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Imaje 4040 Technical File Manual

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T e c h n i c a l F i l e M a n u a l
I m a j e
4 0 4 0
High definition for
customizing cases
101075
101075

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Summary of Contents for Imaje 4040

  • Page 1 T e c h n i c a l F i l e M a n u a l I m a j e 4 0 4 0 High definition for customizing cases 101075 101075...

  • Page 2: Table Of Contents

    Imaje 4040 1. Introduction 1. Introduction ..................4 1. Introduction....................4 2. Safety ....................5 Safety Requirements ................... 5 Certification and Approvals ................. 7 CE Standards & Directives ................7 3. System Specification ................8 Technical Specifications (Hardware) ............8 4.
  • Page 3 Advanced Chipset Features ..............48 Intergraded Peripherals ................49 PnP/PCI Configuration ................50 Set Password .................... 51 Cleaning the vent screens and fan inside the 4040........52 5. XJ500 Print Module ............54 Maintenance ....................54 Theory of Operations................. 56 Trouble Shooting ..................
  • Page 4 Imaje 4040 1. Introduction Electrical Diagram, IDS2/128 ..............81 Drawing, Replacement Printhead, XJ128..........82 7. Table of Figures................. 83...

  • Page 5: Introduction

    Therefore, Imaje cannot be held liable for any malfunction or damage caused by any modification of the use as recommended by Imaje, or for any incident arising from use of the product for any purposes other than those for which it is designed. It is the sole responsibility of the user to take the precautions required by any use to which he or she puts the product.

  • Page 6: Safety

    2. S afety Safety Requirements Imaje disclaims all responsibility regarding the CE directive if the printer is used, altered or installed in any way other than described in this manual. This symbol is used to indicate circumstances that may be dangerous to the user or that cause damage to the equipment.
  • Page 7 ■ Please read all instructions before using the printer for the first time. ■ The printer should be connected to the power supply indicated on the voltage plate. If you are unsure of the type of power supply available, please contact Imaje service personnel.

  • Page 8: Certification And Approvals

    FCC. FCC = Federal Communications Commission CE Standards & Directives Imaje 4040 printers are in accordance with the following European directives applicable to the products: ■ The electromagnetic compatibility directive, EMC Directive 89/336/CEE, and its corresponding European standards.

  • Page 9: System Specification

    General Description The 4040 controller is a high-resolution ink jet printing system. This ink jet printer utilizes state of the art Impulse Piezo printhead technology capable of utilizing a wide variety of inks to print onto a wide variety of media at very high resolution.

  • Page 10: System Specifications

    Imaje 4040 3. System Specifications Printheads: XJ128-200: • Nozzle Count: 128 nozzles (all points addressable) • Horizontal Resolution: 200 DPI • Vertical Resolution: 185 DPI, Capable of printing razor sharp graphics and reliable bar codes. • Print Speed: 140 Feet per minute (FPM) at 200 DPI.

  • Page 11: Controller

    Imaje 4040 4. Controller 4. Controller • The controller is a Windows XP Professional based industrial computer. Maintenance The controller requires very little maintenance. Monthly: Check the fan filters on the bottom of the controller for excessive build up. If clogged up, they need to be removed and either washed with water, or blown off with air.
  • Page 12 Imaje 4040 4. Controller Step 2 Removing Cover Plate. 6. If expanding a controller (adding printheads) remove the Driver Board Cover Plate(s). 7. Remove H2-H4 depending on how many boards you are adding. Figure 3: Removing Cover Plate Step 3 Attaching Anti-Static Wrist Strap.
  • Page 13 Imaje 4040 4. Controller Step 5 Lifting the PCB Plate 11. Once all four screws are loose, lift the plate as shown until the plate moves to the top of the screw slots shown in previous Figure. Figure 6: Lifting the PCB Plate Step 6.
  • Page 14 Imaje 4040 4. Controller Step 8. Securing Driver Board 14. Using the standoffs supplied with the driver board expansion kit, fasten each one loosely, and then tighten them once each screw has threaded in smoothly. Figure 9: Securing Driver Board Step 9.

