5750-212 Revision A Page 1 5750-212 Revision A I.V./700 Ink Jet Printer Service Manual The information contained in this manual is correct and accurate at the time of its publication. Diagraph reserves the right to change or alter any information or technical specifications at any time and without notice. © 1999 Diagraph, Inc. All rights reserved.
5750-212 Revision A Page 2 TABLE OF CONTENTS Basics Basics ...................................................... 2 Product Specifications .................................. 3 Components ............................................... 4 Keypad Assignments..................................... 5 Keystrokes with Command Prompts............. 6-11 Maintenance ................................................. Loading Ink ........................................ 12 Purging All Channels ........................
5750-212 Revision A Page 3 Product Specifications Controller / Ink Delivery System Two models Weight English/European 15 lb. (6.8 kg) English/Asian 15 lb. (6.
5750-212 Revision A Page 4 I.V.
750-212 Revision A Page 5 Keypad Assignments DISPLAY 1 Two-line, twenty character per line, liquid crystal display (LCD). 2 3 4 5 1 LEDs Power LED; lit when the printer has power. Photo-eye LED; on while a product passes by. Print LED; lit when the printer is in print mode. Ink out LED; blinks when the ink can is out of ink. 2 3 5 4 6 7 9 8 10 11 ABC ABC 6 7 8 9 10 11 12 13 14 15 16 17 FUNCTION KEYS PRINT: Starts and stops printing. EDIT: Create, edit or delete a message.
5750-212 Revision A Page 6 Initializing the system Keystrokes & Controller CommandPrompts Self Test Passed User Initializing Select Language 1-English 2-Español 3-Deutsch 4-Français 5- Italiano 6- Suomi 7- Nederlands 8- Svenska 9-Português A-Norsk Set Date 1-No 2-Yes YYYY / MM / DD 1997 02 17 Set Time 1-No 2-Yes HH : MM PM/AM 12 : 42 PM Select Units 1-No 2-Yes 1:Inches 2:Meters Units:1
5750-212 Revision A Page 7 Setting variables through the Set-Up menu Set-Up Menu 1-Date YYYY / MM /DD 1997 02 17 Set-Up Menu 2-Expiration Date Expiration Days 0000 Set-Up Menu 3-Time HH : MM PM/AM 00 : 00 AM Set-Up Menu 4-Work Shifts Set Shifts (1-6): Shift :1 Start: 08:00 Shift Name: A< Set-Up Menu 5-Item Count Start: 0000001 End: 0009999 Change: 01 Set-Up Menu 6-Pallet Count Items per Pallet 0000012 Start: 0000001 End 0009999 Set-Up Menu 7-Message Indent Set Message Indent 000.
5750-212 Revision A Page 8 Adjusting dot sizes Accessing system information Set-Up Menu I-Column Dot Adjus Column Dot Adjust 0 Set-Up Menu J-Single Dot Adjust Dot:1 Dot Size:250 Factory Setting Y/N 1-No 2-Yes :1 Set-Up Menu K-First Dot Adjust 1st Dot Time:000 sec 1st Dot Adjust:1 Dot Adjustment:00 Information 1-Unused Messages Unused Messages: 96 Information 2-Date 1997 / 02 / 17 Information 3-Time 12:32:49 Information 4-Print Speed Print Speed: 40ft/min Information 5-Item Count Item Cou
5750-212 Revision A Page 9 Editing a message Setting the item count 1-New Message 2-Edit Message 2-Edit Message 3-Delete Message Enter Message Name DD< Editing... DIAGRAPH< 1-Save:DD 2-Cancel Changes: DD 2-Cancel Changes: DD 3-Edit: DD 1-New Message 2-Edit Message Name:DD DIAGRAPH< Editing... DIAGRAPH< 1-Save:DD 2-Cancel Changes: DD 2-Cancel Changes: DD 3-Edit: DD 2-Edit Message 3-Delete Message Name:DD DIAGRAPH< 1-Cancel Changes:DD 2-Ok. Delete: DD 2 Editing...
5750-212 Revision A Page 10 Placing the time in a message Placing the date in a message 2 Editing... DD< Editing... DD{13:49}< hh:mm DD{13:49}< hhmm DD{1349}< hh:mmAM/PM DD{13:49PM}< hh DD{13}< mm DD{49}< AM/PM DD{PM}< (1:AM/2:PM) DD{2}< 2 Editing... DD< Editing...
