Loveshaw MicroJet II User manual

Technician's Manual
MicroJet™
Trouble-Shooting
Guide
PART NUMBER: CPM755116-TSG
Classic Style

ii
MicroJet Trouble-Shooting Guide
Technician's Manual
MicroJet™
Trouble-Shooting
Guide
Copyright ©Loveshaw,All RightsReserved

MicroJet Trouble-Shooting Guide
iii
LOVESHAW
an ITW Company
2206 Easton Turnpike, PO. Box 83
South Canaan, PA 18459
Tel: [phone] or 570-937-4921
Fax: [phone]
www.LOVESHAW.com
[email protected]
Loveshaw Europe A Division of ITW LTD.
Unit 9 Brunel Gate
West Portway Industrial Estate
Andover, Hampshire SP10 3SL
ENGLAND
Tel: [phone]
Fax: [phone]
www.LOVESHAW.com
[email protected]
DocumentrevisedMay10,2001. Thisdocumentcovershardwaremaintenanceproceduresforthenew MicroJet Printers. LoveshawanITWCompany
Route296, Box83 SouthCanaan,PA 18459. Divisions:Padlocker CaseSealersPadlockerPackaging SystemsLittleDavidCaseSealersCLittle David
Jet Printers. This documentation is Copyright © 1993, 2000, 2001 Loveshaw.
up dated 2005 by William Diehl
Copyright ©Loveshaw,All R ightsReserved

iv
MicroJet Trouble-Shooting Guide
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A) Ink lamp stays on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B) Ink lamp does not come on when ink container is empty . . . . . . . . . . . . . . . . . 2
C) Unit does not purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D) Heavy printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E) Weak print/output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F)Printing starts heavy and weakens when printing long messages. . . . . . 4
G) Photocell LED(s) does not light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
H) Photocell LED(s) does not turn off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
I) Display does not come up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
J) CPU losing date/time when unit is off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
K) Valve does not print but purges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
L) Valves print but will not purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
M) Pump does not run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
N) Ink leaks from ink bottle cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
O) Product delay/character width changing on product . . . . . . . . . . . . . . . . . . . . 7
P) Ink not drying on product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Q) Nozzle plate weeps ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
R) Nozzle blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
S) Tubing loose on valve ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
T) Unit locks up after installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
U) Tailing output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Low ink lamp/reservoir lead removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Air pump pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
34
40
Changing EPROM Software on CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Copyright ©Loveshaw 2004,All Rights Reserved
PartsListwith ExplodedView....................................... 28

MicroJet Trouble-Shooting Guide
vCopyright ©Loveshaw,All RightsReserved

MicroJ et T rouble-S hooting G uide 1
Head:
Introduction
This document covers hardware procedures for the L oveshaw
MicroJet Printers which include MicroJet II, MicroJet 5x5,
MicroJet Multi II, and MicroJet Multi III. Procedures are
described in a simple list form keyed to hardware fault, so that
technicians can quickly diagnose and fix such problems.
NOTE: R efer to attached assembly drawings when
trouble-shooting system. Further assistance can be obtained by
calling your local distributor or L oveshaw factory service
technician at 1-800-962-2633.
Head:
A) Ink lamp s tays on
*New units shippedfromthefactory containa solution thatwill
cause the lamp to remain on. This solution must be completely
purged out, and ink purgedthrough, beforethelampwill go out.
* Purge unit with lid at approximately 45 degrees, light should
go out.
* If lamp remains on, remove pump cover (Item #21). Page 28.
* With power disconnected, look for broken wire at reservoir
(Item #22) page 28 and test resistance across pins 1 and 2 on
side“A” of four pin connector. R esistanceacross reservoir pins
shouldmeasureapprox. 1.5 meg. ohm(Item#2 ) . Page29. And
figure 6, page 18.
* If lamp remains on, call for service.
Copyright ©Loveshaw 2004, All Rights Reserved

