Service Manual-VIDEOJET

Videojet 1510
Service Manual
P/N 361869-21
Revision: AA, July 2008
Copyright July 2008, Videojet Technologies Inc. (herein referred to as Videojet). All rights
reserved.
This document is the property of Videojet Technologies Inc. and contains confidential and
proprietary information owned by Videojet. Any unauthorized copying, use or disclosure of it without
the prior written permission of Videojet is strictly prohibited.
Videojet Technologies Inc.

1500 Mittel Boulevard Phone: 1-800-843-3610 Offices - USA: Atlanta, Chicago, Los Angeles, Philadelphia
Wood Dale, IL Fax: 1-800-582-1343 INT’L: Canada, France, Germany, Ireland, Japan, Spain,
60191-1073 USA Int’l Fax: 630-616-3629 Singapore, The Netherlands, The United Kingdom
www.videojet.com Distributors Worldwide
Compliance Information
For Customers in the European Union
This equipment displays the CE mark to indicate conformance to the
following legislation.
• BS EN61000-6-4 2007 Generic Emissions Standard for industrial
environments
• BS EN55022 Class A 2006 Emissions Standard for industrial
environments
• BS EN61000-3-2 2006 Harmonic Current Fluctuations
• BS EN61000-3-3 1995 Voltage Fluctuation and Flicker
• BS EN61000-6-2 2005 Generic Immunity Standard for industrial
environments
• BS EN61000-4-2 1995 ESD Requirements
• BS EN61000-4-3 2006 Radiated Susceptibility
• BS EN61000-4-4 2004 Electrical Fast Transient Burst Requirement
• BS EN61000-4-5 2006 Surges Requirements
• BS EN61000-4-6 1996 Conducted Susceptibility
• BS EN61000-4-11 2004 Voltage Dips and Interruptions
Following the provisions of EU EMC Directive 2004/108/EC
For Customers in the U.S.A.

This device complies with Part 15 of the FCC Rules. Operation is subject to
the following two conditions: 1) this device may not cause harmful
interference, and 2) this device must accept any interference received,
including interference that may cause undesired operation.
Warning
Changes or modifications to this unit not expressly approved by the
party responsible for compliance could void the user’s authority to
operate the equipment.
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to Part 15 of the FCC Rules. These limits
are designed to provide reasonable protection against harmful
interference, when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
Rev AA i
Videojet 1510 Service Manual
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is likely
to cause harmful interference in which case the user will be required to
correct the interference at his own expense.
Shielded cables must be used with this unit to ensure compliance with
Class A FCC limits.
The user may find the following booklet prepared by the Federal
Communications Commission helpful: How to Identify and Resolve
Radio-TV Interference Problems. This booklet is available from the U.S.
Government Printing Office, Washington, DC 20402, Stock No. 004-00-
00345-4.
This equipment has been tested and certified for compliance with U.S.
regulations regarding safety and electrical emissions by:
Electromagnetic Testing Services Limited
Pratts Fields
Lubberhedges Lane
Stebbing, Dunmow
Essex, CM6 3BT
England, U K
For Customers in Canada

This digital apparatus does not exceed the Class A limits for radio noise
emissions from digital apparatus set out in the Radio Interference
Regulations of the Canadian Department of Communications.
This equipment has been tested and certified for compliance with
Canadian regulations regarding safety and electrical emissions by:
Electromagnetic Testing Services Limited
Pratts Fields
Lubberhedges Lane
Stebbing, Dunmow
Essex, CM6 3BT
England, U K
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Pour la clientèle du Canada

Le present appareil numerique n’emet pas de bruits radioelectriques
depassant les limites applicales aux appareils numerique de las class A
prescrites dans le Reglement sur le brouillage radioelectrique edicte par le
ministere des Communications du Canada.
Cet équipement est certifié CSA.
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Support and Training
Contact Information
If you have any questions or need assistance, please contact at 1-800-843-
3610 (for all customers within the United States). Outside the U.S.,
customers should contact their distributor or subsidiary for assistance.
Videojet Technologies Inc.
1500 Mittel Boulevard
Wood Dale, IL 60191-1073 U.S.A.
Phone: 1-800-843-3610
Fax: 1-800-582-1343
International Fax: 630-616-3629
Web: www.videojet.com
Service Program
About Total Source® Commitment
Tot al Source® TOTAL SERVICE PLUS RELIABILITY, is the commitment
to provide you - our customer - the complete service you deserve.
The Total Source Commitment

The Total Source® Service Program is an integral part of our business in
providing marks, codes, and images where, when, and how often
customers specify for packages, products, or printed materials. Our
commitment includes:
• Applications support
• Installation services
• Maintenance training
• Customer response center
• Technical support
• Field service
• Extended hours phone assistance
• Parts and supplies
• Repair service
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Customer Training
If you wish to perform your own service and maintenance on the printer,
Videojet highly recommends you to complete a Customer Training Course
on the printer.
Note: The manuals are intended to be supplements to (and not replacements for)
customer training.
For more information on Customer Training Courses, call 1-800-843-3610

(within the United States only). Outside the US, customer should contact a
subsidiary office or their local distributor for further information.
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Table of Contents
For Customers in the European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
For Customers in the U.S.A.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
For Customers in Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Pour la clientèle du Canada. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Support and Training

Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Service Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Customer Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Chapter 1 — Introduction
Videojet 1510 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
About the Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
Related Publications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
Language Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
Content Presentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
The Word ‘Printer’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Positional References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Additional Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
User Interface Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
Chapters in the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
Chapter 2 — Safety
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
General Safety Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
Electrical Safety Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Electrical Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Electrical Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
Fluid Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
Ink and Make-up Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
Cleaning Agent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
Compressed Air Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
UI Related Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
Other Important Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
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Chapter 3 — Main Parts

Printer Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
Main Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
Electronics Compartment Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
Ink Compartment Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
Umbilical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
Connector Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
Back Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10
Electronics Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11
Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11
Control System Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13
Electronics Compartment Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16
Positive Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16
Printer Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17
EHT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–18
Ink Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–18
Ink Core Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–20
Ink Core Module Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–21
Smart Cartridges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23
Positive Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23
Ink Compartment Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23
Gutter Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–24
Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25
Printhead Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25
Printhead Valve Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25
Print Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25
Printhead Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–27
Umbilical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–31
The Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–31
Chapter 4 — Installation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
Tools and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Typical Production Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
Commission the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
Inspect the Ink System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
Log into UI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7
Install Ink and Make-up Cartridges . . . . . . . . . . . . . . . . . . . . . . . . 4–8
Configure the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10
Prime the Ink Core Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12
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Perform Umbilical Purge and System Flush Purge . . . . . . . . . . 4–14

Perform Viscosity Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–16
Clean Stop and Clean Start the Printer . . . . . . . . . . . . . . . . . . . . . 4–17
Perform Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–17
Set the Password Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–19
Install the Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–20
Internal Encoding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–20
External Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–22
Install the Product Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–24
Install the Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–24
Align the Ink Stream . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–26
Perform Calibration and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–30
Calibrate EHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–30
Calibrate Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–32
Chapter 5 — Printer Operation

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
Reset Run Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
Restore Calibration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
Perform Full System Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
Perform Full System Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
Chapter 6 — User Interface

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
Chapter 7 — Replacement Instructions

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
Common Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
How to Open the Electronics Compartment Door . . . . . . . . . . . . 7–3
How to Close the Electronics Compartment Door . . . . . . . . . . . . 7–5
How to Open the Ink Compartment Door. . . . . . . . . . . . . . . . . . . 7–5
How to Close the Ink Compartment Door. . . . . . . . . . . . . . . . . . . 7–7
Control System Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7
How to Remove the Old Control System Board . . . . . . . . . . . . . . 7–7
How to Install the New Control System Board . . . . . . . . . . . . . . . 7–8
Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9
How to Remove the Old Power Supply Unit . . . . . . . . . . . . . . . . 7–9
How to Install the New Power Supply Unit . . . . . . . . . . . . . . . . 7–11
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LCD and FIB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13
How to Remove the Old LCD and FIB Assembly . . . . . . . . . . . . 7–13
How to Install the New LCD and FIB Assembly. . . . . . . . . . . . . 7–16
Keyboard/Electronics Compartment Door . . . . . . . . . . . . . . . . . . . . 7–16
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–16
How to Remove the Old Electronics Compartment Door . . . . . 7–17
How to Install the New Electronics Compartment Door . . . . . . 7–20
Ink Core Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–21
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–21
How to Remove the Old Ink Core Module. . . . . . . . . . . . . . . . . . 7–22
How to Install the New Ink Core Module . . . . . . . . . . . . . . . . . . 7–30
Ink Core Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–35
How to Remove the Old Ink Core Pump . . . . . . . . . . . . . . . . . . . 7–36
How to Install the New Ink Core Pump . . . . . . . . . . . . . . . . . . . . 7–39
Print Engine Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41
How to Remove the Old Print Engine Assembly . . . . . . . . . . . . 7–41
How to Install the New Print Engine Assembly . . . . . . . . . . . . . 7–43
Printhead Valve Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–44
How to Remove the Old Printhead Valve Module . . . . . . . . . . . 7–44
How to Install the New Printhead Valve Module. . . . . . . . . . . . 7–46
Umbilical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–49
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–49
Umbilical Assembly (with Printhead) Replacement . . . . . . . . . . . . . 7–51
How to Remove the Umbilical Assembly (with Printhead) . . . 7–51
How to Install the Umbilical Assembly (with Printhead) . . . . . 7–60
Umbilical Assembly (with Printhead Chassis) Replacement . . . . . . 7–68
How to Remove the Umbilical Assembly (with Printhead Chassis)7–
68
How to Install the Umbilical Assembly (with Printhead Chassis)7–70
Printer Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–73
How to Remove the Old Printer Interface Board . . . . . . . . . . . . 7–73
How to Install the New Printer Interface Board . . . . . . . . . . . . . 7–75
Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–76
How to Remove the Old Power Switch . . . . . . . . . . . . . . . . . . . . 7–76
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How to Install the New Power Switch . . . . . . . . . . . . . . . . . . . . . 7–79

Septum Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–81
How to Remove the Old Ink and Make-up Septa. . . . . . . . . . . . 7–82
How to Install the New Ink and Make-up Septa . . . . . . . . . . . . 7–84
Electronics Compartment Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–85
How to Remove the Old Electronics Compartment Fan . . . . . . 7–85
How to Install the New Electronics Compartment Fan . . . . . . . 7–86
Ethernet Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–87
How to Remove the Old Ethernet Connector . . . . . . . . . . . . . . . 7–87
How to Install the New Ethernet Connector . . . . . . . . . . . . . . . . 7–88
Positive Air Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–89
How to Remove the Old Positive Air Kit . . . . . . . . . . . . . . . . . . . 7–90
How to Install the New Positive Air Kit. . . . . . . . . . . . . . . . . . . . 7–92
Gutter Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–93
Tools and Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–93
How to Remove the Old Gutter Pump . . . . . . . . . . . . . . . . . . . . . 7–94
How to Install the New Gutter Pump. . . . . . . . . . . . . . . . . . . . . . 7–97
Ink Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–98
How to Remove the Old Ink Door . . . . . . . . . . . . . . . . . . . . . . . . 7–99
How to Install the New Ink Door . . . . . . . . . . . . . . . . . . . . . . . . 7–101
Ink System Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–103
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–103
How to Remove the Ink System Fan. . . . . . . . . . . . . . . . . . . . . . 7–103
How to Install the New Ink System Fan. . . . . . . . . . . . . . . . . . . 7–105
EHT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–105
How to Remove the Old EHT Module . . . . . . . . . . . . . . . . . . . . 7–105
How to Install the New EHT Module. . . . . . . . . . . . . . . . . . . . . 7–107
USB Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–108
How to Remove the Old USB Connector . . . . . . . . . . . . . . . . . . 7–108
How to Install the New USB Connector. . . . . . . . . . . . . . . . . . . 7–109
Plug and Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–109
How to Remove the Old Power Cable . . . . . . . . . . . . . . . . . . . . 7–110
How to Install the New Power Cable . . . . . . . . . . . . . . . . . . . . . 7–112
CSB Lithium Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–115
Rev AA v
How to Remove the Old CSB Lithium Battery . . . . . . . . . . . . . 7–115

How to Install the New CSB Lithium Battery . . . . . . . . . . . . . . 7–117
PCB 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–117
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–117
How to Remove the PCB 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–117
How to Install the New PCB 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . 7–119
Chapter 8 — Maintenance
Prime the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2
Umbilical Purge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
System Flush Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6
Nozzle Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–11
Replacement of Ink System Fan Filter for IP65. . . . . . . . . . . . . . . . . . 8–12
How to Remove the Old Ink System Fan Filter for IP65 . . . . . . 8–12
How to Install the New Ink System Fan Filter . . . . . . . . . . . . . . . 8–12
Replacement of Ink System Fan Filter for IP55. . . . . . . . . . . . . . . . . . 8–13
How to Remove the Old Ink System Fan Filter for IP55 . . . . . . 8–13
How to Install the New Ink System Fan Filter for IP55 . . . . . . . 8–13
Replacement of Floor Filter for IP65. . . . . . . . . . . . . . . . . . . . . . . . . . . 8–14
How to Remove the Old Floor Filter IP65 . . . . . . . . . . . . . . . . . . 8–14
How to Install the New Floor Filter IP65 . . . . . . . . . . . . . . . . . . . 8–14
Replacement of Floor Filter for IP55. . . . . . . . . . . . . . . . . . . . . . . . . . . 8–15
How to Remove the Old Floor Filter IP55 . . . . . . . . . . . . . . . . . . 8–15
How to Install the New Floor Filter for IP55 . . . . . . . . . . . . . . . . 8–16
Windows CE Upgrade Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–16
System Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–16
Hardware Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–17
USB Download through Serial Commands . . . . . . . . . . . . . . . . . 8–18
USB Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–20
Chapter 9 — Troubleshooting
Read the Operator Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
Important Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
Startup Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2
Printer Fails to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2
Display Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Backlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
LCD Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
vi Rev AA
Keypad Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5

Display Icons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Alarm Light Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Printer Status Icons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Indicator Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–7
Fault Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–7
Warning Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–14
Voltage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–34
Jet Start and Stop Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–34
Quick Start Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–35
Clean Start Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–36
Clean Stop Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–38
CSB Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–39
Installing DNW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–58
ADC/DAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–58
Ancillary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–58
Charge Amplifier Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–59
Charge Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–59
SRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–60
EHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–60
Levels/Pressure/Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–60
Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–61
Phase Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–61
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–61
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–61
DIN Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–61
Manual Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–62
Chapter 10 — Illustrated Parts List

How to Read the IPL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1
Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–4
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–4
Videojet 1510 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–5
Electronics Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–6
Control System Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–7
Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–7
Electronics Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–8
Power Supply Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–9
Printer Interface Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . 10–10
Electronics Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–11
Positive Air Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–11
EHT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–12
Rev AA vii
Connector Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–12

PCB 2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–13
PCB 1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–13
Ink Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–16
Make-up Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–17
Ink Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–17
Septum Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–18
Ink Core Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–19
Ink Core Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–20
Gutter Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–21
Ink System Filter Assembly - IP65 . . . . . . . . . . . . . . . . . . . . . . . . 10–22
Ink System Filter Assembly - IP55 . . . . . . . . . . . . . . . . . . . . . . . . 10–22
Floor Filter IP65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–23
Floor Filter IP55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–24
Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–28
Printhead Valve Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–28
Print Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–29
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–30
Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–31
Beacon Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–31
Static Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–33
Mobile Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–34
Printhead Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–35
Printer Wall Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–36
Tools Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–39
Chapter 11 — Tools and Spare Part Kits

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1
Basic Start Up Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1
Service Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1
Other Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–2
Spare parts kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3
Comprehensive Spare Parts Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3
Appendix A — Clean/Quick Start and Stop Description

Clean Start/Stop Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
Clean Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2
Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2
Clean Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2
Quick Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–3
Nozzle Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–4
viii Rev AA
Appendix B — Encoder Information

Internal Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–1
When to Use Internal Encoding. . . . . . . . . . . . . . . . . . . . . . . . . . . . B–1
External (Reduce Or Direct) Encoding . . . . . . . . . . . . . . . . . . . . . . . . . B–2
When to Use External Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . B–3
Auto Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–5
When to Use Auto Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–5
Rev AA ix
Introduction
1
Videojet 1510 Printer
The Videojet 1510 is a continuous ink jet printer capable of printing fixed
and variable codes at elevated line speeds upon consumer and industrial
products. The printer is designed to deliver superior uptime, print quality,
and ease of use to its users.
About the Manual

The Videojet 1510 Service Manual is written for the service technician of
the printer. The service manual contains the procedures to install, service,
and troubleshoot the printer.
Related Publications
The Videojet 1510 Operator Manual (Part Number: 361868) is available for
reference.
Language Codes
When you order for these manuals, make sure to add the 2-digit language
code at the end of the part number. For example, the part number of the
Spanish version of the Operator Manual is 361868-04. Table 1-1 on page 1-
2 provides the list of language codes that are used to identify the
translated versions of the manual.
Note: Availability of the Operator Manual is indicated by an asterisk (*).
Availability of the Service Manual is indicated by a plus sign (+). Availability of
the Illustrated Parts List is indicated by the number sign (#). For more
information, contact the Videojet distributor or subsidiary.
Rev AA Videojet 1510 Printer 1-1

Code Language Availability (see note)
01 English (US) * + #
02 French *
03 German *
04 Spanish *
05 Portuguese (Brazilian) *
06 Japanese *
07 Russian *
08 Italian *
09 Dutch *
10 Chinese (Simplified) *
11 Arabic *
12 Korean *
13 Thai *
15 Norwegian *
16 Finnish *
17 Swedish *
18 Danish *
19 Greek *
20 Hebrew *
21 English (UK) * + #
23 Polish *
24 Turkish *
25 Czech *
26 Hungarian *
33 Vietnamese *
34 Bulgarian *
35 Portuguese *
36 Chinese (Traditional) *
Table 1-1: List of Language Codes - 1510
1-2 Related Publications Rev AA

Content Presentation
This manual contains different types of information like safety guidelines,
additional notes, User Interface (UI) terminology and so on. To help you
identify the different types of information, different writing styles are
used. This section describes these writing styles.
The Word ‘Printer’

The word ‘printer’ indicates the Videojet 1510 printer, from this point
onwards, in this manual.
Positional References
Unless stated to the contrary, positions and directions such as left, right,
front, rear, to the right and to the left are given with respect to the printer
when viewed from the front.
Units of Measurement
This manual uses metric units of measurement. The equivalent English
measures are included in parenthesis. For example, 240 mm (9.44 inches)
Safety Information
The safety information includes warning and caution statements.
Warning
The warning statements indicate hazards or unsafe practices that can
result in personal injury or death.
For example:
Warning
The cleaning agent is poisonous if taken internally. Do not drink.
Seek medical attention immediately if ingested.
Caution
The caution statements indicate hazards or unsafe practices that can result
in damage to the equipment.
For example:
Rev AA Content Presentation 1-3

Caution
Do not fit or remove any connector on the printer when the power is
on, otherwise the printer may get damaged.
Additional Notes
Notes provide additional information about a particular topic.
For example:
Note: You can set the password protection for some functions to prevent any
unauthorized access.
User Interface Terminology

The user interface (UI) elements are shown in italics. For example,
Messages (see Figure 1-1).
Figure 1-1. Menu Screen
Keys
Key Style Used
Left arrow key
Table 1-2: Content Presentation Style for Keys
1-4 Content Presentation Rev AA

Key Style Used
Right arrow key
Up arrow key
Down arrow key
Enter key
Esc key
F1 key
F2 key
F3 key
F4 key
Alt key
Ctrl key
Shift key
Table 1-2: Content Presentation Style for Keys
Rev AA Content Presentation 1-5

Abbreviations and Acronyms
Abbreviation Expansion
AC Alternating Current
CSB Control System Board
DC Direct Current
DMM Digital Multi Meter
DVM Digital Volt Meter
EHT Extra High Tension
FPGA Field Programmable Gate Array
IEC International Electrotechnical Commission
LED Light Emitting Diode
LCD Liquid Crystal Display
MOD Modulation
MS Microsoft
PC Personal Computer
PCB Printed Circuit Board
PIB Printer Interface Board
PSU Power Supply Unit
QVGA Quarter Video Graphics Array
SoC System on Chip
SRAM Static Random Access Memory
USB Universal Serial Bus
VDC Volts of Direct Current
WYSIWYG What You See Is What You Get
FIB Front Panel Interface Board
Table 1-3: Abbreviations and Acronyms
1-6 Abbreviations and Acronyms Rev AA

Chapters in the Manual
Chapter Chapter Name Description

No.
1. Introduction Contains the information about this manual, the related

publications, and writing styles used in this manual
2. Safety Contains the safety and hazard information
3. Main Parts Describes the main parts of the printer
4. Installation Explains the installation procedures of different parts of

the printer
5. Printer Operation Contains the information on how to use the UI to setup

and operate the printer
6. User Interface Explains how to use the UI to create and store messages
7. Replacement Explains the procedures to remove and replace the parts

Instructions of the printer
8. Maintenance Provides the maintenance and cleaning procedures of the

printer.
9. Troubleshooting Contains diagnostic and troubleshooting procedures
10. IPL Contains the illustrated parts list of orderable parts
11. Tools and Spare Contains information on tools, spare parts and
Parts Kits accessories and their part numbers
12. Important Contains additional information

Information
13. Encoder Contains encoder setup information

Information
Table 1-4: List of Chapters
Rev AA Chapters in the Manual 1-7

Safety
2
Introduction
The policy of Videojet Technologies Inc. is to manufacture non-contact
printing/coding systems and ink supplies that meet high standards of
performance and reliability. We enforce strict quality control techniques to
eliminate the potential for defects and hazards in our products.
The intended use of the Videojet 1510 printer is to print information
directly onto a product. Use of this equipment in any other fashion may
lead to serious personal injury.
The safety guidelines provided in this chapter are intended to educate the
technicians on all safety issues, so that the printer is serviced and operated
in a safe manner.
General Safety Guidelines

• Always refer to the correct service manuals as per the specific Videojet
printer model.
• Only Videojet-trained personnel must carry out installation and
maintenance work. Any such work undertaken by unauthorized
personnel may damage the printer and will invalidate the warranty.
• To avoid damage to the printer components, use only soft brushes and
lint free cloths for cleaning. Do not use high pressure air, cotton waste,
or abrasive materials.
• The printhead must be completely dry before attempting to start the
printer, otherwise the printhead may get damaged.
• To prevent nozzle clogs, always wear rubber gloves whenever the
nozzle tubing manifold is to be disconnected from the printhead valve
module.
Rev AA Introduction 2-1

Electrical Safety Guidelines

This section explains the safety guidelines related to electrical power
supply and electrical cables.
Electrical Power Supply
Warning
Make sure that the main electrical supply is within the range
indicated by the label next to the main inlet of the printer. If the
voltage ratings are different, do not use the printer and contact your
local supplier.
Warning
Lethal voltages are present within this equipment when it is
connected to the mains electrical supply. Only trained and
authorized personnel must carry out the maintenance work.
Observe all statutory electrical safety codes and practices. Unless it is
necessary to run the printer, disconnect the printer from the mains
electrical supply before removing the covers or attempting any
service or repair activity. Non-adherence to this warning can result
in death or personal injury.
Warning
A high AC voltage is present at the inverter and backlight. Extreme
caution is required when diagnosing failure in these areas.
2-2 Electrical Safety Guidelines Rev AA

Electrical Cables
Warning
Use only the main power cable supplied with the printer. The end of
this cable must have an approved, three-pole, main plug that has a
protective ground conductor.
The electrical power cables, sockets and plugs must be kept clean
and dry.
For pluggable equipment, the socket-outlet must be installed near
the equipment and must be easily accessible.
Warning
Always inspect the cables for damage, wear, corrosion, and
deterioration. Make all grounding/bonding connections void of
areas of paint, ink build-up, and corrosion.
Grounding
Warning
The printer must be connected only to an AC power supply that has
a protective ground conductor and must be according to IEC
requirements or applicable local regulations.
Warning
Do not use the printer if there is any interruption in the protective
ground conductor or if the protective ground conductor is
disconnected. The failure to follow this warning can cause an
electrical shock.
Rev AA Electrical Safety Guidelines 2-3

Warning
Always ground conductive equipment to an earthing electrode or to
the building grounding system with approved cables as per NEC
standards in order to drain all potential static discharge. For
example, a metal service tray to earth ground.
Warning
A resistance reading from the grounded service tray to the
equipment chassis or mounting bracket should be 0 to less than 1
ohm. A resistance check should be made using a safe and reliable
ohmmeter and should be done on a frequent basis
Warning
To ensure safe grounding, the resistance between the mains lead
earth wire and the test points must be less than 1Ω.
Warning
The PCBs contain static sensitive devices. A suitably grounded,
antistatic wrist strap must be worn when working on or handling
PCBs.
Bonding
Warning
Always prevent static discharge from occurring. Use proper
Grounding and Bonding methods. Only use Videojet approved
metallic service trays and ground cables.
2-4 Electrical Safety Guidelines Rev AA

Warning
Always bond conductive equipment together with approved cables
to maintain them at the same potential and minimize static
discharge. For example, printhead to metal service tray.
Caution
Always empty the service trays frequently. Some inks and cleaning
solutions are flammable. Make sure that the waste fluids are
disposed according to HAZMAT.
Fuses
Warning
To ensure continued protection against fire hazards, replace fuses
only with the specified type and rating.
Fluid Safety Guidelines

This section describes the hazards that may occur while handling ink,
make-up fluid, and cleaning solutions, and the safety precautions that a
user must take to prevent the hazards.
Rev AA Fluid Safety Guidelines 2-5

Ink and Make-up Fluid
Warning
The ink and make-up fluid are irritating to the eyes and respiratory
system. To prevent personal injury when handling these substances:
Always wear protective clothing and rubber gloves.
Always wear goggles with side-shields or a face mask. It is also
advisable to wear safety glasses when carrying out maintenance.
Apply barrier hand cream before handling ink.
If ink or make-up fluid contaminates the skin, wash immediately
with soap water. DO NOT use washdown or solvent to clean ink
stains from the skin.
Warning
The ink and make-up fluid are volatile and flammable. They must be
stored and handled in accordance with local regulations.
Do not smoke or use a naked flame in the vicinity of these
substances.
Immediately after use, remove any tissue or cloth that becomes
saturated with these substances. Dispose all such items in
accordance with the local regulations.
In the event that any ink or make-up fluid container is not
completely empty after use, it should be resealed. Only full bottles
are recommended for use when replenishing ink or make-up fluid;
partially filled bottles must be disposed in accordance with the local
regulations.
Warning
When setting up the nozzle, direct the ink stream into a beaker or
suitable container. To avoid the contamination of the ink, do not re-
use any ink collected in this way. Dispose all waste ink in accordance
with the local regulations.
2-6 Fluid Safety Guidelines Rev AA

Warning
Prolonged breathing of make-up fluid or cleaning fluid vapor may
cause drowsiness and/or effects similar to alcoholic intoxication.
Use only in open, well-ventilated areas.
Cleaning Agent
Warning
The cleaning agent is poisonous if taken internally. Do not drink.
Seek medical attention immediately if ingested.
Warning
The cleaning agent is irritating to the eyes and respiratory system.
To prevent personal injury when handling this substance:
Always wear protective rubber gloves and clothing.
Apply barrier hand cream before handling the cleaning agent.
If cleaning agent contaminates the skin, rinse off with running water
for at least 15 minutes.
Warning
The cleaning agent is volatile and flammable. It must be stored and
handled in accordance with local regulations.
Do not smoke or use a naked flame in the vicinity of the cleaning
agent.
Immediately after use, remove any tissue or cloth that becomes
saturated with cleaning agent. Dispose all such items in accordance
with local regulations.
Rev AA Fluid Safety Guidelines 2-7

Caution
Make sure that the cleaning agent is compatible with the ink used
before carrying out printhead cleaning otherwise the printhead may
get damaged.
Compressed Air Safety Guidelines
Warning
Airborne particles and substances are a health hazard. Do not use
high pressure compressed air for cleaning purposes.
UI Related Safety Guidelines
Caution
To prevent unauthorized access to the software, ensure that Clear
Password is executed when exiting from a higher level password.
Caution
Ensure that the correct message name is selected for message
deletion as no message selection confirmation prompt is given. All
messages apart from the TEST MESSAGE will be deleted.
Caution
The Delete User Field option does not ask for confirmation to delete
a user field.
2-8 Compressed Air Safety Guidelines Rev AA

Other Important Guidelines

1 DEGRADED PERFORMANCE. Machine functions that only Videojet-
trained personnel can access are set at Password Level 3 (MASTER
password), these functions must not be given as customer options.
2 EXCESSIVE USE OF MAKE-UP FLUID. As solvent is used during the
stop cycle, repeatedly stopping and starting the printer can lead to
excessive use of make-up fluid or solvent and can lead to a Ink Core
Level High error.
3 QUICK STOP. After a quick stop, the machine must not be left in the
same state for any length of time as drying ink may make restarting
difficult.
4 PRINTER OVERHEATING. Report all overheating incidents to a
maintenance engineer.
5 DAMAGE TO GUTTER. Never attempt to bend the gutter. Its position
is fixed.
6 DAMAGE TO CHARGE ELECTRODE. The charge electrode is not
adjustable so, do not attempt any mechanical adjustments.
7 EQUIPMENT DAMAGE. Adhere to prescribed circuit limitations
when using any external input or output devices with the printer.
8 EQUIPMENT DAMAGE. The DIN connector for the lamp stack must
not have any inductive load placed on it as it may cause damage to the
PCB.
9 EQUIPMENT DAMAGE. Do not fit or remove any connector on the
printer when the power is on, otherwise the printer may get damaged.
10 RISK OF EXPLOSION. If the battery is replaced by an incorrect type,
it will lead to an explosion. Always dispose the used batteries
according to the instructions and local regulations.
11 HEATER. In a fault condition, heater can reach 70 oC. Do not touch

the plate on which the heater is mounted. The failure to follow this
warning can cause personal injury.
Rev AA Other Important Guidelines 2-9

Main Parts
3
Printer Overview
5 1
2
4
1. Electronics Compartment Door 6. Electronics Compartment*

2. Ink Compartment 7. Main Power Switch*
3. Printhead
8. Back Filter*
4. Umbilical
5. Connector Panel
* The components are not shown in the picture.

Figure 3-1: Main Parts of the Printer
Rev AA Printer Overview 3-1

Figure 3-2 shows the schematic diagram of Videojet 1510 printer.
PSU
LCD 0V
5V
FIB 34 way CSB
+15 V
-15 V
Keypad
24 V
50 way 50 way 50 way
Printhead Interface
PIB
Connectors
Ink and
Core Module Make-up
Cartridges
Figure 3-2: System Overview
Cabinet
The cabinet of Videojet 1510 printer is constructed of stainless steel with
an inner fibre lining. The cabinet includes the following parts:
• Control panel
• Electronics compartment door
• Main power switch
• Ink compartment door
• Connector panel
• Umbilical
Refer to Figure 3-3 on page 3-3 to see the parts of the cabinet.
3-2 Cabinet Rev AA

7
2
3
6
4
5
1. Control Panel 5. Handle

2. Main Power Switch 6. Umbilical
3. Electronics Compartment Door 7. Connector Panel
4. Ink Compartment Door 8. Back Filter*
*The component is not shown in the figure.

Figure 3-3: Printer Cabinet
Rev AA Cabinet 3-3

Control Panel
The control panel (Figure 3-4) provides the user interface to the printer.
Refer to Chapter 3 in the Videojet 1510 Operator Manual for more
information.
6
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1 2 3 4 5 6 7 8 9 0
Q W E R T Y U I O P
5 3
A S D F G H J K L
Z X C V B N M
4
1. Status LEDs 5. Display
2. Arrow Keys 6. Contrast Key (Brightness Control)
3. Keypad 7. Function Keys
4. Information Key
Figure 3-4: Control Panel
Main Power Switch

The main power switch (item 1, Figure 3-5) is a green push button to turn
on or turn off the power supply to the printer. You can find the main
power switch on the right side of the printer.
Note: The handles (item 2) are provided for easy movement of the unit.
1
2
1. Main Power Switch

2. Handle
Figure 3-5: Main Power Switch
Electronics Compartment Door

The electronics compartment door (item 3, Figure 3-3 on page 3-3) is
mounted on two hinges and its seal is water resistant when closed. The
3-4 Cabinet Rev AA

door is closed using two M4 x 30 socket head screws. The door contains
control panel (refer to “Control Panel” on page 3-4) and front panel
interface board.
See “Electronics Compartment” on page 3-11 for more information on the
electronics compartment.
LCD and Front Panel Interface Board

The front panel interface board (FIB), provides the interface between the
CSB and the LCD and keyboard. This assembly is located inside the
electronics compartment door.
LCD
Figure 3-6: LCD
Rev AA Cabinet 3-5

1. Keypad Right 4. 34-way Ribbon to CSB

2. Touch Panel (Future Option) 5. Keypad Left
3. Program (Only Used In Production) 6. Mono LCD
Figure 3-7: FIB
Note: A TORX screwdriver is required to separate the FIB from the LCD.
Ink Compartment Door

The ink compartment door (item 4) is mounted on two hinges and its seal
is water resistant when closed. See “Ink Compartment” on page 3-18 for
more information on the contents of this compartment.
Umbilical
The umbilical (item 6) that connects the printer cabinet to the printhead is
attached to the cabinet through a threaded fitting, secured with nuts and
washers.
Connector Panel
The connector panel (item 7, Figure 3-3 on page 3-3) provides inputs for
several types of external devices.
3-6 Cabinet Rev AA

11 1
2
10 3
4
9 5
6
8
7
Cat 5e
1. BCD Message Select Input A 7. USB

2. Reverse Print Input 8. Ethernet
3. Stacklight 9. RS485
4. Shaft Encoder 10. RS232
5. Fault Relay 11. BCD Message Select Input B
6. Product Detector 1
Figure 3-8: Connector Panel
Stacklight Connector
The printer provides an output for a set of status lights through the lamp
stack connector (item 3, Figure 3-8). This is a 6 way DIN connector. The
pin allocation is shown in Table 3-1:
Pin Function
DIN Pin 1 Red lamp negative supply.
DIN Pin 2 Amber lamp negative supply.
DIN Pin 3 Green lamp negative supply.
DIN Pin 4 +24VDC supply to the strobe/siren.

