Imaje 4040 Technical File Manual

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Technical File Manual

Imaje 4040

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101075

Imaje 4040

1. Introduction

1. Introduction ......................................................................................... 4

1. Introduction.............................................................................................. 4

2. Safety ................................................................................................... 5

Safety Requirements................................................................................... 5

Certification and Approvals ......................................................................... 7

CE Standards & Directives.......................................................................... 7

3. System Specification ..........................................................................8

Technical Specifications (Hardware)...........................................................8

Technical Manual Imaje 4040.doc

4. Controller .................................................................... 10

Maintenance..............................................................................................10

Service/Troubleshooting:........................................................................... 10

Troubleshooting......................................................................................... 14

Wiring Diagram.......................................................................................... 16

Power Entry...............................................................................................17

Power Supply 1 .........................................................................................18

Power Supply 2 ......................................................................................... 19

USB........................................................................................................... 20

Product Detect, Encoder ........................................................................... 21

Mouse to Panel Support............................................................................22

Panel Support to CPU............................................................................... 23

Photocell.................................................................................................... 24

Encoder..................................................................................................... 25

Inverter to Panel Support .......................................................................... 26

Controller to Print Module.......................................................................... 27

Schematic, I/O, Driver Board..................................................................... 28

Panel Support Board Schematic, I/O, Overview........................................ 29

Ethernet 10/100Base-T Connector (CN15)............................................... 30

Audio Connector (CN14)........................................................................... 30

Main Power Connector (CN9) ................................................................... 30

Keyboard and PS/2 Mouse Connector (CN12) .........................................30

Floppy Disk Drive Connector (CN20)........................................................31

Parallel Port Connector (CN19)................................................................. 31

IDE Hard Drive Connector (CN13)............................................................ 32

Power and HDD LED Connector (CN11) .................................................. 32

USB Connector (CN17)............................................................................. 32

COM2 RS-232/422/485 Series Port (CN16).............................................. 33

Imaje 4040

1. Introduction

Flat Panel Connector (CN2)...................................................................... 33

External Flat Panel Display Connector (CN4)........................................... 34

Compact Flash Card Connector (CN21) ................................................... 34

Peripheral Power Connector (CN10) ......................................................... 35

COM1 RS-232 Serial Port (CN8)............................................................... 35

LCD Inverter Backlight Connector (CN1) .................................................. 35

CRT Display Connector (CN5).................................................................. 35

LCD Signal Mapping ................................................................................. 36

PC20000301 (PCM-9372) CPU Board Specifications............................... 38

Award BIOS Setup .................................................................................... 41

Imaje 4040 BIOS Settings......................................................................... 45

Standard CMOS Features......................................................................... 46

Advanced BIOS setup............................................................................... 47

Advanced Chipset Features...................................................................... 48

Intergraded Peripherals.............................................................................49

PnP/PCI Configuration .............................................................................. 50

Set Password ............................................................................................ 51

Cleaning the vent screens and fan inside the 4040...................................52

Technical Manual Imaje 4040.doc

5. XJ500 Print Module ...................................................... 54

Maintenance..............................................................................................54

Theory of Operations................................................................................. 56

Trouble Shooting....................................................................................... 57

Vacuum Priming the Printhead.................................................................. 59

Vacuum Priming the XJ500 Head ............................................................. 60

Pressure Priming the XJ500 Printhead ..................................................... 61

Removing/Installing the XJ500 Printhead.................................................. 62

Flushing the XJ500 Printhead................................................................... 65

XJ-500 Head Solvent Based Notes:..........................................................66

IDS2-500 Ink System Circuit Board Schematic, I/O.................................. 67

Drawing, Ink Level Sensor Assembly, IDS2/500 revision.......................... 68

Wiring Diagram, IDS2/500 Print Module, Old............................................ 69

Plumbing Diagram, IDS2/500....................................................................70

6. XJ128 Print Module ...................................................... 71

Maintenance..............................................................................................71

Trouble Shooting....................................................................................... 71

Priming the XJ128 Printhead..................................................................... 73

Procedures for Cleaning a Clogged Printhead (XJ128) ............................ 76

Cleaning a Severe Clog: ........................................................................... 77

Removing/Installing the XJ128 Printhead.................................................. 78

Schematic, I/O PCB, IDS-128 Ink System................................................. 80

Imaje 4040

1. Introduction

Electrical Diagram, IDS2/128 .................................................................... 81

Drawing, Replacement Printhead, XJ128.................................................. 82

7. Table of Figures................................................................................. 83

Technical Manual Imaje 4040.doc

Imaje 4040

1. Introduction

Disconnect the machine from the mains before any operations requiring modules or components to be removed or exchanged.

Liability

Imaje cannot be held responsible if safety instructions and basic safety rules for using and servicing the products are not followed. Any modification or intervention is the responsibility of the user as far as its possible consequences are concerned. The same applies to any use of the product that fails to comply with Imaje specifications. Any modification carried out may be counter to product compliance and the relevant safety standards. Therefore, Imaje cannot be held liable for any malfunction or damage caused by any modification of the use as recommended by Imaje, or for any incident arising from use of the product for any purposes other than those for which it is designed. It is the sole responsibility of the user to take the precautions required by any use to which he or she puts the product.

Use

Technical Manual Imaje 4040.doc

Only use Imaje original spare parts and consumables (ink, cleaning products, and other servicing products). Other types of consumables should not be used without Imaje’s written approval, and any consequences shall be under the entire responsibility of the user.

Servicing

Disconnect the Imaje 4040 Large Character Ink Jet Printing System from the mains before any operations requiring components to be removed or exchanged. Use appropriate tools for any work on the electrical and ink circuits.

We recommend that the interventions be carried out by persons who have been given the appropriate technical training proposed by Imaje.

Conditions

Imaje AB reserves the right to change specifications in both the text and illustrations without prior notice. The contents of the publication may not be copied, either wholly or in part, without permission from Imaje AB.

First published: 2005 Art number: 101075-01 Version: 00

Imaje 4040

2. Safety

2. S afety

Safety Requirements

Imaje disclaims all responsibility regarding the CE directive if the printer is used, altered or installed in any way other than described in this manual.

This symbol is used to indicate circumstances that may be dangerous to the user or that cause damage to the equipment.

This symbol is used to draw your attention to important information that will facilitate work or operations.

Please Note the Following Warnings:

■ Never use sharp or pointed tools when cleaning or replacing the print head.

■ The nozzle plate on the printer head is sensitive to handling. Contact with this

surface must be minimized to prevent damage to the nozzle plate. Damage to the nozzle plate surface can cause a reduction in the performance of the print head.

■ If the XJ-500/ XJ-128 nozzle plate requires cleaning – flood the nozzle plate with the appropriate cleaner (see chapter 4 – Priming the print head). Use only Imaje authorized cleaners. Never clean the nozzle plate with tools. Never wipe the nozzle plate.

■ Never point the nozzle end of a print head at yourself or another person.

Technical Manual Imaje 4040.doc

Imaje 4040

2. Safety

■ Please read all instructions before using the printer for the first time.

■ The printer should be connected to the power supply indicated on the voltage

plate. If you are unsure of the type of power supply available, please contact Imaje service personnel.

■ The printer should be connected to a grounded socket.

■ The printer is equipped with a plug suitable for grounded sockets. This is a

safety measure. If the plug does not fit the power socket, a qualified electrician must replace it.

■ We do not recommend the use of extension cables.

■ The power cable must not be subjected to pressure. Ensure that the printer is

not placed anywhere where the cable can be put under pressure.

■ Check that the power switch is off (in the ‘0’ position) before connecting the power cable.

■ Do not attempt to open the electronic unit or other sealed parts! The user cannot service these parts.

■ Never expose the unit to high humidity or liquids.

■ Ensure that the lighting at the installation site is in accordance with local

regulations.

■ All chemicals, even ink, may present unknown health hazards, and should be treated with caution.

Disconnect the power to the printer and call in qualified personnel under the following conditions:

■ The power cable or plug is damaged or worn.

■ Liquid has been spilled on the printer.

■ Rain or water has leaked into the printer.

■ The printer is not functioning correctly although the user has followed the

instructions.

Technical Manual Imaje 4040.doc

■ The printer has been dropped or the casing has been damaged.

■ The printer is not functioning correctly and requires service.

Imaje 4040

2. Safety

Certification and Approvals

The Imaje 4040 printers are certified in accordance with the requirements for CE marking. CE = European Commission

The Imaje 4040 printers are certified in accordance with the requirements for ETL marking. ETL = Electrical Testning Labs

The Imaje 4040 printers are certified in accordance with the requirements for the FCC. FCC = Federal Communications Commission

CE Standards & Directives

Imaje 4040 printers are in accordance with the following European directives applicable to the products:

■ The electromagnetic compatibility directive, EMC Directive 89/336/CEE, and its corresponding European standards.

■ The Low Voltage Directive 93/68/CEE, and its corresponding European standards.

■ The Machine Directive AFS 1994:48 (98/37/EC), and its corresponding European standards.

■ ETL listed: Conforms to ANSI/UL STD 60950. CERTIFIED TO CAN/CSA C22.2 STD NO.60950-00.

The above referenced product bears the CE mark.

Technical Manual Imaje 4040.doc

Imaje 4040

3. System Specifications

3. System Specification

Technical Specifications (Hardware)

General Description

The 4040 controller is a high-resolution ink jet printing system. This ink jet printer utilizes state of the art Impulse Piezo printhead technology capable of utilizing a wide variety of inks to print onto a wide variety of media at very high resolution.

Controller:

Pentium class processor based PC-104 industrial computer. Running the Windows XP operating system.

Printhead Expansion:

Up to four printheads per controller. Field expandable, add a printhead driver card in 10 minutes. No need to

send into factory or pay for a technician’s visit. Mix and match printhead types with easy “plug and play” technology.

User Interfa ce:

10.4” TFT Color flat panel display with 800x600 resolution.

Integrated, rubberized, waterproof industrial mouse. Industrial membrane QWERTY keyboard. WYSIWYG (what you see is what you get) software. See Software specifications.

Input/Output (I/O):

Printhead Ports: 4 Product Detector Port: 2. Can be used independently or linked together. Encoder Port: 2. Can be used inde pe ndently or linked together. Serial Ports : 1-RS232, 1-RS232,422,485 (Configurable) Parallel Port : 1 USB Port: 1 *Allows easy upload of messages created off line, database files, graphics or software updates via

any type of USB device. And with Windows XP technology there are no worries about drivers.

