Saturn S300 Series,S400 Series,S Series,S600 Series Service Manual
Contents
CONTENTS
Chapter 1 Introduction………………………………………………………1-5
Chapter 2 Safty ………………………………………………………………2-1
Chapter 3 Equipment Description and Component Identification…3-1
Chapter 4 Installation ………………………………………………………4-1
Chapter 5 Ink Jet Printer Operation ………………………………………5-1
Chapter 6 Maintenance ……………………………………………………6-1
Chapter 7 Troubleshooting …………………………………………………7-1
Appendix:
1. Hydraulic System Connecting Figure …………………………8-1
2. Electric System ……………………………………………………8-2
3. Hydraulic System …………………………………………………8-3
4. Printing Speed List ………………………………………………8-4
5. User-defined Font…………………………………………………8-5
6. S400 Series Upgrade Introduction……………………………8-11
Version: 20100420
Introduction
1
In this chapter you will find:
Introduction
z a brief description of the intended use of the machine
z who this manual is intended for, how it is organized, and the
writing conventions that are used to present information
z an introduction to each of the chapters in this manual
WARNING: Read chapter 2, Safety, before attempting to
service operate the equipment.
Turn to page 1-2 for a chapter-level Table of Contents.
1-1
Introduction
Chapter 1 Contents
Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - 1-3
References to the S400 serials printer - - - - - - - 1-3
Printers Supplies - - - - - - - - - - - - - - - - - - - - - -1-3
Who Should Use this Manual? - - - - - - - - - - - - - - - - - 1-4
Writing Conventions Used In this Manual - - - - - - - - - - - - 1-5
1-2
Introduction
Introduction
The S400 Serials Printer is a non-contact ink jet printer designed to print small character messages
onto a product. This equipment is typically used for industrial marking, coding and overprinting. The
technical specialties are listed as followed.
For ease of reading, the S400 Series Printer will be referred to as
References to the
S300/400 Printer
Due to the large variety of SATURN Inks available for use with this
Printer Supplies
the “S480 Printer” or “Printer” throughout the remainder of this
Manual.
product, this printer can print on virtually any surface, texture,
contour or shape.
Contact your SATURN sales representative or distributor if you
have any question regarding supplies selection (inks, make-up
fluids and cleaning solutions) or product application.
1-3
Introduction
Who Should Use this Manual?
Introduction
This Manual is intended for use by SATURN service personnel
and those customers who are qualified to perform their own
printer service and maintenance.
WARNING: Customers who intended to service and maintain the
printer themselves must be qualified personnel,
which are considered those persons who have the
proper technical training (successful completion of a
training course covering this printer), have
experience to work on this equipment, and are aware
of the hazards to which they will be exposed. The
Service Manual is intended to be supplement (and
not a replacement) to training.
The Manual contains information on operating, installing, setting
up, maintaining, troubleshooting, and servicing the printer.
Keep this Manual in a safe location where it can be easily
accessed for reference.
1-4
Introduction
Service Manual Overview
Chapter 2, Safety
This chapter contains important equipment and safety guidelines, as well as the safety writing
conventions used throughout the manual.
Chapter 3, Equipment Description and Component Identification
This chapter shows the location and provides a brief description of each of the main
components in the printhead, the hydraulic and electronic co mpartments of the printer.
Chapter 4, Installation
This chapter includes the necessary procedures when installing the printer and setup the
technical data.
Chapter 5, Printer Operation
This chapter includes an overview of the fluid system, a description of how ink drops are
created and controlled, and detailed functional sequences of operation for electrical, and
hydraulic functions.
Chapter 6, Maintenance
The maintenance chapter lists all recommended scheduled maintenance procedures, ink
maintenance procedures, and procedures to follow to attain th e finest print quality.
Chapter 7. Troubleshooting
This chapter includes the cause, judge, and solutions of printer common fault s.
1-5
Safety
2
Safety
In this chapter you will find:
important safety guidelines to follow when operating the
equipment
important safety guidelines to follow when working with
inks, make-up fluids, and cleaning solutions
important safety guidelines to follow when long-term
shutdown
printhead cleaning
shutdown without cleaning
recovery tube cleaning
WARNING: Read this chapter thoroughly before attempting
Refer to page 2-2 for a chapter-level Table of Contents.
to operate this product.