Maximum Rating = 900 mA
DIN Pin 5 Strobe/siren negative supply
DIN Pin 6 +24V DC common to the traffic lights
Table 3-1: Lamp Stack Connector Pinouts
Rev AA Cabinet 3-7

Shaft Encoder Connector

The printer provides a 12 V (200 mA DC total) output for use by a shaft
encoder with a maximum frequency of 100 kHz. The shaft encoder
connector (item 4) is a 4 way DIN connector. The pin allocation is shown
in Table 3-2.
Pin Function
DIN Pin 1 +15 VDC supply to shaft encoder
DIN Pin 2 Shaft encoder input ‘A’
DIN Pin 3 Shaft encoder input ‘B’
Din Pin 4 0 VDC common
Table 3-2: Shaft Encoder Connector Pinouts
Note: The shaft encoder output must be of the PUSH/PULL type.
Fault Relay
The fault relays connector (item 5) is a 7 way DIN connector. This
connector supports the following relays:
• Relay ‘A’ duplicates the functionality of the green LED on the
keyboard, and you can use the relay to provide a ‘Print Ready’ output.
• Relay ‘B’ duplicates the functionality of the yellow LED on the
keyboard, and you can use the relay to provide a ‘warning’ output.
Electrical Rating:
1A 30V DC
0.3A @ 125V AC Maximum Switch Cap
Pin Function
DIN Pin 1 Relay A - Normally open contact
DIN Pin 2 Relay A - Normally closed contact
DIN Pin 3 Relay A - Common contact
DIN Pin 4 Relay B - Normally open contact
DIN Pin 5 Relay B - Normally closed contact
DIN Pin 6 Relay B - Common contact
DIN Pin 7 Not used
Table 3-3: Fault Relays Connector Pinouts
3-8 Cabinet Rev AA

Product Detector Connector

The printer provides a 12V, 200mA, DC total output for use by a
photoelectric cell (PEC), inductive proximity detector or micro switch. The
product detector connector (item 6, Figure 3-8 on page 3-7) is a 3 way DIN
connector. The pin functions are shown in Table 3-4.
Pin Function
DIN Pin 1 +15 VDC supply to sensor
DIN Pin 2 Sensor output
DIN Pin 3 0 VDC common
Table 3-4: Print Trigger Connector Pinouts
USB Connector
The USB Connector allows for data to be transferred to and from a
connected USB flash drive (item 7, Figure 3-8 on page 3-7).
Ethernet Connector
The ethernet connector (item 8) is used to connect the printer to a remote
computer or network to import data or control the printer remotely.
RS 485 Connector
The RS 485 connector (item 9) is a 5 way DIN connector. Use this to
connect the printer to an RS 485 network to import data or control the
printer remotely.
Pin Function
DIN Pin 1 Line A
DIN Pin 2 Line B
DIN Pin 3 0 VDC Common
DIN Pin 4 -
DIN Pin 5 -
Table 3-5: RS 485 Connector Pinouts
Rev AA Cabinet 3-9

RS 232 Connector
The printer has an RS 232 communication port linked to the COMM1
connector. The RS 232 connector (item 10, Figure 3-8 on page 3-7) is a 5
way DIN connector. The pin allocation is shown in Table 3-6.
Pin Function
DIN Pin 1 0VDC common
DIN Pin 2 Transmit data out from the printer.
DIN Pin 3 Received data into the printer.
Din Pin 4 DTR output from the printer.
Din Pin 5 DCD input to the printer.
Table 3-6: RS 232 Connector Pinouts
Back Filter
The ink compartment draws the air from the outside atmosphere to keep
the compartment cool. The back filter removes the dust from the air that
goes inside the ink compartment (see Figure 3-9). The IP65 version back
filter is optional (see Figure 3-10 on page 3-11).
Back Filter
Figure 3-9: Back Filter (IP55 Version)
3-10 Cabinet Rev AA

Figure 3-10: Back Filter (IP65 Version)
Electronics Compartment
2
7
6
3
5
1. Electronics Compartment Fan 5. Printer Interface Board (PIB)

2. Power Supply Unit (PSU) 6. EHT Module
3. Positive Air Pump 7. Connector Panel Boards
4. Control System Board (CSB)
Figure 3-11: Electronics Compartment
Power Supply Unit

The Power Supply Unit (PSU) is the main source of power to the
printer.The mains input circuit is shown in the Figure 3-12 on page 3-12.
Rev AA Electronics Compartment 3-11

The AC electrical power is supplied through three core cables to the mains
filter. The line and neutral are fed to the On/Off switch. After the On/Off
switch the line and neutral are fed to TB1 connector on the PSU.
Mains Switch PSU
L L
N N
E TB1
Figure 3-12: Mains Input Circuit
TB 1 Connector
Figure 3-13: Power Supply Unit
The PSU features are as follows:

• The mains fuse (T3A 110-240 V) is located in the PSU.
• The PSU provides four DC voltage levels (+24 V DC, +15 V DC, +5 V
DC, and -15 V DC) to the CSB.
• Two fuses are soldered to the PSU board. These two fuses cannot be
reset or replaced.
• The input power to the PSU ranges from 84 to 264 VAC, 50 – 60 Hz.
3-12 Electronics Compartment Rev AA

Control System Board
1. Connectors CN1, CN2 and CN3 6. CPU JTAG

2. Charge Tunnel and Modulation Signal Connector 7. USB 2 Host Device
3. Input Power Connector 8. User Interface Connector
4. LEDs 9. Ethernet Connector
5. JTAG
Figure 3-14: Control System Board
Connectors 1, 2, and 3
The ribbon cables from the PIB connect to the CSB through the connectors
1, 2 and 3 (item 1, Figure 3-14) and relay the data that reaches PIB from
different parts of the printer to the CSB.
Charge Tunnel and Modulation Signal Connector

The charge tunnel and modulation signals are generated on the CSB.
These signals are sent directly to the printhead through the umbilical. All
other input or output signals are sent through the PIB.

Charge 1 MOD Connector
Pin Function
DIN Pin 1 Charge
DIN Pin 2 GND
DIN Pin 3 GND
DIN Pin 4 MOD
Table 3-7: Pin Functions for Charge 1 MOD Connector
Input Power Connector

You can check the voltages at input power connector (item 3) to make sure
that the power supply from the mains power supply is of the correct
value.
Pin Signal
1 +15 V
2 0V
3 +5 V
4 -15 V
5 +5 V
6 +24 V
7 0V
8 N/C
Table 3-8: Pin Connections - Input Power Connector

LEDs
1. Power LED 3. SoC to FPGA LED

2. Print Engine LED 4. Ethernet LED
Figure 3-15: Status LEDs
LED Description
Power Indicates the status of 3.3 VDC
Print Engine flashes when printing is in progress
SoC to FPGA Indicates the status of communications between the

processor and the FPGA
Ethernet Indicates the status of Ethernet communications
Table 3-9: Status LEDs

Electronics Compartment Fan

A cooling fan circulates the air inside the electronics compartment. The
heat is dissipated outside by the fins that are fixed on top of the printer.
Figure 3-16: Cooling Fan
Positive Air Pump

The positive air pump is a standard part for the 1510. The positive air
pump provides dust free air to the printhead and thus prevents the
accumulation of dust in the printhead.
Positive Air Pump

Figure 3-17: Positive Air Pump
Positive Air Filter

The positive air filter is located in the ink compartment. It filters the
positive air pump discharge before it reaches the printhead.

Printer Interface Board
7 8 9 10 1 2 3 4 5
6
1. 10-way Printhead Connector 6. CSB Ribbon Cable Connectors (x3)
2. 12-way Printhead Connector 7. USB Connector
3. EHT Cable Connector 8. PCB1 Connector
4. Positive Air Pump Connector 9. PCB 2 Connector
5. Electronics Compartment Fan Connector 10. PCB 3 Connector
Figure 3-18: Printer Interface Board (PIB) - Electronics Compartment Side
2 1
1. Ribbon Cable Connector from Ink Door 4. 20-way Ink Core Module Ribbon Cable
2. Ink Compartment Fan Connector Connector
3. 16-way Ink Core Module Ribbon Cable
Connector
Figure 3-19: Printer Interface Board (PIB) - Ink Compartment Side
The description of different connectors on the PIB is provided in the

Table 3-10.
Connector Description
10-way Printhead Connector Connection to valves, phase detector, strobe LED, heater and
12-way Printhead Connector thermistor, and gutter detect
EHT Cable Connector Input to EHT module
Positive Air Pump Connector Input to positive air pump
Table 3-10: PIB Connectors

Connector Description
Fan Connector Input to electronics compartment fan
CSB Connectors (x3) Input to CSB
USB Connector External USB (not the USB connection on CSB)
PCB1 Connector RS-232, Ethernet, Photocell, Shaft Encoder, Beacon, I/ O

PCB 2 Connector
PCB 3 Connector
Ink System Ink pump, valves, sensors, level detectors, smart chip supplies
validation system
Table 3-10: PIB Connectors
EHT Module
The extra high tension (EHT) module (item 2, Figure 3-20) generates the
high tension voltage (0 to 8000 VDC) that is supplied to the deflector plate
in the printhead.
1
2
1. Cooling Fan
2. EHT Module
Figure 3-20: Cooling Fan and EHT Module
Ink Compartment
The ink system provides a continuous supply of ink to the printhead at the
correct pressure, temperature and viscosity. The ink system is housed in
the printer cabinet and the different components of the system are
interconnected by PTFE tubing.
3-18 Ink Compartment Rev AA

3
1. Smart Cartridges 3. Ink Core Module
2. Ink Compartment Door 4. Ink Compartment Fan*
*The component is not shown in the picture
Figure 3-21: Ink Compartment
Rev AA Ink Compartment 3-19

Ink Core Module

The ink core module maintains the pressure and viscosity of the ink in the
printer.
1. Ink Core
2. Ink Core Pump
Figure 3-22: Ink Core Module
The ink core module contains the following subsystems:

• Ink core pump
• Ink core
• Mixer tank
• Venturi (for fluid addition)
• Three Pico valves (fluid addition, flush pump control)
• Filtration systems for the ink and the flush
• Pressure damper
• Instrumentation (pressure and temperature sensing)

Ink Core Module Connections

There are three input, three output, and one vent hydraulic connections to
the ink core module.
Connections Type of Tube
Input Hydraulic Connections • Ink addition tube (black-striped tube)

• Gutter pump discharge (blue-striped tube)
• Make-up addition tube (green-striped tube)
Output Hydraulic • Flush supply tube (red-striped tube)

Connections • Ink supply tube (clear tube)
• Ink Commissioning Tube (clear tube)
Vent Vent or breather tube (Clear tube)
Table 3-11: Ink Core Module Connections
Two ribbon cables provide the electrical interface between the ink core
module and the electronic system. The cables connect directly from the ink
core module to the PIB and allow for the transfer of the following signals:
• Ink pump motor control signal
• Pressure sensing signals (2 sensors)
• Ink temperature signal
• Valve control signals
• Mixer tank level detecting signals
• Ink system smart chip information (refer to “Smart Cartridges” on
page 3-23 for additional information).
Ink Core Pump

The ink core pump is a positive displacement gear pump driven by a 24
VDC brushless motor.
The pump provides stable ink pressure to the nozzle during printing and
also provides a flow of ink to other components inside the ink core
module.
Ink Core Module Functions

The phasing and velocity fly-by sensors and supporting circuitry
contribute directly or indirectly to the performance of six critical control
functions during steady-state operation:
• Phasing
• Modulation control
• TOF measurement

• Pump speed control

• Target pressure control
• Viscosity control
The functions of the ink core module are shown in Table 3-12.
Name Function Frequency
Phasing Between prints, charge transfer to test drops is measured by Performed

the LEAD fly-by sensor (phase detector) in order to approximately
synchronize drop charging to drop break-off, thereby 25 times per
optimizing print quality. second
Modulation Between prints, modulation amplitude is validated by Performed

Control performing an abbreviated auto-modulation test using the continuously
LEAD fly-by sensor (phase detector). The amplitude is
changed in small increments whilst measuring the rate of
change of the phase angle in order to verify that the
amplitude setting remains at or near the “appropriate setting”.
TOF Between prints, drop velocity is monitored by measuring the Performed

Measurement TIME OF FLIGHT of the test drops from the LEAD (phase) every TENTH
sensor to the TRAILING (velocity) sensor. The measured phasing test
result is referred to as the “actual velocity”.
Pump Speed A pressure transducer inside of the Core measures “actual Performed
Control pressure”. This pressure is compared to the “target once per
pressure”. The resultant error is used to increase or second
decrease the pump speed.
Target Pressure The “target pressure” represents the nominal pressure the Occur every
Control printer determines that it must operate at in order for the 10 seconds
actual velocity to be equal to the “velocity set point”. The
printer makes modifications to the target pressure by
reviewing the “history” of the velocity error parameter (“PID”
control). “Velocity error” refers to the difference between the
actual velocity and the set point.
Viscosity Once the printer has determined its “target pressure”, it has Occurs every 5
Control the means to perform viscosity adjustments. Determination minutes (if
concerning viscosity is made by comparing the empirically- necessary)
determined “target pressure” to a reference pressure known
as the “temperature-compensated target pressure”. This
value is acquired indirectly from data encoded on the ink car-
tridge Smart Chip. This reference pressure is mathematically
determined and represents the pressure required to acquire
the correct “actual velocity” under ideal viscosity conditions. If
the target pressure deviates from the reference pressure, the
printer attributes this to viscosity variation and responds
accordingly.
Table 3-12: Ink Core Module Functions

Smart Cartridges
Two types of cartridges are used in the printer.
• Ink cartridge - This contains the ink.
• Make-up cartridge - This contains the make-up fluid.
Functions
The cartridge is based on smart chip technology that helps you to:
• Find the accurate level of ink and make-up fluid
• Use correct type of ink or make-up fluid
• Know the expiry date of the ink
1. Smart Chip
2. Septum
Figure 3-23: Smart Cartridges
Positive Air Filter

The positive air filter (item 1, Figure 3-24 on page 3-24) is fitted inside the
ink compartment. The filter filters the air from the discharge of the
positive air pump before the air enters the printhead.
Ink Compartment Fan

This ink compartment fan (item 2) cools the ink compartment.

Gutter Pump
The gutter pump (item 3) is fitted to the rear of the cabinet inside the ink
compartment. The functions of the gutter pump are as follows:
• Vacuum generation for gutter suction
• Vacuum generation to assist in nozzle back flushing
• Ink delivery to the ink core module during printer installation
1. Positive Air Filter

2. Fan
3. Gutter Pump
Figure 3-24: Positive Air Filter, Fan and Gutter Pump

Printhead
The printhead contains the following parts:
• Printhead cover
• Print engine
• Printhead valve module
3 2
1. Printhead cover 3. Knurled Screw
2. Print Engine 4. Printhead Valve Module
Figure 3-25: Printhead
Printhead Cover
The printhead cover (item 1, Figure 3-25) is attached to the printhead with
a knurled screw (item 3). The cover protects the printhead components.
Removal of the cover is sensed by the printer through the cover switch.
When the cover is removed the voltage to the deflector electrodes is
turned off.
Printhead Valve Module

The printhead valve module (item 4) consists of the bleed/gutter valve,
feed valve, feed line, and the head heater.
Print Engine
The print engine (item 2) consists of the nozzle, charge electrodes, time of
flight sensors, deflection plate, and gutter tube.
Rev AA Printhead 3-25

Nozzle
The nozzle (item 8, Figure 3-26 on page 3-27) creates the ink droplets.
Charge Electrode
The charge electrode (item 9) applies an electrical charge to each ink
droplet. The charge applied to the droplet is variable and affects the
position of the droplet on the substrate.
Phase Detectors
The phase detectors (item 12) measure the ink drop velocity and perform
phasing.
Gutter Tube
The gutter tube (item 11) is the return path for the uncharged ink droplets
that are not used for printing. The gutter delivers the ink back into the ink
core.
The gutter detect senses when ink is present in the gutter. The ink feed
tubes are metallic and a signal is fed to one of them. A signal return lead is
connected to the other. When ink (which is conductive) is present, the
signal passes through it to the return lead. The gutter detect signal is then
fed, via the umbilical, to the CSB in the electronics system.
Deflection Plate
The deflection plate (item 10) is supplied with a fixed positive DC voltage
(0 - 8000 VDC) from the EHT Module. This voltage deflects the charged
drops over the top of the gutter, through the printhead slot, and onto the
substrate.
3-26 Printhead Rev AA

1
16 2
5
15 6
14 7
13 8
9
12
10
11
1. Solvent Flush Line 9. Charge Electrode
2. Bleed/Gutter Line 10. Deflection Plate
3. Bleed/Gutter Valve 11. Gutter Tube
4. Feed Valve 12. Phase Detectors (electrodes)
5. Front Manifold 13. Nozzle Cradle
6. Ink Pipe 14. Nozzle Holder
7. Ground 15. Bleed Pipe
8. Nozzle 16. Feed Line
Figure 3-26: Printhead Components
Printhead Operation
The flush supply and ink supply lines merge at Pico valve V1. The ink is
heated as it flows through the manifold assembly to the nozzle. The nozzle
is outfitted with both the feed and the bleed ports. The nozzle bleed port
provides a source of vacuum, used during manual irrigation/
backflushing.

Ink Supply
Make-up Supply
Under Vacuum
V1 V2
1. Gutter Tube 4. Nozzle

2. High Voltage/EHT Plate 5. Heater
3. Charge Electrode
Figure 3-27: Printhead Operation
The flow of ink is as follows:

1 The ink and solvent mixture flows through the feed line (item 16,
Figure 3-26 on page 3-27) into the printhead.
2 The ink and solvent mixture enter the feed valve (item 4).
3 The valves open or close as per the print requirements.
Note: The bleed valve opens and closes as needed during flushing the nozzle
and suppling ink to the nozzle.
4 The ink and the solvent mixture flow into the nozzle.
To adjust the nozzle refer to“Align the Ink Stream” on page 4-26.
5 The piezoelectric crystal vibrate the nozzle at a frequency of around 75
KHz nominal value in the longitudinal direction.
This vibration enables the nozzle to breakup the stream of ink into
droplets.
6 The ink drops enter the charge electrode (item 9) where they are
charged at different voltage levels based on the character to be
generated.
7 The charged ink drops then pass through the EHT/ High Voltage
Field (item 2, Figure 3-27) and over the phase detectors.

8 The High Voltage/EHT plate deflects the charged drops of ink at

various angles depending on the charge placed on the drop at the
moment of breakoff.
9 An electrically conductive ink is supplied under pressure by the ink
core to the nozzle assembly (item 6, Figure 3-28) through the ink feed
pipe (item 1).
10 An ink stream is formed as the ink is forced out of the nozzle jet orifice
(item 5).
A modulation signal is applied to a ceramic transducer which is
clamped to the nozzle assembly. The transducer crystals (item 3 and
item 4) causes the nozzle assembly to vibrate longitudinally, breaking
up the ink stream into droplets, a small distance away (the break up
point) from the nozzle jet orifice. The frequency of modulation is 76.8
kHz (nominal value).
The ink droplets are produced at the same rate as the modulation
frequency and are uniform in size and separated by equal distances.
The nozzle orifice diameter is 70 microns.
5 2
3
4
1. Ink Feed Pipe 4. Crystal Transducer

2. Damping Mass 5. Nozzle Jet Orifice
3. Crystal Transducer 6. Nozzle Assembly
Figure 3-28: Ink Jet Formation
Droplet Charging
11 The charge electrode (item 2 in Figure 3-29) is positioned at the break
up point of the ink stream and extends for several drops either side of
it.
Note: This allows a tolerance for break up position and shields the ink stream
from the influence of the other electrostatic fields. The distance between the
nozzle assembly (item 1) and the charge electrode is 2 mm.

1. Nozzle assembly
2. Charge electrode
Figure 3-29: Charge Electrode
The ink stream and the charge electrode can be considered as the two
electrodes of a capacitor. By raising the charge electrode to a specific
positive voltage (with a charge pulse) the section of the ink system within
the charge electrode will have a negative charge induced on it. When a
drop of ink then breaks from the jet it will have trapped on it a charge
directly proportional to that on the charge electrode. If the positive voltage
is then removed from the charge electrode, the negative charge on the jet
will discharge through the ink jet and nozzle assembly to ground.
However, the drop of ink which has become detached from the jet cannot
discharge as it no longer has a conductive path to ground.
Droplet Deflection
12 The droplet stream passes through an electrostatic field maintained by
the deflector electrodes that are connected to a high tension supply
(typically 6 kV).
13 The negatively charged droplets are deflected by the field towards the
high voltage deflector electrode.
The distance a drop is deflected is proportional to the charge carried,
which is in turn proportional to the voltage applied to the charge
electrode when the drop became detached from the ink jet.
The charged droplets once deflected leave the printhead to form
characters in a dot matrix format on the substrate. Droplets which are
not required for printing are not charged and are therefore not
deflected.

2
1. Deflected Droplet Path 4. Droplet Path to Gutter
2. Substrate 5. Phase Detectors (Electrodes)*
3. Gutter
* The part is not shown in the figure

Figure 3-30: Droplet Deflection
Umbilical
The umbilical has the electrical wiring and ink system tubing from the
printer to the printhead.
The Hydraulic System

This section describes the combined operation of the ink system,
printhead and umbilical to print on a substrate. The Figure 3-31 on page 3-
32 shows the hydraulic system of the printer.
The hydraulic system of the printer consists of the following components:
• Ink cartridge
• Make-up cartridge
• Ink core module
• Umbilical
• Printhead
Rev AA Umbilical 3-31

• Gutter pump
8
1
2
3
4
7 5
6
1. Make-up fluid Addition Tube 5. Make-up fluid Cartridge
2. Gutter Pump 6. Core Module
3. Ink Addition Tube 7. Printhead
4. Ink Cartridge 8. Ink Supply Tube
9. Make-up Tube
Figure 3-31: Hydraulic System Components
3-32 The Hydraulic System Rev AA

Installation
4
Introduction
This chapter describes the procedures to install 1510 printer.
Caution
Only Videojet trained personnel must carry out the installation and
maintenance work. Any such work undertaken by unauthorized
personnel can damage the printer and invalidate the warranty.
Warning
Make sure that the mains electrical supply is within the range
indicated by the label adjacent to the mains inlet of the printer. If the
voltage ratings differ, do not use the printer until you have
consulted your local supplier.
Use only the mains power cable supplied with the printer. This cable
must terminate in an approved, three-pole, mains plug which has a
protective ground conductor.
Keep electrical power cables, sockets and plugs clean and dry at all
times.
Warning
The printer must be connected to an AC power supply, which has a
protective ground conductor in accordance with IEC requirements
or applicable local regulations. Any interruption of the protective
ground conductor or disconnection of the protective ground
terminal may render the apparatus dangerous.

Warning
Lethal voltages are present within this equipment when it is
connected to the mains electrical supply. Observe all statutory
electrical safety codes and practices. Unless it is necessary to run the
printer, disconnect the printer from the mains electrical supply
before removing the covers or attempting any service or repair
activity, otherwise death or personal injury can occur.
Tools and Supplies

Refer to the service tool kit listed in Chapter 11, “Tools and Spare Part
Kits” for the tools and supplies required to install the printer.
Typical Production Line

A typical printer installation is shown in Figure 4-1 on page 4-3, where the
printer (item 6) is mounted on a printer stand (item 7). The printhead
(item 1) is configured to print vertically with the help of a clamp and
bracket assembly. A beacon (item 8) is fitted to the printer.
4-2 Introduction Rev AA

2
8
3
4
MESSA
B INPUTGE
MESSA
A INPUTGE
COMM
PRINT
RS S TRIGG
232
ER
STATU 2
OUTPUS
T
COMM SHAFT
RS S ENCOD
485 ER
RELAY
SWITC
HES
PRINT
TRIGG
ETHER ER
1
NET
USB
1. Printhead 6. Printer
2. Shaft Encoder 7. Printer Stand
3. Shaft Encoder Cable 8. Beacon
4. Photo Cell 9. Printhead Stand
5. Photo Cell Cable
Figure 4-1: Typical Production Line Installation

Unpack and Inspect the Printer

1 Open the shipping box, and make sure that all the parts in the packing
list are present in the box. If any part is missing, contact Videojet
Technologies Inc.
• Refer to Chapter , “Support and Training” for Videojet contact
information.
• Refer to Chapter 10, “Illustrated Parts List” for part numbers.
2 Make sure that there are no damaged parts. If you find any damaged
part, contact Videojet Technologies Inc. to order a new part.
Commission the Printer

This section describes the tasks that a user must perform to commission
the printer.
Inspect the Ink System

1 Turn the knob and open the ink compartment door (see Figure 4-2).
Figure 4-2: Turn the Knob

2 Push the plate (item 2, Figure 4-3 on page 4-5) in the direction shown
to open the ink compartment door (item 1) completely.
4-4 Unpack and Inspect the Printer Rev AA

1. Ink Compartment Door

2. Plate
Figure 4-3: Ink Compartment Door
3 Pull the ink core module out of the ink compartment (see Figure 4-4).

2. Ink Core Module
Figure 4-4: Pull Ink Core Module
Rev AA Commission the Printer 4-5

4 Make sure that the ink core manifold is connected to the ink core
module correctly (see Figure 4-5).
Ink Core Manifold
Figure 4-5: Ink Core Manifold
5 Make sure that all the tubes are connected to the ink core manifold
(see Figure 4-6).
1. Clear Tube (5/32 inch) 5. Blue Stripe Tube (1/8 inch)

2. Red Stripe Tube (1/8 inch) 6. Black Stripe Make-up Tube (1/8 inch)
3. Green Stripe Ink Tube (1/8 inch) 7. Clear Tube (1/8 inch)
4. Air Vent
Figure 4-6: Tubes to Ink Core Manifold
4-6 Commission the Printer Rev AA

6 Connect the air vent tube (item 4, Figure 4-6 on page 4-6) to the fitting
at the bottom rear of the cabinet (if it is not already connected).
7 Push the ink core module into the ink compartment.
8 Close the ink compartment door.
9 Put the printer on a stand or table.
The printer can be mounted on three types of stands: mobile printer
stand, static printer stand, or the wall mounting assembly. Refer to the
respective installation instructions to install the printer on a stand.
Log into UI
10 Connect the printer to the AC power supply and turn on the printer.
The menu screen appears on the display (see Figure 4-7).
Figure 4-7: Menu Screen
11 If you cannot see the display, adjust the contrast using the contrast
adjustment button .
12 Log into the user interface (UI) at level 3 password. On the Password
menu, select Enter Password. The Enter Password dialog box appears.

Use the password generated by the DailyPassword application. The

daily top level password is provided to trained personnel only.
Note: The printer may display a "No Ink Parameters" warning and an "Ink
Core Change" alarm. These are normal indications that the ink core is new
and not programmed.
Install Ink and Make-up Cartridges

13 Open the ink compartment door (refer to Step 1 and Step 2 on page 4-
4).
Warning
The ink, solvent and make-up fluid are irritating to the eyes and
respiratory system. To prevent personal injury when handling these
substances follow the guidelines given below:
with soapy water. DO NOT use washdown or solvent to clean ink
14 Install one new cartridge of ink and one new cartridge of make-up
fluid in the printer.
The printer displays the parameters from the smart chip on the ink
cartridge. Press the Enter key to accept the parameters and program
the ink core module.
After the cartridges are installed, the following events occur:
a. The No Ink Cartridge and No Makeup Cartridge icons
disappear.
Note: If the No Ink Cartridge icon or No Makeup Cartridge icon does not
disappear, pull the cartridge out of the ink compartment and insert again.

b. The Wrong Ink icon and Wrong Makeup icon appear
until the smart chip data is read by the printer. Once, the printer
reads the smart chip data, the screen displays the parameters from
the ink cartridge smart chip. Press the Enter key to accept these
parameters and program the ink core module
c. The icons that show the level of the ink and make-up in the
cartridges appear.
15 Make sure that the part number on the ink cartridge matches with the
part number displayed on the screen. See Figure 4-8.
Figure 4-8: Ink Part Number
16 Verify the ink type and expiration date. Access Calibrate > View Ink
Smart Chip Data menu (see Figure 4-9 and Figure 4-10).

Make sure that the ink type matches with the ink type displayed on
the menu screen (see Figure 4-8 and Figure 4-10 on page 4-10).
Figure 4-9: View Ink Smart Chip Data
Figure 4-10: Ink Smart Chip Data
Configure the Printer

17 Calibrate the EHT. Refer to “Calibrate EHT” on page 4-30.
18 Set date and time. Access Configure > Set Time/Date (see Figure 4-11 on
page 4-11).

Figure 4-11: Set Time/Date
19 Set the nozzle type and the conduit length. Access Configure > System
Settings. The System Settings dialog box appears (see Figure 4-12).
• Make sure that the nozzle type is set correctly for the current
configuration (70 micron).
• Make sure that the conduit length is set correctly for the current
configuration (2m, 3m or 6m).
Figure 4-12: System Settings
20 Make sure that the current printhead elevation is zero. Access

Calibrate > Printhead Elevation. The Printhead Elevation dialog box
appears (see Figure 4-13 on page 4-12).

Note: Keep the printhead at the same height as the point where the umbilical
is attached to the cabinet.
Figure 4-13: Printhead Elevation
Prime the Ink Core Module

21 Select System > Fill Ink Core to prime the printer with the ink (see
Figure 4-14 on page 4-12) and record the time.
Figure 4-14: Fill Ink Core Menu

22 Make sure that the fluid flows in the black-striped tube (item 1,
Figure 4-15) and the blue-striped tubes (item 2).
1. Black Striped Tube

2. Blue Striped Tube
Figure 4-15: Prime Core
23 Monitor the Diagnostics Screen Two to track the Ink Core Level from
Empty to Low to Middle. Select Calibrate > Diagnostics Screen 2. The
Diagnostics Screen 2 appears (see Figure 4-16).
Figure 4-16: Diagnostics Screen 2
24 Replace the ink cartridge with a new cartridge when the printer
warning appears. Continue with Fill Ink Core procedure until the
middle level is achieved.

Perform Umbilical Purge and System Flush Purge

25 Remove the printhead cover screw that fastens the printhead cover to
the printhead chassis and remove the printhead cover (refer to
Figure 4-17).
1. Umbilical 4. Printhead Cover Screw

2. Printhead Cover 5. Printhead Valve Module
3. Print Engine
Figure 4-17: Printhead Cover Removed
Caution
Always wear a set of rubber gloves before disconnecting the nozzle
tubing manifold. This helps to prevent nozzle clogs.
26 Remove the M2 x 6 socket-head-cap screw (item 1, Figure 4-18 on

page 4-15) that attaches the front tubing manifold to the printhead
valve module.
27 Remove the 2-way manifold gasket (item 5).
28 Put the 2-way manifold gasket provided in the bypass kit on the ports
of the printhead valve module.
29 Fit the nozzle bypass manifold (that has the loop of tube) to the
printhead valve module using the M2 x 6 socket-head screw.

4
1. M2 x 6 Socket-head Screw 4. Quick Disconnect
2. Nozzle Bypass Manifold 5. 2 Way Manifold Gasket
3. Tubing
Figure 4-18: Bypass Manifold
30 Open the quick disconnect (item 4, Figure 4-18) in the middle of the
loop and direct the supply side into a receptacle.
31 Start System Flush Purge (select System > System Flush Purge). Refer to
“System Flush Purge” on page 8-5 to perform system flush purge.
32 Observe if the fluid is going through the flush supply line (red stripe)
and eventually exiting the loop.
Make sure that the fluid being ejected is clear (make-up, not ink).
33 Perform umbilical purge (refer to “Umbilical Purge” on page 8-3).
This procedure will not time-out automatically, so perform a quick
stop to stop the umbilical purge process after a few seconds.

