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Dikai DC800 Series Service Manual

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DC800 Series
Service Manual
No: DK 3.08 T240718A-01-CNQQ
All rights reserve to Shanghai DiKai Coding Technology Co., Ltd. It is not allowed to disclose, copy, and
forward this document including any materials contained therein without the written permission.
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  • Page 1 DC800 Series Service Manual No: DK 3.08 T240718A-01-CNQQ All rights reserve to Shanghai DiKai Coding Technology Co., Ltd. It is not allowed to disclose, copy, and forward this document including any materials contained therein without the written permission. Page 1...

  • Page 2: Table Of Contents

    Content Introduction..............................4 About the manual............................4 Warning: ..............................4 Cautions:..............................4 Safty................................4 Introduction............................. 4 General safety guidelines ...........................4 Power supply............................4 Power cable............................. 5 Grounding...............................5 Consumable.............................5 Ink and solvents............................6 Cleaning agents ............................6 Others..............................7 1. Main parts..............................8 1.1 Inkjet machine overall view........................8 1.2 Print head overall view..........................9 1.2.1 Valves on print head........................
  • Page 3 3.4 Icons of status............................35 3.4.1 Status icons ........................... 35 3.4.2 Faulty icon - EHT ........................35 3.4.3 Faulty icon - No cover ......................36 3.4.4 Faulty icon - Charge fault ....................... 36 3.4.5 Faulty icon - Gutter fault ......................37 3.4.6 Faulty icon - ink module empty ....................37 3.4.7 Fault - no ink/solvent ......................37 3.4.8 Fault - expired ink/solvent .......................38 3.4.9 Faulty icon - empty ink/solvent cartridge ..................38...

  • Page 4: Introduction

    Safty Introduction The expected use of the DC800 series inkjet machine is to print information directly onto the product. Using this device in any other way may result in serious personal injury. The purpose of the safety guidelines provided in this chapter is to provide technical education on safety issues in order to maintain and operate the inkjet machine in a safe manner.

  • Page 5: Power Cable

    be disconnected before removing the hood or attempting maintenance or repair activities, otherwise it may cause death or personal injury. Power cable Warning Only the original power cable of the inkjet machine can be used. The plug of the cable must has three poles with a protective grounding connection.

  • Page 6: Ink And Solvents

    Ink and solvents Warning Ink and supplements can irritate the eyes and respiratory system. To avoid personal injury when handling these substances: 1. Be sure to wear protective clothing and rubber gloves. 2. Be sure to wear goggles with side shields or face shields. It is also recommended to wear safety glasses during maintenance.

  • Page 7: Others

    Others Cautions Excessive use of solvents. Repeatedly stopping and starting the ink line may lead to excessive use of solvents. This will cause the viscosity too low and may cause a high liquid level alarm in the mixer tank. Cautions The gutter is damaged.

  • Page 8: Main Parts

    1. Main parts 1.1 Inkjet machine overall view 1. Print head 2. Ink circuit cabinet 3. Electric circuit cabinet 4. Hose 5. Connectors Page 8...

  • Page 9: Print Head Overall View

    1.2 Print head overall view 1.Print head 2.Front cover 3.Gutter 4.Nozzle 5.Phase detector 6.Charger pole 7.Nozzle frame 8.High voltage deflection plate 9.VR valve (solvent supply) 10.VF valve (ink supply) 11.VP valve (back flow) 12.VG valve (recycle flow) 1.2.1 Valves on print head VG valve (recycle flow) It is located between the gutter and the Venturi, and is used to switch on/off recycling of ink and solvent .

  • Page 10: Heating Circuit

    1.2.2 Heating circuit The heating circuit maintains the temperature of the ink at the print head, it consists of a heating element and a temperature sensor. 1.2.3 Nozzle The core of the nozzle is a piezoelectric crystal oscillator, which oscillates under the action of an electric field.

  • Page 11: Charge Pole

    (3) nozzle fastening screws It is used to secure the nozzle to the print head module. (4) Adjusting screws for the front and back positions of the nozzle It is used to fine tune the front and back position of the ink line entering the gutter. (Move the ink line to the middle position of the gutter) (5) Adjusting screws for the left and right positions of the nozzle It is used to fine tune the left and right positions of the ink line entering the gutter.

  • Page 12: Gutter

    1.2.9 Gutter The gutter is where the ink line returns to the ink system. Because the ink is conductive, so if there is ink in the gutter can be detected by sensor, if machine detects there is no ink in gutter, the ink line will be switched off in case of leakage. 1.2.10 High-voltage switch By opening and closing the nozzle cover, use the loose screws of the nozzle cover to turn on/off the high-pressure switch of the nozzle.

