Markem Imaje 9020 User manual

Book for service engineers
internal use only

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Contents

Contents
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Notes:

Contents
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SAFETY 11
■REMINDER 14
■SUPPLEMENT FOR MARKEM-IMAJE TECHNICIANS 14
RESPONSIBILITY 14
HEALTH AND HYGIENE 14
FIRE PREVENTION 15
ENVIRONMENT 16
SYSTEM 16
HANDLING 16
SERVICING -TROUBLESHOOTING 16
CONSUMABLES 17
SAFETY EQUIPMENT FOR MARKEM-IMAJE TECHNICIANS 18
RULES OF CONDUCT FOR MARKEM-IMAJE TECHNICIANS WHEN VISITING CUSTOMERS 19
REMINDER OF THE MAIN SAFETY PICTOGRAMS 21
PRINTER DESCRIPTION 23
■INTRODUCTION 25
■CABINET 26
■OPERATOR INTERFACE 29
■PRINT-HEAD &UMBILICAL 31
■ELECTRONIC COMPARTMENT 34
■HYDRAULIC COMPARTMENT 36
■INDUSTRIAL INTERFACE CONNECTION BOARD 37
■GENERAL SPECIFICATION 41
■ENERGY 43

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INSTALLATION 45
■OOBCL 47
■INSTALLATION OF TWO CELLS 48
■STARTING THE PRINTER FOR THE FIRST TIME 50
■OPERATOR INFORMATION 51
DAILY START-UP 51
SHUTTING OFF THE PRINTER FOR A PERIOD OF LESS THAN THREE WEEKS 52
SHUTTING OFF THE PRINTER FOR MORE THAN THREE WEEKS 52
HEAD OPERATIONS 53
AFTER SALES SERVICE POLICY 59
■ACCESS MAINTENANCE AGREEMENT 61
■STANDARD MAINTENANCE AGREEMENT 67
MAINTENANCE 75
■PREVENTIVE AND PROACTIVE MAINTENANCE TABLE 77
■THREE REASONS WHY 9020/30 PRINTERS REQUIRE MAINTENANCE 78
INK CIRCUIT 78
INK 78
INK/MACHINE PAIR 78
■TO SUM UP 79

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TROUBLESHOOTING 81
■ABBREVIATIONS TABLE USED IN THIS CHAPTER 83
■TROUBLESHOOTING. 84
■MAINTENANCE PROCEDURES 99
SOLENOID VALVE TEST. 99
RELEASING SOLENOID VALVE 0 100
PARTIAL DRAIN 101
FULL DRAIN 101
RINSING THE INK CIRCUIT IC60 101
AUTO-CALIBRATION. 102
■LIST OF SPECIAL SPARE PARTS FOR MARKEM-IMAJE TECHNICIANS 104
■LIST OF THE SPARE PARTS FOR CUSTOMERS WITH SPARE PARTS SHEETS AVAILABLE
IN THIS CHAPTER. 105
■SPARE PARTS SHEETS 106
REPLACING A MODULATION ASSEMBLY 107
REPLACING A RESONATOR 108
REPLACING THE 4SOLENOID VALVE BLOCK 109
REPLACING THE RECOVERY UNIT 110
REPLACING A GUTTER 111
REPLACING THE RECOVERY SOLENOID VALVE 112
REPLACING THE PRINT MODULE 114
REPLACING THE INK CIRCUIT IC60 116
REPLACING THE EHT BLOCK 119
REPLACING THE INDUSTRIAL INTERFACE CARD 120
REPLACING THE CPU BOARD 121
REPLACING THE DISPLAY 123
REPLACING THE PSU BOARD 124
REPLACING THE ADP BOARD 125
REPLACING THE PIEZO BOARD 126
AIR INTAKE FILTER CARTRIDGE AND SEAL (ON AIR PRESSURISATION KIT). 129
REPLACING THE KEYBOARD 130
■ADJUSTMENT SHEETS 131
BREAK-OFF POINT ADJUSTMENT 131
RECOVERY GUTTER ADJUSTMENT 133