5750-212 Revision A Page 11 Placing the date in a message Purging all channels in the system Purging individual channels in the system Editing... DD< Expiration Days 0030 Hold for Long Purge 55/100 Dot: 1 Press i to Exit Dot: 1 Purge: 44/100 Editing...
5750-212 Revision A Page 12 Maintenance Loading Ink Even when the can is empty, the I.V./700 has enough ink in its delivery system to print 400 to 1000 characters after the ink low light begins to flash. 1 Unscrew the old can and set aside. 2 Remove the cap from the new can, invert and screw into the ink receptacle.
5750-212 Revision A Page 13 Purging All Channels Purge the printer at the start of the workday. 1 Hold a disposable towel in front of the printhead. 2 Press PURGE. The printhead will expel ink for approximately two seconds. Continue to press PURGE if you a want a long purge of ink. 3 Clean the face of the printhead with water.
5750-212 Revision A Page 14 Purging with Conditioner Extended shutdowns of a week or more will require purging the printhead with conditioner. 1 Remove the ink canister and attach a canister of conditioner. 2 Hold a disposable towel in front of the printhead. 3 Press PURGE. 4 Continue to press PURGE until the expelled fluid is clear. 5 Remove the conditioner canister and attach the ink canister.
5750-212 Revision A Page 15 Purging Individual Channels Purge a single channel when a dot is missing or undersized. 1 Press and hold ALT and PURGE. 2 Press the corresponding numeric key to select a channel to purge. 3 Hold a disposable towel in front of the printhead. 4 Press PURGE. The printhead will expel ink for approximately two seconds. 5 Clean the face of the printhead with water. 6 Press i to exit or enter another channel to purge and repeat steps 3 and 4.
5750-212 Revision A Page 16 Adjusting the Screen Contrast You can change the contrast on the LCD by using the UP and DOWN arrows with the ALT key. 1 Press and hold ALT and the DOWN arrow. Hold for at least five seconds. The screen contrast will gradually dim. 2 Press and hold ALT and the UP arrow. Hold for at least five seconds. The screen contrast will gradually become darker.
5750-212 Revision A Page 17 Troubleshooting Problems with the I.V./700 divide into three areas: (1) the unit is not printing; (2) the unit is printing but the results are unsatisfactory; and (3) the unit is printing but some aspect of its operation is unsatisfactory. (1) Not Printing ........................................ (2) Unsatisfactory Print ............................. (3) Satisfactory Print but with Problems ...... Hardware Block Diagram ...........................
5750-212 Revision A Page 18 (1) Not Printing, Questions and Solutions Q1 The I.V./700 is not printing and the power LED is not lit. Why? S1 The printer does not have power. Check the following: [1] The barrel plug connection at the base of the controller; [2] The cable connection at the base of the power supply; [3] The barrel plug for a 15 VDC output; [4] The cable connection at the rear of the printhead; [5] The wall receptacle to make sure that it is supplying power.
5750-212 Revision A Page 19 Q3 The I.V./700 is not printing and the ink LED is flashing. Why? Q4 The I.V./700 is not printing but all LED signals are normal. Why? S3 The printer is out of ink. Replace the old ink can with a new can. If the can is not empty, replace it anyway to eliminate the possibility of a can that has lost pressure causing the problem. S4 Address the simplest possibility first: is the I.V.
5750-212 Revision A Page 20 Q5 The I.V.700 is not printing even though all of the LED's are working normally. Q6 The I.V./700 is not printing and ALL the LEDS are blinking. Why? S5 Remove the four Phillips screws from the controller housing and check the cable connection between the printhead and the controller board. Check the continuity of the controller to printhead cable. If the cable is defective, replace it with cable 5750-192. S6 A short-circuit has occurred.
5750-212 Revision A Page 21 (2) Unsatisfactory Print The easiest way to approach any printing problem is to reset the printer to its factory defaults and then print the default "DIAGRAPH" message. This simple procedure avoids all the complications of extreme settings that interfere with the printing process.
5750-212 Revision A Page 22 Q10 The I.V./700 is printing normally but the message is too wide. Why? S10 The character width is too wide or too narrow. Perform one of the following procedures: Increase or decrease the character width by following the directions below for changing the character width. If the unit is using the fixed speed feature then increase or decrease the fixed speed by following the directions below for changing the fixed speed. Q11 The I.V.
