Hitachi UX Twin Nozzle User manual

Service Manual
HITACHI Printer
UX Twin Nozzle Model
Revision February 2017
Version A

[HITACHI IJ Printer Model UX for Dye Ink]
TYPE
Nozzle Diameter
UX-D860W
Standard Model
Standard Character
UX-D
65μm

Contents
1. Introduction································································································1-1
1.1 Safety precautions ·················································································1-1
1.2 Structure of each part in the main body ······················································1-10
1.2.1 External views ·················································································1-10
1.2.2 Main body internal ···········································································1-11
1.2.3 Print head ······················································································1-12
1.3 Installation ···························································································1-13
1.3.1 Power supply wiring···········································································1-13
1.3.2 Installation procedure·········································································1-15
2. Maintenance work ·······················································································2-1
2.1 Setting of service personnel maintenance mode ···········································2-1
2.2 System environment setup ·······································································2-4
2.3 Adjustment/operational checkout ·······························································2-5
2.3.1 Excitation adjustment·········································································2-5
2.3.2 Charging voltage confirmation ····························································2-8
2.3.3 Phase margin test ············································································2-10
2.3.4Auto phase gain adjustment ·······························································2-13
2.3.5 Level sensor confirmation ··································································2-15
2.3.6 Heating unit confirmation ···································································2-18
2.4 Test of solenoid valve/pump ····································································2-20
2.5 Download ····························································································2-22
2.6 Calibration of viscometer ········································································2-24
2.6.1 Calibration of viscometer ···································································2-24
2.6.2 Operation test of viscometer ······························································2-25
2.7 Circulation system environment setup ······················································2-26
2.8 System reset ·······················································································2-27
2.9 Back up ······························································································2-28
2.10 Unit information ··················································································2-29
2.11 Handling of the warning ”Product Speed Matching Error”, etc. ·····················2-31
2.12 Language registration ··········································································2-36
2.13 Fault / Warning log management code ····················································2-38
2.14 Software option set up ·········································································2-40
2.14.1 Software option setup ·····································································2-40
2.15 Time of preparing for printing ································································2-42
2.16 Touch screen setup··············································································2-43
2.17 Logging data·······················································································2-44
2.18 Rescue soft ························································································2-53

3. Maintenance of controlling part·······································································3-1
3.1 Structure of controlling part ····································································3-1
3.2 Controller part ·····················································································3-5
3.2.1 EZJ128 board (controller board) ·························································3-5
3.2.2 Battery ··························································································3-8
3.2.3 LCD ······························································································3-10
3.2.4 Touch panel ····················································································3-12
3.3 Engine part····························································································3-13
3.3.1 EZJ133 board (MPU board) ································································3-13
3.3.2 Battery ··························································································3-17
3.3.3 Model Key ······················································································3-18
3.3.4 Language Key (Option) ·····································································3-18
3.3.5 EZJ125 board (Nozzle1 drive board)·····················································3-19
3.3.6 EZJ134 board (Nozzle2 drive board)·····················································3-22
3.3.7 EZJ127 board (I/O board)···································································3-25
3.3.8 EZJ138 board (Ink circulation module connection board) ·························3-31
3.3.9 EZJ113 board (Power relay board 1) ···················································3-32
3.3.10 EZJ139 board (Power relay board 2) ·················································3-34
3.3.11 EZJ114 board (LED / SW board) ·······················································3-36
3.3.12 EZJ119A board (Relay output board) (Optional board) ·························3-36
3.3.13 EZJ130 board (Software option control board)·······································3-38
3.3.14 EZJ129 board (Software option terminal board)·····································3-40
3.3.15 Multiple Power Supply 1 and 2 ························································3-48
3.3.16 High Voltage Power Supply 1 and 2 ···················································3-51
3.3.17 DC fan ·························································································3-52
3.3.18 LAN communication function·····························································3-52
3.3.19 RFID reader ···················································································3-53
3.3.20 Electrical Connection Diagram ···························································3-55
4. Maintenance of Circulation System ································································4-1
4.1 Structure of Circulation System··································································4-1
4.1.1 Structure of Circulation System····························································4-1
4.1.2Access to the parts on the front side of the equipment ······························4-4
4.1.3Access to the parts on the rear side of the equipment·······························4-6
4.2 Main Ink Tank Maintenance ······································································4-8
4.2.1 Structure of Main Ink Tank···································································4-8
4.2.2 Main Ink Tank Replacement Procedure··················································4-9
4.3 Pressure Reducing Valve Replacement Procedure········································4-12
4.4 ICU Joint Structure and Handling·······························································4-13
4.5 Solenoid Valves Replacement Procedure ····················································4-14
4.6 Pressure Sensor Replacement Procedure···················································4-18