Figure 4-19: Umbilical Purge
34 Remove the nozzle bypass manifold and the 2-way manifold gasket.
35 Fit the front tubing manifold to the printhead valve module using M2
x 6 socket-head-cap screw.
Perform Viscosity Calibration

36 Remove the make-up cartridge from the make-up stall.
37 Start the jet using quick start.
Figure 4-20: Quick Start Jet
You may experience the ink stream toggling initially due to air
bubbles remaining in the system. If the nozzle is clogged, perform

nozzle backflush. (System > Nozzle Flush). Limit the number of

backflushes to 40.
38 Check the position of the ink stream into the gutter:
• If the ink stream is aligned into the gutter, go to the Step 39.
Alignment can be fine-tuned later.
• Otherwise, perform an ink stream alignment, if necessary (refer to
“Align the Ink Stream” on page 4-26). Make sure that the
adjustments are not at either end of the adjustment ranges - if they
are, you may have a nozzle partial clog even if the ink stream is not
severely misdirected. If necessary, do a nozzle backflush (System >
Nozzle Flush).
39 Make sure that the jet startup is complete. The jet running icon on the
home screen should be solid (not blinking) .
40 Make sure that the printer has reached steady state. Steady state
means: actual velocity = velocity set point, + or - 0.1m/sec.
41 Perform viscosity calibration (refer to “Calibrate Viscosity” on page 4-
32).
42 Check the ink stream alignment and fine-tune if necessary. Ink stream
should be centered and no more than 2 to 3 stream widths from the
top of the gutter. The top of the gutter is closest to the EHT plate.
43 Insert the make-up fluid cartridge.
Clean Stop and Clean Start the Printer

44 Put a piece of paper under the printhead (to capture splatter) and
press the F1 key to do a clean stop.
During shutdown if ink splatters inside the printhead, check the ink
stream alignment again and make sure that the flush pump is fully
primed.
45 Put another piece of paper under the printhead and press the F1 key
to do a clean start.
Perform Final Checks

46 Install the printhead cover and make sure that the amber light
extinguishes:

• If the amber light is illuminated with the printhead cover fitted,

check the Current Warnings screen and perform the required
troubleshooting.
47 Use a flow meter and make sure that the positive air flow rate out of
the printhead slot is 4 SCFH.
49 Make sure that the electronics compartment door and the ink
compartment door are closed correctly.
Caution
Do not perform Step 50 until the system is ready for production, as it
affects the viscosity adjustments of the printer.
50 If production printing is desired, measure the vertical distance

between the umbilical exit point on the side of the cabinet and the
bottom of the printhead when it is fitted to the conveyor. This is the
printhead elevation. Enter the value (in centimeters) in the UI.
51 Back up printer settings using a USB flash drive. Select Configure >
Backup System Settings.

Figure 4-22: Backup System Settings
52 Press the Enter key to backup the settings.

53 Validate machine parameters.
Note: If the customer has ordered the positive air pump option, the pump
should be installed now (before the power is switched on). Refer to “How to
Install the New Positive Air Kit” on page 7-92 for information on
installation of positive air pump.
Set the Password Levels

Notes: You must be at Password Level 3 to set the password levels. Do not
divulge the master password to the customer.
Consult the customer and find out which machine functions they want
available to relevant personnel and which passwords they want to use. Set
the passwords for Levels 1 and 2. You can also set the password levels for
the menus. Use the DailyPassword application to generate the password to
be used every day.
Rev AA Set the Password Levels 4-19

Figure 4-23: Password Menu
Caution
Machine functions that only trained personnel can access are set at
Password Level 3 (master password), these functions must not be
given as customer options.
Install the Encoder

When product speed is constant, the printer uses internal encoding.
External encoding (that is shaft encoder) is used when the speed of the
conveyor varies.
Internal Encoding
An internal clock sets the stroke-rate to a constant pace. Refer to “When to
Use Internal Encoding” on page B-1, for more information on internal
encoding.
Do the following tasks to set encoding source to internal source:
1 Navigate to Configure> Shaft Encoder Source. The Print Control menu
appears (see Figure 4-24 on page 4-21).
2 Set the Shaft Encoder Source to Internal.
4-20 Install the Encoder Rev AA

Figure 4-24: Internal Shaft Encoder Source
Note: If the line speed varies, then an external shaft encoder must be fitted in
order to maintain constant message width (refer to “External Encoding” on
page 4-22).
Note: A width of 1 will provide the fastest print that the printer can achieve
in each font using the Internal Shaft Encoder option (refer to Figure 4-25).
The message width is increased by approximately 3% for each increment.
Figure 4-25: Message Width
Refer to “Internal Encoding” on page B-1 for more information.
Rev AA Install the Encoder 4-21

External Encoding
To install an external shaft encoder, do the following tasks:
1 Turn off the printer.
2 Connect the shaft encoder cable to the shaft encoder connector. See the
following pictures for connections:
• Figure 4-26 on page 4-22 - Shows the shaft encoder connector on the
connector panel.
• Figure 4-1 on page 4-3 - Shows the installed shaft encoder and the
related connections.
• Figure 4-27 on page 4-23 - Describes the shaft encoder connector
socket pin layout.
Note: The printer can be configured to accept two shaft encoder (quadrature)
outputs. This allows the printer to compensate for changes in direction of the
production line.
Note: Using quadrature shaft encoders to determine changes of direction

disables the width function (that is, the width must be set to 1). If width
control is required, an external divider box must be provided.
Shaft Encoder Connector
Cat 5e
4-22 Install the Encoder Rev AA

1 2
4 3
Figure 4-27: Encoder - Socket Pin Layout
3 Two LEDs show the operating status of the shaft encoder inputs. Use
the LEDs to confirm a properly connected shaft encoder.
4 Set the Shaft Encoder Source to External. Navigate to Configure> Print
Control in the 1510 UI (Figure 4-28).
Figure 4-28: Print Control Menu
5 Make sure to set the physical parameters for external encoder.
Rev AA Install the Encoder 4-23

Install the Product Sensors

Figure 4-1 on page 4-3 shows a photocell (item 4) connected through a
cable (item 5) to product detector 1 connector on the connector panel.
Note: Product detector 2 is for reverse print and is not a product detector trigger,
but a change in state reverses the direction of print. It has an NPN and PNP
connection. The product detector 2 option requires the use of non-standard system
software.
1 The photocells may be either NPN or PNP devices. Set Jumper JB1 on
the CSB to match the device type.
2 Turn on the printer.
3 Select the photocell source. Access Configure > Photocell Source. The
Print Control menu appears.
Set the relevant photocell level(s) to Active high or Active low
dependant upon the device type. (NPN = Active high: PNP = Active
low). Access Configure > Photocell Levels. The Photocell Levels menu
appears.
Printhead
Product Delay Product
Product Detector
Figure 4-29: Product Delay
Install the Beacon

Do the following tasks to install a beacon:
1 Fit the beacon (item 1, Figure 4-30 on page 4-25) to the beacon
mounting bracket (item 3) using three M4x10 socket-head cap screws
(item 2).
2 Fit the beacon mounting bracket to the printer cabinet (item 1, Figure
4-31 on page 4-25), using three M4x10 socket-head cap screws (item 2)
and three M4 plain nylon washers (item 3).
4-24 Install the Product Sensors Rev AA

1. Beacon
2. M4x10 Socket-head cap Screws (x3)
3. Beacon Mounting Bracket
Figure 4-30: Beacon
2
3
1. Printer Cabinet
2. M4x10 Socket-head cap Screws (x3)
3. M4 Plain Nylon Washers (x3)
Figure 4-31: Beacon Installation
3 Insert the beacon connector into the status output connector on the
connector panel (see Figure 4-32 on page 4-26).
Rev AA Install the Beacon 4-25

Status Output Connector
Cat 5e
The installation of the beacon is complete.
Align the Ink Stream

Two adjustments are required: nozzle vertical adjustment and nozzle
horizontal adjustment.
Warning
The ink and make-up fluid are irritating to the eyes and respiratory
system. To prevent personal injury when handling these substances:
with soap water. DO NOT use washdown or solvent to clean ink
4-26 Align the Ink Stream Rev AA

Do the following tasks to align the ink stream:

1 Loosen the knurled screw and remove the cover from the printhead.
2 Secure the printhead vertically in a suitable stand with the nozzle
pointing downwards. Put a suitable container beneath the printhead
to collect the ink.
3 Disable Gutter Detect and Charge Check, as follows:
a. Press Alt + S. The System menu appears.
Figure 4-33: System Menu
b. Select Gutter Fault Shutdown Enable. The Gutter Fault Shutdown box
appears.
c. Toggle to set the value to Disable.
d. Press the Enter key.
Rev AA Align the Ink Stream 4-27

Optimum jet
position, 2 to 3
times diameter of jet
Gutter
center line
First quarter
of the gutter
Figure 4-34: Ink Jet Gutter Position
4 Perform a quick start. When the ink jet has started, check that the ink
jet is in the correct position in the gutter (Figure 4-34).
Note: You must perform a quick start rather than a clean start when you are
aligning the printhead during the commissioning process. However, if you
are aligning the printhead of a printer that has already been in operation for
some time, you may perform either a quick start or a clean start at this point.
Caution
EQUIPMENT DAMAGE. Never attempt to bend the gutter. Its
position is fixed.
5 Adjust the ink jet position, if necessary using the horizontal

adjustment screws (item 2, Figure 4-35 on page 4-29) and vertical
adjustment screw (item 1). When the adjustment has been made make
sure that the horizontal adjustment screws are tight and the ink jet
position is correct.
4-28 Align the Ink Stream Rev AA

4
3 2
1. Vertical Adjustment Screw 3. Horizontal Locking Screw

2. Horizontal Adjustment Screw 4. Vertical Locking Screw
Figure 4-35: Printhead Adjustment Screw Location
6 When the ink jet position is correct in the gutter, check the ink jet is
flowing through the centre of the charge electrode slot parallel to the
sides of the slot (Figure 4-36).
Equidistant Gap
Figure 4-36: Ink Flow Through Charge Electrode
Rev AA Align the Ink Stream 4-29

Caution
You must not tamper with the printhead charge electrode
components.
7 To direct the ink jet flow through the charge electrode:

a. Release the horizontal adjustment screw (item 2, Figure 4-35 on
page 4-29).
b. Move the block until the jet is in the correct position. Secure the
adjustment screw and check the jet position again.
Perform Calibration and Testing

The system calibration and test procedures must be performed to
commission the machine after the repairs are done to the printer.
Note: If the customer has ordered the positive air pump option, the pump should
be installed now (before the power is switched on). See “Positive Air Kit” on
page 7-89 for information on installation of positive air pump.
Calibrate EHT
Do the following tasks to calibrate the EHT:
1 Loosen the knurled screw and remove the cover from the printhead.
2 Press Alt + l. The Calibrate menu appears.
4-30 Perform Calibration and Testing Rev AA

Figure 4-37: Calibrate Menu
3 Select Calibrate EHT. The EHT Calibration Messages appear based on

the condition.
Figure 4-38: EHT Calibration Messages
4 Press Enter. EHT Calibration Sweep occurs.Refer to Figure 4-39.
Figure 4-39: EHT Calibration Sweep
Rev AA Perform Calibration and Testing 4-31

Calibrate Viscosity
Do the following tasks to perform viscosity calibration:
Note: Perform this procedure immediately after completing the Fill Ink Core
sequence, but before the jet has been started.
1 Keep the printhead at the same height as the point where the
umbilical is attached to the cabinet.
2 Set the printhead elevation value to zero (0). See Figure 4-40.
Figure 4-41: Unlock Ink Compartment Door

4 Remove the make-up cartridge (see Figure 4-42).
Figure 4-42: Cartridge Removal
5 Perform a Quick Start. See Figure 4-43.
Figure 4-43: Quick Start
6 Make sure that the jet startup is complete. The jet running icon on the
home screen should be solid (not blinking) .
7 Make sure that the printer has reached steady state. Steady state
means: Actual Velocity = Velocity Set Point + or -0.1 m/s
For example, see Figure 4-44 on page 4-34.
Rev AA Perform Calibration and Testing 4-33

Figure 4-44: Steady State
8 Perform viscosity calibration. Follow the prompts provided by the

printer, assuming that the ink is known perfect ink. See Figure 4-45.
Note: Perfect ink is the ink that is pulled directly from an ink cartridge
known to be within a specific viscosity range.
Figure 4-45: Viscosity Calibration
9 Put the make-up cartridge into make-up cartridge slot.

10 Enter the correct printhead elevation in the UI. Refer to Figure 4-40 on
page 4-32.
11 Put the printhead into the printhead bracket on the conveyor.

Printer Operation
5
Introduction
Refer to the Operator Manual for the following information:
• How to turn on the printer
• How to Clean Start and Stop the Printer
• How to login for the first time
• How to set the passwords for menus and levels
• How to access other password levels
• How to clear the passwords
• How to view version info
• How to reset and hide the product counter
• How to view and reset run hours
• How to configure the serial port
• How to connect to a remote device
• How to enter service information
• How to create a message
• How to Print Messages
Reset Run Hours

If the Service icon is displayed, the time until the next service is due must
be entered to remove it.
Note: The contact information that is displayed on

screen when this icon appears can be configured by
selecting Enter Service Information in the Data
Logging menu.

1 Navigate to Data Logging > Reset Run Hours.
Figure 5-1: Data Logging Menu
2 Press the Enter key. The Reset Run Hours menu appears.
Figure 5-2: Reset Run Hours Menu
3 Select Set machine alarm hours. Enter the number of hours until the next
ink core change is due. For more information refer to the Table 8-1 on
page 8-1.
4 Set Reset machine run hours to Yes.
5 Configure Set machine alarm hours to the number of hours until the
next air filter inspection is due.
For the recommended interval, refer to Table 8-1 on page 8-1.
6 Set Reset machine run hours to Yes.
7 Press the Enter key to save the settings.
Restore Calibration Parameters

The following procedure may be performed in order to recover previously
backed-up job and printer configuration information from a USB flash
drive:
1 Insert the USB flash drive into the external USB port of the printer.
5-2 Restore Calibration Parameters Rev AA

2 Select Configure >Restore System Settings.
Figure 5-3: Calibrate Menu
3 Press the Enter key to restore the settings.
Perform Full System Backup

Do the following tasks to perform a complete back-up of all
programmable printer files, including job and printer configuration
information:
1 Press the F1 key to stop the ink jet.
2 Insert a USB flash drive into the external USB port of the printer.
3 Select Configure > Full System Backup.
Figure 5-4: Full System Backup
Rev AA Perform Full System Backup 5-3

3) Follow the printer prompts and complete the backup.
Perform Full System Restore

Do the following tasks to recover previously backed-up information from
the USB flash drive:
2 Insert a USB flash drive into the external USB port of the printer.
3 Select Configure > Full System Restore.
Figure 5-5: Full System Restore
4 Use the Right or Left arrow keys to scroll through the available options
to restore.
Figure 5-6: Restore Options
5 Press the Enter key to restore the selected option.
5-4 Perform Full System Restore Rev AA

User Interface
6
Introduction
Refer to Videojet 1510 Operator Manual for information on how to:
navigate in the UI, create the messages, edit the messages, save the
messages, and create the user fields.

Replacement
Instructions 7
Introduction
This section contains complete instructions for the replacement of the
components listed below.
Description Page No.
Replace the Control System Board 7-7
Replace the Power Supply Unit 7-9
Replace the Liquid Crystal Display (LCD) or the Front Panel 7-13
Interface Board (FIB)
Replace the Keyboard/Electronics Compartment Door 7-16
Replace the Ink Core Module 7-21
Replace the Ink Pump 7-35
Replace the Print Engine Assembly 7-41
Replace the Printhead Valve 7-44
Replace the Umbilical Assembly 7-49
Replace the Printer Interface Board (PIB) 7-73
Replace the Electronics Fan 7-85
Replace the Septum Assembly 7-81
Replace the Gutter Pump 7-93
Replace the Power Switch 7-76
Replace the Ethernet Connector 7-87
Replace the Positive Air Filter 7-89
Replace the Ink Door Assembly 7-98
Replace the Ink System Fan 7-103
Replace the EHT Module 7-105
Replace the USB Connector 7-108
Replace the Plug and Power Cable 7-109
Table 7-1:Location of the Instructions

Description Page No.
Replace the CSB Lithium Battery 7-115
Replace the PCB 1, 2 and 3 7-117
Table 7-1:Location of the Instructions
Safety Information
Caution
PERSONAL INJURY. Before you begin any maintenance work,
make sure that the printer is turned off and disconnected from the
AC power supply.
Warning
LETHAL VOLTAGES. Lethal voltages are present within this
equipment when it is connected to the mains electrical supply. Only
trained and authorized personnel can carry out maintenance work.
Observe all statutory electrical safety codes and practices. Unless it is
necessary to run the printer, disconnect the printer from the mains
electrical supply before removing the covers or attempting any
service or repair activity, otherwise death or personal injury may
result.
Caution
ELECTROSTATIC SENSITIVE DEVICES. The printed circuit boards
contain static sensitive devices. A suitably grounded, antistatic wrist
strap must be worn when working on or handling printed circuit
boards.
7-2 Safety Information Rev AA

Caution
PERSONAL INJURY. Only trained service or maintenance
personnel must perform these installation procedures. Qualified
personnel have successfully completed the training courses, have
sufficient experience with this printer, and are aware of the potential
hazards to which they will be exposed.
Common Procedures
How to Open the Electronics Compartment Door

Do the following tasks to open the electronics compartment:
1 Turn off the main power switch of the printer.
2 Turn off the AC power supply to the printer.
3 Disconnect the mains power cord from the outlet.
Warning
Before you open the electronics compartment door, wear anti-static
wrist straps and ground yourself to the chassis of the cabinet. Failure
to follow this warning can cause both personal injury and damage to
the printer.
4 Use the 3 mm allen wrench to remove the two M4 screws (Figure 7-1
on page 7-4) that attach the electronics compartment door to the
printer cabinet.
Rev AA Common Procedures 7-3

Figure 7-1: Electronics Compartment Door
5 Open the electronics compartment door (Figure 7-2).
Figure 7-2: Electronics Compartment Door Opened
7-4 Common Procedures Rev AA

6 Push the latch (item 2, Figure 7-3) downwards to open the control
system board (CSB) (item 1).
1. CSB 3. M4 x 8 Cap-head Screws (x2)

2. Latch 4. Retainer
Figure 7-3: Latch
How to Close the Electronics Compartment Door

Do the following tasks to close the electronics compartment door:
1 Close the CSB (item 1, Figure 7-3).
2 Push the latch (item 2) up and close the CSB.
3 Close the electronics compartment door with the two M4 screws (see
Figure 7-1 on page 7-4).
4 Connect the mains power cord to the electrical outlet and turn on the
power.
How to Open the Ink Compartment Door

Do the following tasks to open the ink compartment door:
1 Stop the production and remove the printer from the print mode.
2 Log into the Videojet 1510 user interface (UI) as level B or level C user.
Rev AA Common Procedures 7-5

5 Push the plate (item 2) in the direction shown to open the ink
compartment door (item 1, Figure 7-5) completely.

2. Plate
Figure 7-5: Ink Compartment Door Opened
7-6 Common Procedures Rev AA

How to Close the Ink Compartment Door

Do the following tasks to close the ink door:
1 Close the ink compartment door and turn the knob to lock the door
(see Figure 7-4 on page 7-6).
2 Connect the mains power cord to the electrical outlet.
3 Turn on the main power switch of the printer.
Tools and Supplies Required
Tool or Supply Quantity
3 mm Allen Wrench 1
Table 7-2:Tools and Supplies
Warning
Read the “Safety Information” on page 7-2 before you perform the
below tasks.
How to Remove the Old Control System Board

Do the following tasks to remove the old control system board (CSB):
1 Open the electronics compartment door. Refer to “How to Open the
Electronics Compartment Door” on page 7-3.
2 Remove the hinge bracket that holds the CSB.
3 Remember all the cable connections to the CSB (Figure 7-6 on page 7-
8).
4 Disconnect all the cable connectors from the CSB.
Rev AA Control System Board 7-7

Figure 7-6: CSB
5 Discard the CSB according to the local regulations.

The removal of the old CSB is complete.
How to Install the New Control System Board

Do the following tasks to install the new CSB:
1 Put the new CSB in the electronics compartment, so that the pins on
the mounting plate fit in the hinge bracket.
2 Connect all the cable connectors to the CSB.
3 Push the latch up and close the CSB.
4 Put the retainer over the hinge pins of the CSB mounting plate.
5 Fit the retainer using the two M4 x 8 cap-head screws (item 3, Figure
7-3 on page 7-5).
6 Close the electronics compartment door. Refer to “How to Close the
The installation of the new CSB is complete.
7-8 Control System Board Rev AA

Power Supply Unit
3 mm Allen Wrench 1
7 mm Nut Runner 1
Warning
below tasks.
How to Remove the Old Power Supply Unit

Do the following tasks to remove the old power supply unit (PSU):
2 Swing open the control system board (CSB) (item 2, Figure 7-7 on
page 7-10).
Rev AA Power Supply Unit 7-9

1. PSU
2. CSB
7-10 Power Supply Unit Rev AA

3 Remove the two M4 nyloc nuts (item 3, Figure 7-8) from the stud (item
2) inside the cabinet.
1. PSU
2. Stud
3. M4 Nyloc Nut
Figure 7-8: PSU Assembly
4 Disconnect the following cables from the PSU (item 1, Figure 7-7 on
page 7-10).
• PSU cable to the 8-way connector on the CSB
• Cable to the 3-way mains connector on the power switch
5 Discard the old PSU according to local regulations.
The removal of the old PSU is complete.
How to Install the New Power Supply Unit

Do the following tasks to install the new PSU:
1 Connect the following cables to the PSU:
• PSU cable from the 8-way connector on the CSB
• 3-way mains connector from the power switch
2 Put the PSU assembly into the lug (see Figure 7-9 on page 7-12) in the
rear of the electronics compartment and then on the two studs.
Rev AA Power Supply Unit 7-11

3 Use the two M4 nyloc nuts to fit the PSU assembly into the lug inside
the cabinet.
Figure 7-9: Lug
4 Close the CSB.

The installation of the new PSU is complete.
7-12 Power Supply Unit Rev AA

LCD and FIB Assembly
Introduction
The LCD and FIB are part of one assembly. Replace the FIB and LCD
together.
T20 Torx Screwdriver 1
Warning
below tasks.
How to Remove the Old LCD and FIB Assembly

Do the following tasks to remove the old LCD and FIB assembly:
Rev AA LCD and FIB Assembly 7-13

1. Electronics Compartment Door 4. FIB Cable

2. K40 x 10 Torx Screws (x4) 5. Ground Wire
3. Inner Display Cover
Figure 7-10: Open Electronics Compartment Door
2 Disconnect the front panel interface board (FIB) ribbon cable (item 4,
Figure 7-10) from the FIB.
3 Remove the four K40 x 10 Torx screws (item 2) at the corners of the
inner display cover (item 3) on the underside of the electronics
compartment door.
4 Disconnect the ground wire from the FIB (item 2, Figure 7-11 on
page 7-15) that is connected to the keypad tag (item 3).
7-14 LCD and FIB Assembly Rev AA

1. Screw
2. Ground Wire
3. Keypad Tags (x2)
Figure 7-11: Ground Wire on Keypad Tag
5 Disconnect the two keyboard-to-FIB ribbon cables (item 1, Figure 7-

12) from connectors X7 and X8 on the periphery of the FIB (item 3).
1. Keyboard-to-FIB Ribbon Cable (x2) 3. FIB

2. K40x10 Torx Screws (x4)
Figure 7-12: Remove the FIB
6 Use T20 Torx driver to unscrew the four K40x10 Torx screws (item 2,
Figure 7-12) from the four corners of the FIB.
7 Remove the old LCD and FIB assembly and discard according to the
local regulations.
The removal of the old LCD and FIB assembly is complete.
Rev AA LCD and FIB Assembly 7-15

How to Install the New LCD and FIB Assembly

Do the following tasks to install the new LCD and FIB assembly:
1 Before you install the new LCD and FIB assembly, peel the protective
film from the new LCD (see Figure 7-13).
2 Fit the new LCD and FIB assembly to the old electronics compartment
door using four K4x10 Torx screws (refer to Figure 7-12 on page 7-15).
.
Figure 7-13: Peel the Protective Film
3 Connect the two keyboard to FIB ribbon cables to connectors X7 and

X8 on the periphery of the FIB (see Figure 7-12 on page 7-15).
4 Connect the ground wire to the FIB (refer to Figure 7-11 on page 7-15).
5 Fit the inner display cover and tighten the four K40 x 10 Torx screws.
Make sure that the cover fits into the gasket all the way round.
6 Connect the FIB ribbon cable to the FIB.
The installation of the new LCD and FIB assembly is complete.
Keyboard/Electronics Compartment Door
Introduction
The spare electronics compartment door comes with the relevant
keyboard overlay (in language required), gasket and fixings screws.
However it does not contain liquid crystal display and front panel
7-16 Keyboard/Electronics Compartment Door Rev AA

interface board (LCD and FIB) assembly, cover, and leads. Hence, the
replacement instructions are same for both the keyboard and electronics
compartment door.
Tools or Supplies Quantity
3 mm Allen Wrench 1
7 mm Nut Spinner 1
Table 7-5:Tools and Supplies Required
Warning
below tasks.
How to Remove the Old Electronics Compartment Door

Do the following tasks to remove the old electronics compartment door:
Note: There is no need to open the Control System Board (CSB).
Rev AA Keyboard/Electronics Compartment Door 7-17

1. Electronics Compartment Door 4. FIB Ribbon Cable

2. K40 x 10 Torx Screws (x4) 5. Ground Wire
3. Inner Display Cover
Figure 7-14: Open Electronics Compartment Door
2 Disconnect the front panel interface board (FIB) ribbon cable (item 4,
Figure 7-14) from the FIB.
3 Use a T20 Torx screwdriver to remove the four K40 x 10 Torx screws
(item 2, Figure 7-14) at the corners of the inner display cover (item 3)
on the underside of the electronics compartment door.
4 Use a T20 Torx screwdriver to remove the six K50 x 12 Torx screws
(item 1, Figure 7-15 on page 7-19) that hold the electronics
compartment door (item 3) to the hinge bracket (item 2).

1. K50 x 12 Torx Screws (x6)

2. Hinge Bracket
3. Electronics Compartment Door
Figure 7-15: Remove the Electronics Compartment Door
5 Remove the electronics compartment door from the printer.

6 Disconnect the ground wire from the FIB (item 2, Figure 7-16) that is
connected to the keypad tag (item 3).
1. Screw
2. Ground Wire
3. Keypad Tags (x2)
Figure 7-16: Ground Wire on Keypad Tag
Rev AA Keyboard/Electronics Compartment Door 7-19

7 Disconnect the two keyboard-to-FIB ribbon cables (item 1, Figure 7-

17) from connectors X7 and X8 on the periphery of the FIB (item 3).
1. Keyboard-to-FIB Ribbon Cable (x2) 3. FIB

2. K40x10 Torx Screws (x4)
Figure 7-17: Remove the FIB
8 Use T20 Torx driver to unscrew the four K40 x 10 Torx screws (item 2)
from the four corners of the FIB.
9 Remove the FIB and LCD assembly from the electronics compartment
door.
10 Keep the FIB and LCD assembly on an antistatic bubble sheet.
11 Discard the electronics compartment door according to the local
regulations.
The removal of the old electronics compartment door is complete.
How to Install the New Electronics Compartment Door

Do the following tasks to install the new electronics compartment door:
1 To attach the old FIB and LCD assembly to the new electronics
compartment door, do the following tasks:
a. Fit the old FIB and LCD assembly to the new electronics
compartment door using four K4 x 10 Torx screws (see Figure 7-17).
b. Connect the ground wire to the FIB (see Figure 7-16 on page 7-19).
c. Connect the two keyboard to FIB ribbon cables to connectors X7
and X8 on the periphery of the FIB (see Figure 7-17).

2 Fit the electronics compartment door to the hinge bracket using the six
K50 x 12 screws (item 1, Figure 7-15 on page 7-19).
3 Fit the inner display cover and tighten the four K40 x 10 screws. Make
sure that the cover fits into the gasket all the way round.
4 Connect the FIB ribbon cable to the FIB.
The installation of the new electronics compartment door is complete.
Ink Core Module
Introduction
The ink core module comes as a single unit. The only part that you can
replace is ink core pump. This instruction sheet describes how to replace
the ink core module with and without the pump.
1. Ink Core Pump

2. Ink Module
Rev AA Ink Core Module 7-21

2.5 mm Allen Wrench 1
3 mm Allen Wrench 1
7 mm Nut Spinner 1
Side Cutters 1
Table 7-6:Tools and Supplies Required
How to Remove the Old Ink Core Module

Do the following tasks to remove the old ink core module:
1 Stop the production and remove the printer from the print mode.
2 Log into the Videojet 1510 UI as level 2 or level 3 user.
3 Press the F1 key for Videojet 1510.
7-22 Ink Core Module Rev AA

5 Remove the ink and the make-up cartridges from their slots in the
module (see Figure 7-20).
Figure 7-20: Cartridge Removal
6 Insert an empty solvent cartridge or a special cartridge into the ink

cartridge slot.
Note: A special cartridge is an empty cartridge used for draining.
Note: Do not remove the special cartridge until the Empty Ink Core routine
is completed. The smart chip on the cartridge is programmed to allow for one
time insertion only.
7 Select Empty Ink Core option for 1510 (see Figure 7-21 on page 7-24).
The contents of the ink core will be pumped into the special cartridge.
Note: The Empty Ink Core process can take up to 10 minutes and may
require two special cartridges.

Figure 7-21: Empty Ink Core
Note: Do not remove the special cartridge until the routine is completed as a
leak can occur.
8 After the Empty Ink Core routine is complete, discard the special
cartridge according to hazardous materials (HAZMAT).
10 Disconnect the mains power cord from the electrical outlet.
11 Push the plate in the direction shown to open the ink compartment
door completely (see Figure 7-22).
Figure 7-22: Plate

13 Disconnect the ink core module ribbon cable (item 1, Figure 7-24)
from the printer interface board (PIB) (see Figure 7-25 on page 7-26).
1. Ink Core Module Ribbon Cable

2. Ground Wire
Figure 7-24: Ink Core Module Manifold

14 Disconnect the ground wire (item 2, Figure 7-24 on page 7-25) from
the printer cabinet (see Figure 7-25).
1. Ribbon Cable Connection to PIB 3. Ring Terminal

2. Spiral Wrap 4. Ground Wire Connection
Figure 7-25: Ground Wire to the Printer Cabinet
15 Cut the ring terminal (item 3, Figure 7-25) from the ground wire and
remove the wire from the spiral wrap (item 2).
16 Loosen and remove the two M3 screws (item 1, Figure 7-26 on page 7-
27) that fasten the ink core manifold (item 2) to ink core module using
2.5 mm allen wrench.

1. M3 Screws (x2)
2. Ink Core Manifold
3. Gasket
Note: You must fit the old ink core manifold to the new ink core module
immediately.
17 Remove the plate on the ink core manifold of the new ink core
module.
18 Fit the old ink core manifold to the new ink core module using the two
M3 screws and new gasket immediately (see Figure 7-26).
Note: Keep the ink core manifold clean.

19 If you need to replace the ink core module along with the pump, there
is no need to remove the pump, discard the ink core module along
with the pump, according to hazardous materials (HAZMAT).
The removal of the ink core module along with the ink core pump is
complete.
20 If you need to replace the ink core module without the pump, you
need to first remove and store the pump, and then replace only the ink
core module. Refer to “How to Remove the Ink Core Pump” on
page 7-28.

How to Remove the Ink Core Pump

Do the following tasks to remove the ink core pump:
21 Use a T10 Torx screwdriver to remove the two K30 x 12 Torx screws
(item 3, Figure 7-27) that fasten the ink core pump cover (item 1) to the
ink core module (item 2).
3
1
1. Ink Core Pump Cover

2. Ink Core Module
Figure 7-27: Ink Core Pump Cover
22 Slide the pump cover down the ribbon cable and remove the cover.
23 Discard the pump cover according to the local regulations.
24 Remember the method of routing the pump wire harness inside the
ink core module.
25 Disconnect the pump wire harness from JP1 connector on the ink core
module interface board.
26 Use the 3 mm allen wrench to remove the two M4 x 35 socket-head-
cap screws (item 1, Figure 7-28 on page 7-29) that hold the pump
saddle clamp (item 2) to the ink core module (item 7).
27 Remove the pump saddle clamp and keep the clamp in a safe location.

28 Disconnect the ground wire from the ink pump earth tag (item 3). See
Figure 7-29 on page 7-30 for reference.
3
4
1. M4 x 35 Socket-head-cap Screw (x2) 5. O-rings

2. Pump Saddle Clamp 6. Ports on the Ink Core Module
3. Earth tag 7. Ink Core Module
4. Ink Core Pump

Ground Wire
Figure 7-29: Ground Wire
Note: Use tissues to absorb the spills from the pump.