5750-212 Revision A Page 23 coming from that channel, then the ink jet orifice remains blocked. Remove the obstruction with a broach Kit (P/N 1902-857, shown below). Q12 The I.V./700 is printing the correct message but all of the ink dots are too small. Why? S12 5. Install the new can of ink into the controller recepticle. 6. Power ON the I.V./700 and wait for a menu to appear. 7. Check the mulitimeter display; you should see a value in the range of 5 to 8 volts DC. The ink pressure is too low.
5750-212 Revision A Page 24 Q13 The I.V./700 is printing the correct message but the characters are out of position and there are a lot of extra dots. Why? S13 The printhead is too far from the product (see the scanned sample at right below). Adjust the printhead until it is closer to the box. The faster the box travels, the closer the printhead must be to the box. Q14 After sitting idle for a few minutes, the first dots printed in the message are too small when the I.V./700 starts printing again.
5750-212 Revision A Page 25 (3) Satisfactory Print with Other Problems Q18 I'm running the I.V./700 eight hours per day and have to replace the ink can every other day. Is this normal? This section covers problems that do not cause the printer to stop printing nor produce unsatisfactory prints. These situations are warnings that more serious problems might be on the way. Q15 Shouldn't I shake the ink can before I install it in the printer? I always have to shake paint cans. S18 S15 No.
5750-212 Revision A Page 26 Hardware Block Diagram HBD1
5750-212 Revision A Page 27 Oscilloscope Plot of Driver Board 15 V Output Veritcal Setting: 5.
5750-212 Revision A Page 28 Oscilloscope Plot of CPU Board 5 V Output Veritcal Setting: 2.
5750-212 Revision A Page 29 Parts Drawings General Assembly ..................................... 30 Controller Assembly .................................. 31 Printhead Assembly ..................................
5750-212 Revision A Page 30 Modular Parts Kits
5750-212 Revision A Page 31 Controller Assembly
5750-212 Revision A Page 32 Printhead Assembly
5750-212 Revision A Page 33 Test Results Declaration of Conformity .......................... 34 Inchscape Testing Services ........................
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5750-212 Revision A Page 36 Appendix A 5750-199N 5750-201N 5750-113N 5750-125N 5750-117N 5750-183N 1902-857N Service Parts Instructions Modular Printhead ..................... 37 Controller ................................. 41 Power Supply ........................... 44 Tubing Kit ................................. 45 & 118N Firmware ...................... 46 External Photosensor ................. 48 Broach Kit ................................
5750-212 Revision A Page 37 I . V . / 7 0 0 Modular Printhead Contents 1 I.V./700 Printhead 1 Installation Instructions Materials Required Clean Wipes Specifications Resolution: 7 dots veritcal, 12 dots/inch horizontal (4.8 dots/cm) Dot Diameter Range: 0.100 inch to 0.125 inch (2.54 mm to 3.175 mm) Recommended Throw Distance: 0.25 in. max (6.35mm) Max. Line Speed: 250 ft/min (76.2 m/min) Photosensors:Two photosensors to measure speed and direction. Operating Pressure: 7psig-9 psig Character Height: .
5750-212 Revision A Page 38 4 Type the value from the bottom of the label identified as "Column Dot =". Press Enter. 5 Press SET-UP then J. The LCD will show "Dot: 1". The controller is waiting for a dot diameter value for the dot from the first valve in the printhead. 6 Refer to the "Dot Size" value for valve 1 on the printhead label and enter it at the prompt. Press ENTER when done. Repeat this operation for all seven valves. 7 After typing the label value for dot 7, press SETUP.
5750-212 Revision A Page 39 5 Press J on the QWERTY keypad. The LCD will prompt for the number of the dot that is not printing like the other dots. The top dot on the printhead is dot number 1 and the bottom dot is dot number 7. 6 Scroll to the number of the problem dot. 7 Press ENTER. 8 The LCD will prompt for a new diameter of the selected dot. Move to the second digit (250) and scroll to a new value. The scroll changes by units of 10. 9 Press SET-UP.