2 MicroJ et T rouble-S hooting G uide
Head:
B ) Ink lamp does not come on when ink c ontainer is
empty
* R emove pump cover (Item #21). Page 28.
* With power disconnected, check continuity across reservoir
pins 1 and2 onfour pinconnector side“A” (Item #2) page 29.
See figure 4 on electrical testing diagram page 18. Circuit
should be open.
* Check resistance of lamp between pins 3 and 4 on four pin
connector on side “ A ”. R esistance should be 25 ohms. If circuit
is open replace lamp (Item #12) Page 28. See LOW INK
LAMP/RESERVOIR LEAD REMOVAL procedure. Page 10.
* Check voltage between pins 1 and 2 on four pin connector on
side “ B ”. A very small voltage of .075 volts DC should be
present. If no voltage is present, replace CPU assembly (Item
#7) Page 28.
* Check voltage between pins 3 and 4 on four pin connector on
side “B ”. V oltage should be 25 volts DC. If no voltage is
present, replace CPU assembly (Item #7) Page 28.
* If lamp remains out, call for service.
Head:
C ) Unit does not purge
* Test pump pressure (Item #11). Page 28. Pressure should be
between 2.0 and 3.0 psi. If pressure is zero, proceed to step
“M”.
* Check ink level in container and replace if empty.
* Check for kinks in tubing and replace, if necessary.
* T est for ink flow from brass cap/ink container: Crimp tubing
going into reservoir from ink container Pg. 15,Pg. 26 (Item 15)
R emove tubing from inlet of reservoir and test for ink flow by
loosening crimp (discharge into container and avoid getting ink
on circuit cards). If no flow is present, replace ink container
and/or brass cap.
Copyright ©Loveshaw 2004, All Rights Reserved

MicroJ et T rouble-S hooting G uide 3
* Test for ink flow from reservoir. Crimp tubing going into
reservoir from ink container. R emove tubing from inlet side of
filter. Pg. 15, 29 Item 23. Carefully loosen crimp and test for
ink flow (discharge into container and avoid getting ink on
circuit cards). If a weak ink flow or no flow is present, replace
reservoir. See LOW INK LAMP/RESERVOIR LEAD REMOVAL
procedure. Page 10.
* Test for ink flow fromfilter: Crimptubinggoinginto reservoir
from ink container. R emove tubing from inlet side or off-center
port of valve, item #3a, page 29. Carefully loosen crimp and
test for flow (discharge into container and avoid getting ink on
circuit cards). If a weak flow or no flow is present replace filter.
Head:
D) Heavy printing
* Check dot size setting (<SIZE> key). L ower if needed.
* Check incoming voltage from transformer. V oltage between
pins 1 and 2 on transformer connector should be approximately
20 volts AC (see figure 5 on electrical testing diagram page
13).
* Purge to remove air.
* Check individual valve adjustment (<ME NU> then 6). L ower
if needed.
* T est pump pressure (2.0-3.0 psi) if higher, adjust. See AIR
PUMP PRESSURE ADJUSTMENT procedure. Page 10.
Head:
E ) Weak print/output
* Check dot size; increase as needed.
* Check purge output; all nozzles to give a 2"stream or
greater.
* If weak printing continues, go to letter “C” testing.
Copyright ©Loveshaw 2004, All Rights Reserved

4 MicroJ et T rouble-S hooting G uide
Head:
F ) P rinting s tarts heavy and weakens when printing
long mes s ages
* Purge for air removal.
* Check purge-should be steady; if not, go to letter “C” testing.
Head:
G ) P hotoc ell L E D(s ) does not light
* T est photocell by placing a white piece of paper directly in
front of unit; L E D(s) should come on. If not, turn photocell
holder(s) gently from side to side and note if L E D light(s) come
on; leave in position that lights L E D(s); slowly pull paper back
from unit and note distance at which L E D goes out; should be
2"or more. If not, replace photocell (Item #16) page 29.
Head:
H) P hotocell L E D(s ) does not turn off
* Check that there is no reflective material in front of unit. If so,
the material should be painted a “flat black” color (infrared
does not reflect well off of a flat black surface.)
* T urn photocell holder(s) gently from side to side and note if
L E D light goes out.
* Power the unit off then on; L ED light should be off, if not, look
for ink or water on board(s) or unit.
* If ink or water is on board-remove and flush/dry overnight.
R e-test next day.
*L E D light is on, and will not go out, replace CPU board (Item
#7) Page 28.
Copyright ©Loveshaw 2004, All Rights Reserved
* Check for dirt or ink on the photocell lens. Clean with
Q Tip and alcohol. If lens has a haze on it, replace photo-
cell (Item #16) page 29.