4.6.1 Pressure Sensor (Nozzle 1) Replacement Procedure·······························4-18
4.6.2 Pressure Sensor (Nozzle 2) Replacement Procedure·······························4-20
4.7 Circulation Unit Replacement Procedure ····················································4-23
4.8 Pump Parts Replacement ·······································································4-25
4.8.1 Pump Unit Replacement Procedure······················································4-25
4.8.2 Drive unit replacement procedure·························································4-28
4.8.3 Pump head replacement·····································································4-30
4.8.4 Motor replacement ············································································4-32
4.8.5 Gear replacement ·············································································4-34
4.8.6 Recovery pump2 drive unit replacement procedure··································4-35
4.8.7 Recovery pump2 pump head replacement ·············································4-37
4.8.8 Recovery pump2 motor replacement procedure ······································4-39
4.8.9 Recovery pump2 gear replacement ······················································4-41
4.9 Circulation Filter and Makeup Filter Replacement Procedure···························4-43
4.9.1 Circulation Filter and Makeup Filter
in Nozzle 1 path Replacement Procedure···············································4-43
4.9.2 Circulation Filter and Makeup Filter
in Nozzle 2 path Replacement Procedure···············································4-44
4.10 Ink Reservoir/Makeup Reservoir Replacement Procedure·····························4-45
4.10.1 Ink Reservoir replacement·································································4-45
4.10.2 Makeup Reservoir replacement··························································4-47
4.11 Solenoid Replacement Procedure ····························································4-49
4.12 Troubleshooting when Fault Occurs in Viscometer·······································4-52
4.12.1 Viscometer removal procedure···························································4-52
4.12.2 Disassembling and washing viscometer ··············································4-54
4.12.3 Viscometer assembly procedure·························································4-55
4.12.4 Viscometer attaching procedure ·························································4-55
4.12.5 Replacing thermistor ········································································4-56
4.13 Print Head Replacement Procedure··························································4-57
4.14 Troubleshooting Procedure for the Circulation System··································4-63
4.15 Repairing Method When the Circulation Route Is Dry or Sticks ·····················4-73
4.15.1 Recovery method when solenoid valve is stuck ·····································4-73
4.15.2 Repairing method for the supply pump·················································4-73
4.15.3 Repairing method for the makeup pump···············································4-74
4.15.4 Repairing method for the circulation pump············································4-74
4.15.5 Repairing method for the recovery pump··············································4-75
4.15.6 Recovery method when the CV assembly is drying/clogging ····················4-76
4.16 Maintenance Work of Intake fan unit ························································4-77
4.16.1 Structure of Intake fan unit································································4-77
4.16.2 Replacement of Intake fan unit···························································4-77
4.17 R air filter Replacement Procedure ··························································4-79

4.18 Check on Exhaust Duct dripping ·····························································4-80
4.19 Circulation system cleaning of printer which uses Ethanol-based ink···············4-81
5. Print head related maintenance ····································································5-1
5.1 Structure of Print head·············································································5-1
5.2 Cable running direction············································································5-2
5.3 Gutter configuration and replacement method ··············································5-3
5.3.1 Gutter configuration···········································································5-3
5.3.2 Replacement method·········································································5-3
5.4 MGV filter replacement ············································································5-4
5.5 Shutoff valve (MV9/MV29) replacement ······················································5-6
5.6 Heating unit replacement ·········································································5-9
5.7 APH board (EZJ135) replacement······························································5-11
5.8 Nozzle replacement ················································································5-12
5.9 Nozzle Orifice Cleaning ···········································································5-15
5.10 Thermistor replacement·········································································5-17
5.11 Deflection Base Replacement Procedure···················································5-19
5.12 Head base Replacement Procedure ·························································5-23
5.13 Head Cable Replacement Procedure························································5-26
6. Troubleshooting ··························································································6-1
6.1 Troubleshooting List················································································6-1
6.2 Faults - Ink-stop type ·············································································6-5
6.3 Faults - Print-stop type·············································································6-47
6.4 Warning conditions (printing continuously performed)·····································6-65
6.5 Faults - No indication on screen·································································6-82
7. Attached Drawing························································································7-1
7.1 Circulation system diagram ·····································································7-1
7.2 Tube Connection Diagram ······································································7-2
7.3 Electrical Connection Diagram ·································································7-3
7.4 Dimensions around charge electrode and deflection electrode·························7-4