29 Gently lift the ink core pump out of the ink core module.
30 Remember the location of the two O-rings (item 5, Figure 7-28 on
page 7-29) that seal the pump inlet and outlet ports and discard the O-
rings.
31 Keep the ink core pump in a safe location to use again.
32 Discard the ink core module (without the pump) according to
hazardous materials (HAZMAT).
The removal of ink core module without the ink core pump is complete.
How to Install the New Ink Core Module

Do the following tasks to install the new ink core module:
• If you have removed the ink core pump from the old ink core module,
you need to fit the old ink core pump to the new ink core module.
Refer to “How to Install the Old Ink Core Pump” to install the old ink
core pump into the new ink core module.
• If you have not removed the ink core pump from the old ink core
module, go to “How to Install the New Ink Core Module” on page 7-
31.
How to Install the Old Ink Core Pump

Do the following tasks to install the old ink core pump into the new ink
core module:
1 Remove the two K30 x 12 Torx screws (item 3, Figure 7-27 on page 7-
28) that fasten the ink core pump cover (item 1) to the ink core module
(item 2).
2 Slide the pump cover down the ribbon cables.

3 Remove the protective plate on the pump mounting block.

4 Discard the screws, plates, and O-rings.
5 Insert the new O-rings on the ports of the pump before you install the
old ink pump.
6 Install the old ink pump over the ports of the new ink core module.
Make sure that the two pins go into the two holes of the ink core
pump correctly (see Figure 7-30).
Pin
Figure 7-30: Pins
7 Connect the ground wire to the pump earth tag (see Figure 7-29 on
page 7-30).
8 Fit the pump saddle clamp over the old ink core pump using M4 x 35
socket-head-cap screws (item 1, Figure 7-28 on page 7-29).
9 Connect the pump wire harness to the JP1 connector on the ink core
10 Feed the ink core ribbon cable and the ground wire towards the back
of the cabinet and slide the cover until it is in the correct position.
11 Fasten the ink core pump cover to the ink core module using the
K30x12 Torx screws.
12 Go to Step 13 to continue with the installation of the ink core module.
How to Install the New Ink Core Module

13 Wind the ground wire around the spiral wrap twice to retain and
reconnect to the earth point in the back.
14 Connect the ground wire to the printer cabinet (see Figure 7-25 on
page 7-26).
15 Connect the ink core module ribbon cable (item 1, Figure 7-24 on
page 7-25) to the PIB.

16 Push the ink core module back into the printer cabinet.
17 Install the smart cartridges. Make sure that the correct fluid types are
used.
18 Close the ink compartment door and turn the knob to lock the door.
21 Select level 2 or level 3 password as the user level to log into the UI.
22 Check the ink system run hours. The system must display 0 hours.
Figure 7-31: View Run Hours
23 Fill the ink core.
Note: The process takes approximately 20 minutes to complete the cycle.
Figure 7-32: Fill Ink Core Option

the printhead chassis and remove the printhead cover (see Figure 7-
33).

3. Print Engine
Caution
To prevent nozzle clogs, always wear rubber gloves whenever the
front tubing manifold is disconnected from the printhead valve
module.
25 Remove the M2 x 6 socket-head-cap screw that attaches the front

tubing manifold to the printhead valve module.
26 Fit the nozzle bypass manifold that has the loop of tube to the
printhead valve module using the M2 x 6 socket-head screw (see

4
2. Bypass Manifold 5. 2 Way Manifold Gasket
3. Tube
27 Perform Umbilical Purge for 10 to 15 minutes (refer to the “Umbilical

Purge” on page 8-3 for procedure).
28 Remove the nozzle bypass manifold and the 2 way manifold gasket.
29 Loosely connect the front tubing manifold along with a new gasket
(do not tighten).
30 Put a full make-up fluid cartridge in the ink compartment.
31 Put a receptacle under the printhead to catch the make-up fluid
during flushing.
32 Perform a System Flush Purge. Refer to the “System Flush Purge” on
page 8-5 for procedure.
Make-up fluid will flow from the two way manifold into the
receptacle. Flushing will automatically stop when the purge cycle is
complete.
33 Tighten the 2 way front tubing manifold to printhead valve module.
34 Perform the quick start (see Figure 7-35 on page 7-35).

Figure 7-35: Quick Start
35 Check the ink stream alignment and adjust if necessary (refer to the
“Align the Ink Stream” on page 4-26 for procedure).
36 Perform a clean stop, and then a clean start to check the performance.
Press the F1 key to perform clean start or clean stop.
Note: Put a paper towel below the printhead when you perform a clean start
and stop.
The installation of the new ink core module is complete.
Ink Core Pump
3 mm Allen Wrench 1
Rev AA Ink Core Pump 7-35

Warning
below tasks.
How to Remove the Old Ink Core Pump

Do the following tasks to remove the old ink core pump:
Figure 7-37 shows how the ink core module ribbon cable, and the
ground wire are routed through the ink pump cover.

2. Ground Wire
Figure 7-37: Ink Core Module Ribbon Cable
7-36 Ink Core Pump Rev AA

2 Use a T10 Torx screwdriver to remove the two K30 x 12 Torx screws
(item 3, Figure 7-38) that fasten the ink pump cover (item 2) to the ink
core module.
1. Ink Core Pump

2. Ink Core Pump Cover
Figure 7-38: Ink Core Pump Cover
3 Lift the ink pump cover and gently slide it towards the back of the
cabinet, exposing the pump.
4 Feed the ink core module ribbon cable and the ground wire through
the pump cover to allow it to be repositioned.
5 Remember the method of routing the pump wire harness inside the
ink core module.
6 Disconnect the pump wire harness from JP1 connector on the ink core
7 Use the 3 mm allen wrench to remove the two M4 x 35 socket-head-
cap screws (item 1, Figure 7-40 on page 7-39) that hold the pump
saddle clamp (item 2) to the ink core module (item 7).
8 Remove the pump saddle clamp.
9 Disconnect the ground wire from the ink core pump earth tag (item 3).
See Figure 7-39 on page 7-38 for reference.

Ground Wire
Figure 7-39: Ground Wire
Note: Use tissues to absorb the spills from the pump.

10 Gently lift the ink core pump out of the ink core module.
11 Remember the location of the two O-rings (item 5) that seal the pump
inlet and outlet ports and discard the O-rings.

3
4
1. M4 x 35 Socket-head-cap Screws 5. O-rings

2. Pump Saddle Clamp 6. Ports on the Ink Core Module
3. Earth Tag 7. Ink Core Module
4. Ink Core Pump
12 Dispose the ink core pump as per local regulations.

The removal of the old ink core pump is complete.
How to Install the New Ink Core Pump

Do the following tasks to install the new ink core pump:
1 Insert the new O-rings (item 5, Figure 7-40) on the ports of the pump
before you install the new pump.
2 Install the new ink pump onto the mounting block.

Make sure that the two pins go into the two holes of the ink core
pump correctly (see Figure 7-41).
Pin
Figure 7-41: Pins
3 Connect the ground wire to the pump earth tag (see Figure 7-39 on
page 7-38).
4 Fit the pump saddle clamp over the new ink core pump using M4 x 35
socket-head-cap screws (item 1, Figure 7-40 on page 7-39).
5 Connect the pump wire harness to the JP1 connector on the ink core
6 Put the ink core pump cover over the ink core module in correct
position.
7 Feed the core ribbon cable and the ground wire towards the back of
the cabinet and slide the cover until it is in the correct position.
8 Fasten the ink core pump cover to the ink core module using the
K30x12 Torx screws.
9 Push the core module back into the printer cabinet.
10 Close the ink compartment door. Refer to “How to Close the Ink
Compartment Door” on page 7-7.
The installation of the new ink core pump is complete.

Print Engine Assembly
Tool or Supplies Quantity
Table 7-8: Tools and Supplies
How to Remove the Old Print Engine Assembly
3
4
11
10
5
9
6
1. M2 x 6 Socket-head-cap Long Screw (x6) 7. Print Engine Gasket

2. Nozzle Assembly 8. M2 Spring Washer
3. Charge Electrode 9. Printhead Valve Module
4. Deflector Plate 10. Front Tubing Manifold Gasket
5. Print Engine Deck 11. Front Tubing Manifold
6. Gutter Tube
Figure 7-42: Print Engine
Rev AA Print Engine Assembly 7-41

Do the following tasks to remove the old print engine assembly:

1 Turn off the mains power switch of the printer.
43).

3. Print Engine
4 Remove the six M2 x 6 socket-head-cap screws (item 1, Figure 7-42 on

page 7-41) that are used to fasten the print engine to the chassis.
Caution
module.
5 Remove the M2 x 6 socket-head-cap screw that fastens the front

tubing manifold (item 11) to the printhead valve module (item 9).
6 Tilt the print engine to one side carefully to access the undercarriage.
7 Remove the M2 x 6 socket-head-cap screw and M2 spring washer
(item 8) that attach the EHT/HV wire (red wire) to the undercarriage
of the print engine.
8 Apply pressure vertical to the print engine deck as the gutter slides
into the chassis.
9 Discard the old print engine, print engine gasket, and the front tubing
manifold gasket according to local regulations.
7-42 Print Engine Assembly Rev AA

The removal of the old print engine assembly is complete.
How to Install the New Print Engine Assembly

Do the following tasks to install the new print engine assembly:
1 Take the new print engine assembly and fit the new print engine
gasket (item 7, Figure 7-42 on page 7-41) to the print engine.
2 Put the front tubing manifold gasket (item 10) into the manifold.
3 Attach the EHT/HV wire (red wire) to the undercarriage of the print
engine using one M2 x 6 socket-head-cap screw and one M2 spring
washer (item 8).
4 Carefully fit the print engine to the chassis and make sure to align the
gutter tube with its opening in the chassis.
Note: Make sure that the gutter is installed correctly or gutter can be pushed
out of place.
5 Visually inspect that the print engine gasket is seated properly before
securing the print engine to the chassis.
6 Fit the print engine to the chassis using the six M2 x 6 socket-head-cap
screws (item 1).
9 Log into user interface (UI) using Level 3 password.
10 Perform a system flush purge (refer to the “System Flush Purge” on
page 8-5 for procedure).
11 Fit the front tubing manifold (item 11, Figure 7-42 on page 7-41) to the
printhead valve module (item 9) using one M2 x 6 socket-head-cap
screw.
12 Run the printer for approximately 15 minutes to let the printer
stabilize.
13 Perform viscosity calibration (refer to Service Manual for procedure).
14 Turn on the inkjet and check the ink stream alignment. If required,
align the ink stream (refer to Service Manual for procedure).
15 Fit the printhead cover to the printhead chassis using the printhead
cover screw.
16 Perform EHT calibration (refer to Service Manual for procedure).
The installation of the new print engine assembly is complete.
Rev AA Print Engine Assembly 7-43

How to Remove the Old Printhead Valve Module

Do the following tasks to remove the old printhead valve module:
Note: Make sure that the printhead is above the level of the ink core module when
performing this procedure. Otherwise, the ink in the ink core module may flow
through the umbilical and leak through the tubing manifold once it is removed.

44).

3. Print Engine
7-44 Printhead Valve Module Rev AA

Caution
module.
4 Remove the M2 x 6 socket-head-cap screw (item 4, Figure 7-45) that

attaches the front tubing manifold (item 5) to the printhead valve
module (item 2).
2
8
3
7
4
6 5
1. M2 x 6 Socket-head-cap Screw (x6) 6. Front Tubing Manifold Gasket

2. Printhead Valve Module 7. Rear Tubing Manifold Gasket
3. Printhead Valve Module Gasket 8. 3 Way Manifold Assembly (Rear Tubing
4. M2 x 6 Socket-head-cap Screw Manifold)
5. 2 Way Manifold Assembly (Front 9. M2 x 6 Socket-head Cap Screw (x2)
Tubing Manifold)
Figure 7-45: Printhead Valve Module
5 Remove the two M2 x 6 socket-head-cap screws (item 9, Figure 7-45)

that attach the rear tubing manifold (item 8) to the printhead valve
module.
6 Remove the six M2 x 6 socket-head-cap screws (item 1) that attach the
printhead valve module to the chassis.
7 Lift the front and rear tubing manifolds away from the printhead
valve module.
Note: Prevent the bending of the tubing to avoid the damage to the tubing.
Rev AA Printhead Valve Module 7-45

8 Carefully lift and remove the printhead valve module from the
chassis.
9 When the printhead valve module is removed from the chassis,
carefully rotate the printhead valve module to one side to access the
undercarriage.
10 Detach the gutter tube from the gutter return pipe (item 2, Figure 7-
46) carefully.
Note: Replace the gutter tube if found damaged.

11 Discard the old printhead valve module gasket (item 3, Figure 7-45 on
page 7-45), front tubing manifold gasket (item 6) and rear tubing
manifold gasket (item 7) according to the local regulations.
The removal of the old printhead valve module is complete.
1. Printhead Valve Module

2. Gutter Return Pipe
Figure 7-46: Gutter Return Pipe
How to Install the New Printhead Valve Module

Do the following tasks to install the new printhead valve module:
1 Fit the new rectangular printhead valve module gasket onto the
chassis.
Note: Make sure that the tab on gasket is aligned to the notch on chassis.
2 Tilt the new printhead valve module to one side and insert the gutter
tube into the gutter return pipe.
3 Press the printhead valve module into the chassis.
Note: Make sure that the printhead valve module gasket is seated correctly.

4 Fit the printhead valve module using M2 x 6 socket-head-cap screws

in the order given below:
a. Fit the first screw, facing the module with the printhead pointing to
the right (see Figure 7-47).
Figure 7-47: Order of Placing Screws - First Screw
b. Fit the second screw (see Figure 7-48).

.
Figure 7-48: Order of Placing Screws - Second Screw
5 Fit the remaining four screws in any order.

6 Fit the rear tubing manifold to the printhead valve module using the
two M2 x 6 socket-head screws and the new rear tubing manifold
gasket.
7 Put the 2 way manifold gasket provided in the bypass kit on the ports
Rev AA Printhead Valve Module 7-47

4
2. Nozzle Bypass Manifold 5. 2 way Manifold Gasket
3. Tube

11 Log into the User Interface (UI).
12 Perform umbilical purge (refer to the “Umbilical Purge” on page 8-3).
13 Perform system flush purge (refer to the“System Flush Purge” on
page 8-5).
15 Put the new front tubing manifold gasket on the ports.
16 Fit the front tubing manifold to the printhead valve module using a
M2 x 6 socket-head screw.
cover screw.
The installation of the new printhead valve module is complete.

Umbilical Assembly
Introduction
The umbilical assembly with printhead (see Figure 7-50) contains new
print engine and new printhead valve module attached to a new
printhead chassis. Refer to “Umbilical Assembly (with Printhead)
Replacement” on page 7-51.
Figure 7-50: Umbilical with Printhead
The umbilical assembly with printhead chassis (see Figure 7-51 on page 7-
50) comes without the print engine and printhead valve module attached.
So, remove the old print engine and printhead valve module from the old
printhead chassis and attach the modules to the new printhead chassis.
Refer to “Umbilical Assembly (with Printhead Chassis) Replacement” on
page 7-68.
Rev AA Umbilical Assembly 7-49

Figure 7-51: Umbilical with Printhead Chassis
7 mm Nut Driver 1
T10 TORX Screwdriver 1
#2 Phillips Screwdriver 1
Side Cutters 1
1.5 mm Allen Wrench (for print engine and 1

printhead valve module replacement)
3 mm Allen Wrench 1
Crimp Pliers 1
Sharp Knife 1
Bypass Kit (Part Number 399247) 1
7-50 Umbilical Assembly Rev AA

Umbilical Assembly (with Printhead) Replacement
How to Remove the Umbilical Assembly (with Printhead)

Do the following tasks to remove the umbilical assembly along with
printhead:
3 Turn the knob and open the ink compartment door (see Figure 7-52
and Figure 7-53 on page 7-52).
4 Push the plate (item 2, Figure 7-53 on page 7-52) in the direction
shown to open the ink compartment door (item 1) completely.
Rev AA Umbilical Assembly (with Printhead) Replacement 7-51

5 Pull the ink core module out of the ink compartment.

2. Plate
Figure 7-53: Open Ink Compartment Door
6 Loosen and remove the two M3 screws that fasten the ink core
manifold to the ink core module using the 2.5 mm allen wrench (see

2. Ground Wire
7-52 Umbilical Assembly (with Printhead) Replacement Rev AA

1. M3 Screws (x2)
2. Ink Core Manifold
3. Gasket
7 Remove the p-clip in the back of the cabinet that holds all the tubes.
8 Remove the spiral wrap that holds the tubes that connect to the ink
core manifold (see Figure 7-54 on page 7-52).
9 Cut the tubes shown in Figure 7-56 on page 7-54 with a sharp knife 16
mm away from the face of the ink core manifold.
Caution
Do not remove the ground wire (item 5, Figure 7-54 on page 7-52)
that is connected to ink core.
Note: Keep the tubes to use again during the installation.
Note: Use tissues to absorb the spills.

1. Clear Tube (5/32”) 4. Blue Stripe Tube (1/8”)

2. Green Stripe Ink Tube (1/8”) 5. Black Stripe Make-up Tube (1/8”)
3. Air Vent
Figure 7-56: Cut Tubes
10 Cut the 5/32 inch tube from the gutter pump manifold with a sharp
knife, 16 mm away from the face of the gutter pump manifold.
11 Pull the tubes out of the p-clips and make sure that the blue and
brown sleeved tubes kept.
12 Cut the tube left on the gutter pump manifold barb vertically down
with a knife and remove the tube.
Warning
the printer.
13 Use the 3 mm allen wrench to remove the two M4 screws (see Figure
7-57 on page 7-55) that fasten the electronics compartment door to the
printer cabinet.

Figure 7-57: Electronics Compartment Door
14 Open the electronics compartment door (see Figure 7-58).
Figure 7-58: Electronics Compartment Opened
15 Push the latch down to open the control system board (CSB). See
Figure 7-59 on page 7-56.

1. CSB
3. Latch
Figure 7-59: Latch
16 If the positive air kit is fitted, then do the following steps, else go to
Step 17 on page 7-56.
a. Disconnect the silicon tubes that are connected to the inlet and
outlet of the positive air pump.
b. Disconnect the yellow striped tube (routed through the tube
interface) from the positive air filter.
c. Pull the yellow striped tube out of the p-clips.
17 Remove the four K30 x 10 pan-head torx screw (item 2, Figure 7-60 on
page 7-57) that attach the tube interface (item 1) on the dividing floor
(item 3) inside the electronics compartment.

1. Tube Interface
2. K30 x 10 Pan-head Torx Screw (x4)
3. Dividing Floor
Figure 7-60: Remove Tube Interface
18 Release the p-clips that hold the following cables:

• 21 core (connects to the PHEAD1 and PHEAD2 connectors) and
other cables
• Red EHT plug, the EHT cable and the fan cable
• PSU cable and other cables
Note: Remember the connections to connect the cables again during the
installation.
19 Disconnect the connectors PHEAD1 and PHEAD2 connectors from
the printer interface board (PIB).
Note: The RF clamp holds the 21 core cable.

20 Remove and keep the two nuts that attach RF clamp to the cabinet (see
21 Disconnect the red EHT plug from the EHT.

RF Clamp
Figure 7-61: RF Clamp
22 Cut the ty-raps that hold the charge tunnel cable along with the PSU
cable.
23 Disconnect the 4-way charge tunnel wire connector from the control
system board (CSB).
24 Disconnect the printhead ground wires that are connected inside the
25 Remove the four M4 x 8 counter-sunk screws (item 1, Figure 7-62 on
page 7-59) that attach the conduit assembly (item 2) to the printer
cabinet.

1. M4 x 8 Counter-sunk Screw (x4)

2. Conduit Assembly
3. Elbow Gasket
Figure 7-62: Remove Conduit
26 Pull the wires and tubes along with the ink core manifold and tube
interface out of the opening on the side of the cabinet.
27 Discard the old umbilical assembly along with the printhead
according to local regulations.
The removal of the umbilical assembly with the complete printhead is
complete.

How to Install the Umbilical Assembly (with Printhead)

Do the following tasks to install the umbilical assembly along with the
printhead:
1 Route the tubes and cables of the new umbilical through the opening
on the side of the cabinet along with the ink core manifold and the
tube interface into the electronics compartment.
2 Route the ink core manifold and the yellow striped tube through the
hole in the dividing floor.
3 Put the elbow gasket in the correct position on the opening on the side
of the cabinet.
4 Tighten the four M4 x 8 counter-sunk screws to fasten the conduit
assembly to the printer cabinet (see Figure 7-62 on page 7-59).
5 Connect the printhead ground wires inside the electronics
compartment.
6 Reconnect the PHEAD1 and PHEAD2 connectors to the printer
interface board (PIB).
7 Group the following cables into the p-clips:
• 21 core (connects to the PHEAD1 and PHEAD2 connectors) and
other cables
• Red EHT plug, the EHT cable and the fan cable
• PSU cable and other cables
8 Refit all the p-clips to the cabinet.
9 Wrap the three ty-raps around the charge tunnel cable along with the
PSU cable.
10 Connect the red EHT plug to EHT.
11 Reconnect the 4-way charge tunnel wire connector to the CSB.
12 Fit RF cable clamp over the 21 core cable in area where braid is
exposed.
Caution
Make sure that the RF clamp is seated over the exposed braid so that
the braid is grounded to the cabinet.
13 Fit the RF clamp using the two nuts (see Figure 7-61 on page 7-58).

14 Tighten the four K30 x 10 pan-head torx screws to fasten the tube
interface on the dividing floor inside the electronics compartment (see
15 If the positive air pump is fitted then, do the following tasks:
a. Connect the silicon tube to the yellow striped tube that is routed
from the umbilical. Crimp the silicon tube and the yellow striped
tube with the O-clip.
b. Connect the silicon tube to the outlet of the positive air pump.
Figure 7-63: Route Yellow Striped Tube
c. Remove the sealing cap from the end of the yellow striped tube.
d. Route the yellow striped tube through the hole in the tube interface
(see Figure 7-63) and through the p-clips inside the ink
compartment.
e. Connect the yellow striped tube to the outlet of the positive air
filter.
f. Remove the sealing cap from the other end of the yellow striped
tube in the electronics compartment.
g. Fit the silicon tube to the yellow striped tube.
h. Connect the silicon tube to the inlet of the positive air pump.
16 Close the CSB.
17 Fasten the electronics compartment door to the printer cabinet using
the four M4 screws.

18 Route the 5/32 inch tube through the p-clip and connect the tube to
the barb on the gutter pump manifold.
19 Group the following tubes using the spiral wrap:
• Black stripe tube
• Green stripe tube
• Blue stripe tube
• 5/32 inch clear tube
• 1/8 inch clear tube and red stripe tube from the new printhead
20 Connect all the tubes to the correct ports on the ink core manifold (see
Figure 7-64).
1. Clear Tube (5/32 inch) 5. Blue Stripe Tube (1/8 inch)

2. Red Stripe Tube (1/8 inch) 6. Black Stripe Make-up Tube (1/8 inch)
3. Green Strip Ink Tube (1/8 inch) 7. Clear Tube (1/8 inch)
4. Air Vent
Figure 7-64: Tubes to Ink Core Manifold
21 Use the two M3 screws to fasten the ink core manifold to ink core
module (see Figure 7-55 on page 7-53).
22 Take all the tubes but the vent tube and the ground wire to the ink
core and wrap the spiral wrap.
23 Fit the p-clip at the rear of the cabinet to hold the tubes.

65).

3. Print Engine
Caution
module.

tubing manifold (item 11, Figure 7-66 on page 7-64) to the printhead
valve module (item 9).

3
4
11
10
5
9
6
1. M2 x 6 Socket-head-cap Screw (x6) 6. Gutter Tube

2. Nozzle Assembly 7. Print Engine Gasket
3. Charge Electrode 8. M2 Spring Washer
4. Deflector Plate 9. Printhead Valve Module
5. Print Engine Deck 10. Front Tubing Manifold Gasket
11. Front Tubing Manifold
28 Remove the front tubing manifold gasket (item 10, Figure 7-66) and
keep it in a safe location to use again.
31 Reconnect the mains power cord from the electrical outlet.

4
2. Bypass Manifold 5. 2 Way Manifold Gasket
3. Tubing

34 Put a receptacle under the printhead to catch the make-up fluid
during flushing.
35 Perform an umbilical purge to prime the ink supply system (see
Figure 7-68 on page 7-66). Refer to the Service Manual for the
umbilical purge procedure.

Figure 7-68: Umbilical Purge
36 Perform a system flush purge (see Figure 7-69 on page 7-66). Refer to
the Service Manual for the detailed system flush purge procedure.
Make-up fluid will flow from the two way manifold into the
receptacle. Flushing will automatically stop when the purge cycle is
complete.
Figure 7-69: System Flush Purge

40 Perform EHT calibration (see Figure 7-70). Refer to the Service Manual
for the detailed procedure.
Figure 7-70: Calibrate EHT
41 Run the printer for approximately 15 minutes to let the printer

stabilize.
42 Perform viscosity calibration (refer to Figure 7-71). Refer to the Service
Manual for the detailed procedure.
Figure 7-71: Viscosity Calibration
43 Turn on the inkjet and check the ink stream alignment. Refer to the
Service Manual for the detailed procedure of ink stream alignment.
cover screw.
The installation of umbilical assembly with complete printhead is
complete.

Umbilical Assembly (with Printhead Chassis)

Replacement
How to Remove the Umbilical Assembly (with Printhead Chassis)

Do the following tasks to remove the umbilical assembly (with printhead
chassis):
How to Remove the Print Engine from Old Printhead

Do the following tasks to remove the print engine:
the printhead chassis and remove the printhead cover (see Figure 7-65
on page 7-63).
4 Remove the six M2 x 6 socket-head-cap screws (item 1, Figure 7-66 on
page 7-64) that are used to fasten the print engine to the chassis.
Caution
module.

tubing manifold (item 11) to the printhead valve module (item 9).
6 Apply pressure vertical to the print engine deck as the gutter slides
into the chassis.
7 Tilt the print engine to one side carefully to access the undercarriage.
8 Remove the M2 x 6 socket-head-cap screw and M2 spring washer
(item 8) that attach the EHT/HV wire (red wire) to the undercarriage
of the print engine.
9 Discard the print engine gasket, and the front tubing manifold gasket
according to the local regulations.
The print engine removal is complete.
7-68 Umbilical Assembly (with Printhead Chassis) Replacement Rev AA

How to Remove the Printhead Valve Module from Old Printhead

Do the following tasks to remove the printhead valve module:
Note: Make sure that the printhead is above the level of the ink core module when
you do this procedure. Else, the ink in the ink core module can flow through the
umbilical and leak through the tubing manifold after it is removed.
2
8
3
7
4
6 5
1. M2 x 6 Socket-head-cap Screw (x6) 6. Front Tubing Manifold Gasket
2. Printhead Valve Module 7. Rear Tubing Manifold Gasket
3. Printhead Valve Module Gasket 8. 3 Way Manifold Assembly (Rear Tubing
4. M2 x 6 Socket-head-cap Screw Manifold)
5. 2 Way Manifold Assembly (Front 9. M2 x 6 Socket-head Cap Screws (x2)
Tubing Manifold)
10 Remove the two M2 x 6 socket-head-cap screws (item 9, Figure 7-72)

that attach the rear tubing manifold (item 8) to the printhead valve
module.
11 Keep the rear tubing manifold in the old printhead chassis.
12 Remove the six M2 x 6 socket-head-cap screws (item 1) that attach the
printhead valve module to the chassis.
13 Lift the front and rear tubing manifold away from the printhead valve
module.
Note: Prevent the bending of the tubing, because the tubing can get
damaged.
14 Carefully lift the printhead valve module from the chassis.
Rev AA Umbilical Assembly (with Printhead Chassis) Replacement 7-69

15 When the printhead valve module is removed from the chassis,

carefully rotate the printhead valve module to one side to access the
undercarriage.
16 Detach the gutter tube from the gutter return pipe (item 2, Figure 7-
73) carefully.
17 Discard the old printhead valve module gasket (item 3, Figure 7-72 on
page 7-69), and rear manifold tubing gasket (item 7) according to the
local regulations.
1. Printhead Valve Module

2. Gutter Return Pipe
Figure 7-73: Gutter Return Pipe
The printhead valve module removal is complete.

18 Follow Step 3 on page 7-51 till Step 26 on page 7-59 under “How to
Remove the Umbilical Assembly (with Printhead)” on page 7-51.
19 Discard the old umbilical assembly and the printhead chassis
The removal of the umbilical assembly with printhead chassis is complete.
How to Install the Umbilical Assembly (with Printhead Chassis)

Do the following tasks to install the umbilical assembly:
1 Follow Step 1 on page 7-60 till Step 25 on page 7-62 under “How to
Install the Umbilical Assembly (with Printhead)” on page 7-60.

How to Install the Printhead Valve Module

Do the following tasks to install the printhead valve module:
2 Fit the new rectangular printhead valve module gasket onto the
chassis.
Note: Make sure that the tab on gasket is aligned to the notch on chassis.
3 Tilt the printhead valve module to one side and insert the gutter tube
into the gutter return pipe.
Note: Replace the gutter return tube if the tube is damaged.

4 Press the printhead valve module into the chassis.
Note: Make sure that the printhead valve module gasket is seated correctly.
5 Attach the printhead valve module using M2 x 6 socket-head-cap
screws in the order given below:
a. Fit the first screw, facing the module with the printhead pointing to
the right (see Figure 7-74).
Figure 7-74: Order of Placing Screws- First Screw
b. Fit the second screw (see Figure 7-75)

.
Figure 7-75: Order of Placing Screws- Second Screw
6 Fit the remaining four screws in any order.

7 Remove the cap attached to the rear manifold on the new chassis. The
gasket comes out.
8 Put the rear manifold gasket on the ports of the old printhead valve.
Rev AA Umbilical Assembly (with Printhead Chassis) Replacement 7-71

9 Fit the old rear tubing manifold to the printhead valve module using
the two M2 x 6 socket-head screws.
The printhead valve module installation is complete.
How to Install the Old Print Engine

Do the following tasks to install the old print engine:
10 Take the old print engine assembly and fit the new print engine gasket
(item 7, Figure 7-66 on page 7-64) to the print engine.
11 Attach the EHT wire (red wire) to the undercarriage of the print
engine using one M2 x 6 socket-head-cap screw and one M2 spring
washer (item 7).
12 Fit the new print engine gasket.
13 Carefully fit the print engine to the chassis and make sure to align the
gutter tube with its opening in the chassis.
Note: Make sure that the gutter is installed correctly or gutter can be pushed
out of place.
14 Visually inspect that the print engine gasket is seated properly before
securing the print engine to the chassis.
15 Fit the print engine to the chassis using the six M2 x 6 socket-head-cap
screws (item 1).
The print engine installation is complete.
16 Follow the steps from Step 29 on page 7-64 to Step 38 on page 7-66.
18 Follow the steps from Step 40 on page 7-67 to Step 44 on page 7-67.
The installation of the umbilical assembly with printhead chassis is
complete.

Printer Interface Board
3 mm Allen Wrench 1
Warning
below tasks.
How to Remove the Old Printer Interface Board

Do the following tasks to remove the old printer interface board (PIB):
1 Open the electronics compartment door (refer to “How to Open the
Electronics Compartment Door” on page 7-3).
Note: Before removal, remember the connectors connected to the PIB.

2 Disconnect all the connectors from the PIB (see Figure 7-76 on page 7-
74).
3 Open the ink compartment door (refer to “How to Open the Ink
Compartment Door” on page 7-5) and pull the ink core module out to
access the PIB connectors.
4 Disconnect all the connectors from the PIB (see Figure 7-77 on page 7-
74).
Rev AA Printer Interface Board 7-73

7 8 9 10 1 2 3 4 5
6
1. 10-way Printhead Connector 6. CSB Ribbon Cable Connectors (x3)
2. 12-way Printhead Connector 7. USB Connector
3. EHT Cable Connector 8. PCB1 Connector
4. Positive Air Pump Connector 9. PCB 2 Connector
5. Electronics Compartment Fan Connector 10. PCB 3 Connector
Figure 7-76: PIB Connectors - Electronics Compartment Side
2 1
1. Ribbon Cable Connector from Ink Door 4. 20-way Ink Core Module Ribbon Cable
2. Ink Compartment Fan Connector Connector
3. 16-way Ink Core Module Ribbon Cable
Connector
Figure 7-77: PIB Connectors - Ink Compartment Side
5 Remove the six M4 screws (item 1, Figure 7-78 on page 7-75) and M4
ET washers (item 2) to detach the PIB (item 3) from inside the cabinet.
6 Remove the gasket (item 4).
7 Discard the PIB, M4 screws, washers and gasket according to the local
regulations.
7-74 Printer Interface Board Rev AA

1. M4 Screws (x6) 3. Printer Interface Board

2. ET Washers (x6) 4. Gasket
Figure 7-78: PIB Inside the Cabinet
The removal of the old PIB is complete.
How to Install the New Printer Interface Board

Do the following tasks to install the new PIB:
1 Put the gasket on the dividing floor over the six upstanding threaded
bushes in the electronics compartment.
2 Put the new PIB on the gasket.
3 Fit the new PIB to the cabinet with M4 screws and M4 ET washers.
4 Reconnect all the cables and connectors above and below the new PIB.
5 Close the CSB.
The installation of the new PIB is complete.
Rev AA Printer Interface Board 7-75

Power Switch
Screwdriver 1
Nr.1 Posidrive 1
3 mm Allen Wrench 1
7 mm Nut Spinner 1
Adjustable Pipe Pliers (to hold and 1

tighten the ring nut on switch)
Warning
below tasks.
How to Remove the Old Power Switch

Do the following tasks to remove the old power switch:
2 Do the following tasks to detach the power supply unit (PSU) (item 1,
Figure 7-79 on page 7-77) assembly from the electronics compartment:
a. Disconnect the following cables from the PSU:
• Cable to the 8-way connector on the CSB
• Cable to the 3-way mains connector on the power switch.
b. Release the PSU cable from the p-clips.
c. Remove the two M4 nyloc nuts (item 3) from the studs (item 2)
inside the electronics compartment.
d. Keep the PSU in a safe location.
7-76 Power Switch Rev AA

1. PSU
2. Studs
3. M4 Nyloc Nut
3 Pull the contact block (item 3, Figure 7-80 on page 7-78) covered by the
sleeve (item 4) upwards to disconnect the claws. Or, use a screwdriver
to release the claws.
4 Push the sleeve backwards away from the contact block.
Caution
Do not unbend the terminals, the terminals can break.
Note: Remember the positions of the terminals.