MicroJ et T rouble-S hooting G uide 5
Head:
I) Dis play does not come up
* Check if pump is running; if not, check that transformer is
operating properly (figure 3 on electrical testing diagram page
13).
* If pump is running, check AC fuse under pump cover (Item
#4 page 28) and replace if blown.
* If fuse continues to blow, replace power supply board (Item
#3 page 28).
* If fuse does not blow, test voltage at valve board, insure 20-
pin ribbon connector is seated properly. If proper voltage is
present replace CPU.
* If proper voltage is not present, call for service.
Head:
J ) C P U los ing date/time when unit is off
* R eset and monitor for 24 hours with unit off.
* If retest fails, CPU battery must be replaced.
* If CPU looses date/time with unit on, replace CPU.
Head:
K ) Valve does not print but purges
* Plug a working valve in that position and test. If printing
occurs, replace valve. If no printing occurs, replace CPU (Item
#7). Page 28.
Copyright ©Loveshaw 2004, All Rights Reserved
CPU with round/coiled cable, See Fg. 19, Page 21
for Battery placement.
CPU with ribbon cable, See Fg. 20, Page 25 for
Battery placement.
See Page 12 for replacement instructions.

6 MicroJet Trouble-Shooting Guide
Head:
L) Valves print but will not purge
* Test continuity of purge switch (on valve board ) with unit
off and purgeswitch depressed. Replaceif defective; should be
zero ohms.
* Test valveboardresistor/diodefor proper values(figure7 on
electrical testing diagram, page 13).
Head:
M) Pump does not run
* Remove transformer power cord from unit and check for
proper voltage at connector (figure 5 on electrical testing
diagram page 13). Replace transformer if defective.
* Removepump cover (Item #21, page28) and check electrical
connectors on pump (figure 3a on electrical testing diagram
page 13). If proper voltage is present at pump and pump is not
running, removewires(2) going to pump, and check resistance
across pump coil (figure 3b on electrical testing diagram page
13).
* If no voltage is present at pump connectors call for service.
Head:
N) Ink leaks from ink bottle cap
* Remove brass connector (Item # 6 and 7 , page 29) and
check for presence of “ O” rings on the under side of brass
connector and replace if missing or damaged.
* Tighten container cap.
* Reposition container and check for leaks.
* If leak continues, replace bottle with a new one and retest.
* If leak continues, replaceink bottlecap assembly.
Copyright ©Loveshaw 2004,All RightsReserved
Part # CPMA75-104 (=Items # 5,6,7,27,28 Page # 29).

MicroJ et T rouble-S hooting G uide 7
Head:
O) P roduc t delay/character width changing on product
* Check the orientation of box to Microjet — it must be
perpendicular.
* Clean photocell filters (Item #14, page 29) with water, and
check that both photocell L E D lights come on when product
passes by. If photocell L E D does not come on, go to procedure
“G”.
* Check to insure no extraneous spaces are inserted before or
after text in message. If so, delete extra spaces.
* If problem continues, check for dark colored bands on box.
(Photocells will not detect black). T est with a blank box.
* If product delay/character width continues to move, call for
service.
Head:
P ) Ink not drying on product
* Check dot size setting ( <SIZE > key); lower if needed.
* Check pump pressure-should be between 2.0 and 3.0 psi. If
pump pressure is out of adjustment, see AIR PUMP PRES SURE
ADJUSTMENT procedure.
* Check to be sure box is not waxy or oily (make sure substrate
surface has not changed).
Head:
Q) Nozzle plate weeps ink
* Wipe nozzle plate with a damp paper towel and check to see
if ink forms on nozzle plate.
* If ink does not form on nozzle plate, print 5-10 boxes and
check. If ink forms, replace nozzle plate tubing.
* R emove valve at location generating weeping.
* Connect valve to a 9 volt battery and flush water into outlet
post with a syringe and a piece of .040 tubing.
Copyright ©Loveshaw 2004, All Rights Reserved