  • Page 15: Troubleshooting

    Imaje 4040 4. Controller Troubleshooting Symptom: No power upon startup Possible cause Possible solution • Check AC connections Poor AC connection • Check fuse Blown AC fuse • Check line conditioner power and connection if using a line UPS (Uninterruptible Power conditioner.
  • Page 16 Imaje 4040 4. Controller Symptom: Photocell lights up but no print Possible cause Possible solution • Run a piece of paper in front of the print head with one hand, and with The Print Speed the other hand trigger the photocell. If the printer prints, then you can and or Margin determine if the printer is printing to early or too late.

  • Page 17: Wiring Diagram

    Imaje 4040 4. Controller Wiring Diagram Figure 11: Wiring Diagram (ES20000101)

  • Page 18: Power Entry

    Imaje 4040 4. Controller Power Entry Figure 12: Power Entry (CH20001401)

  • Page 19: Power Supply 1

    Imaje 4040 4. Controller Power Supply 1 Figure 13: Power Supply 1 (CH20001601)

  • Page 20: Power Supply 2

    Imaje 4040 4. Controller Power Supply 2 Figure 14: Power Supply 2 (CH20001301)

  • Page 21: Usb

    Imaje 4040 4. Controller Figure 15: USB (CH20001501)

  • Page 22: Product Detect, Encoder

    Imaje 4040 4. Controller Product Detect, Encoder Figure 16: Product Detect: Encoder (CH20002102)

  • Page 23: Mouse To Panel Support

    Imaje 4040 4. Controller Mouse to Panel Support Figure 17: Mouse to Panel Support (CH20002001)

  • Page 24: Panel Support To Cpu

    Imaje 4040 4. Controller Panel Support to CPU Figure 18: Panel Support to CPU (CH20001801)

  • Page 25: Photocell

    Imaje 4040 4. Controller Photocell Figure 19: Photocell (SS10000401)

  • Page 26: Encoder

    Imaje 4040 4. Controller Encoder Figure 20: Encoder (SS10000501)

  • Page 27: Inverter To Panel Support

    Imaje 4040 4. Controller Inverter to Panel Support Figure 21: Inverter to Panel Support (CH20001701)

  • Page 28: Controller To Print Module

    Imaje 4040 4. Controller Controller to Print Module Figure 22: Controller to Print Module (CH20000701)

  • Page 29: Schematic, I/O, Driver Board

    Imaje 4040 4. Controller Schematic, I/O, Driver Board Figure 23: Schematic, I/O, Driver Board...

  • Page 30: Panel Support Board Schematic, I/O, Overview

    Imaje 4040 4. Controller Panel Support Board Schematic, I/O, Overview Figure 24: Panel Support Board Schematic, I/O, Overview...

  • Page 31: Ethernet 10/100Base-T Connector (Cn15)

    Imaje 4040 4. Controller Ethernet 10/100Base-T Connector (CN15) Table 1: Ethernet 10/100Base-T connector (CN15) Signal XMT+ XMT- RCV+ RCV- Audio Connector (CN14) Table 2: Audio Connector Signal Signal LINE OUT R LINE IN R LINE OUT L LINE IN L...

  • Page 32: Floppy Disk Drive Connector (Cn20)

    Imaje 4040 4. Controller Floppy Disk Drive Connector (CN20) Table 5: Floppy Disk Drive Connector (CN20) Signal Signal DENSITY SELECT DRIVE TYPE INDEX* MOTER O* DRIVE SELECT 1* DRIVE SELECT 0* MOTER 1* DIRECTION* STEP* WRITE DATA* WRITE GATE* TRACK 0*...

  • Page 33: Ide Hard Drive Connector (Cn13)

    Imaje 4040 4. Controller IDE Hard Drive Connector (CN13) Table 6: IDE Hard Drive Connector (CN13) Signal Signal IDE RESET* DATA 7 DATA 8 DATA 6 DATA 9 DATA 5 DATA 10 DATA 4 DATA 11 DATA 3 DATA 12...

  • Page 34: Com2 Rs-232/422/485 Series Port (Cn16)

    Imaje 4040 4. Controller COM2 RS-232/422/485 Series Port (CN16) Table 17: COM2 RS-232/422/485 Series Port (CN16) RS-232 Port RS-422 Port RS-485 Port TxD-+ DATA+ TxD- DATA- RxD+ RxD- Flat Panel Connector (CN2) Table 12: Flat Panel Connector (CN2) Signal Signal...