5 Loosen the four screws (item 1) and remove the terminals (item 2)
using Nr.1 posidrive.
6 Disconnect the terminals from the contact block.
Rev AA Power Switch 7-77

4
3
1. Screws 3. Contact Block

2. Terminals 4. Sleeve
Figure 7-80: Remove Terminals
7 Use a large pair of mole grips or adjustable pipe pliers to grip the
contact block holder (item 3, Figure 7-81) and twist backwards.
The contact block holder comes out or breaks. The lock ring (item 2) is
released.
Note: Apply considerable force to separate the two portions of the power
switch.
8 Extract the actuator body (item 1) of the switch out of the handle.
2 1
1. Actuator Body
2. Lock Ring
3. Contact Block Holder
Figure 7-81: Power Switch Disassembled

9 Discard all the parts of the power switch according to the local
regulations.
The removal of old power switch is complete.
How to Install the New Power Switch

Do the following tasks to install a new power switch:
1 Remove the lock ring from the actuator of the new power switch.
2 Do not remove the rubber gasket.
3 Insert the actuator body into the printer handle.
The key on actuator body must align with the key in the handle.
4 Fit the lock ring from inside the electronics compartment.
5 Align and fix the contact block holder to the switch actuator.
Note: The black legs on the actuator align with the rectangular hole in the
contact block holder and this can be fitted in two different orientations.
6 Connect the terminals to the rear of the new contact block.
7 Cover the terminals with the sleeve.
8 Do the following tasks to fit the PSU:
a. Connect the contact block to the contact block holder of the power
switch.
b. Put the PSU assembly into the lug (see Figure 7-82 on page 7-80) in
the rear of the electronics compartment and then on the two studs.
c. Use the two M4 nyloc nuts to fit the PSU assembly to the studs.
Rev AA Power Switch 7-79

Figure 7-82: Lug
d. Connect the 3-way connector from the switch to the PSU.
Figure 7-83: Power Switch Installed
9 Close the CSB.

The installation of the new power switch is complete.

Power Switch Wiring Information

The Figure 7-84 shows the power switch connections for both US and
Europe. Refer to Table 7-13 for more information.
Figure 7-84: Power Switch
Connection Europe USA
1A Mains Cable Live (brown) Mains Cable Live (black)
1B Wire to 3-way Connector Wire to 3-way Connector

(brown) (brown)
2B Mains Cable Neutral Mains Cable Neutral

(blue) (white)
2A Wire to 3-way Connector Wire to 3-way Connector

(blue) (blue)
Table 7-13:Power Switch Wiring Information
Septum Assembly
Side Cutters 1
3 mm Allen Wrench 1
7 mm Nut Spinner 1
2.5 diameter x 100 mm pin 1
Light Hammer 1
Sharp Knife 1
Rev AA Septum Assembly 7-81

Warning
below tasks.
How to Remove the Old Ink and Make-up Septa

Do the following tasks to remove the old ink and make-up septa:
1 Open the ink compartment door (refer to “How to Open the Ink
Compartment Door” on page 7-5).
2 Remove the smart cartridges, so that the ink and make-up septa are
seen (see Figure 7-85).
2 1
1. Ink Septum
2. Make-up Septum
Figure 7-85: Ink and Make-up Septa
3 Use the 2.5 mm pin and hammer to knock out the hinge pin (item 2,
Figure 7-86 on page 7-83) from the right hand side hole of the door.
The pin comes out of the hole on the left side of the door.
4 Pull the hinge completely, so that the door is released.
7-82 Septum Assembly Rev AA

Note: Take care not to bend the hinge pin. Keep the hinge pin to use again.
1. Lug
2. Hinge Pin
Figure 7-86: Hinge Pin
5 Cut the ink tube (item 1, Figure 7-88 on page 7-84) and the make-up
tube (item 6) 16 mm from the face of the ink and make-up septa (item
4) using a sharp knife.
6 Remove the two K30 x 12 screws (item 2) to release the clamp (item 5).
7 Is the length of the ink and make-up tubes enough to use again during
the installation of new septa?
• If Yes, proceed to Step 8.
• If No, disconnect the other end of the ink and make-up tubes from
the ink core manifold (see Figure 7-87). Discard the pipes according
to the local regulations.
1. Ink Tube (Black Stripe)

2. Make-up Tube (Green Stripe)
Rev AA Septum Assembly 7-83

8 Remove the three K30 x 8 screws (item 3) on each septum to remove

the two septa.
9 Discard the septa according to the local regulations.
6 1
2
3
1. Ink Tube (Green Stripe) 4. Ink/Make-up Septum (x2)

2. K30 x 12 Screw (x2) 5. Clamp
3. K30 x 8 Screw (x6) 6. Make-up Tube (Black Stripe)
Figure 7-88: Cartridge Stall Rear Side
The removal of the old ink and make-up septa is complete.
How to Install the New Ink and Make-up Septa

Do the following tasks to install the new ink and make-up septa:
1 Fit the ink and make-up septa to the smart cartridge stalls using the
six K30 x 8 screws (item 3, Figure 7-88).
2 If you have discarded the ink and make-up tubes during the removal
procedure, connect one end of the ink and make-up tubes to the ink
core manifold (see Figure 7-87 on page 7-83).
3 Put the clamp in the position shown in Figure 7-88.
4 Guide the ink tube, make-up tube, ribbon cable, gutter pump cable,
and the valve cable through the clamp, and fit the clamp to the ink
and make-up septa using the two K30 x 12 screws.
5 Connect the other end of the ink and make-up tubes to the ink and
make-up septa.
7-84 Septum Assembly Rev AA

6 Fit the smart cartridges.

7 To fit the ink compartment door into the hinge, do the following tasks:
a. Reinsert the hinge pin to the left side of the door with the lug on the
left side of the hinge pin.
b. The hinge pin is hammered with the 2.5 mm pin until resistance is
felt. The hinge pin is locked.
Note: Make sure that the pipes and cables move freely when the door is
opened and closed. Adjust the clamp if necessary.
The installation of the new ink and make-up septa is complete.
Electronics Compartment Fan
3 mm Allen Wrench 1
Nr.2 Posidrive 1
7 mm Spanner 1
7 mm Nut Spinner 1
Warning
below tasks.
How to Remove the Old Electronics Compartment Fan

Do the following tasks to remove the old electronics compartment fan:
Rev AA Electronics Compartment Fan 7-85

2 Before you continue to remove the fan, remember the location where
the fan cable is connected on the printer interface board (PIB).
3 Disconnect the fan connector (item 7, Figure 7-89) from the PIB.
4 Release the P-clips. The fan wiring drops down through the P-clips.
5 Use Nr.2 posidrive and 7 mm spanner to remove the two M4 x 16
counter-sunk screws (item 6, Figure 7-89) and two M4 nyloc nuts
(item 5) and remove the finger guard (item 4).
6 Use the 3 mm allen wrench to remove the four M4 x 10 cap-head
screws (item 3) and four M4 ET washers (item 2) that hold the fan
(item 1) to the printer cabinet.
7 Discard the fan according to the local regulations.
The removal of the old electronics compartment fan is complete.
.
7
1
2
3
1. Fan 4. Finger Guard

2. M4 ET Washer (x4) 5. M4 Nyloc Nut (x2)
3. M4 x 10 Cap-head Screw (x4) 6. M4 x 16 Counter-sunk Screw (x2)
Figure 7-89: Remove Fan
How to Install the New Electronics Compartment Fan

Do the following tasks to install the new electronics compartment fan:
1 Fit the new fan to the printer cabinet using the four M4 x 10 cap-head
screws and four M4 ET washers.
7-86 Electronics Compartment Fan Rev AA

2 Fit the finger guard using the two M4 x 16 counter-sunk screws and
two M4 nyloc nuts.
3 Guide the fan connector through the P-clips and connect to the PIB.
The installation of the new electronics compartment fan is complete.
Ethernet Connector
3 mm Allen Wrench 1
Adjustable spanner or pipe pliers to give 1

minimum 33A/F
Warning
below tasks.
How to Remove the Old Ethernet Connector

Do the following tasks to remove the old ethernet connector:
2 Disconnect the Ethernet cable (a special 90 degrees cable) between the
Ethernet connector (item 8, Figure 7-90 on page 7-88) and the CSB
Ethernet connection.
Rev AA Ethernet Connector 7-87

1 2
8
7
6 5
1. Stud 5. Ground Cable
2. Ring Terminal 6. Lock Nut
3. M4 ET washer 7. Rubber Washer
4. M4 Nyloc Nut 8. Ethernet Connector
Figure 7-90: Ethernet Connector
3 Remove the M4 nyloc nut (item 4) and M4 ET washer (item 3) on the

M4 ring terminal (item 2) attached to the stud (item 1) on the printer
cabinet.
4 Disconnect the ground cable (item 5).
5 Loosen and remove the lock nut (item 6).
6 Detach the old ethernet connector from the printer cabinet.
7 Remove the rubber washer (item 7).
8 Discard the old connector, locknut and the rubber washer.
The removal of the old ethernet connector is complete.
How to Install the New Ethernet Connector

Do the following tasks to install the new Ethernet connector:
1 Make sure that the rubber washer is on the ethernet connector.
2 Align the key feature in the washer with the key feature on the
connector body.
3 Insert the ethernet connector into the hole in the printer cabinet.
Make sure that the key on the ethernet connector aligns with the key
in the cabinet hole.
4 Fit the ethernet connector with the lock nut inside the printer cabinet.
7-88 Ethernet Connector Rev AA

5 Connect one end of the ground cable to the ethernet connector.

6 Connect the M4 ring terminal end of the ground cable to the stud
using the M4 nyloc nut and M4 ET washer.
7 Connect the ethernet cable between the Ethernet connector and the
CSB ethernet connection. The 90 degree end must be fitted to the
connector on the side panel.
9 Fit the dust cap to the connector.
The strap on the dust cap has a small hole at the free end. Push it over
the pin at the side of the connector body.
The installation of the new ethernet connector is complete.
Positive Air Kit
3 mm Allen Wrench 1
7 mm Nut Driver 1
Crimp Pliers 1
Warning
below tasks.
Rev AA Positive Air Kit 7-89

How to Remove the Old Positive Air Kit
Note: This kit includes the positive air pump and positive air filter.
Do the following tasks to remove the old positive air kit:

Ink Compartment Door” on page 7-5.
2 Disconnect the printhead tube (yellow stripe tube, silicon tube and the
O-clip) (item 2, Figure 7-91).
3 Disconnect the filter tube (yellow stripe tube and the silicon tube)
(item 3) that is connected to the inlet of the positive air pump (item 1).
Note: The other end of the filter tube is connected to the outlet of the positive
air filter that is fitted inside the ink compartment.
3 2 1
1. Positive Air Pump
2. Printhead Tube
3. Filter Tube
Figure 7-91: Positive Air Pump
4 Remove the M4 nyloc nut (item 3, Figure 7-92 on page 7-91) that
attaches the P-clip (item 2) to the rear of the printer cabinet. Keep the
P-clip to use again.
5 Release the 5-way connector cable from the P-clip.
6 Use a nut driver to remove the other M4 nyloc nut (item 4) from the
pump mount.
7-90 Positive Air Kit Rev AA

4 3 2 1
1. Air Pump Bracket 3. M4 Nyloc Nut
2. P-clip 4. M4 Nyloc Nut
Figure 7-92: Remove Positive Air Pump
7 Disconnect the 5-way connector cable (item 1, Figure 7-93) from the
printer interface board (PIB).
1. 5-way Connector Cable

2. Positive Air Pump Cables
Figure 7-93: Positive Air Pump Cable
8 Discard the positive air pump according to the local regulations.
Rev AA Positive Air Kit 7-91

9 Open the ink compartment door. Refer to “How to Open the Ink
10 Disconnect the filter tube (item 1, Figure 7-94) from the outlet of the
positive air filter (item 2).
11 Pull the filter tube from the interface board and discard the tube
12 Pull the positive air filter from the terry clip (item 3) and discard the
filter according to the local regulations.
1. Filter Tube (yellow striped)

2. Positive Air Filter
3. Terry Clip
Figure 7-94: Positive Air Filter
The removal of the old positive air kit is complete.
How to Install the New Positive Air Kit

Do the following tasks to install the new positive air kit:
1 Put the new positive air pump assembly on the studs inside the
2 Put the P-clip on the top stud.
3 Fit the P-clip with M4 nyloc nut using 7 mm nut driver.
4 Route the 5-way connector cable through the P-clip.
5 Tighten the other M4 nyloc nut using the 7 mm nut driver.
7-92 Positive Air Kit Rev AA

6 Connect the 5-way connector cable to the connection labeled A_PUMP

on the PIB.
7 Fit the silicon tube to the outlet of the positive air pump.
8 Slide the O-clip over the silicon tube.
9 Push the yellow stripe printhead tube into the silicon tube
approximately 25 mm (0.98 inches).
10 Crimp the O-clip in position to retain the silicon tube and the
printhead tube.
11 Fit the silicon tube to the inlet of the positive air pump.
12 Push the yellow stripe filter tube into the silicon tube approximately
25 mm (0.98 inches).
13 Push the other end of the filter tube into the ink compartment through
the interface board.
15 Push the new positive air filter into the terry clip.
Note: The direction of the flow on the positive air filter must point upwards.
16 Connect the filter tube to the outlet of the positive air filter.
The installation of the new positive air kit is complete.
Gutter Pump
Tools and Supplies
7 mm Nut Spinner 1
T10 Torx Driver 1
Light Hammer 1
Rev AA Gutter Pump 7-93

Sharp Knife 1
Side Cutter 1
2.5 D x 100 mm Long Pin (to 1

knock the hinge pin out)
How to Remove the Old Gutter Pump

Do the following tasks to remove the old gutter pump:
Figure 7-95) from the right hand side hole of the door.
The pin comes out of the hole on the left side of the door.
1. Lug
2. Hinge Pin
4 Pull the ink core module from inside the ink compartment.
5 Disconnect the ground wire that is connected to the ink compartment
door from the stud inside the ink compartment.
6 Disconnect the 4-way gutter pump connector (item 5, Figure 7-96 on
page 7-95) and 2-way valve connector (item 1) from the PCBs on the
cartridge holder. Both components connect to connectors labeled J2.
7-94 Gutter Pump Rev AA

The gutter pump connector has four colored wires. The valve
connector has two black wires.
5 1
2
4
3
1. 2-way valve Connector 4. Cartridge Holder
2. K30 x 12 Pan-head Torx Screw (2) 5. 4-way Gutter Pump Connector
3. Cable Clamp
Figure 7-96: Cartridge Holders
7 Use the T10 torx driver to remove the K30 x 12 pan-head screws (item
2, Figure 7-96) and release the cable clamp (item 3) that holds the
gutter pump cables, valve cables, green stripe ink tube, black stripe
make-up tube, and the ribbon cables.
8 Use the 7 mm nut spinner to remove the two nuts that attach the P-
clips (item 6, Figure 7-97 on page 7-96) to the floor of the ink
compartment.
9 Detach the black cable from the cable bundle (this cable contains the
wires for the gutter pump and the valve).
10 Push the blue and brown sleeves up the pipes on the gutter pump
manifold to access the tubes.
Note: Use tissues to retain spill from the tubes.

11 Cut the following tubes approximately 16 mm (0.63 inch) away from
the face of the gutter pump manifold with a sharp knife.
a. Clear tube connected to the front right port
b. Clear tube connected to the front left port
c. Blue striped tube connected to the rear port

12 Using the 7 mm nut spinner, remove the two M4 nyloc nuts (item 3,
Figure 7-97) that attach the gutter pump bracket (item 4) to the rear
wall of the ink compartment.
2
3
5
7 6
1. Blue Stripe Pipe with Blue Sleeve 5. Clear Pipe
2. Clear Pipe with Brown Sleeve 6. P-clip
3. M4 Nyloc Nuts (x2) 7. Commissioning Valve
4. Gutter Pump Bracket
Figure 7-97: Gutter Pump Assembly
13 Remove the gutter pump assembly from the ink compartment.

The removal of the old gutter pump is complete.
7-96 Gutter Pump Rev AA

How to Install the New Gutter Pump

Do the following tasks to install the new gutter pump:
1 Put the new gutter pump in the ink compartment. Fit the three tubes
to the pump manifold according to the following instructions:
• Clear tube (item 2, Figure 7-98) to the front right port
• Clear tube (item 3) with brown sleeve to the front left port
• Blue striped tube (item 1) with blue sleeve to the rear port
3 1
1. Blue Stripe Tube with Blue Sleeve

2. Clear Tube
3. Clear Tube with Brown Sleeve
Figure 7-98: Gutter Pump Tubes
2 Using the 7 mm nut spinner, fit the two M4 nyloc nuts that attach the
gutter pump assembly to the rear wall of the ink compartment (see
3 Add the two black cables to the cable bundle and route the bundle
through the P-clips.
4 Using the 7 mm nut spinner, secure the P-clips to the floor of the ink
compartment.
5 Route the cable bundle, green stripe ink tube, black stripe make-up
tube, and the ribbon cable through the cable clamp (see Figure 7-96 on
page 7-95).
6 Connect the 2-way valve connector and 4-way gutter pump connector
to the PCBs.
• The connector with the two black wires (2-way) plugs into J2 on the
PCB on make-up cartridge holder.
• The connector with the four colored wires (4-way) plugs into J2 on
the PCB on the ink cartridge holder.

7 To fit the ink compartment door into the hinge, do the following tasks:
a. Reinsert the hinge pin to the left side of the door with the lug on the
left side of the hinge pin.
b. The hinge pin is hammered with the 2.5 mm pin until resistance is
felt. The hinge pin is locked.
8 Connect the ground wire to the stud inside the ink compartment. Use
the 7 mm nut spinner.
Note: When the door is fitted, check that the cables and tubes can move freely
when the door is closed and opened. The cables and tubes must not be
strained.
The installation of the new gutter pump is complete.
Ink Door Assembly
2.5 D x 100 mm Long Pin (to 1

knock the hinge pin out)
Light Hammer 1
7 mm Nut Spinner 1
10 mm Spanner 1
T10 Torx Driver 1
Sharp Knife (to cut tubes) 1
7-98 Ink Door Assembly Rev AA

How to Remove the Old Ink Door

Do the following tasks to remove the old ink door:
Figure 7-99) from the right hand side hole of the ink door assembly.
1. Lug
2. Hinge Pin
3 The pin comes out of the hole on the left side of the door.
5 Use the 7 mm nut spinner to disconnect the ground wire that is
connected to the ink compartment door from the stud inside the ink
compartment.
6 Disconnect the 4-way gutter pump connector (item 7, Figure 7-100 on
page 7-100) and 2-way valve connector (item 1) from the PCBs on the
cartridge holder (item 5). Both components connect to connectors
labeled J2.
Rev AA Ink Door Assembly 7-99

7 1
2
6
3
5
4
1. 2-way valve Connector 5. Cartridge Holder
2. Ink Tube (Green Stripe) 6. Make-up Tube (Black Stripe)
3. K30 x 12 Pan-head Torx Screw (2) 7. 4-way Gutter Pump Connector
4. Cable Clamp
Figure 7-100: Cartridge Holder
7 Use the T10 torx driver to remove the K30 x 12 pan-head screws (item
3, Figure 7-100) and release the cable clamp (item 4) that holds the
gutter pump and valve cables, the 14 way ribbon cable, the black (item
6) and green stripe pipes (item 2).
8 If you want to keep the old 14-way ribbon cable, disconnect the 14-
way headers from the PCBs on the ink door. Else, go to step 9.
9 If the ribbon cable must be replaced, do the following:
a. Release the P-clips that retain the 14-way ribbon cable in the ink
system.
b. Disconnect the 14-way ribbon cable from the underside of the
c. Remove and discard the 14-way ribbon cable.
10 If you must reuse the black and green stripe tubes then do the
following tasks. Else, go to step 11.
a. Pull out the ink core module from the ink compartment.
b. Disconnect the ink core manifold.

c. Cut the green striped tube and black stripe tube (item 1 and item 2,
Figure 7-101) with a sharp knife 16 mm from the face of manifold.
d. Cut the tubes left on the barb fittings vertically downwards and
remove tubes.
e. The black and green stripe tubes is pulled back through the spiral
wrap and the P-clips.
1. Ink Tube (Green Stripe)

2. Make-up Tube (Black Stripe)
11 If the pipes are not short on the existing door, then pull the tubes off
or cut with a sharp knife from the septum tubes.
12 Discard the old door according to local regulations.
The removal of the old ink door assembly is complete.
How to Install the New Ink Door

Do the following tasks to install the new ink door assembly:
1 Align the new ink door assembly carefully.
2 Reinsert the hinge pin to the left side of the ink door assembly with
the lug (item 1, Figure 7-99 on page 7-99) on the left side of the hinge
pin.
3 The hinge pin is hammered with the 2.5 mm pin until resistance is felt.
The hinge pin is locked.
4 If the old door tubes are used, insert the tubes into the septum
connections. If new pipes are used then, do the following tasks:
a. Route the new black and green stripe tubes through all the p-clips
and the spiral wrap.
Rev AA Ink Door Assembly 7-101

b. Connect the pipes to the ink core manifold.

c. Push the ink core module into the ink compartment.
5 If the old 14-way cable is used then, reconnect the 14-way headers to
the relevant PCBs. If you want to install a new 14-way cable, do the
following tasks:
a. Route the ribbon cable through all the P-clips
b. Connect the ribbon cable to the PIB.
6 Connect the 4-way gutter pump connector and 2-way valve connector
to the PCBs on the cartridge holder. Both the connectors connect to J2
connectors on the PCB. Refer to Figure 7-102.
7 Use the T10 torx driver to attach the cable clamp with the K30 x 12
pan-head screws that holds the gutter pump cables, valve cables,
green stripe ink tube, black stripe make-up tube and the 14-way
ribbon cable. Refer to Figure 7-102.
Figure 7-102: Septum Connections
8 Tighten all the p-clips.

9 Connect the ground wire that is connected to the ink compartment
door from the stud inside the ink compartment.
Note: After the door is fitted, check that the cables and tubes can move freely
when the door is closed and opened. The cables and tubes must not be
strained.

10 Adjust the two M6 nuts (item 5, Figure 7-103) and two M6 washers
(item 4) on the stud (item 2) to give the required compression to the
door gasket (item 1).
1
2
3
4
5
1. Door Gasket 4. M6 Washer (x2)
2. Stud 5. M6 Nut (x2)
3. Latch
Figure 7-103: Latch
The installation of the new ink door assembly is complete.
Ink System Fan
3 mm Allen Wrench 1
How to Remove the Ink System Fan

Do the following to remove the ink system fan:
Rev AA Ink System Fan 7-103

2 Pull the ink core module (item 3, Figure 7-104) out of the ink
compartment.
1. Cartridges
3. Ink Core Module
3 Detach the fan guard (item 4, Figure 7-105) from the fan housing (item
2).
4 3
1. M4 ET Washer (x4) 3. M4 x 10 Cap Head Screw (x4)
2. Fan Housing 4. Fan Guard
Figure 7-105: Ink Fan Assembly
4 Disconnect the fan cable from the printer interface board (PIB).
5 Remove the four M4 x 10 cap-head screws (item 3) and four M4 ET
washers (item 1) to detach the fan housing from the raised mounting
box located at the back of the ink compartment.
Keep the four M4 x 10 cap-head screws and the four M4 ET washers to
use again.
7-104 Ink System Fan Rev AA

6 Discard the ink system fan as per the local regulations.

The removal of the old ink system fan is complete.
How to Install the New Ink System Fan

Do the following tasks to install the new ink system fan:
1 Attach the new fan housing to the raised mounting box located at the
back of the ink compartment using the four M4 x 10 cap-head screws
and four M4 ET washers.
2 Connect the fan cable to the PIB.
3 Attach the fan guard to the fan housing.
The installation of the new ink system fan is complete.
EHT Module
3 mm Allen Wrench 1
7 mm Nut Driver 1
How to Remove the Old EHT Module

Do the following tasks to remove the old EHT Module:
2 Disconnect the EHT cable (item 3, Figure 7-106 on page 7-106) from
the PIB.
3 Disconnect the EHT plug (item 1) from the EHT module.
Rev AA EHT Module 7-105

1
2
3
1. EHT Plug
2. P-Clip
3. EHT Cable
Figure 7-106: EHT Plug and Cable
4 Release p-clips (item 2) that hold the EHT cable.

5 Use the 7 mm nut driver to remove the two M4 Nyloc nuts (item 2,
Figure 7-107) that attach the EHT Module (item 1) to the cabinet.
6 Dispose the old EHT Module according to the local regulations.
1. EHT Module
2. M4 Nyloc Nuts (x2)
Figure 7-107: Removal of EHT Module

The removal of old EHT Module is complete.
7-106 EHT Module Rev AA

How to Install the New EHT Module

Do the following tasks to install the new EHT Module:
1 Place the new EHT Module on the cabinet.
2 Use the 7 mm nut driver to tighten the two M4 nyloc nuts to attach the
EHT Module to the cabinet.
3 Connect the EHT cable from the new EHT Module to the PIB.
4 Reconnect the EHT plug.
5 Position the new EHT cable in the p-clips and refit.
6 Close the CSB assembly.
8 Perform EHT Calibration (see Figure 7-108).
Figure 7-108: Calibrate EHT
The installation of the new EHT Module is complete.
Rev AA EHT Module 7-107

USB Connector
3 mm Allen Wrench 1
Adjustable spanner or pipe pliers 1

to give minimum 33A/F
How to Remove the Old USB Connector

Do the following tasks to remove the old USB connector:
2 Disconnect the USB cable (item 2, Figure 7-109) from the USB 2 on the
3 1
1. Lock Nut 3. Rubber Washer

2. USB Cable 4. USB Connector
Figure 7-109: USB Connector
3 Loosen and remove the locknut (item 1, Figure 7-109).

4 Detach the old USB connector (item 4) from the printer cabinet.
7-108 USB Connector Rev AA

5 Remove the rubber washer (item 3).

6 Discard the old connector, locknut and the rubber washer.
The removal of the old USB connector is complete.
How to Install the New USB Connector

Do the following tasks to install the new USB connector:
1 Make sure rubber washer is on connector body. Align the key feature
in the washer with the key feature on the connector body.
2 Insert the USB connector into the hole in the printer cabinet.
Make sure that the key on the connector body aligns with the key in
the cabinet hole.
3 Fit the lock nut (with the USB cable) inside the printer cabinet.
4 Connect the other end of the USB cable to USB 2 on the PIB.
5 Close the CSB.
6 Fit the dust cap to the connector.
The strap on the dust cap has a small hole at the free end. Push it over
the pin at the side of the connector body.
The installation of the new USB connector is complete.
Plug and Power Cable
Nr.1 Posidrive 1
3 mm Allen Wrench 1
24mm Spanner 1
Rev AA Plug and Power Cable 7-109

How to Remove the Old Power Cable

Do the following tasks to remove the old power cable:
2 Do the following tasks to detach the power supply unit (PSU)
assembly from the electronics compartment:
a. Remove the two M4 nyloc nuts (item 3, Figure 7-110 on page 7-110)
from the studs (item 2) inside the electronics compartment.
b. Disconnect the following cables from the PSU:
• PSU cable from the 8-way connector on the CSB.
• 3-way mains connector from the power switch.
c. Disconnect the ty-raps securing the charge/modulation cable to the
PSU cable.
1. PSU
2. Studs
3. M4 Nyloc Nut
d. Keep the PSU in a safe location.

3 Pull the contact block (item 3, Figure 7-111 on page 7-111) covered by
the sleeve (item 4) upwards to disconnect the claws, or use a
screwdriver to release the claws.
4 Push the sleeve backwards off the contact block.
7-110 Plug and Power Cable Rev AA

Caution
Do not unbend the terminals, the terminals can break.
Note: Remember the positions of the terminals.

5 Loosen the four screws (item 1) and remove the terminals (item 2)
using Nr.1 posidrive.
6 Disconnect the terminals from the contact block.
4
3
1. Screws 3. Contact Block

2. Terminals 4. Sleeve
Figure 7-111: Remove Terminals
7 Remove the M4 nyloc nut (item 3, Figure 7-112) and M4 ET washer

(item 1) and disconnect the ground wire from the ground stud (item
5).
8 Remove the M20 x 1.5p lock nut (item 2).

1. M4 ET Washer 4. Cable Gland

2. M20 x 1.5p Nut 5. Ground Stud
3. M4 Nyloc Nut
Figure 7-112: Remove Cable Gland
9 Disconnect the plug from power cable.

10 Release the cable-strain-relief-clamp nut on the cable gland.
11 Open the cable gland by inserting a screwdriver on either side.
12 Hinge open the gland and slide the gland from the cable.
13 Pull the disconnected power cable through the hole in the electronics
compartment.
14 Discard the power cable with the plug according to local regulations.
The removal of the old power cable is complete.
How to Install the New Power Cable

Do the following tasks to install the new power cable:
1 Slide the M20 x 1.5p lock nut over the free end of the new power cable
(see Figure 7-113 on page 7-113).

Figure 7-113: Power Cable
2 Insert this free end of the power cable through the hole in the cabinet
from inside the electronics compartment.
3 Connect the power cable to the switch contact block at the correct
terminals with the four screws using Nr.1 posidrive (see Figure 7-114
and Table 7-24 on page 7-113).
Figure 7-114: Power Switch - US and Europe
Table 7-24 shows the wiring details of the power switch.
Connection Europe USA
1A Mains Cable Live (brown) Mains Cable Live (black)
1B Wire to 3-way connector Wire to 3-way connector

(brown) (brown)
2B Mains Cable Neutral (blue) Mains Cable Neutral (white)
2A Wire to 3-way Connector Wire to 3-way Connector (blue)

(blue)
Table 7-24:Wiring Information
4 Pull the sleeve back on the contact block.

5 Connect the contact block to the mains switch assembly.
6 Reconnect the ground wire to the ground stud with the M4 nyloc nut
and M4 ET washer.
7 Slide the new cable gland over the free end of the power cable
towards the hole in the cabinet from outside.

Do not close the cable gland at this stage.

8 Push any excess cable in the electronics compartments out through
the hole.
9 Locate the gland in the hole and on the support bracket below this
hole. Close the cable gland near the hole.
10 Tighten the M20 x 1.5p lock nut.
11 Tighten the cable strain relief nut on the cable gland to retain the
cable.
12 Do the following tasks to fit the PSU:
a. Connect the below cables:
• Connect the 8-way cable to the CSB.
• Connect the 3-way connector from the switch to the PSU.
b. Put the PSU assembly into the lug (see Figure 7-115 on page 7-114)
in the rear of the electronics compartment and then on the two
studs.
c. Use the two M4 nyloc nuts to fit the PSU assembly to the studs.
Figure 7-115: Lug
d. Ty-rap the charge/modulation cable to the PSU cable.

13 Connect the new plug to the power cable.
14 Close the CSB.
The installation of the new power cable is complete.

CSB Lithium Battery
3 mm Allen Wrench 1
How to Remove the Old CSB Lithium Battery

Do the following tasks to remove the old CSB lithium battery:
2 Use the 3 mm allen wrench to remove the two M4 x 8 cap-head screws
(item 3, Figure 7-116) that holds the retainer (item 4).
3 Push the latch (item 1) down to open the control system board (CSB)
(item 2).
1. Latch 3. M4 x 8 Cap-head Screws (x2)

2. Control System Board 4. Retainer
Figure 7-116: Latch
4 Locate the CSB lithium battery (Figure 7-117).

5 Lift the battery clamp and remove the old CSB lithium battery.
Rev AA CSB Lithium Battery 7-115

1
2
1. Battery Clamp
2. Lithium Battery
6 Dispose the old CSB lithium battery according to local regulations.