Ethernet (LAN) Port: 1 (10/100 base T). For networking using Net-Jet PS2 Port: 1. For use with external keyboard, PS2 Wedge scanner, etc. Video Port: 1. For use with external monitor.

Processor:

Via-Eden Pentium class 400MHZ and 800 MHZ standard.

Memory:

Operating Memory: 256mb PC100 D-RAM Image Memory: 8MB, capable of printing an image up to 500 nozzles tall at 360 DPI up to 8 feet in length.

Storage:

20GB Hard Drive (minimum) Message storage is virtually unlimited.

Electrical Requirements:

120VAC/60HZ, 240VAC/50HZ

Environmental Ratings:

Operating temperature 0-50 deg. C, 32-122 Deg. F. to 90% RH, non-co ndensing

Cabinet Construction: Stainless Steel, splash proof design features gasket seal protection.

Safety Agency Compliance:

UL, CE, TUV, GS, CSA

™

software.

Technical Manual Imaje 4040.doc

Imaje 4040

3. System Specifications

Printheads: XJ128-200:

• Nozzle Count: 128 nozzles (all points addressable)

• Horizontal Resolution: 200 DPI

• Vertical Resolution: 185 DPI, Capable of printing razor sharp graphics and reliable bar codes.

• Print Speed: 140 Feet per minute (FPM) at 200 DPI.

• Maximum Print Height: 0.7 inches (17mm)

• Ink: Oil, Solvent, UV (UV types are limited in this head due to lack of temperature compensation).

• Throw distance: Optimal-1mm, Maximum-5mm

• Shock resistance: Since the Xaar printheads were originally designed for desktop and wide area format printers;

they are designed to be able to be moved very rapidly. Thus, these printheads are extremely robust, tolerate

shock and resist depriming far better than most other industrial printheads such as Trident printheads.

• Operating temperature: 35 deg. F (2C) to 105 deg. F (41C). These temperatures are designated for optimal performance and are conservative. The printhead can actually perform fairly up to 115 Deg. F (46C).

XJ500-180

• Nozzle Count: 500 nozzles (all points addressable)

• Horizontal Resolution: 200 DPI

• Vertical Resolution: 180 DPI, Capable of printing razor sharp graphics and reliable bar codes.

• Print Speed: 150 Feet per minute (FPM) at 200 DPI.

• Maximum Print Height: 2.8 inches (70mm)

• Ink: Oil, Solvent, UV

• Throw distance: Optimal-1mm, Maximum-5mm

• Shock resistance: Since the Xaar printheads were originally designed for desktop and wide area format printers;

they are designed to be able to be moved very rapidly. Thus, these printheads are extremely robust, tolerate shock and resist depriming far better than most other industrial printheads such as Trident printheads.

Ink Delivery System:

• The IDS-128 ink delivery system utilizes a 500ml disposable bag in box ink cartridge. This IDS is currently used in conjunction with the XJ128 and XJ126 printhead s. It is made of Stainless Steel and chemically inert materials to be compatible with solvent, oil, UV, and aqueous based inks. Using this IDS, the XJ126 and XJ128 may be set up to print at almost any angle.

• Flashing red Ink Low LED.

• The IDS2-500 ink delivery system utilizes a 500ml disposable bag in box ink cartridge. The IDS2-500 can also

be fitted with a bulk feed ink delivery system called “Ultra-Tank™”. This IDS is currently used in conjunction with the XJ500 printhead. It is made of Stainless Steel and chemically inert materials to be compatible with solvent, oil, UV, and aqueous based inks. Using this ID, the XJ500 may be set up to print horizontally, vertically or at 45 a degree angle.

• Flashing red Ink Low LED.

Print Module:

• The Print Module consists of the printhead, ink delivery system and printhead bracket assemble as one assembly, ready to install. This is available in several variations.

Inks:

Types: Oil base, Solvent Base, UV Curable, Security (invisible), USDA, IR readable. Colors: Cyan, Magenta, Yellow, Black, Red, Blue, Green, White Opaque, Yellow Opaque, Orange Opaque, Powder Blue Opaque.

Technical Manual Imaje 4040.doc

Imaje 4040

4. Controller

• The controller is a Windows XP Professional based industrial computer.

Maintenance

The controller requires very little maintenance. Monthly: Check the fan filters on the bottom of the controller for excessive build up. If clogged up, they need to be removed and either washed with water, or blown off with air.

Service/Troubleshooting:

Adding or Replacing a Driver Board

You many need to add a driver board for driving additional print heads

Tools Required

1. One Philips Screw Driver (Small tip).

2. One 5mm nut driver.

Figure 1: Tools Required to Add/Replace a Driver Board

Technical Manual Imaje 4040.doc

Figure 2: Removing Jack Screws

Step 1 Remove Jack Screws

3. With power off, set the Controller onto a firm flat workspace.

4. Rotate Controller onto its side.

5. Remove the Jackscrews from any currently installed Driver Boards (indicated by H1-H4).

Imaje 4040

4. Controller

Step 2 Removing Cover Plate.

6. If expanding a controller (adding printheads) remove the Driver Board Cover Plate(s).

7. Remove H2-H4 depending on how many boards you are adding.

Figure 3: Removing Cover Plate

Figure 4: Attaching Anti-Static Wrist Strap

Step 3 Attaching Anti-Static Wrist Strap.

8. Attach Anti-Static strap to wrist and

9. Connect the clip to the case for proper ground. Make sure that the

Mains (AC) cable is connected to power, but power turned off

Step 4 Loosen PCB Mounting Plate

10. Using a Philips Screw Driver, loosen (do not remove) all four screws in the slotted holes on the PCB mounting plate.

Technical Manual Imaje 4040.doc

Figure 5: Loosening PCB Mounting Plate

Imaje 4040

4. Controller

Step 5 Lifting the PCB Plate

11. Once all four screws are loose, lift the plate as shown until the plate moves to the top of the screw slots shown in previous Figure.

Figure 6: Lifting the PCB Plate

Figure 7: Tightening the PCB Plate Screws

Step 6. Tightening the PCB plate screws.

12. Upon lifting the PCB mounting plate, re-tighten at least one screw to hold the plate into place so that the drive boards may be removed or installed.

Step 7. Installing the Driver Board

13. Line up the pins on the PC140 bus and push the driver board onto the board beneath it.

Technical Manual Imaje 4040.doc

Figure 8: Installing the Driver Board

Imaje 4040

4. Controller

Step 8. Securing Driver Board

14. Using the standoffs supplied with the driver board expansion kit, fasten each one loosely, and then tighten them once each screw has threaded in smoothly.

Figure 9: Securing Driver Board

Figure 10: Driver Board Installed

Step 10, 11, 12. Securing PCB Plate

Step 9. Driver board Installed with

Standoffs attached.

15. Your new driver board is now installed

16. Repeat in reverse steps 6 then 5 then

Technical Manual Imaje 4040.doc

Imaje 4040

4. Controller

Troubleshooting

Symptom: No power upon startup

Possible cause Possible solution

• Poor AC connection

• Blown AC fuse

• UPS (Uninterruptible Power

Supply) or Line conditioner not turned or defective

• Problem at AC power source (wall outlet).

Symptom: Upon Power up, Fan comes on, but the display does not illuminate

Possible cause Possible solution

• The Inverter cable is loose or disconnected.

Shine a flashlight onto the display to view if Windows can be seen on the display. If so, open the controller door and check the inverter cable connection at both ends. See wiring section.

Check AC connections Check fuse Check line conditioner power and connection if using a line

conditioner. Try plugging printer directly into AC power to be sure UPS or line conditioner is OK.

Check AC voltage at source, or try another source.

Technical Manual Imaje 4040.doc

• Display cable loose or disconnected.

• Inverter Bad

• Display bad

• Bios Re-set (this can

happen when the CMOS battery dies)

Shine the flashlight onto the display. If Windows cannot be viewed, then the display is not functioning. Open the controller door and check the connection on the display cable at both the display side and the CPU board side.

If inverter cables are connected ok, the inverter may need to be replaced.

If cable connections are all ok, replace the display. If the BIOS becomes re-set, this is usually caused by a dead C-MOS

battery. The CMOS battery has a life of about 5 years replace the battery, then attach an external CRT monitor to the video port, because the system has defaulted back to factory settings. You will need to re-set the bios settings so that your panel display will work. There is a BIOS Flash utility saved on the hard drive of the system for convenient re-load. If the re-load does not work, see the BIOS section of this manual for making BIOS adjustments.

Imaje 4040

4. Controller

Symptom: Photocell lights up but no print

Possible cause Possible solution

• The Print Speed and or Margin are set incorrectly

• Product detect/encoder settings incorrect

• PD/Enc. Connector loose at Driver Board input

Symptom: In NJ Processor the Printhead Icon has an “X” through it.

Possible cause Possible solution

• DIP Switch on one of the Driver Boards set incorrectly

• Driver board not seated properly

• Defective Driver Board

Possible cause Possible solution

• Hard drive cable disconnected.

• Hard Drive crashed

Run a piece of paper in front of the print head with one hand, and with the other hand trigger the photocell. If the printer prints, then you can determine if the printer is printing to early or too late. Adjust Margin and or print speed accordingly.

Check that these settings match the hardware configuration. Ex. If using a PD but no Enc. Only PD should be enabled. Check that the linked/independent mode settings are correct according to hardware set up.

Open door and check that the connector is connected to driver board. See wiring diagram. To ensure PD signal, check that LED on driver board lights when PD is tripped. Also, check the Encoder LED. It should light when the encoder is connected and moving or at a resting state on a pulse. If both LED’s light, connectivity is secure. If this symptom occurs on any head other than head 1, check that the linking cable is connected. See wiring diagram.

Check the dipswitch settings on the corresponding board(s) that are X’d out. If switch setting ok, board could be faulty.

Check that the Driver Board(s) is seated fully and that the pins are properly lined up. If correct, driver board could be faulty.

Replace Driver Board

Symptom: Boot Failure/Boot Errors

*Often when a driver board is added, the technician disconnects the HD cable and then forgets to re-connect it. Re-connect it.

