Domino A-SERIES Operation And Maintenance Manual

DOMINO A--SERIES
INK JET PRINTER
OPERATION AND
MAINTENANCE
MANUAL

DECLARATION OF CONFORMITY

We,
declare under our sole responsibility that the products,
Domino A300 and Pinpoint, A200 & A100 Printers
to which this declaration relates, are in conformity with the following standards:
EN50081--2 1992 Class B : Electromagnetic Compatibility (Conducted), EN50082--2 1992 : Electromagnetic Compatibility, General Immunity Standard EN55022--1 1987 Class A : Electromagnetic Compatibility (Radiated) EN60204 Part 1 : Safety of Machinery -- Electrical Equipment of Industrial Machines EN60950 : Safety of Information Technology Equipment, including Electrical Business Machines
following the provisions of:
73/23/EEC : Low Voltage Directive 89/336/EEC : EMC Directive.
Bar Hill, Cambridge, 17th July 1998 D.W. Reed
(2) 27080 Issue 1 Sept 98
DOMINO A--SERIES
INK JET PRINTER
OPERATION AND MAINTENANCE MANUAL
This manual, Domino Part No. 27080, is for use in the maintenance of Domino A300 and Pinpoint, A200 and A100 printers.
For instructions on how to operate the printer, refer to the Domino A--Series Operator’s Pocketbook, Domino Part No. 27090.
Users of this ink jet printer are warned that is is essential to read, understandandactaccordingtotheinformationgiveninPart1:Health andSafety. Thispartofthemanualalsospecifiesasetofsymbolswhich are used elsewhere in the manual to convey special warnings or requirements. It is,therefore,essentialthat users arealso familiarwith these symbols and act accordingly.
All rights reserved. No part of this publication may be reproduced, stored on a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of Domino UK Ltd.
Domino UK Ltd has a policy of continuous product improvement,the Company therefore reserves the right to modify the specification contained in this manual without notice.
E Domino UK Ltd 1998
For sales, service and inks please contact:
Domino UK Ltd Domino Amjet Inc
Bar Hill 1290 Lakeside Drive Cambridge CB3 8TU Gurnee IL.60031 England U.S.A. Tel: 01954 782551 Tel: 847 244 2501 Fax: 01954 782874 Fax: 847 244 1421
27080 Issue 1 Sept 98 (3)
FCC Notice
Thisequipmenthasbeentestedandfoundtocomplywiththelimitsfor a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment.
Thisequipmentgenerates,usesandcanradiateradiofrequencyenergy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communication. Operation of this equipment in a residential area is likely to cause harmfulinterference,in whichcase,the userwillbe requiredtocorrect the interference at his own expense.
Ifthis equipmentdoes causeharmful interferencetoradioortelevision reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:
D Re--orientate or relocate the receiving antenna D Increase the separation between the equipment and receiver D Connect the equipment into an outlet on a circuit different from
that to which the receiver is connected
D Consultthedealeroranexperiencedradio/TVtechnicianforhelp.
Any changes or modifications not expressly approved by the manufacturercouldvoidtheuser’sauthoritytooperatetheequipment.
(4) 27080 Issue 1 Sept 98
DOMINO A--SERIES
INK JET PRINTER
OPERATION AND MAINTENANCE MANUAL
CONTENTS
CHAPTER 1 Part 1 Health and Safety
Basic requirements and symbol explanations.
Part 2 Introduction
Including printer specification, menu map and use of the front panel.
CHAPTER 2 Part 3 Operation
Start up, shut down, cartridge and reservoir replacement and how to create a message.
Part 4 Display Messages and Fault Finding
Message interpretation and basic fault--finding.
Part 5 Reference
Glossary of terms and screen descriptions with details of the options.
CHAPTER 3 Part 6 Printer Description
Print head, cabinet, electronics and ink systems.
Part 7 Maintenance
General and periodic maintenance, jet alignment and ink changes.
Part 8 Repair
Print head, electronics system and ink system.
Part 9 Spares and Accessories
Accessories, consumables, tools and spares.
Part 10 Options
Additional parts for the printer.
Appendix A Installation
Installation and preparation for use. Index To locate a subject in the manual. Appendix B Compressor Driven Airdryer
Instructions and maintenance. Appendix B Air Driven Airdryer
Instructions and maintenance.
