Hitachi IJ PH User manual

Service Manual
HITACHI Printer
Model PH
Revision Aug. 2011
Version First edition

[ Revision of PH service manual ]
Revision Chapter Revised Page
− − − −

Contents
1. Introduction····················································································································1-1
1.1 Safety precautions ·································································································1-1
1.2 Structure of each part in the main body ·································································1-7
1.2.1 External views (PH-D)·······················································································1-7
1.2.2 Main body internal (PH-D) ················································································1-8
1.2.3 Print head ········································································································1-9
1.3 Installation ··············································································································1-10
1.3.1 Wiring of power supply ····················································································1-10
1.3.2 Installation procedure (PH-D) ···········································································1-13
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·············································································2-6
2.3.1 Excitation adjustment························································································2-6
2.3.2 Charging voltage confirmation ········································································2-8
2.3.3 Phase margin test ···························································································2-9
2.3.4 Auto phase gain adjustment ············································································2-12
2.3.5 Level sensor confirmation ···············································································2-14
2.3.6 Heating unit confirmation ················································································2-15
2.4 Test of solenoid valve/pump ···················································································2-16
2.5 Download ···············································································································2-18
2.6 Calibration of viscometer ·······················································································2-20
2.6.1 Calibration of viscometer ·················································································2-20
2.6.2 Confirmation of the ink viscosity coefficient ····················································2-22
2.6.3 Operation test of viscometer ···········································································2-23
2.7 Ink concentration control ·······················································································2-24
2.8 System reset ·········································································································2-25
2.9 Back up ·················································································································2-26
2.10 Unit information ···································································································2-28
2.11 Handling of the warning ”Product Speed Matching Error” ··································2-29
2.12 Language registration ·························································································2-30
2.13 Fault / Warning log management code ·······························································2-32
2.14 Software option set up ························································································2-34
2.15 Rescue Memory Card ························································································2-36

3. Maintenance of controlling part·····················································································3-1
3.1 Construction of controlling part ·············································································3-1
3.2 Controller part·········································································································3-3
3.2.1 EZJ124 board (controller board)·······································································3-3
3.2.2 Battery···············································································································3-7
3.2.3 Power supply for LCD backlight········································································3-8
3.2.4 Control panel·····································································································3-8
3.2.5 Front panel assembly Replacement Procedure ··············································3-9
3.2.6 LCD assembly Replacement Procedure···························································3-13
3.3 Engine part···············································································································3-18
3.3.1 EZJ93 board (MPU board)················································································3-18
3.3.2 EZJ106 board (NH board)·················································································3-22
3.3.3 EZJ95 board (I/O board)···················································································3-23
3.3.4 EZJ99 board (Optional board) ··········································································3-26
3.3.5 Multiple Power Supply ···················································································3-30
3.3.6 High voltage power supply ··············································································3-30
3.3.7 Fan Replacement Procedure ··········································································3-31
3.3.8 Exhaust Filter Replacement Procedure ··························································3-33
4. Maintenance of Circulation System ·············································································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 ···················································································4-8
4.5 Pump Unit Replacement Procedure········································································4-10
4.6 Solenoid Valves Replacement Procedure·······························································4-12
4.7 Pressure Sensor Replacement Procedure······························································4-14
4.8 Circulation Unit Replacement Procedure································································4-15
4.9 Troubleshooting when Fault Occurs in Viscometer·················································4-18
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. Print head-related maintenance····················································································5-1
5.1 Outline structure of print head and how to remove each cover ······························5-1
5.2 Nozzles Replacement Procedure (appendix: nozzle drive conditions)···················5-2
5.3 Deflecting base Replacement Procedure································································5-6
5.4 Cover switch Replacement Procedure····································································5-9
5.5 Sealing valve (MV9) Replacement Procedure ························································5-10
5.6 Heating unit Replacement Procedure······································································5-12
5.7 Gutter base group Replacement Procedure····························································5-13
5.8 Head base Replacement Procedure·······································································5-14
5.9 Replacing EZJ98 Board (APH Sensor Board)·························································5-16
6. Troubleshooting·············································································································6-1
6.1 Troubleshooting List·································································································6-1
6.2 Faults - Ink-stop type ·····························································································6-3
6.3 Faults - Print-stop type·····························································································6-22
6.4 Warning conditions (printing continuously performed)············································6-33
6.5 Faults - No on-screen indications············································································6-43
6.6 Miscellaneous··········································································································6-53
7. Attached Drawing ··········································································································7-1
7.1 Circulation system diagram ····················································································7-1
7.2 Electrical Connection Diagram ··············································································7-2
7.3 Circulation sequence ·······························································································7-3
7.4 Dimensions around charge electrode and deflection electrode······························7-5
7.5 Excitation curve ······································································································7-6