Replace hard drive

Technical Manual Imaje 4040.doc

• Memory Failure

• CPU Board Failure

• BIOS Problem

Replace memory (RAM) module on CPU board Replace CPU board

See Technical Bulletin

Imaje 4040

4. Controller

Wiring Diagram

Technical Manual Imaje 4040.doc

Figure 11: Wiring Diagram (ES20000101)

Imaje 4040

4. Controller

Power Entry

Technical Manual Imaje 4040.doc

Figure 12: Power Entry (CH20001401)

Imaje 4040

4. Controller

Power Supply 1

Technical Manual Imaje 4040.doc

Figure 13: Power Supply 1 (CH20001601)

Imaje 4040

4. Controller

Power Supply 2

Figure 14: Power Supply 2 (CH20001301)

Technical Manual Imaje 4040.doc

Imaje 4040

4. Controller

USB

Technical Manual Imaje 4040.doc

Figure 15: USB (CH20001501)

Imaje 4040

4. Controller

Product Detect, Encoder

Technical Manual Imaje 4040.doc

Figure 16: Product Detect: Encoder (CH20002102)

Imaje 4040

4. Controller

Mouse to Panel Support

Technical Manual Imaje 4040.doc

Figure 17: Mouse to Panel Support (CH20002001)

Imaje 4040

4. Controller

Panel Support to CPU

Technical Manual Imaje 4040.doc

Figure 18: Panel Support to CPU (CH20001801)

Imaje 4040

4. Controller

Photocell

Technical Manual Imaje 4040.doc

Figure 19: Photocell (SS10000401)

Imaje 4040

4. Controller

Encoder

Technical Manual Imaje 4040.doc

Figure 20: Encoder (SS10000501)

Imaje 4040

4. Controller

Inverter to Panel Support

Technical Manual Imaje 4040.doc

Figure 21: Inverter to Panel Support (CH20001701)

Imaje 4040

4. Controller

Controller to Print Module

Technical Manual Imaje 4040.doc

Figure 22: Controller to Print Module (CH20000701)

Imaje 4040

4. Controller

Schematic, I/O, Driver Board

Technical Manual Imaje 4040.doc

Figure 23: Schematic, I/O, Driver Board

Imaje 4040

4. Controller

Panel Support Board Schematic, I/O, Overview

Technical Manual Imaje 4040.doc

Figure 24: Panel Support Board Schematic, I/O, Overview

Imaje 4040

4. Controller

Ethernet 10/100Base-T Connector (CN15)

Table 1: Ethernet 10/100Base-T connector (CN15) Pin Signal 1 XMT+ 2 XMT3 RCV+ 4 N/C 5 N/C 6 RCV7 N/C 8 N/C

Audio Connector (CN14)

Table 2: Audio Connector Pin Signal Pin Signal 1 LINE OUT R 2 LINE IN R 3 GND 4 GND 5 LINE OUT L 6 LINE IN L 7 GND 8 GND 9 MIC IN 10 RESERVED FOR MIC 2

Main Power Connector (CN9)

Table 3: Main Power Connector (CN9) Pin Signal 1 +12V 2 GND 3 GND 4 +5V

Keyboard and PS/2 Mouse Connector (CN12)

Table 4: Keyboard and Mouse Connector (CN12) Pin Signal 1 KB DATA 2 MS DATA 3 GND 4 VCC 5 KB CLOCK 6 MS CLOCK

Technical Manual Imaje 4040.doc

Imaje 4040

4. Controller

Floppy Disk Drive Connector (CN20)

Table 5: Floppy Disk Drive Connector (CN20) Pin Signal Pin Signal 1 GND 2 DENSITY SELECT 3 GND 4 N/C 5 GND 6 DRIVE TYPE 7 GND 8 INDEX* 9 GND 10 MOTER O* 11 GND 12 DRIVE SELECT 1* 13 GND 14 DRIVE SELECT 0* 15 GND 16 MOTER 1* 17 GND 18 DIRECTION* 19 GND 20 STEP* 21 GND 22 WRITE DATA* 23 GND 24 WRITE GATE* 25 GND 26 TRACK 0* 27 GND 28 WRITE PROTECT* 29 GND 30 READ DATA* 31 GND 32 HEAD SELECT* 33 GND 34 DISK CHANGE* *Low Active

Parallel Port Connector (CN19)

Table 7: Parallel Port Connector (CN19) Pin Signal Pin Signal 1 STROBE* 2 AUTOFD* 3 D0 4 ERR 5 D1 6 INIT* 7 D2 8 SLCTINI* 9 D3 10 GND 11 D4 12 GND 13 D5 14 GND 15 D6 16 GND 17 D7 18 GND 19 ACK* 20 GND 21 BUSY 22 GND 23 PE 24 GND 25 SLCT 26 N/C *Low Active

Technical Manual Imaje 4040.doc

Imaje 4040

4. Controller

IDE Hard Drive Connector (CN13)

Table 6: IDE Hard Drive Connector (CN13) Pin Signal Pin Signal 1 IDE RESET* 2 GND 3 DATA 7 4 DATA 8 5 DATA 6 6 DATA 9 7 DATA 5 8 DATA 10 9 DATA 4 10 DATA 11 11 DATA 3 12 DATA 12 13 DATA 2 14 DATA 13 15 DATA 1 16 DATA 14 17 DATA 0 18 DATA 15 19 SIGNAL GND 20 N/C 21 HDD 0 22 GND 23 IO WRITE 24 GND 25 IO READ 26 GND 27 HD READY 28 N/C 29 HDACK 0* 30 GND 31 IRQ14 32 N/C 33 ADDR 1 34 N/C 35 ADDR 0 36 ADDR 2 37 HARD DRIVE SELECT 0* 38 HARD DISK SELECT 1* 39 IDE ACTIVE 40 GND *Low Active

Power and HDD LED Connector (CN11)

Table 8: Power and HDD LED Connector (CN11) Pin Signal 1 +5V 2 GND 3 Power LED+ (+5V) 4 Power LED- (GND) 5 HDD LED + 6 HDD LED -

USB Connector (CN17)

Table 9: USB Connector (CN17) Pin Signal Pin Signal 1 +5V 2 +5V

Technical Manual Imaje 4040.doc

3 UV- 4 UV5 UV+ 6 UV+ 7 GND 8 GND 9 Chassis GND 10 N/C

Imaje 4040

4. Controller

COM2 RS-232/422/485 Series Port (CN16)

Table 17: COM2 RS-232/422/485 Series Port (CN16) Pin RS-232 Port RS-422 Port RS-485 Port 1 DCD N/C N/C 2 DSR N/C N/C 3 RXD N/C N/C 4 RTS N/C N/C 5 TxD N/C N/C 6 CTS N/C N/C 7 DTR N/C N/C 8 RI N/C N/C 9 GND N/C N/C 10 GND N/C N/C 11 N/C TxD-+ DATA+ 12 N/C TxD- DATA13 N/C RxD+ N/C 14 N/C RxD- N/C

Flat Panel Connector (CN2)

Table 12: Flat Panel Connector (CN2) Pin Signal Pin Signal 1 VDDSAFES5 (+5V output) 2 VDDSAFE5 (+5V output) 3 GND 4 GND 5 VDDSAFES3 (+3.3V output) 6 VDDSAFE3 (+3.3V output) 7 N/C 8 GND 9 P0 10 P1 11 P2 12 P3 13 P4 14 P5 15 P6 16 P7 17 P8 18 P9 19 P10 20 P11 21 P12 22 P13 23 P14 24 P15 25 P16 26 P17 27 P18 28 P19 29 P20 30 P21 31 P22 32 P23 33 GND 34 GND 35 SHFCLK 36 FLM 37 M/DE 38 LP

Technical Manual Imaje 4040.doc

39 N/C 40 ENAVEE

Imaje 4040

4. Controller

External Flat Panel Display Connector (CN4)

Table 13: External Flat Panel Display Connector (CN4) Pin Signal Pin Signal 1 GND 2 GND 3 P24 4 P25 5 P26 6 P27 7 P28 8 P29 9 P30 10 P31 11 P32 12 P33 13 P34 14 P35 15 GND 16 GND 17 N/C 18 N/C 19 N/C 20 N/C

Compact Flash Card Connector (CN21)

Table 14: Compact Flash Card Connector (CN21) Pin Signal Pin Signal 1 GND 2 D03 3 D04 4 D05 5 D06 6 D07 7 *CS0 8 A10 9 *ATA SEL 10 A09 11 A08 12 A07 13 +5V 14 A06 15 A05 16 A04 17 A03 18 A02 19 A01 20 A00 21 D00 22 D01 23 D02 24 -IOCS16 25 *CD2 26 -CD1 27 D11 28 D12 29 D13 30 D14 31 D15 32 -CS1 33 *VS1 34 -IORD 35 *IOWR 36 -WE 37 INTRQ 38 +5V 39 *CSEL 40 -VS2 41 *RESER 42 IORDY 43 *INPACK 44 -REG 45 *DASP 46 -PDIAG

Technical Manual Imaje 4040.doc

47 D08 48 D09 49 D10 50 GND *Low Active

Imaje 4040

4. Controller

Peripheral Power Connector (CN10)

Table 15: Peripheral Power Connector (CN10) Pin Signal 1 -5V 2 GND 3 -12V

COM1 RS-232 Serial Port (CN8)

Table 16: COM1 RS-232 Serial Port (CN8) Pin Signal 1 DCD 2 RxD 3 TxD 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9 RI

LCD Inverter Backlight Connector (CN1)

Table 10: LCD Inverter Backlight Connector (CN1) Pin Signal 1 +12V 2 GND 3 ENABKL 4 VBR 5 +5V

CRT Display Connector (CN5)

Table 11: CRT Display Connector (CN5) Pin Signal Pin Signal 1 Red 9 VDDC 2 Green 10 GND 3 Blue 11 N/C 4 N/C 12 DDCSDA 5 GND 13 H-SYNC 6 GND 14 V-SYNC 7 GND 15 DDCSCL