2-1
Safety
Chapter 2 Contents
Introduction - - - - - - - - - - - - - - - - - - - - - - - - - -2-3
Safety Terms - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4
Fire Prevention Statements- - - - - - - - - - - - - - - - -2-4
Danger Statements - - - - - - - - - - - - - - - - - - - -2-4
Warning Statements - - - - - - - - - - - - - - - - - - - 2-4
Caution Statements - - - - - - - - - - - - - - - - - - - 2-4
Equipment Safety Guidelines - - - - - - - - - - - - - - - - - - 2-5
Comply with Electrical Codes - - - - - - - - - - - - - - - 2-5
Avoid Breathing Exhaust Vapors - - - - - - - - - - - - - 2-5
Do Not Remove Warning Labels - - - - - - - - - - - - - 2-5
Ink Safety Guidelines - - - - - - - - - - - - - - - - - - - - - 2-6
No Smoking - - - - - - - - - - - - - - - - - - - - - - - 2-6
Wear Safety Glasses - - - - - - - - - - - - - - - - - - -2-6
Avoid Skin Contact - - - - - - - - - - - - - - - - - - - 2-6
Dispose of Ink Properly - - - - - - - - - - - - - - - - - 2-6
Store Inks Properly - - - - - - - - - - - - - - - - - - - -2-6
Ground the Service Tray - - - - - - - - - - - - - - - - - 2-6
Ink and make-up fluid caution items- - - - - - - - - - - - - - - - - - - - 2-7
Long-term Shutdown- - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8
Printhead Cleaning- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-8
Shutdown without Auto Flush - - - - - - - - - - - - - - - - - - - - - 2-9
Recovery Tube Cleaning - - - - - - - - - - - - - - - - - - - - - - - - -2-10
2-2
Safety
Introduction
z The policy of Saturn Technologies Ltd. is to manufacture non-contact printing/coding systems
and ink supplies which meet high standards of performance and reliability. We enforce strict
quality control techniques to eliminate the potential defects and haza rds in our products.
z The intended use of the S480 printer is to print information directly onto a product. Use of this
equipment in any other fashion may lead to serious personal injury.
z The safety guidelines provided in this chapter are intended to educate the operator on all safety
issues in order to operate the printer in a safe manner.
z The safety guidelines provided in this chapter are intended to educate the operator on all safety
issues in order to install, service, and maintain the printer in a safe manner.
z Before using this printer, thoroughly read this chapter and follow the guidelines strictly.
z You must use Saturn’s ink、make-up, or the warranty period will stop automatically.
z Please find technical support from distributor directly. Do not use untrained staff in the warranty
period, or the warranty period will stop automatically.
z Filter and O ring are consumables, which are not included in warranty, please replace on time.
2-3
Safety
Safety Conventions Used in this Manual
Fire prevention statement The ink and make-up fluid are both flammable and may cause fire.
Danger Statements Danger statements:
Please keep any fire five meters away from the printer, and set up
the printer in dry environment
are used to indicate immediate hazards which WILL result in
severe personal injury or death
have a triangular symbol with an
immediate left
are always found before the step or piece of information to
Warning Statements Warning statements:
are used to indicate hazards or unsafe practices which could
have a triangular symbol with an exclamation point to the
are always found before the step or piece of information to
Caution Statements Caution statements:
are used to indicate hazards or unsafe practices which could
is preceded by the word "DANGER"
which they refer
result in severe personal injury or death
immediate left
is preceded by the word “WARNING”
which they refer
result in minor personal injury or product or
property damage
exclamation point to the
have a triangular symbol with an
immediate left
is always preceded by the word CAUTION
2-4
exclamation point to the
Safety
Equipment Safety Guidelines
WARNING: Always observe the following safety guidelines when
Comply with Electrical Codes
Shutdown the power before opening printer door;
Do not insert tweezers, screw driver or any steel material into ink
ejection hole at the end of printhead. When the printer is ready to
print, a high voltage (approximately 6 kV) is applied to the
deflection electrode section in the printhead.