8 MicroJ et T rouble-S hooting G uide
* R eplace valve and retest.
* Connect tubing to outlet of valve from the nozzle plate and
purge
* R epeat backflush and purge if necessary
* If weeping persists, replace valve.
Head:
R ) Nozzle blocked
* R emove tubing from center port of valve that supplies fluid to
blocked nozzle.
* Connect drain hose (from maintenance kit) to tubing attached
to back of nozzle plate (Item #10). Page 29.
* Place other end of drain tubing outside of unit and drain into
a container.
* Place tubing end of syringe with cleaner, over orifice that is
blocked andapply pressure (you will see fluidmovedown drain
tube).
* Continue flushing until tubing is clear of ink.
* Disconnect syringe and reconnect tubing to valve port.
* Purge and retest.
* R epeat if necessary.
* If nozzle is still blocked, replace the nozzle plate assembly.
Head:
S ) Tubing loos e on valve ports
* If tubing is brittle, replace with new .050 X .070 tubing (p/n
CPJ00-024-0).
* If tubing is not hard, remove the valve (clamp off all pressure
lines first) and cut off 1/8" from ends and reposition on valve.
* Note: B oth valve port and tubing end must be dry to ensure a
tight fit. Dry tubing end by rolling the corner end of a paper
towel into a fine point and insert into tubing end.
Copyright ©Loveshaw 2004, All Rights Reserved

MicroJ et T rouble-S hooting G uide 9
Head:
T) Unit locks up after ins tallation
* Connect transformer to a Power B ackup Supply UPS
(available from L oveshaw).
* Supply a dedicated line plus use regulated supply.
* Insure A.C. outlet has a proper ground.
* Make sure the conveyor line is properly grounded to a low
impedance ground (less then 5 ohms).
* If you are unable to unlock the MicroJet by turning it on and
off, preform the 666 SL AM function (see operators manual for
additional information on 666 SL A M).
Head:
U) Tailing output
* Check distance between head and substrate; should be 1/2"
max.
* Check dot size setting, readjust global and individual.
* Make sure unit is level and not being subject to excessive
vibration.
* Purge system of air with lid at approximately 45 degrees.
* Check pumppressure(seeAIR PUMP PRESSURE ADJUSTMENT
procedure, page 10).
* Check tubing lengths going from valve to nozzle plate (see
nozzle plate drawing).
* B ackflush all nozzles
* Change nozzle plate (Item #10, page 29).
* Increase character width and check line speed.
Copyright ©Loveshaw 2004, All Rights Reserved

10 MicroJ et T rouble-S hooting G uide
F igure 1. P in extraction.
Head:
L ow ink lamp/res ervoir lead removal
T o remove either low ink lamp leads or reservoir leads from the
four pin connector, follow steps as listed:
* Turn unit off.
* Open lid.
* R emove ink bottle; place cap on bottle and set aside
* R emove two screws from pump cover, one on each edge, and
set aside.
* Disconnect four pin connector from modular board to
lamp/reservoir leads by pulling male
and female of connector apart.
* If a pin extraction tool is not
available, use a fine point object (i.e.,
an X -acto™ knife), to push two locks
of male pins inward towards pin body.
* As locks of pin are being folded in,
firmly tug wire away from connector.
* R epeat for each pin removed.
* Firmly tug wire away from connector.
* R epeat for each pin removed.
Head:
Air pump pres s ure adjus tment
* Turn unit off.
* Open lid.
* R emove ink bottle; place cap on bottle and set aside.
* R emove two screws from pumpcover, one each edge, and set
aside.
Copyright ©Loveshaw 2004, All Rights Reserved

* C arefully flip cover upside down and lay on unit where
instruction label is located. (Note that the reservoir will stay
attached to underside of pump cover).
* R emove tubing from bellows shaft.
* T urn the brass knob
clockwise for higher
presser or counter
clockwise for lower
presser.
* R eplace tubing onto
bellows shaft.
* Place pump cover back
into position and tighten
the two screws.
* V erify pump pressure at air port of the brass bottle cap using
gauge assembly and turn the unit on.
* R epeat procedure to obtain desired pump pressure.
MicroJet Trouble-Shooting Guide 11
Copyright ©Loveshaw 2004, All Rights Reserved