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8 GND

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LCD Signal Mapping

Table 18: LCD Signal Mapping Pin Name 16-Bit DSTN 24-Bit DSTN 18-Bit TFT 24-Bit TFT 36-Bit TFT PD0 LB3 B0 R00 PD1 LB2 B1 R10 PD2 LB1 LB1 B0 B2 R01 PD3 LB0 LB0 B1 B3 R11 PD4 UB3 B2 B4 R02 PD5 UB2 B3 B5 R12 PD6 UB1 UB1 B4 B6 R03 PD7 UB0 UB0 B5 B7 R13 PD8 LG3 G0 R04 PD9 LG2 LG2 G1 R14 PD10 LG1 LG1 G0 G2 R05 PD11 LG0 LG0 G1 G3 R15 PD12 UG3 G2 G4 G00 PD13 UG2 UG2 G3 G5 G10 PD14 UG1 UG1 G4 G6 G01 PD15 UG0 UG0 G5 G7 G11 PD16 LR3 R0 G02 PD17 LR2 LR2 R1 G12 PD18 LR1 LR1 R0 R2 G03 PD19 LR0 LR0 R1 R3 G13 PD20 UR3 R2 R4 G04 PD21 UR2 UR2 R3 R5 G14 PD22 UR1 UG1 R4 R6 G05 PD23 UR0 UG0 R5 R7 G15 PD24 B00 PD25 B10 PD26 B01 PD27 B11 PD28 B02 PD29 B12 PD30 B03 PD31 B13 PD32 B04 PD33 B14 PD34 B05 PD35 B15

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PC20000301 (PCM-9372) CPU Board

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Figure 25: CPU PCB Component Side

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PC20000301 (PCM-9372) CPU Board Specifications

1.1 Introduction

The PCM-9372 is a low-power Eden processor single board computer (SBC) with audio controller, a 4X AGP SVGA controller, a PCI 10/100 Base-T Ethernet interface, 2 Channel LVDS interface, and one PC/104 expansion connector. The PCM-9372’s design is based on a 3.5” HDD form factor that provides a convenient connector layout for easy assembly, more efficient cable connections and better overall embedded system integration. When using a VIA Eden processor, the PCM-9372 achieves outstanding performance that surpasses most SBC’s in its class. This compact (only 5.7” X 4”) unit offers all the function of a single board industrial computer, but still fits in the space of a

3.5” floppy drive. On board features include, two serial ports (one RS-232, one RS-232/422/485) one multi-mode parallel (ECP/EPP/SPP) port, two USB (Universal Serial Bus) ports, a floppy drive controller, and a keyboard PS/2 mouse interface. The built-in high-speed PCI IDE controller supports both PIO and UDMA/100 bus master modes. Up to four IDE devices can be connected, including large hard disks, CD-ROM drives, and tape backup drives. The PCM-9372 features power management to minimize power consumption. It complies with the “Green Function” standard and supports Doze, Standby and Suspend modes. In addition, the board’s watchdog timer can automatically reset the system or generate an interrupt if the system stops due to a program bug or EMI.

1.1.1 Highly integrated multimedia SBC

The real estate is well packed on this tightly designed 3.5” single board computer (SBC) with an onboard new VIA Embedded low power Eden processor. The Via Eden processor uses advanced

0.15µ/0.13µ CMOS technology with 128KB L1 cache memory and 64 KB L2 Cache memory. This board can operate without a fan at temperatures up to 60 degrees centigrade (140 degrees Fahrenheit) and typically consumes fewer than 12 Watts while supporting numerous peripherals. This SBC includes a 4X AGP controller, an AC’97 audio interface, a PCI Ethernet interface, and 2 channel LVDS interface. Its design is based on the 3.5” SBC form factor that supports the PC/104 interface for ISA module upgrades. Other on-board features include an LPT, 2 USB’s, and 2 serial ports: 1 RS-232, and 1 RS232/422/485. The SSD solution supports CompactFlashX cards Type I and Type II.

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1.2 Features

• Embedded VIA low-power Eden processor

• Supports one 36 bit TFT LCD panel, with up to 1024 X 768 resolution

• Supports 2 channel LVDS interface

• 100/10Base-T Ethernet interface, IEEE 802.3U compatible

• Supports wake-in-LAN with ATX power supply

• 2 serial ports (one RS-232 and one RS-232/422/485)

• USB interface complies with USB Rev. 1.10

• 62-level Watchdog timer by system reset or IRQ

• 1 IDE channels support up to UDMA/100

1.3 Specifications

1.3.1 Standard 3.5” Biscuit SBC Function

• CPU: Onboard Eden 667 MHz (PCM-9372F-M0A1) or Via Eden 400 MHz processor

(PCM-9372-J0A1) with 128KB L1 cache memory.

• BIOS: Award 256 KB Flash memory.

• System Memory: One 144-pin SODIMM socket accepts 64MB up to 512 MB SDRAM.

• 2

• Enhanced IDE Interface: One channels support up to two EIDE devices. BIOS auto-detect

• FDD Interface: Supports up to two FDD’s.

• Serial ports: Two serial RS-232 ports. COM1: RS-232, COM2 RS-232/422/482.

• Parallel Port: One parallel port, supports SPP/EPP/ECP mode.

• Keyboard/Mouse Connector: Supports standard PC/AT keyboard and a PS/2 mouse.

• Power Management: Supports power saving modes including Normal/Standby/Suspend

• Watchdog Timer: 62 level timer intervals.

• USB: Two USB 1.1 compliant Universal Serial Bus ports.

• Expansion: One PC104 Connector for ISA control board.

• Solid State Disk: Supports on 50-pin socket for CFC type I/II.

Cache Memory: 64 KB on the processor.

PIO Mode 3 or Mode 4, supports up to UDMA 66/100 mode.

modes, APM 1.2 compliant.

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1.3.2 VGA/LCD Interface

• Chipset: VIA Twister chip with integrated Savage4 2D/3D/ Video Accelerator.

• Frame Buffer: Supports 4/8/16/32MB frame buffer with system memory

• Interface: 4X AGP VGA/LCD interface. Support for 9, 12, 15, 18, 24, 36 bit TFT and

optional 16 or 24 bit DSTN panel

• Display Mode: CRT modes: 1280 X 768 @ 16bpp (60Hz), 1024 X 768 @ 16bpp (85Hz): LCD/Simultaneous Modes: 1280 X 1024 @ 16bpp (60 Hz), 1024 X 768 @ 16bpp (60 Hz)

• LVDS: supports 2 Channel (2 X 18 Bit) LVDS interface.

1.3.3 Ethernet Interface

• Chipset: RTL 8100

• Ethernet Interface: IEEE 802.3u 100BASE-T Fast Ethernet compatible.

• I/O address switching setting

• Built-in boot ROM

1.3.4 Audio Function

• Chipset: VIA 82C686

• Audio Controller: AC’97 ver. 2.0 compliant Interface.

• Audio Interface: Microphone in, line in, line out.

1.3.5 Mechanical an d Environmental

• Dimensions: 145 X 102 mm (5.9” X 4.22”)

• Power Supply Voltage: -5V +/-5% and +12V +/-5%

• Power Requirements: Max 4.5A @ -5V, 1.3A @ +12V (within 5ms after power on)

Typical 2.08A @ -5V, 0.08A @ +12V (w/Eden-400, 128MB) Typical 2.33A @ -5V, 0.08A @ +12V (w/Eden-667, 128MB)

• Operating Temperature: 0 – 60 degrees Celsius (32 – 140 degrees Fahrenheit)

• Weight: 0.85 kg (weight of total package)

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Award BIOS Setup

Important: The password is 5457500 and must be entered to gain access to the bios.

2.1 System Test and Initialization

These routines test and initialize board hardware. If the routines encounter an error during the test, you will either hear a few short beeps or see and error message on the screen. These are two kinds of errors: fatal and non-fatal. The system can usually continue the boot up sequence with non-fatal errors. Non-fatal error messages usually appear on the screen along with the following instructions.

Press <F1> to RESUME

Write down the message and press the F! key to continue the boot up sequence.

2.1.1 System Configuration Verification

These routines check the current system configuration against the values stored in the board’s CMOS memory. If they do not match the program outputs an error message. You will then need to run the BIOS setup program to set the configuration information in memory. These are three situations in which you will need to change the CMOS settings

1. You are starting your system for the first time.

2. You have changed the hardware attached to your system.

3. The CMOS memory has lost power and the configuration information has been erased.

The PCM-9372 Series CMOS memory has an integral lithium battery backup. The battery backup should last ten years in normal service, but when it finally runs down you will need to replace the complete unit.

Award’s BIOS ROM has a built in Setup program that allows users to modify the basic system configuration. This type of information is stored in battery backed CMOS RAM so that it retains the Setup information when the power is turned off.

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2.2.1 Entering Setup

Power on the computer and press <Del> immediately. This allows you to enter setup.

Figure 26: Entering Setup

Figure 27: Standard CMOS Features Setup

2.2.2 Standard CMOS Features Setup

When you choose the Standard CMOS Features option from the initial setup screen menu, the screen shown to the left is displayed. This standard setup menu allows users to configure system components such as date time, hard drive, floppy drive and display. Once a field is highlighted, online help information is displayed in the left bottom of the menu screen.

2.2.3 Advanced BIOS Features Setup

By choosing the Advanced BIOS Features Setup option from the initial setup screen menu the screen to the left will be displayed. This sample screen contains the manufacturer’s default values for the PCM-9372 Series.

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Figure 28: Advanced BIOS Features Setup

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2.2.4 Advanced Chipset Features Setup

By choosing the Advanced Chipset Features option from the initial setup screen menu, the screen to the left will be displayed. This sample screen contains the manufacturer’s default values for the PCM-9372 Series.

Figure 29: Advanced Chipset Features Setup

Figure 30: Integrated Peripherals

2.2.5 Integrated Peripherals

By choosing the Integrated Peripherals option from the initial setup screen menu, the screen to the left will be displayed. This sample screen contains the manufacturer’s default values for the PCM-9372 Series.

2.2.6 Power Management Setup

By choosing the Power Management Peripherals option from the initial setup screen menu, the screen to the left will be displayed. This sample screen contains the manufacturer’s default values for the PCM-9372 Series.

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Figure 31: Power Management Setup

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2.2.7 PnP/PCI Configurations

By choosing the PnP/PCI Configuration option from the initial setup screen menu, the screen to the left will be displayed. This sample screen contains the manufacturer’s default values for the PCM-9372 Series.

Figure 32: PnP/PCI Configuration

Figure 33: PC Health Status

2.2.8 PC Health Status

The PC Health Status option displays information such as CPU and Motherboard temperatures, fan speeds, and core voltage.

