINTER L ONG STOP 74
S HUT - DOWN THE PRINTER FOR A PERIOD OF LESS THAN THREE WEEKS 74
S HUT - DOWN THE PRINTER FOR A PERIOD OF MORE THAN THREE WEEKS 74
TROUBLESHOOTING 79
■ A BBREVIATIONS TABLE USED IN THIS CHAPTER 81
■ T ROUBLESHOOTING . 81
■ M AINTENANCE PROCEDURES 98
V ALVES TEST 98

Contents
A36163-C.doc
7/189
R ELEASING VALVE EV0 99
P ARTIAL DRAIN 100
F ULL DRAIN 100
I NK CIRCUIT RINSING IC60 100
A UTO - CALIBRATION . 101
■ L IST OF SPECIAL SPARE PARTS FOR M ARKEM -I MAJE S ERVICE E NGINEERS . 103
■ L IST OF THE SPARE PARTS FOR CUSTOMERS . 103
■ S PARE PARTS SHEETS 104
M ODULATION ASSEMBLY REPLACEMENT 105
R ESONATOR REPLACEMENT 106
4 VALVES BLOCK REPLACEMENT 107
G UTTER ASSEMBLY REPLACEMENT 108
R ECOVERY GUTTER REPLACEMENT 109
R ECOVERY VALVE REPLACEMENT 110
P RINT MODULE REPLACEMENT 112
I NK CIRCUIT MODULE (IC60) REPLACEMENT 114
EHT BLOCK REPLACEMENT 116
I NDUSTRIAL INTERFACE BOARD REPLACEMENT 117
CPU BOARD REPLACEMENT 118
D ISPLAY REPLACEMENT 120
PSU BOARD REPLACEMENT 121
ADP BOARD REPLACEMENT 122
R ESONATOR BOARD REPLACEMENT 123
A IR INTAKE FILTER CARTRIDGE REPLACEMENT ( AIR PRESSURISATION KIT ). 126
K EYBOARD REPLACEMENT 127
■ A DJUSTMENT SHEETS 128
B REAK - OFF POINT ADJUSTMENT 128
R ECOVERY GUTTER ADJUSTMENT 131
T WO PHOTOCELLS MODE ADJUSTMENT 132
HYDRAULICS 135
■ S OLENOID VALVE HYDRAULIC CIRCUIT (P RINTER STOPPED ) 137
■ O NE - WAY VALVES HYDRAULIC CIRCUIT (P RINTER STOPPED ) 137
■ O NE - WAY VALVES HYDRAULIC CIRCUIT (P RINTER STOPPED ) 138
■ D IAGRAM OF THE HYDRAULIC CIRCUIT (N ORMAL OPERATION ) 138
■ D IAGRAM OF THE HYDRAULIC CIRCUIT (N ORMAL OPERATION ) 139
■ D IAGRAM OF THE HYDRAULIC CIRCUIT (J ET STOPPED WITH MAKE UP ) 140
■ I NK CIRCUIT : PRINCIPLE OF OPERATION 141

Contents
A36163-C.doc
8/189
■ P RINT HEAD 142
■ D IAGRAM OF RECOVERY GUTTER SOLENOID VALVE E. 143
■ R ECOVERY GUTTER 143
■ P RINCIPLE OF TRANSFERS 144
■ I NK FILTERS 146
■ M AKE UP FILTER 146
■ C ALIBRATED TUBES ( RESTRICTION ) 146
■ C ONSTANT INK CONCENTRATION PRINCIPLE 147
■ J ET SPEED CALCULATION AND ADJUSTMENT 148
J ET SPEED CALCULATION 148
A UTOMATIC JET SPEED ADJUSTMENT 148
■ N EGATIVE PRESSURE MEASURING AND ADJUSTMENT 149
M EASURING OF THE NEGATIVE PRESSURE 149
A DJUSTMENT OF THE NEGATIVE PRESSURE 149
■ R INSING OF RECOVERY GUTTER SOLENOID VALVE (E) 149
ELECTRONICS 151
■ 9020/9030 E LECTRONIC A RCHITECTURE 153
■ CPU C ONNECTIONS 153
■ CPU C ONNECTIONS 154
■ CPU BOARD CONNECTORS IDENTIFICATION 155
■ I NDUSTRIAL INTERFACE BOARD CONNECTORS 156
■ E XTERNAL CONNECTORS 157
■ P RODUCT S ENSORS RANGE 158
GENERAL INFORMATION 161
■ I NK JET PRINTING 163
■ M ATRIX PRINTING 163
■ D EVIATED CONTINUOUS INK JET 163
■ D EVIATED CONTINUOUS INK JET 164
M ODULATION ASSEMBLY 165
P IEZO - ELECTRIC RESONATOR 165
R ECOVERY GUTTER 165
C HARGE ELECTRODE 165
■ A LGORITHMS 166
U SING ALGORITHM WITH 9020 AND 9030 PRINTERS 166

