Book for service engineers

Internal use only

S
 Content

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Content

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Content

CONTENT ........................................................................................................................................... 3

SAFETY .............................................................................................................................................. 9

■ REMINDER........................................................................................................................................ 11
■ COMPLIANCE TO STANDARDS ............................................................................................................ 11
■ SAFETY ............................................................................................................................................ 11
■ RULES OF CONDUCT FOR TECHNICIANS WHEN VISITING CUSTOMERS .................................................... 12

PRINTER DESCRIPTION .................................................................................................................. 13

■ OVERVIEW ....................................................................................................................................... 15
■ MAIN FEATURES ............................................................................................................................... 16
■ UMBILICAL CONFIGURATIONS (G/M HEADS) ....................................................................................... 16
■ CABINET DIMENSIONS ....................................................................................................................... 17
■ HEAD DIMENSIONS ............................................................................................................................ 18
■ M/G PRINT HEADS PARTS ................................................................................................................. 19
■ ELECTRONIC COMPARTMENT ............................................................................................................. 20
■ USER INTERFACE .............................................................................................................................. 20
■ HYDRAULIC COMPARTMENT .............................................................................................................. 21
■ 9222 & 9232 MAIN DIFFERENCES ..................................................................................................... 22
■ GENERAL SPECIFICATION .................................................................................................................. 23

MAIN PRODUCT FEATURES ........................................................................................................... 25

CHARACTER HEIGHT ............................................................................................................................ 27

FONTS AND ALGORITHMS ..................................................................................................................... 27
HEAD OBJECT DISTANCE ...................................................................................................................... 29
MESSAGE / JOB CONTENT .................................................................................................................... 29
PROMOTIONAL CODING ........................................................................................................................ 30
DATA MATRIX....................................................................................................................................... 31
BARCODES .......................................................................................................................................... 32
COUNTERS .......................................................................................................................................... 32
MESSAGE/JOB STORAGE ...................................................................................................................... 32
PARENT/CHILD .................................................................................................................................... 33
SIMPLIFIED PROTOCOL ........................................................................................................................ 34
TOOLS ................................................................................................................................................ 35
CUSTOM FONT ..................................................................................................................................... 35
FILES FORMAT..................................................................................................................................... 36
COMPATIBILITY .................................................................................................................................... 37
PRINTER INSTALLATION ........................................................................................................................ 38
STANDARDIZED PRODUCT SENSOR ....................................................................................................... 40

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Content
POSITIVE AIR PUMP KIT......................................................................................................................... 41
EXTERNAL COMMUNICATION ................................................................................................................. 41
INDUSTRIAL INTERFACE ........................................................................................................................ 42
■ PLANET PORTAL ............................................................................................................................... 44

PRE-INSTALLATION INSTALLATION TRAINING ........................................................................... 45

START-UP INSTRUCTION (APPROXIMATELY 30 MINUTES) ......................................................................... 47

■ ADJUST THE METERING MODE (ONLY 9232E) .................................................................................... 49
TACHO STEP CALCULATION .................................................................................................................. 49
TACHO STEP CALCULATION .................................................................................................................. 49
TUNING OF THE METERING DISTANCE .................................................................................................... 50
■ OPERATOR INSTRUCTION .................................................................................................................. 52
OBJECTIVES ........................................................................................................................................ 52
CUSTOMER TRAINING CONTENT ............................................................................................................ 52
9232 INSTALLATION VALIDATION CHECKLIST ......................................................................................... 53
■ DEMO MODE ..................................................................................................................................... 54
SAFELY TRANSPORTING THE PRINTER ................................................................................................... 54

AFTER-SALES .................................................................................................................................. 57

■ AFTER SALES POLICY....................................................................................................................... 59

SPARE PARTS POLICY .......................................................................................................................... 59
PRINT MODULE - ENR POLICY .............................................................................................................. 60
SPARE PARTS FOR MI FSE .................................................................................................................. 62
■ SPARE PARTS FOR CUSTOMER (ONLINE CATALOGUE= HTTPS://MI.SPELOG.COM/) .......................................... 63
INK CIRCUIT (1) ................................................................................................................................... 63
INK CIRCUIT (2) ................................................................................................................................... 64
ELECTRONIC ....................................................................................................................................... 64
PRINT MODULE (G R1 HEAD) ............................................................................................................... 65
PRINT MODULE (M HEAD) .................................................................................................................... 65
MAINTENANCE POLICY ......................................................................................................................... 66
UI SIMULATOR ..................................................................................................................................... 67
PRINTER INFORMATION ........................................................................................................................ 67
START & STOP LOG FILE ...................................................................................................................... 69
■ ESCALATION PROCESS ..................................................................................................................... 70
CLAIM PROCESS .................................................................................................................................. 70

MAINTENANCE ................................................................................................................................ 71

■ GENERAL ......................................................................................................................................... 73
PRESSURE PUMP REPLACEMENT PERIODICITY ....................................................................................... 74
INK FILTER REPLACEMENT PERIODICITY ................................................................................................. 74
■ MAINTENANCE ALARMS .................................................................................................................... 75
FILTER KIT .......................................................................................................................................... 75
FLUSHING & MAINTENANCE KIT............................................................................................................. 75

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Content
INK 9182 ALARM.................................................................................................................................. 76
SPECIFIC MAINTENANCE FOR CARBON BLACK INK (9554, 9139, 9139S) ................................................. 78
PREVENTIVE MAINTENANCE .................................................................................................................. 79
CURATIVE MAINTENANCE...................................................................................................................... 80
■ NEXT MAINTENANCE ALARM RESET.................................................................................................... 81
■ MAINTENANCE HISTORY .................................................................................................................... 81
■ PREVENTIVE MAINTENANCE CHECK LIST (PM) ................................................................................... 82
■ DRAINING & RINSING RECOMMENDATIONS ......................................................................................... 89
SHUT-DOWN > 2 WEEKS ....................................................................................................................... 89
STORAGE TIME > 2 MONTHS ................................................................................................................. 89

TROUBLESHOOTING....................................................................................................................... 91

■ INTRODUCTION ................................................................................................................................. 93
■ PROFILES......................................................................................................................................... 93
■ STATUS ........................................................................................................................................... 94
GENERAL STATUS ................................................................................................................................ 94
■ MAINTENANCE MENU ........................................................................................................................ 96
INK CIRCUIT MAINTENANCE MENU .......................................................................................................... 96
HEAD MAINTENANCE MENU .................................................................................................................. 98
■ MI PROFILE ...................................................................................................................................... 99
MI ENGINEER PROFILE ......................................................................................................................... 99
WHEN TO USE MI MENU? ................................................................................................................... 101
SAFETY ............................................................................................................................................. 102
■ ERROR CODE & TROUBLESHOOTING CHART ..................................................................................... 105
TROUBLESHOOTING TABLES ............................................................................................................... 106
■ LIST OF SPECIAL SPARE PARTS FOR M-I TECHNICIANS ..................................................................... 132
■ LIST OF SPECIAL SPARE PARTS (OUT OF CATALOGUE) ..................................................................... 134
EHT PLATE RECOGNITION .................................................................................................................. 136
CONNECTING THE MI TECHNICIAN TOOL .............................................................................................. 137
DRAINING AND FLUSHING PROCEDURE ................................................................................................ 138
STORAGE TIME > 2 MONTHS ............................................................................................................... 138
■ ACCESSIBILITY TO THE IC PARTS ..................................................................................................... 139
OBJECTIVE ........................................................................................................................................ 139
PROCEDURE...................................................................................................................................... 139
■ SPARE PARTS SHEETS .................................................................................................................... 141
MOTOR SPEED................................................................................................................................... 166
BREAK-OFF POINT ADJUSTMENT ......................................................................................................... 168
BREAK-OFF TABLE ............................................................................................................................. 169
CALIBRATION OF ADDITIVE TRANSFER PUMP PTR2 ............................................................................... 170
PARTIAL INK TRANSFER MODE ........................................................................................................... 171

ELECTRONICS ............................................................................................................................... 173

■ DIAGRAM BLOC .............................................................................................................................. 175

■ POWER SUPPLY .............................................................................................................................. 176
■ NEP BOARD (ENM50529) .............................................................................................................. 176

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Content
DIAGRAM BLOCK (NEP BOARD) .......................................................................................................... 177
■ TECHNOLOGY INTERFACE BOARD .................................................................................................... 177
CONNECTIONS OVERVIEW .................................................................................................................. 178
DIAGRAM BLOCK (TECHNOLOGY INTERFACE BOARD) ........................................................................... 179
■ INK CIRCUIT BOARD ........................................................................................................................ 180
COMPONENT LAY-OUT INK CIRCUIT BOARD .......................................................................................... 180
■ PRINT HEAD BOARD ........................................................................................................................ 181

HYDRAULICS ................................................................................................................................. 209

LOCATION OF THE DIFFERENT COMPONENTS ....................................................................................... 210

■ PART IDENTIFICATION ..................................................................................................................... 211
FILTER .............................................................................................................................................. 211
INK CIRCUIT START –UP / MAIN STEPS ................................................................................................. 213
VISCOSITY MEASUREMENT / MAIN STEPS ............................................................................................. 216
INK LEVEL MEASUREMENT / MAIN STEPS .............................................................................................. 218
INK TRANSFER PHASE ........................................................................................................................ 219
STAND BY MODE (AVAILABLE ONLY FOR 9232E) .................................................................................. 220
■ JET START-UP AND SHUT-DOWN ...................................................................................................... 222

SOFTWARE .................................................................................................................................... 227

GENERAL .......................................................................................................................................... 229

OPERATING SYSTEM .......................................................................................................................... 229
9450 APPLICATION SOFTWARE............................................................................................................ 229
■ SOFTWARE INSTALLATION / UPDATE PROCEDURE ............................................................................. 230
GENERAL .......................................................................................................................................... 230
SOFTWARE PACKAGE ......................................................................................................................... 230
PREPARATION ................................................................................................................................... 231
FIRMWARE INSTALLATION (STANDARD) ............................................................................................... 232
INSTALLATION REPORT ...................................................................................................................... 234
■ FACTORY CONFIGURATION SETUP.................................................................................................... 235
PRINTER CONFIGURATION .................................................................................................................. 235
PREVENTIVE MAINTENANCE DATA ....................................................................................................... 237
9232 CAPACYT TOOL ...................................................................................................................... 237
HISTORIES ERASURES ........................................................................................................................ 238
■ INTERFACE FOR MI SERVICE ENGINEER ........................................................................................... 238
MI ENGINEER PROFILE ....................................................................................................................... 241
■ COPY SCREEN ................................................................................................................................ 244
PREPARATION ................................................................................................................................... 244
USE .................................................................................................................................................. 244
■ SIMULATOR .................................................................................................................................... 245
INSTALLATION & LAUNCHING .............................................................................................................. 245
USE .................................................................................................................................................. 245
■ ALGORITHMS.................................................................................................................................. 246
CODIFICATION ................................................................................................................................... 246

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 Safety

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Safety

Notes:

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Safety

■ Reminder
Please read all the safety instructions that appear in the manuals provided to customers.

■ Compliance to standards
All our products are imposed to meet certain standards depending on local legislations.

Any (local) modification and or alteration to our equipment other than

communicated by MARKEM-IMAJE DS department, either by a MI employee or
a customer is therefore strictly forbidden.

The uses of non MARKEM-IMAJE parts or drilling a hole in the cabinet are
examples which affect the compliance to standards.
Keep this in mind at any time and make sure the customer does the same.

■ Safety
Although we are able to meet a large variety of applications with our product range, there is one
application which we cannot meet: Hazardous environments
A hazardous environment is defined as a place where concentrations of flammable gases,
vapours, or dusts occur.

It is strictly forbidden to use any product of MARKEM-IMAJE in an environment

which is determined as hazardous environment

The safety precautions mentioned in the operators, service and installation

instructions should be understood, communicated to the customer and
followed up at any time without any exceptions.

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Safety

■ Rules of conduct for technicians when visiting customers

Technicians must comply with the safety rules in effect at the customer's site:
Prevention plan: Technicians must request and examine the customer's prevention plan (where
applicable) in advance or upon arriving at the customer's site.

- Traffic areas,

- Authorization to use spark-producing tools,

- Authorizations to perform work,

- Necessary accreditation (chemical, electrical, etc….)

If the business being visited does not provide specific equipment, technicians must wear Markem-
Imaje personal protective clothing at least.

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 Printer
description

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Printer description

Notes:

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Printer description
■ Overview
9200 series are replaced by 9400 series.

9232
A40029 9232 1G IP56 9232E 9232S 9222
A40030 9232 1M IP56
A40031 9232 1G IP66 A44051 9232E 1G IP56 A45963 9232S 1G IP56 A44235 9222 1G IP56
A40032 9232 1M IP66 A45962 9232E 1M IP56 A45964 9232S 1M IP56

“Standard” Applications Extrusion Speed

(Cables, tubes, profiles...) (Beverage, Can) “Standard” Applications

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Printer description

■ Main Features

Two firmware versions available:

- One standard (9232,9232S, 9222),
- One for Extrusion market (9232E)

Two types of Print Head:

M head: Font height up to 24 dots
Resolution = 2.8 or 4.5 dots/ mm
No M head for 9222 printer
G head: Font height up to 32 dots
Resolution = 2.8 dots/ mm

Very high printing speed range up to

16m/s
Up to 4.6 m/s for 9222 printer

Two Ink circuit: contrast version running

with pigmented ink (9232E) & standard
version (9232, 9232S, 9222)

The printer is designed to be put on a table

(MI accessory)

■ Umbilical configurations (G/M heads)

By default, the umbilical configuration is straight (Angle=0°). Additionally, three others umbilical
configurations could be selected with the SAP configurator (270°/180°/90°).

Note: Only straight configuration (Angle=0°) for 9222 printers.

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Printer description
■ Cabinet dimensions

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Printer description
■ Head dimensions
9232/9222 G R1 Print Head (old generation)

Minimum radius of curvature (r):

100mm/3.93 inch in static
150mm/5.90 inch in dynamic

This old generation of head is replaced by

new 9450 print head generation using
REN/ENR process.
(See after sales policy section)

9232/9222 M and G R2 printed head (based on 9400 series)

9232 ENM/ENR Print Module process

(TB150406)

Compatible with old G head generation

- Jet Position
- Head-Object Distance

9232 ENM/ENR Print Module process

(TB150406)

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Printer description

M head (Only 9232)

Units:
mm
[inch]

■ M/G Print heads parts

G Head M Head
1 8

2 2b

3b
5 6 7
7
4 4a

ID Designation G head M head Comments

1/1b Modulation Assembly ENM38980 ENM44528 -
2/2b Charge electrode - - Included with Spare part “Active plate” (7)
3 Deflection Plate ENM40783 ENM46263
4 Gutter Block ENM38941 -
4a Gutter Sensor ENM38973 -
5 4ELV Blocks ENM47086 ENM46408
6 Print Head Board ENM39168 -
ENM40161= Not Available
7 Head Cover including EHT ENM40161 ENM45670
ENM45670= Technical approval needed
- Ink Filter ENM46708(Printer produced prior w23-2014)
8 Pressurization outlet - - -

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Printer description

■ Electronic compartment

Power Supply board NEP board (ENM38177)

(ENM40189) Techno board (ENM39368)

Industrial interface
board (ENM40202)

9222 NEP boards:

w/o Ethernet ENM44241
w/ Ethernet ENM44091
■ User interface
Current Job in
Alarm and fault
production
Printer/jet notifications
USB
Status
connected Zoom (Job)

Consumable
Management

Start-up/Shut down

Job management
(Creation, modification…) Profil management

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Printer description
■ Hydraulic compartment

Air Treatment Unit

(ENM40206)

Ink Circuit

9232 Pressure pump (ENM5629)

9232E Pressure pump(ENM44514)

Cartridge holders

INK CIRCUIT

Peltier Condenser

Vapour Exhaust Pressure sensor +

Anti-pulse
Ink Circuit Board

Ink filter

Transfer pumps
& Electrovalves

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Printer description
■ 9222 & 9232 Main Differences

Features 9222 9232

IP rating IP56 IP56/IP66

Umbilical length 3m 3m/6m

Hardware Umbilical configuration Only straight(Angle=0°) All (0°,90°,180°,270°)
Condenser No Yes

Head type G 1.1 G1.1/M1.1

Connectivity Ethernet Optional Standard

Up to 3 lines
Number of lines Up to 5 lines
Guidelines limited to 3 lines

Character height Up to 24 dots Up to 32 dots

Max printing speed Up to 4.6 m/s Up to 6.6 m/s

Printing resolution 2.8 dot/mm (G) 2.8 dot/mm (G) - 4.5 dots/mm(M)

Number of counters 2 15

Number of postdate 2 6
Printing
Number of shift code 1 limited to type 1 3

Barcode / 2D code No Yes

Printing height
Up to 8,5mm (0.33 inch) Up to 11,4mm (0.45 inch)
Resolution 2,8 dots/mm (71dpi)

10 or 30 mm (G head)
Head/object distance 10 or 30 mm (G head)
7 or 14 mm (M head)

Ink and air filter Every 18 months Every 18 months

Standard ink=14000 hours

Maintenance Micro-pigmented ink= 6000h
Standard ink=10000 hours
Pressure pump For 9232E:
Micro-pigmented ink= 6000h
Micro-pigmented ink/pigmented= 8000h

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Printer description
■ General specification
Physical characteristics
Printer body(LxPxh) .................... 360mm x 304mm x 555mm
Print head (LxPxh): G head: 229mm x 45mm x 45mm
Dimensions (mm) M head: 231mm x 45mm x 45mm
Umbilical length: 3000 mm or 118 inches
6000 mm or 236 inches
Complete machine ........................... 25 kg without options and ink
Weight (kg)
Cartridge ........................................... 0.8Kg
Stainless steel 304L
Operating limits
Operating temperature [5°C to + 40°C] Use of certain inks can limit the temperature range
Humidity 10 to 90 % without condensation
Altitude 3000m maximum
Protection IP56 (standard configuration)/IP66 (Optional configuration)/EN60529
Installation details
Working position Vertical for the printer cabinet/ Any position for print head
[- 2 m & + 2 m] for umbilical 3m
Maximum height offset
[-1m & +2m] for umbilical 6m (print head vertical down or horizontal)
between head and Printer
[0m & +2m] for umbilical 6m (print head vertical up)
cabinet No setting required
Head / Object distance G head: 10 and 30 mm / M head: 7 and 14 mm
Possible with limited ink range, refer to IRS
Head movement
(Maximum acceleration: 10m/s². Max linear speed: 1m/s)
Compliance with standard
CE marking
Conformity with the machine directive, the EMC directive and the low
Safety
voltage directive: CEI 60950 (EN60950) + Safety standard ISO 13849
Certification cULus-GS
Electromagnetic compatibility Emissions: EN 61000-6-4 / Immunity: EN 61000-6-2
Vibrations : NF EN 22247 / NF EN 60068-2-29
Impacts: NF EN22248 (falls/impacts)/NFH00 -60 NFH00-41, 47, 58, 59
Energy
100 - 120V 0.5A alternative (Automatic switching)
200 - 240V 0.3A alternative (Automatic switching).
Power supply
Frequency 50 or 60 Hz
Power 60 VA.
Max: 0.12 grams of water/m³ (0.15 oz. of water/cubic
Air quality
foot) – 1 PPM of oil and size of particle < 5μ
Air pressurized (head Filtration 90% (particle > 0.1μm)
pressurization option) Flow rate 800 Nl/hour (0.47 scfm) for a IP56 version equipped
with air pressurisation at 7 bar (101 PSI)
Nominal pressure 5 < P <8 bar (72.5 < P < 116 PSI)

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Printer description

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Main product
features

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Main product features

Notes:

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Main product features

■ Printer features
 Large choice of fonts and algorithms,
 Industrial barcodes,
 History recording for maintenance interventions,
 Printer availability and additive consumption,
 Faults with corresponding running data.
 Character height up to 24 drops (M) or 32 drops (G),
 Print speed up to 6.6 m/s (9232, 9232S)
 G : resolution 2.8 dots/mm (71dpi),
 M: Resolution = 4.5 dots/ mm (printing resolution: 115 dpi)
 Head/object distance: from 5 to 30 mm,

Character height

The print head has one jet with the possibility to print characters and customized logos up to 32
dots in height. Refer to the printing capabilities sheet available on MI web site for details.

Fonts and Algorithms

Fonts:
a
Standard fonts (a) are: Latin, Arabic, Hebrew, Greek, Chinese, Cyrillic, Chimney, and Japanese
The range of font size (b) is expressed in dots from 5 up to 32 dots. b
The file extension of the fonts used on the 9232 is (*.mif): xxx.mif

Algorithms:
There are several algorithms (c) available to fulfil customer’s
expectation: Quality, Speed, and Height…
All algorithms are available in the printer. The Algorithms are divided
in 2 packages and selected automatically depending on the print
head configuration: c
Quality (jet speed 20 m/s) or Speed (jet speed 23 m/s)

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Main product features

Caution: The print head configuration in particular for speed is depending on

the Ink Running Specification

9232

xx

In order to optimize the printing quality, the 9232 printer can change the algorithm according to the
printing speed. In this mode (automatic mode), the printer selects automatically the most suitable
algorithm according to the conveyor speed.

There are two algorithm selection modes:

Automatic:
If the algorithm number is «0000» in the
message parameter, the printer selects
the best algorithm by itself

Manual:
If the algorithm is different from "0000"
in the message parameters, the printer
will only use this algorithm for printing.

Printing capabilities are detailed in the 9200 Capabilities document (available on planet)

This table gives the most suitable algorithm

according to the printing speed, number of
lines in the message, resolution…

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Main product features

Head object distance

The head/object distance (d) depends on the head type as follow:

G head M head
Standard resolution 2.8 dots/mm 4.5 dots/mm

Head – object distance 10 and 30 mm 7 and 14 mm

Message / Job content

Up to 5 lines can be defined for each job; it could be up to 4 Kbytes. Each job/message is
named (up to 20 ASCII char) & numbered (1 to 998). A job is composed with several blocks.
Extension file for job is: *.mim (M-I Message)

Blocks

Lines

This includes printing parameters (18 bytes) and variable attributes (when it applies):
Counter (49 bytes per counter),
Barcode 1D (24 bytes + data per BC)
Barcode 2D (14 bytes + data per BC)
QR code ()

Shift Code (9 bytes for mode 1, 12 bytes for mode 2, 46 bytes for mode 3)

Postdate (8 bytes per postdate)

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Main product features

A job is composed with several blocks. Blocks can be protected for modification or
given free for the standard operators.
Blocks can be:

Text

Symbol (Glyphs, Characters, logo…)

Graphics (pictures, logo…)

External Variable (up to 20 per job)

Date/Time/Postdate

Shift code

Custom date

Counter (up to 15 per job)

Bar Code (up to 4 different barcodes per job)

Unique code

Promotional coding

Promotional coding or unique code consists of sending a unique value to the printer. In that
sense, each product coded has a unique printed message. One message = one product.
The solution consists of embedding an amount of data on a media (USB stick) that are
automatically pulled after each Dtop signal.

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Main product features

Installation:
Set the printer in the Production Settings Factory. The selection case
allows the operator to use the promotion coding in standalone mode. If
not activated, the promotion coding can be used in V24 mode.

Restrictions and limitation

1. In case the printer is switched off from the mains, data are lost from the queue. Only data
remaining into the USB key are saved.

2. In case the operator changes the message in production or modifies the existing message,
data are lost from the queue. Only data remaining in the USB key are saved.

3. The unique code must be in ASCII character from 20h to 7Fh.

Note: Consult User Manual A48586 for more details.

Data matrix

Three (3) algorithms are especially dedicated to 16, 18 and 24 dots height printing.

Head font size Algorithm Head – Object

Resolution
type (dots) number distance (mm)
16 dots 316

18 dots 318 Horizontal : 2.6

G head 10 mm
Vertical : 2.6
24 dots 324

16 dots 316
18 dots 318 Horizontal : 3.9
M head 7 mm
Vertical : 3.9
24 dots 324

Recommendations
Stable product movement: no vibration, product with a flat surface and well guided.
Angle of distortion: Adjust the tilt of the head in order to compensate the speed effect
(inclination of the raster)
Tacky encoder is mandatory: The tacky encoder is mandatory to ensure a constant length of
the Data matrix in spite of the speed variations.
Head sense installation: The L pattern has to be printed with the less deviated dots.
We recommend sens1 and 4.