2.2.9 Load Optimized Defaults

Load Optimized Defaults loads the default system values directly from ROM. If the stored record created by the Setup program should ever become corrupted (and therefore unusable) these defaults will load automatically when you turn the PCM-9372 Series system on.

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Figure 34: Load Optimized Defaults

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2.2.10 Save and Exit Setup

If you select this option and press <Y> then <Enter> the values entered in the setup utilities will be recorded in the chipset’s CMOS memory. The microprocessor will check this every time you turn you system on and use the settings to configure the system. This record is required for the system to operate.

2.2.11 Exit Without Saving

Selecting this option and pressing <Enter> lets you exit the setup program without recording any new values or changing old ones.

Imaje 4040 BIOS Settings

Press the DEL key to enter Bios setup

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Figure 35: Entering BIOS

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4. Controller

Category Option Setting

ENSURE THE “NUM LOCK” LIGHT IS ON

Standard CMOS Features

Figure 36: Entering Standard CMOS

Date (mm:dd:yy) Current Date Time (hh:mm:ss) Current Time (24hr) Drive A None

Press <Esc>

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Figure 37: Standard CMOS Settings

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Advanced BIOS setup

Figure 38: Entering Advanced BIOS

First Boot Device [HDD-0] Second Boot Device Disabled Third Boot Device Disabled Boot Other Device Disabled Boot Up Floppy Seek Disabled

Press <Esc>

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Figure 39: Advanced BIOS Settings

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Category Option Setting

Advanced Chipset Features

Figure 40: Entering Advanced Chipset

USB Mouse Support may not be an option on some CPU boards

Panel Type [TFT 800x600 LVDS] USB Keyboard Support Enable USB Mouse Support Enable On Chip Sound Disabled

Press <Esc>

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Figure 41: Advanced Chipset Settings

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4. Controller

Intergraded Peripherals

Figure 42: Entering Integrated Peripherals

On Chip IDE Channel1 Disabled Onboard Legacy Audio Disabled

Scroll Down

To View

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Press <Esc>

Onboard

Legacy Audio

Figure 43: Integrated Peripherals Settings

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PnP/PCI Configuration

Figure 44: Entering PnP/PCI

Configuration

Press <Esc>

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PNP OS Installed YES

Figure 45: PnP/PCI Configuration Settings

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Set Password

Figure 46: Entering Set Password

Set Password 5457500 Confirm Password 5457500

Save & Exit Setup

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Figure 47: Set Password

Press “F10” to “save” (Y/N) Y

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4. Controller

Cleaning the vent screens and fan inside the 4040

Required tools

• Compressed air with blow gun o Optional (Compressed cleaning spray

aerosol)

• 4040 lid key (MP10002203)

Figure 48: Required Tools

Figure 49: Shut Down Controller

Instructions

1. Use normal shut down procedures to shut

2. Use the lid key to unlock the controller lid

3. In the bottom of the controller, locate the

4. Use the air gun to remove dust and debris

down and power off the controller. Click on the “New Message” icon.

by turning counter clock-wise. Open the lid.

intake screen near the back left hand corner.

by blowing directly on the screen downward from the inside to out.

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Figure 50: Locate Filters

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5. In the bottom of the controller, locate the exhaust fan near the front right corner.

Figure 51: Blow Out Filters

Figure 52: Blow Out Fan

6. Use small short bursts of air to remove dust and debris.

can damage the fan and/or components.)

7. Use small bursts of air to blow away dust and debris from between the system boards and CPU heat sink.

air pressure can damage the fan and/or components.)

(Note: excess air pressure

(Note: excess

(PIC)

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Figure 53: Blow Out Board Stack

8. To finish, blow out the entire controller to remove any loose particles.

Imaje 4040

5. XJ500 Print Module

Figure 54: Clean Out Controller

5. XJ500 Print Module

The XJ500 Print Module consists of two major components:

• The IDS2/500 Ink Delivery System (Ink Circuit)

• The Xaar, XJ500 Printhead

Maintenance

With Oil Based Inks Using oil based inks to print strictly onto porous substrates; there is virtually no maintenance necessary. Since oil based ink dries by absorption only, ink can be left inside the printhead for very long periods of time (weeks, even months). After periods as long as this at most a slight amount of priming (2-3 pumps) may be necessary. Once the printhead is primed, the printer should keep running as long as you put ink into it.

Semi-Annual Preventive Maintenance Procedure:

(The following procedures should be performed approximately twice a year for high volume customers and approximately once a year for low to moderate use customers).

1. Open the cover on the print module and lift out the ink tray.

2. Disconnect the ink lines from the ink tray. Using the luer fittings stored inside the print module, cap the ink lines.

3. Replace the filter and o-rings in the filter assembly attached to the ink tray. See drawing on page 102.

4. Set aside the ink tray, needle facing up.

5. Disconnect the ink low light connected to the power distribution board. This is a locking connector; do not forcefully remove.

6. Remove the 6 “Phillips” head screws and lift the case off the print module.

7. Release the wire holding the inkbottle in place. Carefully lift the bottle out of the holder so it can be emptied into a waste container. (It is not necessary to disconnect the ink lines to complete this operation).

8. Empty ink from both bottles.

9. Using a tube cutter or razor knife cut all four tubes ½” away from bottle.

10. Remove the bottles.

11. Visually inspect each bottle - Replace bottles that appear to have any level of contamination. This includes any settled material at the bottom of the bottle. Do not reconnect the ink lines at this time. Clean any bottles that do not appear to be contaminated. Fill with approximately 1 inch of cleaner, swirl around container rinsing bottom and sides, pour into waste container, and repeat. Do not reconnect the ink lines at this time.

12. Replace the pressure switch if the old style switch is still installed. (Per NAM Technical bulletin # TB28-052704A).

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13. Reconnect the tubing to “New” or “Freshly” cleaned inkbottles. Be certain all tubes are pressed onto the fittings firmly and are numbered properly. Attachment C is an ink flow diagram.

14. The filter kit should be replaced if there is ink present in the filter. See drawing on page 102.

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5. XJ500 Print Module

15. Remove the nozzle plate cover (It is not necessary to completely remove the screws; the nozzle plate cover is slotted and will slide off once the screws are loosened. Remove the 6 “Phillips” head screws and carefully slide the print head shell toward the nozzle plate to remove. CAUTION – the head shell may contain ink, remove carefully.

16. Disconnect the ink lines at the print head. Start with the top fitting and work down. DO NOT use any tools when removing or reconnecting the ink lines they should be finger tight only. Using a tool may damage the print head connectors.

17. Fill each bottle with approximately two inches of cleaner. Replace the lid on each bottle. Using the priming bulb flush the ink lines until the cleaner runs clear. Fluid will discharge from all four lines simultaneously.

18. Reconnect the ink lines. Start from the bottom and work toward the top. DO NOT use any tools; the fittings should be only finger tight.

19. Check fluid level in the bottles, refill if necessary. Do not exceed two inches. Using the priming bulb, flush the print head until all nozzles stream clear.

20. Reassemble the print head assembly.

21. Empty any remaining cleaner from the bottles into the waste container.

22. Refill both bottles with fresh ink. Do not overfill. Ink should be filled to the top of aluminum bottle holder.

23. Reassemble the print module.

24. Introduce an ink bag.

25. Visually inspect the 4040 controller, look for damage or abuse.

26. Blow out the cover screens and the fan.

27. Connect the print module to a 4040 controller. Turn on power and allow the controller to boot.

28. Using the priming bulb, Re-prime the print head.

29. Check your solenoid sensors, while priming Both LED’s (solenoid 1 and solenoid 2) should illuminate, the ink low light may not illuminate for several minutes. Squeeze the ink bag, within 20 seconds the solenoid lights should turn off.

30. Because the print head has been disconnected you must vacuum prime the print head. Vacuum the print head for at least thirty seconds at 15-20 inches Hg vacuum. Test print.

31. Change the Ink Filter and O-rings underneath the ink tray.

As needed:

• Install new ink

• Pressure prime the printhead

• Empty the ink waste container

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5. XJ500 Print Module

Theory of Operations

Theory of Operation during the Priming Process:

• Air is pumped into the ink reservoirs (7) via the Air Filter (11) using the Priming Pump (9). *The purpose of the air filter is to prevent particulates from the atmosphere from entering into the ink.

• Simultaneously, the positive air pressure is sensed by the Pressure switch (5).

• The Pressure Switch then opens, which closes Solenoid Valves 1 and 2 (3).

• With the Solenoid Valves closed, the air pressure being forced into the Ink Reservoirs pushes the ink out into the

Printhead (1).

• As the ink is pushed out of the Reservoirs and into the head, the ink level in the ink reservoirs decreases. When the ink level becomes low enough, the Ink Level Floats (10) will detect this and send a signal to open the Solenoid Valves (3). The Solenoid Valves however are being kept closed by the pressure switch to prevent the air from taking the path of least resistance and filling up the Ink Bag (2) with air.

• When the air pressure is let off, the Solenoid Valves (3) will finally open allowing ink to re-fill the Ink Reservoirs (7). Whenever the one or both of Solenoid Valves are open and ink is filling, the amber colored LED, labeled o n ink tank Res. 1 or Res. 2 will illuminate. Since the fill rates will be slightly different for each reservoir the LEDs will not always illuminate simultaneously.

Theory of Operation during the Printing Process:

• As the Printhead (1) ejects ink onto the print target, the Ink Reservoirs (7) feed the Printhead. There are four ink inputs to the printhead, all corresponding a particular ink tube out of the Ink Reservoirs. The ink lines are numbered in order, beginning from the bottom. The lower Ink Reservoir is Res. 1 and the upper Reservoir is Res. 2. Ink lines 1 and 2 exit from Res.1 and ink lines 3 and 4 exit from Res. 2. The printhead is divided into four quadrants with its own ink input, beginning from the top, 1-4.

• Depending on the design of the printed message, different quadrants of the Printhead (1) may use more ink volume. Therefore Res. 1 may need to be re-filled more often than Res. 2 and vice versa.

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• The Ink reservoirs are supplied ink from the Ink Bag (2). When the ink level inside the bag becomes low, it will take too long to fill the Ink Reservoirs. There is a 5 minute (approximately) timer in the software that times how fast the Ink Reservoirs fill. If one or both of them take longer than 5 minutes to fill, the Ink Low Light (8) will flash on and off. If the light stays on, then it is time to replace the bag. *Occasionally if the system was primed excessively and one or both of the ink reservoirs is abnormally low, ink refill will require more than 5 minutes. In this case the light will flash and then turn off when the reservoir(s) is refilled.