Exercise caution to avoid electric shock, injury, and fire.
Avoid Breathing Exhaust Vapors
During operation, the printer exhausts vapors through the muffler.
These vapors may be flammable and present a healthy hazard. For
these reasons, do not allow the exhaust to be confined to an area
that does not have proper ventilation or near a source of ignition.
Printer exhaust fumes are generally heavier than air, so keep all
sources of ignition away from low areas where fumes may travel or
accumulate. Ensure that no welding operations are performed
within 5 m of the printer.
Do Not Remove Warning Labels
Do not, under any circumstances, remove or obstruct any warning
or instruction labels in the printer.
WARNING: Do not place the printer in an explosive atmosphere.
If emergency occurs, press the power switch to turn off the power.
Use the printer at the temperature with 0—40°C and relative
humidity of 30-90%, or will cause fault to printer.
Do not mix different types of ink together, or will cause printer fault
Printer should link to ground well, or will affect printing.
installing, operating, servicing, or maintaining the
printer and associated equipment.
2-5
Safety
Ink Safety Guidelines
WARNING: Always observe the following safety guidelines when
No Smoking
Do not smoke when near the printer or printhead. Explosion or fire
Ground the Service Tray Ground the Saturn service tray to the printer, and install the
may result if the printer exhaust fumes are subjected to an ignition
source.
Wear Safety Glasses
Wear safety glasses with side shields (or equivalent eye protection)
when handling any ink, make-up fluid or cleaning solution. If
splashed into your eyes, flush eyes with water for 15 minutes and
see a doctor immediately.
Avoid Skin Contact
Wear butyl rubber gloves when handling any ink, make-up fluid or
cleaning solution. Avoid contact with skin and mucous membranes
(nasal passage, throat). Upon contact with skin, remove any
contaminated clothing and wash area with soap and water. See a
doctor if irritation persists.
Dispose of Ink Properly
Do not pour any ink, make-up fluid, or cleaning solution into sinks,
sewers, or drains. Waste disposal must comply with local
regulations; contact the appropriate regulatory agency for further
information.
Store Consumables Properly
The ink and make-up fluid are both flammable and may cause fire,
and must be stored properly. Consult the appropriate regulatory
agency for further information
printhead into the service tray when test printing or dumping ink
from the printhead. This is necessary to avoid the possibility of
electrostatic discharge which may result in fire.
working with any ink, make-up fluid, or cleaning
solution.
2-6
Safety
Ink and Make-up Fluid Caution Items
1. Ink and make-up replenishment
While the printer is operated, the ink and make-up are automatically transferred at fixed intervals
from the ink or make-up tank to the main ink supply pipe for replenishment purposes. If the ink or
make-up sufficiency alarm is issued, add ink or make-up to the tank within 60 minutes. If such
replenishment procedure is not completed within 60 minutes, the printer comes to a stop.
2. Ink replacement
Refer to “System Maintainence ”.
During printer operated, ink will polluted by dust. Long-term running will cause to badly charge
of ink. Replace the ink refer to the table as below;
Replacement periods Type Numbers
Operating hours Period
Normal black ink R1182 800-1200 hours 8 month
Low viscosity ink R1180 800-1200 hours 8 month
Invisible blue ink R1360 600-1000 hours 6 month
Alcohol endurable ink R1582 600-1200 hours 8 month
High adhesive ink R1782 600-1200 hours 6 month
White pigment ink R1000 600-1000 hours 6 month
Edible ink R1960 300-600 hours 3 month
3. Store requirement
1) The ink and make-up must be hermetically sealed and stored in a cool dark place(0 to 20 ℃)
2) Using the ink and make-up before “Unseal period”.
3) Once the ink unsealed, please use it as soon as possible, if the ink in the printer over the
time which in above table, that means the ink can not be used any more.
4) Once the make-up unsealed, please add into the ink jet printer within one year. Do not need
to change the make-up.
Caution
: Waste ink and make-up can not be poured into sewer or public places.
2-7
Safety
Long-term Shutdown Guidelines
Please refer to the procedure of "auto flush" in the system maintenance. Long-term shutdown
requires that you drain out the ink from the printer and flush the ink system. This is necessary, as left
ink in the system will dry/solidify, causing problems when re-commissioning the printer.