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HYDRAULICS 135
■SOLENOID VALVE HYDRAULIC CIRCUIT (PRINTER STOPPED) 137
■NON RETURN VALVE HYDRAULIC CIRCUIT (PRINTER STOPPED) 138
■DIAGRAM OF THE HYDRAULIC CIRCUIT (NORMAL OPERATION) 139
■DIAGRAM OF THE HYDRAULIC CIRCUIT (JET STOPPED WITH MAKE UP) 140
■INK CIRCUIT:PRINCIPLE OF OPERATION 141
■PRINT HEAD 142
■DIAGRAM OF RECOVERY GUTTER SOLENOID VALVE E. 143
■RECOVERY GUTTER 143
■PRINCIPLE OF TRANSFERS 145
■INK FILTERS 147
■MAKE UP FILTER 147
■CALIBRATED RESTRICTORS 147
■CONSTANT INK CONCENTRATION PRINCIPLE 148
■JET SPEED CALCULATION AND ADJUSTMENT 149
JET SPEED CALCULATION 149
AUTOMATIC JET SPEED ADJUSTMENT 149
■NEGATIVE PRESSURE MEASURING AND ADJUSTMENT 150
MEASURING OF THE NEGATIVE PRESSURE 150
ADJUSTMENT OF THE NEGATIVE PRESSURE 150
■GUTTER SOLENOID VALVE RINSING 151
ELECTRONICS 155
■9020/9030 ELECTRONIC ARCHITECTURE 157
■CPU CONNECTIONS 158
■CONNECTORS ON CPU BOARD 159
■CONNECTORS ON INDUSTRIAL INTERFACE BOARD 160
■EXTERNAL CONNECTORS 161

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GENERAL INFORMATION 163
■INK JET PRINTING 165
■MATRIX PRINTING 165
■DEVIATED CONTINUOUS INK JET 166
RESONATOR BLOCK 167
PIEZO-ELECTRIC RESONATOR 167
RECOVERY GUTTER 167
CHARGE ELECTRODE 167
■ALGORITHMS 168
USING ALGORITHM ON 9020 AND 9030 PRINTERS 168
CALCULATION OF THE MAXIMUM SPEED OF AN ALGO: 169
USING RESTRICTION: 169
ALGORITHM TABLE 170
ALGOS CURVPRINT 171
CURVPRINT.SPEEDS TABLE 171
■PRINTING,PRESSURE,SPEED 172
CONTROLLING THE QUALITY OF INK 172
INK UNDER PRESSURE 172
■ATMOSPHERIC PRESSURE,ABSOLUTE PRESSURE,RELATIVE PRESSURE 173
ATMOSPHERIC PRESSURE 173
ABSOLUTE PRESSURE 173
RELATIVE PRESSURE 173
PRESSURE IN A LIQUID 174
RELATIONSHIP BETWEEN EJECTION SPEED AND PRESSURE 175
PHYSICAL LAW: 175
CALCULATING THE EJECTION SPEED 176
BERNOULLI'S THEOREM 176
■FUNDAMENTAL UNITS 177
MASS 177
LENGTH 177
VOLUME 177
MASS,WEIGHT AND FORCE 177
PRESSURE 177
■EXERCISE: 178

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Safety

Safety
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■Reminder
Please read all the safety instructions that appear in the manuals provided to customers.
■Supplement for Markem-Imaje technicians
Responsibility
Markem-Imaje machines must not be modified by customers without the prior
permission of Markem-Imaje. They must be used in accordance with the
specifications in the operator's manual. Changes to non-Markem-Imaje machines
must be performed by customers.
Health and Hygiene
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. Technicians are strongly advised to wear a protective mask in the absence
of a specific ventilation system.

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The electronic circuit boards pose an electrocution hazard if touched.
Fire prevention
Follow the instructions on the safety data sheet (SDS) for each consumable used
to the letter.
Have a foam, CO2 or powder fire extinguisher placed in the immediate vicinity
of the printer (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 1 meter radius around the
print head, particularly when performing maintenance and cleaning.