Contents
A36163-C.doc
9/189
C ALCULATION OF THE MAXIMUM SPEED OF AN ALGO : 167
U SING RESTRICTION : 167
A LGORITHM TABLE 168
A LGOS CURVPRINT 169
CURVPRINT. SPEEDS TABLE 169
■ P RINTING , PRESSURE , SPEED 170
C ONTROLLING THE QUALITY OF INK 170
I NK PRESSURE 170
■ A TMOSPHERIC PRESSURE , ABSOLUTE PRESSURE , RELATIVE PRESSURE 171
A TMOSPHERIC PRESSURE 171
A BSOLUTE PRESSURE 171
R ELATIVE PRESSURE 171
P RESSURE IN A LIQUID 172
R ELATIONSHIP BETWEEN EJECTION SPEED AND PRESSURE 173
P HYSICAL LAW : 173
C ALCULATING THE EJECTION SPEED 174
B ERNOULLI ' S THEOREM 174
■ F UNDAMENTAL UNITS 175
M ASS 175
L ENGTH 175
V OLUME 175
M ASS , WEIGHT AND FORCE 175
P RESSURE 175
■ E XERCISE 176
APPENDIX 177
■ B ASIC P RE - INSTALLATION F ORM 178
■ C OMPLEX P RE - INSTALLATION F ORM 181
■ O UT O F B OX C HECKING L IST 185
■ I NSTALLATION V ALIDATION C HECKLIST 186
■ I NSTALLATION C ERTIFICATE 187

Contents
A36163-C.doc
10/189
Notes:

A36163-C.doc
11/189
Safety

A36163-C.doc
12/189

Safety
A36163-C.doc
13/189
■Reminder
Please read all the safety instructions included in the Markem-imaje user manuals
provided to customers.
■Supplement for Markem-Imaje service engineers
Responsibility
Printers must not be modified by customers without the validation of Markem-
Imaje. Printers must be used according with the specifications of the user manual. .
Health and safety
The safety data sheet (SDS) on the following pages is provided as an example
only.
Always read the SDS for consumables used by a customer carefully.
Ink-resistant gloves and safety glasses must be worn during filling and cleaning
operations. Makem Imaje service engineers are strongly advised to wear a protective
mask in the absence of a specific ventilation system.

Safety
A36163-C.doc
14/189
Do note touch electronic boards if the printer is not disconnected from the main power.
Fire prevention
Follow the instructions on the safety data sheet (SDS) for each MI consumables
Have a foam, CO2, or powder fire extinguisher placed close to the printer area
(distance of 10 meters maximum).
Do not use spark-producing equipment (drills, grinders, welders, etc.) within a 5
meter radius around the printer.)
Do not place electrical equipment (bulbs, etc.) within a 1meter radius around the
print head, particularly when performing maintenance and cleaning.

Safety
A36163-C.doc
15/189
Always keep away from open flame. Never smoke near the printer. Place a sign with the
follow information “NO SMOKING FLAMMABLE INK” near the printer.
Containers of ink, additive and cleaning solution must be closed and stored in a ventilated
place or an adapted cabinet.
Environment
Take the necessary precautions if the printer is used in an electrostatic environment.
System
The printer must be connected to a single-phase grounded outlet with the power cable
supplied by Markem-Imaje. The standard wall outlet must be above the printer in an easy-
to-access location.
Handling
If the printer is filled with its consumables, move it vertically. Do not tip it over.
Drain completely the printer before to move it in a horizontal position.
Servicing - troubleshooting
If a specific vapor exhaust system is not in use, wear the personal protective equipment
mentioned earlier (mask).
NO SMOKING –
FLAMMABLE INK

Safety
A36163-C.doc
16/189
Consumables
Consumables and the printer
The Markem-Imaje printer is delivered with the right consumables according with the ink
type selected by the customer.
We strongly advise to do not replace the ink type.
Markem-Imaje equipment is guaranteed. In order to have a correct printer management,
use always the Markem-Imaje consumables appropriated.
Consumables use
Consumables must be used before the expiration date mentioned on the label. Beyond
this date, they are no longer 100% compliant with the original specifications for use.
Safety equipment for Markem-Imaje service engineers
Refer to the safety equipment list dedicated to the service engineers
Rules of conduct for Markem-Imaje service engineers when visiting
customers
Safety
MI Service engineers must comply with the safety rules in effect at the customer's site:
Prevention plan: MI Service engineers must request and examine the customer's
prevention plan (where applicable) on the customer's site.
- Traffic areas
- Authorization to use spark-producing tools
- Authorizations to perform work
- Necessary accreditation (chemical, electrical, etc.)

A36163-C.doc
17/189
Printer
Description

Printer description
A36163-C.doc
18/189
Notes:

Printer description
A36163-C.doc
19/189
■Introduction
Two printer versions are available:
Markem-Imaje 9020
Markem-Imaje 9030
9020 is available in one configuration:
IP 54, mono-print head, single jet, G type.
9020 key points:
Ergonomic operator interface
Easy management and access to the consumable cartridges
PCMCIA card for back up
Logo creation
Up to 4 lines
Up to 100 messages
Large choice of barcodes, including Datamatrix
9030 is available in several configurations:
IP 54 or IP 65, mono-print head, single or twin-jet, G or M type.
9030 key points:
Ergonomic operator interface
Easy management and access to the consumable cartridges
PCMCIA card for back up
Logo creation
Up to 8 lines (twin jet configuration)
Up to 880 messages
Large choice of barcodes, including Datamatrix
Ethernet connection (option)
IP65 rating (option)

Printer description
A36163-C.doc
20/189
■Cabinet
9020 and 9030 are composed of a cabinet and a print head linked by a 3 meter umbilical.
Front view Rear view
(with printer holder)
The cabinet must be installed vertically by the fixing points located on the rear side
A distance of 90mm (MI support deep) is necessary between the back of the printer and
the stand (wall) this allow to open correctly the right door.
The cabinet (9020 and 9030) is manufactured out of stainless steel (304L quality)
9030 IP65 printer requires a connection to plant air).
Two doors allow access to the following areas:
•The right side allows to access to the hydraulic compartment (consumable
cartridges, ink circuit & PCMCIA slot).
•The left side allows to access to the electrical compartment (industrial interface,
electronic boards & EHT block, pressurisation kit).