5750-212 Revision A Page 40 The second line of the LCD will prompt for "Dot Adjustment." If this dot is small in the sample print (see the first sample below), increase the value by 10 which increases the size of the dot for the first print. If the dot was full-size, DO NOT enter a new value: leave the existing value and press ENTER 8 The display will change to "1st Dot Adjust:2" for the second valve. Press ENTER and the second line will prompt for "Dot Adjustment.
5750-212 Revision A Page 41 I.V./700 Controller Contents 1 Controller Assembly 1 Instruction set Record the Printhead Settings Replacing the controller will eliminate all message formats and printhead values. Use the chart at right to record the column dot value and the settings for single dot diameters and first dot values. If the old controller is inoperable, skip to the next section, "Disconnecting the Old Controller", and use the label on the bottom of the printhead.
5750-212 Revision A Page 42 Disconnecting the Old Controller 1 Unplug the barrel connector [A]. Initialization 2 Unscrew the ink container and set aside [C]. 3 Disconnect the signal cable from the printhead [B]. 1 Press and hold both ALT and the left arrow key while connecting the power. Release the keys when "Erase all messages?" appears on the LCD. Press 1 for "No" and then ENTER. 4 Disconnect the ink line from the printhead [D].
5750-212 Revision A Page 43 Printhead Adjustments The next instructions cover transferring the previously recorded values to the I.V./700 controller. The "chart" in these instructions is the one filled in on page 1 of these instructions. Start by unplugging the controller. 1 Simultaneously press ALT and INFORMATION and plug in the barrel connector. Release the keys when the display shows the information menu. 2 Press SET-UP. The LCD will show the extended menu with additional choices.
5750-212 Revision A Page 44 I.V./700 Power Supply Contents 1 I.V./700 Power Supply 5750-113 1 Instruction Sheet 5750-113N Tools None required. Specifications Input: 100V - 240V 0.7A 50/60Hz Output: 1.5V - 2.
5750-212 Revision A Page 45 I.V./700 [B] Tubing Kit [C] 5 7 5 0 - 1 2 5 N Typical Installation This tubing kit enables you to replace a damaged ink line segment between an I.V./700 controller and an I.V./700 printhead. The illustration above shows a typical installation. Installation Notes _Unscrew the ink can from the controller and set aside before starting the ink line replacement.
5750-212 Revision A Page 46 I.V./700 Firmware 5 7 5 0 - 1 1 7 N & 1 1 8 N WARNING: ESD SENSITIVE DEVICE. OBSERVE PRECAUTIONS. Use anti-static protection throughout these procedures. Follow the directions included with disposable wrist strap. Record the Printhead Settings Replacing the firmware (chips U3 and U4) will eliminate all message formats and printhead values. Use the chart above to record the column dot value and the settings for single dot diameters and first dot values.
5750-212 Revision A Page 47 Installing the New Chips 1 Remove the chip set from the foam packing and match labels of "U3" and "U4" with the chip sockets on the controller board. 2 Orient chips with the notches at the top-towards the LCD screen. Ensure that no pins are bent. 3 Carefully align pins and firmly push each chip into its socket. DIP socket clips will snap into place when the chips are seated correctly.
5750-212 Revision A Page 48 I.V./700 External Photosensor These instructions cover the configuration of the I.V./700 ink jet printer with the external photosensor. Contents External Photosensor [1] and bracket [2] 5750-113 Photosensor/Controller Cable [3] 5750-182 Instruction Sheet 5750-183N Configuration See the diagram on page 2 for the configuration command sequence. Note dimension "X" in the illustration at right--the distance from the center of the photosensor to the center of the printhead.
5750-212 Revision A Page 49 of the distance from the edge of the product to the first printed character plus the distance from center-to-center of the photosensor and the printhead. For example, if you wanted the message to be printed 2 inches from the leading edge of the product and the X dimension is 10 inches, then the indent setting is 12 inches. See the User's Manual on setting the message indent.
5750-212 Revision A Page 50 I.V./700 Contents 1 Broach & Cardboard Tube 1 Instruction Sheet Broach Kit 1902-857N 1902-857 1902-857N Tools Conditioner, Wipes, Flashlight Using the Broach WARNING: Improper use of a broach can damage the printhead membrane. 1. Make sure the broach pin does not extend out of the handle any more than 0.10 inch. This will ensure that the broach pin will not poke a hole in the membrane and cause internal leaking. 2. Wipe the front plate clean with a cloth and conditioner. 3.