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Always keep away from open flame. Never smoke near the printer. Place a sign with the
words “NO SMOKING – FLAMMABLE INK” near the printer.
Containers of ink, additive and cleaning solution must be closed and stored in a ventilated
room or a fireproof 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 cord provided
with it. The standard wall outlet must be above the printer in an easy-to-access location.
Handling
If the printer contains consumables, move it vertically. Do not tip it over.
Drain the printer completely before moving it in a position other than vertical.
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
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Consumables
Consumables and the printer
The Markem-Imaje printer has been factory set for the ink type selected by the customer at
ordering.
We strongly advise against changing the ink type.
Using another type of ink, additive or cleaning product will severely damage the printer.
Markem-Imaje equipment is guaranteed only if used with Markem-Imaje consumables.
Use of consumables
Refer to the safety data sheets (SDS) for the ink before using a consumable.
Consumables must be used before the expiration date on the label. Beyond this date, they
are no longer 100% compliant with the original specifications for use.

Safety
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Safety equipment for Markem-Imaje technicians
Code Description
A20281 Safety boots Size 40 (7½ U.S.)
A20282 Safety boots Size 41 (8 U.S.)
A20283 Safety boots Size 42 (8½-9 U.S.)
A20284 Safety boots Size 43 (9½-10 U.S.)
A20285 Safety boots Size 44 (10½ U.S.)
A20286 Safety boots Size 45 (11-11½ U.S.)
A10937 Latex gloves - CE marked (× 20) Palm widths: 7-7.5 cm
A10936 Latex gloves - CE marked (× 20) Palm widths: 8-8.5 cm
A38559 Latex gloves Size XL
A12762 Markem-Imaje smock Size 2 (medium)
A12763 Markem-Imaje smock Size 3 (large)
A12765 Markem-Imaje smock Size 4 (X-large)
A16820 Markem-Imaje smock Size 5 (XX-large)
A18588 Respirator
A16089 Polypox liquid soap
A16091 Blick 1000 barrier cream
A16092 Actilis topical cream
A20853 Personal eyewash
A12158 Eyewash station
A20592 Ear plugs
A20387 Wide vision safety glasses
EN6771 Additive transport case

Safety
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Rules of conduct for Markem-Imaje technicians when visiting
customers
Safety
Technicians must comply with the safety rules in effect at the customer's site:
Prevention plan: Technicians must request and examine the customer's prevention plan
(where applicable) in advance or upon arriving at the customer's site.
- Traffic areas
- Authorization to use spark-producing tools
- Authorizations to perform work
- Necessary accreditation (chemical, electrical, etc.)
If the business being visited does not provide specific equipment, technicians must wear
Markem-Imaje personal protective clothing at least (see list).
System
Neither the printer nor the maintenance stand should be located in a traffic area. The
entire system must be easy to access. The print head must be at least 1 meter away from
all electrical devices, flames, etc.
The following safety equipment must be installed near the printer:
- Eyewash
- Safety glasses
- Appropriate gloves
- Protective mask
Make sure the head, conduit and printer do not vibrate.
The conduit should be free of wear caused by rubbing.
Check the antistatic system (antistatic brush and grounding braid) used where plastic film
is manufactured/converted, extrusion is performed, surfaces rub against each other, etc.
Markem-Imaje technicians are not permitted to modify the customer's electrical system.
The customer is responsible for providing compressed air, electricity and other utilities.
All sources of electric power should outside a 1 meter radius around the head of the
machine while it is running and during cleaning/maintenance.

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Block drafts within the vicinity of the print heads.
Check the condition of the machine power sources.
Check the machine and stands for proper grounding.
A suitable fire extinguisher should be located no more than 10 meters from the machine.
Work
Leave the area clean after completing maintenance.
Pick up all cloths and clean all traces of ink on the console.
Dispose of waste in the appropriate receptacles (check with customer).
With the customer, go over any problems that may arise on account of the system's
current configuration:
Training
Servicing
Changes
Installation
Maintenance tray accessibility and stability
Accessories
Etc.
Make sure the doors on the printer close correctly.
Follow up maintenance with a production check.
If the printer is to be moved, obtain the customer's permission first and use the
appropriate tools.