Cleaning of Print Head
Most of ink used in printer is fast dry ink. This type of ink will come to dry and solidify immediately.
The "auto flush" function ensures that the nozzle and gutter will be cleaned when the printer is
starting up and shutting down.
Some ink sprayed out of the nozzle over time will accumulate on the charge deflection plate/nozzle
plate, causing the ink stream unable to spray out. It is necessary to clean the printhead manually.
(1) Take off nozzle cover, spray out make-up on nozzle plate, charge deflection, H.V. deflection
electrode and gutter, clean out printhead.
Screw for Printhead Cover
Do not clean this area with
cleanings.
Use wet paper with cleanings
to clean this area.
Charge Electrode
Cleaning
Range
(2) Clean out the nozzle as the picture shows. Can not spray out make-up to other area.
(3) Dry the printhead using the rubber pipette bulb.
z Ensure the nozzle, charge electrode, H.V. deflection electrode, gutter and surrounding area
are clean enough.
z Do not force make-up to flow inside the nozzle.
Nozzle
Nozzle Plate
H.V. Deflection Electrode
Gutter
2-8
Safety
Shutdown without Auto Flush
Press the
this shutdown frequently in a short period of time will cause surplus adding of make-up to the
system. If the shutdown time is less than 30 seconds, you should perform the quick shutdown
procedure.
Quick shutdown: If the shutdown time is less than 30 seconds you may perform the quick
Print Status
Print Key for 2 seconds, the printer will start to shutdown with a "system cleaning”. Using
shutdown procedure to avoid surplus adding of make-up. This procedure will
shorten shutdown time. Shutdown without auto flush is used normally for
maintenance purposes only.
(Green LED)
z Press “Print Key”, green LED will off, and status area will indicate “Printer is
ready”;
System St atus:
Printer is ready
System Maintainence-1
2007/12/26 12:00
Ink On/Off Print Test
H.V. On/Off
Current Flow Time:
z Enter “System Maintainence-1”, select “Ink On/Off”, status area will display
“Printer is Shutting down H.V.”, “Printer is Shutting down”. When the ink in
recovery tube is drain out, you can turn off the switch to maintain the printer.
Caution
① After finishing maintenance on the printer using "shutdown without auto flush"
it is important to note that if you intend not to use the printer for some time you
must perform the normal shutdown procedure to make sure that the ink recovery
tube is perfectly clean.
② After finish the maintenance, if need to start up again, manually cleaning the
nozzle procedure is needed to perform to make sure the ink stream perfectly
recover to the gutter.
:
2-9
Safety
Recovery Tube Cleaning
If the printer is running for a long time without auto flush, the recovery tube may accumulate some
ink and will need to be cleaned.
Caution
: Do not perform recovery tube cleaning more than twice.
2-10
Equipment Description and Component Identification
3
Equipment Description and
Component Identification
In this chapter you will find:
a brief description of the two main printer assemblies --- the
control unit and the printhead
the location and a brief description of the function of the main
components in the hydraulic, and electronic compartments of
the printer, as well as the printhead
Turn to page 3-2 for a chapter-level Table of Contents.
3-1
Equipment Description and Component Identification
Chapter 3 Contents
Equipment Description- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3
Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3
Control Unit- - - - - - - - - - - - - - - - - - - - - - - - - - 3-4
Hydraulic Compartments - - - - - - - - - - - - - - - - - - - - - 3-4
Electronic Compartments- - - - - - - - - - - - - - - - - - - - - 3-5
Keyboard - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5
The Printhead- - - - - - - - - - - - - - - - - - - - - - - - - 3-6
Component Identification - - - - - - - - - - - - - - - - - - - - 3-7
Introduction- - - - - - - - - - - - - - - - - - - - - - - - - 3-7
The Location and Description of a Main Component- - - - 3-7
Hydraulic Components - - - - - - - - - - - - - - - - 3-7
Electronic Components - - - - - - - - - - - - - - - 3-14
Printhead Components - - - - - - - - - - - - - - - 3-16
3-2
Equipment Description and Component Identification
Introduction The S400 Series printer is comprised of two basic assemblies
-- the control unit and the printhead -- connected by an umbilical
assembly (a flexible conduit containing electrical and fluid lines).