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5. XJ500 Print Module

Trouble Shooting

With Oil Based Inks

Symptom: Ink will not prime into print head.

Possible cause Possible solution

Shipping seal not removed from nozzle face. Remove the shipping seal from the nozzle face.

Luer fittings on air intake tube not connected inside ink system. Ink system will not hold air pressure when pumped

Symptom: Ink low LED will not turn off and Res. 1 or Res. 2 LED will not turn off.

Possible cause Possible solution

Ink Bag empty Check ink bag. If empty, replace. The Priming Bulb valve

is closed with bottles still pressurized.

Clogged Ink Fill Needle.

Ink bottle sensor(s) malfunctioning or disconnected.

Make sure that there is no pressure on the system by ensuring that the priming bulb valve is open. If there is even a slight amount of pressure, the “fill” solenoid valves will never open to re-fill the sub-reservoirs. *This would be noticeable because the head would weep slightly, which should cause poor print quality, even drop out starting at the bottom portion of the head, working upward. Sometimes a small piece of the rubber septum can tear off when a new ink bag is inserted, clogging the needle. Remove the ink bag and poke a paper clip or small wire into the needle from the top. If there is debris inside the needle, this action will loosen it and it will fall into the ink filter. This is ok and will not harm performance.

Check the wire connections inside IDS. The odds of one of the sensors themselves failing are extremely low.

Lift ink tray and connect the luer fittings inside the ink delivery system (IDS). Lift the ink tray and check for leaks in ink sub-reservoir bottles inside IDS.

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5. XJ500 Print Module

Symptom: Print quality is degraded, i.e. missing lines (dots), spattered print (satellites), sections of the

printed image missing.

Possible cause Possible solution

Too much throw distance Printhead has ingested air. This is typical after servicing a printhead or upon initial installation if vacuum priming was not performed sufficiently.

Printhead Starvation Starvation can occur if the printhead has been raised to much in relationship to the

Printhead flooding (weeping)

Debris stuck to nozzle plate

Printhead clogged The printhead could be internally clogged, but this is very rare. See section below

Make sure that proper product handling is in place and that guide rails are adjusted to that the product is within 1-5mm, especially if printing barcodes. The easiest way to tell if the printhead has ingested air is the following: The print begins to drop out, gradually becoming worse. You pressure prime the head and recover the nozzles, but within a short period of time the symptoms repeat and the nozzles drop out again. THIS IS ALWAYS AIR. You can determine that all of the air is out of the printhead and that vacuum priming was sufficient by the following method. After vacuum priming, pressure prime for a few pumps. On the firs pump, if there is still air trapped inside the head you will see tiny bubbles (like foam) come out of the upper nozzles. If this happens, vacuum prime again and repeat the process. This can happed from excessive shock, or if the printer was allowed to run low enough on ink (well after the bag was empty) that the sub-reservoirs actually ran low enough to ingest ink into the printhead. This symptom may also occur immediately after initial installation or after servicing the printhead if vacuum priming was not sufficient. Vacuum priming is necessary if printhead will not recover and maintain prime with a significant pressure prime using the hand pump.

IDS. The brackets have marking on them and the dimensions are called out in the user manual and in this manual. Lower the printhead according to the markings on the brackets. Starvation can also occur under extremely high through put. Meaning, very fast line speed, coupled with fast print repetition rate and large message. If the printhead cannot maintain prime under these circumstances, the printhead may be lowered slightly until it will maintain prime. To get a true reading, a vacuum prime will be necessary each time the printhead loses prime. The printhead will weep if it is adjusted too low in relation to the IDS. Raise the head according to the bracket markings. Positive pressure will also cause weeping. See section above regarding “Ink low LED will not turn off”. Sometimes in very dirty, dusty conditions, debris can land on the nozzles and stick to the wet ink on the nozzle plate causing some nozzles to become deflected. Pressure prime the printhead with 2-3 pumps to displace the debris and clear nozzles.

on “Flushing Printheads” to attempt to recover the clogged nozzles.

Printhead or section of printhead dead

Technical Manual Imaje 4040.doc

Scabbing, nozzles crusted over with dried ink.

It is possible although rare for a printhead to fail electrically. If a complete section of nozzles is out and you cannot recover any of them by priming or vacuum priming, there is a good chance that an ASIC inside the printhead has failed. In this case, the printhead must be replaced. This only happens with solvent base. To recover, pressure prime for 2-3 pumps. Make sure that the Voltage-Spit/Buzz settings are appropriate for the ink type.

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5. XJ500 Print Module

Vacuum Priming the Printhead

Before operating the system you must remove all the air from the ink lines and printhead. This can be accomplished by a combination of two methods. For maximum print quality vacuum priming may be necessary. Vacuum – A cap is fitted over the nozzle plate. A vacuum is applied for a short time drawing out any excess air. Vacuum purging is highly effective at removing air from the printhead. Recommended when doing an initial installation, or when ink lines have been detached. Pressurizing – positive pressure is applied to the ink supply. The ink delivery system is fitted with a hand pump to provide a simple method for purging. This method is used when a partial de-prime has occurred.

1. Loosen the four thumbscrews holding the nozzle cover.

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Figure 55: Loosen Thumb Screws

Figure 56: Remove Cover

2. Gently remove the cover as shown.

3. Once the Nozzle Cover is removed, remove the rubber nozzle seal from the inside of the cover. Keep this seal in a safe place in the event that the equipment ever needs to be shipped again.

Figure 57: Remove Seal

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5. XJ500 Print Module

Vacuum Priming the XJ500 Head

Place the vacuum cap over the printhead. There is a slot along the side of the printhead. The tab on the vacuum cap should be inserted into the slot. This must be done carefully to create a vacuum. Hold the vacuum cap firmly assuring that the rubber gasket is sealed to the face of the printhead. Squeeze the hand pump

Figure 58: Vacuum Priming

The vacuum priming operation should be performed during installation or after maintenance requiring printhead exchange or if the tubing is disconnected. The vacuum pump is necessary to remove trapped air bubbles from tubing and inside the printhead. To use the vacuum pump follow step one on the previous page. For care of the vacuum take the following precautions. When connecting the vacuum

1 Make sure that the ink jar is empty before you start. 2 Ensure that the ink jar is screwed on tightly to ink jar cover. This will prevent ink spills and leaking

during the vacuum process.

3 During the vacuum process pay special attention to the ink jar, to ensure that the jar does not over fill.

Although the ink jar is transparent when it begins to receive ink products it’s transparence will diminish and seeing through the jar will become difficult. It may be necessary .to remove the jar from the jar holder to how full the jar is. Failure in properly monitoring ink levels in the ink jar will result in being sucked into the pump and spraying out.

4 After you have finished the vacuum process empty the ink jar. It is a good idea to wrap the cap in an

absorbent cloth to absorb any excess ink product and prevent spills.

Use a spray cleaner or flushing solution used with the ink that you are using to keep the vacuum pump clean.

Technical Manual Imaje 4040.doc

rapidly for 20 to 30 seconds. Both air and ink will be pulled through the printhead into a collection jar. When performing this procedure the ink jet system might indicate WARNING Low Ink. This is OK.

Caution – recommended vacuum pressure is 700 m/bar, do not exceed 900 m/bar.

Remove the vacuum cap. After performing the vacuum priming procedure proceed to the pressure priming function.

Step 1 - Vacuuming

Imaje 4040

5. XJ500 Print Module

Pressure Priming the XJ500 Printhead

Occasionally debris may settle on the outside of the nozzles or a small air bubble may trap in one or more of the nozzles. The appearance will be as if there are lines through the print. To recover those nozzles, simply do a pressure prime instead of a vacuum prime. If the symptoms recur then vacuum prime the head again.

Squeezing the priming pump to pressure prime the printhead.

Be sure to turn the air valve back counter clockwise to release the pressure when finished priming.

Figure 59: Pressure Priming

There is no need to catch the ink or to wipe the head when printing horizontally. The printhead will catch the excess ink into its own reservoir.

Results of pressure priming the printhead. In purges out of the nozzles and flows down the nozzle face into a containment area in the bottom of the printhead housing. The waste ink will drain into the ink waste container. If after priming, there is excess ink on the face of the printhead cover, it may be wiped of using a lint free wipe so that the excess ink does not smear onto the box.

1. Squeeze the priming pump 3 times and let the pressure off.

2. Perform a test print.

3. If the lines remain, repeat step 1.

Technical Manual Imaje 4040.doc

Imaje 4040

5. XJ500 Print Module

Removing/Installing the XJ500 Printhead

1. Loosen the four thumbscrews or Philips screws (depending on version) enough to slide the faceplate off.

Technical Manual Imaje 4040.doc

Figure 60: Loosen Thumb Screws

Figure 61: Loosen Side Cover Screws and Remove

Figure 62: Visually Inspect Printhead

Figure 63: Loosen Fittings

2. After loosening the corresponding screws to loosen the side cover, remove it.

3. Visually inspect the printhead for damage or abnormalities.

4. Using a ½ inch or 12 mm box end wrench turn the black fitting counter clockwise about ¼ - 1/2 turn to loosen. You may loosen all four fittings with the wrench and then use your fingers to keep turning the fittings until they come off.

*Note: Be sure that the printhead is at a position above the ink or the ink system is empty when removing tubes. Otherwise a lot of ink will drip out of the tubes and leave a large mess.

Imaje 4040

5. XJ500 Print Module

5. Carefully remove the tube from the printhead by pulling straight back. Repeat for all four tubes.

Figure 64: Remove Tubing from Printhead

Figure 65: Do Not Remove Black and White Fittings

Figure 66: Remove Cable from Printhead

6. Do not remove the black and white ferrule fittings from the tube so they do not get lost. If they accidentally come off, be sure to re-assemble according to this photo.

7. Remove the cable connector using two index fingers. Pull gently back until the connector is removed.

8. Once removed, pull back and inspect. Make sure that it is clean and dry (free of ink) before re-connecting.

Technical Manual Imaje 4040.doc

Figure 67: Visually Inspect Cable

Imaje 4040

5. XJ500 Print Module

Figure 68: Remove Printhead Mounting Screws

9. Remove the printhead mounting screws and store in a safe place.

10. When the 3-printhead mounting screws are removed, notice that the holes in the head shell are slotted. When re-installing the printhead, be sure to slide the screws all the way forward, pushing the printhead close to the nozzle protector plate. This will decrease the inherent throw distance.