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Main product features

Sens 1 Sens 2 Sens 3 Sens 4

Horizontal resolution: the tacky division has to be set to get a horizontal resolution of 2,6 dots
/mm (G head) and 3.9 dots /mm (M head).
THT value: Check that the THT value indicated in the MI Engineer menu is the one indicated
on the Print module.

Barcodes

9232 barcodes capabilities: EAN 8, EAN 13, UPCA & UPCE, 2/5 interleaved, Barcode 39
Counters

Up to 15 Counters can be added to one single job. They can be incremented and reset by
external signals or by internal settings. An external signal can be given to inform the end value
has been reached.

Message/job storage

 The printer can “Store” up to 999 Jobs.

 From the main repository up to 255 jobs could be selected to be part of the “Library”
of the printer.
 Any job in library could be selected using parallel interface (8bit input on Industrial
Interface) or serial link protocol.
 Extra input on industrial interface allows Job sense change.

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Main product features

Parent/Child

This feature could be used when sending a job in production (with parameters) to several printers
connected together. In this case, it should be necessary to identify a printer as a “parent” and
others as “Children”.
Parent Children

By default, the configuration of a printer is “Children”. The configuration of the parent/child feature
is done in the printer configuration menu:

Enter IP address and S/N of printers

connected as a children

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Main product features

Simplified Protocol

The Simplified Protocol is now embedded on the printer. It can be used through the serial ports
and through the Ethernet. It includes the following features:

1/ "Job name selection": Job selection from the store (By Name) (9232E mode 1 only).

2/ "Job library selection": Job selection from Library (By position) (9232E mode 1 only).

3/ "Simplified - external variable": Update external variable in active Job.

Overview

The format of the frame is “STX (ASCII DATA) ETX”. There is no response from the printer.
When an error is detected, the User Interface displays the "External com error" Warning (without
port origin).

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Main product features

Tools

Conversion of files from 9020/9030/9040 to 9232 format is performed by CoLOS GRAPHICS.

GCG Files (*.GCG)

S7S Files (*.S7S)

MIF files (*.MIF)
Binary format
MIF Files (*.mif)

Custom font

There is no font editor with 9450c. It is necessary to use CoLOS GRAPHICS to create custom
font. (Name=admin/Password=admin)
Create a bitmap (font type) and save it (as a MIF file) and upload it on a USB key or on a SD
disk.

Connect the USB key to the printer and upload the font in the printer.

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Main product features
Create a new message, select font “MILogo” and add the symbol in the message.

Save the message and select it in production.

Files Format

Fonts Idem 9232: MIF files (*.mif)

Algo Idem 9232: MIA Files (*.mia)

Message Idem 9232: MIM files (*.mim)

The V24 protocol is identical to the 9232 printer with additional commands.
V24
Consult the Network Interface Manual A48602.

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Main product features

■ Accessories

Compatibility

The printer is equipped with the connections for the MARKEM-IMAJE standard accessories.

Accessories Compatible with

1 2

1-Standard Printer bracket

2-Standard Stainless steel table

5
3 3-Standard print head support
4-Standard head/Printer stand
5-Print head quick fixation

7
7-Standardized Product Sensor
8-Standard Encoder
9
8
9- Configurable encoder

Previous CIJ alarm tower(A34791)

10 10-New Alarm A43931 + cable A43941
11

(kit A34792)

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Main product features

Printer installation

See Instruction manual for details about printer installation.

9232 could be mounted on stand thanks

to the dedicated bracket stand support kit
including stability weights.

Bracket
(Stand mounting)

Maintenance tray

9232 could be mounted on wall

support thanks to the dedicated
bracket wall support kit

Bracket
(Wall mounting)

Note: Consult the 9232 spare parts catalogue for details about accessories
Online catalogue : https://mi.spelog.com/

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Main product features
Print head installation
Distance between the 2 fixing screws is the same as 9030, 9040 (E=65mm), so the use of
existing head support is possible.

Head support

E
E

E
E
F
G
F

Plug & play with 9030 heads (x, y and z axis): Compatible with 9040 head thanks to
 Same head/object distance (G head), existing interface bracket:

 Same position for the printing (F=58.8mm)  On y and z axis but gap of 12 mm on “x” axis
 G = F + 12mm
 Mechanical adaptation on site could ensure
the compatibility: Use the bracket interface
Head Support.

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Main product features

Standardized product sensor

The following table gives the part number of the product sensor and the required cable
to connect on the printer. (Note: For each sensor, the cable is ordered separately)

Product Sensor Required Notes/Applications

Sensor type Cables
Name ref Picture

Universal (standard
DIFFUSE
PROXIMITY
A45638 A45652 applications): Cardboard,
paper, plastic…

Transparent product
requiring precision like
POLARIZED bottling line, glass…
RETRO REFLEX
A45639 A45652
Universal (Standard
application): Cardboard,
paper, plastic…
Photoelectric
CONTRAST A45645 No picture A45652 Film with dark mark
Sensors

COLOR A45646 A45652 Film with mark

FORK A45647 A45654 Bottling line

Application with precision in

BACKGROUND
SUPPRESSION
A45643 No picture A45652 term of product guiding
Transparent product

Inductive INDUCTIVE
M18
A45642 A45652 Metallic can
Sensor

Electronic component (small

GLASS parts)
FIBER
A45640 A45652
Application with difficult
integration (small place)
Optical
Sensors
Electronic component (small
GLASS_FIBER
parts)
THROUGH A45641 A45652
Application with difficult
BEAM
integration (small place)

Note: Consult the 9232 spare parts catalogue for details about accessories
Online catalogue: https://mi.spelog.com/

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Main product features

Positive air pump kit

The positive air pump kit (A44425) is an autonomous which compressor

permits pressurization of the print head to avoid any dust from the
environment being introduced to the printer.
The compressor requires no compressed air coming from the customer’s
industrial network.

It can be used in dusty environments only; the positive air pump kit does
not replace the Air treatment unit, the compressor cannot be used in
humid environments.

The compressor can be mounted on the printer using the location normally
used for the classic air treatment unit.

Positive air pump / Air Treatment Unit

Printer configuration Environment

KIT
IP56 IP66 Humid dust
ENM40206
Air treatment unit without switch x x x
A40205 Air treatment unit x x x
A44425 Positive air pump kit x x

Note: Cleaning frequencies for print head when using the compressor are:

- Once a week for print speed < 200m/min

- Once every three days for print speed > 200m/min

The Autonomous Compressor improve the printing autonomy for print speed > 200m/min

External communication

The printer is standard equipped with an Ethernet (RJ45) communication port for complete
printer control.
For updates and or data transfer the printer offers 2 ports: USB port or SD port.

Limitation: SD up to 2 Gb supported, SD HC and SD XC are not supported.

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Main product features

Industrial Interface

The industrial interface offers a wide variety of inputs and outputs to meet special and more
complex customer’s applications.

► Connection of customers “trigger” signal (cell, switch, PLC),

► Control of trigger signal by Inhibit signal input,
► Connection of customers “encoder” signal,
► Output for Warning and Alarm (opto-coupled and or Relays contact. The relays l
contact could be served for example to stop the production line.
► Connection of a second cell for object speed measurement,
► Printer ready output signal,
► Counters management (increment and reset) plus end value output signal,
► Switching ON/OFF the printer by external signal,
► Message selection from a predefined series of messages (library) by one input signal
plus control of selection sense, ascending or descending. For head movement
applications for example,
► Message selection by message number (Hexadecimal or Binary coded),
► Message print sense control (reverse printing)
► Serial communication either RS232 or RS422 mode for complete printer control

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Main product features

■ History recording

Several data are stored to facilitate the daily use of the printer by the customer and the intervention
of the MI service technician.
These data can be saved on a USB stick or SD card for analysis purposes.

Printing: print counts per message with start and end date and time over the
last two months for the messages manually selected. Message selection by
external signals is not taken into account.

Maintenance: All interventions (maintenance and or part replacement) can be

recorded in the printer. This is a manual procedure (except the maintenance).

Availability / consumption: The availability of the printer (100% = printer

always available without faults when needed) and average Additive
consumption plus the average temperature (based on the ink temperature are
measured for each month.

Warnings / Faults: Recent faults and warnings are recorded with a direct link
to the running status history which can be of use for the service technician for
diagnosis purpose.

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 Main product features

■ Planet portal
The aim of the DS Technical Support Planet is to give easier access to the information (last
Technical Bulletin, BfSE, check lists…) plus Software/Firmware.

The web link is http://blvsapep32:50000/irj/portal and the entry point is new technical support.

Entry point
(global support)

Entry point
(CIJ support)

Entry point
(9232 support)

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Pre-installation
Installation
Training

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Pre-installation Installation Training

Notes:

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Pre-installation Installation Training

Start-up instruction (approximately 30 minutes)

An Initial start-up instruction sheet is provided in the printer package. This instruction sheet gives the
best practices and some important recommendations which are mandatory to perform during the
start-up of the printer after a storage period.

1. Place the print head on the Maintenance tray

and plug the printer into the mains

2. Test of the ink circuit Electro valves

Pull the ink circuit out of the
Press the Activation Button to operate each Electro cabinet in order to be able to hear
Valve (1 through 5). When an Electro Valve is piston slap and transfer pump
operated, a piston slap should be heard. rotation.

Note: if no piston slap is heard, continuously press

the Activation Button to induce quick activation
and deactivation of the Electro Valve.

3. Test of the Transfer Pumps

Press, and hold for five (5) seconds, the Activation

Button to activate Transfer Pumps P1 and P2.
When a pump is activated, the rotation should be Note: for 9232E there is one additional Electro
heard. Valve 10

4. Test of the print head Electro valves Stay near by the print head in order to be
able to hear piston slap.
Press the Activation Button to operate each Electro
Valve (6 through 9). When an Electro Valve is
operated, a piston slap should be heard.

Note: If no piston slap is heard, continuously press

the Activation Button to induce quick activation
and deactivation of the Electro Valve.

5. Plug in the Ink and Additive Cartridges

Reminder for 9232E: shake the ink cartridge before

plug in.

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Pre-installation Installation Training
6. Start the printer

Press the switch.

When the jet starts - after approximately five
(5) minutes - unplug the ink cartridge. This will
Wait for the jet start and unplug
limit the quantity of ink that will be transferred
the ink cartridge
into the printer.
Fault 2060 or 2070 may appear and the jet may
stop even if the jet is correctly recuperated.
This is due to the additive contained in the Acknowledge the fault if necessary
umbilical. Acknowledge the fault and restart
the jet if necessary. Wait for the complete start (approx. 10 min)
The complete start can take up to fifteen (15)
minutes including the jet start above (this takes
more time for 9232E than for standard version)
7. 9232E only: acknowledge fault 4040
With 9232E printer the fault 4040 will appear.
Acknowledge the fault and restart the printer. Acknowledge the fault 4040 and press

8. Perform nozzle unblocking function for

two (2) minutes

9. Perform a stability check for two (2)

minutes

10. Clean and dry the print head

11. Stop the printer (short stop) and drain

the ink circuit manually
This will remove ink with low viscosity
due to the initial start up

12. Plug the ink cartridge put back the ink

circuit in the cabinet and close the door

13. Start the printer and wait for five (5) Wait five (5) minutes before using the printer
minutes after jet start
Viscosity = viscosity reference  2s
14. Check the printer parameters
Motor speed = 2000 rpm  100 (2200 for 6m umbilical)

IMPORTANT
DO NOT MODIFY FACTORY SETTINGS (BY-PASS, BREAK-OFF POINT, EHT VALUE...) WHICH ARE OPTIMAL

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Pre-installation Installation Training
■ Adjust the Metering Mode (only 9232E)
The process to configure correctly the metering mode with metric interface requires adjusting
firstly the “Tacho step” parameter and then to adjust correctly the metering distance to get the
real printed metering distance expected by the customer.

Tacho Step Calculation

The calculation depends of two (2) parameters: the type of encoder and the circumference
wheel.

MI Encoder pulse circumference wheel

Case “tacho step”
(rpm) (mm)
1 5000 200 40 µm
2 5000 500 100 µm
3 2500 200 80 µm

Tacho step (µm) = Tacho perimeter (mm) x 1000

Tacho resolution

NOTE:
Tacho Input (hardware) allows a maximum frequency of around 250 KHz.
Max print speed (mm/s) = 250 000 x “Tacho step”
Do not use MI encoder 5000 pulses/200mm for high speed up to 1000 m/min.

Tacho Step Calculation

Set the tacho step in the advanced printer settings.

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 Pre-installation Installation Training

Tuning of the metering distance

The principle is to define the distance expected between jobs, to start and print the customer
production, and to measure the real distances between the prints.

Reset or update
Select
counter value Distance
“on the Fly”. calibration

MODE 2 & 3
Expected value is the distance defined when creating the
production, in this example, this value is A (mm) = 1000mm.
Measured value is the distance between two (2) jobs1
measured in production.

To define the expected value, start the production to print

few meters and then measure the distance between the
beginnings of 2 consecutive jobs1.

Enter this measured value (Ameasured) in the dedicated field.

The function will calculate automatically the calibration
factor to apply.
if the measured value is 995 mm, the calibration factor is -
0.5%.
Notes: For each new calibration, it is possible to reset the factor
using the dedicated button at the bottom of the screen.
The Tacho Step cannot be changed in this menu.
.

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Pre-installation Installation Training

Mode 4 & 5
Expected values are the distance defined when creating
the production. In this example, these values are A (mm) =
1000 and B = 200 mm.
Measured values are the distance between two jobs 1 (A)
and the common distance between Job1/Job2 and
Job2/Job2 measured in production.

To define the expected value, start the production to print

few meters and then measure the distance A and B.
A measured

HHH 1250 1250 1250 HHH

Bmeas

Bmeas
Encoder
Enter the measured values (Ameasured & Bmeasured) in the
dedicated field. The function will calculate automatically
the calibration factor to apply.
If Ameasured = 1025 mm and Bmeasured = 205mm, the
calibration factor is + 2.5%.

Notes: For each new calibration, It is possible to reset the factor

using the dedicated button at the bottom of the screen.
The Tacho Step cannot be changed in this menu.

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Pre-installation Installation Training

■ Operator Instruction
Objectives

Customers training package are available on Planet, three courses are available:

Basic Training Course

Advanced Training Course
Technical Training Course

Customer training content

Operator & Technician Customer Technical staff

Short Basic Basic Training Advanced Technical Training
Training objectives/contents
Instruction* Course Training Course Course
Safety rules X X X X
MI group presentation + local operation X X X
Vocabulary linked to the printer X X X (technical)
Ink jet technology X X (deeper)
Start-up and shut-down X X X X (reminder)
Consumables replacement X X X X (reminder)
Message selection & modification X X X X (reminder)
Message creation X X X (reminder)
Message parameters adjustment X X X (reminder)
Printer settings / installation X
Print head maintenance Cleaning only X X (deeper)
Basic faults and remedies basic faults only X
Advanced troubleshooting X
Accessories connection X
Safeguarding Backup/ restore (messages) X X
Regular maintenance (Air & ink filters kit) ** X X
Advanced maintenance (Air & ink filters kit) + pump X X
Customer parts replacement (First aid kit) * X
Parts adjustment X
Quiz & Evaluation form X X X
Duration 2 to 3 hours 1 day 2 days 3 days
Qualified
Recommended Trainer MI Installer Qualified Trainer Qualified Trainer
Trainer

* Prerequisites: The customer should be familiar with Markem-Imaje CIJ technology.

The training material used on site should be a “flipchart”
** Regular Maintenance: the operator changes the ink filter or specific cleaning operations.

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Pre-installation Installation Training
9232 Installation Validation Checklist

Safety
Installation safety compliance (“No smoking” sign, extinguisher, glass…)  Not Ok  Ok
Printer has to be installed far from permanent crossing of mobiles or people  Not Ok  Ok
No explosive environment and Ventilated location (see instruction manual)  Not Ok  Ok
Printer far from source of heat or fire or sparks  Not Ok  Ok
Printer has to be connected to suitable power supply & correct earth  Not Ok  Ok
Installation
Head maintenance tray installed  Not Ok  Ok
Presence of pressurization kit if difficult environment (humid and/or dusty)  Not Ok  Ok
Plant air clean & filtered if applicable  Not Ok  Ok
Presence of positive air pressure pump if dusty environment  Not Ok  Ok
No vibration on cabinet, umbilical, print-head and accessories  Not Ok  Ok
Machine installed with definitive bracket  Not Ok  Ok
Umbilical correctly installed (no vibration, correct bent, no axis rotation, correct speed-acceleration)  Not Ok  Ok
Cables correctly attached  Not Ok  Ok
Cables not too long (mainly for RS232 connection)  Not Ok  Ok
Cable shielding correctly connected  Not Ok  Ok
Grounding of machine stands  Not Ok  Ok
Stands fixed on the floor  Not Ok  Ok
Printing layout validated by the customer  Not Ok  Ok
«Tacho step» parameter correctly set according to the tacho encoder installation  Not Ok  Ok
If barcode application, the barcode is readable  Not Ok  Ok
Production follow-up made  Not Ok  Ok
Print test at the maximum speed of the production line  Not Ok  Ok
Ensure the encoder is tensioned and making a good & clean contact with the conveyor  Not Ok  Ok
Head object distance is correct  Not Ok  Ok
The level distance between the head and cabinet is ok (see Ink Running Specification)  Not Ok  Ok
No leakage, no fault on the printer  Not Ok  Ok
Factory setting set correctly (including installation date and maintenance data)  Not Ok  Ok
Printer backup done (printer parameters and messages)  Not Ok  Ok
Operator information and documentation
Printer maintenance suitcase complete & available  Not Ok  Ok
Printer manuals given and available for operator  Not Ok  Ok
Initial operator training supplied  Not Ok  Ok
Local MI technical service centre known by customer (phone, fax…)  Not Ok  Ok
Ink & additive safety data sheet known and available by the customer  Not Ok  Ok
Ink Running Specification sheet known and available by the customer  Not Ok  Ok
Consumable storage explained and available  Not Ok  Ok
The MI working area is clean after the installation  Not Ok  Ok

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Pre-installation Installation Training

■ Demo mode
For demonstration purposes the printer can be start up in a DEMO mode. Before starting
the printer, the demo mode should be enabled in the Start Stop menu.

This mode is a special economic mode in terms of ink use at start-up which gives the
possibility to start up the printer without using a full cartridge of ink. This mode also includes
a draining function upon switching the printer off at the end of a demonstration.

If the printer contains no ink it will transfer approximately 300cc (≈ 40mm ink level) of
ink and fill the additive reservoir (± 150cc).
The start-up takes about 10minutes. The printer is now ready for the demonstration.
► The printer should be drained before transporting it in any kind of vehicle
► The demo mode is not available with 9232E series
► If the printer does contain ink the demo mode does not work, the printer will start-up
normally
► The demo mode will switch automatically to normal mode if the ink level reaches the low
level alarm. The printer will transfer the remaining ink of the cartridge.
► If the demonstration is much ink consuming, it is advisable to remove the ink cartridge
once the initial transfer is terminated.

Safely transporting the printer

When switching the printer off in demo mode, the printer

proposes to drain the additive reservoir into the ink tank. If the
printer is supposed to be transported in a vehicle, answer yes
and once the printer is off, drain manually the ink circuit.

► If the ink level > 80mm the ink circuit must be manually drained before confirming the drain of
additive to the ink tank to avoid overfilling.

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Pre-installation Installation Training
■ Shut down
Automatic shutdown is implemented in order to allow for a better rinse of the print head
and to reduce the risk of blocking.
When the operator selects a standard shut down (printer OFF < 3days), and if the temperature is
higher than 35°C, the printer will automatically force a “Long shut down” (printer OFF > 3days).

Effective shutdown
(Selected by the printer according to
temperature)

Lon
g

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Notes

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After-sales

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After-sales

Notes:

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After-sales

■ After Sales Policy

Spare parts policy

Spare part policy for Ink circuit

The spare part policy is in line with the reduction of the TCO. There are no more
complicated modules used, the ink circuit can be repaired at component level by
customers and technician (pump, electro valves, filter, sensor….).

Spare part policy for Print Module

Some components defined as spare parts of the print module are less suitable for
print head maintenance operations at the customer’s site. That’s why we identified
two (2) types of components for existing Print Module spare parts, relating to each
type of intervention:

 Category 1: Suitable for service at customer site,

 Category 2: Suitable for service at customer site with

Category 1: Suitable for service at customer site

P/N Description Picture Recommendations
4 Electro Valve Bloc (G head)
ENM47086
(For G R1 Head: not sealed)
4 Electro Valve Bloc
ENM46408
(M head and G R2 head: sealed)

ENM40783 Deflection Plates Kit (G head)

MI recommends using
these parts for Print
Module repair at the
ENM46263 Deflection Plates Kit (M head) customer site.

If changing these parts

ENM38980 Modulation Assembly GS (G head) does not fix the failure,
Replace GS type Print Module replacement
ENM51312 Modulation Assembly GC (G head) (ENM38980) only for is mandatory.
9175 ink

ENM40038 Modulation Assembly GL (G head)

ENM44528 Modulation Assembly (M head)

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After-sales

Category 2: Not Suitable for service at customer site

There are technical risks to use these parts for service at customer site.
Take the highest degree of caution and rigour when replacing these parts
(Follow procedures provided in the SPS section)
P/N Description Picture Recommendations

ENM38941 Gutter Block

ENM39168 Print head Board

Cover – G head
ENM40161 (including EHT Note: EHT cover are no
block) longer available
Cover – M head
ENM45670 (including EHT
block)

Print Module - ENR policy

REN 9232 G head Print Module is systematically transformed in ENR 9450 G head Print Module
by the local repair center.

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After-sales
9232 G R1 Print Head  9232 R2 Print head
Indeed, bit to bit, the 9232 print module (G head) will be replaced by the full tightness 9450 print
module (G head). The list below provides the matching between Print modules 9232 and 9450.

R1 R2

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After-sales

Spare parts for MI FSE

Print Head
ENM25683: HEAD INK FILTER 9232
(Printer produced <week23-2014)

ENM46708: HEAD INK FILTER 9232

(Printer produced > week23-2014)
(Printer equipped with R2 Head type)

ENM47086 4 Electro Valve Bloc (G R1 head)

ENM46408 4 Electro Valve Bloc (M head and R2 head)

ENM38941 Gutter Block

ENM39168 Print Head Board

ENM40161 Cover – G head (including EHT block)

ENM45670 Cover – M head (including EHT block)

Electronic compartment

ENM39519 – Display

ENM38177 – NEP board 9232

ENM39368 – Techno board
ENM44241 - NEP board 9222 w/o internet
ENM44091 - NEP board 9222 w/ internet

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 After-sales

Ink Circuit

ENM39007 Anti pulse box Assembly Kit

ENM39000 Ink Circuit 9232 3m

ENM43686 Ink Circuit 9232 6m
ENM44050 Ink Circuit 9232E
ENM44098 Ink Circuit 9222

■ Spare parts for Customer (Online catalogue= https://mi.spelog.com/)

Ink Circuit (1)

ENM27878 Pump – pressure 9222

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After-sales

Ink Circuit (2)

Electronic

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After-sales

Print Module (G R1 Head)

Print Module (M Head)

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After-sales

P/N Description Remark

ENM45075 PRINT MOD-9232-3M-IP56-KFGL-STRAIGHT -
ENM45076 PRINT MOD-9232-3M-IP56-KGS-STRAIGHT -
ENM45077 PRINT MOD-9232-3M-IP66-KFGL-STRAIGHT -
ENM45078 PRINT MOD-9232-3M-IP66-KGS-STRAIGHT -
ENM47017_CFG Print Module M head -9232-1M-Configurable -

Maintenance policy

The printer maintenance is based on 2 shifts (4000 h/year) or 3 shifts (6000 h/year) use.
The maintenance is divided in two types of maintenances:

>> Preventive Maintenance

Flushing, Pressure pump & filter replacement

This kit is replaced by the customer.