The removal of the old CSB lithium battery is complete.
7-116 CSB Lithium Battery Rev AA

How to Install the New CSB Lithium Battery

Do the following tasks to install the new CSB lithium battery:
1 Push the new CSB lithium battery under the battery clamp.
2 Swing the CSB assembly into the closed position.
3 Attach the retainer with the two M4 x 8 cap-head screws. Use the 3
mm allen wrench.
The installation of the new CSB lithium battery is complete.
PCB 1, 2 and 3
Introduction
The printer is provided with PCB 1 and PCB 2 on the connector panel.
There are three standard connectors on each PCB. PCB 3 is optional.
The instructions given below are for PCB 2 only. You must follow the
same instructions for PCB 0, PCB 1 and PCB 3.
3 mm Allen Wrench 1
7mm Nut Spinner 1
Special Din Spanner 1

(P/N 234657)
How to Remove the PCB 2

Do the following tasks to remove the old PCB 2:
1 Open the electronics compartment door. Refer to “How to Close the
2 Remove and keep the connector plugs that are fitted to the connectors
on PCB 2.
Rev AA PCB 1, 2 and 3 7-117

3 Push the latch and open the control system board.

4 Disconnect the 14-way ribbon cable from PCB 2 from the printer
interface board (PIB).
5 If you must replace PCB 1 and PCB 3 then, disconnect the following
ribbon cables form the PIB:
• 20-way ribbon cable connected to the PCB 1
• 16-way ribbon cable connected to the PCB 3
4 3 2 1
1. PCB 2 4. Earthing Tab
2. M4 Nyloc Nut 5. PCB 1
3. M4 ET Washer
Figure 7-118: PCB 2
6 Remove and discard the M4 nyloc screw (item 2, Figure 7-118) and M4
ET washer (item 3) that attach the earthing tab (item 4) to the cabinet.
7 Use the special din spanner to detach the lock nut (item 4, Figure 7-119
on page 7-119) from the connectors on the PCBs.
8 Remove and discard PCB 2 (item 1, Figure 7-118) according to local
regulations.
7-118 PCB 1, 2 and 3 Rev AA

1. PCB 3 3. PCB 1
2. PCB 2 4. Lock Nut
9 Discard the PCBs as per local regulations.

The removal of the old PCBs is complete.
How to Install the New PCB 1, 2 and 3

Do the following tasks to install the new PCB 2:
1 Insert the new PCB 2 into their correct positions from inside the
2 Fit the PCBs with the lock nuts from outside.
3 Fit the earthing tabs to the cabinet with the M4 nyloc screw and M4 ET
washer.
4 Tighten the M4 nyloc screws and M4 ET washers that attach the
earthing tabs to the cabinet.
5 Connect the 14-way ribbon cable from PCB 2 to the PIB.
6 Close the control system board.
7 Fit the dust caps to all the connectors.
The installation of the new PCBs is complete.
Rev AA PCB 1, 2 and 3 7-119

Maintenance
8
The preventative maintenance schedules mentioned in this chapter must
be carried out by a suitably trained maintenance technician.
Actual intervals depend on machine running hours. The figures below are
based on eight hours usage per day. If the actual usage is higher, the
intervals should be reduced.
Task Medium
Clean the Printhead Weekly
Replace the Core Module 9,000 hours
Replace the Ink pump 18,000 hours (for every other ink core)
Replace the Fan Filter (IP55) 2,000 hours
Replace the Floor Filter (IP55) Will be replaced with the Ink Core Module
Replace the Fan Filter (IP65) 2,000 hours
Replace the Floor Filter (IP65) Will be replaced with the Ink Core Module
Replace the Positive Air Filter 2,000 hours
Replace the Dry Air Kit Filter 2,000 hours
Table 8-1: Preventative Maintenance Schedule
Warning
It is possible that in a fault condition the heater can reach 70 °C. Do
not touch the plate on which heater is mounted. The failure to follow
this warning can cause personal injury.
Rev AA 8-1
Prime the Printer
Warning
HANDLING CLEANING AGENT. The cleaning agent is irritating to
the eyes and respiratory system. To prevent personal injury when
handling this substance:
Always wear protective rubber gloves and clothing.
If cleaning agent contaminates the skin, rinse off with running water
for at least 15 minutes.
1 Select System > Fill Ink Core. This process primes the printer with ink.
Record the prime time.
Figure 8-1. Fill Ink Core Command
2 Observe if the ink is going through the black-striped and blue-striped

tubes. During this process, it should take approximately 22 minutes
for the ink core to change status from empty to middle.
Note: Make sure that there are no leaks in tubing and fittings.
3 Check the ink cartridge. If empty, replace with a new cartridge.
8-2 Prime the Printer Rev AA

Umbilical Purge
The umbilical purge option is used to flush the ink core module before
fitting the nozzle.
Caution
Do not fit the nozzle before you perform this procedure.
Perform umbilical purge in the following conditions:

• To prevent debris from blocking the nozzle if the printer has not been
used for a long time
• If contamination of the umbilical is suspected
• If a new umbilical has been fitted
• If the ink color or type is to be changed
Do the following tasks to perform umbilical purge:
the printhead chassis and remove the printhead cover (see Figure 8-2).
.

2. Print Engine 5. Umbilical
3. Printhead Cover Screw
Figure 8-2. Printhead Cover Removed
Rev AA Umbilical Purge 8-3

Caution
nozzle tubing manifold is to be disconnected from the printhead
valve module deck.

6 Fit the nozzle bypass manifold that has the loop of tube to the
Figure 8-3).
4
2. Bypass Manifold 5. 2-way Manifold Gasket
3. Tube Loop
Figure 8-3. Nozzle Bypass Manifold

8-4 Umbilical Purge Rev AA


10 Select umbilical purge option (see Figure 8-4).
Figure 8-4. Umbilical Purge Command
11 The purge option runs for 15 minutes.

cover screw.
System Flush Purge

The system flush purge procedure is usually performed during the
commissioning of the printer.
Nozzle bypass manifold 1
Table 8-2: Tools and Supplies Required
Rev AA System Flush Purge 8-5

Cartridges of clear solvent (appropri- 5

ate to ink base)
Ink cartridge case with a smart chip 1

programmed for ink
Empty container for recovered ink Minimum 1 liter capacity
1.5 mm ball driver 1
Syringe or Wash Bottle 1
Clean solvent 1 liter
Safety glasses 1
Procedure
Do the following tasks to perform system flush purge:
3 Make sure that the printhead is installed on a correct mounting
bracket and is directed into a suitable container.
4 Turn the knob and open the ink compartment door.
5 Remove the ink and the make-up fluid cartridges from the cartridge
holders.
the printhead chassis, and remove the printhead cover (see Figure 8-2
on page 8-3).
Caution
nozzle tubing manifold is to be disconnected from the printhead
valve module.

8 Manually flush the nozzle assembly with a clean solvent. Use a
syringe or wash bottle to do this task.
8-6 System Flush Purge Rev AA

9 Fit the nozzle bypass manifold and the 2 way manifold gasket to the
printhead valve module (refer to Figure 8-3 on page 8-4).
10 Open the quick disconnect (item 4, Figure 8-3 on page 8-4).
11 Put the container for recovered ink under the nozzle bypass manifold.
13 Turn on the main power switch of the printer. The menu screen
appears on the display.
14 Navigate to Password menu. The menu shown in Figure 8-5 appears.
Figure 8-5. Password Menu
15 Select Enter Password submenu. The Enter Password dialog box appears
(see Figure 8-6).
Figure 8-6. Enter Password Dialog Box
16 Enter the Level 3 password and press the Enter key. The system allows
you now to access all the menus in the UI.
17 Navigate to System menu and disable the Gutter Fault Shutdown.

Figure 8-7. Gutter Fault Shutdown Command
18 Select System > Quick Start Jet.
Figure 8-8. Quick Start Jet Command
The ink flows from the nozzle bypass manifold until the ink core
empty level is reached.
19 When the ink flows from the nozzle bypass manifold, introduce
solvent into the gutter for 30 seconds.
20 Put the recovered ink aside for re-use if required (it is not required
again during this procedure).
21 Close the quick disconnect in the nozzle bypass manifold.

22 Fit one of the solvent cartridges into the ink cartridge stall (with the
smart chip programmed for ink) and fit this into the ink bottle holder
(the right-hand holder) of the door.
23 Select System > Fill Ink Core. The ink core pump should stop when the
middle level is reached.
Figure 8-9. Fill Ink Core Command
24 If the pump does not stop within 4 minutes, do the following tasks:
This condition occurs when the fluid is not conductive because of
dilution in ink.
a. Remove the cartridge from the stall and check if the cartridge is
empty.
b. If the cartridge is empty, proceed to Step 25.
c. If there is still some fluid in the cartridge, return it to the stall and
allow the pump to run for a further minute, before checking again.
25 Select System > Umbilical Purge and allow the printer to purge the
umbilical with solvent for a minimum of 5 minutes (refer to
“Umbilical Purge” on page 8-3).
26 After 5 minutes, stop the umbilical purge using Quick Stop.
27 Select System > System Flush Purge. Record the time.

Figure 8-10. System Flush Purge Command

28 Observe if fluid is going through the red-striped tube (flush supply
line). This process will take about 44 cycles.
29 Press the Enter key.
30 Press Y to confirm, or N to cancel the operation.
• Make sure that a receptacle is placed beneath the printhead to
collect the used make-up fluid.
• The make-up fluid must be removed from the printhead to
complete the procedure.
• If make-up fluid is not visible, repeat the procedure.
• If air is visible in the effluent, repeat the procedure.The procedure
will take approximately 10 - 15 minutes
31 The printer takes between 3 and 4 minutes to empty the ink core. At
about this time, listen for the sound of the pump changing, as it begins
to race when the level of fluid in the ink core drops below the pick-up
tube. At this point, stop the printer by switching it off at the mains.
32 Repeat instructions for the remaining solvent cartridges (Step 22 to
Step 31).
33 Remove the final empty solvent cartridge and the nozzle bypass
manifold.
34 Refit the front tubing manifold of the nozzle.
35 Disconnect the 3-way manifold from the printhead valve module and
disconnect the 3 printhead tubes from the ink system in the cabinet
(clear tube, red-striped tube and larger gutter tube).

36 Expel fluid from the printhead tubes with clean air.

37 Reconnect the printhead tubes to the ink system tubes and refit the 3-
way manifold to the heater manifold.
39 Fit the printhead cover to the printhead.
Nozzle Flush
Perform the nozzle flush in the following conditions:
• If a nozzle has been clogged with dried ink
• If the jet break up is asymmetric.
Do the following tasks to perform nozzle flush:
the printhead chassis and remove the printhead cover (see Figure 8-2
on page 8-3).
2 Support the printhead in a suitable stand and place a container
underneath to catch any extra solvent.
3 If the nozzle is clogged, initiate System > Nozzle Flush.
Figure 8-11. Nozzle Flush Option
If nozzle does not clear, seek assistance to have nozzle inspected by

engineering.
4 Press the Enter key. The nozzle orifice should be irrigated with
washdown to clear any blockages.
Rev AA Nozzle Flush 8-11

5 The nozzle flush remains active for 2 minutes, but can be stopped at
any time by pressing the F1 key.
Replacement of Ink System Fan Filter for IP65
How to Remove the Old Ink System Fan Filter for IP65
Do the following tasks to remove the old ink system fan filter:
1 Turn the knob and open the ink system fan filter cover (item 2,
Figure 8-12).
2 Remove the fan filter element (item 1) from the fan filter cover.
1. Fan Filter Element

2. Fan Filter Cover
Figure 8-12. Ink System Fan Filter - IP65
3 Discard the fan filter element according to the local regulations.

The removal of ink system fan filter for IP65 is complete.
How to Install the New Ink System Fan Filter

Do the following tasks to install the new ink system fan filter:
1 Insert the new ink system fan filter element inside the fan filter cover.
2 Close the ink system fan filter cover carefully.
The installation of ink system fan filter for IP65 is complete.
8-12 Replacement of Ink System Fan Filter for IP65 Rev AA

Replacement of Ink System Fan Filter for IP55
How to Remove the Old Ink System Fan Filter for IP55
Do the following tasks to remove the old ink system fan filter:
1 Turn the knob and open the ink system fan filter cover (item 2,
Figure 8-13).
2 Remove the fan filter element (item 1) from the fan filter cover.
1. Fan Filter Element IP55

2. Fan Filter Cover
Figure 8-13. Ink System Fan Filter - IP55
3 Discard the old fan filter according to the local regulations.

The removal of old ink system fan filter for IP55 is complete.
How to Install the New Ink System Fan Filter for IP55
Do the following tasks to install the new ink system fan filter:
1 Insert the new ink system fan filter element inside the fan filter cover.
2 Close the ink system fan filter cover carefully.
The installation of new ink system fan filter for IP55 is complete.
Rev AA Replacement of Ink System Fan Filter for IP55 8-13

Replacement of Floor Filter for IP65
How to Remove the Old Floor Filter IP65

Do the following tasks to remove the old floor filter:
1 Loosen the four M4 x 40 cap-head screws (item 1, Figure 8-14) and
remove the screws.
2 Detach the ink core support channel (item 2).
3 Remove the filter element (item 3) from the filter tray (item 6).
4
5
1. M4 x 40 Cap-head Screw (x4) 4. Filter Clamp

2. Ink Core Support Channel 5. M4 x 8 Cap-head Screw (x6)
3. Filter Element 6. Filter Tray
Figure 8-14. Floor Filter - IP65
4 Discard the old floor filter element according to the local regulation.
The removal of old floor filter for IP65 is complete.
How to Install the New Floor Filter IP65

Do the following tasks to install the new floor filter:
1 Insert the new floor filter element on the filter tray.
2 Attach the ink core support channel.
8-14 Replacement of Floor Filter for IP65 Rev AA

3 Tighten the M4 x 40 cap-head screws.

The installation of new floor filter for IP65 is complete.
Replacement of Floor Filter for IP55
How to Remove the Old Floor Filter IP55

Do the following tasks to remove the old floor filter:
1 Loosen the four M4 x 40 cap-head screws (item 1, Figure 8-15) and
remove the screws.
2 Detach the ink core support channel (item 2).
3 Detach the ink side filter top (item 3) and ink side filter base (item 4).
4 Remove the floor filter element (item 5) from the cabinet base.
3
4
5
1. M4 x 40 Cap-head Screw (x4) 4. Ink Side Filter Base

2. Ink Core Support Channel 5. Floor Filter Element
3. Ink Side Filter Top
Figure 8-15. Floor Filter - IP55
5 Discard the old floor filter element according to the local regulations.
The removal of old floor filter for IP55 is complete.
Rev AA Replacement of Floor Filter for IP55 8-15

How to Install the New Floor Filter for IP55

Do the following tasks to install the new floor filter:
1 Insert the new floor filter element on the cabinet base.
2 Attach the ink side filter base and ink side filter top above the floor
filter element.
3 Attach the ink core support channel.
4 Tighten the M4 x 40 cap-head screws.
The installation of new floor filter for IP55 is complete.
Windows CE Upgrade Procedure
Equipment Quantity
“A to A” USB Cable 1
Serial Cable (MS1227 or 80200258) 1
Laptop 1
CSB Pack (bundled software files) 1
System Backup
You must perform a full system backup in order to safeguard the existing
data of the customers, as the subsequent steps that you will be performing
will erase all existing data. Refer to “Perform Full System Backup” on
page 5-3.
8-16 Windows CE Upgrade Procedure Rev AA

Hardware Connections
Do the following tasks to establish hardware connections:
1 Turn off the power supply to the printer.
Warning
the printer.
2 Open the electronics compartment.

3 Connect the "A to A" USB cable from the USB connection of the laptop
to the USB connection on the left side of the CSB.
4 Configure SW2 as follows:
1 OFF
2 OFF
3 OFF
4 ON
5 ON
6 OFF
This ensures that the CSB is set to the USB device mode.
5 Connect the serial cable from the DB-9 port on the laptop to the 5-pin
DIN connector on the side of the printer.
WINDOWS XP
Laptop should establish USB connection with the printer, and prompt for
a new hardware device and look for a suitable driver. Guide it to the
secbulk.sys and secbulk.inf files in the USB directory of the CSB Pack bundle.
WINDOWS 2000
7 Do the following tasks to install the driver for windows 2000:
a. Navigate to Start> Settings> Control Panel.
b. Select Add/Remove Hardware.
Rev AA Windows CE Upgrade Procedure 8-17

c. Navigate through the associated Wizard and Troubleshooter.

When prompted to identify the needed driver, select the secbulk.sys
and secbulk.inf files in the USB directory of the CSB Pack bundle.
8 Turn off the printer.
USB Download through Serial Commands

Do the following tasks to initiate USB download through serial
commands:
1 Configure Hyper terminal on the laptop with the following
specifications:
• 115,200 baud
• 8 data bits
• No parity
• 1 Stop Bit
• No flow control
3 Monitor the terminal software display. You must press the space bar
on the laptop within 5 seconds.
The code that appears on the terminal display is shown in Figure 8-16.
Figure 8-16.Terminal Display
You can see a countdown to Initiating image launch.

You have 5 seconds from power-up in which to press the space bar. If
you miss it, turn off the printer and try again.
4 The "EBoot menu" should be provided through Hyper terminal (see
Figure 8-17).
Figure 8-17.Eboot Menu
5 Go through the following sequence of steps to prepare for USB (or

Ethernet) download on the laptop, and to ensure that the downloaded
image is programmed to NAND (thereby making the board
standalone bootable).
Note: The first four steps can be modified as necessary.

a. Press '4' to show (Reset to factory default configuration)
b. Press '8' until Kernel Debugger shows DISABLED
c. Press '5' until Startup Image: shows LAUNCH EXISTING
d. Press '6' until Program disk image into SmartMedia card shows
ENABLED
e. Press 'T' (Clear the sector info for steploader and Eboot)
f. Press 'S' (Protect the StepLoader)
g. Press '9' (Format Boot Media for BinFS)
h. Press 'W' (Write Configuration Right Now)
i. Finally, press 'U' to initiate USB Download

USB Download
Do the following tasks for USB download:
1 Run dnw.exe software. This application is located in the USB folder of
the CSB Pack bundle.
2 Make sure that USB:OK is displayed (see Figure 8-18).
Figure 8-18.USB: OK
3 Select USB Port > UBOOT(WINCE500) > UBOOT and the screen
shown in Figure 8-19 appears.
Figure 8-19.USB Port Menu

4 Navigate to the required location and select the appropriate.bin file.

Click the Open button (see Figure 8-20).
Figure 8-20..bin File
5 The USB download gets initiated.

6 Once the download is complete you should see the image (see
Figure 8-21) appear in the Hyper terminal display and this is the
image being committed to NAND Flash.
Figure 8-21.Terminal Window Display
7 The following code should appear in Hyper terminal (and WinCE and
then the UI will start on the printer) (see Figure 8-22).
Figure 8-22.Terminal Window Display
8 The printer will prompt the user to load the 43s interface. Make the
appropriate selection.

9 Once the printer has booted, it will automatically go into the EHT
Calibration procedure.
Note: These settings (EHT Calibration) were erased during the upgrade.
10 Enter the Level 3 password.
11 The printer will have loaded a software version and a firmware
version as part of the CE upgrade process.
12 You can check the version information under Data Logging.
13 Additional changes to the software and firmware versions may be
accomplished by using the normal process and the USB flash drive.

Troubleshooting
9
Read the Operator Manual
The Videojet 1510 Operator Manual (Part Number 361868) contains the
troubleshooting procedures that an operator is allowed to perform. Refer
to the operator manual for these procedures.
This chapter contains the troubleshooting procedures that only a service
technician is allowed to perform.
Warning
It is possible that in a fault condition the heater can reach 70 °C. Do
not touch the plate on which heater is installed. The failure to follow
this warning can cause the personal injury.
Important Guidelines
• Before you perform fault diagnosis or do any repairs described in this
section, Videojet recommends you to move the printer from the
production line to a clean environment.
• When a fault condition occurs, the first step in locating the reason for
the fault must be to check the following:
• The fault and status icons displayed on the display.
• The status LEDs on the CSB.
• Table 9-6 on page 9-7 through Table 9-8 on page 9-14 list the possible
printer status icons. These tables contain either remedial action or a
reference to more detailed fault finding information.
Rev AA Read the Operator Manual 9-1

Startup Problems
Printer Fails to Start
Possible Cause Remedial Action
No main power supply Make sure that the main power supply is turned on. To turn on
the printer, press the green push button.
Main power supply input cable 1. Make sure that the cable that provides the main power
disconnected or defective supply is connected.
2. Check the continuity of the cable. If the cable is defective,
repair or replace the cable.
Printer main power supply fuse Check the F1 fuse in the PSU. Replace the fuse if necessary.
failed
Faulty mains switch Check mains power switch. Replace the switch if the switch is
faulty.
Cable between mains switch and 1. Check the cable connections. Reconnect if necessary.
PSU is disconnected or faulty 2. Check the cable for continuity. Replace if faulty.
PSU output not reaching the Check LEDs 1, 2, 3, 4 and 5 on CSB (see Figure 9-1 on
CSB page 9-3).
Cable between PSU and CSB is 1. Check if the cable between PSU and CSB is connected.
faulty or disconnected Reconnect if necessary.
2. Check the cable for continuity, replace if faulty.
PSU fuse failed Check the fuse, replace if necessary.
PSU faulty Replace PSU (see “Power Supply Unit” on page 7-9).
CSB failed 1. Make sure that LEDs 1, 2, 3, 4 or 5 on CSB are illumi-

nated.See Figure 9-1 on page 9-3.
2. Change CSB (see “Control System Board” on page 7-7).
Table 9-1: Printer Startup Problem and Remedies
9-2 Startup Problems Rev AA

5 4 3 2
1. CSB 4. SoC to FPGA LED
2. Power LED 5. Ethernet LED
3. Print Engine LED
Figure 9-1: Status LEDs
Display Faults
Backlight
Warning
LETHAL VOLTAGES. A high AC voltage is present at the inverter
and backlight. Extreme caution is required when diagnosing failure
in these areas.
Rev AA Display Faults 9-3

Note: Some DVMs may not show the 1000 V AC correctly. Use an oscilloscope
fitted with a high voltage probe to measure the voltage.
Backlight inverter faulty 1. Check for 24 V DC at 3 way input connector on backlight converter
(Pins 1 and 2 on I/O board B/LIGHT connector).
2. Check for 1000 V AC at output leads from backlight inverter (Pins 3
and 5).
3. If 24 V DC is present but 1000 V AC is missing, change the LCD/
backlight assembly (see “LCD and FIB Assembly” on page 7-13).
Cable from CSB to 1. If 24 V DC is not present at backlight inverter but is present at Pins 1
backlight is and 3 of B/LIGHT connector on I/O board, make sure that the cable is
disconnected or faulty connected between the CSB and the backlight.
Backlight faulty If 1000 V AC is present at output of backlight inverter but backlight is not
illuminated, change the LCD/Backlight assembly (see “LCD and FIB
Assembly” on page 7-13).
CSB door board faulty Check for 24 V DC on pins 1 and 3 of B/LIGHT connector on I/O board. If
24 V DC is not present, change CSB (see “Control System Board” on
page 7-7).
Table 9-2: Display Backlight Failure
LCD Faults
LCD contrast not set

Press to set the contrast.
correctly
Ribbon cable between CSB Check the cable for continuity. Replace if faulty.
and LCD is faulty
CSB faulty Change the CSB (see “Control System Board” on page 7-7).
LCD faulty Change the LCD assembly.
Table 9-3: LCD Failure
9-4 Display Faults Rev AA

Keypad Faults
Ribbon cable between CSB and 1. Make sure that the ribbon cable between CSB and the
keypad is disconnected or faulty keypad is connected.
CSB faulty Change the CSB

(see “Control System Board” on page 7-7).
Keyboard faulty Change the keyboard.

(see “Keyboard/Electronics Compartment Door” on page 7-
16).
Table 9-4: Keypad Failure
Rev AA Display Faults 9-5

Display Icons
Alarm Light Conditions
Alarm Light Description

Color
Red Jet Off, No warnings. All Relays off
Amber Jet On, Warning present, Print not enabled and Relay 2 set.
Green Print Enabled, No Warnings and Relay 1 set
Green and Print Enabled, Warning Present, Relay 1 and 2 set

Amber
Red and Jet off, Warning Present and Relay 2 set

Amber
No Lights Jet Running, No Warnings, and Print disabled. All Relays are off
in this mode
Table 9-5: Alarm Light Conditions
Printer Status Icons

The printer status icons are divided into three groups:
• The indicator icons. The indicator icons show the status of the ink jet.
• The fault icons. When a fault condition occurs, the printer stops
printing.
• The warning icons. When a warning condition occurs, the printer
continues to print until the warning condition becomes a fault
condition.
9-6 Display Icons Rev AA

Indicator Icons
Icon Name Description
Jet Running The ink jet is running and the machine is

ready to print. When the machine starts, the
icon flashes.
Jet Stopped Indicates that the ink jet is stopped. When

the machine stops, the icon flashes.
Table 9-6: Indicator Icons
Fault Icons
Fault Reason Causes Action
Charge The charge Excessive 1. Check electronics compartment temperature

Error amplifier is electronics on diagnostics screen.
over compartment 2. Check to ensure that electronics compartment
temperature temperature. fan is turning.
OR invalid 3. Keep electronics compartment door open and
charge data. see if compartment temperature drops;
attempt restart.
4. If fault returns, lower print rate and monitor
electronics compartment temperature.
Defective CSB 1. Check test points related to charge amplifier:

TP50, TP72, CHG.
2. Replace the CSB (see “Control System
Board” on page 7-7).
Table 9-7: Fault Icons
Rev AA Printer Status Icons 9-7

EHT Trip Excessive The printhead 1. Clean and dry the printhead.
current in the is dirty or wet 2. Restart the inkjet; monitor for ink build-up on
EHT circuit as the printhead during printing operations if
measured by possible.
the CSB.
The EHT circuit 1. Stop the ink jet.

is not 2. Perform "Calibrate EHT".
calibrated 3. Restart the inkjet; monitor system
performance.
Short in 1. Stop the inkjet and de-energize the printer.

umbilical or 2. Unplug the EHT wire from the EHT power
EHT resistor supply.
3. Measure the resistance between the EHT
wire and the EHT plate.
4. f open or short circuit exists, remove the
Printhead Engine and inspect the EHT
resistor.
5. Replace the umbilical.
Defective EHT Replace the EHT power supply.

power supply
Defective CSB Replace the CSB.
9-8 Printer Status Icons Rev AA

Gutter Jet is on, ink Nozzle is 1. Perform a nozzle back flush.

Fault stream is not clogged 2. Restart the inkjet and make sure that the ink
detected in stream is entering the gutter.
the gutter for
more than 5
seconds
Inadequate ink 1. Check for the presence of pump fault

pressure 2. Check the actual pressure using diagnostics
screens.
Ink stream is 1. Perform a nozzle flush.

misaligned 2. Restart the inkjet and confirm that the ink
stream is entering the gutter.
3. Perform an ink stream alignment.
No vacuum 1. Clean the printhead.

2. Perform a nozzle flush and check for flow in
the return line to confirm the proper operation
of the vacuum system.
3. Remove the Print Engine and inspect the
length of tubing between the gutter and the
Printhead Valve Module for clogs.
4. Loosen Valve V2 (VP and VG) and clean.
The gutter 1. Remove the Print Engine and inspect the

sense chamber gutter sense chamber.
is defective 2. Check CSB test point 45 for the gutter sense
signal
3. Check umbilical wires related to the gutter
sense signal.
4. Replace the umbilical.
Ink Core The "low" New Perform "Fill Ink Core" procedure to establish
Empty level sensor installation. correct level in ink core module.
in the ink core
module is
uncovered.
"Ink Core Low" Refer to “Ink Core Level Low” on page 9-26.
and printer is
unable to add
ink.

Pump Fault The pump Leak 1. Inspect ink compartment, electronics com-
speed is partment, and umbilical for leaks.
>98% of the 2. Repair if possible.
maximum
value and the
actual
pressure is
>0.2 bar
below the
target
pressure.
Erroneous 1. Inspect the electrical connections between

pressure the ink core module and the PIB, and between
indication the PIB and the CSB.
2. Check and compare the voltage readings at
the test points related to pump and pressure:
TP20, TP21, TP22, and TP47. Also, remove
the top cover of the ink core module and
measure the voltage between points + Press
and - Press.
Defective 1. Inspect the electrical connections between the

pump. ink core module and the PIB, and between the
PIB and the CSB.
2. Open the pump compartment, and inspect the
pump.
3. Replace the pump.
Ink too thin. 1. Check the diagnostics screen.

2. Compare the "target pressure" with the
temperature-compensated target pressure.
3. If the "target pressure" is significantly less
than (1 bar) than the temperature-
compensated target pressure, the ink is too
thin.
4. Recover the viscosity by allowing the jet to run
continuously, or by draining and re-priming
the system.
Erroneous 1. Clean the printhead.

velocity 2. Check the diagnostics screen.
indication 3. Compare the "actual velocity" with the
"velocity set point".
4. Remove the printhead engine and measure
the resistances between the copper pads on
the underside of the Printhead Engine; com-
pare to the expected values.
5. With an oscilloscope, check the waveforms at
the CSB test points related to velocity: "PHA",
TP69, TP58, TP59, TP60, TP61.

Cabinet The cabinet The electronics 1. Open the electronics compartment.

Too Hot temperature compartment is 2. Inspect the electronics compartment compo-
measured by overheated. nents for any damage or overheating.
the CSB is 3. If possible, operate the printer with the
above 80° electronics compartment door open and
Celsius monitor the "Electronics Temperature" via the
diagnostics screen.
The ambient 1. Move the printer to a location where the ambi-

temperature is ent temperature is lower, or attempt to lower
too high. the temperature at the current location.
2. Monitor the "Electronics Temperature" via the
diagnostics screen.
The heat sink is Remove the insulation/obstruction from the

insulated or vicinity of the heat sink.
obstructed.
The mains 1. Check the voltages from the mains power

power supply is supply being supplied to the CSB.
defective. 2. Replace the mains power supply
The CSB is Replace the CSB

defective.
Ink System Ink core

Service module is in
Overdue use for more
than 8000
hours

Unable to The printer Ink core level is Refer to “Ink Core Level High” on page 9-25.
Control has been "high" and
Viscosity unable to target pressure
perform has been >.1
automatic bar above
viscosity temperature-
control for an compensated
interval of 30 target pressure
minutes or for 1 hour.
greater.
No make-up Refer to “No Make-up Cartridge” on page 9-23

cartridge, or
invalid make-
up cartridge,
and target
pressure has
been >.1 bar
above
temperature-
compensated
target pressure
for 1 hour.
Printer is Refer to “Phase Threshold Error” on page 9-17

unable to
obtain a phase
profile for ½
hour.
Printer is Refer to “No Time for TOF” on page 9-30.

unable to
measure
velocity for ½
hour.
Mod Driver Mod amplifier Amplifier over

Chip Over hardware has temperature
Temperatu shutdown.
re
Rasters Not enough

Memory memory to
Overflow store all
Detected requested
raster tables

Valve Error Hardware

- Contact error in valve
the Service hit / hold drive
Department circuit
Bad Unable to
Phasing obtain phase
data during
startup
Modulation Hardware
Readback error, ADC
Failed readback
invalid

Warning Icons
Warning Reason Causes Action
Printhead The printhead The printhead Allow the inkjet to run - the printhead
Temperature temperature is has temperature should correct itself.
Too High 3° Celsius (temporarily)
greater than overheated.
setpoint, with
head heater
enabled.
The ambient If print quality or performance issues are

temperature is noted, consider operating the printer in a
too high. cooler environment if possible.
Defective 1. Check the voltages from the mains power

power supply. supply being supplied to the CSB.
2. Replace the mains power supply.
Defective 1. Inspect the electrical connections between

temperature the CSB and the PIB, and between the
control circuit PIB and the umbilical
(short) 2. Remove the Printhead Valve Module.
Inspect the electrical connections between
the Printhead Valve Module and the deck.
3. Measure the resistances between the cop-
per pads on the underside of the Printhead
Valve Module and compare these to the
expected values.
4. Check the umbilical wires for continuity.
Incorrect Requested
Raster or raster table not
Raster loaded into the
Family Name system.Warnin
g appears
immediately
Table 9-8: Warning Icons

Printhead The measured The printhead Allow the inkjet to continue to run - the
Temperature printhead has not yet printhead temperature should correct itself.
Too Low temperature is reached
more than 3° operational
Celsius below temperature.
the target
temperature.
Error duration
before warning
is 30 seconds
The ambient If print quality or performance issues are

temperature is noted, consider operating the printer in a
too low. cooler environment if possible.
Defective 1. Check the voltages from the mains power

power supply. supply being supplied to the CSB.
2. Replace the mains power supply.
Defective 1. Inspect the electrical connections between

temperature the CSB and the PIB, and between the
control circuit PIB and the umbilical.
(open) 2. Remove the Printhead Valve Module.
3. Inspect the electrical connections between
the Printhead Valve Module and the deck.
4. Reset the Printhead Valve Module, start
the printer and monitor printhead
temperature
5. If problem persists, Measure the
resistances between the copper pads on
the underside of the Printhead Valve
Module and compare these to the
expected values.
6. Check the umbilical wires for continuity
TOF Too Measured jet

High velocity is
more than
10% above
target figure.
Warning
appears
immediately

TOF Too Low Measured jet

velocity is
more than
10% below
target figure.
Warning
appears
immediately
Charge Error Operator has

Shutdown disabled
Disabled machine
shutdown on
charge error.
Warning
appears
immediately
Gutter Fault Operator has

Shutdown disabled
Disabled machine
shutdown on
gutter fault.
Warning
appears
immediately
Printhead Lid switch The printhead Replace the printhead cover

Cover circuit is open cover is
Removed removed
Open circuit Inspect the cabling from the umbilical to the

PIB and from the PIB to the CSB
Defective lid 1. Stop the inkjet and de-energize the printer.

switch 2. Remove the Print Engine and inspect the
lid switch.
3. Measure the resistances between the
copper pads on the underside of the
Printhead Engine and compare readings
to the expected values.
4. Check umbilical wires for continuity.
Defective CSB Check measurement at TP56 on the CSB.