Figure 69: Assure Forward Positioning When Reinstalling

Figure 70: Place Printhead Upside Down

Technical Manual Imaje 4040.doc

Figure 71: Remove Four Cap Screws

11. With screws removed, lift printhead from base and place upside down onto a clean work surface.

12. With Printhead upside down on work surface, remove the four cap screws from the printhead mounting block (see exploded diagram for screw sizes).

Imaje 4040

5. XJ500 Print Module

Flushing the XJ500 Printhead

1. Syringe with filter for flushing

Figure 72: Syringe with Filter for Flushing

Figure 73: Flushing with Syringe

Figure 74: Cleaning Solution Streaming from Head

2. Flushing with Syringe

3. Cleaning Solution Streaming from Head

Technical Manual Imaje 4040.doc

Imaje 4040

5. XJ500 Print Module

XJ-500 Head Solvent Based Notes:

Daily Shut Down:

The system may be left on or simply turned off. Either way, there is no need to flush. Capping the printhead is optional.

Daily Print Head Maintenance:

During start up, if any lines are missing in the print field, prime the printhead using the hand pump a couple of times. No wiping is necessary. DO NOT wipe the nozzle face as this can cause irreparable damage. Simply let the excess ink drain into the head shell and then into the waste bottle.

Flushing with cleaner:

Flush with cleaner only if necessary, generally determined by a clogged print head. Starting with the ink line labeled number 1, remove the black tube fitting. Attach a syringe filled with cleaner to the fitting located on the print head and flush slowly cleaner. Cleaner will stream from only the top quarter of the head associated with the ink input port being used. Run one full syringe through the print head. Refill the syringe and repeat the same procedure on each fitting leading into the print head. A vacuum prime is generally necessary after flushing the print head

Solvent Incompatibility:

Fluids used for cleaning print heads, either for flushing out as a post manufacture stage or for displacing ink during testing, MUST be compatible with the inks and the print head. The manufacturer MUST supply any fluids introduced into the print head.

Your Inkjet printer inks are not compatible with many common solvents, for example IPA, acetone and water. When these polar solvents are mixed with the ink, the pigment or dye may coagulate. This may cause blockages and lead to print head failure or permanent damage. Be certain that you use the correct solution for the ink. The use of unauthorized or incompatible fluids can have a catastrophic effect. Solventbased inks require solvent-based cleaners.

Technical Manual Imaje 4040.doc

Imaje 4040

5. XJ500 Print Module

IDS2-500 Ink System Circuit Board Schematic, I/O

Technical Manual Imaje 4040.doc

Figure 75: IDS2-500 Ink System Circuit Board Schematic, I/O

Imaje 4040

5. XJ500 Print Module

Drawing, Ink Level Sensor Assembly, IDS2/500 revision

Technical Manual Imaje 4040.doc

Figure 76: Exploded Drawing, Chassis, IDS2/500 Ink Delivery System (PM20000201)

Imaje 4040

5. XJ500 Print Module

Wiring Diagram, IDS2/500 Print Module, Old

Technical Manual Imaje 4040.doc

Figure 77: Wiring Diagram: IDS2/500 Print Module, Old (ES30000102)

Imaje 4040

5. XJ500 Print Module

Plumbing Diagram, IDS2/500

Technical Manual Imaje 4040.doc

Figure 78: Plumbing Diagram, IDS2/500 (PM30000203)

Imaje 4040

6. XJ128 Print Module

The XJ128 Print Module consists of two major components:

• The IDS128 Ink Delivery System (Ink Circuit)

• The Xaar, XJ128 Printhead

Maintenance

With Oil Based Inks

Using oil based inks to print strictly onto porous substrates; there is virtually no maintenance necessary. Since oil based ink dries by absorption only, ink can be left inside the printhead for very long periods of time (weeks, even months). After periods as long as this at most a slight amount of priming (2-3 pumps) may be necessary. Once the printhead is primed, the printer should keep running as long as you put ink into it. Annual:

• Change the Ink Filter and O-rings underneath the ink tray.

As needed:

• Install new ink

• Pressure prime the printhead

Trouble Shooting

With Oil Based Inks

*Comments that apply to solvent based inks.

Symptom: Ink will not prime into print head.

Possible cause

• Shipping seal not removed from nozzle face.

• Ink system will not hold air pressure when pumped

• Clogged Ink Fill Needle.

Technical Manual Imaje 4040.doc

• Ink Bag empty

Symptom: Print quality is degraded, i.e. missing lines (dots), spattered print (satellites), sections of the

Possible solution

Remove the shipping seal from the nozzle face.

Re-seat lid and make sure that it seals.

Sometimes a small piece of the rubber septum can tear off when a new ink bag is inserted, clogging the needle. Remove the ink bag and poke a paper clip or small wire into the needle from the top. If there is debris inside the needle, this action will loosen it and it will fall into the ink filter. This is ok and will not harm performance.

Check ink bag. If empty, replace.

printed image missing.

Imaje 4040

6. XJ128 Print Module

Possible cause Possible solution

• Too much throw distance

Make sure that proper product handling is in place and that guide rails are adjusted to that the product is within 1-5mm, especially if printing barcodes.

• Printhead has ingested air.

• Printhead Starvation

• Printhead flooding (weeping)

• Debris stuck to nozzle plate

• Printhead clogged

• Printhead or section

of printhead dead

• *Scabbing, nozzles crusted over with dried ink.

Pressure priming the XJ128 by pumping the 2-3 times is usually adequate to recover the nozzles. Repeat if necessary.

Starvation can occur if the printhead has been raised to much in relationship to the IDS. The brackets have marking on them and the dimensions are called out in the user manual and in this manual. Lower the printhead according to the markings on the brackets. Starvation can also occur under extremely high through put. Meaning, very fast line speed, coupled with fast print repetition rate and large message. If the printhead cannot maintain prime under these circumstances, the printhead may be lowered slightly until it will maintain prime. To get a true reading, a vacuum prime will be necessary each time the printhead loses prime. The printhead will weep if it is adjusted too low in relation to the IDS. Raise the head according to the bracket markings. Positive pressure will also cause weeping. This is evident if you see the head dripping. Sometimes in very dirty, dusty conditions, debris can land on the nozzles and stick to the wet ink on the nozzle plate causing some nozzles to become deflected. Pressure prime the printhead with 2-3 pumps to displace the debris and clear nozzles. The printhead could be internally clogged, but this is very rare. See section below on “Flushing Printheads” to attempt to recover the clogged nozzles.

This only happens with solvent base. To recover, pressure prime for 2-3 pumps. Make sure that the Voltage-Spit/Buzz settings are appropriate for the ink type.

Technical Manual Imaje 4040.doc

Imaje 4040

6. XJ128 Print Module

Priming the XJ128 Printhead

1. Loosen screws holding nozzle protector plate.

Figure 79: Loosen 128 Nozzle Plate Screws

Figure 80: Remove Nozzle Plate

Figure 81: Prepare to Print

2. Remove the nozzle protector plate

3. With printhead exposed, prepare to prime the printhead for the first time.

4. Close the air valve on the priming pump by rotating clockwise

Technical Manual Imaje 4040.doc

Figure 82: Close the Air Valve

Imaje 4040

6. XJ128 Print Module

5. Pump the priming bulb continuously for 10 seconds.

6. Be sure to turn the air valve back counter clockwise to release the pressure when finished priming.

Figure 83: Pump the Priming Bulb

Figure 84: Hold Lint Free Wipe Up to Nozzle

7. Hold a Lint Free wipe up to the nozzles while priming.

8. Gently blot the excess ink away from the face of the printhead using only factory-approved lint free wipes. *Never wipe or rub the nozzle plate. Only blot. Never touch the nozzle plate with anything other than factory approved wipes.

Technical Manual Imaje 4040.doc

Figure 85: Blot Excess Ink Off Printhead

Figure 86: Re-attach Nozzle Plate

9. Re-attach the nozzle protector plate.

Imaje 4040

6. XJ128 Print Module

10. Press the nozzle cover flush up against the nozzles and tighten the screws.

Figure 87: Tighten Nozzle Plate Screws

Figure 88: Priming into Container

Figure 89: Quick Prime

11. Another method is to prim into a container, then blot the excess ink away.

*Note: Once the printhead has been initially

primed an occasional quick prime 2-3 pumps is necessary to clear a nozzle. To perform this quick prime, it is not necessary to remove the nozzle protector plate. Simply prime the head and let the ink drip through the gap in the bottom of the head shroud into a wipe (towel) or container.

Technical Manual Imaje 4040.doc

Imaje 4040

6. XJ128 Print Module

Procedures for Cleaning a Clogged Printhead (XJ128)

Flushing XJ128 Print Module using a bag of

flushing solution. This procedure flushes the entire print module but is the easiest way. This is the only recommended method to flush when using pigmented inks.

*DO NOT USE THIS METHOD WITH THE XJ500

Figure 90: Prime 128 Module Using a Bag

Figure 91: Prime 128 Module Using a Syringe

Flushing XJ128 Print Module using syringe.

*DO NOT USE THIS METHOD WITH THE XJ500

Technical Manual Imaje 4040.doc

Imaje 4040

6. XJ128 Print Module

Cleaning a Severe Clog:

If flushing does not work, this is the last resort.

A print head can be cleaned using an ultrasonic cleaner.

1. Remove the entire print head shell. Do not remove the print head.

2. Fill the cleaning syringe with approved solvent.

3. Attach the cleaning syringe to the ink line fitting on the outside of the head shell.

4. Flush a small amount solvent through the print head.

5. Place the print head assembly (upright) into a container filled to 1 inch with clean solvent.

6. Place this container into the ultrasonic cleaner. The ultrasonic cleaner should be filled with water.

7. Run the cleaner for 30 minutes and remove the print head. Do not exceed 30 minutes

with ultrasonic cleaner on. However, the printhead may soak for up to 3 hours with the USC off. Leaving on for too long causes significant heat that softens some of the potting compounds in and around the head.