27080 Issue 1 Sept 98 (5)
(6) 27080 Issue 1 Sept 98
DOMINO A--SERIES
INK JET PRINTER
OPERATION AND MAINTENANCE MANUAL
AMENDMENT RECORD
Amendment Date
All Parts at Issue 1 September 98 Appendix B : Compressor Driven Airdryer April 98 Appendix B : Air Driven Airdryer April 98
27080 Issue 1 Sept 98 (7)
(8) 27080 Issue 1 Sept 98
DOMINO A--SERIES
INK JET PRINTER
OPERATION AND MAINTENANCE MANUAL
In order that the machine continues to comply with the standards required by the certification, the following components must not be altered in any way or replaced by other types.
COMPONENT DOMINO
PART NO.
HV PSU 12170 Advance HI Volt GM7--19
PSU Assy 37758 Bulgin Power
Filter
Mains/Power
Switch
Mains/Power
Plug 3 Way
Mains/Power
Socket 7 Way
Mains/Power
PCB Assy
External
Interface
Fuse 20x5 (T)
1A
Fuse 20x5 (T)
4A
13492 Shaffner
37744 EAO 61--8420.12
13496 Bulgin PX0730/P
13498 Bulgin PX0744/S
25109 Domino 25109
01210 Little Fuse 213.001.MA000
01229 Little Fuse 218.004.MA000
MANUFACTURER MANUFACTURER
PART NO.
SAX110--34
Source
FN332--3/05
Bulgin
PS02/A0320/63
27080 Issue 1 Sept 98 (9)
(10) 27080 Issue 1 Sept 98
PART 1 : HEALTH AND S AFETY
CONTENTS
INTRODUCTION Page 1--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic Requirements 1--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage 1--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fire Risk 1--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spillages and Disposal 1--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYMBOLS 1--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27080 Issue 1 August 98 1--1
HEALTH AND SAFETY
1--2 27080 Issue 1 August 98
HEALTH AND SAFETY
HEALTH AND SAFETY
INTRODUCTION
Domino supplies Safety Data Sheets (SDS’s)giving specific safety information with each of its ink, make--up and wash fluids. There are also warnings on each container. The following notes are for general guidance only.
Basic Requ irements
When used correctly, printing inks do not cause problems. However, everybody using them should be familiar with the appropriate safety standards and be aware of the precautions that should be taken. The following are basic requirements.
D Proper standards of industrial practice relating to cleanliness and
tidiness must be maintained
D Inks and their containers must be stored and handled with care D All who come into contact with inks must be properly instructed
in their use.
Directions for safe working practices vary according to the environment. The following are broad principles so that necessary precautions may be taken.
D Contact with the mouth must be avoided. Therefore eating,
drinkingorsmoking, or any personal habits oractionswhichmay transfer ink to the mouth, must be avoided
D Contact with the eyes must be avoided. Suitable eye protection
must always be worn whenever there is any risk of splashing or misting. If ink does get into theeyes,firstaid treatment is toflood theaffectedeyefor15minuteswithsalinesolution,(orcleanwater ifsalinesolutionisnotavailable),takingcarenottoallowthewater to run into an unaffected eye. Medical aid must be obtained immediately
D Most inks contain solvents which may injure the skin. Warning of
this is given on the SDSs. Barrier creams should be used and protective clothing worn
27080 Issue 1 August 98 1--3
HEALTH AND SAFETY
D Many inks contain materials which vaporise easily and can be
inhaled. Good ventilation is necessary
D Any usedcleaning materials,e.g.rags, paperwipes,are apotential
fire hazard. They must be collected for safe disposal after use
D After exposure to ink, all possible traces must be washed off as
soon as possible at the nearest washing facility.
Certain inks are allowed for use where they can be in indirect contact with food. In these cases, the following precautions must be observed in addition to those appropriate to hygiene:
D The inks must only be used in printers supplied from new for use
with these inks. Any repairsand replacementsmust use genuine, new and unused spare parts
D The inks must not be used in printers which have previously been
used, at any time, for any other purpose.
In other words, a printer using ”food grade” ink can be converted for use with other inks, but a printer which has used other inks must not be converted for use with food grade ink.
Storage
Printing inks must be stored in well--ventilated buildings, or in areas set aside for the purpose, chosen for safety in case of fire. Materials based on volatile, flammable solvents must be stored in accordance with local regulations.
Fire Risk
For an electrical fire, do not use water. If water must be used, such as inthe caseof aNitro--cellulose inkfire (seebelow) thepowerMUST BE REMOVED first.