Maintenance Kit 9232E: P/N A44945
Maintenance Kit 9232: P/N A40846
Maintenance Kit 9222: P/N A44502

>> Air/Ink filter Maintenance (A40989)

The kit replacement has a fixed interval of 18

month. In general filters are replaced by the
customer as on-site labour and travel cost are
not included in a service agreement.

Service agreements
Although the preventive maintenance can be done by the customer, Service agreements are
highly recommended during the initial sale and every time when visiting a customer without
service agreement.

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After-sales

■ Help desk
UI Simulator

A User interface simulator is available on Planet and should be installed on a PC. The version of
the simulator follows the version of the printer software version.

Planet directory: Global Technical support ► CIJ ► 9232/9232E ► Software and firmware download

Printer information

When a customer requests some support, it is important to know the useful printer
information (Serial Number, installation date, software version…).
Guide the customer through printer menu: Tools ► Services ► Information ► Printer

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After-sales

■ Histories and Running Status

The printer records history of several data: “Printing”, “Availability / Consumption” and “Warning
and Faults Histories are saved automatically. The maintenance data is filled manually and keeps
track of all the parts changed. It is important when changing any part to enter it.

Printing history
The Printing History enables the customer to see the number of prints realized with a
certain job.

Maintenance history The printer has a maintenance record and should be used for each part replacement
either by the customer or by a MI engineer.
Refer to the operator’s manual for spare parts replacement recording.
Always record any parts replaced
Additive Consumption: The additive consumption is monitored and displayed as an
average per month. The Additive consumption is expressed in ml/h. The value is
Additive Consumption refreshed every 10 minutes when the jet is on. Otherwise it is updated upon a jet
& Printer Availability operation. The value restarts at 0mL/h at the beginning of each month. The value of
consumption depends on: temperature, ink type and umbilical length.
Printer Availability: Basically it expresses the time the printer is available for
production in relation to the time the printer is demanded to be available for
production. The availability is expressed in percentage over a period of one month. The
history goes up to 24 months.
Warnings / Faults
This history keeps track of recent faults and warnings (with a maximum of 33 lines) for
the last 2 months.

When the printer in powered on, it constantly buffers the printer parameters to create
a log file. Approximately every 10 minutes a sample of the printer data is saved. When
a fault occurs the preceding 10 minutes are saved.
The printer displays a selection of parameters, the complete printer data can be
Running status transferred on a SD card or an USB memory stick
(History) file These files are of extreme use for the development department and must be always
attached to any technical claim (JIRA) addressed the TDS department

When transferring the Running status, 2 files are saved on the destination chosen.
- Serial number_PrnContexts_0.txt for the current month and
- Serial number_PrnContexts_1.txt for the previous month

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After-sales
The files are text files in which the
data is semi-colon (;) separated. It
can be visualized with Excel

The following data can be found in the file:

Name Description Name Description

JetSpeed Speed of the jet (m/s) ViscoSetPoint Reference viscosity value
HeadTemp Temperature in the head (°C) AdditiveCounter -
motorSpeed Speed of the motor (rpm/mn) tankInkLvl Ink level in the tank
motorSpeedSetPoint Reference of the speed motor(rpm/mn) CKMin Sensor/Jet distance, nominal
pressure Pressure of the Jet (bars) CKMax position offset

pressureSetPoint Reference pressure of the jet (bar) Piezo Reference tension of the piezo
TempHardware Temperature in the electronic compartment (°C) BreakOff Measured break of point
TempInk Temperature of the ink (°C) Recup Rate of recuperation
Viscosity Viscosity of the ink FaultList List of printer faults

Start & Stop Log File

When transferring the running status file, one (1) file is dedicated to record the printer
start-up and printer stop. This file is the “PrinterEventFile”

Note: The potential blockage of an electro valve in the

print head could be due sometimes to an erroneous
choice of the printer shutdown (i.e.: for a long period a
standard stop could be selected instead of a long
stop).

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After-sales

■ Escalation process
A technical claim is escalated to MI industry (TDS) by using JIRA software, when the issue
cannot be solved locally.
Important: When creating a technical claim it is advised to attach the running status
(History) files of the printer to the claim.

Claim process

The reporting of a claim is exclusively done by using JIRA.

Main steps of the Process are:

The local level 2 escalates the request to TDS

► JIRA if local specialist needs support
► Print Sample if no local facilities to perform the sample

TDS investigates
► Internal database, tests in lab, request to R&E for help.

TDS proposes a solution within 48-72 hours

► Provides answer to Pre / Post sales information requests
► Executes printing sample & send it back with recommendations.
► Provides a short term action (solution or action plan) for claim.

Level 2 validates the proposal

► The L2 confirms acceptance of the proposed solution
► The L2 can request additional investigation
► The L2 verifies the sample or requests additional samples.
► The L2 validates the proposed short term action
► The L2 requests another if the proposed action is not relevant.
(Note: Long term action has to be proposed and validated as well).

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Maintenance

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Maintenance

Notes:

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Maintenance

■ General
The printer maintenance is based on 2 shifts (4000 h/year) or 3 shifts (6000 h/year) use.
The maintenance is divided in two types of maintenances:

>> Preventive Maintenance

Flushing, Pressure pump & filter replacement
This kit is replaced by the customer.
Maintenance Kit 9232E: P/N A44945
Maintenance Kit 9232: P/N A40846
Maintenance Kit 9222: P/N A44502

>> Air/Ink filter Maintenance (A40989)

The kit replacement has a fixed interval of 18

months. In general filters are replaced by the
customer as on-site labour and travel cost are
not included in a service agreement.

Regular
9232 - 9232S 9232E 9222
maintenance
>> Air/Ink filter
Maintenance Every 18 months Every 18 months Every 18 months
(A40989)
Standard Pressure Pump Reinforced Pressure Pump Standard Pressure
(ENM5629) (ENM44514) Pump (ENM27878)
>> Pressure pump Every 14 000 h (standard Every 14 000 h (standard Every 10 000 h
(filters must be ink) ink) (standard ink)
changed as well) Every 8 000 h
Every 6 000 h Every 6 000 h
(micro-pigmented or
(micro-pigmented ink) (micro-pigmented ink)
pigmented ink)
The pump replacement is included in a maintenance service agreement.
Air filter could be replaced before ink filter in case of dusty environment.

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Maintenance

Pressure pump replacement periodicity

Due to the high flow in the pump (pressure + vacuum through Venturi), the estimated
pressure pump life time is 14 000 hours for standard ink.
For Special inks (see SP12) the estimated life time of the pressure pump decreases to
6000 or 8 000 hours according to the printer model.

Pressure pump flow =

- Viscosity measurement
+
- Venturi system
+
- Ink pressure in the head

Ink filter replacement periodicity

The printer has been designed mainly for 2 shifts (4000 h/year) or 3 shifts (6000 h/year)
applications production. So we recommend replacing the ink filter 18 months after
installation. It must also be changed every time the pump is replaced.

Ink filter flow = Ink flow in the head

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Maintenance

■ Maintenance alarms
For both maintenances the customer is informed through alarms on the screen.

Filter Kit

The filter kit replacement has a fixed interval of 18 month and is in-depended of the
running hours. Four (4) weeks before the filter kit replacement due-date, an alarm will
rise.

Note:
- The filter kit is replaced by the customer even when they have a service agreement

Flushing & Maintenance kit

Printer flushing and pressure pump replacement periodicity depend on the ink type
used. When replacing the pressure pump, ink and air filters are replaced as well. The
printer will set the correct interval depending on the ink configuration of the printer.

Notes:
- The Flushing & maintenance kit replacement is included a service agreement.
- Printer must be installed eight (8) weeks maximum after its production date.
- After 8 weeks of storage, a printer must be rinsed to be stored again for 8 weeks.

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Maintenance
Ink 9182 Alarm

If printer runs using ink 9182, the print head requires specific maintenance which is
embedded in the printer (Alarm Code 5300); describing the step-by-step operation the
operator should perform. It avoids risk of issues and improves the printing performance.
After 100 hours of jet running with 9182 ink, the following pop up explains how to perform
the maintenance. After performing the procedure click on Fix issue and confirm that the
head cleaning has been done in order to reset the related counter.

Click on «Clear fault» or « Exit», the same

warning screen will pop up in 8 hours

The cleaning is performed with a specific tool: The cleaning Swab ENM42727.The following
instruction sheet is included in each cleaning swab box:

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Maintenance
Specific maintenance with MC151 (only 9232E)

Maintenance frequency
Every 6 months depending on the customers’ application consumption.

Maintenance Operations
Draining and flushing twice + Filter replacement

Parts to be changed

Kit A49151:

x1 ENM38113: INK EXHAUST CONNECTOR 100µm

x2 ENM38107 CONNECTOR BARBED FILTER 100 µm
x1 A49150 SEAL VISCO TUBE + TUBE VISCO CALIBRATED-CERAMIC

Filter kit A40989 INK/AIR FILTER + OUTLET FOAM

ENM25683: HEAD INK FILTER 9232

(Printer produced <week23-2014 )
ENM46708: HEAD INK FILTER 9232
(Printer produced > week23-2014)

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Maintenance

Specific maintenance for Carbon Black ink (9554, 9139, 9139S)

If printer runs using Carbon Black ink (9554, 9139, 9139S), the print head requires specific
maintenance with 5909 maintenance liquid as described in the following procedure:

G head (step 5)

Note: Procedure is similar for the G head. Only step 5 is different

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Maintenance
■ Maintenance record & fault clearing

Preventive maintenance

The maintenance alarms (5210-5230) are only cleared from the list when
recording a preventive maintenance in the maintenance record menu of the
printer. Following the replacement of the kit, click on preventive maintenance
menu of the printer (Services ► Maintenance ► Maintenance record).

1-Select Preventive
maintenance menu

2-Select the kit

3- Enter the batch

number of the kit

Note: The kit is now recorded and can be found in the maintenance history.

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Maintenance

Curative maintenance

The record of replaced parts shall be done for preventive and curative maintenance.
All replacement of spare parts could be recorded by selecting predefined category of parts
or by entering directly the batch number of the parts (Other parts).

Ink Circuit

Electronic

Print head

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Maintenance

■ Next maintenance alarm reset

The counter for the “filter kit” replacement alarm is reset to 18 months when entering the
part replacement in the maintenance record as described above.
When entering the part replacement of the “maintenance kit” in the maintenance record
both counters, “Filter kit” and “maintenance kit “ replacement due-date and hours are reset
as the maintenance kit contains the filter kit.

Refer to “Software” section - Preventive maintenance data” to set the installation date
and/or start date of maintenance agreement.

Important:
When clearing the maintenance kit alarm both the filter kit and the maintenance kit
due data are reset as the maintenance kit includes the filter kit.

■ Maintenance history
When recording the maintenance kit, the history is updated with the relevant data.

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Maintenance

■ Preventive Maintenance Check list (PM)

General Information
Field Service Engineer:
Date: DD/MM/YY Service Order:

Company Name:
Printer model:  IP56
Software & Version:
Contact Name:  IP66

Address / Location: Serial #:

Options & Configurations:
# of Shifts Running:
City/State/Zip:

Phone (optional):  Production unit

Unit type: Line #
 Backup unit

General Appearance YES NO Comment

Printer installed correctly.
Ensure stands (Cabinet + Print head) are securely mounted.
System free from obstructions.
Cabinet in Good Condition. Overall appearance of equipment free
of damage, clean and complete.

Physical Connections secure and in good condition.

Printer Currently in Use.

Print head in Good Condition.

Environment:  Dry  Damp  Wet  Hot  Cold  Dirty  Dusty (check all that apply)
Package per minutes :
Pre & Post PM Checks Pre PM Post PM Pre & Post PM Checks Pre PM Post PM
Print a Test Image below or attach it Print Trigger / Sensors Firmly
to the report Mounted, Connected and/or
Adjusted Alignment for Straight
Printer
Review Print Quality with customer
Prints
Printer Securely Mounted Unit Functioning Correctly
Encoder or Substrate Speed,
Overall Cleanliness of System
measuring device functionality

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Maintenance

Cleaning and Checks (Wear protective gloves for all cleanings):

Task Replacement
Required Tasks Material #
Performed Recommended
Maintenance kit recorded in the maintenance record (to reset
 Yes -
counter)
Inspect for broken part on print head - recommend replacing  Yes  Yes
Clean display, check viewing of the display and touch screen
functionality. If display is unreadable or damaged - recommend  Yes  Yes
replacing.

Check rotation of ink cabinet fan  Yes  Yes

General appearance of ink circuit, no leaks, no bended tube  Yes  Yes

Adjust pressure pump by-pass (motor speed should be 2000 rpm)

 Yes
Pressure:_________ Viscosity: _________
Fault detection:
Head cover absent or not detected
 Yes  Yes
Jet out of gutter or not detected
Drop deviation power supply failure
Adjustment
Required Checks Material# Checked
Needed

Jet stable and centered  Yes  Yes  No

Correct Break-off point  Yes  Yes  No

Head/object distance as specified  Yes  Yes  No

No vibrations on head and cabinet  Yes  Yes  No

Position of umbilical (no vibrations, radius of curvature > 100 mm)  Yes  Yes  No

Correct grounding of cabinet, head and stand  Yes  Yes  No

Review current version of operating firmware and upgrade to

-  Yes -
latest version.
 Yes
Latest mandatory upgrades/improvements installed per TB - -
 No

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Maintenance

Operational Test after Maintenance

Verified
Description Comments

Printer Start-up correctly with no errors or faults.

Ink, verify the ink that is being used is still within its lot shelf life.
Old ink may cause poor print quality.

Verified
Description Comments


Print Registration - After reassembling printer run test prints on

customers packaging and verify print is being applied to the
correct location and you are able to adjust print position and still
maintain print quality for operation.

Select different jobs - Select different customer’s jobs and verify

that they are selected and correctly printed.

Status Beacon & LED System Check - Verify that all power, fault
and warning indicators properly illuminate.

Print Quality Acceptable to Customer - Is the final print job

acceptable for customer’s production?

Comments & Recommendations:

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Maintenance

■ Print head operations

This menu allows performing the basic head maintenance operation:

Unblock Nozzle:
This function is used when there is no jet or the jet is deviated.
Intro. Cleaning Solution:
This function is used when the jet is deviated.
Check Jet Stability:
This function is used when the jet is unstable.
Adjust jet:
This function is used to set the position of the gutter if the jet
is not centered in the gutter
Jet stop: Stop only the jet. Not the Ink circuit
Jet start: Restart the jet after a Jet stop.

Jet stop/ Jet stop

The jet only needs to be stopped when performing maintenance on the print head.
Re-start the jet after maintenance operation.
Cleaning of the print head:
► Stop the jet.
► If the jet is stopped, the recovery valve is closed to prevent any ink being drawn into
the recovery gutter.
► Place the print head vertically on its maintenance tray.
► Clean the print head (modulation assembly, charge electrode, deflection plates, and
gutter block) with the cleaning solution.
► If the print head cover is dirty (inside or outside), hold it above the maintenance tray
and clean it with the cleaning solution.
► Dry the print head and cover with the drying tool.
► Start the jet and check the jet stability
► If any faults, then place the print head in production position.

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Maintenance

Unblock Nozzle

This function is used when there is no jet or the jet is deviated.

There are three (3) phases in the cycle (phase 1-2-3).

B A C D
Phase 2
Phase 1
The Status of the print head valves during these Phase 3
phases are the following:

H6
H7 Purge H8 Additive H9 Recuperation
Pressure
(B) (C) (D)
(A)
Phase 1 Open Closed Closed Closed
Phase 2 Open Open Closed Closed
Phase 3 Closed Open Closed Closed

These phases follow each other automatically and

the cycles repeat themselves as long as the “Unblock
Nozzle” function is ON.

Procedure
► Activate “Unblock Nozzle” operation in the menu

► If the jet appears, activate “Check Jet Stability” operation for approx. 30 seconds
and check the jet position.

► If the jet is correct, stop it, clean the print head, dry and re-start the jet.

If the jet does not appear within 15 minutes after selecting “Unblock Nozzle” operation,
replace the modulation assembly.

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Maintenance
Intro. Cleaning Solution

This function is used when the jet is deviated.

This function has only one phase and does not have a time limit.

B A C D

The Status of the print head valves during these

phases are the following:

H6 H8
H7 Purge H9 Recuperation
Pressure Additive
(B) (D)
(A) (C)
Phase 1 Closed Open Closed Closed

The pressure in the modulation chamber is negative the

entire time the function is on.

Procedure
► Activate “Intro Cleaning Solution” operation in the menu.

► Use the cleaning solution under the nozzle in order to suck additive in the canon (20
seconds, alternatively air/additive)

► Activate “Check Jet Stability” operation for approx. 30 seconds and check the jet
position.

► If the jet is correct, stop it, clean the print head, dry and re-start the jet.

:
The additive suction can be checked in the print head (blue hose in the ink circuit
compartment).
Bubbles of air, additive and ink should flow from the conduit to the ink circuit.

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Maintenance
Check Jet Stability

This function is used when the jet is unstable.

This function does not have a time limit.

The Status of the print head valves during these phases

Phase 2
are the following: Phase 1

H6 H9
H7 Purge H8 Additive
Pressure Recuperation
(B) (C)
(A) (D)
Phase 1 Open Open Closed Open
Phase 2 Open Closed Closed Open

The modulation assembly is always supplied with ink.

Opening and closing of the drain solenoid valve makes
modified the pressure in the modulation assembly, expel
the air bubbles and stabilize the jet position in the gutter.

Procedure
► Activate “Check jet Stability” operation for 30 seconds.

► If the jet is correct, stop it, clean the print head, dry and re-start the jet

If it is necessary to replace the modulation assembly, stop the printer and refer to the chapter
“Spare parts sheet/Modulation assembly replacement”.

Refreshment

This function is used to ensure the same viscosity everywhere in the printer.

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Maintenance

■ Draining & Rinsing recommendations

Shut-down > 2 weeks

For a printer stop > 3 weeks: the printer must be drained and rinsed
Once drained and rinsed, the printer can be stored away for up to two (2) months.
(Draining and rinsing procedure is available in the user manual)

Storage time > 2 months

If the storage time > 2 months, Drain and rinse it again

In storage condition, the printer must be drained and rinsed every two (2) months.

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Maintenance
Notes:

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Troubleshooting

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Troubleshooting
Notes:

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Troubleshooting

■ Introduction
Before troubleshooting the printer, it is important to know:
 The basics of Ink jet,
 How to operate the printer,
 What it can and what it cannot do,
 The basic maintenance operations,

Three (3) important menus are dedicated to help FSE to diagnosis an issue. These menus are:

1-Status menu
Jet status, Ink pressure, Motor speed, recuperation level…..
 Status Menu Overview

2-Maintenance menu
Draining and flushing operations, maintenance operations for IC and head…
 Maintenance Menu Overview

3-MI Engineer menu

Advanced printer settings, printer factory settings…
 MI Menu Overview

■ Profiles
To prevent unskilled use of the active screens three levels of profiles are available:

Operators (Basic): These profiles are for standard daily use.

Advanced profile: All functions are available except date modification

(Default password “0000”). This profile is able to configure parameters
of Operator profiles.

MI profile: All functions are available including a special interface used

mainly for development & manufacturing. This interface may be of
help for the expert field service engineers.
How to activate? (See Software section – MI Engineer profile)

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Troubleshooting

■ Status
General status

A general status overview of the printer can be obtained using status menu.

Parameters Description
Jet status Stopped / Running / …
Jet speed Depending on the head configuration (20m/s or 23m/s)
Ink pressure to obtain the Jet speed required (the pressure depends on
the ink type, its viscosity, its temperature and the hydraulic resistance)
Pressure
should be between 2,3 and 2,6bars for 20m/s jet speed and 3,2 and
3,4bars for 23m/s jet speed at 20°C
Motor speed to obtain the ink pressure (the speed is directly related to the
Motor speed pressure required for the jet speed) The efficiency of the pressure pump
and thus the motor speed can be adjusted with the by-pass (~2000rpm)
The temperature of the ink at the ink circuit level. It should be within the
Ink temperature
range according to the IRS of the ink used in the printer
The temperature measured on the head board. It should be within the
Head Temperature
range according to the IRS of the ink used in the printer
Printer counter Number of prints done so far
It is the optimum viscosity the ink should have expressed in seconds.
Viscosity reference This value is ink and temperature related and used for the viscosity
management
Actual viscosity of the ink. It should be close to the viscosity reference.
If Viscosity >0, 3 sec above the reference, the printer will add additive to
lower the viscosity. If Viscosity < 0, 3 sec than the reference, the printer
can not interfere. The value will automatically increase when the printer is
Viscosity running as the additive contained in the ink evaporates. Temperature
change has a direct influence on the viscosity: when the temperature
drops, the viscosity increase. When the temperature raises the viscosity
decreases.

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Troubleshooting
Parameters Description
Value representing the flow of ink/air in the gutter (measured in the
gutter) Normal running values is between 250 and 700. When the ink jet
Recuperation level
is well centered in the gutter, a low value indicates a good suction and a
high value a poor suction.

The voltage on the piezo to obtain controlled drop creation. This value is
automatically calculated by the printer when launching the “Adjust break-
Piezo value
off point” function. It can also be set manually in the MI-engineer
interface. A count is equal to 0, 8 volt

A number between 0 and 11 indicating the phase used for optimum drop
charge. Twelve phases are available (0-11). The phase giving the
optimum drop charge is permanently calculated and adjusted if
necessary. The number used does not indicate good or bad. A constant
Active phase
fluctuation of +/- 2 is normal. The break-off point and the jet alignment
number
between the charge electrodes should be correct for good functioning of
the automatic optimum phase calculation. A Bigger / unstable fluctuations
indicate a problem which can be related to: head cleanness, adjustments,
ink quality, or to a hydraulic / electronic problem

The level of ink in the ink circuit measured in mm. The ink level is used
for the viscosity management and the autonomy calculation. When the
level drops below 30mm the printer will transfer the contents of a full
cartridge to the ink circuit (in several steps). At 10mm the printer shuts
Ink level down automatically to prevent hydraulic damage. At 15mm a second
warning is raised to indicate that the ink cartridge should be replaced. At
a first start-up after installation or draining + flushing, the ink level is
around 90 mm after 1hour. When the ink cartridge is replaced at the first
warning (30mm) the ink level is around 120 mm after 1hour.

Note: for pigmented inks the printer will only start transferring ink after alarm and or fault
clearing. The ink cartridge should be shacked before transferring to avoid any clogging

The number of hours the printer has being powered on (mains

Printer counter
connected).

Ink circuit counter The number of hour the ink circuit has been running so far (printer on).

The date the filter kit is due to be replaced. The replacement interval is 18
Filter kit month for all inks. Four weeks before, the printer will warn the operator.
replacement The counter is set for the next 18 month at the date the parts are
acknowledge in the maintenance record.

The number of hours left before the maintenance kit should be replaced.
The replacement interval depends on the ink: standard inks = 140000
Maintenance kit hours and special inks = 6000/8000 hours interval. The counter is reset at
replacement the date the parts are acknowledged in the maintenance record. The
Filter kit counter is reset as well as they are included in the maintenance
kit.

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Troubleshooting

■ Maintenance menu
The maintenance menu allows performing:

Draining /flushing operation (printer or modules)

Ink Circuit maintenance operations

Head maintenance operations

Recording the maintenance operations

Inhibition of faults

The printer allows using maintenance menu to check the correct working of hydraulic parts or to
unblock them in case of blockage issue. This is available for ink circuit and Print Head.

Ink circuit maintenance menu

This menu allows manipulating:

 Each individual active parts of the Ink Circuit (electro valves, transfer pump),
 Each electro valve from the 4 electro valve block (Print Head),
This menu gives also the value printer parameters like Pressure, ink temperature and level….

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Troubleshooting

Note: It is important to fully understand and have in mind the hydraulic scheme.

An overview of the hydraulic circuit with its active parts.

These parts are electrically controllable.