8. Reinstall print head immediately and follow procedures for priming the print head.

Technical Manual Imaje 4040.doc

Figure 92: Cleaning a Severe Clog

Imaje 4040

6. XJ128 Print Module

Removing/Installing the XJ128 Printhead

1. Remover the front and side covers.

Figure 93: Remove Front and Side Covers

Figure 94: Pull Off Ink Tubing

Figure 95: Remove Screws Holding 128 Printhead

2. Pull off the ink tube using thumb and forefinger.

3. Using a hex key, remove each of the four screws holding the printhead in place.

4. Twist the luer fitting counter clock wise to loosen and disconnect the ink tubes.

Technical Manual Imaje 4040.doc

Figure 96: Disconnect Lure Fittings

Imaje 4040

6. XJ128 Print Module

5. Pull out the printhead so that you can get a good grip to remove the electrical connector.

Figure 97: Pull Printhead Out

Figure 98: Remove Connector

Figure 99: Re-Attach the Printhead

6. Remove the connector and pull the printhead away.

7. Re-attach the printhead by re-connecting the ink tubes and the reversing steps 6 through

8. At this point, you are ready to re-attach the covers and test the printhead.

Technical Manual Imaje 4040.doc

Figure 100: Re-Attach Covers and Test Printhead

Imaje 4040

6. XJ128 Print Module

Schematic, I/O PCB, IDS-128 Ink System

Technical Manual Imaje 4040.doc

Figure 101: Schematic, I/O PCB, IDS-128 Ink System

Imaje 4040

6. XJ128 Print Module

Electrical Diagram, IDS2/128

Technical Manual Imaje 4040.doc

Figure 102: Electrical Diagram, IDS2/128 (ES20000201)

Imaje 4040

6. XJ128 Print Module

Drawing, Replacement Printhead, XJ128

Technical Manual Imaje 4040.doc

Figure 103: Drawing, Replacement Printhead, XJ128 (PH20000401)

Imaje 4040

12. Table of Figures

7. T able of Figures

Figure 1: Tools Required to Add/Replace a Driver Board............................................................................................... 10

Figure 2: Removing Jack Screws......................................................................................................................................10

Figure 3: Removing Cover Plate ......................................................................................................................................11

Figure 4: Attaching Anti-Static Wrist Strap ..................................................................................................................... 11

Figure 5: Loosening PCB Mounting Plate........................................................................................................................11

Figure 6: Lifting the PCB Plate........................................................................................................................................ 12

Figure 7: Tightening the PCB Plate Screws .....................................................................................................................12

Figure 8: Installing the Driver Board................................................................................................................................12

Figure 9: Securing Driver Board...................................................................................................................................... 13

Figure 10: Driver Board Installed.....................................................................................................................................13

Figure 11: Wiring Diagram (ES20000101)......................................................................................................................16

Figure 12: Power Entry (CH20001401)............................................................................................................................17

Figure 13: Power Supply 1 (CH20001601) ......................................................................................................................18

Figure 14: Power Supply 2 (CH20001301) ......................................................................................................................19

Figure 15: USB (CH20001501)........................................................................................................................................20

Figure 16: Product Detect: Encoder (CH20002102).........................................................................................................21

Figure 17: Mouse to Panel Support (CH20002001) ......................................................................................................... 22

Figure 18: Panel Support to CPU (CH20001801) ............................................................................................................23

Figure 19: Photocell (SS10000401)..................................................................................................................................24

Figure 20: Encoder (SS10000501) ...................................................................................................................................25

Figure 21: Inverter to Panel Support (CH20001701)........................................................................................................26

Figure 22: Controller to Print Module (CH20000701) .....................................................................................................27

Figure 23: Schematic, I/O, Driver Board.......................................................................................................................... 28

Figure 24: Panel Support Board Schematic, I/O, Overview .............................................................................................29

Figure 25: CPU PCB Component Side.............................................................................................................................37

Figure 26: Entering Setup................................................................................................................................................. 42

Figure 27: Standard CMOS Features Setup...................................................................................................................... 42

Figure 28: Advanced BIOS Features Setup......................................................................................................................42

Figure 29: Advanced Chipset Features Setup...................................................................................................................43

Figure 30: Integrated Peripherals......................................................................................................................................43

Figure 31: Power Management Setup...............................................................................................................................43

Figure 32: PnP/PCI Configuration.................................................................................................................................... 44

Figure 33: PC Health Status ............................................................................................................................................. 44

Figure 34: Load Optimized Defaults ................................................................................................................................44

Figure 35: Entering BIOS................................................................................................................................................. 45

Figure 36: Entering Standard CMOS................................................................................................................................46

Figure 37: Standard CMOS Settings ................................................................................................................................46

Figure 38: Entering Advanced BIOS................................................................................................................................47

Figure 39: Advanced BIOS Settings.................................................................................................................................47

Figure 40: Entering Advanced Chipset.............................................................................................................................48

Figure 41: Advanced Chipset Settings..............................................................................................................................48

Figure 42: Entering Integrated Peripherals.......................................................................................................................49

Figure 43: Integrated Peripherals Settings........................................................................................................................49

Figure 44: Entering PnP/PCI Configuration.....................................................................................................................50

Figure 45: PnP/PCI Configuration Settings......................................................................................................................50

Figure 46: Entering Set Password.....................................................................................................................................51

Figure 47: Set Password ...................................................................................................................................................51

Figure 48: Required Tools................................................................................................................................................ 52

Technical Manual Imaje 4040.doc

Figure 49: Shut Down Controller ..................................................................................................................................... 52

Figure 50: Locate Filters...................................................................................................................................................52

Figure 51: Blow Out Filters..............................................................................................................................................53

Figure 52: Blow Out Fan ..................................................................................................................................................53

Figure 53: Blow Out Board Stack.....................................................................................................................................53

Imaje 4040

12. Table of Figures

Figure 54: Clean Out Controller.......................................................................................................................................54

Figure 55: Loosen Thumb Screws....................................................................................................................................59

Figure 56: Remove Cover.................................................................................................................................................59

Figure 57: Remove Seal....................................................................................................................................................59

Figure 58: Vacuum Priming .............................................................................................................................................60

Figure 59: Pressure Priming............................................................................................................................................. 61

Figure 60: Loosen Thumb Screws....................................................................................................................................62

Figure 61: Loosen Side Cover Screws and Remove.........................................................................................................62

Figure 62: Visually Inspect Printhead ..............................................................................................................................62

Figure 63: Loosen Fittings................................................................................................................................................62

Figure 64: Remove Tubing from Printhead......................................................................................................................63

Figure 65: Do Not Remove Black and White Fittings......................................................................................................63

Figure 66: Remove Cable from Printhead........................................................................................................................63

Figure 67: Visually Inspect Cable .................................................................................................................................... 63

Figure 68: Remove Printhead Mounting Screws..............................................................................................................64

Figure 69: Assure Forward Positioning When Reinstalling .............................................................................................64

Figure 70: Place Printhead Upside Down.........................................................................................................................64

Figure 71: Remove Four Cap Screws...............................................................................................................................64

Figure 72: Syringe with Filter for Flushing......................................................................................................................65

Figure 73: Flushing with Syringe.....................................................................................................................................65

Figure 74: Cleaning Solution Streaming from Head ........................................................................................................ 65

Figure 75: IDS2-500 Ink System Circuit Board Sche mat i c, I/O.......................................................................................67

Figure 76: Exploded Drawing, Chassis, IDS2/500 Ink Delivery System (PM20000201)................................................68

Figure 77: Wiring Diagram: IDS2/500 Print Module, Old (ES30000102)....................................................................... 69

Figure 78: Plumbing Diagram, IDS2/500 (PM30000203)................................................................................................70

Figure 79: Loosen 128 Nozzle Plate Screws ....................................................................................................................73

Figure 80: Remove Nozzle Plate......................................................................................................................................73

Figure 81: Prepare to Print................................................................................................................................................73

Figure 82: Close the Air Valve.........................................................................................................................................73

Figure 83: Pump the Priming Bulb...................................................................................................................................74

Figure 84: Hold Lint Free Wipe Up to Nozzle................................................................................................................. 74

Figure 85: Blot Excess Ink Off Printhead......................................................................................................................... 74

Figure 86: Re-attach Nozzle Plate.................................................................................................................................... 74

Figure 87: Tighten Nozzle Plate Screws...........................................................................................................................75

Figure 88: Priming into Container....................................................................................................................................75

Figure 89: Quick Prime.................................................................................................................................................... 75

Figure 90: Prime 128 Module Using a Bag......................................................................................................................76

Figure 91: Prime 128 Module Using a Syringe................................................................................................................76

Figure 92: Cleaning a Severe Clog...................................................................................................................................77

Figure 93: Remove Front and Side Covers.......................................................................................................................78

Figure 94: Pull Off Ink Tubing.........................................................................................................................................78

Figure 95: Remove Screws Holding 128 Print hea d..........................................................................................................78

Figure 96: Disconnect Lure Fittings ................................................................................................................................. 78

Figure 97: Pull Printhead Out...........................................................................................................................................79

Figure 98: Remove Connector..........................................................................................................................................79

Figure 99: Re-Attach the Printhead ..................................................................................................................................79

Figure 100: Re-Attach Covers and Test Printhead........................................................................................................... 79

Figure 101: Schematic, I/O PCB, IDS-128 Ink System....................................................................................................80

Figure 102: Electrical Diagram, IDS2/128 (ES20000201)...............................................................................................81

Figure 103: Drawing, Replacement Printhead, XJ128 (PH20000401).............................................................................82

Technical Manual Imaje 4040.doc

Imaje AB reserves the right to modify the technical characteristics of the product without prior notice.

No binding pictures. Photos: X

Reproduction, in whole or in part is prohibited.

English version

Imaje S.A.

Head Office 9, rue Gaspard Monge BP 110 26501 Bourg-lès-Valence Cedex France

Tel: (33) 4 75 75 55 00 Fax: (33) 4 75 82 98 10

http:// www.imaje.com

Manufacturer Imaje AB

Säterigatan 20 SE-417 64 Göteborg SWEDEN

Tel: (46) 31 65 69 00 Fax: (46) 31 65 69 83

http:// www.imaje.com

Imaje 4040 Technical File Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1. Introduction

Safety Requirements

Certification and Approvals

Theory of Operation during the Priming Process:

Theory of Operation during the Printing Process: