Dover Markem-Imaje 5400 Manuals

Manuals and User Guides for Dover Markem-Imaje 5400. We have 4 Dover Markem-Imaje 5400 manuals available for free PDF download: Service Manual, Installation And Setup Manual, Operation Manual, Instruction Manual

Dover Markem-Imaje 5400 Service Manual (200 pages)

Brand: Dover | Category: Printer | Size: 16 MB

Table of Contents
5
General Information
13
Welcome to the Model 5200/5400
15
What's in this Guide
15
Glossary
16
Specifications
17
Dimensional Drawing
18
Safety Information
19
Certification
19
Automatic Startup
20
Safety Labels
21
Location of Safety Labels
21
Foreseen Use
23
Misuse
23
Training Programs
23
Label and Symbol Identification
24
Removal from Service
27
Basic Operation
29
Basic Components
31
The Power Switch
33
Powering on the Coder
33
Powering off the Coder
34
The User Interface Module
35
LED Indicators
36
Navigation
37
Menu Functions
37
Function Keys
37
ENTER and EXIT Keys
37
START and STOP Keys
37
Directional Arrow Keys
37
Select Characters Dialog Box
39
Using the Keyboard
40
The Printhead
41
Care and Cleaning
43
Reliability Centered Maintenance
45
Daily Cleaning of the Printhead
46
Purging
47
Purging Printheads in the down Jetting Position
47
Auto Purge Spacing Guidelines
48
Jet Testing
49
Wiping
50
Cleanup
51
Cleaning the Bottle Sensor and Reflective Tape
52
Stuck Bottle Removal
53
Diagnostic Tools
55
Diagnostic Guidelines
57
Signal Lights
57
LED Indicators on the Print Station
57
Signal Tower Lights
58
LED Indicator on the Printhead
59
LED Indicator on the Control Board
60
Switch Pack SW2 Settings on the Control Board
60
Machine Diagnostics Menu
61
Access Level
62
Version Information Menu
62
Ink System
63
Melt Temperature
64
Hold Temperature
64
Upper Float Sensor
64
Lower Float Sensor
64
Printhead 1 - 4 Array Temperature
65
Printhead 1 - 4 Reservoir Temperature
65
Printhead 1 - 4 Ink Level
65
Ink Line 1 - 4
65
Ink Pump
66
Printhead 1 - 4 Low Vacuum
66
Printhead 1-4
67
State
67
Ink
67
Temperature
67
Array Thermistor
67
Reservoir Thermistor
68
Array Heater
68
Reservoir Heater
68
Ink Level Sense
68
Ink Line Heater
69
Ink Line Current
69
Ink Line Status
69
Printhead Voltage
69
Printhead Lamp
70
Encoder Speed
70
Purge Button
70
Purge Count
70
Jet Test Button
70
Ink Delivery Module
71
State
71
Bottle Sensor
71
Melt Thermal State
71
Melt Thermistor
72
Melt Heater
72
Fan
72
Hold Thermal State
72
Hold Thermistor
73
Hold Heater
73
Upper Float
73
Lower Float
73
Pump Motor
74
Pump Cycle Time
74
Pump Home Switch
74
Current Pump Count
74
Filter Usage Count
75
Print Station
75
Ink Door Switch
75
Ink Door Solenoid
75
Line Voltage
75
Enclosure Temperature
76
Product Sensor 1 and 2 (PS1 and PS2)
76
Remote Purge (PS4)
76
Encoder 1 and 2
76
Fault Relay
76
Busy Relay
76
VPC 1-2 and 3-4
77
High Vacuum Pump
77
High Vacuum Duty Cycle
77
High Vacuum Minimum Run Time
78
Low Vacuum Duty Cycle 1 and 3
78
Purge Solenoid 1 and 3
78
Low Vacuum Duty Cycle 2 and 4
79
Purge Solenoid 2 and 4
79
User Interface
79
Contrast
79
Beeper
80
Status Lights
80
Ink Lights
80
Fault Lights
80
Key Pressed
80
Ocu
81
Reject Relay
81
Reader Sensor (1 and 2)
82
Reader Scan Enable (1 and 2)
82
Reader Data (1 and 2)
82
Product ID Sensor
83
Product ID Scan Enable
83