Phase The printer is The printhead Clean and dry the printhead.
Threshold unable to is dirty
Error acquire a
phase profile
with the phase
threshold set
to the
minimum
value.
The ink stream 1. Perform a nozzle backflush.

is misaligned. 2. Restart the inkjet.
3. If the ink stream is still misaligned, perform
the ink stream alignment procedure.
No break-off. 1. Perform a visual inspection to verify break-

off.
2. If break-off does not exist, perform a
cursory check of electrical connections on
the Print Engine and in the electronics
compartment.
3. Attempt to set the modulation manually to
obtain break-off.
4. If break-off cannot be obtained, check the
modulation signal on the CSB. If the mod-
ulation signal does not exist, see below
(“CSB failed").
5. If the modulation signal is present on the
CSB, check for the modulation signal in
the printhead.
6. Remove the Print Engine and check its
electrical connections.
7. Replace the Print Engine.
"Phase 1. Check the "Phase Charge" setting.

Charge" 2. Adjust the "Phase Charge" setting to
incorrectly set. recover the phase profile.
Electrical 1. Check the electrical connections between

malfunction in the CSB and the PIB, and between the
TOF circuit. PIB and the umbilical.
2. Remove the Print Engine and check its
electrical connections.
3. Check the resistances between the copper
pads on the underside of the Printhead
Engine, and compare results with the
expected values.
4. Check for continuity in the umbilical wires.

No charge 1. With the ink jet running but the printer not
pulses. printing, check for the presence of charge
pulses at the charge tunnel.
2. If no pulses are present, check for the
presence of charge pulses at TP "CHG" on
the CSB
3. Check for continuity in the umbilical wires.
CSB failed With test equipment, check for presence of all

related signals on CSB: TP38, CHG, PHA.

Ink Viscosity The target The ink is too The printer should add make-up fluid to
Too High pressure is >.1 thick. correct its viscosity.
bar above the Monitor the progress of make-up additions
temperature- using "Diagnostics Screen Three". If the
compensated printer does not appear to be attempting to
target add make-up (allow at least five minutes for a
pressure make-up addition to be attempted), see
causes below.
If make-up addition capability is confirmed but
printer operations are impaired by thick ink,
consider flushing the system.
The make-up 1. Install or reset the make-up cartridge.

cartridge is 2. Verify that the "no make-up" icon
removed or extinguishes.
seated
improperly.
The make-up 1. Install a cartridge of the correct make-up

cartridge is of type.
the wrong type. 2. Verify that the "wrong make-up" icon
extinguishes
The make-up 1. Open the ink compartment door and gently

add line is slide the ink core module forward.
disconnected 2. Locate the GREEN-striped tube behind
or leaks. the ink core module.
3. Make sure that the quick disconnect in this
line is secure and that the line is not
leaking.
The ink core 1. Confirm condition by checking icons on

module level is home screen.
"high". 2. To clear the condition, perform these
steps:
• Direct the printhead into a service tray.
• Disable the "gutter fault".
• Raise the ink stream above the catcher.
3. Allow the ink stream to jet into the service
tray until the ink core module level is
restored to normal.
The ink core Replace the ink core module

module level is
defective

Ink Viscosity The target The ink is too 1. Allow the inkjet to run so that the excess
Too low pressure is >.1 thin. make-up fluid evaporates. The following
bar below the actions will help to recover the viscosity:
temperature- • Avoid nozzle backflushing and improper
compensated printhead cleaning (with the vacuum
target applied).
pressure. • Exercise the "Quick Start" and "Quick
Stop" options whenever possible.
• Run Gutter Pump at maximum speed.
• Check for flow in the GREEN-striped
tube, to make sure that make-up is not
being inadvertently added.
2. If printer operations are impaired by thin
ink, consider flushing the system. Or, com-
plete the following steps:
• Direct the printhead into a service tray.
• Disable the "gutter fault".
• Raise the ink stream above the catcher.
• Allow the ink stream to jet into the service
tray until the viscosity is restored (the
printer will add fresh ink to compensate
for system losses).
Pressure too The actual Printer Printer will correct itself

High pressure is transient
more than 0.2
bar above the
target
pressure.
Erroneous 1. Inspect electrical connections between the

pressure ink core module and the PIB, and between
indication. the PIB and the CSB.
2. Replace the ink core module. Check and
compare the voltage readings at the test
points related to pump and pressure:
TP20, TP21, TP22, and TP47. Also,
remove the top cover of the ink core
module and measure the voltage between
points + Press and - Press.

Pressure Too The actual Printer Printer will correct itself.

Low pressure is transient.
more than 0.2
bar below the
target
pressure.
Leak 1. Inspect the ink compartment, electronics

compartment, and umbilical for leaks.
2. Repair if possible.
Erroneous 1. Inspect the electrical connections between

pressure the ink core module and the PIB, and
indication. between the PIB and the CSB.
2. Check and compare the voltage readings
at the test points related to pump and
pressure: TP20, TP21, TP22, and TP47.
Also, remove the top cover of the ink core
module and measure the voltage between
points + Press and - Press.
Defective pump 1. Inspect electrical connections between the

ink core module and the PIB, and between
the PIB and the CSB.
2. Open the pump compartment, and inspect
the pump.
No Ink No ink No ink Insert an ink cartridge into the proper

Cartridge available for cartridge is cartridge holder.
addition to the present
Core
The ink Remove the empty cartridge and insert a new

cartridge is ink cartridge.
empty
The printer is 1. Ensure that the ink cartridge is seated

unable to read correctly in its receptacle.
the ink 2. Remove the ink cartridge. Check that the
cartridge Smart smart chip is present and is clean.
Chip 3. If another ink cartridge is available, insert it
into the printer and see if the printer can
read its smart chip.
4. Check that the smart chip reader (inside
the receptacle) is positioned correctly and
is clean.
5. Check the electrical connections between
the smart chip reader and the PIB board,
and between the PIB board and the CSB.

Wrong Ink Ink type in A cartridge 1. Remove the ink cartridge.

Cartridge cartridge containing the 2. Check the label on the ink cartridge to
incompatible wrong ink type confirm the ink type.
with ink core has been 3. Insert a cartridge of the correct ink type
module. inserted into into the printer
Fluid Ref and the printer
fluid Type
must match
ink core
module.
A make-up 1. Remove the cartridge.

cartridge was 2. Check the label on the cartridge to confirm
accidentally fluid type.
inserted into 3. Insert a cartridge of the correct ink type
the ink into the printer.
cartridge holder
The smart chip 1. Remove the cartridge.

on the ink 2. Check the label on the cartridge to confirm
cartridge is fluid type.
programmed 3. Insert a cartridge of the correct ink type
incorrectly or into the printer.
does not match
the label.
Ink Cartridge Ink past expiry

Expired date
Ink Cartridge Less than 5% Ink used for Insert a new ink cartridge into the proper
Low of the ink in printing cartridge holder after ink out.
the ink
cartridge
remains.
Ink Cartridge Ink cartridge

Empty smart chip
data 0%
Ink This ink

Insertions cartridge
Exceeded inserted more
than TEN
times

No Make-up No make-up No Insert a make-up cartridge into the proper

Cartridge available for make-up cartridge holder.
addition to the cartridge is
Core present
The Remove the empty cartridge and insert a new

make-up make-up cartridge
cartridge is
empty
The printer is 1. Ensure that the make-up cartridge is

unable to read seated correctly in its receptacle.
the make-up 2. Remove the make-up cartridge. Check
cartridge Smart that the smart chip is present and is clean.
Chip. 3. If another make-up cartridge is available,
insert it into the printer and see if the
printer can read its smart chip.
4. Check that the smart chip reader (inside
the receptacle) is positioned correctly and
is clean.
5. Check the electrical connections between
the smart chip reader and the PIB board,
and between the PIB board and the CSB.
Wrong Make- The cartridge A cartridge 1. Remove the make-up cartridge

up Cartridge inserted into containing the 2. Check the label on the make-up cartridge
the make-up wrong make-up to confirm the make-up type.
cartridge type has been 3. Insert a cartridge of the correct make-up
holder inserted into type into the printer.
contains the the printer
wrong make-
up type.
An ink cartridge 1. Remove the cartridge

was 2. Check the label on the cartridge to confirm
accidentally fluid type.
inserted into 3. Insert a cartridge of the correct make-up
the make-up type into the printer.
cartridge
holder.
The Smart 1. Remove the make-up cartridge

Chip on the 2. Check the label on the make-up cartridge
make-up to confirm the make-up type.
cartridge is 3. Insert a cartridge of the correct make-up
programmed type into the printer.
incorrectly or
does not match
the label.

Makeup Less than 5% Make-up Make preparations to insert a fresh make-up

Cartridge of the make-up evaporation cartridge into the proper cartridge holder.
Low in the make-up used during "jet Replace the cartridge following "make-up
cartridge on" operations. out".
remains.
Clean Start / Viscosity is too

Stop low, so clean
Inhibited start / stop
inhibited to
prevent
solvent
addition
Makeup This makeup

Insertions cartridge
Exceeded inserted more
than TEN
times

Ink Core The "high" Excessive 1. Use "Quick Start" and "Quick Stop" options
Level High level sensor in starts and until ink core module level is restored
the ink core stops. 2. Keep jet running to burn off excess make-
module is up.
covered 3. If printer operation is impaired by high ink
core module level ("unable to control vis-
cosity"), raise the ink stream above the
catcher to restore the ink core module
level to normal.
Excessive 1. Use "Quick Start" and "Quick Stop" options

nozzle until ink core module level is restored.
backflushing. 2. Keep jet running to burn off excess make-
up.
3. If printer operation is impaired by high ink
level to normal.
Improper 1. Use "Quick Start" and "Quick Stop" options

printhead until ink core module level is restored.
cleaning 2. Keep jet running to burn off excess make-
up.
3. If printer operation is impaired by high ink
level to normal.
Leak 1. Check for flow in the black or green striped

tubing (ink and make-up add line).
2. If flow is present continuously, disconnect
the line and check for presence of vac-
uum.
3. Replace the Core Module.

Ink Core The "middle" Ink usage The printer should add ink to restore ink core
Level Low level sensor in during printing. module level to "middle". However, if the
the mixer tank printer is attempting to add ink, but the level is
is uncovered. not restored, perform the following:
1. Confirm that the printer is attempting to
add ink by monitoring the "ink add valve"
on the diagnostics screen. The screen
should indicate that the valve is opening.
2. If the printer is not attempting to add ink,
check to make sure that a valid cartridge
of the correct ink type is inserted into the
ink cartridge receptacle.
3. If the printer is attempting to add ink, but
the level is not restoring, troubleshoot the
ink addition system as follows:
1. Ensure that the ink cartridge is not actu-
ally empty
2. Stop the jet and perform a "valve test".
Verify that the ink add valve is opera-
tional. If it is not operational, remove
and clean the valve.
3. Inspect the black-striped tubing and the
ink receptacle septum needle for
obstruction
4. Troubleshoot the venturi system - use
the temporary gauge manifold to check
the venturi vacuum.
5. Replace the Core.

Cabinet Hot The cabinet The electronics 1. Open the electronics compartment.
temperature compartment is 2. Inspect the electronics compartment com-
measured by overheating. ponents for damage or overheating.
the CSB is 3. If possible, operate the printer with the
greater than electronics compartment door open and
70º Celsius monitor the "Electronics Temperature" via
the diagnostics screen
The ambient 1. Move the printer to a location where the

temperature is ambient temperature is lower, or attempt
too high. to lower the temperature at the current
location.
2. Monitor the "Electronics Temperature" via
the diagnostics screen.
The heat sink is Remove the insulation / obstruction from the

insulated or vicinity of the heat sink.
obstructed.
The mains 1. Check the voltages from the mains power

power supply is supply being supplied to the CSB.
defective. 2. Replace the mains power supply if found
faulty
The CSB is The CSB is defective.

defective.
Ink Core The ink core

Insertions module has
Exceeded been
disconnected /
reconnected
more than
TEN times

Pump RPM The pump Leak 1. Inspect the ink compartment, electronics
Near Max speed is >98% compartment, and umbilical for leaks.
of the 2. Repair if possible
maximum
value.
Defective pump 1. Inspect electrical connections betwixt the

Core and the PIB, and between the PIB
and the CSB.
2. Open the pump cover, and inspect the
pump.
Ink too thin. 1. Check the diagnostics screen.

2. Compare the "target pressure" with the
temperature-compensated target pres-
sure.
3. If the "target pressure" is significantly less
than (1 bar) than the temperature-compen-
sated target pressure, the ink is too thin.
4. Recover the viscosity by allowing the jet to
run continuously, or by flushing and re-
priming the system.
Defective pump 1. Inspect electrical connections between the

Core Module and the PIB, and between
the PIB and the CSB.
2. Open the pump cover, and inspect the
pump.
Erroneous 1. Clean the printhead.

velocity 2. Check the diagnostics screen.
indication. 3. Compare the "actual velocity" with the
"velocity set point".
4. Change the Print Engine.
Ink Core Ink core

Empty module low
probe is
uncovered -
tank close to
empty or
empty
Pump Fault Pump near

max RPM &
pressure low
No Ink Core No data from

ink core smart
chip - ink core
not plugged in

Ink Core Ink core 40 hours Make preparations to change the Core.
Service Soon module very remaining on
(0.5% Left). near end of the Core Smart
service life Chip
Service Soon module remaining on
(2% Left) nearing end of the Core Smart
service life Chip.
Service Soon module remaining on
(5% Left) nearing end of the Core Smart
service life Chip
Product Compile time

Delay Too greater than
Short product delay.
Inter-print Insufficient
Gap Too time to
Short compile
between
prints.
Print Queue Too many

Too Deep products
between PEC
and printhead.
Print Overlap Print starts

before end of
current print.

No Time to Less than 10 The line speed Reduce the line speed, if possible
Phase milliseconds is too fast
from the end
of one print to
the beginning
of the next.
The distance Increase the distance between adjacent

between products, if possible.
adjacent
products is too
short.
The message Reduce the message length, if possible.

is too long.
The selected Reenter the message using a smaller font, if

font is too big. possible.
No Time for The printer is No phase 1. Observe "Diagnostics Screen One". Note
TOF unable to profile. the Phase Profile.
acquire an 2. If phase profile is not present (all zeroes),
"actual allow the printer to adjust the phase
velocity" and threshold to attempt to acquire a phase
thus cannot profile.
perform TOF 3. If the phase threshold is reduced to the
velocity minimum value and a phase profile still
control. has not been acquired, see causes and
perform actions under “Phase Threshold
Error” on page 9-17".
The printer is 1. Observe "Diagnostics Screen One". Note

unable to set the Phase Profile.
the modulation 2. If the phase profile is erratic (1's and 0's
automatically. present, but randomly), the modulation
value acquired automatically by the printer
may be erroneous.
3. Perform a visual inspection in the
printhead to confirm incorrect modulation
value.
4. Attempt to manually set the modulation to
restore break-off; monitor diagnostics
screen to assess status of automated
controls.
5. If modulation cannot be restored manually,
see causes and actions under “Phase
Threshold Error” on page 9-17.

Overspeed The message The current line 1. Reduce the line speed.
cannot be speed is too 2. If "Shaft Encoder Source" is Internal,
printed at the fast. adjust the width to obtain the desired
required width characters per inch.
The current 1. Increase the width setting.

width setting is 2. Test the print to see if the warning condi-
too low. tion gets cleared.
The "max 1. Edit the current message; examine the

printed dots" "max printed dots" parameter.
parameter is 2. Reduce the "max printed dots" to the
too high minimum allowable value.
The selected Create a new message - use a smaller font if

font is too this is feasible. Ensure that the "max printed
large. dots" is set to the minimum allowable value.
Maximum Print go
Print Rate received less
Exceeded than one
millisecond
from last print
go
No Valid Ink Ink core

Parameters module not
programmed
or invalid
values in
smart chip
Possible Ink Ink cartridge

Coefficient coefficients do
Update not match ink
core module
coefficients
USB External USB Defective, or Use a different USB flash drive

Connection device improper, USB
Is Over drawing flash drive.
Current excessive
current
Suspected Heater set to

Head Heater 100% for over
Failure one minute to
achieve set
temperature

Creating Software busy.

Raster Raster being
Catalog replaced.
Cannot print.
Bad Nozzle!!! Nozzle taking

Please excessive
Replace Or current -
Repair possible short
Tank Not Ink Core still

Filling LOW after
FIVE attempts
to add ink to
increase level
DAC Charge DAC

Overflow not operating
correctly -
CSB hardware
fault
DAC Comms Charge DAC

Error not operating
correctly -
CSB hardware
fault
Tuning Nozzle tuning Modulation Enable "Auto tuning".

Required is required and voltage about
the "Auto to adjust itself
Tuning" outside of the
function is control range
disabled. (0 - 200 VAC)

TOF Warning The "actual Erroneous TOF Clean and dry the printhead.
velocity" measurement.
deviates from
the "velocity
set point" by +/
- 1%.
Nozzle partially Perform a nozzle backflush.

obstructed.
Improper See actions above for "the printer is unable to

modulation set the modulation automatically".
setting.
Pump or See causes and actions above under

pressure "Pressure Too Low".
problem.
Service Due Printer The life of ink Replace the Core.

requires core module is
servicing. over
Valve error 1. Run a " Valve Test " and a " Hardware Self
Test " to try to determine which valve is
problematic.
2. If valve or valves are not functioning,
check electrical connections. Attempt to
clear any clogged valves.
3. If all the valves are functioning, check CSB
test points related to valves to identify
potential electrical issues. They are: TP 1
through TP16, TP30, TP68.

Voltage Checks
The Table 9-9 is a representation of the POWER connector with the
voltages shown for each pin. Use Pin 2 as the 0 V reference.
Power
Connector
Figure 9-2: CSB Power Connectors
Note: Allow ± 5% tolerance on all voltages except -24V which is allowed at

±10%. The power connector must be connected to the CSB to carry out this check.
PIN 4 PIN 8
-15V -24V
PIN 3 PIN 7
+5 V 0V
PIN 2 PIN 6
0V +24 V
PIN 1 PIN 5
+15 V +5 V
Table 9-9: CSB POWER Connector Voltage Check
Jet Start and Stop Diagnostics

Use the following flow charts to diagnose problems because of dirty inkjet
starts and stops.
9-34 Voltage Checks Rev AA

Quick Start Diagnostics
Visually inspect
nozzle alignment
print engine
and
ink
Figure 9-3: Quick Start Diagnostics Flowchart
Rev AA Jet Start and Stop Diagnostics 9-35

Clean Start Diagnostics
make-up
Clean the make-up Replace the PH

valve in the PH valve module
Back flush the nozzle
System flush prime

Refer to........
Sheet 1
9-36 Jet Start and Stop Diagnostics Rev AA

print engine
No
Is Break-up Yes
Back flush the nozzle Go to sheet 1
Symmetrical
Is the ink
No
drawn into the
gutter
Yes
print engine
Sheet 2
Figure 9-4: Clean Start Diagnostic Flowchart
Rev AA Jet Start and Stop Diagnostics 9-37

Clean Stop Diagnostic
make-up?
Flush the nozzle valve
PH valve module
Figure 9-5: Clean Stop Diagnostics
9-38 Jet Start and Stop Diagnostics Rev AA

CSB Test Points
Figure 9-6: Test Points 1 to 16
Rev AA CSB Test Points 9-39

The CSB test points are described in Table 9-10.
Test Name Test Equipment Measurement

Point Required
TP1 Valve Control Voltmeter Measure the voltage at TP1.

Common The voltmeter must read approximately 5VDC.
TP3 Valve 0 (Make- Voltmeter Measure the voltage at TP3.

up fluid add • A reading > 4 VDC indicates that the valve is
valve monitor) currently de-energized (shut).
• A reading < 1 VDC indicates that the valve is
currently energized (open).
TP4 Valve 1 (Gutter- Voltmeter Measure the voltage at TP4.

to-jet pump #2 • A reading > 4 VDC indicates that the valve is
TP5 Valve 2 (Gutter- Voltmeter Measure the voltage at TP5.

to-jet pump #1 • A reading > 4 VDC indicates that the valve is
TP6 Valve 3 (Flush Voltmeter Measure the voltage at TP6.

Pump Vacuum • A reading > 4 VDC indicates that the valve is
Valve Monitor) currently de-energized (shut).
TP7 Valve 4 (Flush Voltmeter Measure the voltage at TP7.

pump pressure • A reading > 4 VDC indicates that the valve is
TP8 Valve 5 Voltmeter Measure the voltage at TP8.

(drain valve • A reading > 4 VDC indicates that the valve is
monitor) currently de-energized (shut).
TP9 Valve 6 (Head Voltmeter Measure the voltage at TP9.

feed valve • A reading > 4 VDC indicates that the valve is
TP10 Valve 7(Head Voltmeter Measure the voltage at TP10.

flush valve • A reading > 4 VDC indicates that the valve is
Table 9-10: CSB Test Points
9-40 CSB Test Points Rev AA


Point Required

gutter valve • A reading > 4 VDC indicates that the valve is

purge valve • A reading > 4 VDC indicates that the valve is
TP13 Valve 10 - Not used
Table 9-10: CSB Test Points (Continued)
Figure 9-7: Test Point 17, 18, 19, and 63


Point Required
TP17 Photocell one Voltmeter Used to determine "Active state" of photocell.

Block the photocell with a product and measure
the voltage at TP17.
• A reading > 3VDC indicates that the photo-
cell is ACTIVE HIGH.
• A reading <.5VDC indicates that the photo-
cell is ACTIVE LOW.
TP18 Shaft encoder Oscilloscope Used to verify if the shaft encoder is supplying
one pulses to the printer.
1. Make sure that the encoder is connected to
the printer and start the conveyor.
2. Measure the signal at TP18. The following
output is considered to be good.


Point Required
TP19 Shaft encoder Oscilloscope Used to verify if the shaft encoder is supplying
two pulses to the printer.
1. Make sure that the encoder is connected to
the printer and start the conveyor.
2. Measure the signal at TP19.
Note: A signal will be present only if a
quadrature (two-phase) encoder is in use.
Figure 9-8: Test Point 20 and 21


Point Required
TP20 Pump tacho Oscilloscope Used to verify if the ink pump is turning when the
ink pump is energized.
TP21 Pump set Voltmeter Used to verify the analog signal provided by the
point FPGA to the pump driver circuit to set the
TARGET PRESSURE. 1 bar =.28 VDC.
TP22 Pump Voltmeter Measure the voltage at TP22 with a voltmeter.

enable A reading of 3.3VDC indicates that the CSB is
providing an ON signal to the pump motor driver.
+5V 5 VDC Voltmeter Used to verify if the filtered 5VDC level on the
(TP23) CSB.
Measure the voltage at TP23. Measured voltage
should be approximately +5VDC.
V FPGA core Used to verify the FPGA Core voltage on the

CORE voltage CSB. Measure the voltage at TP25. Measured
(TP25) voltage should be approximately +1.5VDC.
+12 +12 VDC Voltmeter Used to verify regulated +12 VDC produced on
ANAL the CSB. Measure the voltage at TP26. Measured
(TP26) voltage should be approximately +12VDC.
-12V -12 VDC Voltmeter Used to verify regulated -12 VDC produced on
(TP27) the CSB. Measure the voltage at TP27. Measured
voltage should be approximately -12VDC.
+24V +24 VDC Voltmeter Used to verify unfiltered +24 VDC provided to the
(TP28) CSB from the mains power supply. Measure the
voltage at TP28. Measured voltage should be
approximately +24VDC.
-24V -24 VDC Voltmeter Used to verify unfiltered -24 VDC provided to the
(TP29) CSB from the Mains power supply. Measure the
voltage at TP29. Measured voltage should be
approximately -24VDC.


Point Required
+22V 22V Pump Voltmeter Used to verify 22 VDC produced for the pump
(TP31) driver circuit. Measure the voltage at TP31.
Measured voltage should be approximately
22VDC.
TP38 Modulation Oscilloscope Used to verify output modulation signal supplied

MOD by the CSB to the nozzle. With inkjet running,
measure signal at TP38. The following picture
shows a good signal.


Point Required
TP41 Level probe Voltmeter or Used to verify the common electrical drive signal in
common Oscilloscope the Core (ink core module) level detection circuit.
• If a voltmeter is used, the voltage shall read 1.6
VDC.
• If an oscilloscope is used, a good signal will
look like the signal shown in the following
figure.
TP42 Level probe Voltmeter or Used to confirm whether the "high" sensor in the
0 (ink core Oscilloscope ink core module is covered or uncovered.
High) • If a voltmeter is used and the sensor is cov-
ered, a voltage of 1.6 VDC indicates that the
sensor is uncovered.
• A voltage <.7 VDC indicates that the sensor is
covered.
• If an oscilloscope is used, the following signal
indicates that the sensor is uncovered.


Point Required
TP43 Level probe Voltmeter or Used to confirm whether the middle sensor in the
1 (ink core Oscilloscope ink core module is covered or uncovered.
Middle) • If a voltmeter is used and the sensor is cov-
• A voltage <.7 VDC indicates that the sensor is
covered.
TP44 Level probe Voltmeter or Used to confirm whether the low sensor in the ink
2 (ink core Oscilloscope core module is covered or uncovered.
Low) • If a voltmeter is used and the sensor is cov-
• A voltage < 0.7 VDC indicates that the sensor
is covered.


Point Required
TP45 Gutter Voltmeter or Used to confirm the status of the gutter detect
sense Oscilloscope circuit.
• If a voltmeter is used and ink is present in the
gutter, voltage should read < 0.7 VDC.
• A voltage of 1.6 VDC indicates that the gutter
detect chamber is empty.
is expected if the gutter detect chamber is
empty.
TP47 Ink Voltmeter Used to verify the electrical output of the pressure
pressure transducer that monitors the ink pump output in the
Core. 1 bar = 0.8 VDC.
TP48 Vacuum Voltmeter Used to verify the electrical output of the pressure
transducer that monitors the vacuum in the make-
up fluid addition system in the Core Module.


Point Required
CHG Charge Amplifier Oscilloscope Use the oscilloscope to measure the signal
(TP51) at TP51.
When the ink stream is ON, and the printer
is not printing, ability to acquire the
following signal indicates that the charge
amplifier circuit is functioning properly.
HEADT Printhead Voltmeter Use the voltmeter to measure the signal at

(TP53) Temperature TP53. This represents the analog output of
the printhead temperature sensor. 0.055
VDC = 1° Celsius.
INKT Ink temperature Voltmeter Use the voltmeter to measure the signal at
(TP54) TP54. This represents the analog output of
the core temperature sensor. 0.055 VDC =
1° Celsius.
TP55 Strobe Oscilloscope Use the oscilloscope to measure the signal

at TP55. This represents the digital signal
used to drive the printhead strobe LED. A
good signal will look as follows.


Point Required
TP56 Printhead cover Voltmeter Use the voltmeter to measure the signal at
TP56.
• If the printhead cover is removed, the
measured voltage should be 3.3 VDC.
• If the printhead cover is fitted, the mea-
sured voltage should be < 0.5 VDC.
PHA Phasing Oscilloscope Use the oscilloscope to measure the signal

(TP57) at TP57. This represents the analog signal
being detected by the first TOF sensor in
the printhead. A good signal will look as
follows.

Point Required
3V3 3.3 VDC Voltmeter Used to verify the output of the 3.3 VDC
(TP62) voltage regulator (chip U44) on the CSB.
Measure the voltage at TP62. Measured
voltage should be approximately 3.3 VDC.
TP63 Photocell two Voltmeter Used to determine "Active state" of

photocell #2 ("Reverse Print Input").
Block the photocell with a product and
measure the voltage at TP17.
• A reading > 3VDC indicates that the
photocell is ACTIVE HIGH.
• A reading <.5VDC indicates that the
photocell is ACTIVE LOW.
TP68 Valve common Voltmeter Monitor during start-up sequence or valve

monitor test procedure to verify application of "hit"
voltage by valve driver circuit.


Point Required
TP69 Velocity Oscilloscope Use the oscilloscope to measure the

VEL signal at TP69. This represents the analog
signal being detected by the second TOF
sensor in the printhead. A "good" signal
will look as follows.

Point Required
+15V +15 VDC Voltmeter Used to verify unfiltered +15 VDC provided
to the CSB from the Mains power supply.
Measure the voltage at "+15V". Measured
voltage should be approximately +15VDC.
-15V -15 VDC Voltmeter Used to verify unfiltered -15 VDC provided
to the CSB from the Mains power supply.
Measure the voltage at "-15V". Measured
voltage should be approximately -15VDC.
TP30 V Valve drive hold Voltmeter Used to verify the onboard voltage
HOLD voltage generated and used to hold solenoid valves
open following actuation. Measure the
voltage at TP30. Measured voltage should
be approximately +6 VDC.
TP72 Charge supply Voltmeter Used to verify the negative output voltage
negative supplied by the Charge Amplifier Supply to
the Charge Amplifier.
voltage should be approximately -24 VDC.


Point Required
TP2 Hit drive Voltmeter Used to verify that the valve drive circuit is
being supplied with the correct electronic
signal to enable the application of "hit"
voltage when solenoid valves are actuated.
Measure the voltage at TP2.
• If the measured voltage is +3.3 VDC,
the "hit" circuit is turned off (this is the
steady-state condition).
• If measured voltage is 0 VDC, the "hit"
circuit is turned on (indicating that
valves are being opened).
TP76 Voltage Reference Voltmeter Used to measure the positive reference

VREFP Positive voltage provided to the DAC on the CSB.
voltage should be approximately +4.08
VDC.
TP77 DAC OUTPUT 6 Voltmeter
TP39 Modulation first Oscilloscope This test point allows for the measuring of
stage the first-stage modulation signal at the
output of chip U45. Measure the signal at
TP39 using an oscilloscope. A good signal
will look as follows.
VREFN Voltage reference Voltmeter Used to measure the negative reference

negative voltage provided to the DAC on the CSB.
Measure the voltage at "VREFN". Measured
voltage should be approximately -4.08 VDC.
TP71 DAC OUTPUT 7 Voltmeter


Point Required
MODV Modulation voltage Voltmeter The Modulation Voltage Monitor is an output

monitor of the modulation circuit used by the CSB to
track modulation voltage. Measure the
voltage at "MODV". Measured voltage
should be less than 2 VDC, and will change
as the automodulation routine is performed.
TP67 Modulation Power Oscilloscope TP67 allows for the measuring of the
Amplifier modulation sine wave on the primary side of
Transformer the modulation power amplifier transformer.
Primary Measure the signal at TP67 with an
oscilloscope. A good signal will look as
follows.
TP37 Modulation Power Oscilloscope Same as TP67, except TP37 is located on

Amplifier the opposite side of the transformer.
Transformer Measure the signal at TP37 with an
Primary oscilloscope. A good signal will look as
follows.


Point Required
TP24 EHT Setpoint Voltmeter Allows for the measurement of the signal
being provided to the EHT circuit to
establish the EHT voltage.
Measure the voltage at TP24.
1. A voltage between 0 and +24 VDC will
be measured, depending upon the cur-
rent “Character height”.
2. Vary the “Character height” and check to
make sure that the voltage at TP24 var-
ies accordingly.
TP 40 Modulation Current Voltmeter The Modulation Current Monitor is an output

MODI Monitor of the modulation circuit used by the CSB to
track modulation current. Measure the
voltage at TP40. Measured voltage should
be less than 1 VDC, and will change as the
automodulation routine is performed.
TP65 Modulation Data Oscilloscope TP65 allows for the monitoring of the data
signal supplied by the FPGA to the
modulation circuit. Measure the signal at
TP65 with an oscilloscope. A good signal
will look like this.


Point Required
TP66 Modulation Clock Oscilloscope TP66 allows for the monitoring of the clock
signal supplied by the FPGA to the
modulation control circuit.
Measure the signal at TP66 with an
oscilloscope. A good signal will look like the
following figure.
TP58 Phasing Signal Oscilloscope This test point allows for the monitoring of
Amplified the processed phasing signal downstream
of chip U14 on the CSB. Measure the signal
at TP58 with an oscilloscope. A good signal
will look like the following figure.