  • Page 13: Ink System Overall View

    1.3 Ink system overall view The ink system continuously supplies ink to the print head at the correct pressure, temperature, and viscosity settings. 1. Fan 2. Ink/solvent socket 3. Solvent cartridge 4. Ink cartridge 5. Ink module 6. Pressure buffer, Cleaning agents pump 1.3.1 Fan in the ink cabinet Ventilate and cool the ink cabinet.

  • Page 14: Ink Module

    1.3.2 Ink module Ink module（Back view) Items Descriptions 1 Gear pump Replaceable gear pump 2 Main filter Main filter for ink system 3 Damping filter Secondary filter for ink system 4 Tee connector Three ways connector 5 VM valve Valve for solvent addition 6 VI valve Valve for ink addition 7 Adaptor board...

  • Page 15: Dc800 Ink Schematic

    1.3.3 DC800 ink schematic 1.3.4 Ink system running principle Function of ink system Transport ink to the nozzle under constant pressure and temperature. Ensure there is sufficient ink and solvent. Ensure that the ink maintains a specific viscosity corresponding to the ink temperature and the type of ink used.

  • Page 16: Viscosity Measurement

    Name of valves Valve Name Valve Name Solvent addition valve Rinsing valve Ink addition valve Gutter valve Viscosity valve Solvent pump valve Ink supply valve Purging valve 1.3.5 Viscosity measurement Whenever the inkjet machine is running, the system will automatically check the viscosity of the ink through the viscosity measure system (VMS).

  • Page 17: Nozzle Cleaning

    This method turns off the ink line supply system without cleaning the nozzle, so when the ink line stops, the nozzle will be filled with ink. Do not leave the machine in this state for a long time, because the ink in the nozzle may get stuck and make restarting fault.

  • Page 18: Add Solvent To Ink Module

    1.3.12 Add solvent to ink module The solvent flows into the ink module from the solvent cartridge as follows: When the actual VMS value is higher than the set value, the solvent addition valve VM will intermittently power on, and solvent will flow from the solvent cartridge to ink module by vacuum generated from the Venturi tube until until the ink viscosity in the ink core returns to normal.
  • Page 19 Definition of J-IO14: Pin No. Color Description Blue Connect to VV solenoid valve V-. Bule/White Connect to VV solenoid COM (V+). Orange Connect to VL solenoid valve V-. Grey Connect to VL solenoid valve COM (V+). Connect to ink module level detector HIGH. Pink Connect to ink module level detector MIDDLE.
  • Page 20 Definition of J- VAL1 (VM & VI) Pin No. Color Description Not used. Not used. Orange Connect to VI solenoid valve. Orange Connect to VI solenoid valve. Brown Connect to VM solenoid valve. Brown Connect to VM solenoid valve. Definition of J- VAL2 (VV&...

  • Page 21: Gear Pump

    1.3.14 Gear pump Pin No. Color Signal Function White PUMP-CTRL Control voltage signal of pump. PUMP-PWR Control voltage input of DC24V. Black Green PUMP-SPD Control speed signal. 1.3.15 Pressure buffer & cleaning pump combination device The cleaning pump is a diaphragm pump consisting of two pump housings, a flexible diaphragm, and two one-way valves.

  • Page 22: Venturi

    1.3.16 Venturi It is a device for generating negative pressure. 1.3.17 Filters The main purpose of the main filter is to provide filtered ink to the nozzle for printing. This main filter is 5 microns (if using special ink, it is recommended to replace it with 20 microns).

  • Page 23: Pressure And Temperature Sensor

    1.3.18 Pressure and temperature sensor They are used to detect the pressure and temperature of the ink system. Pin No. Color Signal Function Blue +5V. Purple Temp. Temperature signal. Black +5V. Yellow Pres. Pressure signal. Black 1.3.19 Solenoid valve VM solvent addition valve: When the actual viscosity exceeds the set viscosity and VM is powered on, the solvent is drawn from the solvent cartridge to the ink module by vacuum from Venturi.

  • Page 24: Ink & Solvent Cartridge And Level Detect Board

    VL solvent pump valve: The VL valve controls the supply of vacuum or pressure to the cleaning pump kit, which controls the cleaning pump kit to push the solvent to the nozzle during the "cleaning on/off" process. When VL is powered off, by applying vacuum to the diaphragm of the cleaning pump to allow solvent to be sucked from the cleaning solvent cartridge into the cleaning pump chamber.

  • Page 25: Level Detect Board

    1.3.21 Level detect board 1.4 Overview of circuit system Pin No. Color Signal Function +5V. Black Black Synchronize signal. Communicate signal. Items Name Description Power supplier DC24 power supplier. Communicate board Adapt board for inputs and outputs. Main board Controlling all the systems. Display Touch screen.

  • Page 26: Power Supplier

    1.4.1 Power supplier The power functions are as follows: * The power supply provides +24 VDC to the main board. * The input power range of the power supply is 100 to 240 VAC, 50-60 Hz. Items. Color Signal Function Brown Input AC 100~240V.

  • Page 27: Communicate Board

    1.4.3 Communicate board Encoder, photoelectric sensor, USB, Ethernet port, serial port, alarm light interface. Items. Name Function Ethernet Used for connecting external network. Used for external data replication/transmission. SWNC Used for connecting encoder. ALED Used for connecting alarm device. RS485 Used for communication.
  • Page 28 D. Alarm light: The alarm light adopts three color lights: red, yellow, and green. In order to distinguish between different types of emergency situations or warnings. Pin. Color Function Connect to red wire of alarm light . Yellow Connect to yellow wire of alarm light. Green Connect to green wire of alarm light.

  • Page 29: Main Board

    1.4.4 Main board Items. Name Function Socket for mini SD card. Flat socket Connect to J-MIAN cable from I/O adaptor board. Ethernet connector Socket for Ethernet. Power for fan. Touch Connect to touch screen. Connect to cable for display. 1.4.5 I/O adaptor board Page 29...
  • Page 30 Items. Name Function EXT-SIG Socket for cable from communicate board. PWR-IN Socket for power input. Socket for cable from J-L014 at ink module. Socket for cable from L-L012 at ink module. J-MIAN Socket for cable from main board. Socket for cable from COM-CB. Socket for fan in ink cabinet.

  • Page 31: Lcd Screen

    1.4.6 LCD Screen Items. Name Function LCD display cable Connect to socket TOUCH at main board. Touch screen cable Connect to socket LCD at main board.. Page 31...

  • Page 32: Maintenance

    2. Maintenance The preventive maintenance projects mentioned in this chapter must be operated by trained and authorized person. The actual interval depends on the running time of the machine. The table below is based on the usage of eight hours per day. If the actual usage is much more, the interval time should be more short.

  • Page 33: Replace The Fine Filter

    2.2 Replace the fine filter The fine filter is an auxiliary filter of ink system. During maintenance, when replacing the main filter system, pollutants may accidentally enter the pipeline, and the fine filter can filter out these particles. The filter material is stainless steel, with an aperture size of 5 microns. Replace the fine filter: 1.

  • Page 34: Troubleshooting

    3. Troubleshooting 3.1 Read the user manual The DC800 series user manual contains some troubleshooting instructions that allow the inkjet machine operators to perform them. Except for these information. Please refer to the operator manual for more details. This chapter contains troubleshooting steps that are only allowed to be performed by trained or authorized technicians.

  • Page 35: Icons Of Status

    3.4 Icons of status The status icons of the inkjet machine are divided into three groups: Status icons - These icons display the status of inkjet machine; Fault icons - These icons indicate that the inkjet machine is in a faulty condition. In the situation, the inkjet macine will stop printing.

  • Page 36: Faulty Icon - No Cover

    3.4.3 Faulty icon - No cover Icon. Principle Reason Advice High voltage Print head cover is 1. Install the print head in the cover. circuit break removed. 2. Make sure the print head is fixed in the cover. off. Print head cover 1.

  • Page 37: Faulty Icon - Gutter Fault

    3.4.5 Faulty icon - Gutter fault Icon. Principle Reason Advice Ink can’t be Nozzle is blocked. Check if the ink line jets into the gutter. detected in Ink line’s position is 1. Perform "nozzle cleaning" and "cleaning the gutter not correct. shutdown"...

  • Page 38: Fault - Expired Ink/Solvent

    3.4.8 Fault - expired ink/solvent Name Principle Reason Advice Solvent The solvent The solvent 1. Check the expire date on the label. cartridge is cartridge or cartridge or ink 2. Check the system date setting of inkjet expired. ink cartridge cartridge is expired.

  • Page 39: Faulty Icon - Vms Cannot Be Emptied

    please set the viscosity value higher or replace the ink. 3.4.11 Faulty icon - VMS cannot be emptied Icon. Principle Reason Advice In mixing To much ink in the 1. After the warning of "mixing tank full" is tank, the high mixing tank.

  • Page 40: Faulty Icon - Mixing Tank Is Full In Ink Module

    3.4.13 Faulty icon - mixing tank is full in ink module Icon. Principle Reason Advice In VMS, the Faulty valve. 1.Clean the VV valve. high level pin 2.When the VV valve is powered off, make sure can not that no ink flow into the VMS. dectect ink 3.

  • Page 41: Appendix: Dimensions

    Appendix: Dimensions For inkjet machine: For printer head: Page 41...
  • Page 42 For stand frame: DK Print, Marks EachMoment! The remainder of this page is intentionally left blank. Page 42...

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