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Troubleshooting

Head Maintenance menu

This menu is dedicated to the maintenance operations of the Print Head and it is divided in
two sub menu:
 EV maintenance: Automatic cleaning sequence in case of mechanical blockage.
 All operation: Link to standard and specific maintenance operations.

Includes the tools dedicated to the “standard”

maintenance operations on the Head (Nozzle Dedicated to clean/unblock electrovalves or
unblocking, Check stability, additive modulation assembly in the print head including
Introduction...etc.) plus an extra maintenance the following automatic sequences:
tool (Unblock gutter) to specifically unblock the
gutter valve.  Ink level (tank) measurement
 Unblocking ink EV
 Unblocking nozzle (ink EV open)
 Unblocking nozzle (additive EV open)
 Unblocking and cleaning vacuum EV

Note: This sequence can be activated in two (2)

ways: Manually by selecting the “EV
maintenance” icon in the head Maintenance
menu or automatically for a 2060 Fault by
selecting “Fix issue”.

Step1: Ink level measurement

Step 2: Unblocking ink EV
Step 3: Unblocking nozzle (ink EV open)
Step 4: Unblocking nozzle (additive EV open)
Step 5: Unlocking and cleaning vacuum EV

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Troubleshooting

■ MI profile

MI Engineer profile

A dedicated MI engineer interface is available in the printer. This interface is hidden for
customer but available in the MI engineer profile.

Note: Most functions are for development purposes or dedicated to perform some specific operations like: Printer
configuration reset of the Break-off point table, EHT setting…

Printer Status

Head Status

Piezo value
EHT value

Jet Start/Stop
with/without additive

Break-off point table

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Troubleshooting
Electrovalves

Do not use these functions

Commands

Ink transfer mode

Standby mode activation (period)

Each 600 min (10 hours)
Do not modify without DS approval

Test of Alarms and faults

Printer Factory Settings

(See Software section –
Factory settings setup)

Windows explorer

Photocells, tacky, Peltier auto tests

Test of the touch screen

Not available

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Troubleshooting

When to use MI menu?

The four (4) major reasons to go in the MI Engineer menu are:

- To set the Factory setting after a NEP board replacement,
- To set the EHT value after a Print Module/NEP board replacement,
- To consult the RFID data,
- To reset the piezo value after a Modulation assembly replacement.

Print Module replacement

Modulation assembly NEP board replacement
replacement

Reset the piezo value Setting the EHT value

Note: Consult the spare part sheet for the detailed replacement procedures:
Print module replacement
NEP board replacement

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Troubleshooting
Safety

To replace a module in the ink circuit:

The module must be drained and the printer unplugged from the main
supply
Use individual protection equipment

For basic maintenance operations on Print head:

The print head must be placed on a maintenance tray
Use individual protection equipment

To replace parts in the print head:

The printer must be stopped and unplugged from the main supply
The print head must be placed higher than the printer cabinet
Use individual protection equipment

To replace electronic boards in the printer:

The printer must be stopped and unplugged from the main supply

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Troubleshooting

Troubleshooting tables

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Troubleshooting

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Troubleshooting

■ Error code & Troubleshooting chart

In the table here after:
“A” means Alarm (printing is possible)
“F” means Fault (printing is impossible)

The template of the troubleshooting table is the following:

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Troubleshooting

Troubleshooting Tables

0000 – 0999 NEP

0010 Fault/alarm history corrupted 9232
INCIDENT The fault and alarm history is emptied.
PROBLEM The fault and alarm history is emptied.
CAUSE Power cut
TS STEPS The Fault/alarm history has been erased due to the power disruption
The history file cannot be recovered, and a new file has been started. No action is necessary

0020 Time / Date corrupted RTC initialisation error 9232

INCIDENT No printing. Date is reset to 01-01-2008
PROBLEM The system date is now set to 01-01-2008; the date previously had been OK.
CAUSE Initialization error/ Lithium Battery on NEP board is out of order
TS STEPS Check if time and date are correct: Enter time and date; save & exit. [Setting►Printer►Date/Time]

0021 Unable to communicate with Print Unit via internal 9232

communication channel
INCIDENT Communication error

PROBLEM The printer does not start up

CAUSE Volatile memory error - Channel in blocked state/ Software error/Defective NEP board

TS STEPS Check if error is permanent: Disconnect the printer from mains and reconnect
If still fault, Re install software
Defective NEP board: Replace NEP board and test.

1000 – 1499 Faults Printing

1000 Font used not available 9232
INCIDENT The selected message or the message received via external communication contains one or more
fonts which are not available in the printer.
PROBLEM The message cannot be printed.
CAUSE Required fonts are not available in the printer, or the font file is damaged.
The Host Computer providing the font(s) for the message is offline, or connection has failed
TS STEPS Required fonts are not available in the printer
Download the missing fonts used in the current message into the printer
The Host Computer providing the font(s) for the message is offline or connection has failed
Check the communications with the host computer providing the fonts for this message
Delete the message and create a new message with existing fonts

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1010 Algorithm used not available 9232

INCIDENT The selected message or the message received via external communication contains an algorithm
which is not adapted to the print speed
PROBLEM The message cannot be printed.
CAUSE Print parameters are incorrect for this job
TS STEPS Check and correct settings of print parameters: Modify job settings of the current job/message and
if needed for future job/message modify [Setting ►Job/variable or Setting ►Printing]

1020 Job selected not available 9232

INCIDENT The printer receives a trigger (print go signal) during printing sequence.
PROBLEM The message cannot be printed.
CAUSE Position of cell regarding print head/Bad printer or job setting/Defective trigger
Line noise interference from external devices connected to serial link
TS STEPS Check correct settings of print parameters: Decrease physically distance between cell and print
head [Setting ►Job/variable or Setting ►Printing]
Change the setting and test / Check the message length / Check the tacho division
Defective trigger: Check electrical connection of tacho/cells. Replace tacho or cell and test
Line noise interference from external devices connected to serial link
Check continuity of ground between printer, print head, conveyer, external device connected
through RS232: Check with a scope that line noise interference does not disturb the printer (on serial
link RS232 for instance).

1040 Invalid job content 9232

INCIDENT The selected message contains an invalid barcode input
PROBLEM The message cannot be printed.
CAUSE Wrong Data or inappropriate data defined in the Job
TS STEPS Wrong Data or inappropriate data defined in the Job
Check the correctness of the Job content, some rules are defined for barcode.

1500 – 1999 Alarms Printing

1500 Incorrect print speed 9232
INCIDENT Printing speed too high with tachometer.

PROBLEM Incorrect horizontal printing

CAUSE Tacho division is not correct
TS STEPS Check the Tacho division [Job ► Job Setting - Increase the tacho division]

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1510 Backup time too long for data flash 9232

INCIDENT Backup time too long for data flash
PROBLEM Not defined
CAUSE Software bug/Defective NEP
TS STEPS Software bug: Restart the printer
Defective NEP: Change the NEP board

1520 Duplicate print attempt 9232

INCIDENT Two conditions required::
-“ Non double print” active
- 2 consecutive trigger received for the same message
PROBLEM The second trigger is not taken into account.
CAUSE Not defined
TS STEPS Check timing of message sending versus trigger signal (Dtop)

1530 Print speed too low 9232

INCIDENT Print speed measurement by cell (condition)
The calculated print speed is too low to be treated ( time out)
PROBLEM Incorrect print resolution
CAUSE Print Speed setup is incorrect

TS STEPS Print Speed setup is incorrect: Check and correct setup for print speed measurement by cell(s)

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Troubleshooting

2000 – 2499 Faults Print Head

2000 Communication error with print head 9232

See 2500

2010 Drop creation power supply failure 9232

INCIDENT The Head Board has encountered a fault to supply the 80V to the piezo
PROBLEM No print
CAUSE Dirty Print Head / Defective Modulation Assembly / Defective Print Head Board
TS STEPS Dirty Print Head: Clean and dry the Head.
Defective Modulation Assembly: Replace the Modulation Assembly and test.
Defective Print Head Board: Clean the print Print Head Board if ink deposit and test it.
If still fault, Replace the board.
If still fault, Replace the Print Module

2020 Drop charge power supply failure 9232

INCIDENT The Board head has encountered a fault to supply the 350V for the drop charge.
PROBLEM No print
CAUSE Dirty Print Head / Defective Print Head Board
TS STEPS Dirty charge electrode (Print Head): Clean and dry the charge electrode.
Defective Print Head Board: Clean the print Print Head Board if ink deposit and test it.
If still fault, Replace the board.
If still fault, Replace the Print Module

2030 Drop deviation power supply failure 9232

INCIDENT Power consumption too high to create the Very High Voltage.

PROBLEM No print
CAUSE Defective or dirty EHT plate / Defective Print Head Board / Defective cover head (EHT block)
TS STEPS Defective or dirty EHT plate: Clean and dry the Head.
If still fault, Remove the left EHT plate and active the EHT plate from UI:
Go to [Services►MI Engineer►IUI for lab►Head] and Switch ON the EHT.
If no more fault: replace the EHT plate and re-adjust the break-off point.
Defective Cover head: Replace the Head cover (including the EHT block) and test.
If still fault, Replace the Print Module
Defective Print Head: Board Clean the print Print Head Board if ink deposit and test it.
If still fault, replace the board.
If still fault, Replace the Print Module

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2040 Electro valves power supply failure 9232

INCIDENT Pulse width modulation (hold tension of electro valve missing)
PROBLEM No print - Electro valve power cut
CAUSE Defective 4 ELV block
Defective Print Head Board
TS STEPS Defective 4 ELV block: Acknowledge the fault and restart the printer.
Integrity of the 4 ELV block electrical connection/ Defective 4ELV block
Clean the connection board of the 4 ELV block if ink deposit on it and test.
If still fault, replace the 4 ELV block and test.
Defective Print Head Board or connection
Check the connection between Print Head Board and 4ELV block (flat cable)
Clean the Print Head Board if ink deposit on it and test it.
If still fault, replace the board,
If still fault, replace the Print Module

2050 Head cover absent or not detected 9232

INCIDENT No signal from cover sensor
For safety reasons, the HT is off when the head cover is removed.
PROBLEM No print
CAUSE Defective magnet of head cover
Defective (magnet) sensor
TS STEPS Defective magnet of head cover:
Check if head cover is in correct position.
Check the magnet: UI: Go to [Services►MI Engineer►IUI for lab►Head] and switch OFF the EHT.
Simulate the head cover presence by holding a magnet against the recuperation assembly.
Start the jet. Check if the stroboscopic led lit off.
If Yes: Replace the cover.
Defective Gutter sensor:
Check connection between the Gutter block and the Print Head Board (flat cable).
If connection is OK, replace Gutter block and test.
If still fault, replace the Print Module

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2060/2061 2060-Jet not detected / 2061-Jet out of gutter

Fault 2060 during the starting up of the jet:

The default is potentially due to a blockage of

an electro valve after a printer shutdown. In
this case, the printer proposes to fix this issue
by starting the automatic “EV maintenance”
sequence.
Note: In case of unsuccessful of the procedure,
perform the operations of the troubleshooting
guide.
Step1: Unblocking ink EV
Step 2: Unblocking nozzle (ink EV open)
Step 3: Unblocking nozzle (additive EV open)
Step 4: Unlocking and cleaning vacuum EV

Fault 2061 when the jet is running:

To fix automatically this fault, a specific

sequence could be launched by using the fix
issue button.

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2060/2061 2060-Jet not detected / 2061-Jet out of gutter 9232

INCIDENT The recovery detector did not detect the jet in the gutter or the detection was too weak or
detect ink overflowing
PROBLEM Jet stopped – No Print
CAUSE

[Services ► Maintenance ► Fault override]

Recuperation fault = inhibit
Head cover fault = Inhibit

[Services ► Maintenance ► Head operations]

Perform jet stability check

Perform a visual inspection of the jet, 4 cases:

Case#1 Jet is out of the gutter

Case#2 No jet
Case#3 Jet stable in the gutter with correct suction
Case#4 Jet overflow

TS STEPS CASE#01A: JET IS OUT OF THE GUTTER (FAULT 2060 DETECTED)

Dirty nozzle plate / Defective Modulation Assembly
Use the user manual and the printer menu : [Tools ►Head operations]
Perform maintenance plus cleaning operations on the Print Head: Unblock Nozzle, check stability….
If still fault, replace the Modulation Assembly and test.
If still fault, replace the Print Module.
CASE#01B: JET IS OUT OF THE GUTTER (FAULT 2060 IS NOT DETECTED)
Jet not well positioned (see alarm 2510) / 2060 recuperation fault is inhibited / Dirty Gutter Sensor,
Gutter sensor sealing failure
Go to [Services►MI Engineer►IUI for lab►Head] and perform the command “Jet start with additive”
followed by the command “Jet stop with additive” in order to eliminate all residual ink.
If still fault, replace the Gutter Sensor.
If still fault, replace the Print Module

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Troubleshooting
2060/2061 2060-Jet not detected / 2061-Jet out of gutter 9232

CASE#02: NO JET (INK IS UNDER NOMINAL PRESSURE)

Clogged Nozzle plate / Defective 4ELV block
Use the user manual and the printer menu: [Tools ► Head operations]
Perform maintenance plus cleaning operations on the Print Head (Unblock Nozzle, check stability….).
Refer to IRS if a specific cleaning is required according to ink type.
If still fault, check functionality of the pressure solenoid valve :
Go to [Services ► Maintenance ►Ink circuit] and test the pressure valve,
If piston slap not heard: replace the 4 ELV block and perform stability Check.
If still fault, replace the Modulation Assembly,
If still fault, replace the Print Module.

CASE#03: JET OVERFLOW

Defective 4ELV block, dirty/damaged suction pipe, Venturi or Print Module blocked
Go to [Services ► Maintenance ►Ink circuit].
Check if the Recuperation valve Ev9 or Gutter block are not blocked (Manual activation).
Perform a manual unblocking: press and hold down the valves command.

If still blocked:
Go the [Services ► Maintenance ►Head ►All operation ►All operation]
Perform an automatic “Unblock gutter”

If still fault
Visual inspection of the pipe (no damaged),
Put the print head below the ink circuit and close Ev9.
Disconnect the recuperation tube of the Print Module and check if the suction is effective (put additive in
the tube to check)
If recuperation defective, perform a manual draining of the printer. Dismount the Venturi and clean it.
If is fault:
Replace the 4 ELV block and perform stability check and test.
If still fault, replace the Print Module.

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Troubleshooting
2060/2061 2060-Jet not detected / 2061-Jet out of gutter 9232
CASE#04A: JET IN THE GUTTER WITH CORRECT SUCTION
(NOT DETECTED OR INCORRECT DETECTION)
Jet in the gutter, no overflow & Recuperation level > 800

Defective 4ELV or Gutter sensor

Inhibit the Recuperation fault [Services ► Maintenance ►Fault override]
Start the Jet and stop the Pressure valve H6 in order to stop the jet [Services ►Maintenance► Ink circuit]
Check the recuperation level [tools ►Head Operation]

If Recuperation level is low [ 100] If Recuperation level is still high (>100)

Defective 4ELV contact (ink deposit, poor

contact...) or connection.

Dirty gutter sensor or sensor sealing failure.

Dismount the 4ELV block & check the cleanness
Replace the Print Module
of the connection. If ink pollution clean it and
test.
If still fault, replace the Print Module

CASE#4-B: JET IN THE GUTTER AND RECUPERATION LEVEL <1

Gutter sensor & the Print Head board: defective connection

Replace the Print Module

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Troubleshooting

2070 Drop (phase) detection 9232

INCIDENT No Drop (phase) detection
PROBLEM When printing: stops printing and EHT off. The jet remains on.
CAUSE Incorrect Ink parameters or Incorrect ink /Dirty print head/Defective break off point/
Defective Modulation assembly/Defective gutter block connection
TS STEPS Incorrect Ink or parameters
Go to [Services ►Information ►printer] and check ink/additive in the factory setting. Check the
quality, the viscosity parameters.
Dirty Print Head
Action: Perform maintenance plus cleaning operations on the print head (Unblock Nozzle, check
stability….). Use the menu: [Tools ►Head operations]
Bad Break Off Point
Action: Perform an automatic Break off point (check first that the jet speed is correct)

Defective Modulation assembly: No drop (visual inspection with magnifier)

Test continuity of Modulation assembly with Ground (< 10 Ohms), between
Modulation assembly body (B) and the screw at the left (A).
if no continuity  Check the tightening of the screw
If continuity is OK  Change the Modulation Assembly
A
B
Defective Modulation assembly: Bad break off point (inspection with magnifier)
Check the continuity between the Print
Head Board and the Modulation assembly
(between the screw on the top of the
Modulation assembly (A) body and the
screw behind the Modulation assembly
connected to the board (B). B

If continuity is OK,
 Change the Modulation Assembly
If still fault, replace the Print Module
A

Defective gutter block connection/Gutter block

Check the connection with the Print Head Board.
If connexions are OK, replace the gutter block.
If still fault, replace the Print Module
Defective Print Head Board
Clean the Print Head Board if ink deposit on it and test it.
If still fault, replace Print Head Board.

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Troubleshooting

2500 – 2999 Alarms Print Head

2500 Communication error with print head 9232

INCIDENT Received data not updated except drop charge set to 0 when printing

PROBLEM No print or incorrect print

CAUSE The communication between technology board and Print Head Board incorrect

TS STEPS The communication between technology board and Print Head Board incorrect
1 - Check electrical connections of the umbilical
(Umbilical<> Print head - Umbilical<>Technology board)
2 - Check the technology board: Replace by a new one and test.

2510 Jet not well positioned 9232

INCIDENT Amplitude of drop charge is too weak / strong (forward / backward) and/ or Jet speed measurement
out of limit (left / right)
PROBLEM The print may be of bad quality. The print head may get dirty.
CAUSE Dirty or defective Modulation assembly
TS STEPS Dirty or defective Modulation assembly
1 - Go to [Tools ►Head operations]
Perform maintenance plus cleaning operations on the print head (Unblock Nozzle, check
stability….).
2 – Replace the Modulation Assembly and test :
(Switch OFF the printer. Keep the head higher than printer)

2520 Incorrect break of point adjustment, jet maintenance advised 9232

INCIDENT The print head status is not consistent to perform a break off point.
PROBLEM Incorrect print

CAUSE Dirty head /Jet not stable/Defective modulation assembly

TS STEPS Dirty or defective Modulation assembly

1 - Go to [Tools ►Head operations]
Perform maintenance plus cleaning operations on the print head (Unblock Nozzle, check
stability….).
2 – Replace the Modulation Assembly and test :
(Switch OFF the printer. Keep the head higher than printer)

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Troubleshooting
4000 – 4499 Faults Ink Circuit

4000 Time out emptying measurement chamber 9232

INCIDENT The pressure transmitter did not sense the empty threshold level (atmospheric pressure reference
value) within the predefined time.
PROBLEM The printer stops immediately with a correct head shut down procedure.
CAUSE High pressure variations in the IC/ Clogged hose/ Defective or clogged parts of the IC
TS STEPS High pressure variations in the IC
Check the vapour outlet circuit for any obstruction.
Clogged hose
On IP66 version: check if the hose does not blow on top of the level sensor CP1.
Defective or clogged parts - Check functionality of parts of the IC
1 – Check electrical connection of transfer pump P1 – Electro valves Ev1
2 – Check working of transfer Pump P1 and electro valves Ev1:
Go to [Services ► Maintenance ► Ink circuit maintenance]
Check: Ink transfer pump (P1) – Ink supply electro valve (Ev1).
If one is defective part: Drain the printer & Replace It.
Preventive action: Clean the other parts to prevent potential clogging.

4010 Time out viscosity measurement 9232

INCIDENT Either the low or high level viscosity threshold where not reached within the predefined time.

PROBLEM The printer stops immediately with a correct head shut down procedure.

CAUSE Constant level electro valve (Ev2) : Defective or clogged

Viscosity restrictor or Calibrated leak 0,3 mm or Filtering connector clogged
TS STEPS Defective or clogged Ev2 - Check functionality of parts of the IC
1 – Check electrical connection of transfer pump P1 – Electro valves Ev1 and Ev2
2 – Go to [Services ► Maintenance ► Ink circuit maintenance]
Check EV2 “Constant level electro valve”
If EV2 is defective part: Drain the printer & Replace It.
Preventive action: Clean the other parts (restrictor, leak and filter) to prevent potential clogging
if necessary.
Viscosity restrictor or Calibrated leak 0,3 mm or Filtering connector clogged
Drain the printer, dismount Ev2, calibrated leak 0, 3 mm, filtering connector connected to Ev2 and
clean them.

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4020 Ink level too high 9232

INCIDENT The maximum ink level in the in the IC (135mm) has been reached.
PROBLEM The printer stops immediately with a correct head & IC shut down procedure.
CAUSE Incorrect Ink parameters or Incorrect ink/Ink Level in the tank too high/
Defective seal or level sensor CP1
TS STEPS Incorrect Ink or parameters - Check the ink parameters
Go to [Services ► MI Engineer] and check ink type in the factory setting
Ink Level in the tank too high
Drain manually the tank and restart the printer with fresh ink
Defective seal or level sensor CP1
Check the ink level in the drain outlet : Outlet is not full : Test the level sensor
Go to [Services ► Maintenance ►Ink circuit maintenance]
Switch EV1, EV2 on way 1-2 and EV3 on way 2-3 switch ON the ink pressure pump P1.
The level should reach 150 mm in less than 10 min. Replace level sensor if test is Fail.

4030 Viscosity too high 9232

INCIDENT The viscosity is 10s higher than the ink reference viscosity
PROBLEM The printer stops immediately with a correct head & IC shut down procedure.
CAUSE Incorrect Ink parameters or Incorrect ink / Defective or clogged parts of the IC
TS STEPS Incorrect Ink or parameters - Check the ink parameters
Go to [Services ►MI Engineer] and check ink in the factory setting
Defective or clogged parts of the IC
1 – Check electrical connection of Ev2
2 - Check the correct working of Ev2
Go to [Services ► Maintenance ► Ink circuit maintenance]
Activate the constant level electro valve (Ev2), If defective: Drain the printer & replace It.
3 – Clean the potential clogged parts
If Ev2 works correctly, drain the printer and clean: the viscosity restrictor, the calibrated leak 0, 3
mm and the filtering connector to prevent potential clogging.

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Troubleshooting

4040 No more ink 9232

INCIDENT The ink level is 10mm and refill cycle from ink cartridge has failed. The ink level (= 10mm) is just
enough for correct shut down and restart of the printer
PROBLEM The printer stops immediately with a correct head & IC shut down procedure.
CAUSE Empty ink cartridge/ Defective or clogged parts / Clogging of the Ink needle (contrast circuit)
TS STEPS Empty ink cartridge
Check the ink level in the cartridge, If empty: Plug a new one.
Defective or clogged parts of the IC
1 – Check electrical connection of the pump P1 and electro valves Ev1 and Ev3.
2 - Check the correct working of the pump P1 and electro valves Ev1 and Ev3.
If the draining outlet is full of ink: Check functionality of the parts of the IC.
Go to [Services ► Maintenance ► Ink circuit maintenance]
Check ink transfer pump (P1) - Ink supply electro valve (Ev1) and Ink level electro valve (Ev3). If
one is defective, drain the printer and replace it
Clogging of the Ink needle - Check the cleanness of the ink needle
Go to [Services ► Maintenance ► Ink circuit maintenance]
Switch Ev1 and Ev6 on way 3. Dismount the ink needle and clean it.

4050 No more Additive 9232

INCIDENT The remaining additive level in the reservoir of the IC is just sufficient for correct shut down and
restart of the jet.
PROBLEM The printer stops immediately with a correct head & IC shut down procedure.
CAUSE Empty additive cartridge /Defective or clogged parts of the IC
TS STEPS Empty additive cartridge - Check the level of additive in the cartridge
If empty : Replace additive cartridge
Defective or clogged parts of the IC
1 - Check electrical connection of the pump P2 and electro valve Ev5.
2 - Check the correct working of the pump P2 and electro valve Ev5.
Go to [Services ► Maintenance ► Ink circuit maintenance]
Check additive transfer pump (P2) and Additive supply electro valve (Ev5). If one is defective, drain
the printer and replace it.
3 - If P2 and EV5 work correctly.
Drain & clean the calibrated leak 0,3mm (connected to the additive anti pulse air pocket)

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Troubleshooting

4060 Cooling fan Failure 9232

INCIDENT Rotation signal is not detected from one or both fans

PROBLEM If the fan does not operate correctly, the printer does not start or it stops.