12 MicroJ et T rouble-S hooting G uide
Head:
B attery R eplacement
1) Turn unit off.
2) Open lid and remove 4 screws from inside of top half of
unit. R emove 2 jack screws that secure CPU board to
CPU/K E Y PAD assembly and position L CD keypad so that you
have access to CPU board.
3) If battery is soldered into CPU board:
A) R emove old battery.
B) Note polarity of new battery and solder in place.
If battery is in battery holder:
A) R emove old battery.
B ) Note polarity of new battery and slide into holder.
4) R eassemble CPU/K E Y PA D assembly and test unit.
B attery R eplacement
Caution, Risk of explosion if battery is replaced by an incorrect type.
Dispose of used batteries accordingto the instructions.
L I T HI UM B A T TE R Y WA R NI NG
CAUT IO N! This product contains a lithium battery. T here is danger of explos ion if battery is
incorrectly replaced. R eplace only with a Duracell DL 2430 or equivalent. Make sure the battery is
ins talled with the correct polarity. Discard us ed batteries according to manufacturer's instructions .
ADV AR S EL! Lithiumbatteri - E ksplosjonsfare. V ed utskifting benyttes kun batteri som anbefal t (D uracell
DL2430) av apparatfabri kanten. B rukt batteri returneres apparatleverandøren.
ADV AR S EL! Lithiumbatteri - Eksplosjonsfare ved fejlagtig håndtering. Udskiftningmå kun ske med batteri
av samme fabri k(Duracel l DL 2430) at og type. Levér det brugte batteri til bage til l everandøren.
V AR OIT US! Paristo voi räfähtää, jos se on vi rheelli sesti asennettu. V aihda paristo ainoastaan
lai tevalmistajan suosittelemaan tyyppin (Duracell DL 2430). Hävi tä käytetty paristovalmistajan ohjeiden
mukaisesti.
V AR NING! E xplosionsfar vid felaktigt batteribyte. Använd samma batterityp eller en ekvival ent typ
(Duracell DL 2430) som rekommenderas av apparatti llverkaren. K assera använt batteri enl igt fabrikantens
instruktion.
A TTENTION! Il y a danger d’explsi on s’ il y a remplacement incorrect de la batterie. R emplacer uniquement
avec une batterie du même type (Duracell DL 2430) ou d’un type équivalent recommandèpar le constructeur.
Mettre au rebut les batteries usagées conformèment aux i nstructi ons du fabri cant.
Copyright ©Loveshaw 2004, All Rights Reserved.
3 V olt L ithium B attery
Part Number CPMD75-009-0
Part Number C PM 75-015-
0

MicroJ et T rouble-S hooting G uide 13
F igures 3A, 3B , 4, 5a, 5b, 6, 7. As sorted measurements.
Copyright© Loveshaw 2004, All Rights Reserved.
T R OUB L E SH OOT I NG C H A R T
CHE CK ING A IR PUMP COIL A SSE M B L Y CPM 75-208-B
L OW INK L IGHT C ONNE CT OR C HE CK
POW E R SUPPL Y T R A NSFOR ME R C HE CK
CPM11-003-120 CPM75-003-115
CPM11-003-240 CPM75-003-240
L OW INK L IGHT C ONNE CT OR
DIODE R E SIST OR
CPJ00-009-0 & 25 OHM
SE T ME T E R T O V ~ A ND
T A K E R E A DI NG ON
T W O T E MINAL
CONNE CT T O POW E R .
IT SHOUL D B E 19.5
V AC . POW E R SHOUL D
B E ON.
SE T ME T E R T O OHM S
A ND T A K E R E A DI NG
ON DI SC ONNE C T E D
T E R MI NA L S W IT H
POW E R OFF UNIT .
IT SHOUL D B E 32
OHMS.
SE T ME T E R T O DC V OL T A GE .
NOT E :
T W O T OP W IR E AR E FR OM R E SE R V OI R A ND
B OT T OM T W O A R E FR OM T HE L AMP.
POW E R MUST B E ON.
SE T ME T E R T O A C V OT A GE .
ME A SUR E T HE T R A NSFOR ME R
PL UGE D INT O A N A C OUT L E T .
SE T ME T E R
T O OHM S
PI N #1 R E T UR N
PI N #2 HOT (primary)
PI N #3 HOT (secondary)
PIN #4 NO C ONNE C TION
PI N #1 HOT (primary)
PI N #2 R E T UR N
PI N #3 HOT (secondary)
Figure 3a Figure 3b
Figure 4
Figure 5a Figure 5b
Figure 6 Figure 7

14 MicroJ et T rouble-S hooting G uide
F igure 8. P ower harnes s as sembly.
Copyright ©Loveshaw 2004, All Rights Reserved.
With Illuminated Switch
With Black Switch

MicroJ et T rouble-S hooting G uide 15
Copyright ©Loveshaw 2004, All Rights Reserved.
Air
Pump
Ink
Bottle
Brass
Cap
Filter
Check
Valvle
Reservoir
Figure9.