1-1
1. Introduction
1.1 Safety precautions
● Before using the printer, thoroughly read the following safety precautions for optimum printer use.
● All the instructions set forth in this manual are important and must therefore be observed without
fail.
● 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.
● 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.
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).
WARNING
CAUTION
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”.
SAFETY PRECAUTIONS (Continued)

1-2
●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.
③Secure adequate space for the ink/makeup handling area and printer
installation site. At least 400 m3must be provided per print head.
●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.
●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.
SAFETY PRECAUTIONS (Continued)
WARNING
Installation Environment of Printer
CAUTION

1-3
●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.
●Make sure the ground wire is properly connected to the ground
of the electrical outlet.
Failure to do so could result electrical shock or fire.
●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.
● 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.
● Use the power cable that is designated in this manual.
● Wire the power supply in accordance with this manual.
WARNING
SAFETY PRECAUTIONS (Continued)
Grounding
Cable handling
WARNING

1-4
● 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 vapors of ink or 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.
●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.
SAFETY PRECAUTIONS (Continued)
WARNING
Ink and Makeup Handling

1-5
●Since the ink and makeup contain organic solvents, observe the
following handling precautions.
①When 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.
②When 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.
③Since 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.
CAUTION
SAFETY PRECAUTIONS (Continued)

1-6
●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.
●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.
●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.
● 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.
●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.
SAFETY PRECAUTIONS (Continued)
WARNING
Main Body Handling

1-7
●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 and/or side cover off (terminal block transfer, EZJ113 or
EZJ 139 board replacement, etc.).
Failure to do so could result electrical shock, injury or fire.
●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.
●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.
●The printer must be managed in compliance with all appropriate
regulations.
Read and understand the appropriate Safety Data Sheet (SDS) before using any
ink or makeup.
●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 Safety Data Sheet (SDS). The SDS can be accesses
from the following web site or from our sales office.
URL http://www.hitachi-ies.co.jp/ijp
●The ink and makeup, their waste solution, used wiping papers and
empty containers are flammable. Waste disposal must comply with
appropriate regulations. Consult the appropriate regulatory agency
for further information.
WARNING
SAFETY PRECAUTIONS (Continued)
Electrical Parts Handling
CAUTION
WARNING
Related Regulations

1-8
● Only persons who have completed an operator training course
for Hitachi IJ printer can operate and service the printer.
If the printer is operated or serviced incorrectly, it may malfunction or break
down.
● Do not attempt to make repairs for any purpose other than
operation or maintenance.
●Use Hitachi approved consumables and periodic replacement arts.
Using products that are not designated by Hitachi could cause s failure in
certain functions.
●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.
●Keep all fire away.
○Ink and Makeup are flammable.
○All fire must be kept away from the machine.
○Spilled Ink and Makeup must be wiped off and dried up immediately.
●Caution when handling Ink/Makeup
○Storage must comply with local regulatory requirements.
○Read and understand Safety Data Sheet (SDS).
○Be sure to wear protective gloves and safety goggles.
○If the Ink/Makeup in used is an organic solvent, it must be managed in compliance
with the Ordinance on the prevention or Organic Solvent poisoning.
Refer to the "Instruction Manual" and the "Handling guidance of each ink" for details.
CAUTION
SAFETY PRECAUTIONS (Continued)
Others
WARNING

