Dover Imaje 9020 Troubleshooting Manual
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Dover Imaje 9020 Troubleshooting Manual

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SECTION 06 Troubleshooting
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Summary of Contents for Dover Imaje 9020

  • Page 1 Troubleshooting Troubleshooting SECTION 06 Troubleshooting 1/54...
  • Page 2 Troubleshooting ■ Troubleshooting. The first thing to do is read the help message displayed on the printer. The table on the following pages provides details about the circumstances surrounding each alarm or fault displayed. The first column gives the number (in ascending order) and type of each alarm or fault: A: alarm, printing may continue D: fault, printing disabled The third column lists checks, causes, remedies and solutions by order of probability.
  • Page 3 Troubleshooting A / D Description Context Check / Cause / Remedy / Solution Consequences CRC EEPROM The CRC calculated when the printer is switched on is Ink module different than the CRC incorrect stored. Consequences: The IMM time counter information is lost, but the module continues to run as usual.
  • Page 4 Troubleshooting A / D Description Context Check / Cause / Remedy / Solution Consequences Internal The dialogue between the Restart the printer CPU processor and the communication Printing processor was timeout interrupted at start-up. Consequences: Printing is disabled. Incorrect The data received from the Check the value of the check byte and whether the external connection are identifiers used to communicate with the printer...
  • Page 5 Troubleshooting A / D Description Context Check / Cause / Remedy / Solution Consequences Duplicate print Three conditions are required Check timing of sending of messages and Dtop. for this fault to appear: non autorised the serial link is used. the “Print-out no double up”...
  • Page 6 Troubleshooting A / D Description Context Check / Cause / Remedy / Solution Consequences CRC(RAM) Ink Appears after the CPU is Check the position of the battery jumper on the Incorrect reset. CPU. Check the voltage of the CPU battery. Consequences: Replace the CPU Stored data (IMM time...
  • Page 7 Troubleshooting A / D Description Context Check / Cause / Remedy / Solution Consequences Read/write error Impossible to read or write to on Ink Mod the IMM EEPROM during EEPROM operation. Consequences: The IMM counter values are no longer saved. The printer continues to operate as normal.
  • Page 8 Troubleshooting A / D Description Context Check / Cause / Remedy / Solution Consequences Algorithm not The message selected or Check the algorithms available and load the missing available sent over the serial link ones in the *.HEM file. contains an algorithm number not available in the printer.
  • Page 9 Troubleshooting A / D Description Context Check / Cause / Remedy / Solution Consequences EMPTY ADDITIVE After several attempts to Cartridge Cartridge pump additive from the Not empty cartridge, the printer Correctly positioned in cartridge holder indicates that the cartridge is Properly perforated tip O-ring empty.
  • Page 10 Troubleshooting A / D Description Context Check / Cause / Remedy / Solution Consequences U1: Additive Valve The negative pressure Cartridge malfunction measured while additive is - Empty being pumped from the - Hollow needle blocked by unperforated tip cartridge is too high O-ring.
  • Page 11 Troubleshooting A / D Description Context Check / Cause / Remedy / Solution Consequences Ink concentration During printing the working Check the following parameters: out of pressure required for proper specifications jet speed is outside the P = Head height difference f(T) curve.
  • Page 12 Troubleshooting A / D Description Context Check / Cause / Remedy / Solution Consequences Ink transfer The time needed at start-up Condenser vent. timeout and during operation for the Clean condenser to drain to the accumulator via SVs 4 and 3, Test solenoid valves 2, 3 and 4.
  • Page 13 Troubleshooting A / D Description Context Check / Cause / Remedy / Solution Consequences Pump The ink pump compression Test solenoid valves 0, 1, 2, 3 and 4 performance ratio is insufficient. incorrect Consequences: No direct consequences. The printer remains ready. Printer empty.
  • Page 14 Troubleshooting A / D Description Context Check / Cause / Remedy / Solution Consequences Ink concentration The pressure during Check the faults 53 and 70 out of range operation is far outside in this table tolerances in the curve P = f(T) Rinse the printer.
  • Page 15 Troubleshooting A / D Description Context Check / Cause / Remedy / Solution Consequences High Voltage The printer detected an Cleanliness of deflection plates insulation failure insulation fault on the EHV Cleaning with soapy water and letting dry may solve lines during operation the problem.
  • Page 16 Troubleshooting Pressure servo If the air pocket is too small Test solenoid valves 3 and 4 control during operation, the pressure inside is disrupted when ink is added, making jet speed control impossible. Consequences: The IMM stops. Printing is disabled. SECTION 06 Troubleshooting 16/54...

  • Page 17: Solenoid Valve Test

    Troubleshooting ■ Maintenance procedures Solenoid valve test. The “Test solenoid valves” function makes it possible not only to know (by listening) whether a solenoid valve responds to a command signal, but also to release a stuck solenoid valve by actuating it several times. WARNING: Ink or additive may splash out during the procedure.
  • Page 18 Troubleshooting Releasing solenoid valve 0 WARNING: Ink or additive may splash out during the procedure. Take precautions, and wear gloves and safety glasses. COMMENT: It is not necessary to remove the IMM from the console to release solenoid valve 0. Turn the printer On and select “Test ink solenoid valve U0”.
  • Page 19 Troubleshooting Releasing solenoid valves 5 and 6 WARNING: Ink or additive may splash out during the procedure. Take precautions, and wear gloves and safety glasses. The IMM must first be removed from the console and laid on its side. Control U9 is no longer available??????? SECTION 06 Troubleshooting 19/54...
  • Page 20 Troubleshooting Partial drain This will empty the ink in the buffer tank without rinsing it. A depressurized empty cartridge is necessary. Follow the instructions that appear on the screen. WARNING: Follow the instructions carefully to avoid spilling any fluid. Wear gloves and safety glasses.

  • Page 21: Auto Calibration

    Troubleshooting Auto-calibration. ■ When to perform auto-calibration □ After replacing the IM □ After replacing the CPU □ After replacing the IMM ■ Why perform auto-calibration The jet speed control ensures print quality over time. The control depends on the ink type and several printer components (such as the printing module and the ink management module).
  • Page 22 Troubleshooting Do not let the head and jet operate for too long on its maintenance stand if the stand is not at the working position. Confirm “Auto-calibration: No”. Start the jet. Wait 10 minutes or so (regardless of the ink type) for the ink temperature to be even.
  • Page 23 Troubleshooting ■ List of special spare parts for Imaje technicians Sale of the parts in the table below is reserved to Imaje technicians. All other spare parts appear in the spare parts and accessories catalog. Part Description Comments number A28591 Recovery assembly with Seals and hardware equipped single jet...

  • Page 24: Spare Parts Sheets

    Troubleshooting Spare parts sheets INTRODUCTORY NOTE: The spare parts sheets (FPR) in this section were written with preventive maintenance in mind. During curative maintenance it is not always possible to follow the recommended procedures in full (e.g. it might not be possible to drain the ink circuit if a solenoid valve is blocked).
  • Page 25 Troubleshooting Replacing a modulator assembly ■ Tools: 1.5 mm Allen wrench CAUTION: Turn off the printer and unplug it from its AC outlet. Residual ink may pour out, take appropriate precautions. Perform this operation in a dust-free environment. ■ Disassembly: □...

  • Page 26: Replacing A Resonator

    Troubleshooting Replacing a resonator ■ Tools: 1.5 mm Allen wrench; resonator clamping/loosening rod. CAUTION: Turn off the printer and unplug it from its AC outlet. Residual ink may pour out, take appropriate precautions. Perform this operation in a dust-free environment. ■...
  • Page 27 Troubleshooting Replacing the nozzle plate. ■ Tools: 1.5 mm Allen wrench; 2.5 mm flat-bladed screwdriver. CAUTION: Turn off the printer and unplug it from its AC outlet. Residual ink may pour out, take appropriate precautions. Perform this operation in a dust-free environment. ■...

  • Page 28: Replacing The 4 Solenoid Valve Block

    Troubleshooting Replacing the 4 solenoid valve block ■ Tools: 1.5 mm Allen wrench. CAUTION: Turn off the printer and unplug it from its AC outlet. Position the head higher than the printer console. Residual ink may pour out, take appropriate precautions. Perform this operation in a dust-free environment.

  • Page 29: Replacing The Recovery Unit

    Troubleshooting Replacing the recovery unit ■ Tools: 2.5 mm flat-bladed screwdriver CAUTION: Turn off the printer and unplug it from its AC outlet. Residual ink may pour out, take appropriate precautions. ■ Disassembly: □ Remove the four screws at the corners of the recovery assembly and remove it. Pay attention to the seals (O-rings around pins).
  • Page 30 Troubleshooting Replacing a recovery gutter ■ Tools: 0.9 mm Allen wrench, Imaje gutter adjustment tool. CAUTION: The jet must be stopped. Residual ink may pour out, take appropriate precautions. ■ Disassembly: □ Loosen the pressure screw on the same side as the gutter to be replaced, by half a turn.