  • Page 35: External Flat Panel Display Connector (Cn4)

    Imaje 4040 4. Controller External Flat Panel Display Connector (CN4) Table 13: External Flat Panel Display Connector (CN4) Signal Signal Compact Flash Card Connector (CN21) Table 14: Compact Flash Card Connector (CN21) Signal Signal *CS0 *ATA SEL -IOCS16 *CD2 -CD1...

  • Page 36: Peripheral Power Connector (Cn10)

    Imaje 4040 4. Controller Peripheral Power Connector (CN10) Table 15: Peripheral Power Connector (CN10) Signal -12V COM1 RS-232 Serial Port (CN8) Table 16: COM1 RS-232 Serial Port (CN8) Signal LCD Inverter Backlight Connector (CN1) Table 10: LCD Inverter Backlight Connector (CN1)

  • Page 37: Lcd Signal Mapping

    Imaje 4040 4. Controller LCD Signal Mapping Table 18: LCD Signal Mapping Pin Name 16-Bit DSTN 24-Bit DSTN 18-Bit TFT 24-Bit TFT 36-Bit TFT PD10 PD11 PD12 PD13 PD14 PD15 PD16 PD17 PD18 PD19 PD20 PD21 PD22 PD23 PD24 PD25...
  • Page 38 Imaje 4040 4. Controller PC20000301 (PCM-9372) CPU Board Figure 25: CPU PCB Component Side...

  • Page 39: Pc20000301 (Pcm-9372) Cpu Board Specifications

    Imaje 4040 4. Controller PC20000301 (PCM-9372) CPU Board Specifications 1.1 Introduction The PCM-9372 is a low-power Eden processor single board computer (SBC) with audio controller, a 4X AGP SVGA controller, a PCI 10/100 Base-T Ethernet interface, 2 Channel LVDS interface, and one PC/104 expansion connector.
  • Page 40 Imaje 4040 4. Controller 1.2 Features • Embedded VIA low-power Eden processor • Supports one 36 bit TFT LCD panel, with up to 1024 X 768 resolution • Supports 2 channel LVDS interface • 100/10Base-T Ethernet interface, IEEE 802.3U compatible •...
  • Page 41 Imaje 4040 4. Controller 1.3.2 VGA/LCD Interface • Chipset: VIA Twister chip with integrated Savage4 2D/3D/ Video Accelerator. • Frame Buffer: Supports 4/8/16/32MB frame buffer with system memory • Interface: 4X AGP VGA/LCD interface. Support for 9, 12, 15, 18, 24, 36 bit TFT and optional 16 or 24 bit DSTN panel •...

  • Page 42: Award Bios Setup

    Imaje 4040 4. Controller Award BIOS Setup Important: The password is 5457500 and must be entered to gain access to the bios. 2.1 System Test and Initialization These routines test and initialize board hardware. If the routines encounter an error during the test, you will either hear a few short beeps or see and error message on the screen.
  • Page 43 Imaje 4040 4. Controller 2.2.1 Entering Setup Power on the computer and press <Del> immediately. This allows you to enter setup. Figure 26: Entering Setup 2.2.2 Standard CMOS Features Setup When you choose the Standard CMOS Features option from the initial setup screen menu, the screen shown to the left is displayed.
  • Page 44 Imaje 4040 4. Controller 2.2.4 Advanced Chipset Features Setup By choosing the Advanced Chipset Features option from the initial setup screen menu, the screen to the left will be displayed. This sample screen contains the manufacturer’s default values for the PCM-9372 Series.
  • Page 45 Imaje 4040 4. Controller 2.2.7 PnP/PCI Configurations By choosing the PnP/PCI Configuration option from the initial setup screen menu, the screen to the left will be displayed. This sample screen contains the manufacturer’s default values for the PCM-9372 Series. Figure 32: PnP/PCI Configuration 2.2.8 PC Health Status...

  • Page 46: Imaje 4040 Bios Settings

    2.2.11 Exit Without Saving Selecting this option and pressing <Enter> lets you exit the setup program without recording any new values or changing old ones. Imaje 4040 BIOS Settings Press the DEL key to enter Bios setup Figure 35: Entering BIOS...