Manyinks usedin inkjetprintingcontainNitro--celluloseas thebinder and remain highly flammable when dry. Observe all warnings given on the machine and the following safety instructions:
D If there has been an accumulation of dried ink, do not use ferrous
metal (iron or steel) scrapers to remove it, as they can produce sparks
1--4 27080 Issue 1 August 98
HEALTH AND SAFETY
D If dry Nitro--cellulose based ink ignites, it will generate its own
oxygenand canonly beextinguished bylowering thetemperature with water
D If a Nitro--cellulose fire occurs, ENSURE THAT THE
ELECTRICAL POWER IS IMMEDIATELY REMOVED FROM THE PRINTER BEFORE water is used to extinguish the fire.
Fire risk is a most important consideration where printing inks are storedandused. Thedegreeoffirehazardwillvaryconsiderablyfrom one type of ink or wash to another.
Water--based inkswillnot burn, althoughinksbased on water--alcohol mixtures may burn if there is sufficient alcohol present. Prolonged exposureof water--based systemstohigh temperatures mayevaporate the water to give a flammable residue.
Solvent--based inks offer a greater degree of hazard depending on the particular solvent or solvent combination. When there is a particular hazard the appropriate information is given on the SDS.
Ink jet printers place small electrostatic charges on the ink drops used for printing. In most circumstances, such as when they arrive at the print surface, these electrostatic charges are either conducted away or cannotaccumulate. However,duringmaintenance,printdropsmaybe collected in a container, such as a beaker. It is essential that this container is made of conducting material and is securely connected to ground/earth. The electrostatic chargeswill then be safely conducted to ground/earth.
If there is a fire, there is a likelihood that dangerous fumes will arise from printing inks. For this reason ink must be stored where it can be reached quickly by the fire fighting service, and where it will not spread beyond the store.
27080 Issue 1 August 98 1--5
HEALTH AND SAFETY
Spillages and Disposal
WARNING: Some dried inks are highly flammable. Clean up
allink spillagesimmediately. Do notallow theink to dry or allow any build--up of dried ink spills.
Spillages must be cleaned up as soon as possible with the appropriate solventmaterials andwith regardtothesafetyofpersonnel. Caremust be taken to prevent spillages or residue from cleaning up entering drains or sewage systems.
Inks and associated fluids are materials which conduct electricity. Therefore, power to the printer must be switched off while spillages inside the printer cabinet are being cleaned up.
Printing inks and associated fluids must not be treated as ordinary waste. They must be disposed of using approved methods according to local regulations.
1--6 27080 Issue 1 August 98
HEALTH AND SAFETY

SYMBOLS

The following symbols are used in this manual. Where they appear next to a procedure or instruction, they have the significance and importance of written warnings and cautions.
Eye protection must be worn.
Protective clothing must be worn.
The equipment must be switched off and power removed.
Only trained personnel should carry out this procedure.
Beware of Electrostatic Discharge (ESD). Electrostatic precautions must be used.
D Switch off machine first D Wear a wristband connected to ground D Avoid wearing clothing which can build up electrostatic voltages D Use ESD protective bags to transport PCBs D Only place PCBs on a mat made from a material which will
dissipate electrostatic voltages and which is connected to ground.
27080 Issue 1 August 98 1--7
HEALTH AND SAFETY
1--8 27080 Issue 1 August 98
PART 2 : INTRODUCTION
CONTENTS
GENERAL Page 2--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRINTER SPECIFICATION 2--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print Head 2--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cabinet 2--6.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data Input 2--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ink System 2--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environment 2--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 2--7.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRINTER CONTROL 2--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Control Panel 2--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display 2--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On/Off Switching 2--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Topic Keys 2--11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Purpose Keys 2--12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Help Key 2--13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Currency Key 2--13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Password System 2--13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unicode Character Entry 2--14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Importing and Exporting Data 2--14. . . . . . . . . . . . . . . . . . . . . . . . . .
User Port 2--14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT PANEL TOPIC KEY MENUS 2--15. . . . . . . . . . . . . . . . . . . . . . .
27080 Issue 1 August 98 2--1
INTRODUCTION
INTRODUCTION
GENERAL
This manual provides:
D A basic introduction to the printer and how to use the front panel,
with procedures that demonstrate how to manage the printer
D Reference sections describing the functions and messages
presented through the front panel
D A full description of the ink and electronics systems D Maintenance and repair procedures.