CAUSE Defective fan running / Defective Fan command

TS STEPS Defective fan running - Check fan running

Make sure nothing is blocking the fan blades
Make sure the fans are clean and turn smoothly
Check if they are properly connected.
Replace fan
Defective Fan command - Check NEP or CIJ techno board
Check on the board connector (with a multi meter) if the power supply of the Fan is OK. If not,
replace the technology board or the NEP board.

4070 Ink transfer pump blocked (P1) 9232

INCIDENT The current draw is too high
PROBLEM Printer stops
CAUSE Defective transfer pump P1
TS STEPS Defective transfer pump P1 – Check the working of P1
1 - Check electrical connection of the pump P1.
2 - Check the correct working of the pump P1.
Go to [Services ► Maintenance ► Ink circuit maintenance]
Check ink transfer pump (P1). If defective, drain the printer and replace it

4080 Additive transfer pump blocked (P2) 9232

INCIDENT The current draw is too high

PROBLEM Printer stops

CAUSE Defective transfer pump P2

TS STEPS Defective transfer pump P2 – Check the working of P2

1 - Check electrical connection of the pump P2.
2 - Check the correct working of the pump P2.
Go to [Services ► Maintenance ► Ink circuit maintenance]
Check additive transfer pump (P2). If defective, drain the printer and replace it.

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Troubleshooting

4090 Drain pump blocked (P3) 9232

INCIDENT The current draw is too high
PROBLEM Printer stops
CAUSE Defective Drain pump P3
TS STEPS Defective drain pump P3 – Check the working of P3
1 - Check electrical connection of the pump P3.
2 - Check the correct working of the pump P3.
Go to [Services ► Maintenance ► Ink circuit maintenance]
Check correct working of Drain pump (P3). If is defective, replace it

4100 Technology board electronic fault 9232

INCIDENT No initialization possible

PROBLEM Printer does not start

CAUSE Defective NEP board

TS STEPS Defective NEP

Switch OFF the printer and replace NEP board and test.
If still fault, replace de technology board too.

4110 Technology board electro valve power supply fault 9232

INCIDENT Ink circuit electro valve power supply failure
PROBLEM Printer does not start
CAUSE Defective Techno board
TS STEPS Defective Techno board
Switch OFF the printer. Replace techno board and test.
If still fault, replace de NEP board too.

4120 Draining fault 9232

INCIDENT No pressure variation detected
PROBLEM Impossible to drain the printer
CAUSE Defective drain pump P3
TS STEPS Defective drain pump P3
1 - Check if procedure is respected according to User manual.
If not replace the pump or use a new draining Kit.
2 - Check electrical connection of the pump P3.
3 - Check the correct working of the pump P3.
Go to [Services ► Maintenance ► Ink circuit maintenance]
Check correct working of Drain pump (P3). If is defective, replace it

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Troubleshooting

4130 Level sensor out of specification 9232

INCIDENT Prior to transfer a new ink cartridge the pressure transmitter test failed.

PROBLEM The printer stops immediately with a correct head shut down procedure.

CAUSE Defective seal of level sensor CP1 / Defective level sensor CP1
TS STEPS Defective seal or level sensor CP1 – Test maximum measuring level
Test maximum measuring level by manually filling the constant level chamber.
Go to [Services ► Maintenance ► Ink circuit maintenance]
Switch EV2, EV1 on way 1-2 and EV3 on way 2-3, Start the ink pressure pump P1.
The level should reach 150 mm in less than 10 min. If test fail replace level sensor
*

4140 Printer shutdown not complete 9232

INCIDENT The Ink Circuit has been stopped incorrectly.
PROBLEM Risk to block hydraulic parts
CAUSE Incorrect using of the printer / Power outages
TS STEPS If it appears at the next start-up of the printer, the user can start the IC only if Fault 4140 is
cleared.
Once Fault 4140 is cleared, it is saved in the Warning Fault history. To view the history of this alarm,
refer to the Running Status file.

4500 – 4999 Alarms Ink Circuit

4500 Low additive level 9232

INCIDENT No level increase when adding solvent from the cartridge

PROBLEM Printer starts using the additive from the reservoir of the ink circuit

CAUSE The additive cartridge is empty / Defective or clogged parts of the IC

TS STEPS The additive cartridge is empty

Replace the additive cartridge
Defective or clogged parts of the IC
1 - Check electrical connection of the pump P2 and electro valve Ev5.
2 - Check the correct working of the pump P2 and electro valve Ev5.
Go to [Services ► Maintenance ► Ink circuit maintenance]
Check Additive transfer pump (P2) and Additive supply electro valve (Ev5). If one is defective,
drain the printer and replace it.
3 - If P2 and EV5 work correctly.
Drain the printer and clean the calibrated leak 0,3mm (connected to the additive anti pulse air
pocket)

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Troubleshooting

4510 Low ink level 9232

INCIDENT The ink level in the ink reservoir is les then 25 mm.
Refill cycle from ink cartridge has failed
PROBLEM No functional effect
CAUSE The ink cartridge is empty / Defective parts
TS STEPS The ink cartridge is empty
Replace the ink cartridge
Defective or clogged parts of the IC
1 – Check electrical connection of the pump P1 and electro valves Ev1.
2 - Check the correct working of the pump P1 and electro valves Ev1.
If the draining outlet is full of ink: Check functionality of the parts of the IC.
Go to [Services ► Maintenance ► Ink circuit maintenance]
Check Ink transfer pump (P1) and Ink supply electro valve (Ev1).
If one is defective, drain the printer and replace it

4520 Time out ink level measurement 9232

INCIDENT The ink level did not stabilized within 10min
PROBLEM The measurement is averaged and used
CAUSE High pressure variations in the ink circuit
TS STEPS High pressure variations in the ink circuit - Check the vapour outlet
Check the vapour outlet circuit for any obstruction: Get the ink circuit out of the cabinet. Take care
of electrical wires from CIJ board connected to the IC
For IP65 version: check if the hose does not blow on top of the pressure transmitter CP1.

4530 Ink pressure out of range 9232

INCIDENT The ink pressure is lower than 1bar or higher then 4bar
PROBLEM No functional effect
CAUSE Ink parameter / Pressure pump / Pressure sensor
TS STEPS Incorrect Ink or parameters - Check the ink parameters
Go to [Services ►MI Engineer] and check ink in the factory setting
Pressure pump
P < 1 bar : Worn pressure pump
Restart the printer. If the problem still occurs: Drain the printer and replace the pressure pump.
Pressure sensor
P > 3.6 bars : Defective pressure measure
Restart the printer. If the problem still occur : Replace CP2 pressure / temperature cell

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Troubleshooting

4540 Motor speed out of range 9232

INCIDENT The motor speed of the pressure pump is lower than 1000 rpm or higher than 3500rpm.
PROBLEM Low print quality
CAUSE Incorrect by-pass adjustment / Clogged main filter or head filter /
Malfunctioning / Worn pressure pump
TS STEPS Incorrect by-pass adjustment
Adjust by-pass to obtain a motor speed of 2000rpm
Clogged main filter or head filter
Perform a complete rinsing of the printer.
Malfunctioning / Worn pressure pump
Drain the printer and replace the pressure pump.

4560 Ink temperature too high 9232

INCIDENT The temperature of the ink is > 60°C measured by CP2 (temperature cell)
PROBLEM Low contrast of print Fault 2070 “Drop (phase) detection” may appear
CAUSE Defective temperature measure
TS STEPS Defective temperature measure
Restart the printer. If the problem still occur : Replace CP2 pressure / temperature cell

4570 Viscosity too low 9232

INCIDENT The measured viscosity is < 10sec then the reference viscosity

PROBLEM Low print quality

CAUSE Incorrect Ink types or Ink parameters / CP1 (pressure transmitter) seal / Defective part (Ev4)
TS STEPS Incorrect Ink or parameters - Check the ink parameters
Go to [Services ► MI Engineer] and check ink in the factory setting
Defective seal or level sensor CP1
Go to [Services ► Maintenance ►Ink circuit maintenance]
Switch EV2, EV3 and EV1 on way 1 and switch ON the ink pressure pump P1.
The level should reach 150 mm in less than 10 min. Replace level sensor if test is Fail.
Defective part (Ev4)
1 – Check electrical connection of the electro valves Ev4.
2 - Go to [Services ► Maintenance ► Ink circuit maintenance]
Activate Anti pulse electro valve (Ev4). If defective, drain the printer and replace it

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4580 Critical ink level 9232

INCIDENT Printer on, Ink level measurement cycle

PROBLEM No functional effect

CAUSE The ink level in the ink reservoir is critical (15mm )and the ink cartridge is empty

TS STEPS Replace ink cartridge. See further fault 4040

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5000 – 5999 Printer

5000 Invalid production settings file (Default used) 9232

INCIDENT Printer boot

PROBLEM The printer application does not start

CAUSE The file “ProductionSettings.cfg” could not be read.

TS STEPS The file “ProductionSettings.cfg” could not be read.
Create a new configuration file

5010 Time out on print unit initialisation 9232

INCIDENT Printer boot

PROBLEM The printer does not initialize and the printer can not be started

CAUSE Loading the application data from the NEP to the PU ( print unit) not in time

TS STEPS 1 - Re-boot the printer

2 - Check if the “NOR-Flash disk is not full
3 - Re-install software
4 - Defective- NEP board : Replace it.-

5020 Unable to save production settings 9232

INCIDENT When modifying the HT and or piezo frequency

PROBLEM Modifications not taken into account

CAUSE The new settings could not be saved

TS STEPS 1 - Check if the “NOR-Flash disk is not full

2 - Defective- NEP board : Replace it.-

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5030 Invalid printer settings file (Default used) 9232

INCIDENT On printer boot

PROBLEM Default values are generated and the printer boots normally.

CAUSE The file “Printer9232Settings.cfg” could not be read

TS STEPS The file “Printer9232Settings.cfg” could not be read

Set the correct values at «Tools >Settings>Printing»
& «Tools>Settings>Printer>Configuration>Start/Stop».
Once done confirm the modifications by pressing on “OK” button. This action will create a new file.

5040 Unable to save printer settings 9232

INCIDENT When modifying the customers preferences

PROBLEM Modifications not taken into account

CAUSE The new settings could not be saved

TS STEPS 1 - Check if the “NOR-Flash disk is not full

2 - Defective- NEP board: Replace it.

5050 Printer initialization FAILED 9232

INCIDENT Followed by fault 5000 or 5010

PROBLEM The printer application does not start

CAUSE See faults 5000 and or 5010

TS STEPS See faults 5000 and or 5010

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5060 Unable to initialize the PU system DATA 9232

INCIDENT Following fault 5010 and may also follow fault 5050

PROBLEM The printer application does not start

CAUSE Loading the application data from the NEP to the PU ( print unit) not possible

TS STEPS 1 - Re-boot the printer

2 - Check if the “NOR-Flash disk is not full
3 - Re-install software
4 - Defective- NEP board: Replace it.

5070 Unable to initialize the PU Machine DATA 9232

INCIDENT Following fault 5010 and may also follow fault 5050

PROBLEM The printer application does not start

CAUSE Loading the application data from the NEP to the PU ( print unit) not possible

TS STEPS 1 - Re-boot the printer

2 - Check if the “NOR-Flash disk is not full
3 - Re-install software
4 - Defective- NEP board: Replace it.

5080 Printer can’t execute the command here 9232

INCIDENT When pressing a key button

PROBLEM None

CAUSE Minor software error

TS STEPS Please report via a Technical deviation claim

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5090 Unable to save printer functioning data 9232

INCIDENT While printer on stage, printer functioning data is saved on a regular base.

PROBLEM Previous value used

CAUSE Printer functioning data could not be saved

TS STEPS 1 - Re-boot the printer

2 - Check if the “NOR-Flash disk is not full
3 - Re-install software
4 - Defective- NEP board: Replace it.

5100 low additive autonomy 9232

Only once displayed, if the printer is powered off without
clearing this alarm, it will be re-displayed on printer on /
power on
INCIDENT The additive cartridge is empty. The remaining additive autonomy in the additive reservoir is 24
hours ≤ autonomy > 8 hours.
PROBLEM No consequence, the printer continues to use additive from the cartridge prior to use it from its
reservoir
CAUSE The additive cartridge has not been replaced at alarm 4500- low additive level

TS STEPS 1 - Replace additive cartridge

2 - Check correct positioning of the cartridge
See further Fault 4540 No more additive

5110 Critical additive autonomy 9232

Displayed every hour, if the printer is powered off without
clearing this alarm, it will be re-displayed on printer on /
power on
INCIDENT The additive cartridge is empty. The remaining additive autonomy in the additive reservoir is ≤ 8
hours
PROBLEM No consequence, the printer continues to use additive from the cartridge prior to use it from its
reservoir
CAUSE The additive cartridge has not been replaced at alarm 4500- low additive level and 5100

TS STEPS
1 - Replace additive cartridge
2 - Check correct positioning of the cartridge
See further Fault 4540 No more additive

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5120 Missing plant air 9232

INCIDENT When starting ink circuit or while ink circuit running on IP65 printers and printers with head
pressurization kit
PROBLEM The ink circuit does not start or it stops

CAUSE Printer functioning data could not be saved

TS STEPS Check the plant air is connected :

minimum pressure: 4 bar / minimum flow rate: 400l/h
Air conditioner : filter, pressure switch and connections

5130 External Communication Time Out 9232

INCIDENT When network connectivity used - Client request failed / not taken into account

PROBLEM Client request failed / not taken into account

CAUSE Communication error

TS STEPS Client shutdown/hung while communicating with the printer : Restart client
Communication channel/link broken or unreliable :
Check channel reliability
Wrong communication protocol used at client side :
check protocol used (refer to appropriate manual)

5140 External Communication Data fault 9232

INCIDENT When network connectivity used - Client request failed / not taken into account

PROBLEM Client request failed / not taken into account

CAUSE Communication error

TS STEPS The requested command cannot be executed in the current machine context (not-allowed
operations, locked files, etc).
Check settings
Malformed command due to channel transmission errors (detected via checksum)
Check channel continuity
Malformed or improper command due to a wrong protocol implementation at client side
refer to appropriate manual

5150 internal SD card test failed 9232

INCIDENT On printer boot

PROBLEM UI font is not loaded missing character are replaced by squares.

Changing UI language not possible
CAUSE Internal SD card is missing, corrupted or not identified

TS STEPS Check if the SD card on the NEP board meets the specifications

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5300 Periodic head cleaning 9232
INCIDENT After 100 hours of jet running with 9182 ink, a pop up informs the operator that it’s time to perform
the maintenance
PROBLEM Risk to block the nozzle of the modulation assembly
CAUSE -

TS STEPS Click on fix issue and Follow the maintenance instructions given by the printer.

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Troubleshooting

■ List of special Spare Parts for M-I Technicians

Print Module
Ref. Description Content Picture
Assembled gutter
ENM38973 1 sensor + 1seal
sensor
4 Electro Valve Bloc
ENM47086
For PM G R1 head
4 Electro Valve Bloc -
ENM46408 For PM M Head
For PM G R2 head

Gutter block + 2 seals + 1

ENM38941 Gutter block
screw

ENM39168 Board - Head 1 board + 2 screws

3 seals (1 front cover + 2

A46265 Seal Kit top of the print head) +
screws

Hydraulic Compartment
Ref. Description Content Picture

ENM39000 Ink Circuit 9232 3m

ENM43686 Ink Circuit 9232 6m
-
ENM44050 Ink Circuit 9232E
ENM44098 Ink Circuit 9222

ENM39007 Anti-pulse box

-
Assembly Kit

1 condenser
ENM40379 Cell –Peltier condenser
+ 1 seal + 2 screws
Strainer –
ENM38113 1 strained + 1 seal
Filtering connector
Venturi assembly
ENM38114
Umbilical length = 3 m
1 Venturi + 1 seal
Venturi assembly
ENM43471
Umbilical length = 6 m

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Electronic Compartment
Ref. Description Content Picture
1 board + 1 fixing
ENM39368 Board – CIJ Technology Picture not available
bracket

ENM38177 NEP 9232

1 board + spacers +
ENM44241 NEP 9222 w/o Ethernet
screws
ENM44091 NEP 9222 w/ Ethernet

1 display fitted with

its protection + 1
ENM39519 Display – Assembly
glue + 4 caps + 4
nuts

Tools
Ref. Description Content Picture

Ink cannula on
A40771 Flushing tool solvent cartridge
adaptator.

M-I flushing technician

A41894 1 M-I flushing tool
tool

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■ List of special Spare Parts (out of catalogue)

An Out-Of-Catalogue Sales Request is mandatory to validate order for the following parts

Ref. Description
A39007 Pressure sensor housing

A40310 Cartridge 9232 double rotate

A43472 Restrictor for 6m length

A36864 Restrictor for 3m length

A38979 Recuperation isolator

ENM38107 Connector Barbed Filter M5 - 2.7 KIT

Note 1 : The main differences between Ink Circuit 3m/6m umbilical are the following :

Diff#01- Venturi are differents:

ENM38114: Venturi assembly Umbilical 3 m
ENM43471: Venturi assembly Umbilical 6 m

Diff#02- Restrictors are differents:

A36864: Restrictor Umbilical 3 m
A43472: Restrictor Umbilical 6 m

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Troubleshooting

■ Modulation Assembly Identification

For G head type, there are two types of modulation assembly relating to:
 GS: Standard inlet cone height,
 GC: New Standard inlet cone height
 GL: Large inlet cone height

Note: GC type replaces GS type

The shape of the hole in the nozzle affects the jet and the break-off point stability.
For some type of inks a small cone improves jet/break-off point stability, for other inks a large
cone is better.

The entry profile is different for S, L and C types

The Nozzle Plate thickness is different

for S, L and C types

The output diameter is the same for S, L and C

types. It is the G-Head diameter.

Refer to the Ink Running Specification to know which type must be used for the ink.

Modulation Assembly

Type GS GL GC M

Part Number ENM38980 ENM40038 ENM51312 ENM44528

Color

Black White Dark red

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Troubleshooting

EHT plate recognition

There are different EHT plates mounted depending on the head type:

G Head M Head

Common plate G – plate M head plate

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Troubleshooting

■ Draining and flushing the printer

The MI technician draining and flushing tool has the same functionality as the
disposable/recyclable maintenance kit.
Tools / parts required:
 MI Technician tool,
 Flushing adapter,
 Waste drum,
 Additive Cartridges (x2)

Connecting the MI technician tool

Pull out the ink circuit (do not completely pull it out of the cabinet).
Connect the M-I technician flushing tool as follow:

Securely fasten a loop above

ink circuit for example over the
cartridge holders
The MI flushing tool should be
placed at the same level or slightly
below the ink circuit Securely fasten the fir tree
connector by sliding the clamp
over the fir tree connector

Waste drum (3 liters minimum)

Securely fasten this end of the

hose to prevent any accidental
spillage

MI flushing tool composed of a

draining pump (P3) and tubes

Power supply the draining pump

on the ink circuit connector

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Troubleshooting

Draining and Flushing procedure

Refer to the user manual for the complete Draining and Flushing procedure.
Once the printer is ready, disconnect the M-I technician flushing tool, dismount the empty
cartridges and put in place the ink circuit.

In order to avoid drying of the MI technician tool, connect the pump outlet tube to the inlet tube
(stainless steel connector).

Storage time > 2 months

If the storage time > 2 months, Drain and rinse it again.

In storage condition, the printer must be drained and rinsed every two (2) months.

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Troubleshooting

■ Accessibility to the IC parts

Objective

Most hydraulics parts are located under the ink circuit: Electro-valves, Transfer pumps, Venturi,
Filtering connectors, Viscosity restrictor….
In order to dismount and replace them, the ink circuit must be drained, pulled out and placed on
its side outside the cabinet.

Procedure

Recommendations:
Do not pull the ink circuit out of the cabinet whilst mounted on a stand: printer can fall forwards.
Perform this operation in a dust-free environment.

Tools: 3 mm, 2, 5 mm Allen keys

 Turn off the printer and unplug it from its AC outlet.

 Place the printer on a table.

 Remove the ink and additive cartridges

 Unscrew the 2 locking screws of the cartridge support.

 Pull out the ink circuit.

 Put the ink circuit drainage outlet into a waste drum (A)
(Wait five minutes minimum)
 During this time, dismount the cartridges support plate
(Three(x3) screws)
A
 When there is no more ink in the drainage tube: remove the ink circuit
from the printer. Move the “release” handle (on top of the ink circuit)
in the direction of the arrow

NOTE: If you need to drain the additive reservoir as well, starts the printer before draining the printer and
shut down the printer in DEMO mode. When the pop-up message appears asking to transfer the additive to
the ink tank, drain the printer as described above and then confirm by clicking on yes leaving the draining
outlet connected to the waste drum. Wait until the printer is off and there is no more fluid coming out.

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Troubleshooting

 Disconnect the Techno board connectors (B).

 Remove the ink circuit support (C),

 Note: only for changing P1, P2, IC1, IC2, IC3 and IC5

 Lay down the ink circuit on its side. The components are now accessible.

 Pay attention to the hydraulic connection with the umbilical

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Troubleshooting

■ Spare parts sheets

Take all possible precautions to avoid spilling or splashing ink or make up.
Whenever parts with seals are disassembled, they should be reassembled
with new seals.

Always record any parts replaced

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Troubleshooting

Spare parts sheets

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Troubleshooting

■ Spare parts sheets

List of Spare part sheet available in this section:

SPS Print Module/Print head (SPS PHxx)

SPS PH00 Print Module replacement
SPS PH01 Replacing the Filter - head (G/M head) – ENM46708
SPS PH02 Replacing the 4 Electro valve block (G/M head) – ENM46408
SPS PH03 Replacing the gutter block (M/G Head) - ENM38941
SPS PH04 Replacing the Gutter Sensor (M/G Head) – ENM38973
SPS PH05 Replacing the Modulation Assembly (G Head) - ENM400338/ENM44528
SPS PH06 Replacing the Modulation Assembly (M Head) – ENM47391
SPS PH07 Replacing the Cover - including EHT block (M/G head) – ENM47458
SPS PH07 Replacing the Print Head Board – ENM39168

SPS Ink Circuit (SPS ICxx)

SPS IC01 Replacing the Cell – Peltier Condenser – ENM40379
SPS IC02 Replacing the Pressure / temperature sensor assembly – ENM39006
SPS IC03 Replacing the Level sensor – ENM39084
SPS IC04 Replacing one (Common) Electro valve
SPS IC05 Replacing the Rinsing Electro valves (EV6, EV7)
SPS IC06 Venturi assembly – 3 m (ENM38114) – 6m (ENM43471)
SPS IC07 Strainer – Filtering connector – ENM38113

SPS Electronic (SPS ELxx)

SPS EL01 Replacing Boards – CIJ Technology + NEP – ENM48472
SPS EL02 Replacing Touch screen - ENM48467

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Troubleshooting

SPS PH00 Print Module replacement 1/4

Special Tools -

- Do not stop the ink Circuit.

- Stop de jet in the head operation menu.
Prerequisite - The print head shall be placed on its maintenance trail,
- You will use meanly the ink maintenance menu to perform the steps
below : [Tools►Services►Maintenance►IC maintenance]

Remarks -
Step A : Rinsing of the purge circuit
A1 In the maintenance menu:

A2 Close “Anti-pulse additive” (IC4) in position 1-2.

A3 Switch “Additive supply” (IC5) in position 2-3.

A4 Start the “additive transfer pump P2”.

Open “Additive” (H8) and “Purge” (H7).

A5
Note: Deactivate ink transfer pump (P1) if active

When additive becomes to cross the “Purge” : Press and

A6 hold down the “Purge” (H7) to repetitively switch it
(time>10 sec) Tube of Purge:
Blue tube Ø1.6 mm
When the tube of purge is clean (full additive, no more
A7 ink): Close the “Additive” (H8) and stop “additive transfer
pump P2”.

Let the Purge tube (Ø1.6 mm) to absorb the air using the
A8
venturi aspiration. Does not close the “Purge” (H7).

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SPS PH00 Print Module replacement 2/4

Step B : Rinsing of the Recuperation circuit

Place the head in a beaker with 100 ml (or more) of additive identical to
B1
the one supplied with the machine.

In the maintenance menu: Open “Recup” (H9)

B2
Remark: “Purge” (H7) is still open.

When additive becomes to cross the recuperation tube(Ø2.7 mm):

B3 Press and hold down the “Recup” (H9) to repetitively switch it (10 sec
or more). Recup tupe :
Transparent tube Ø2.7 mm

When the tube of recuperation is clean (full additive, no more ink):

Remove the beaker and let the recuperation tube to absorb the air by
B4
aspiration.
Note: Check that purge tube is still full of air (no Ink)

When both Recup tube (Ø2.7mm) and Purge tube (Ø1.6 mm) are full of
B5
air: Set a motor speed reference of 0 rpm for the pressure pump.

B6 Close the “Recup” (H9) and the “Purge” (Ev7)

Step C : Rinsing of the pressure circuit

In the maintenance menu:
C1 Check that IC4 is still in position 1-2 & IC5 is still in position 2-3
Start the additive transfer pump P2
C2 Open “Additive” (H8) and the “Pressure” (H6).
When additive becomes to cross the pressure tube (Ø1.6mm): Press and
C3
hold down the “Pressure”(H6) to repetitively switch it (10 sec or more).

When the pressure tube is clean (no more ink):

C4 Close the additive transfer pump P2,
Close the Additive (H8) and the Pressure (H6).
Pressure :
C5 Unplug the printer from the main power. Red tube Ø1.6mm
C6 Drain manually the printer.

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SPS PH00 Print Module replacement 3/4

Step D : Replace the Print module

D1 During operation Keep a beaker close to you and paper.

Cut the additive tube (1.1mm). Leave the stainless steel fir tree
D2
connector on the cable from the Ink circuit

Cut the recuperation tube (2.7mm). Leave the stainless steel fir tree
D3
connector on the cable from the Ink circuit.

Cut the Pressure tube (1.6mm). Leave the stainless steel fir tree
D4
connector on the cable from the Ink circuit.

Cut the Purge tube (1.6mm). Leave the stainless steel fir tree
D5
connector on the cable from the Ink circuit.

Disconnect mechanically and electrically the umbilical and replace by

D6
a new one.
Step E : Printer Configuration

E1 Check the printer configuration

Install the last version of the software (if necessary)

Enter the MI password (MI profile)

In the MI Engineer menu (ToolsServicesMI EngineerIUI for labHead):
Set the EHT value which is indicated on the Print head.

Remarks:
E2
1- If the printer runs with the ink MB243: Add + 200V to
the value which is indicated on the Print head.

In the Factory settings(ToolsServicesMI EngineerFactory settings): Set

the “4ELV block” part number

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SPS PH00 Print Module replacement 4/4

Step E : Start-up

Before starting the printer

E1
Drain manually the tank by using the drain hose

Start the printer

Check the viscosity in the head operation menu.
The condition is viscosity = Viscosity reference ± 2s
E2 If the viscosity is OK go to the next step (E3).
Wait 10 minutes, if the condition is still not OK
Unplug the printer from the main power,
Drain manually the printer one more time,
Re-start the printer

Viscosity OK: In the head operation page, perform :

E3 Stability: 5 min
Refreshment: 5 min

When the jet is stable, clean the head et restart the

E4
jet.

Resetting the break-off point table: In the MI-Engineer

menu (ToolsServicesMI EngineerIUI for labHead) set the
E5
piezo value to 0 to reset the entire table.

After the table reset, the printer will raise a Drop

(phase) Detection fault (F2070).
E6
In order to avoid this problem set a piezo value to
150
150.

150

Go to the Head Operations menu and perform a break

E7
off point adjustment

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SPS PH01 Filter - head (G/M head) – ENM46708/ENM25683 1/1

Special Tools -
Turn off the printer and disconnect it from the AC power
Prerequisite
Take appropriate individual protections

Residual ink may come out

Remarks Perform this operation in a dust-free environment

Disassembly

Remove the cover head.

1
1 Unscrew the four (x4) screws
holding the filter cover and
remove it.

Remove the filter and the two (2) Residual ink may come out, take
O-ring seals: appropriate precautions

- - One is in the cover,

2
- - The other is under the filter.

Clean and dry the filter housing.

Reassembly

Change filter and seals. 2

Put the cover back in place
3 (Cross tighten)
Re–assemble all parts in the
reverse order.

Testing

Start the printer

Check for leakages.
Perform a Check stability sequence 3
Record the replaced part in the
maintenance menu of the printer

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SPS PH02 4 solenoid valve block (G/M head) – ENM46408/ENM47086 1/1

Special Tools -

Turn off the printer and disconnect it from the AC power

Prerequisite Take appropriate individual protections
Keep print head higher than the printer cabinet

Residual ink may come out

Remarks
Perform this operation in a dust-free environment

Disassembly
Remove the cover head. 1
Unscrew the CHC screws (x2)
1
holding the 4 ELV block and
remove it.

Pay attention to the seals (A): They

could be stuck on the support (B):
remove them if necessary.

Use cleaning solution to clean the

2
mating surface on the 4 ELV block
B
and the contact board and dry it.

Seals (A) = One rectangular 3-hole

gasket + one square 4-hole gasket. 2

Reassembly A

Re–assemble all parts in the

3
reverse order.

Testing

In the maintenance menu, test

electrically H6, H7, H8 and H9.
Start the printer
Check for leakages.
Perform a Check stability sequence.
Record the replaced part in the
maintenance menu of the printer.

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SPS PH03 Gutter block (M/G Head) – ENM38941 1/1

Special Tools -
Turn off the printer and disconnect it from the AC power
Prerequisite Take appropriate individual protections
Keep print head higher than the printer cabinet
Not suitable for service on customer site
Remarks Residual ink may come out
Perform this operation in a dust-free environment
Disassembly

Remove the cover head.

Disconnect the fat cable of the back A
cover (EHT) and remove it.
1
Disconnect the flat cable (A) of the 1
gutter block and unscrew the two
(x2) screw of the print head board.
Insulation part
Release the gutter block (x1 CHC
screw).
2
Carefully remove the gutter block
and clean the surroundings.

Reassembly
Place the new seals :
- O ring seal on the gutter block.
3 - Rectangular seal into the head
plate. 2
Do not bend the flat cable

Testing

Start the printer

Check for leakages.

Check the recuperation level
Check the state of the jet (stability, 3
position in the gutter)
Record the replaced part in the
maintenance menu of the printer

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SPS PH04 Gutter Sensor (M/G Head) – ENM38973 1/1

Special Tools -
Turn off the printer and disconnect it from the AC power
Prerequisite Take appropriate individual protections
Keep print head higher than the printer cabinet
Residual ink may come out
Remarks
Perform this operation in a dust-free environment

Disassembly

Remove the cover head.

Disconnect the fat cable of the back
cover (EHT) and remove it.
1 1
Disconnect the flat cable (A) of the
gutter block and unscrew the two
(x2) screw of the print head board.

Carefully remove the gutter block Insulation part

(x1 CHC screw) and clean the
surroundings.
2
Remove the gutter sensor by
pulling of the insulation part.
Clean the surroundings.
Reassembly
Place the new seal between the 2
pins of the gutter sensor and place
the sensor in the head. 2
3
Reassemble all part in the reverse
order
Do not bend the flat cable

Testing

Start the printer

Check for leakages.
Check the recuperation level
Check the state of the jet (stability, 3
position in the gutter)
Record the replaced part in the
maintenance menu of the printer

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SPS PH05 Modulation Assembly (G Head) – ENM38980/ENM51312 1/1

Special Tools -

Turn off the printer and disconnect it from the AC power

Prerequisite Take appropriate individual protections
Keep print head higher than the printer cabinet

Remarks Make sure that modulation assembly is conform with head type and ink

Disassembly

Remove the protection cover to

gain access to the Modulation
assembly.
1 1
Unscrew the captive screw placed
in the middle of the Modulation
assembly.

Remove the modulation assembly

2 by pivoting it to the right direction.
This might need some force!

Reassembly

Replace the modulation assembly 2

by a new one.
3
Replace the two (2) O-ring.
Fasten the screw “very” tight

Testing

Start the printer

Check for leakages. 3
Record the replaced part in the
maintenance menu of the printer
Adjust the break-off point

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Troubleshooting
SPS PH06 Modulation Assembly (M Head) – ENM47391 1/1
Special Tools -
Turn off the printer and disconnect it from the AC power
Prerequisite Take appropriate individual protections
Keep print head higher than the printer cabinet

Remarks -

Disassembly

Disconnect the electrical wire of

1 the Modulation assembly (x1 CHC - 1
1.5 mm).

Remove the modulation assembly

2
(x2CHC - 1.5mm)

Remove the modulation assembly

3 by pivoting it to the right direction. 2
This might need some force!

Reassembly

Replace the modulation assembly

4 by a new one (ENM47391), 3
Replace the two (2) O-ring.

Testing

Start the printer

Check for leakages.
Record the replaced part in the
maintenance menu of the printer
Adjust the break-off point

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Troubleshooting

SPS PH07 Cover - including EHT block (M/G head) – ENM47458 1/1
Special Tools -

Prerequisite Turn off the printer and disconnect it from the AC power

Remarks
Disassembly
1 Remove the cover head (x3 CHC )
1
Carefully remove the cover and
disconnect the flat cable by
2
unclamping it from the connector
(A).
A
Place the new seal on the new
3
cover (B).

Reassembly 2

Reconnect the flat cable on the

print head board (push the clamp
of the connector).
4
Position the cover and make sure
that electrical wires are not 3
squeezed at the top of the cover.

Testing
B
Start the printer
Record the replaced part in the
maintenance menu of the printer

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Troubleshooting

SPS PH08 Print Head Board – ENM39168 1/1

Special Tools -

Prerequisite Turn off the printer and disconnect it from the AC power

Remarks -

Disassembly

1 Remove the cover head (x3 CHC). 1

Carefully remove the cover and

disconnect:
 The EHT flat cable (A) C B
2 A D
 The 4ELV block flat cable (B)
 The umbilical electrical cables(C)
 The gutter block connector (D)
2
Remove the board (x2 Phillips
screw).
Note: The 2 screws ensure the
3 electrical continuity
Pay attention to the insulation part
of the gutter sensor pin.

Reassembly
3
Reconnect all connectors on the new
print head board.
Re-assemble all cables.
4
Position the cover and make sure
that electrical wires are not squeezed
at the top of the cover. Insulation
part
Testing

Start the printer

Record the replaced part in the
maintenance menu of the printer

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Troubleshooting

SPS IC01 Cell – Peltier Condenser – ENM40379 1/1

Special Tools -

Prerequisite Turn off the printer and disconnect it from the AC power

Remarks The Peltier condenser is a fragile part!

Disassembly

Pull out the ink circuit.

On the top of the IC:
1
Unscrew the two (2) fixing screws (A)
of the slide and remove it
A
Unscrew the three fixing screws (C)
of the support and remove it. 1
2 Unscrew the two fixing screws of the
radiator (B) and remove it.

Disconnect the Peltier condenser and

remove it. Remove the square seal
under the Peltier condenser
3 CAUTION: identify the correct
positioning of the condenser (the red
wire on the + side, the black wire on 2
the – side).

Reassembly
Place the new seal. Connect and
place the new Peltier condenser and
4
re-assemble all parts in the reverse
order. 3

Testing

Start the printer

Test it in the MI engineer menu

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Troubleshooting

SPS IC02 Pressure / temperature sensor assembly – ENM39006 1/1

Special Tools -
Drain manually the printer
Prerequisite Turn off the printer and disconnect it from the AC power
Take appropriate individual protections

Remarks
Disassembly
Cut and remove the clamp collar
placed around the sensor. Unscrew
1 the four CHC screws holding the
assembly and remove it by pulling
and turning.

Remove the seal and clean the

2
surroundings. 1

Reassembly

Re–assemble all parts in the reverse

4 order and make sure use the new
seal.

Testing
2

Start the printer

Check for leakages
Adjust motor speed if necessary (see
adjustment sheets section of the
book). 3

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Troubleshooting

SPS IC03 Level sensor – ENM39084 1/1

Special Tools -
Stop the printer
Prerequisite Take appropriate individual protections

Remarks -

Disassembly

When changing the Level Sensor,

make sure the measurement
chamber is empty before starting to
replace the new sensor.
Proceed as follow:
1
 Activate EV1 (position 2-3)
1  Activate Ev3 (position 2-3)
 Activate Ink Transfer Pump P1
 Wait 30 seconds

Note: this operation avoids ink

overflow of the measurement
chamber.

Unscrew the screw & remove the

clamp(C).
2
Disconnect and remove the sensor
by pulling it upwards.

Reassembly 2
Place first the seal in the ink circuit to C
ensure correct tightness.
3
Reassemble the parts.
Stop the Transfer pump

Testing

Start the printer

Check for leakage and correct
working

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Troubleshooting

SPS IC04 (Common) Electro valve ENM37928 1/1

Special Tools -
Drain manually the printer
Prerequisite Take appropriate individual protections
Turn off the printer and disconnect it from the AC power

Remarks -

Disassembly

Remove the ink circuit support (A)

(Nut 7mm)
Pay attention, do not bend the
1 hydraulic tube
Note: The ink transfer pump remains
1
on the ink circuit support, pay
attention to its hydraulic and
electrical connections. A

Disconnect the electrical cable

according to the electrovalve
Locating the direction of assembly of
2 the EV before remove it (NC/NO 2
position)
Remove the electrovalve

Reassembly

Mount the new electrovalve

4
Mount the ink circuit support

Testing

Test electrically the electrovalve in

the maintenance menu.
Start the printer

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Troubleshooting

SPS IC06 Venturi assembly – 3 m(ENM38114) – 6m(ENM43471) 1/1

Special Tools -
Take appropriate individual protections
Prerequisite Turn off the printer and disconnect it from the AC power
Ink circuit drained

Remarks Residual ink may come out, take appropriate precautions

Disassembly Bottom of the IC

1 Remove the hose from the connector 1

Unscrew the venturi assembly.

2 Remove the seal and clean.

Reassembly
2

Re–assemble all parts in the reverse

3 order and make sure you have placed
the new seal

Testing

Start the printer

Check for leakages and correct
functioning

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Troubleshooting

SPS IC07 Strainer – Filtering connector – ENM38113 1/1

Special Tools -
Take appropriate individual protections
Prerequisite Turn off the printer and disconnect it from the AC power
Ink circuit drained

Remarks Residual ink may come out, take appropriate precautions

Disassembly Bottom of the IC

Remove the hose from the connector

1
1

Unscrew the strainer filtering

2 connector.
Remove the seal and clean.

Reassembly 2

Re–assemble all parts in the reverse

4 order and make sure you have placed
the new seal

Testing

Start the printer

Check for leakages and correct
functioning

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Troubleshooting

SPS EL01 Boards – CIJ Technology + NEP – ENM48472 1/1

Special Tools -
Take appropriate individual protections
Prerequisite Turn off the printer and disconnect it from the AC power
Make a full back-up of the printer

Remarks Take anti-static precautions

Disassembly
1
Disconnect all connectors from the
1 CIJ Technology board in the ink
circuit compartment.

Remove the PSU board rack

2
(including fan).

Disconnect all connectors which are

connected to the NEP/CIJ boards. 2
3 Unscrew partially the two CHC
screws (A) to release the NEP rack
(including CIJ board).

Reassembly
Transfer the SD card (2Gb min) from
the replaced NEP board to the new
4 NEP board.
Mount the new kit NEP board and CIJ
board in the printer.

Testing
Start the printer 3
Check the firmware version
embedded on the NEP board, if it is
not the last one, install the last one.
During installation, configure the
Production setting factory (Ink type,
printer type, and printer S/N, head
A
configuration….)
Go in the MI engineer and set the
EHT value indicated on the Umbilical
Adjust the Break-off point A

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Troubleshooting

SPS EL02 Display - Assembly – ENM48467 1/2

Special Tools -
Take appropriate individual protections
Prerequisite Turn off the printer and disconnect it from the AC power

Remarks The power supply rack (board + fan) must be dismounted!

Disassembly

Disconnect the flat cable and

1 unscrew the four (4) nuts holding the
display assembly.

Remove/ un-stick the plastic cover

and remove the display assembly.
2
Remove all glue residues and de-
grease thoroughly.

Unpeel the protective see-through

film (A) on the conductive parts of
3
the new display. There is one on each
side.

Unpeel and fold the protective film A A

4 (B) in two (2) opposite locations
without totally removing the film.
B

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Troubleshooting
SPS EL02 Display - Assembly – ENM48467 1/2

Carefully remove the film and set in

place the new display. Stick the new
5 display into position by using your
thumbs to press all around the
display.

Reassembly
Tighten the four (4) nuts by adjusting
the display in the plane of the
4 cabinet.
Re-assemble all parts and re-connect
all cables in reverse order.

Testing

Start the printer

Calibrate the touch screen.

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Troubleshooting

■ Adjustment sheets

Charge electrode

The charge electrode is the only one mechanical adjustment on the print head.
It could be necessary to adjust the charge electrode after modulation assembly replacement.
The jet must be accurately adjusted in the centre of the electrode to ensure the best drop
charge.

Positioning Locking
Screw Screw Positioning
Locking
Screw
Screw

G head M head

Proceed as follows to adjust the charge electrode while the jet is on:

 Loosen the Locking screw using 1,5 mm Allen key,

 Turn right or left the eccentric positioning screw to adjust its position

 Tighten the locking screw

 Adjust in order to make the jet centered into the electrode.

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Troubleshooting
Motor speed

The motor speed must be set according to jet speed and umbilical length as follow:

To set the motor speeds proceed as follows:

1- Display the Head operations window.

2- Check that the Jet status of the printer is Running
3- Locate Motor speed and Jet(s) speed.

4- To set the motor speed, go to the Ink circuit maintenance menu, set the
speed in the “Motor speed reference” field.

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Troubleshooting

Adjust the by-pass in front of the pressure in order to obtain:

Pressure (bars) = Pressure reference (bars)

By-pass adjustment

Allen key
3/32

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Troubleshooting

Break-off point Adjustment

This function allows adjusting automatically the tension provided to the piezo of the modulation
assembly in order to transform the continuous jet into drops. This function is an integrated
feature available in the head operations menu.
The printer is locked during 15 minutes in order to perform BOP sequence. BOP sequence is
composed of Jet stabilization (10 minutes) and Break-off point (3 minutes) as follow:

MI profile

Jet stabilization
(10 min)

Break –off point

adjustment (3min)

No
Correct
Break-off point?

Yes

Second time (x2) Number of BOP

failed attempts?

First time (x1)

Before a break off-point adjustment, the print head must be clean and the jet must be stable.
The adjustment should be used when facing bad print quality or after changing the Modulation Assembly.
For harsh environment (T (°C)), it might be necessary to re-adjust it.

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Troubleshooting
Break-off Table

After the replacement of a modulation assembly the entire BOP table must be reset. Tis can be
done of two ways according to the profile selected.

MI Profile
MI profile Customer
 Go to the MI-Engineer menu, select “Head Status”
 Click on button “MODIFY” for setting the piezo value

 Set the Piezo value to “0” and click “MODIFY”

Note: After the table reset, the printer will raise a Drop (phase) Detection fault (F2070).
This is normal when the Piezo value is set to 0.
 Return to the Head Operations page and select “Adjust break off point”.

MI Profile

 Go to the maintenance menu to reset the break off table

The entire BOP table is reset when the Modulation Assembly replacement Maintenance Record Menu
is filled in.

 After that, go to the Head Operations page and select “Adjust break off point”.

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Troubleshooting

Calibration of Additive transfer pump Ptr2

The calibration of the additive transfer pump PTR2 is required to define the correct pressure of
additive needed to rinse the recuperation way when the jet is stopped with additive.

It is mandatory to perform the calibration in the following cases after the replacement of
the additive transfer pump.

To calibrate the pump proceed as follows:

 As a prerequisite, the jet must be running,

 Go to the MI engineer interface, in the menu “Commands” click on “Calibrate PTR2 press”.

 The calibration takes approximately 5 minutes.

Wait until the jet goes back to the “ready” state. (see status bar)

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Troubleshooting

Partial Ink Transfer Mode

For some inks, a partial Transfer mode is activated. This mode allows avoiding potential risk of
overflowing by the condenser due to foam. This mode is available in the UI for labs menu:

Partial Ink Transfer commands:

3 positions : Auto, ForceEnable or ForceDisable

Anti-Foam status:
2 states: True (activated), False (Not Activated)

By default, configuration of this mode is in Auto Mode Status (no partial transfer)
For some inks (see list below) true status is activated (Partial transfer activated).
Do not change status without MI support approval.

Partial Ink Trf

Inks Partial Ink Trf Enabled
Control
9590 Auto True
9560 Auto True
9243 Auto True
9284 Auto True
9513 Auto True
9660 Auto True
All other 9232 inks Auto False

It is strictly forbidden to use this mode with pigmented or semi-pigmented ink.

If the Partial Ink Transfer mode is used, the time remaining indicator on the User Interface
provides partial information concerning the ink autonomy.

After each new ink configuration in the factory setting or change of Partial Ink Transfer
command, unplug the printer from the main power source and restart it to take into account the
new configuration.

Prior to updating a printer working with 9590 ink, the printer will switch from Standard
Operating mode to Partial Ink Transfer mode. This ensures that the ink tank does not exceed 65
mm.

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Troubleshooting

Notes

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Electronics

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Electronics

Notes:

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Electronics

■ Diagram bloc
Diagram bloc is the following:

Industrial
interface
(Optional)

Touch screen
Techno
Screen
adapter
board Print Head
Board

EHT
Power supply NEP board
Block
(+24V only)

Ink tank Ink circuit board

board

Sensors
Electrovalves Pumps Sensors
Pumps

Electrovalve
s

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Electronics
■ Power supply
The power supply only delivers 24Volts.
All other required voltages are generated on the different boards based on the 24V.
The power supply is short circuit protected.

■ NEP board (ENM50529)

The NEP board is divided in 2 different units: DAta Management Unit and the Print Unit.
The NEP board is mounted directly on the Technology interface board.
The Data management Unit is based on windows CE 6.0 operating system and handles the
standard functions and data which do not require real time action. The data can be either internal
or external.
 User Interface (Message creation, setting parameters…),
 Communications (Ethernet, USB …),
 Data storage (on board memory + extension by SD card)
The Print Unit is based on Markem-Imaje operating system and handles the print specific functions
and data which require real time action. It processes data coming from the Data Management Unit
from the specific technology interfaces.
Computing the data needed to drive the print head: Message preparation, variable elements
(counters…), message transformation (raster generation…), print sequencing.

Techno board

NEP board

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Electronics

Diagram Block (NEP board)

Supervision level
(Windows CE support and peripherals management) Impression level

SRAM SDRAM Flash

Power Supplies SD Card DDR Flash FPGA 512KO 16MO 4/8MO
2.75v/1.35v 64MO 64MO

Multimedia Application Processor Power Supplies

JTAG 1.2v/1.5v
(IMX27)
1.8v/2.5v
ColdFire
Reset GPIO (16) 5207

Print head/Ink Circuit

PHY’s PHY

Industrial Interface
GPIO+SPI+I2C
Screen

Keyboard

COM 1

USB Ethernet PU 2
COM 2

SPI + I²C

COM 1
Ethernet 10/100
USB OTG

RTC JTAG
USB Host

BDM
Battery

NEP Core Connector (200)

■ Technology interface board

The technology interface board is the interface between the NEP board and the print technology
used, in this case CIJ. The NEP board is mounted directly on this board and is electrically
connected through one connector.
The two(2) main functions are:
 Mechanically assuring the fixation and accessibility of the USB connector and the SD slot
 Electrically dispatching and collecting all the signals from the technology concerned. These
signal are adapted (amplified, converted, opto-coupled, filtered, buffered …) if needed on this
board.
Adaptive card for CIJ technology:
 SD socket,
 USB port Host and Device,
 Ethernet (10/100 Mb) connector,
 Trigger, Encoder, Beacon connectors,
 Power supplies +3.3, +5 +15V.