  • Page 47: Standard Cmos Features

    Imaje 4040 4. Controller Category Option Setting ENSURE THE “NUM LOCK” LIGHT IS ON Standard CMOS Features Date (mm:dd:yy) Current Date Time (hh:mm:ss) Current Time (24hr) Drive A None Figure 36: Entering Standard CMOS Figure 37: Standard CMOS Settings Press <Esc>...

  • Page 48: Advanced Bios Setup

    Imaje 4040 4. Controller Advanced BIOS setup First Boot Device [HDD-0] Second Boot Device Disabled Third Boot Device Disabled Boot Other Device Disabled Boot Up Floppy Seek Disabled Figure 38: Entering Advanced BIOS Figure 39: Advanced BIOS Settings Press <Esc>...

  • Page 49: Advanced Chipset Features

    Imaje 4040 4. Controller Category Option Setting Advanced Chipset Features Panel Type [TFT 800x600 LVDS] USB Keyboard Support Enable USB Mouse Support Enable On Chip Sound Disabled Figure 40: Entering Advanced Chipset USB Mouse Support may not be an option...

  • Page 50: Intergraded Peripherals

    Imaje 4040 4. Controller Intergraded Peripherals On Chip IDE Channel1 Disabled Onboard Legacy Audio Disabled Scroll Down To View Figure 42: Entering Integrated Peripherals Onboard Legacy Audio Figure 43: Integrated Peripherals Settings Press <Esc>...

  • Page 51: Pnp/Pci Configuration

    Imaje 4040 4. Controller PnP/PCI Configuration PNP OS Installed Figure 44: Entering PnP/PCI Configuration Figure 45: PnP/PCI Configuration Settings Press <Esc>...

  • Page 52: Set Password

    Imaje 4040 4. Controller Set Password Set Password 5457500 Confirm Password 5457500 Figure 46: Entering Set Password Figure 47: Set Password Press “F10” to “save” (Y/N) Save & Exit Setup...

  • Page 53: Cleaning The Vent Screens And Fan Inside The 4040

    Imaje 4040 4. Controller Cleaning the vent screens and fan inside the 4040 Required tools • Compressed air with blow gun o Optional (Compressed cleaning spray aerosol) • 4040 lid key (MP10002203) Figure 48: Required Tools Instructions 1. Use normal shut down procedures to shut down and power off the controller.
  • Page 54 Imaje 4040 4. Controller 5. In the bottom of the controller, locate the exhaust fan near the front right corner. Figure 51: Blow Out Filters 6. Use small short bursts of air to remove dust and debris. (Note: excess air pressure can damage the fan and/or components.)

  • Page 55: Xj500 Print Module

    Imaje 4040 5. XJ500 Print Module Figure 54: Clean Out Controller 5. XJ500 Print Module The XJ500 Print Module consists of two major components: • The IDS2/500 Ink Delivery System (Ink Circuit) • The Xaar, XJ500 Printhead Maintenance With Oil Based Inks Using oil based inks to print strictly onto porous substrates;...
  • Page 56 25. Visually inspect the 4040 controller, look for damage or abuse. 26. Blow out the cover screens and the fan. 27. Connect the print module to a 4040 controller. Turn on power and allow the controller to boot. 28. Using the priming bulb, Re-prime the print head.

  • Page 57: Theory Of Operations

    Imaje 4040 5. XJ500 Print Module Theory of Operations Theory of Operation during the Priming Process: • Air is pumped into the ink reservoirs (7) via the Air Filter (11) using the Priming Pump (9). *The purpose of the air filter is to prevent particulates from the atmosphere from entering into the ink.

  • Page 58: Trouble Shooting

    Imaje 4040 5. XJ500 Print Module Trouble Shooting With Oil Based Inks Symptom: Ink will not prime into print head. Possible cause Possible solution Shipping seal not removed from nozzle face. Remove the shipping seal from the nozzle face. Luer fittings on air intake tube not connected Lift ink tray and connect the luer fittings inside the ink inside ink system.
  • Page 59 Imaje 4040 5. XJ500 Print Module Symptom: Print quality is degraded, i.e. missing lines (dots), spattered print (satellites), sections of the printed image missing. Possible cause Possible solution Too much throw Make sure that proper product handling is in place and that guide rails are adjusted distance to that the product is within 1-5mm, especially if printing barcodes.

  • Page 60: Vacuum Priming The Printhead

    Imaje 4040 5. XJ500 Print Module Vacuum Priming the Printhead Before operating the system you must remove all the air from the ink lines and printhead. This can be accomplished by a combination of two methods. For maximum print quality vacuum priming may be necessary.

  • Page 61: Vacuum Priming The Xj500 Head

    Imaje 4040 5. XJ500 Print Module Vacuum Priming the XJ500 Head Step 1 - Vacuuming Place the vacuum cap over the printhead. There is a slot along the side of the printhead. The tab on the vacuum cap should be inserted into the slot.

  • Page 62: Pressure Priming The Xj500 Printhead

    Imaje 4040 5. XJ500 Print Module Pressure Priming the XJ500 Printhead Occasionally debris may settle on the outside of the nozzles or a small air bubble may trap in one or more of the nozzles. The appearance will be as if there are lines through the print.

  • Page 63: Removing/Installing The Xj500 Printhead

    Imaje 4040 5. XJ500 Print Module Removing/Installing the XJ500 Printhead 1. Loosen the four thumbscrews or Philips screws (depending on version) enough to slide the faceplate off. Figure 60: Loosen Thumb Screws 2. After loosening the corresponding screws to loosen the side cover, remove it.
  • Page 64 Imaje 4040 5. XJ500 Print Module 5. Carefully remove the tube from the printhead by pulling straight back. Repeat for all four tubes. Figure 64: Remove Tubing from Printhead 6. Do not remove the black and white ferrule fittings from the tube so they do not get lost.
  • Page 65 Imaje 4040 5. XJ500 Print Module 9. Remove the printhead mounting screws and store in a safe place. Figure 68: Remove Printhead Mounting Screws 10. When the 3-printhead mounting screws are removed, notice that the holes in the head shell are slotted.

  • Page 66: Flushing The Xj500 Printhead

    Imaje 4040 5. XJ500 Print Module Flushing the XJ500 Printhead 1. Syringe with filter for flushing Figure 72: Syringe with Filter for Flushing 2. Flushing with Syringe Figure 73: Flushing with Syringe 3. Cleaning Solution Streaming from Head Figure 74: Cleaning Solution Streaming from Head...

  • Page 67: Xj-500 Head Solvent Based Notes

    Imaje 4040 5. XJ500 Print Module XJ-500 Head Solvent Based Notes: Daily Shut Down: The system may be left on or simply turned off. Either way, there is no need to flush. Capping the printhead is optional. Daily Print Head Maintenance: During start up, if any lines are missing in the print field, prime the printhead using the hand pump a couple of times.

  • Page 68: Ids2-500 Ink System Circuit Board Schematic, I/O

    Imaje 4040 5. XJ500 Print Module IDS2-500 Ink System Circuit Board Schematic, I/O IDS2-500 Ink System Circuit Board Schematic, I/O Figure 75:...

  • Page 69: Drawing, Ink Level Sensor Assembly, Ids2/500 Revision

    Imaje 4040 5. XJ500 Print Module Drawing, Ink Level Sensor Assembly, IDS2/500 revision Figure 76: Exploded Drawing, Chassis, IDS2/500 Ink Delivery System (PM20000201)

  • Page 70: Wiring Diagram, Ids2/500 Print Module, Old

    Imaje 4040 5. XJ500 Print Module Wiring Diagram, IDS2/500 Print Module, Old Figure 77: Wiring Diagram: IDS2/500 Print Module, Old (ES30000102)

  • Page 71: Plumbing Diagram, Ids2/500

    Imaje 4040 5. XJ500 Print Module Plumbing Diagram, IDS2/500 Figure 78: Plumbing Diagram, IDS2/500 (PM30000203)

  • Page 72: Xj128 Print Module

    Imaje 4040 6. XJ128 Print Module 6. XJ128 Print Module The XJ128 Print Module consists of two major components: • The IDS128 Ink Delivery System (Ink Circuit) • The Xaar, XJ128 Printhead Maintenance With Oil Based Inks Using oil based inks to print strictly onto porous substrates; there is virtually no maintenance necessary.
  • Page 73 Imaje 4040 6. XJ128 Print Module Possible cause Possible solution • Make sure that proper product handling is in place and that guide Too much throw rails are adjusted to that the product is within 1-5mm, especially if distance printing barcodes.