Theprinterconsistsofaprinthead connectedtoastainlesssteelcabinet by way of a flexible conduit. The cabinet contains an ink system and a controlling electronic system operated through a panel on the cabinet upper door. The printers are shown on pages 2--2, 2--3 and 2--4, with internal views of thecabinetupper(electronic) and lower (inksystem) compartments shown on pages 6--7 and 6--8.
27080 Issue 1 August 98 2--5
INTRODUCTION
PRINTER SPECIFICATION
Print Head
Standard Finish: Aluminium alloy, Tufram coated Dimensions: Width: 40mm (1.575”)
Depth: 42.5mm (1.673”) Height: 280.5mm (11.05”)
Weight: 1.0kg (2.2lbs) Nozzle size: Pinpoint only: Spacing from print surface: Pinpoint only: Working height relative to
cabinet base:
Conduit Length: 3 or 6 metres (10ft and 20ft)
60 or 75 micron
40 micron
12mm (0.47”) nominal
4mm (+/-- 1mm)
3m conduit: +/--2m (8ft 2ins)
6m conduit: +/--3m (10ft) (A300/A200
only)
A300 Pinpoint and A100: 3m only
Cab inet
Standard Finish: Brushed 316 stainless steel (A300)
Brushed 304 stainless steel (A200 & A100)
IP Rating: A300 is IP65 (1977)
A200/A100 are IP53 (1977)
Dimensions (A300 & A200):
Width: 475mm (18.7”) --not incl. handles
Depth: 245mm (9.65”) --not incl. front panel Height: 715mm (28.15) --not incl. feet
Weight (A300 & A200) (incl. fluids):
Dimensions (A100): Width: 450mm (17.7”) -- not incl. handles
Weight (A100) (incl. fluids): 33kg (72.6lbs) Control Panel: Polyester, Membrane touch button
For cabinet and print head installation dimensions, see Installation page A--13.
36kg (79lbs)
Depth: 245mm (9.46”) Height: 650mm (25.6”)
Data Input (Optional)
Interface: Serial, RS232, RS485 Rate: 110 -- 38.4kBaud software configurable
2--6 27080 Issue 1 August 98
INTRODUCTION
Ink System
Ink Capacity (Reservoir): 1.2 litres (0.32 US gall.) -- automatically
metered Ink Capacity (Cartridge): 825ml (0.218 US gall.) Make--up Capacity
(Reservoir): Make--up Capacity
(Cartridge): Ink Viscosity Control: Automatic Viscometer Ink Bleed Control: Automatic Start--Up/Shut--Down Working Pressure: Pinpoint only:
600 ml (0.16 US gall.) nominal --
automatically metered
825ml (0.218 US gall.)
Automatic, 2900mBar (42 psi) nominal
Automatic, 4000mBar (60psi) nominal
Environment
Temperature Range (working):
Temperature Range (Storage):
Humidity: 10 -- 90% RH (non--condensing) Electrical Supply: 90--132V/180--264V 50/60Hz single phase
+5° to +45°C (42°F to 112°F)
--20° to +60°C (--4°F to +140°F) (machine dry storage, wet dependent upon fluids)
Auto ranging, 200VA, internal fuse rating 4A
General
Acoustic Noise Level: Not more than 70 dBA Positive Air Pressure (print
head):
Product detector/Shaft encoder connectors:
Shaft Encoder Input: Open collector or TTL encoder Beacon Connector (option): Bulgin ”Buccaneer” 7 way socket Alarms Connector (option): Bulgin ”Buccaneer” 9 way plug User Port Connector (option): Bulgin ”Buccaneer” 25 way socket Communications Port
connector (option): Power connector: Bulgin ”Buccaneer” 3 way plug,
Internal or external supply. Max external supply pressure to cabinet 1 bar. (A100 is internal only)
Bulgin ”Buccaneer” 6 way socket. 12V 100mA for photocell or
proximity detector
Bulgin ”Buccaneer” 9 way socket
cable supplied
27080 Issue 1 August 98 2--7
INTRODUCTION
PRINTER CONTROL
The printer is switched on by pressing the black button--switch on the side of the cabinet. This supplies power to the whole printer and after a short period control of the printer is transfered to the front panel.

Control Panel

Theprinter iscontrolledexclusivelythroughthefrontpanel. Thereare two types of keys:
D Permanent keys with fixed functions (these form the majority of
keys)
D Function keys with functions which can change under software
control.