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Electronics

Connections overview

J1 NEP Connector board J11 Tacky (Encoder)

J2 Power Supply J12 Alarm accessory
J3 Touch Screen Interface(IHM) J13 Trigger accessory
J4 SD card J14 Industrial interface option
J5 USB Device J15 Pressure pump (DC motor) supply
J6 USB Host J16 Fan (Ink Circuit)
J7 Ethernet J17 Not used
J8 Umbilical (PMAI Head) J18 Not used
J9 Fan (electronic compartment) J19 Ink Circuit Board

J13 J11 J12

J2

J3

J7
Status LED

J1 ly

J14

J5 J18
J9

J6 J17

J4 J19 J15

J8
J16
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Electronics

Diagram Block (Technology interface board)

+24V
Display +15V
screen Buffer
Print
Assembly +5V
Data head
Touch Clock
screen Controller
LVDS

ELV
Electro
Ethernet valve driver
Fault

Pump
Transfer
Ink
NEP board connector
Fault pump driver
USB device circuit
(3x)

Pump Pressure
pump
USB host Fault
driver

Plant air
SD slot (only IP65)
24V

3V3 Data

24V Power +5V Industrial

supply Interface
+15V
Trigger

24V indus 24V indus

Encoder

24V indus Encoder

Fan 24V
Rotation Trigger
(x2) 24V indus

3x Alarm
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 Electronics

■ Ink circuit board

This board is simply a connection board. It provides power supply for transfer and draining pumps,
Peltier cell, pressure transmitter, temperature sensor and all Ink Circuit electro valves.

Component lay-out Ink circuit board

Additive transfer pump

Pressure transmitter (level sensor)

Peltier

Pressure + temperature sensor

Technology board

EV6: Ink Contrast

(Specific 9232C,E)

EV5: Additive supply

Draining transfer pump

EV4: Anti-pulse/Additive

EV3: Ink level

Ink transfer pump

EV2: Constant level

EV1: Ink supply

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Electronics
■ Print head board
All the analog signals of the print head are processed directly on the print head board. The print
head board communicates with the NEP using Low Voltage Differential Signaling (LVDS) via the
Technology board.
For each drop creation a full serial data exchange is established between NEP board and print
head board.

Print head board overview

Flex Gutter Sensor

Flex 4ELV block

Gutter Block

Ground

EHT Block Umbilical

Block 4 electro valve

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 Electronics

Block diagram Print head board

Pressure Additive
Gutter
Purge

+80V
4 ELV Temperature

Piezo
Driver sensor Piezo
Amp

0v
Fault

+ 350V

electrode
Charge
Charge
Ombilic Amp
DATA - 15V
LVDS FPGA

Deflection plate
CLK CLK
Value Bloc
Fault EHT

strobo
Led

Phase (speed)
Power control

sensor
Measurement
Amp
+24V +350V
Power supply +80V
+15V
Gutter detection
management
-15V
+3.3V Recuperation
+5V
+1,5 clock
v

Cover detection Ink resistance reference

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Electronics
■ Industrial Interface board
The industrial interface board is optional. It is used when the application needs other in and
outputs then provided with the 3 connectors for the photocell, encoder and illuminating alarm
accessories. All input and outputs have a status led.

Component lay-out Industrial interface board

Technology board

J1 connector

Status LED
(E/R Techno board)

J5 connector

J2 connector

Status LED
(Optional inputs)
J3 connector

J4 connector

J6 connector
Wire section: 1.5 mm² max.

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Electronics

■ Input /Output specification

Characteristics of Industrial Power supply
Voltage = + 24VDC, Power = 500mA max.
This power supply is separated from the +24V of the printer and managed on the Technology
interface board.
It is used to power the 3 external accessory connections on the side of the cabinet and available
on the industrial interface board.
The power consumption of the accessories connected on the cabinet should be taken into account
when connecting any accessories peripherals to the industrial interface.
Input types: Opto-coupled
1. Sense ( -/+) insensitive

2. +5 to +30 Volts Auto current limited : 10kHz (encoder 250kHz)

3. Protection diode accepts up to 70V reverse voltage

4. Bi- mode (P / N)

5.

Note: Refer to the technical specifications of the accessories for further details.

Output type: Transistor (Opto-coupled)

6. Sense ( -/+) sensitive

7. +50 Volts/ 100mA

8. Bi- mode (P / N)

Relay: +30 Volts / 1A maxi

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Electronics

Trigger & encoder

There are two different ways to connect trigger or encoder:

►Using the standard accessory connectors

J13 J11
CELLULE TACHY

Black = Trigger
Blue = Encoder

These 2 inputs are simply routed on the Industrial interface board. The actual electronics, to treat the
signals, are on the Technology board. They are available even when the (optional) industrial board is not
fitted.
CAUTION: The accessory connectors for these 2 signals are in parallel with the connections on
the industrial interface board.

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Electronics

►Using the optional industrial interface connections

J2

J2

Industrial interface board J2

1 GND 2 +24V

3 ENCODER COMMON 4 ENCODER CH-B

5 ENCODER CH-A 6 TRIGG-a

7 - 8 TRIGG-b

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Electronics

Alarm & Fault (Ready)

There are three different ways to connect trigger or encoder:

►Using the standard connectors

J12
BEACON

Yellow = Illuminating alarm

Ready
Alarm
Fault

Three (3) signals are used: Ready, Alarm and Fault.

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Electronics

J5
RL40
RL41

J6

Using Relays
2 relays are available on the industrial interface board (RL40/RL41)
+ 30 Volts / 1A maxi
Transistor (opto-coupled)
P or N Mode +50 Volts/ 100mA

J6

Alarm NC
Alarm Com

Alarm NO

Fault NC
Fault Com
J5

Fault NO

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Electronics

Industrial interface board J5 Industrial interface board J6

1 2 1 2
3 4 3 4
5 6 5 FAULT+ 6
7 8 ALARM NC 7 FAULT- 8
9 ALARM COM 10 ALARM NO 9 ALARM+ 10
11 FAULT COM 12 FAULT NO 11 ALARM- 12
13 FAULT NC 14 13 14
15 GND 16 15 16

In the I/O configuration, select the alarm and fault relay configuration

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Electronics

Serial link

Data Transmission

TXD-1 : Data V24/RS232C (serial 1)

J5 TXD-2 : Data V24/RS232C (serial 2)
TX2+ and TXD2-: Data RS422 (serial2)

Data Reception
RXD-1 : Data V24/RS232C (serial 1)
RXD-2 : Data V24/RS232C (serial 2)
RX2+ and RXD2-: Data RS422 (serial2)

Note: (Ground) Common with V24/RS232C (only)

In the network connectivity, configure the serial link

Refer to the “Network interface Manual” for detailed information.

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Electronics

Miscellaneous inputs

These inputs are only available on the industrial interface board. They are isolated from each
other.
Inputs are opto-coupled with automatic current limitation. (P or N Mode, + 5 to + 30V, 10 KHz)

Industrial interface board J3

1 GND 2 + 24V
3 INHIBIT TRIG-a 4 CELL2-a
5 INHIBIT TRIG-b 6 CELL2-b
7 INC/TRG MESS-a 8 INVERSE MESS-a
9 INC/TRG MESS-b 10 INVERSE MESS-b
11 LIBRARY SENSE-a 12 COUNTR INCRx-a
13 LIBRARY SENSE-b 14 COUNTR INCRx-b
15 COUNTR INCRy-a 16 COUNTR INCRy-b

Industrial interface board J4

1 GND 2 + 24V
3 COUNTR RESETx-a 4 COUNTR RESETy-a
5 COUNTR RESETx-b 6 COUNTR RESETy-b
7 STOP PRINT-a 8 ON/OFF-a
9 STOP PRINT-b 10 ON/OFF-b
11 MODE-a 12
13 MODE-b 14
15 GND 16

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Electronics

Message number

This input is only available on the industrial interface board.

It consists of 8 inputs with one common to simplify the connection (opto-coupled with automatic
current limitation) P or N Mode, + 5 to + 30V, 10 KHz

Industrial interface board J2

1 GND 2 + 24V
3 4
5 6
7 COM DATA-b 8
9 D7-a 10 D6-a
11 D5-a 12 D4-a
13 D3-a 14 D2-a
15 D1-a 16 D0-a

Refer to the “Network interface Manual” for detailed information.

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Miscellaneous outputs

These transistor (opto-coupled) outputs are only available on the industrial interface board
(except Ready, see Alarm and Fault)
They are isolated from each other.
P or N Mode +50 Volts/ 100mA;

Industrial interface board J6

1 PRINTER READY+ 2 PRINTG-
3 PRINTER READY - 4 PRINTG +
5 FAULT+ 6 OUT-3+
7 FAULT- 8 OUT-3-
9 ALARM+ 10 COUNTR END +
11 ALARM - 12 COUNTR END -
13 OUT-1+ 14 OUT-2+
15 OUT-1- 16 OUT-2-

Refer to the “Network interface Manual” for detailed information.

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Network

The network input is standard available (no need for optional industrial interface board).
The RJ45 connector is on the Technology interface board. On the side of the printer there is a
cable gland available to pass a network cable.

RJ45 connector

Cable gland

The Ethernet connection could be configured in two different modes:

 DHCP mode (Dynamic Host Configuration Protocol)

 Fixed IP address mode

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■ Input / output signals description

Printing Settings

[Top-Object mode]
It determines if the printer should continue printing after the trigger signal:
Select “Stop” >> message printing stops as soon as the trigger signal returns to low.
Select “Continue” >> message printing continues even if the trigger signal returns to low.

Test print example 123456789

9. message

10. «TRIGGER»
11. Message printed in Test print example 123456789
continue mode
Message printed in Test print example 1
stop mode

[Operation]
“Job Number Select” activated«TRIGGER» is de-activated. (See § “Job selection Inputs”)

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[Horizontal resolution (1/10)]

It determines the horizontal print resolution in dots/cm which is equal to Htrame/cm.
The print speed should be equal to the object speed to be true.
The default value is 28, equal to the [Vertical resolution (1/10)]
[Vertical resolution (1/10)]
Different choices of vertical resolution according to the message content (Data matrix, QR
code) and according the head object distance.

[Non Double printing]

This setting prevents a message to be printed more than once. After a message has been
printed a new message should be selected or send through external communication. (This
function is not compatible with selection by parallel interface or library mode). [Operation]
should be set to “Standard”
12.

[Trig active edge]

Determines at which edge of the trigger signal the printer starts printing.
“Rising” >> the rising edge is taken into account for printing.
“Falling” >> the falling edge is taken into account for printing.

Test print example 0123456789AB

message

«TRIGGER»

Test print example 0123456789AB

Rising edge

Test print example 0123456789AB

Falling edge

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13.
Job setting
[Mode]
Determines the printing action related to the “trigger signal”:
”Unique” >> one print per trigger signal
”Repetitive” >> the message is repeated as long as the trigger signal is active. The spacing
between the messages is set in the [Repetitive interval] setting. [[Trigger active edge] should
be “Rising”
”Multitop” >> the message is printed x times as defined in the setting [Multitop number] and
with a spacing as defined in the setting [Repetitive interval].
[Trig filtering (µs)]
“XXX µs” >> the minimum time the signal should be active before taking it into account. The
default setting is 200µs. Noise on the trigger input can cause random “unexpected” prints.
Modifying this value can eliminate this phenomenon.
[Forward margin] / [return margin]
The margin is the spacing (delay) between the trigger signal and the actual start of printing. It
allows exact horizontal positioning of the message on the object to be printed without
mechanical adjustments of the cell and or the print head. The value can be from 3 to 9999 and
represents either mm or Htrames depending of the [unit] setting.
This value is saved with the job.
[Unit]
Unit is used in combination with [forward margin] / [return margin] and [Repetitive interval
“mm” >> the margin or the interval value entered is a distance expressed in mm, The Object
speed should be entered correctly or in the case of speed measurement (cell or encoder) it
should be setup correctly.
The [Horizontal resolution (1/10)] setting should be set to the default value 28 for correct
distance conversion of the margin or interval into mm.
“Htrame” >> the margin or the interval represents empty rasters. The value of the [Horizontal
resolution (1/10)] has a direct influence on the margin and or the interval; a low resolution
increases the margin or interval and vice versa.
Secondary function(s): Object Speed measurement
A trigger signal generated by a cell, detecting the object to be printed, can also be used for its
speed measurement. In this case the signal from the cell is used to generate two internal
signals: print trigger and print speed.

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ONE CELL SPEED MEASUREMENT

Main function
Measure the object speed. The object speed is measured using 1 cell. The cell should be
connected to the trigger input. The time of cell activation by the object together with the
manually entered object length [Intercell length] is used to calculate the object speed (see
object speed section).

See software configuration section

Trigger
Photocell
Detector

Objet
Conveyor

9mm < Object length < 1097mm

Behaviour / related setting

The signal from the cell is used to generate two internal signals: Print trigger & Print speed.
Following the above the printer can only start printing once the object has passed the cell.
Printing starts on the falling edge.

Time measurement

Object 1 speed Object 2 speed Object 3 speed

Trigger input

Internal Trigger

Print margin

Object 1 Object 2 O
printing

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Software configuration

Parameters Set to Notes

[Speed measurement] cells -

[Number of cells] 1 cell -

[Trig active edge] rising -

[Intercell length (mm)]: 9mm < Object length < 1097mm Enter the object length in mm.

[Trig filtering(µs)] The correct value is internally forced. Any

N/A
[Dtop filtering (µs)]: value entered is not taken into account.

For Quality = 0, 98 x object length

Product speed -
For speed 1, 13 x object length

Object speed
The speed measurement needs a minimum object speed for correct functioning.
This minimum depends on the object length and the printer configuration.

Vmin (mm/s) = Object length (mm) x Piezo frequency (hertz)

65535
G Quality = jet speed 20m/s ==> Piezo frequency = 64350 Hertz
G Speed = jet speed 23m/s ==> Piezo frequency = 74000 Hertz

As a first rule to calculate the minimum speed you can use the following calculation:

For G-Quality = 0, 98 x object length

For G-speed 1, 13 x object length

There is no limit on the maximum speed (except the maximum printing speed allowed by the
printer according to the message content).

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TWO CELL SPEED MEASUREMENT

Main function
Measure the object speed. The object speed is measured using 2 cells:
One cell is connected to the TRIGGER input on the printer cabinet.
The second cell is connected to the CELL2 input on the industrial interface.

Industrial interface
Use CELL2-a and CELL2-b

See software configuration section

Trigger Cell2
Objet
Conveyor D

9mm< D< 1097mm

9mm < Object length < 1097mm

Behaviour / related setting

The time measured together with the manually entered Intercell length is used to calculate the
object speed. The CELL2 signal should rise before the next object detection by the TRIGGER
cell. The TRIGGER cell starts a timer and the CELL2 stops the timer.

Object 1 Object 2 Object 3

Trigger input

Object 1 Object 2 Object 3

Cell2 input

Internal Trigger

Print margin

Object 1 Object 2 Object 3

printing
Time measurement

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Software configuration
Parameters Set to Notes
[Speed measurement] cells -

[Number of cells] 2 cells -

[Trig active edge] rising -

Enter the distance between the 2 cells in
[Intercell length (mm)]: 9mm < Object length < 1097mm
mm.
[Trig filtering(µs)] The correct value is internally forced. Any
N/A
[Dtop filtering (µs)]: value entered is not taken into account.

For Quality = 0, 98 x object length

Product speed -
For speed 1, 13 x object length

Printing adjustment
Use the forward margin parameters to adjust printing in the printing field.

Encoder

Main function
Accurate synchronization of printing (print speed measurement)

Related setting
Parameters Set to Notes
[Speed measurement] Tacho -

The tacho division is

a number between 1 Depending on the mechanical transmission of the object
and 63 and is used speed to the encoder and the encoder used, the number of
[Tacho division] pulses per mm of object movement will differ. The tacho
to divide the pulses
received from the division input allows dividing the amount of pulses in order
encoder. to obtain the required 2.8 pulses per mm which correspond
to the print resolution.

Behaviour / related setting

14. [Tacho step (µm)] : Enter the distance between two pulses in µm

MI Encoder pulse (rpm) circumference wheel (mm) Theorical “tacho step”

2500 200 80 µm
5000 500 100 µm
5000 200 40 µm

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Alarm & fault

Main function
Inform the operator about the status of the printer through the illuminated accessory

Behaviour / related setting

Secondary function(s)
Alarm output and the fault output are available on the industrial interface board.
This signal can be used to manage the production line: to stop the conveyer for example.

PRINTER READY

Main function
Informs when the printer is ready to print (jet on and ready to print)
This signal is available on the Yellow alarm connector and on the industrial interface board. On
the accessory connector it is connected to the green light of the 3 element alarm.

INVERSE MESS

Main function
Reverse the print sense. It starts with the last raster and ends with the first raster based on the
actual print sense of the job.

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INHIBIT TRIG

Main function
Inhibit the «TRIGGER» signal. The « INHIBIT TRIG » signal should be present at least 30µs before the
«TRIGGER» signal for correct functioning.

Behaviour / related setting

15. [Operation]: Only taken into account for “Standard job” operation

16. [Active edge]: “Rising edge”: Trigger signal is inhibited when the signal is present at
least 30µs before the rising edge of the «TRIGGER» signal.

17. “Falling edge”: Trigger signal is inhibited when the signal is present at least 30µs before
the rising edge of the «TRIGGER» signal and remains till after the falling edge. See further
Trigger.

INHIBIT TRIG
No Print

Trigger

INHIBIT TRIG
No Print
Active edge = Rising
Trigger

INHIBIT TRIG
Print
Active edge = Falling
Trigger

>30us

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Job (Message) selection Inputs

MODE – COMMON DATA / D0 ~ D7 – INC/TRG MESS – LIBRARY SENSE

A mix of these functions allows to set the starting point (first message to be printed) when using a
message library and incrementing or decrementing message selection.

Main function
Switching between:
 Hexadecimal or BCD
 Message selection (from the library) by number or by increment (next/previous).
COMON DATA / D0 ~ D7
Job (Message) number selection.
INC/TRG Mess
Validates the job number proposed on inputs D0 to D7 and starts printing of the job.
LIBRARY SENSE
Determine the sense (numerical ascending or descending order) of the library.

Job D0 to D7 MODE
Choice Confirmation and/or comments Start Printing
Selection Inputs Input

Standard JOB Manually NA NA - TRIGGER

Job number INC/TRG

selected by 0 Hexadecimal
JOB NUMBER MESS
parallel DO…D7 (The Trigger
SELECT
interface or input is not
by UI. 1 BCD
used)

INC/TRG
0
First job MESS
number to
be printed
LIBRARY LIBRARY SENSE=0
selected by INC/TRG
(Library creation DO…D7 the job number TRIGGER
parallel MESS
required) increases.
interface or
by UI. 1
LIBRARY SENSE=1 INC/TRG
the job number
decreases MESS

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ON / OFF

Main function
Switch on or off the printer with an external command.

Behaviour / related setting:

Depending on the actual status of the printer it will switch on or off when activating the «ON /
OFF» input. This input is monitored as soon as the printer is booted up.

COUNTR INCRM x & y

Main function
Increment a counter by external command. The increment value depends on the settings of the
counter.

Behaviour / related setting

There are 15 counters available. The inputs x and y can be set in any counter and the same
counters can be used in different messages. Activating an input affects all the counters in all
the messages programmed with this input.

Increment type
”Input x” >> the counter is incremented by the value set in “step value” when input «COUNTR
INCRMx» is active.
”Input y” >> the counter is incremented by the value set in “step value” when input «COUNTR
INCRMy» is active.
”Input x or y” >> The counter is incremented by the value set in “step value” when input
«COUNTR INCRMx»or «COUNTR INCRMy» is active.

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COUNTR RESET x & y

Main function
Reset a counter by external command.

Behaviour / related setting

There are 15 counters available. The inputs x and y can be set in any counter and the same
counters can be used in different messages. Activating an input resets all the counters in all
the messages programmed with this input.

External reset
”Input x” >> the counter is set to its initial value when input «COUNTR RESETx» is active.
”Input y” >> the counter is set to its initial value when input «COUNTR RESETy» is active.
”Input x or y” >> the counter is set to its initial value when input «COUNTR RESETx» or
«COUNTR RESETY» is active.

COUNTR END

Main function
Give an external signal when the counter has reached its end value.
This output can be set in any counter and to more than one counter at the same time.

Activate output
”No” >> the output «COUNTR END» is not activated at when the counter has reached its end
value.
”Yes” >>the output «COUNTR END» is activated when the counter has reached its end value.

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CONNECTOR LED Designation

ENCODER COMMON ENCODER COMMON
ENCODER CH-A ENCA ENCODER CHANNEL A
ENCODER CH-B ENCB ENCODER CHANNEL B
TRIG-a / TRIG-b TRIG TRIGGER
CELL2-a / CELL2-b CELL CELL 2
INHIBIT TRIG -a
INHT INHIBIT TRIGGER
INHIBIT TRIG -b
COUNTR RESETx -a
RESx COUNTER RESET x
COUNTER RESETx -b
COUNTR RESETy -a
RESy COUNTER RESET y
COUNTR RESETy -b
COUNTR INCRMx -a
INCx COUNTER INCREMENT x
COUNTR INCRMx -b
COUNTR INCRMy -a
INCy COUNTER INCREMENT y
COUNTR INCRMy-b
COUNTR END +
CEND COUNTER END
COUNTR END –
COM
DATA-b
D0-a D0
… … DATA
D7-a D7
MODE-a
SEL MODE
MODE-b
INC/TRG MESS -a INCREMENT / TRIGGER
IMES
INC/TRG MESS -b MESSAGE
LIBRARY SENSE -a LIBRARY SENSE
LIBS
LIBRARY SENSE -b
INVERSE MESS -a
INVM INVERSE MESSAGE
INVERSE MESS -b
ON/OFF-a
ONOF ON/OFF
ON/OFF-b
STOP PRINT –a
STOP STOP PRINTING
STOP PRINT -b
PRINTER READY +
RDY PRINTER READY
PRINTER READY –
OUT-1 +
OUT1 OUT1
OUT-1 –
OUT-2 +
OUT2 OUT 2
OUT-2 –
OUT-3 +
OUT3 OUT 3
OUT-3 –
PRINTG+ PRINTING
PRIN
PRINTG–

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CONNECTOR LED Parameters

RXD-1 RXD1 RS232-1
RTS-1
TXD-1 TXD1
CTS-1
RXD-2 +
RS-422
RXD-2 –
TXD-2 +
TXD-2 –
RXD-2 RXD2 RS232-2
TXD-2 TXD2
RS232-IMP
PRINTER (RXD)
PRINTER RXD
PRINTER (TXD) PRINTER TXD
ALARM COM ALARM COMMON
ALARM NC ALARM NORMALLY CLOSED
ALARM NO ALARM NORMALLY OPEN
FAULT COM FAULT COMMON
FAULT NC FAULT NORMALLY CLOSED
FAULT NO FAULT NORMALLY OPEN
ALARM +
ALRM ALARM
ALARM –
FAULT +
FAUL FAULT
FAULT –

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■ Diagrams of the hydraulic circuit

Location of the different components

Ev6: Ink contrast

Added on contrast IC 21 12
13
9232E 10

8 26
9 11

5
1 34
3 4 6 7
28
27

17
30
2 19
22
20 31
15 25
16
29
18

32
33
1NC 3NO 14

1 Additive cartridge 12 Main filter 23 Drain hose

2 Ink cartridge 13 Pressure + temperature sensor 24 Ceramic calibrated tube
3 Additive reservoir 14 Pressure pump 25 Calibrated leak 0,3mm
4 Venturi (Depending on umbilical
Level chamber 15 26 Calibrated leak 0,3mm
length)
5 Measurement chamber 16 Ink transfer pump 27 Additive filter
6 Ink reservoir 17 Additive transfer pump 28 Filtering connector
7 Constant level chamber 18 Electro valve 1: Ink supply 29 Filtering connector
8 Additive anti pulse air pocket 19 Electro valve 2: Constant level 30 Ink head filter
9 Condenser + Peltier cell 20 Electro valve 3: Ink level 31 4 electro valve block
10 Electro valve 4: Anti pulse /
Pressure transmitter 21 32 Modulation assembly
additive
11 Ink anti-pulse bellows 22 Electro valve 5: Additive supply 33 Gutter block
34 Electro valve 6: Ink contrast

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■ Part identification
Filter
Filters in connectors are identifiable by a cut around the fitting.

Additive anti pulse

Air pocket

Antipulse/additive
(IC4)

Additive FILTER
CONNECTOR BARBED
FILTER 100 µm
(ENM38107)

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Venturi assembly
Filtering
ENM38114 (3m)
connector
ENM43471 (6m)
(ENM38113)

CONNECTOR BARBED
FILTER 100 µm
(ENM38107)

CONNECTOR BARBED
FILTER 100 µm
(ENM38107)

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Ink Circuit start –up / Main steps

Step1: Check required ink level to work

When IC is starting up, the ink level Electro valve EV3 is switched
alternatively on way 1 and way 3, the level in the measurement chamber
increases while the required minimum level to work is exceeded.
Note: If the ink level is not sufficient to start correctly: the circuit will
pump ink from the cartridge and fill the tank.

Part/Parameters State/Value
EV3-Ink Switch alternatively on way 1 and way 3
Ink Level 28 mm

CP1
Step2: Emptying the level chamber and initializing the
pressure transmitter
A draining of the measurement chamber is carried out and a calibration of
the pressure transmitter CP1 is done. The ink goes from the level
chamber to the ink reservoir: Ink transfer pump P1 is activated, Ink supply
Ev1 and ink level Ev3 are switched on way 3.

Part/Parameters State/Value
EV3-Ink level Way 3
Ev1-Ink supply Way 3
P1-Ink transfer pump Running
Ink Level Minimum

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Step 3: Minimum level of ink in the level chamber

The ink goes from the ink reservoir to the level chamber through Ev3 switched on
way 1 until the minimum level is reached.

Part/Parameters State/Value
EV3-Ink level Way 1

Step 4: checking additive reserve level

The additive goes from the cartridge to the additive reservoir

until the additive reservoir overflows into the level chamber:
Additive transfer pump P2 is activated, Additive supply Ev5 is
switched on way 1.
The overflow is detected by level increase in the level chamber.

Part/Parameters State/Value
EV5-Additive supply Way 1
EV4- Anti pulse / additive Way 1
P2-Additive Transfer Pump Running

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Step 5: the pressure pump starts

The motor speed of the pressure pump MP1 increases

until the former reference pressure is reached.

Part/Parameters State/Value
MP1- Pressure pump 2000+/-100 rpm
Ink pressure Pref

1NC 3NO

Step 5: Jet Start-up (with additive)

The jet will start with additive in order to clean the hydraulic components in the print head.
Additive transfer pump P2 push additive from the additive tank (V3) to the print head.

Part/Parameters State/Value
P2-Additive transfer pump Running
EV4- Anti pulse / additive Way 1
EV5-Additive supply Way 3
H8 – Additive Open
H9-Recuperation Open

H9 H8

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Part/Parameters State/Value
H9 H8
H8 – Additive Open
H9-Recuperation Open H7
H7-Purge Open

Part/Parameters State/Value
H8 – Additive Closed H9 H8
H9-Recuperation Open
H6
H7-Purge Closed H7
H6-Ink Open
Jet Speed ~ 20 m/s

Viscosity measurement / Main steps

Step 1: filling the constant level chamber

Ev2 is switched on way 1 in order to make the ink
going to the constant level chamber.

Part/Parameters State/Value
EV2-Constant level Way 1
MP1- Pressure pump 2000+/-100 rpm

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Step 2: Emptying the level chamber

A draining of the measurement chamber (V2) is carried out; the
ink goes from the measurement chamber to the ink reservoir:
Ink transfer pump P1 is activated, Ink supply Ev1 and ink level
Ev3 are switched on way 3.
The constant level chamber is still overflowing.

Part/Parameters State/Value
EV3-Ink level Way 3
Ev1-Ink supply Way 3
P1- Ink transfer Running until empty level chamber

Step 3: Waiting high level in the level chamber

The printer measures the time necessary to reach the high level
in the measurement chamber to get the viscosity value in
seconds. The ink comes from the constant level chamber
through the calibrated ceramic tube.
The constant level chamber is still overflowing.

Step 4: End of viscosity measurement

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Ink level measurement / Main steps

Step 1: Stopping constant level chamber filling

Ev2 is switched on way 3 in order to make the ink going to the ink
reservoir instead of the constant level chamber. The ink goes from
the constant level chamber to the measurement chamber through
the calibrated ceramic tube.

Part/Parameters State/Value
EV2-Constant level Way 3

Step 2: Balancing the constant level chamber and

the ink reservoir
Ev3 is switched on way 1 in order to make the ink going from
the ink reservoir to the constant level chamber (or vice versa
if the level in the level chamber is higher than in the ink
reservoir).

Part/Parameters State/Value
EV3-Ink level Way 1
V2,V1,V4 Balancing

Step 3: Waiting for stability in the level chamber

When the level is stable in the level chamber the ink transfer is complete. The level is the same
in the level chamber, the constant level chamber and the ink reservoir
Then ink level is measured in the level chamber.

Step 4: End of ink level measurement

Once the ink level has been measured, the viscosity measurement starts again.

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Ink transfer phase

Step 1: Ink cartridge detection

The ink level is too low for printing: an ink transfer is required.
The ink transfer phase starts with a detection test of ink cartridge and with a check of the correct
working of the pressure transmitter (CP1). Furthermore, before each phase of ink transfer, a
“forced” draining of the measurement chamber is carried out: Ink transfer pump P1 is activated,
Ink supply Ev1 and ink level Ev3 are switched on way 3.

Step 2: Filling the ink reservoir

During ink transfer phase, ink inside the cartridge is
pumped by ink circuit during two minutes. The ink goes
from cartridge to the ink reservoir: Ink transfer pump P1 is
activated, ink supply Ev1 is switched on way 1 and ink
level Ev3 is switched on way 3.

Part/Parameters State/Value
Ev1-Ink supply Way 1
P1- Ink transfer Running until empty level chamber

1NC 3NO

Step 3: Waiting for stability in the level chamber

After each phase of ink transfer, the ink level is measured in
the level chamber.
The level must be the same in the level chamber, the
constant level chamber and the ink reservoir. While the level
of ink does not exceed the limit level, previous steps (1 and
2) are carried out.

Part/Parameters State/Value
EV3-Ink level Way 1
V2,V1,V4 Balancing

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Step 4: Specific Rinsing for contrast ink circuit

When special inks are used with the contrast IC and after
the ink cartridge transfer, the printer performs a rinsing of
the ink transfer circuit to eliminate residual pigment. The
additive transfer pump P2 is activated, additive supply Ev5
is switched on way 3, anti-pulse Ev4, ink supply Ev1 and
ink contrast Ev6 are switched on way 1.

Part/Parameters State/Value
P2-Additive transfer pump Running
EV5-Additive supply Way3 EV6

EV4-Anti-pulse Way1
EV1-Ink supply Way1
EV6- Ink Contrast Way1

Stand By mode (available only for 9232E)

The standby mode is performed when the printer is OFF every 2 hours during 15 minutes.
This mode is implemented with printers equipped with a contrast ink circuit (9232E) running with
ink based on pigment.

Step 1: filling the Level chamber

Motor of the pressure pump is powered and set to ~1500 rpm.

EV2 is switched on way 1. The ink from reservoir goes to the
constant level chamber.
Through the ceramic calibrated tube, the ink goes from the
constant level chamber to the measurement chamber. The
level measurement is filled to its maximal value.

Part/Parameters State/Value
EV2-Constant level Way1
MP1- Pressure pump 1500 rpm

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Step 2: Emptying the Level chamber

A draining of the measurement chamber (V2) is carried out; the
ink goes from the measurement chamber to the ink reservoir: Ink
transfer pump P1 is activated, Ink supply Ev1 and ink level Ev3
are switched on way 3.

Part/Parameters State/Value
EV3-Ink level Way 3
Ev1-Ink supply Way 3
P1- Ink transfer Running until empty level chamber

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■ Jet start-up and shut-down

During printer start-up and shut-down, the modulation assembly is pre-rinsed at jet start-up and
post-rinsed at jet shut-down in order to guarantee an optimum start-up of the jet and longer jet
stability during normal operation.
The recuperation channel is also rinsed as the additive follows the same trajectory as the ink.

4 Electrovalves block

1 A B
Additive 2
Ink Modulation assembly
3 A B
6 7
Purge
A B

5 A B 4
Recuperation Gutter

Depending on the ink type and the ink temperature, different cycles will be used. The difference
will be noticed for example in the number of activations of head elv’s.
The ink pressure for jet start-up is based on the last memorized pressure giving a correct jet
speed. At each jet shut-down (and or printer shut down) the pressure is memorized for the next
jet start-up.
The pressure of the additive is close to the ink pressure needed for a correct ink jet (between 2
and 3 bars) This pressure guarantees the smooth passage from additive to ink during jet start-up
and vice versa during jet shut down.
The recuperation channel is sealed from ambient air as soon as the jet is off. This avoids ink
drying in the recuperation channel and eventually ink spilling through the gutter.

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Hydraulics

■ Jet principles

Break off point (BOP)

The break off point is where a drop separates from the jet and
should occur between the charge electrodes. An incorrect
break off point results in satellite drops (little drops between
the main drops) and/or insufficient or no drop charge. The
break off point can be observed with a magnifier. Behind the
charge electrode there is a led which lights at the frequency
of the piezo to be able to observe the drops “frozen”.
The break off point is automatically optimized in relation to
the temperature in the print head by adjusting the voltage
applied to the piezo in the modulation assembly.

Automatic BOP Adjustment

The optimum break-off point is determined automatically by the printer and stored in a table
each time a “break-off point adjustment” is activated.
This table is divided in ten temperature ranges of 5°C depending on the temperature measured
in the print head (from 13 to 62°C). For each range of temperature corresponding an optimum
break-off point value (PZ0 ……. PZ9).
The table is the following:

13°- 17° 18°- 22° 23°-27° 28°- 32° 33°- 37° 38°- 42° 43°-47° 48°- 52° 53°- 57° 58°- 62°

PZ0 PZ1 PZ2 PZ3 PZ4 PZ5 PZ6 PZ7 PZ8 PZ9

Note: The value stored is a count value. A count is equal to 0,8Volt.

If the piezo table is empty between two stored values, the software automatically performs an
interpolation between these two values to set the piezo at the considered temperature.
This value is not recorded in the table but they are used until the temperature range change.

The piezo curve is not necessarily linear and not increasing systematically
Do not fill the table manually!

If the temperature is over 54°C, the piezo value PZ9 is used.

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Hydraulics

Example: 3 values are stored in the table.

13°- 17° 18°- 22° 23°-27° 28°- 32° 33°- 37° 38°- 42° 43°-47° 48°- 52° 53°- 57° 58°- 62°
150 250 300

These values can be displayed from the MI engineer menu:

0 150 0 0 250 0 0 0 300 0

From these values the printer is able to attribute a piezo value for each temperature range.

Piezo

350

300
45 49
250
25 29
200

150
10 14
100

50

0
0 10 20 30 40 50 60
Temperature

Notes:
For a new printer, only one value is stored in the table.
If only one value is stored, this value is used in the entire table.
The table is filled or updated for each “break-off point adjustment “(Any previous value is
overwritten).

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Hydraulics

Phase determination (Charge synchronization)

The optimum charge synchronization is determined by charging two consecutive drops (out of
twelve) at 12 different phases. When these 2 drops pass the phase detection cell it will sense a
current peak. The phase resulting in the highest peak is the one used for charge
synchronization.

Jet speed calculation

The jet speed is calculated using V=d / t (m/s).

The distance d is the height of the active part of the detecting sensor. The time t is the travel
time of a drop over the distance d.

Piezo frequency

Each modulation assembly could be supplied by two different frequencies: 64,35KHz (G head-
20m/s), 74 KHz (G head - 23m/s) and 83,30KHz (M head - 20m/s).

Jet position

The shape of the detection cell (gutter sensor) allows detecting the Back – Front position of the
jet. The amplitude of the signal reveals the left – right position of the jet.

BOP

t = travel time passing detection cell (one drop)

d
Gutter
Sensor

Back - Front Jet speed (v) = d/t

Left - Right

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Hydraulics

■ Jet in the gutter principle

The presence or non-presence of ink in the gutter is measured with a current in the gutter
assembly. The actual conductivity of the ink is measured elsewhere and used as reference to
obtain an accurate measurement.
3 cases are possible:
The current is to low indicating no or insufficient ink flow in the gutter
>>>> “Jet out of gutter or not detected” fault follows.

The current is too high, indicating an overflow of the gutter

>>>>> “Jet out of the gutter or no detected” fault follows.

The current is within the limits

>>>> No fault

Ink

Gutter
Comparator

A
R ink

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General
Operating system

The 9232 printer application software runs on Windows CE 6.0 CORE operating system. The
operating system is not embedded but installed at the factory on the NEP PCB.
It consists of two parts:
 NEP-EBOOT (Boot loader)
 NEP-NK (WinCE OS)

9450 application software

The application software uses several configuration files.

ProductionSettings.cfg: This file contains the factory settings for correct functioning of the
machine. Some values are common and others are relative to the machine configuration (ink
type / head configuration / IP level)

Note: In some cases you might need to change it (See §“Factory configuration setup”)

Package Version & Print unit

Print unit boot

Operating System boot

FPGA Print Head

FPGA NEP

OS data management WIN CE

User Interface

Data management

The print head electronic circuitry is build up around a FPGA. This means it needs to be
programmed. This cannot be done in the field. Print head PCB are programmed in the factory.

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■ Software installation / update procedure

General

A software update should only be performed following and if requested through a Technical
Bulletin. Special attention should be paid to the compatibility of the software with the hardware of
the printer.
As it is very important that installed base takes an advantage / benefits of all improvement
included in this new software version (corrections and new features) the instruction is to upgrade
systematically “at the next visit” and to record the printer firmware version in SAP (for SAP
countries).
Recording procedure in SAP are the following:
 Update Firmware Version of Equipment Directly In SAP: CRM-SU-DOC 022 V1
 Capture Firmware Version of an Equipment Using MST: CRM-SU-DOC 024 V1
 Update Firmware Version of Equipment via TRT: CRM-SU-DOC 023 V1

Software package

The software package consist of the original software for the printer and for the same version a
simulator which can be installed on a PC.

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Preparation

Firmware release is available and downloadable from planet using a USB key or a SD card (up
to 2 Gb).

Entry point
(Global support)

Entry point
(CIJ support)

Entry point
(9200 support)

Entry point
(9200 Firmware)

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Firmware Installation (Standard)

Before any upgrade, pull the running status files of the printer.
 Disconnect the printer from the AC power

 Plug the USB key in the printer and Reconnect from the AC power

 The printer will automatically boot from the media and the installation starts
automatically

 First, the printer executes the package checker to check the integrity of the data

Please, do not quit the package checker when is running

Pay attention, in some cases if the OS version is obsolete, the
package checker could be executed two times

 The Installation program will check the version installed and remove all irrelevant
files (ignore any faults messages like “file not found”),

 Several applications for the different platforms will be installed / updated.

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 This process will take approximately 10 minutes. Do not interrupt the update
procedure

 Configure the factory parameters according to the customer needs and the
hardware configuration of the printer as follow:

Selectable ink type

(commercial name)

Select the IP level

(IP55 or IP65)
Selectable head type
(G or M)

P/N of 4ELV block,

Selectable umbilic check on the print head
lenght (3 or 6m) if P/N matches

Contrast circuit: Not Select: Unique coding option

applicable - Quality (20m/s)
- Speed (23m/s)

By default, the production settings reflect the printer configuration. Take a particular care when
modifying them: all is not possible or allowed

 Click on Next>> and Create All files to validate the configuration

 Click on Exit and disconnect the printer from the AC power

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 Remove the USB Key containing the firmware. Otherwise the printer will re-install
the software at the next power on.

 Capture the firmware version of the printer in SAP:

Installation Report

In cases of software installation issues, a report named InstallLog (.txt), containing the
installation history is available and downloadable from the NOR Flash of the printer File
explorer. This report traces all steps of the installation and highlights potential installation
issues.
The procedure to upload to an SD card is as follows:

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■ Factory configuration setup

The Factory settings menu is a special configuration tool available to configure the printer.
This tool is launched automatically after a software update. It can also be launched through
the “MI Engineer” interface. [Tools ► Service ►MI Engineer ► Factory settings]
This tool gives you the following possibilities:

 Configure the printer (Hardware),

 Set the data for the maintenance warnings,

 Erase histories
Printer configuration

The MI 9450 printer application firmware uses several configuration files. These files are
created in the MI factory for each individual printer as some of them depend on the printer
configuration (Ink type, printer type, IP level…).
Check and enter the correct settings concerning the printer.
Selectable ink type
(commercial name)

Select the IP level

(IP55 or IP65)
Selectable head type
(G or M)

P/N of 4ELV block,

Selectable umbilic check on the print head
lenght (3 or 6m) if P/N matches

Contrast circuit: Not Select: Unique coding option

applicable - Quality (20m/s)
- Speed (23m/s)

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Click on Next>> and Create All files to validate the configuration

Re-boot the printer by disconnecting the printer from the AC power

Check in the information page for the correct printer configuration and software version.

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Preventive maintenance data

The preventive maintenance data is used to calculate and warn the customer when the
next maintenance is due; that consists in replacing filter kit & maintenance kit.
In the case the printer has lost the history, it is possible to set manually the dates of the
last interventions based on the maintenance contract or service order.
[Tools ►Service►MI Engineer►Factory settings]

Press on the « Advanced » button (1) then on the « prev maint data » button

Enter the correct date and Ink

circuit running hours and
press on the « Save » button.

Press the « EXIT» button.

Disconnect/Reconnect the printer from the AC power.

9232 CAPACYT tool

Complete Back-up of the printer.

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Histories erasures

The history files of the printer can be erased in the case they do not reflect the reality.
Press on the « Histories » button (1). Choose the histories type (2) to erase and/or the
number of month to delete (3).

1
2 3

■ Interface for MI Service engineer

A dedicated MI engineer interface is available on the printer. This interface is protected
under the MI engineer profile.

Note: Most functions are for development purposes or dedicated to perform some
specific operations like: configuration of the ink partial transfer, calibration of Ptr2,
reset of the Break-off point table, test of external signals…..

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Printer Status

Head Status

Modification of the Piezo value

EHT value modification

Jet Start/Stop
with/without additive

Modification of the Break-off point table

Electrovalves

EV1 Pipe/Cannula cleaning sequence

(In case of blockage)

Checking of EV1 pipe sequence

P1 cleaning sequence (In case of blockage)

Commands

Partial transfer activation

Standby mode (Not available)

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Test of Alarms and faults

Consumables information (Signal

detection, remaining volume, batch
number…)

Windows explorer

Photocells, tacky, Peltier auto tests

Test of the touch screen

Not available

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MI engineer profile

The MI engineer profile is a hidden advanced profile. It is activated by a dynamic password

based on the date of the printer.

To activate the MI engineer profile, hold down the advanced

button more than 2 seconds and enter the MI password

Password calculation:
1- Write down today’s date: DD/MM/YYYY
2- Divide each number by four and record the remainder in the box provided
3- Add one (1) to each number and record the sum in the box provided

DAY DAY MTH MTH YR YR YR YR

TODAY'S DATE
DIVIDE BY 4 4 4 4 4 4 4 4
REMAINDER
ADD 1 1 1 1 1 1 1 1 1
TODAY'S PASSWORD
EXAMPLE: 29 MAY 2002
DAY DAY MTH MTH YR YR YR YR
TODAY'S DATE 2 9 0 5 2 0 0 2
DIVIDE BY 4 4 4 4 4 4 4 4
REMAINDER 2 1 0 1 2 0 0 2
ADD 1 1 1 1 1 1 1 1 1
TODAY'S PASSWORD 3 2 1 2 3 1 1 3

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■ History (Log) file

General

When the printer runs, it constantly buffers the printer parameters to create a log
file. Printer parameters are saved into a log file every 10 minutes and when a fault
occurs, the previous 10 minutes are saved.
The printer displays a selection of parameters, the complete printer data can be
transferred on a SD card or an USB memory stick

These files are extremely valuables for R&D department and should always be attached to any
technical claim addressed the TDS department

Files Transfer

The log file can be transferred on USB/SD card by using the transfer function.

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Files Use

FRxxxxxxxx_PrnContexts:
These files give the recording of printer parameters, alarms and faults.

Header data (printer configuration): Printer

S/N, head type, ink type, installation date…

The following parameters can be found in the file:

Name Description Name Description

JetSpeed Speed of the jet (m/s) ViscoSetPoint Reference viscosity value
HeadTemp Temperature in the head (°C) AdditiveCounter -
motorSpeed Speed of the motor (rpm/mn) tankInkLvl Ink level in the tank
motorSpeedSetPoint Reference of the speed motor(rpm/mn) CKMin Sensor/Jet distance, nominal
pressure Pressure of the Jet (bars) CKMax position offset

pressureSetPoint Reference pressure of the jet (bar) Piezo Reference tension of the piezo
TempHardware Temperature in the electronic compartment (°C) BreakOff Measured break of point
TempInk Temperature of the ink (°C) Recup Rate of recuperation
Viscosity Viscosity of the ink FaultList List of printer faults

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■ Copy screen
At any time and whatever the status of the printer, you can make a copy of the screen.
This can be useful for training material as well when encountering a problem and you need
to visualize it (for example when creating a Technical claim towards the TDS department).

Preparation

This function is only available using a SD card.

Create a Text file on a SD card called “CopyScreen.txt”.

Use

Insert the SD card in the printer containing the “copyscreen.txt” file. The printer will detect
the file and automatically create a bitmap file type “YYMMDD-HHMMSS.bmp”.
Remove and re-insert the SD card for each copy screen request. Blinking of the screen
indicates the file has been created and is saved on the SD card

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■ Simulator
A simulator is available which runs on a normal windows pc. This tool is very useful for
training purposes and for the Help Desk to guide a customer through the printer.

Installation & Launching

Download simulator file from planet, unzip it on your hard drive disk. In the folder “simulator”
click on the file “IUI9032_Windows.exe” to launch the simulator

Use

Simulates a printer on:

CTRL+1 => simulate Warning / CTRL+2 => simulate Fault
CTRL + SPACE => simulate a trigger
ALT + F4 => while in the main window, close and exit the application.

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■ Algorithms
Codification

The 9450 algorithms are *.mia files loaded into the 9450 printers.

Codification of the algorithms is as follows:

HJDD_RR_LxDO_YT_zzz_NNNN.mia
Algorithm number from 0001 to 9999

Number of drops used for a complete printed raster

Y =L for linear / N for Non linear

T = P for Pre-engineered / F for Calculated / D for
linear with dynamic repositioning / S for high Speed

L = number of lines
DO = number of Drops per line

Vertical resolution (1/10 mm)

DD = Head/object distance in millimeter

J = N for Normal jet speed (G head: 20 m/s)
H for High jet speed (G head: 23 m/s)
H = G for G head – M for M head

Example: GN10_28_3X07_LD_051_1006.mia
G head - Normal jet speed - Head/object distance 10 mm
Resolution 28
3 lines of 7 drops
Linear - with dynamic repositioning
51 drops used for a complete raster
Algorithm number 1006

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 Markem-Imaje Industries
9, rue Gaspard Monge
BP 110
26501 Bourg-lès-Valence Cedex
France

A42072-Version AD : + 33 (0) 4 75 75 55 00
 www.markem-imaje.com
July 2016

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