  • Page 74: Priming The Xj128 Printhead

    Imaje 4040 6. XJ128 Print Module Priming the XJ128 Printhead 1. Loosen screws holding nozzle protector plate. Figure 79: Loosen 128 Nozzle Plate Screws 2. Remove the nozzle protector plate Figure 80: Remove Nozzle Plate 3. With printhead exposed, prepare to prime the printhead for the first time.
  • Page 75 Imaje 4040 6. XJ128 Print Module 5. Pump the priming bulb continuously for 10 seconds. 6. Be sure to turn the air valve back counter clockwise to release the pressure when finished priming. Figure 83: Pump the Priming Bulb 7. Hold a Lint Free wipe up to the nozzles while priming.
  • Page 76 Imaje 4040 6. XJ128 Print Module 10. Press the nozzle cover flush up against the nozzles and tighten the screws. Figure 87: Tighten Nozzle Plate Screws 11. Another method is to prim into a container, then blot the excess ink away.

  • Page 77: Procedures For Cleaning A Clogged Printhead (Xj128)

    Imaje 4040 6. XJ128 Print Module Procedures for Cleaning a Clogged Printhead (XJ128) Flushing XJ128 Print Module using a bag of flushing solution. This procedure flushes the entire print module but is the easiest way. This is the only recommended method to flush when using pigmented inks.

  • Page 78: Cleaning A Severe Clog

    Imaje 4040 6. XJ128 Print Module Cleaning a Severe Clog: If flushing does not work, this is the last resort. A print head can be cleaned using an ultrasonic cleaner. 1. Remove the entire print head shell. Do not remove the print head.

  • Page 79: Removing/Installing The Xj128 Printhead

    Imaje 4040 6. XJ128 Print Module Removing/Installing the XJ128 Printhead 1. Remover the front and side covers. Figure 93: Remove Front and Side Covers 2. Pull off the ink tube using thumb and forefinger. Figure 94: Pull Off Ink Tubing 3.
  • Page 80 Imaje 4040 6. XJ128 Print Module 5. Pull out the printhead so that you can get a good grip to remove the electrical connector. Figure 97: Pull Printhead Out 6. Remove the connector and pull the printhead away. Figure 98: Remove Connector 7.

  • Page 81: Schematic, I/O Pcb, Ids-128 Ink System

    Imaje 4040 6. XJ128 Print Module Schematic, I/O PCB, IDS-128 Ink System Figure 101: Schematic, I/O PCB, IDS-128 Ink System...

  • Page 82: Electrical Diagram, Ids2/128

    Imaje 4040 6. XJ128 Print Module Electrical Diagram, IDS2/128 Figure 102: Electrical Diagram, IDS2/128 (ES20000201)

  • Page 83: Drawing, Replacement Printhead, Xj128

    Imaje 4040 6. XJ128 Print Module Drawing, Replacement Printhead, XJ128 Figure 103: Drawing, Replacement Printhead, XJ128 (PH20000401)

  • Page 84: Table Of Figures

    Imaje 4040 12. Table of Figures 7. T able of Figures Figure 1: Tools Required to Add/Replace a Driver Board ....................10 Figure 2: Removing Jack Screws............................10 Figure 3: Removing Cover Plate ............................11 Figure 4: Attaching Anti-Static Wrist Strap ........................11 Figure 5: Loosening PCB Mounting Plate........................
  • Page 85 Imaje 4040 12. Table of Figures Figure 54: Clean Out Controller ............................54 Figure 55: Loosen Thumb Screws ............................ 59 Figure 56: Remove Cover..............................59 Figure 57: Remove Seal..............................59 Figure 58: Vacuum Priming ............................. 60 Figure 59: Pressure Priming ............................. 61 Figure 60: Loosen Thumb Screws ............................
  • Page 86 No binding pictures. Photos: X Imaje AB reserves the right to modify the technical characteristics of the product without prior notice. Reproduction, in whole or in part is prohibited. English version Imaje S.A. Manufacturer Head Office 9, rue Gaspard Monge...

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