Point Required
TP59 Velocity Signal Oscilloscope This test point allows for the monitoring of
Amplified the processed velocity signal downstream of
chip U15 on the CSB.
Measure the signal at TP59 with an
oscilloscope. A good signal will look like the
signal shown in the following figure.
TP60 Phasing trigger 'A' Oscilloscope This test point allows for the monitoring of
the trigger signal supplied by chip U16 to
the FPGA. Measure the signal at TP60 with
an oscilloscope. A "good" signal will look
like this:


Point Required
TP61 Phasing trigger 'B' Oscilloscope This test point allows for the monitoring of
the trigger signal supplied by chip U16 to
the FPGA. Measure the signal at TP61 with
an oscilloscope. A good signal will look like
this.
TP50 HV Charge Supply Voltmeter Used to verify the positive output voltage
Positive supplied by the Charge Amplifier Supply to
the Charge Amplifier. Measure the voltage
at TP50. Measured voltage should be
approximately +312 VDC.

Installing DNW
1 When the CSB device is connected to a PC for the first time you will be
prompted to install drivers. Choose C:\500051\Installers\USB
Driver\secbulk.inf.
2 To configure the software, select Options under the Configuration
menu:
Figure 9-9: Configure Menu
3 Change the download address to 0x3020000.
Figure 9-10:
4 Click OK button.
ADC/DAC
This test checks that the ADC device can be accessed and the cabinet
temperature is less than 60 ºC.
Ancillary
This test does the following checks:

• Checks a standing current through the beacon current input is in

range.
• Checks the current drawn when switching dummy loads with the
ancillary switch (head heater, cabinet fan, and air pump outputs).
• Checks for fixed voltages on the head temperature [2.47, 2.90] and ink
temperature [1.93, 2.34] sensors.
• Turns the LED strobe off and checks the gutter is dry (square wave
present).
• Turns the LED strobe on and checks the gutter is wet (square wave
not always present).
• Turns VALVEDRIVE_5 off and checks the cover switch is open (input
high).
• Turns VALVEDRIVE_5 on and checks the cover switch is closed
(input low).
• Checks the ink bottle smart chip memory starts with the string “INK”.
• Checks the solvent bottle smart chip memory starts with the string
“SOL”.
• Checks the ink core module smart chip memory starts with the string
“MIX”.
• Checks the CSB smart chip is present.
Charge Amplifier Supply

• Checks that the charge amplifier supply (test point HV+) is initially
about 20V and the switching FET (Q8) is inactive.
• Turns on the charge amplifier supply (sets a charge scale not equal to
zero) and checks the supply is now about 310V and the switching FET
is active.
Charge Amplifier
• Writes and reads all bits of the charge DAC to test the interface
between it and the FPGA.
• Sets the charge scale to full (0x3FF would give 409.6 V output, if the
supply were that high).

• Attempts to move the charge output up and down using the charge
and phase offset registers (one bit of charge offset = 0.4 V positive,
phase offset same but negative) until it is within the range ±1 V.
• Checks that increasing the phase offset moves the output negative by
0.4 V.
• Checks that increasing the charge offset moves the output positive by
0.4 V.
• Halves the charge scale.
• Re-establishes the charge output within the range ±1 V.
• Checks that the output moves by 0.2 V when the charge offset is
increased by one bit.
SRAM
This test checks writes sixteen random values to the SRAM at each single
address bit transition (0, 16, 32, 64, 128...) then reads and checks all values
are correct.
EHT
• Checks for a fixed voltage on EHTVMON [2.41, 3.04].
• Checks for a fixed voltage on EHTIMON [1.83, 2,61].
• Ramps the EHT setpoint into a fixed load and checks the measured
current is correct.
Levels/Pressure/Vacuum
• Checks for a fixed voltage on the pressure signal [2.15, 2.63].
• Checks for a fixed voltage on the vacuum signal [2.68, 4.10].
• Switches on only VALVEDRIVE_6, 7 and 8 in turn and checks that
only level sensor INK1, 2 then 3 is shorted respectively.

Modulation
This test ramps the modulation into a fixed load and checks the measured
voltage and current are correct.
Phase Detector
• Checks for a fixed voltage on the phase detector input [2.75, 3.85].
• Checks for a fixed voltage on the velocity detector input [0.91, 2.15].
• Sweeps the phase and velocity thresholds from below to above these
fixed voltages to check the comparators work.
Pump
This test runs the pump driver (using the RELAY4-6 outputs to emulate
rotation on the Hall sensor inputs) into a dummy load and checks the
current drawn is correct and the TACHO output matches the Hall sensor
inputs.
Valves
Turns on VALVEDRIVE_9 to VALVEDRIVE_13 only in turn and checks
the valve driver current is within range.
DIN Interface
• Checks for connections between the following beacon drive and PEC/
SENC signals.
Beacon Drive PEC/SENC Signals
Green PEC1
Amber SENC2
Red SENC1
Strobe PEC2

• Checks for connections between the following relays, valves and

message select signals.
VALVEDRIVE_0 MSEL0
VALVEDRIVE_1 MSEL1
VALVEDRIVE_2 MSEL2
VALVEDRIVE_3 MSEL3
VALVEDRIVE_4 MSEL4
RELAY1 MSEL5
RELAY2 MSEL6
RELAY3 MSEL7
• Checks for connections between the following signals.
RELAY1 RELAY7
RELAY2 PELTEMP_D
RELAY3 PELTEMP_C
Manual Tests
This test sets the modulation up as a 250Vpp 76.8kHz sine wave and a
300V high staircase waveform on the charge and asks the user to check
them on the scope.
The user is then asked to turn the board off and check the bleed valve
holdup circuit works by checking the brightness of the BLEED LED on the
test box.

Illustrated Parts List
10
The Illustrated Part List (IPL) contains the illustrations and the parts lists
for the different assemblies in the printer. The parts lists give the part
numbers, description and quantity of all the items and the modules in the
printer. You can order the items and the modules for which the part
numbers are given.
How to Read the IPL

This section describes how the higher assemblies are broken down to their
related sub assemblies and other separate parts.
Illustrations
Table 10-1 on page 10-2 shows the symbols used to indicate the different
levels of main assemblies in a printer, and the sub assemblies under the
main assembly.
Rev AA How to Read the IPL 10-1

Assembly Symbol
Main Assembly
Sub Assembly 1
Sub Assembly 2
Sub Assembly 3
Sub Assembly 4
Table 10-1: Symbols Representation - Assemblies
Indicates further explosion.
Alphabets
• An alphabet is assigned to the main assemblies of a printer and each
sub assembly under the main assembly. See Figure 10-1 on page 10-3.
For example: If A, B, C and D identify the main assemblies of a
printer, then the alphabets E,F, and so on identify sub assemblies
below each main assembly in a sequence.
• The alphabets assigned to main assemblies are used only for one time.
• The alphabets “I” and “O” are not used because they look like the
numbers 1 and 0.
10-2 How to Read the IPL Rev AA

Numbers
A natural number (1,2,3.....) is assigned to the stand alone parts (in
ascending order) through out the breakdown of main assemblies. See
Figure 10-1.
Note: The numbers assigned to main assemblies can be used only for one time.
Printer
A B C D
E F 1 E F G E F G 1 2 3
H J 2 1 2 3
3 4 5 6
Figure 10-1: Graphical Representation of the Different Subassemblies and Parts
Rev AA How to Read the IPL 10-3

Tables
Figure 10-2 describes the styles used to show the explosion of the main
assemblies in parts lists.
Main Assembly
Subassembly 1
Subassembly 2
Parts under the

Subassembly OR
Stand-alone Part
Figure 10-2: Representation of the different Subassemblies and parts

in the Table
Notes
Notes provide useful information. Some examples for note are as follows:
Note: To order this item, use part number of item 9 in this table.
Note: This screw is a part of Core Module.

Note: This item can be ordered separately.
10-4 How to Read the IPL Rev AA

Videojet 1510 Printer
Figure 10-3: Main Parts of the Printer
Table 10-2 shows the sub assemblies of the printer.
Item Descriptions
A Electronics Compartment
B Ink Compartment
C Umbilical
D Printhead
Table 10-2: Videojet 1510 Printer Assemblies
Rev AA Videojet 1510 Printer 10-5

Electronics Compartment
E
A
2
F
View A
1 View A
H
K
J G
Figure 10-4: Electronics Compartment

Figure 10-5: Control System Board Assembly
Power Switch
2
Figure 10-6: Power Switch

Electronics Door Assembly
E M
N 6
3
4
5 7
8
Figure 10-7: Electronics Door Assembly
Display Door
10
M 11
12
13
15
14
Figure 10-8: Display Door

LCD and FIB Assembly
16
N
17
Figure 10-9: LCD and FIB
Power Supply Unit Assembly
F 18
19
20
21
22
Figure 10-10: Power Supply Unit Assembly

Printer Interface Board Assembly
G 23
24
25
26
Figure 10-11: Printer Interface Board Assembly

Electronics Fan Assembly
H
27
28
29
30
31
32
Figure 10-12: Electronics Fan Assembly
Positive Air Pump Assembly
J
33
34
35
Figure 10-13: Positive Air Pump Assembly

EHT Module
K
36
37
Figure 10-14: EHT Module
Connector Panel
L
38
39
40
42 41

PCB 2 Assembly
39
Figure 10-16: PCB 2 Assembly
PCB 1 Assembly
40
Figure 10-17: PCB 1 Assembly

Item Number P/N Description Qty
A Electronics Compartment
1 500074 Control System Board (CSB) 1

2 219041 Power Switch 1
E Electronics Door Assembly
3 Membrane Ground Wire 1

4 M4 Nyloc Nut 1
5 M4 ET Washer 2
6 Display Ground Wire 1
7 Display Rear Cover 1
8 K40 x 10 Pan-head Torx Screw 4
9 M4 x 10 Cap-head Screw 1
M 399116 Display Door with Keypad (English)
10 Display Gasket 1
11 Display Front Moulding 1
12 Keypad Standard 1
13 VJC Membrane 1
14 M4 Washer 2
N 399091 Liquid Crystal Display and Front Panel

Interface Board Assembly
17 LCD and FIB Assembly 1
F 399077 Power Supply Unit (PSU)
18 PSU 1
19 PSU Mounting Plate 1
20 M3 ET Washer 4
Table 10-3: Electronics Compartment

22 M4 Nyloc Nut 2
G 399078 Printer Interface Board (PIB) Assembly
24 M4 ET Washer 6
25 PIB 1
26 PIB Gasket 1
H 399079 Electronics Fan Assembly
27 Fan, 60 mm 1
28 M4 ET Washer 2
30 Finger guard, 60 mm 1
31 M4 Nyloc Nut 2
32 M4 x 16 Counter Sunk Screw 2
J 500084 Positive Air Pump Assembly
33 Positive Air Pump 1

34 P-Clip 1
35 M4 Nyloc Nut 2
K 399081 EHT Module Assembly
36 M4 Nyloc Nut 2
37 EHT Module 1
L Connector Panel
38 500096 PCB 3 Assembly 1

41 399084 USB Connector 1
42 399083 Ethernet Connector 1
Table 10-3: Electronics Compartment (Continued)

Ink Compartment
F
Figure 10-18: Ink System
Ink Cartridge
Figure 10-19: Ink Cartridge

Make-up Cartridge
Figure 10-20: Make-up Cartridge
Ink Door Assembly
Figure 10-21: Ink Door Assembly

Septum Assembly
N
10
9
8
6
5
4
Figure 10-22: Septum Assembly

Ink Core Module Assembly
12
F 11
Figure 10-23: Core Module

Ink Core Pump
L 13
14
15
Figure 10-24: Ink Core Pump Assembly
M
19
18
17
16
Figure 10-25: Ink Core Module Without Pump

Gutter Pump Assembly
20
21
Figure 10-26: Gutter Pump Assembly
Ink System Fan
H
22
23
24
25
Figure 10-27: Ink System Fan Assembly

Ink System Filter Assembly - IP65
26
27
Figure 10-28: Ink System Filter Assembly - IP65
Ink System Filter Assembly - IP55
28
29
Figure 10-29: Ink System Filter Assembly - IP55

Floor Filter IP65
K 30
31
32
33
34
35
Figure 10-30: Floor Filter IP65

Floor Filter IP55
36
37
38
39
40
Figure 10-31: Floor Filter IP55

Air Filter
41
Figure 10-32: Air Filter
1 Ink Cartridge 1
2 Make-up Cartridge 1
E 399071 Ink Door Assembly
3 Hinge Pin 1
N 399073 Septum Assembly

5 M3 ET Washer 2
6 Tube and Ribbon Cable Clamp 1
8 Black Stripe Tube (Ink System) 1
9 Septum 2
10 Green Stripe Tube (Make-up System) 1
Table 10-4: Ink Compartment

F 399069 Ink Core with Pump
11 Ink Core Pump Cover 1

L 399076 Ink Core Pump
14 Saddle Clamp 1
15 Ink Core Pump 1
M 399070 Ink Core Module without Pump
16 M3 x 7 Manifold Screw 2
17 Ink Core Manifold (Male) 1
18 Ink Core Manifold Gasket 1
19 Ink Core Manifold (Female) 1
G 399171 Gutter Pump Assembly
20 M4 Nyloc Nut 2
21 Gutter Pump and Valve 1
H 399080 Ink System Fan Assembly
22 M4 ET Washer 4
24 Fan 1
25 Fan Guard 1
J Ink System Filter Assembly
399238 IP65
26 Filter Element 1
27 Filter Cover 1
399239 IP55
28 Filter Element 1
29 Filter Cover 1

K Floor Filter Assembly
Refer to Ink System IP65

Filter Assembly - IP65
31 Ink Core Support Channel 1
32 Filter Element 1
33 Filter Clamp 1
35 Drip Tray 1
Refer to Ink System IP55
Filter Assembly - IP55
37 Ink Core Support Channel 1
38 Ink Side Filter Top 1
39 Ink Side Filter Base 1
40 Filter Element 1
41 Refer to Table 10-3 on Air Filter 1
page 10-14 - Positive
Air Pump Assembly

Printhead
D E
Figure 10-33: Printhead
E
2
7 4

Print Engine
8
F
9
10
11
15
14
12
13
D Printhead
E 399181 Printhead Valve Module 1
2 Gutter Valve 1
3 Printhead Valve Module Deck 1
4 Printhead Valve Module Gasket 1
5 Feed Valve 1
6 Rear Manifold Gasket 1
7 3 Way Manifold Assembly (Rear Tubing 1

Manifold)
F 399180 Print Engine
Table 10-5: Printhead Assembly

9 Nozzle Assembly 1
10 Charge Electrode 1
11 Deflector Plate 1
12 Print Engine Deck 1
13 Print Engine Gasket 1
14 Front Tubing Manifold Gasket 1
15 2 Way Manifold Assembly (Front Tubing 1

Manifold)
Cables
3 2
1
Figure 10-36: Cables
1 500072 Ribbon Cable Assembly Display 1
2 399052 Ribbon Cable Assembly Smart Chip and 1

Pump 14 Way
3 500078 50 Way Ribbon Cables 3
Table 10-6: Cables
10-30 Cables Rev AA

Optional Accessories
Beacon Assembly
Figure 10-37: Beacon Assembly
Rev AA Optional Accessories 10-31

Dry Air Kit Assembly
4
5
6
Figure 10-38: Dry Air Kit Assembly
10-32 Optional Accessories Rev AA

Static Stand
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Figure 10-39: Static Stand

Mobile Stand
24
25
26
27
28
37
36
35
29
30
31
32
33
34
Figure 10-40: Mobile Stand

Printhead Stand
38
39
49
40
41
42
43
44
48 45
47
46
Figure 10-41: Printhead Stand

Printer Wall Mount
50
51
52
53
Figure 10-42: Printer Wall Mount
399089 Beacon Assembly
1 Beacon 1
2 M4x10 Socket-head Cap Screw 3
3 Beacon Mounting Bracket 1
399090 Stealth Air Dryer Assembly
4 Stealth Air Dryer Mounting Bracket 1
5 M4 Nylon Washers 2
6 M4 x 10 Socket-head Cap Screw 3
7 Stealth Air Dryer 1
8 1/4 inch-20 x 1 inch Socket-head Screw 2

399099 Static Stand
9 M6 x 16 Long Flat Socket-head Screw 4
10 Adapter Plate 1
11 M5 Flat Washers 4
12 M5 Spring Lock Washers 4
13 M5 x 20 Long Socket-head Screw for IP55 Printers (or) 4

M5 x 30 Long Socket-head Screw for IP65 printers
14 Column Top Plate 1
15 M6 Flat Washer 4
16 M6 Spring Lock Washer 4
17 M6 Hex Nut 4
18 Column 1
19 Cap-head Hex Screw, 1/4” x 20 UNC x 0.625 4
20 Flat Washer 4
21 Column Bottom Plate 1
22 Floor Plate 1
23 3/8” - 16 Flat Point Socket-head, 1” Long 4
399100 Mobile Stand
24 M6 x 16 Long Flat Socket-head Screw 4
25 Adapter Plate 1
26 M5 Flat Washer 4
28 M5 x 20 Long Socket-head Screw for IP55 Printers (or) 4

M5 x 30 Long Socket-head Screw for IP65 Printers
29 Column 1
30 Acorn Hex Nut 2
31 Flat Washer 4
32 Castors 4
33 Legs 2

34 Hex-head Bolt 2
35 M6 Hex Nut 4
37 M6 Plain Washer 4
399086 Printhead Stand
38 Clamp Assembly 1
39 Vertical Tube 1
40 Printhead Cross Tube 1
41 Printhead Mount Assembly 1
42 M6 x 8 Grub Screw 2
43 M10 Nut 8
44 M10 Washer 8
45 Stand Base Plate 1
46 M16 X 40 Hex Bolt 1
47 Adjustable Foot 4
48 399093 Anti-vibration Mounting 4
49 Umbilical Clamp Assembly 1
399201 Printer Wall Mount
50 Wall Mounting Stand 1
51 Stand Cups 4
52 Clamp Washer 4
53 M5 x 30 Socket-head Screw or M5 x 20 Socket-head 4

Screw

Tools Kit
There are several tool and spare parts kits consisting of normal
maintenance items for the Videojet 1510 printer.
The Service Tool Kit

Table 10-8 lists the service tool kit items and their part numbers.
Description Qty
7 mm Nut Driver 1
#2 Phillips Screwdriver 1
Screwdriver 1
Nr.2 posidrive 1
Nr.2 posidrive 1
Side Cutters 1
3/16” Allen Wrench 1
Open-ended Wrench 1
3 mm Allen Wrench 1
4 mm Allen Wrench 1
2.5 diameter x 100 mm pin 1
Light Hammer 1
Sharp Knife 1
Adjustable Pipe Pliers (to hold and tighten ring nut on switch) 1
Adjustable spanner or pipe pliers to give minimum 33A/F 1
Crimp Pliers 1
2.5 D x 100 mm Long Pin (to knock the hinge pin out) 1
Table 10-8: Service Tool Kit Parts List
Rev AA Tools Kit 10-39

Description Qty
7 mm Spanner 1
10 mm Spanner 1
9/16 inch Spanner 2
13 mm Spanner 1
17 mm Spanner 1
24 mm Spanner 1
1/2 inch Spanner 2
14 mm Masonry Drill 1
Flow Meter (P/N 356230) 1
Spirit Level 1
Table 10-8: Service Tool Kit Parts List
10-40 Tools Kit Rev AA

Tools and Spare Part
Kits 11
Tools
Basic Start Up Kit

The basic start up kit (P/N 378232) includes the following:
Description Part Number
Safety glasses 28000035
Squeeze bulb 21000170
Wash bottle, 250cc 202047
Latex gloves 209953
Hand cleaner SP212321
Cleaning pan, steel 217035
Magnifier loupe 355269
Service Tool Kit

The Service tool kit (P/N 378228) consists of the following.
Pipe pliers 5260001115
Tube cutter 5260001112
Nut driver set 5260001118
Allen hex driver set 5260001119
Pozi drive screwdriver #1 5260001108
Pozi drive screwdriver #0 5260001116
Nozzle adjusting tool 1000370224
Manifold flush block 200-0466-247
Knife, retractable 217043
Rev AA Tools 11-1

Ultra sonic bath 5260001120
Reverse action tweezers 5260001107
Syringes, with slip tips 5000118001
Wrench, open end, 8mm x 10 mm 526-0001-124
Din socket wrench 526-0001-123
IC removal tool, mini-fit 526-0001-113
Pump priming adapter 2000466246
Filler cup wrench 100-043S-193
Electronics compartment key 500-0048-133
Printhead cleaning station 378337
Blow bulb 21000170
Serial download cable 80200258
EHT trip tool 100-0370-265
EHT printhead cover 100-0370-264
Tubing, 1/4 O.D. cobothane, 3.5 ft 251410
Magnifier, illuminated 3.5x 203023
Other Tools
Additional tools that may be useful for service personnel include the
following:
• a laptop computer with Windows NT 4 or greater installed
• standard field service tools, including a DVM and oscilloscope
11-2 Tools Rev AA

Spare parts kits
Comprehensive Spare Parts Kit

The comprehensive spare parts kit (P/N 378231) contains the following:
Basic spare parts kit 378230
CPU board 200-043S-166
PSU 200-0390-102
I/O board 200-0430-260
EHT Module 200-0390-239
Pressure transducer 378254
Pressure transducer O-ring, front 500-0031-164
Pressure transducer O-ring, back 500-0031-201
System manifold 100-0370-200
Phase detector assembly 200-3900-298
Charge electrode assembly 200-3900-135
22 Meg EHT resistor 522-0080-226
Ink Core sensor kit 378269
Rev AA Spare parts kits 11-3

Clean/Quick Start and
Stop Description A
Clean Start/Stop Standards
The following illustrations show the minimum acceptable standards for
clean start and clean stop. Compare these to samples obtained by placing a
sheet of blank paper directly under the printhead.
(samples are
shown actual size)
Typical clean
start-up/shutdown
Typical dirty
start-up/shutdown
Minimum standard
required
Figure A-1: Clean Start/Stop Test Illustrations
Rev AA Clean Start/Stop Standards A-1

Clean Start
This method starts on flush (pure solvent) in order to dissolve any ink
residues in the jet orifice. It then bleeds on flush to remove air from the
nozzle before switching to ink, eliminating ink splash and spray during
start-up.
The Clean Start Jet Sequence is as follows:
1 The solvent from the filter is forced through the umbilical connection
into the printhead.
2 At the printhead, the solvent enters the heater manifold and passes
into the main fluid path between the jet valve and the nozzle.
3 The jet starts when the nozzle becomes pressurized by the solvent
flow.
4 If the previous stop was a clean stop, the jet will consist of almost pure
solvent. The flow of solvent quickly removes any ink residues in the
jet orifice.
5 Fluid in the jet is caught by the gutter and directed to the ink core.
6 Approximately ten seconds after the flush pump switches off, the
bleed valve closes and ink continues to flow through the jet at 4 bar.
7 Modulation is switched on and the ink pressure changes to give the
correct jet velocity.
8 Heater manifold temperature is allowed to reach the correct value
before enabling the phasing checks on the jet.
Quick Start
This method starts without a flushing sequence, and uses the ink supply
to bleed air from the nozzle.
Clean Stop
This method switches from ink to flush in order to purge the nozzle. This
method allows time for the manifold, nozzle and jet orifice to be purged of
ink before stopping the jet.
The Clean Stop Jet Sequence is as follows:
1 Deflector plate voltages are switched off before beginning this
sequence.
A-2 Clean Start Rev AA

2 The ink pressure is set to 4 bar and the modulation voltage switches
off.
3 To increase the ink flow through the nozzle body, the bleed valve
switches on.
4 The flush pump valve switches on applying solvent pressure to the
printhead.
5 Pure solvent is forced through the filter to the printhead mixing
solvent into the ink stream in the heater manifold.
6 Approximately one second after the solvent starts to mix with the ink,
the feed valve (V6) in the cabinet switches off, removing ink pressure
from the printhead.
7 Ink ceases to flow into the heater manifold and the solvent flushes ink
from the nozzle body.
8 Five seconds later the bleed valve switches off and then switches on
again, introducing solvent into the jet valve, which inhibits ink
residues forming whilst the machine is switched off.
9 The jet valve (on the heater manifold) switches off, ensuring that no
ink diffuses into the solvent. At this point, no ink should be present in
the nozzle body.
10 The gutter valve switches off, increasing the suction on the bleed
system. After a short pause, the bleed valve switches off.
11 After another short pause, the gutter valve switches on to clear any
fluid from the gutter.
12 Once the gutter valve switches off, the main ink pump also switches
off.
Quick Stop
Note: This sequence is used to manually stop the jet for a short period, or to
automatically stop the jet during an EHT trip, charge error, etc.
This method switches off the ink without flushing the nozzle or manifold.
Hence the manifold and the nozzle are full of ink when the jet stops. The
machine must not be left in this state for long periods, as drying ink in the
jet orifice may make restarting difficult. This procedure is primarily
intended for situations where the machine may be stopped and restarted
several times in quick succession. Under these conditions, the use of
solvent may become excessive and cause dilution of the ink.
Rev AA Quick Stop A-3

Nozzle Flush
When Nozzle flush is selected, the vacuum from the venturi is applied to
the return side of the nozzle, creating suction at the nozzle orifice. Solvent
is applied to the nozzle orifice to clear any blockage.
Nozzle flush will automatically time out after 2 minutes but can be
stopped at any time before that by pressing F1 key Abort Flush.
A nozzle flush can be started with the jet running or stopped. If the jet is
running, selecting Nozzle flush will first of all de-energize feed valve V6
to stop the flow of ink to the nozzle.
A-4 Nozzle Flush Rev AA

Encoder Information
B
Internal Encoding
This is used when product speed is constant. An internal clock sets the
stroke-rate to a constant pace. Refer “When to Use Internal Encoding” on
page B-1, for more information about internal encoding.
When to Use Internal Encoding

Internal coding is used when the product speed is constant. The internal
clock of the printer is set to the speed of the product in feet per minute
(FPM) or meters per minute (MPM)
Note: Internal encoding is also used when test printing a sample message. For
information on test printing a sample message, refer to...
It is necessary to determine the product speed. Below are four methods

that can be used to determine the product speed.
Rev AA Internal Encoding B-1

Method 1
Use a handheld tachometer that is calibrated to measure linear surface
speed in FPM or measure the revolutions per minute of the pulley.
Convert RPM to surface speed by using the following formula
Surface speed (FPM) = [Πd x (RPM)]/12
where Π = 3.14
where d = pulley diameter in inches
Method 2
Establish a reference mark on the conveyor belt and measure how many
inches (one inch equals 25.4 mm) this mark moves in 5 seconds. This
number is equal to the conveyor speed in FPM
Method 3
If you know the number of products produced per minute on the line, the
size of the product, and the gap between each product, you can calculate
the product speed.
For example:
1200 products per minute are produced on the line, each product is 2.5
inches wide, and there is a one inch gap between each product.
Conveyor speed = [(products per minute) x (size + gap)]/12
where size and gap are in inches
Method 4
It is also possible to use the printer’s product counter to determine the
number of products per minute, and then calculate the line speed as
shown in “Method 3”.
External (Reduce Or Direct) Encoding

A shaft encoder is used when the speed of the conveyor varies. Shaft
encoders may either be direct coupled or divided-down:
• A direct encoder maintains a 1:1 ratio between the encoder
pulses and print strokes.
• A divided-down encoder is used when the conveyor speed
requires fewer pulses than the actual output of the shaft encoder.
The following are the three methods to do encoding:
This is used when product conveyor speed is not constant. A shaft
encoder must be used with this selection. The shaft encoder monitors
B-2 External (Reduce Or Direct) Encoding Rev AA

changes in conveyor speed and varies the stroke rate accordingly. Select
REDUCE if the encoder rate input must be electrically divided down for
use. Select DIRECT if the encoder input can be used without dividing.
Refer “When to Use External Encoding” on page B-3, for more
information about external encoding.
When to Use External Encoding

External coding is used when printing is required when the speed of the
product and conveyor changes. In this case, a shaft encoder is required.
The shaft encoder is coupled to the conveyor at a point where the selected
conveyor shaft and the conveyor are turning together. The shaft encoder
will provide either one pulse or many pulses (which are mathematically
divided) for each vertical stroke of the message.
d = distance of conveyor (product) travel per revolution of shaft

Figure B-1: Product Distance
Required shaft encoder:

Pulses per Revolution (PPR) = d x (strokes per inch)
Where strokes per inch = (strokes per character) x (characters per inch)
Example 1
Given information:
d = 23 inches
5 x 7 matrix
10 characters per inch
6 strokes per character
(five printed strokes from the 5 x 7 character, plus one “guard” stroke that
leaves a space between the characters.)
23 inches per revolution x 60 strokes per inch = 1380 PPR
Rev AA External (Reduce Or Direct) Encoding B-3

Example 2
If the standard 1800 PPR shaft encoder is to be used as shown in Example
1, it will be necessary to provide some type of gearing to supply the
required 60 pulses per inch as shown in Figure B-2.
Figure B-2: External Shaft Encoder

To determine the required gearing, the following method is used.
1800 PPR/1380 PPR = 1.3 or 1:3:1 gear ratio
2 1
1. Pulley b
2. Pulley a
Figure B-3: External Shaft Encoder - With Pulley
If the diameter of “a” = 2.0 inches, then the diameter of “b” is 2.6 inches
(2.0 inches x 1.3 = 2.6 inches). For one rotation of “a”, 1380 pulses are
produced from the 1800 PPR shaft encoder.
If that same 1800 PPR shaft encoder is connected directly to the shaft on
the conveyor, the calculation would be as follows:
(1800 pulses per revolution)/(23 inches per revolution) = 78 pulses per
inch
(78 pulses per inch) / (6 strokes per character) = 13 characters per inch
Since the standard calls for 10 characters per inch (refer to Example 1), the
message would be compressed on the product.
B-4 External (Reduce Or Direct) Encoding Rev AA

Auto Encoding
This is used when the product speed varies from that of the conveyor
(product slippage). With this selection, the signal from the product
detector is used to determine product speed. Refer “When to Use Auto
Encoding” on page B-5, for more information about auto encoding.
When to Use Auto Encoding

Auto Encoding is used when the speed of the product is changing due to
slippage on the conveyor or when the product is allowed to fall through
guides from one level to another.
When set for Auto Encoder, the printer will determine the speed of each
individual product, and then code that product at a set stroke rate. The
printer needs a product detector installed in order to work with auto
encoding. In addition, the length of the detect area (the amount which the
detector senses) must be known and entered into the printer.
Product
Motion
Product Detect Jumper Set

for Negative Edge Trigger
Product
No Product
{
Pulse Width = Product Speed

Detector Signal
Figure B-4: Auto Encoding
Example 1
Given information:
Detect area = 5 inches (127 mm)
Pulse width of this product = 0.1 seconds
Then, Product speed = 5 inches/0.1 seconds = 50 inches per seconds
(127.0 mm/0.1 s = 1270.0 mm/s)
Rev AA Auto Encoding B-5

(50 inches per second x 60 seconds per minute)/(12 inches per feet) = 250
FPM
(1270 mm/s x 60 s/minute)/1000 mm/m = 76.2 MPM
B-6 Auto Encoding Rev AA

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Videojet 1510

Videojet Technologies Inc.

For Customers in the U.S.A.

For Customers in Canada

Pour la clientèle du Canada

The Total Source Commitment

For more information on Customer Training Courses, call 1-800-843-3610

Support and Training

Chapter 3 — Main Parts

Perform Umbilical Purge and System Flush Purge . . . . . . . . . . 4–14

Chapter 5 — Printer Operation

Chapter 6 — User Interface

Chapter 7 — Replacement Instructions

LCD and FIB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13

How to Install the New Power Switch . . . . . . . . . . . . . . . . . . . . . 7–79

How to Remove the Old CSB Lithium Battery . . . . . . . . . . . . . 7–115

Keypad Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5

Chapter 10 — Illustrated Parts List

Connector Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–12

Chapter 11 — Tools and Spare Part Kits

Appendix A — Clean/Quick Start and Stop Description

Appendix B — Encoder Information

About the Manual

Rev AA Videojet 1510 Printer 1-1

Code Language Availability (see note)

Table 1-1: List of Language Codes - 1510

1-2 Related Publications Rev AA

The Word ‘Printer’

Rev AA Content Presentation 1-3

User Interface Terminology

Figure 1-1. Menu Screen

Key Style Used

Left arrow key

Table 1-2: Content Presentation Style for Keys

1-4 Content Presentation Rev AA

Key Style Used

Right arrow key

Down arrow key

Table 1-2: Content Presentation Style for Keys

Rev AA Content Presentation 1-5

Abbreviations and Acronyms

CSB Control System Board

DMM Digital Multi Meter

DVM Digital Volt Meter

EHT Extra High Tension

FPGA Field Programmable Gate Array

IEC International Electrotechnical Commission

LED Light Emitting Diode

LCD Liquid Crystal Display

PCB Printed Circuit Board

PIB Printer Interface Board

PSU Power Supply Unit

QVGA Quarter Video Graphics Array

SoC System on Chip

SRAM Static Random Access Memory

USB Universal Serial Bus

VDC Volts of Direct Current

WYSIWYG What You See Is What You Get

FIB Front Panel Interface Board

Table 1-3: Abbreviations and Acronyms