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”.
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●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.
WARNING
CAUTION

●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
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).
1-1

SAFETY PRECAUTIONS (Continued)
 
●Ensure that there is no flame- or arc-generating device around the
printer.
The ink and makeup 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, remove static 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 contain organic solvents, install the
printer at an adequately ventilated location.
①Never install the printer in an enclosed space.
②Connect exhaust equipment to the printer in order to prevent it from filling with
organic solvent vapor.
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●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.
●Be sure to shut off the power before replacing electrical
components (power, PC board, etc.). Be sure to unplug the power
cable from the electrical outlet before performing work with the
inlet cover .
Failure to do so could result electrical shock, injury or fire.
●Use an AC voltage of 100 to120 V or 200 to 240 V 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.
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●Use the power cable that is designated in this manual.
●Wire the power supply in accordance with this manual.
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WARNING
1-2

SAFETY PRECAUTIONS (Continued)
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●Never drain the ink or makeup waste solution into a public sewer
system.
Waste disposal must comply with all appropriate regulations.
Consult the appropriate regulatory agency for further information.

●Exercise caution to avoid inadvertently disconnecting, forcibly
pulling, or bending piping tubes.
Since the ink and makeup 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 enters your eyes or mouth, immediately flush with warm or
cold water and consult a physician.
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●While the printer is operating, do not look into the ink ejection hole
in the end of the print head.
Ink or makeup may enter your eyes or mouth or soil your hands or clothing.
If any ink or makeup enters your eyes or mouth, immediately flush with warm or
cold water and consult a physician.
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●Before servicing the printer, be sure to stop the ink ejection.
Because ink or makeup may splash into your eyes or mouth or onto your hands
or clothing. If any ink or makeup enters your eyes or mouth, immediately flush
with warm or cold water and consult a physician.
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●If an earthquake, fire, or other emergency occurs while the printer
is engaged in printing or just turned on, press the Main power
switch to turn off the power.
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●The printer must be managed in compliance with all appropriate
regulations.
●Use Hitachi approved consumables and periodic replacement
parts.
Using products that are not designated by Hitachi could cause s failure in
certain functions.
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WARNING
1-3

SAFETY PRECAUTIONS (Continued)
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●When charging a refill of ink or makeup, exchanging ink, or
otherwise handling ink or makeup, take enough care not to spill
ink or makeup.
If you spill any ink or makeup by mistake, wipe it off neatly and
promptly with wiping paper or something similar. Do not close the
maintenance cover 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 inside the printer and it is not completely dry. Why?
Because vapors of ink or makeup will stay inside the printer and
may catch on or cause a fire.
If you find it hard to wipe the printer when it is turned on, stop it with the
maintenance cover open. Power it down, and then wipe it off again.
●If you wish to clean the casing of the printer with wiping paper
impregnated with makeup, be sure to do so with the power off.
Attempting to clean it when the power is on will cause makeup or vapors of
makeup to enter the printer, possibly catching on or causing a fire.
When the cleaning is over, open the maintenance cover and make sure that no
makeup has entered and no vapors remain inside.
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●Should you find a leak of ink or makeup inside the printer while the
printer is running or being maintained, wipe it off promptly with
wiping paper or something similar. Then, with the maintenance
cover open, stop the printer, power it down, and repair the leak.
Continuing operation with a leak of ink or makeup will cause an anomaly,
resulting in abnormal printing.
Ink and makeup are flammable. They may therefore catch on or cause a fire.
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●If you wish to receive ink particles 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 particles used for printing are electrically charged. An ungrounded beaker has
a gradually rising charge, possibly catching on or causing a fire.
●Ensure that all electrical wiring, connections and grounding comply
with applicable codes. Properly connect the printer to its dedicated
ground.
Failure to do so could result in electrical shock or fire.
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●When welding, keep enough space between the IJ printer and the
welding work area to prevent the arc from starting a fire. Also, be
sure to insulate the print head and IJ printer frame to keep the
welding current from flowing to the control section of the printer,
and to make a separate ground connection for the printer.
Exercise caution to avoid electric shock and fire.
WARNING
1-4