Product ID Data
83
Ink Usage
84
Job Prints Per Bottle
84
Printhead (1-4) Number of Pixels
84
Printhead (1-4) Image Density
84
Printhead (1-4) Prints/Bottle
84
Imaging/Printing
85
Activate Timing
85
Label Rendering
85
Print Cycle
85
Printing (Head 1-4)
86
Time Fields
86
Incremental Fields
86
Remote Select
86
Remote Variable Fields
87
State Logger
88
Action Logger
88
MCU Logger
88
Statistics
88
Troubleshooting
89
Troubleshooting Guidelines
91
Error and Warning Messages
91
Troubleshooting Chart
92
Not Printing
93
Printing Poorly
93
Cannot Purge Printhead
95
Cannot Jet Test Printhead
96
Jets Fire Continuously
96
Image Prints Continuously (in Print Mode)
96
Enclosure Ink Leak
97
Cannot Read Display
98
Machine will Not Power up
100
Machine Resets
100
Machine Locks up
100
Communications Are Lost
100
Job Not Found
101
Field Replaceable Parts
103
Proper Handling of a Circuit Board
105
Replacing the VPC Module
105
What You will Need
105
Preparation
105
Removal
105
Replacement
106
Final Steps
106
Replacing the User Interface Module (UIM)
107
What You will Need
110
Preparation
110
Removal
110
Replacement
110
Replacing the Printhead
110
What You will Need
112
Preparation
112
Removal
112
Replacing the Ink Delivery Module (IDM)
112
What You will Need
114
Preparation
114
Removal
114
Replacing the Ink Level Sensor (ILS) in the IDM
114
What You will Need
118
Preparation
118
Removal
118
Replacing the Ink Pump Motor and Ink Pump Piston
118
Replacement
121
Final Steps
121
Replacing the IDM Filter
122
What You will Need
122
Preparation
122
Removal
122
Replacement
123
Final Steps
123
Replacing the Ink Line
124
What You will Need
124
Preparation
124
Removal
124
Replacement
124
Final Steps
125
Replacing the Control Board
126
What You will Need
126
Preparation
126
Removal
126
Replacement
126
Final Steps
127
Replacing the Printhead Volt Board
128
What You will Need
128
Preparation
128
Removal
128
Replacement
130
Final Steps
130
Replacing the I/O Panel Assembly
131
What You will Need
131
Preparation
131
Removal
131
Replacement
134
Final Steps
134
Replacing the Transformer(S)
135
What You will Need
135
Preparation
135
Removal
135
Replacement
136
Final Steps
136
Replacing the Soft Start Board
137
What You will Need
137
Preparation
137
Removal
137
Replacement
138
Final Steps
138
Replacing the Vacuum/Ground Line
139
What You will Need
139
Preparation
139
Removal
139
Replacement
139
Final Steps
139
Replacing the Printhead Data Cable
140
What You will Need
140
Preparation
140
Removal
140
Replacement
140
Final Steps
140
Spare Parts Kit
141
4-40 Pan Head Phillips Screws
141
M4 Pan Head Phillips Screws
141
Thermistor
141
Holding Chamber Thermistor
141
Melt Chamber Thermistor
142
Cartridge Heater with Thermostat
143
Holding Chamber Cartridge Heater with Thermostat (400W)
143
Melt Chamber Cartridge Heater with Thermostat (200W)
144
Limit Switch
144
Replacing the Ink Door Lock Limit Switch
144
Replacing the Pump Stroke Counter Limit Switch
145
Reflective Tape on Bottle Guide
145
Fuse Kit
146
Fuses on Backplane Board
146
Fuses on Printhead Volt Board
147
Fuse on VPC Board
148
Replacing the Low Vacuum Diaphragm Pump
148
Printhead Soak Kit
149

Dover Markem-Imaje 5400 Installation And Setup Manual (136 pages)

Brand: Dover | Category: Industrial Equipment | Size: 3 MB

Table of Contents
5
SECTION 1 General Information
11
General Information Section
13
Welcome to the Model 5200/5400
13
What's in this Guide
13
Related Documentation
14
Glossary
14
Specifications
15
Dimensional Drawing
16
Safety Information
17
Certification
17
Automatic Startup
18
Safety Labels
19
Location of Safety Labels
19
Foreseen Use
21
Misuse
21
Training Programs
21
Label and Symbol Identification
22
Removal from Service
25
SECTION 2 Installation
27
Installation Section
29
Machine Requirements
29
Environmental
29
Ventilation
29
Electrical
29
Printing Limitation
30
Installing the Model 5200/5400
30
Installing the Enclosure
31
AC Power Cord and Plug
32
Changing the Voltage Configuration
33
Installing the Printhead
36
Assembling the Printhead Stand
36
Assembling the Mounting Pole
38
Mounting the Printhead
39
Down Jetting Mounting Position
42
Software Parameters for the Printhead Jetting Position
43
Connecting Umbilical Lines
44
Connecting the Ink Line Inside the Enclosure
44
Connecting Vacuum and Electrical Lines to the I/O Panel
48
Connecting Umbilical Lines to the Printhead
49
Installing Options
50
Installing a Product Sensor
50
Installing an External Encoder
52
Installing the Serial Interface
53
Ethernet Host Port Setup
54
Installing the Signal Tower
55
Installing the Keyboard
56
Fault Relay Cable
56
Optional Control Unit (OCU)
58
After Installation
60
Getting Started
61
Connecting the AC Power
61
Powering on the AC Power
61
Setting Software Parameters
62
Where to Find Information on Software Parameters
62
Recording Your Setup Parameters
63
SECTION 3 Machine Setup Menu
65
Software Introduction
67
The Keypad
67
Displaying the Machine Setup Menu
68
Access Level
69
User Interface
70
Units
70
Language
71
Key Beeper
71
LCD Contrast
71
Clock Settings
72
Printhead Settings
73
Printhead Enable
73
Fixed Space Mode
74
Fixed Space Standby
74
Encoder Settings
74
Print Trigger
75
Print Direction
75
Image Orientation
75
Mirror Image
76
Image Density
76
Registration/Fixed Spacing
76
PH Orientation
77
Purge Time
78
Auto Purge
78
Auto Purge Time
78
Auto Purge Frequency
79
Ink Line Preheat
79
Ink Line Power
79
ILS Set Point
80
Warm-Up Mode
80
Array Temp
80
Reservoir Temp
80
Printhead Voltage
81
Printhead Vacuum Settings
81
Vertical Vacuum
81
Horizontal Vacuum
81
Down Vacuum
81
Custom Vacuum
82
Printhead Mapping
83
Print Station Settings
83
Melt Chamber Temp
84
Hold Chamber Temp
84
Allocation Prompt
84
Database Mode
84
Slanted Printhead
85
TAP Mode
85
Ack Update Var Fields
85
Purge Prompt Time
85
Remote Purge
86
Keyboard Port Mode
86
Pad Leading Zeros
86
Default Leap Year
86
Product Sensor Settings
87
Sensor Debounce
87
Sensor Trigger Edge
87
Var. Encoder Settings
87
Var. Encoder Ratio
87
Jet Pack Spacing
88
OCU Settings
88
Consecutive Fails
88
Reject Relay on Time
88
Reject Relay Delay Distance
89
Reject Relay Delay Trigger
89
Verify both
89
Reader Port Settings
89
Product ID Port Settings
93
Remote User Interface
96
Shutdown Settings
97
Password Settings
98
Passwords
99
Top Menu Security
99
Main Menu Security
100
Default Access Level
100
Top Menu Time-Out
100
Communications
101
Get All Font Files
101
Get All Logo Files
101
File Transfer Time
101
Host Port Settings
102
Protocol
102
Baud Rate
102
Node Number
102
Comms Mode
102
Pkt Timeout Test
103
Pkt Process Timeout
103
Ethernet Settings
104
ASCII Comms
105
ASCII Port
105
Baud Rate
105
Ack. ASCII Comms
105
Custom Codes
106
Machine ID
106
Line ID
107
Inc Start Val
107
Year Codes
107
Month Codes
107
Week Codes
108
Day Codes
108
Weekday Codes
108
Hour Codes
108
Shift Codes
109
Of Shift Codes
109
Shift Code
109
Shift ID
109
Start Time
110
Finish Time
110
Valid Days
110
SSCC Settings
111
SSCC Start Value
111
SSCC End Value
111
SSCC Current Value
111
Date Change
112
Start of Day
112
First Day of Week
112
Date Language
112
BBE Group Setting
113
Date Change Frequency
113
Date Change Day
113
Date Change Rate
113
Date Change Time
114
Date Change Rounding
114
Date Prompt Type
114
Date Language
114
Image Settings
115
Host Update Fields
115
Update Time Fields
115
Wide Head Spacing
115
Log Job Data
115
Save Variable Data
116
5200/5400 Job Files
116
Set Time Updates BBE
116
Full Text Inversion
117
Printhead Image Offset
117
Printhead Left Edge Opt
117
Printhead Right Edge Opt
118
Error Conditions
118
Initialization
119
Reset to Factory Defaults
119
Store User Settings
119
Reset Counts
119
Reset Pump Count
119
SECTION 4 Database Management
121
The Database Management Menu
123
Retrieve Files
123
View Files
124
Backup Files
125
Delete Files
125
Advanced
125
Clear Database
126
Delete Job Files
126
Restore Default Jobs
126
Defragment Database
126
Ram Database
126
SECTION 5 Troubleshooting
127
Troubleshooting Section
129
Troubleshooting Guidelines
129
Error and Warning Messages
129
Diagnostic Guidelines
129
Signal Lights
129
LED Indicators on the Print Station
130
Signal Tower Lights
131
Status Led
131
LED Indicator on the Printhead
131
Machine Diagnostics Menus
132
Version Information Menu
133
Print Registration
133
Not Printing
133
Ink Pump Stalls or Ink Does Not Reach the Printhead
133
Cannot Change the Print Trigger Parameter
133
Encoder Line Speed
134
Partial Images Print
135