The main areas of the front panel are identified in the diagram below.
Topic Keys
Jet
On/Off
Key
Character
Set Keys
A1006_1
Displa y
Display
Front Panel Keyboard Layout
Cursor Keys
Data Entry Keys
Increment
Keys
Function
Keys
The display presentation has the following basic structure. Alertbar shows amessagewhen a printeralertis raised. Themessage
flashes until acknowledged bypressingany character key or thespace key,after whichthe messageis displayedcontinuously. Whenthealert condition is cleared,themessageis cleared. If two or more alerts exist
2--8 27080 Issue 1 August 98
INTRODUCTION
Alert Bar
Status Bar
Working Area
Information Bar
Key Option Bar
Screen Number
Print Symbol
Scroll Arrow
simultaneously, the highest priority alert is displayed. An unacknowledged alert is always at a higher priority than any other acknowledged alert. Screen messages are detailed in Part 4.
Status bar shows status and other non--alert information. Working area provides a general presentation area for the function in
use. Informationbar usually showswhich levelis currentlyselected, but is
also used for general information. Key option bar shows up to four key options at any one time,
presentingthemaslabelsforthefour functionkeysimmediatelybelow the screen. The options are scrolled left and right in groupsof four by the keys on each side of the function keys, which appear when thereis morethanfourkeyoptions. Scrollingresultsinthekeylabelschanging, with the functions of the keys also changing to correspond with the labelling.
Screen n umber provides a numerical identity for each screen. Scroll arrow shows that the screen detail extends off the display. The
up-- and down--cursor keys must be used to show the hidden detail. Print symbol shows printing as each Print Go signal is received. At
very slow print rates the symbol will appear to flash, but typical print rates will give the appearance of a continuous symbol.
Jet On/Off Switching
TheJetOn/Off switchispressed toswitchon the jetandpressedagain to switch off the jet. It is necessary to press the switch for two seconds as a precaution against accidental use. The switch also carries the following indicators:
Power On Indicator shows when the power is switched on at the switch on the side of the cabinet.
Red Alert Indicator shows the printer has a fault which prevents printing. The indicatorflasheswhilethe alert is unacknowledged and
27080 Issue 1 August 98 2--9
INTRODUCTION
Power On
Indicator
Jet On/Off
Key
Red Alert
Indicator
Amber Alert
Indicator
Green
Indicator
displays steadily when the alert is acknowledged. It is extinguished when the fault is cleared.
Amber Alert Indicator shows the printer has a fault that requires attention. Theindicatorflasheswhilethealertisunacknowledgedand displays steadily when the alert is acknowledged. It is extinguished when the fault is cleared.
Green Indicator flashes while the printer is starting up or shutting down and displays steadily when the printer is printing or ready to print. It is extinguished by a fault or when the jet is not running.
2--10 27080 Issue 1 August 98
INTRODUCTION
Topic Keys
Thetopic keyseach opensets ofscreenoptions. These areshown inthe diagram on pg. 2--8 and described in detail in Part 5 : Reference.
Message Editor Provides access to the message
creation utilities.
Message Store Provides access to the stored
Messages.
Print Setup Provides access to the utilities
controlling the message being printed, e.g. message orientation.
Machine Setup Provides access to adjustments
in setting up the printer.
Service Provides access to the printer for
the Service engineer.
utilities.
Message Monitor
Shows the message currently being printed.
Lock--out Switches on password
protection, where used.
27080 Issue 1 August 98 2--11
General Purpose Keys
Cursor Keys Four permanent keys used to
Increment Keys Two permanent keys used to
INTRODUCTION
move the cursor around the screen.
increment and decrement values shown on the screen and marked with the highlight bar. The effect of these keys on settings and values is immediate.
Option Key Bar Scroll Keys
Two keys used to scroll the functions in the keybar.
Function Keys Keys with functions identified
by the names in the keybar immediately above.
Delete Key Deletes entries marked by the
highlight bar.
Alternative Character Set -­Left (Blue)
Press this key to select the top left blue character on each character key. Also (used with the + and -- keys) controls screen contrast.
Alternative Character Set -­Right (Green)
Press this key to select the top right green character on each character key.
Shift Lock Key Changes characters to lower case
until pressed again to return to upper case characters.
Shift Key Hold down to change characters
to lower case.
Enter Key Press this key to put data into
the system to complete an action.
2--12 27080 Issue 1 August 98
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