SAFETY PRECAUTIONS (Continued)
●Use the printer in an ambient temperature prescribed for each nozzle
diameter and ink and 30 to 90%RH (no condensation) environment.
①When using the printer in 85 to 90%RH environment, air purge the print head.
②Using the printer outside the specified conditions may cause abnormal printing and
erroneous operation and trouble.
●Since the ink and makeup contain organic solvents, observe the
following handling precautions.
①Secure adequate space for the ink/makeup handling area and printer installation
site. At least 200 m3must be provided per print head.
②Ensure that adequate ventilation is provided.
When handling the ink or makeup, wear protective gloves and safety goggles to
avoid direct skin contact. If the ink or makeup comes into contact with skin, wash
thoroughly with soap and warm or cold water.
③When transferring the ink or makeup 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
makeup.
④Since the vapor pressure of the makeup is generally high, if the ambient
temperature is high such as in the summer, etc., the internal pressure will rise and
makeup could spurt out when the outside cover is removed. Therefore, when
unplugging,
●do not hold the bottle near your face
●place the can on a level surface
●open while covering the opening with a rag, etc.
●Ink and makeup must be stored as flammable liquids. Storage must
comply with local regulatory requirements. Consult the appropriate
regulatory agency for further information.
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●Ink and makeup must be handled in compliance with the Industrial
Safety and Health Law and PRTR Law (environmental contaminant
discharge/emigration/transfer registration). For information on
handling, see the Material Safety Data Sheet (MSDS). The MSDS can
be accesses from the following web site or from our sales office.
URL http://www.hitachi-ies.co.jp/ijp
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●If extraneous noise enters the printer, it may malfunction or break
down.
For maximum noise immunity, observe the following installation and
wiring precautions.
①Ensure that 100 to 120 VAC or 200 to 240 VAC power cables are not bundled with
other power supply cables.
②Insulate the printer main body and print head so that they do not come into direct
contact with the conveyor or other devices.
③If the employed print 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.
④Be sure that the print target detector wiring is not bundled together with other
power supply cables.
CAUTION
1-5

SAFETY PRECAUTIONS (Continued)
●When handling PC boards and electric parts, be careful of static
electricity.
PC boards and electric parts mount elements weak against static electricity. When
handling PC boards and electric parts remove the static electricity by wearing a
suitably grounded anti-static wrist band.
●A touch panel is employed for data entry to operation screen.
When manipulating the Touch panel, use only fingers. If the touch
panel is operated with metal and/or sharp objects such as ball
point pen, it may malfunction or break down.
CAUTION
1-6

1.2 Structure of each part in the main body
1.2.1External views (PH-D)
1-7
Exhaust duct connection port
Air-purge connection port
See section "1.2.6, Print
head air purge" in the
instruction manual.

1.2.2 Main body internal (PH-D)
1-8

1.2.3 Print head
1-9
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1.3.5 Print head
Note: Meaning of orifice plate lot number
6 A12345
Serial number
Nozzle diameter
6:
65μm
Position of
lot number
Orifice plate

1.3 Installation
1.3.1Wiring 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
1-10
min18
7 to 10
38.5 - 44.5
Max25
Max60
Max30
Pay attention to the direction
of the cable.
Unit: mm
・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
!