1-9
●Tenir hors de portée du feu.
○L’encre et la composition sont inflammables.
○Tenir la machine hors de portée du feu.
○Nettoyez et séchez immédiatement les projections d’encre et de composition.
●Soyez prudent lorsque vous manipulez l’encre/la composition
○Le stockage doit respecter les obligations réglementaires locales.
○Lisez attentivement la fiche signalétique de sécurité de l’appareil (FSSP).
○Assurez-vous de porter des gants et des lunettes de protection.
○Si l’encre/la composition utilisée est un solvant biologique, vous devez le manipuler
conformément au décret sur la prévention des empoisonnements par solvant biologique.
Reportez-vous au «Mode d’emploi» et aGT «Conseils de manipulation de chaque type d’encre»
pour plus de détails.
●When replaced with an incorrect type of battery, the battery is in
danger of exploding. Be sure to replace the battery with the one
specified by parts list.
When disposing of the battery (lithium battery), you must comply with local
regulatory requirements. Consult the appropriate regulatory agency for further
information.
●Si vous remplacez avec un mauvais type de batterie, elle risque
d’exploser. Assurez-vous d’utiliser une batterie indiquée dans la
liste des pièces..
Lorsque vous jetez la batterie (au lithium), vous devez respecter les obligations
réglementaires locales. Consultez l’agence de réglementation appropriée pour
obtenir de plus amples informations..
AVERTISSEMENT
SAFETY PRECAUTIONS (Continued)
WARNING
ATTENTION

1-10
1.2 Structure of each part in the main body
1.2.1 External views
(1)External views
(2)External views (Rear side)
Air-purge
Connection port
Exhaust duct
Connection port

1-11
1.2.2 Main body internal
［Appearance with inner cover removed］
Makeup
cartridge bottle
Makeup
reservoir
Inner cover
Ink cartridge bottle
Ink reservoir
Lever handle
Ink filter
Recovery filter1
Main ink tank
Recovery filter2
Lever handle
Pressure adjusting screw

1-12
1.2.3 Print head
Print head cover lock thumbscrew
Charge electrode1
Nozzle orifice1
Minus deflection electrode1
Charge electrode2
Plus deflection electrode1
Gutter1
Gutter2
Plus deflection electrode2
Minus deflection electrode2
Nozzle orifice2
Note:
Meaning of orifice plate lot number
Position of
lot number
Orifice plate
6 A12345
Serial number
Nozzle diameter
6: 65μm

1-13
1.3 Installation
1.3.1 Power supply wiring
[Applicable power cable]
Use a power cable that meets the following requirements:
- Connector specifications: IEC inlet connector (3-pin, L-type)
Cable of following shape and dimensions
- Outer diameter: Ø7 - 10 mm
- Min. conductor size: 0.75 mm2
- Max. cable length: 5 m (cable should be as short as possible)
Other specifications: Cable should conform to safety standards in the country s
where it is used.
Precautions concerning UL:
If the printer is used in North America, use the cable that meets the following
requirements in addition to those given above.
- Standard: UL/CUL certified
- Rating: 125 V, 7A or more
- Plug: NEMA5-15P
- Cable: Type SJT, 18AWG, 60 °C or higher
- Cable length: 1.5 - 4.5 m
•Use the proper plug. Be sure to ground properly.
•Locate the equipment near an electrical outlet and arrange so it can be easily
disconnected.
•Use a power cable that is within the specified range.
•Do not bundle the light electrical cable together with the power cable outside the
unit so the light electrical signals (connection signals to the various signal
connections and external communication connectors) are not affected by noise
from the power cable.
Caution
！
Min. 18
Ø7 to Ø10
10
38.5 to 44.5
Max. 25
Max. 60
Max. 30
*Be careful of orientation of part
to be inserted and cable.
Unit: [mm]

1-14
１Remove the inlet cover. (Fastening screws x 4)
２Mount the power cable in the inlet and mount the inlet cover.
Be sure to unplug the power cable from the electrical outlet before
performing work.
Be careful not to get shocked when checking with the cover open.
Precautions concerning electrical shock
•Be sure to mount the inlet
cover.
•Wrap the attached cable seal
around the power cable and
set in the position shown in
the figure.
Caution
Cable seal
Power cable
Inlet base
Inlet cover
Side cover
Inlet cover