  • Page 31: Replacing The Recovery Solenoid Valve

    Troubleshooting Replacing the recovery solenoid valve ■ Tools: 1.5 mm Allen wrench; 2.5 mm flat-bladed screwdriver; 7 mm box wrench CAUTION: Turn off the printer and unplug it from its AC outlet. Position the head higher than the printer console Residual ink may pour out, take appropriate precautions.
  • Page 32 Troubleshooting ■ Reassembly: □ Solder the control wires to the new solenoid valve. □ Connect the intake hose and slide the sleeve. □ Fit new seals (two O-rings) to the new solenoid valve. □ Position the solenoid valve in its housing (check that it is oriented correctly) then retighten the nut.

  • Page 33: Replacing The Print Module

    Troubleshooting Replacing the print module ■ Tools: 2 mm Allen wrench; 2.5 mm Allen wrench. CAUTION: Rinse and drain the printer then turn it off and unplug it from its AC outlet. Residual ink may pour out, take appropriate precautions. ■...
  • Page 34 Troubleshooting Replacing the ink management module ■ Tools: 5 mm Allen wrench; 2.5 mm Allen wrench. CAUTION: Rinse and drain the printer then turn it off and unplug it from its AC outlet. If you are unable to use the automatic "Drain/rinse" function due to problems on the ink circuit you may use the procedure below to drain the ink management module manually.
  • Page 35 Troubleshooting CAUTION: If the "drain/rinse" function has not been performed, the accumulator may contain ink under pressure. Take particular precautions when draining it. Connect the printer to the electrical supply, hold the hydraulic half-connector on the ink circuit side in an appropriate receptacle (500 cm , half-closed) and manually open solenoid valve "U11, Accu.
  • Page 36 Troubleshooting Reassembly: □ Fit the two screws to the new ink management module. □ Bring up the new ink management module in order to connect the venting hose and the CPU ribbon cable. □ Insert the two screws into the corresponding slots and the two bottom mounts in their brackets.
  • Page 37 Troubleshooting Replacing the EHV block ■ Tools: 2.5 mm Allen wrench; 2 mm Allen wrench. CAUTION: Turn off the printer and unplug it from its AC outlet. ■ Disassembly: □ Open the left side door. □ Disconnect the two connectors from the EHV wires and the EHV control connector. □...

  • Page 38: Replacing The Industrial Interface Card

    Troubleshooting Replacing the industrial interface card ■ Tools: 2.5 mm Allen wrenches; 2.5 mm flat-bladed screwdriver. CAUTION: Unplug the printer from its AC outlet. ■ Disassembly: □ Open the left side door. □ Disconnect all the wires connected to the industrial interface board terminal blocks (cell, tachometer, etc.).

  • Page 39: Replacing The Cpu Board

    Troubleshooting Replacing the CPU board ■ Tools: 2.5 mm Allen wrenches. CAUTION: If possible, save the messages to a PCMCIA card. Unplug the printer from its AC outlet. ■ Disassembly: □ Open the printer's left side door. Remove the two screws then disconnect the industrial interface board from the CPU board without removing the wires connected to □...
  • Page 40 Troubleshooting ■ Reassembly: □ Before inserting the new board, check that jumper S32 is in the ON position. □ Connect the display to the new CPU board (see the "Replacing the display" sheet). □ Insert the three screws on the right side of the board but do not tighten them. □...

  • Page 41: Replacing The Display

    Troubleshooting Replacing the display ■ Tools: 2 mm Allen wrenches. CAUTION: Unplug the printer from its AC outlet. ■ Disassembly: □ Remove the CPU board (see the "Replacing the CPU board" sheet). There is no need to store the messages. □...

  • Page 42: Replacing The Psu Board

    Troubleshooting Replacing the PSU board ■ Tools: 2.5 mm Allen wrenches. CAUTION: Unplug the printer from its AC outlet. ■ Disassembly: □ Open the left side door. □ From the outside of the printer, unscrew the three screws which hold the power supply board to the heatsink.