Dover Markem-Imaje 5400 Operation Manual (67 pages)

Brand: Dover | Category: Printer | Size: 2 MB

Table of Contents
5
Section 1

7
- General Information
  7
- Welcome to the Model 5200/5400
  9
  - What's in this Guide
    9
  - Related Documentation
    10
- Before You Begin
  11
- Glossary
  12
- Safety Information
  15
  - Certification
    15
  - Automatic Startup
    16
  - Safety Labels
    17
  - Location of Safety Labels
    17
  - Foreseen Use
    19
  - Misuse
    19
  - Training Programs
    19
- Label and Symbol Identification
  20
- Removal from Service
  23
Section 2

25
- Basic Operation
  25
- Basic Components
  27
- The Power Switch
  29
  - Powering on the Coder
    29
  - Powering off the Coder
    30
- The User Interface Module
  31
  - LED Indicators
    32
  - Navigation
    33
    
    Menu Functions
    33
    
    Function Keys
    34
    
    ENTER and EXIT Keys
    34
    
    START and STOP Keys
    35
    
    Directional Arrow Keys
    35
    
    Select Characters Dialog Box
    35
    
    Using the Keyboard
    36
- The Printhead
  37
  - Jet Test and Purge Buttons
    37
  - Printhead Status
    37
Section 3

39
- Printing
  39
- Powering on the Coder
  41
- The Top Level Menu
  42
  - Selecting a Job
    43
  - Previewing a Job
    45
- Production Printing
  46
- Adding Ink
  47
  - Adding an Ink Bottle
    47
  - Adding an Ink Block
    48
- Making Adjustments
  49
  - Setting the LCD Contrast
    49
  - Setting the Registration
    51
- Database Management
  54
Section 4

55
- Cleaning and Care
  55
- Daily Cleaning of the Printhead
  57
  - Purging
    58
  - Jet Testing
    59
  - Wiping
    60
- Cleanup
  60
Section 5

61
- Troubleshooting
  61
- Troubleshooting Guidelines
  63
- Signal Lights
  63
- Unreadable Display
  65
- Beep Due to Open Ink Door
  66
- The Purge Button Does Not Function
  66

Dover Markem-Imaje 5400 Instruction Manual (37 pages)

Brand: Dover | Category: Printer | Size: 4 MB

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