(1) Remove the Inlet cover.(Fixing screw 4 locations)
(2) Insert the power cable to the Inlet.
Inlet cover
(4 fixed screws）
Power Cable
1-11

(3) Mount the inlet cover.
Tape the seal around the outside
of the cable and as in the drawing,
and insert it into the holder as shown
in above.
CAUTION
Power cable
Inlet Cover
1-12

1.3.2 Installation procedure (PH-D)
1-13
Perform an installation work of the unit according to the following procedure
at the unpacking.
Step Work Related page
1 Selection of ink type
(Touch screen operation) 2.2 System environment setup
2 Makeup ink replenishment
Instruction manual 7.4 Makeup ink
replenishment
3 Ink stream alignment
(For filling makeup ink path and adjusting
ink stream position)
Instruction manual
7.7 Adjusting the Ink
stream position
4 Ink replenishment (first replenishment)
(Replace a solvent with ink) Instruction manual 7.5 Ink replacement
5 Ink drainage
(Drainage ink due to insufficient
replacement of a solvent with ink)
Instruction manual
7.5 Ink replacement
6 Ink replenishment
(second replenishment)
(Fill ink into a circulating system)
Instruction manual
7.5 Ink replacement
7 Viscometer calibration
(Touch screen operation, automatic
acquisition)
* This step is not required for the model
PXR-H
2.6
Calibration of viscometer
8 Pressure adjustment
(Set pressure to the standard value of
every ink)
Instruction manual
7.12 Pressure adjustment
9 Adjustment of excitation voltage
(Touch screen operation, automatic
acquisition)
2.3.1
Excitation adjustment
10 Adjustment of APH gain
(Touch screen operation, automatic
acquisition)
2.3.4
Auto phase gain
adjustment
11 Setting of excitation voltage
(Confirm the real printing state and the ink
drop mode and then, set the excitation
voltage)
Instruction manual
7.13 Excitation setting
adjustment
12 Readjustment of APH gain
(Touch screen operation, automatic
acquisition)
2.3.4
Auto phase gain
adjustment
13 Editing Print Data, etc.
(Print start delay, character height, etc.)
Instruction manual
3. Editing Print Data and
Printing
4. Setting the Operating
Environment
5. Auxiliary Function
6. Communication
14
Back up (Service personnel maintenance mode) 2.9 Back up
* [Caution]
The viscometer calibration will not be performed correctly if the step 5 and 6 are
skipped.


2. Maintenance work
A screen for use in the maintenance work by a service personnel is described.
2.1 Setting of maintenance mode by service personnel
For the maintenance work by a service personnel, restrictions on use of the following
functions are removed.
- System environment setup
- Adjustment/operational checkout
- Solenoid valve/pump test
-Download
1 Select the maintenance in a menu and then select Password protection.
2 Execute Limitation change and Input a password “PHDO” and press
Enter password.
Caution
1. The password “PHDO” is a special password to enable the
predetermined screen related to the control of IJP. Do not tell
this password to the customer.
2. Even when the customer sets the password in the password
protection, the “PHDO” has priority.
!
2-1

3 When passing the password judgment, the "service personnel
Caution
After the completion of the service maintenance work, be sure to return
the setting of the “service personnel maintenance” to “1” (protect) (when
the power supply is turned off, the display of the “service personnel
maintenance” automatically turns to non-display (protect)).
maintenance" is displayed and therefore, select "0" and press the
Back key.
4 The Prev. menu Next menu switching key is displayed and thereby the
menu for the service personnel maintenance can be displayed.
!
Features of the service personnel maintenance mode
No. Functions Contents
1 Maintenance menu The second page of the maintenance menu can be
displayed.
2 User environment
setup screen
The excitation V-ref. warning can be displayed.
3 Operation
management
screen
The cumulative operating time can be changed.
4 Operation
management
screen
The heating unit temperature and the ink temperature can
be displayed.
5 Excitation V update
screen
The indicator value of excitation voltage output and the
ambient temperature can be displayed.
6 Select language
screen
The language saving and input mode are possible.
2-2