  • Page 43: Replacing The Adp Board

    Troubleshooting Replacing the ADP board Tools: 1.5 mm Allen wrench; 2.5 mm flat-bladed screwdriver; tweezers. CAUTION: Turn off the printer and unplug it from its AC outlet. Disassembly: □ Disassemble the rear head cover □ Unscrew the two screws from the ADP board and withdraw it from its housing. □...

  • Page 44: Replacing The Piezo Board

    Troubleshooting Replacing the piezo board Tools: 1.5 mm Allen wrench; 2.5 mm flat-bladed screwdriver; 7 mm box wrench; 4 mm box wrench; tweezers. CAUTION: Turn off the printer and unplug it from its AC outlet. The head must be rinsed and partially drained. Place the head higher than the ink circuit.
  • Page 45 Troubleshooting OPTIONAL BUT RECOMMENDED FOR BETTER ACCESS TO THE PIEZO BOARD: Unscrew the screw holding the two ground braids attached to the body of the recovery solenoid valve. Remove the recovery assembly. To avoid damaging the assembly, loosen the four screws in the corners of the assembly one full turn (do not loosen the central screw), detach the recovery assembly, remove the four screws and gently remove the recovery assembly by pulling it free in...
  • Page 46 Troubleshooting Reassembly: CAUTION: Before reassembly, check that all items are clean and wipe off any traces of ink or additive. □ Solder the wires onto the new board and plug the connector back in. □ Put the board back in place, taking care to engage the control screws correctly in the corresponding potentiometers.
  • Page 47 Troubleshooting Replacing a potentiometer The break-off point adjustment potentiometers are located on the piezo board. ■ Tools: 1.5 mm Allen wrench; 2.5 mm flat-bladed screwdriver; 7 mm box wrench; 4 mm box wrench; tweezers. CAUTION: Perform a "Partial drain" then stop the printer and unplug it from the AC outlet.
  • Page 48 Troubleshooting OPTIONAL BUT RECOMMENDED FOR BETTER ACCESS TO THE PIEZO BOARD: Unscrew the screw holding the two ground braids attached to the body of the recovery solenoid valve. Remove the recovery assembly. To avoid damaging the assembly, loosen the four screws in the corners of the assembly one full turn (do not loosen the central screw), detach the recovery assembly, remove the four screws and gently remove the recovery assembly by pulling it free in...
  • Page 49 Troubleshooting ■ Reassembly: CAUTION: Before reassembly, check that all items are clean and wipe off any traces of ink or additive. □ Install a new potentiometer and solder it in place. □ Put the piezo board back in place, taking care to engage the control screws correctly in the corresponding potentiometers.
  • Page 50 Troubleshooting Air intake filter cartridge and seal (on air conditioner). ■ Tools: 2.5 mm flat-bladed screwdriver. CAUTION: The printer must be disconnected from the power supply and the compressed air network. ■ Disassembly: □ Open the left side door. □ For easier access, disconnect the quick couplings on the three hoses then withdraw the air conditioner assembly.

  • Page 51: Replacing The Keyboard

    Troubleshooting Replacing the keyboard ■ Tools: Bottle of alcohol or acetone. Absorbent paper. CAUTION: Unplug the printer from its AC outlet. ■ Disassembly: □ Open the left side door and disconnect the keyboard ribbon cable from the CPU board. □ Detach the keyboard by pulling from an angle. □...

  • Page 52: Break-Off Point Adjustment

    Troubleshooting ■ Adjustment sheets Break-off point adjustment Tools: Safety glasses and gloves; magnifying glass (eyepiece); 2.5 mm screwdriver Preparation: □ Place the head on its maintenance stand. □ Turn on the jet(s) for at least 30 minutes. □ Remove the head cover. Note: each jet on a multijet head has its own potentiometer (right jet - right potentiometer, etc.).

  • Page 53: Troubleshooting

    Troubleshooting Figure 2 Potentiometer Magnifying glass (eyepiece) Potentiometer direction Charge electrode Satellite drops Break-off point CORRECT ADJUSTMENT Inspection and tests: □ Close the head cover. Cancel any faults that appear. □ Run printing tests and readjust if necessary. SECTION 06 Troubleshooting 53/54...

  • Page 54: Recovery Gutter Adjustment

    Troubleshooting Recovery gutter adjustment Tools: □ Safety glasses and gloves; 0.9 mm Allen wrench; gutter adjustment tool. Preparation: □ Place the head on its maintenance stand. □ Confirm the Production / Maint / Jet maintenance / Adjust jet function. □ Remove the head cover. Adjustment: □...

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Imaje 9030

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