Refer to Figure 3-1.
Figure 3-1. S400 Series Printer
3-3
Equipment Description and Component Identification
Control Unit
Hydraulics Compartment
(Fluid pan)
For more information
The control unit consists of the hydraulic and electronic
compartments of the printer, as well as the keyboard
(Refer to Figure 3-2).
The hydraulics compartment is located behind the front
door of the control unit (refer to Figure 3-2). This is where
ink and makeup fluid are stored, monitored, and
maintained to ensure proper fluid viscosity. This is also
where pressure is applied to the ink to ensure proper
velocity of the ink drops at the printhead.
Caution
commonly referred to as the “fluid pan”.
Refer to Hydraulic Components on page 3-7 for
information on the main components found in the
hydraulics compartment.
Keyboard
Lower Door
(Open before
maintaining or
filling ink and
makeup in)
Ink Tank
Figure 3-2. The Control Unit
: The hydraulics compartment is also
Upper Door
Makeup Tank
Support Tray
(loosen the
screw to pull
out the tray)
Power
Supply
Hydraulics
Compartment
Umbilicals
Ports
3-4
Equipment Description and Component Identification
n
Electronic Compartments
For more inf ormatio
Keyboard
Figure 3-3. Keyboard
Electronic compartments are set in the upper door (refer to
Figure 3-2). The main function is to control all the electronic
signal.
Refer to Electronic Components on page 3-16 for
information on the main components found in the
electronic compartment.
The keyboard is located on the front of the control unit (refer
to Figure 3-2). The keyboard consists of control keys, an alpha
keypad, and a display screen (refer to Figure 3-3). Use the
keyboard to operate the printer.
3-5
Equipment Description and Component Identification
The Printhead The printhead is connected to the control unit by the umbilical
assembly. The printhead receives pressurized ink through the
umbilical, and turns the ink stream into tiny electrically
charged ink droplets which are deflected onto a substrate to
form a printed code.
For more information
Refer to Printhead Components on page 3-15 for information
on the main components found in the printhead.
Refer to Chapter 5, Inkjet Printer Operation，for more
information on how the printhead works.
Figure 3-4. Printhead
3-6
Equipment Description and Component Identification
Component Identification
Introduction This section identifies the location and describes the function
of the main components included in the hydraulic, pneumatic,
and electronic compartments of the control unit, as well as the
main components in the printhead.
Only main printer components are covered in this section.
This section is divided into the following subsections:
Hydraulic Components - - - - - - - - turn to page 3-7
Electronic Components - - - - - - - turn to page 3-13
Printhead Components - - - - - - -- turn to page 3-15
Hydraulic Components Refer to Figure 3-5 and Figure 3-6 for the location of the main
hydraulic components, and refer to the following pages to find
a brief description of the function of the components.
Caution
components.
: Open the lower door to check the hydraulic
3-7
Equipment Description and Component Identification
Viscosimeter
Ink Pouring Orifice
Ink Pressure
Regulator
Ink Tank
Support Tray
Figure 3-5. Hydraulics Compartment-1 (with support tray pulled out)
1. Ink Pressure Gauge
The ink pressure gauge indicates the amount of air pressure (in
psi and bar) applied to the ink supply cylinder. This pressure is
commonly referred to as "ink pressure”. The ink pressure is
controlled by adjusting the ink pressure regulator (refer to page
3-10).
2. Ink Pressure Regulator
The ink pressure regulator is used to adjust the ink pressure, and
accordingly to change the speed of the ink steam. According to
the style of ink and the measure of print head, ink pressure is
usually set at 2.8- 3.5 bar(40- 50 psi).
WARNING: Do not adjust the ink pressure regulator unless
you are performing the “Viscosity Calibrate”
procedure. (Refer to page 6-26)
3-8
Ink Pressure
Gauge
Makeup Pouring
Orifice
Makeup Tank
Equipment Description and Component Identification
3. Ink Tank
The ink tank stores fresh ink for printer.
4. Makeup Tank
The Makeup tank stores Makeup and adds Makeup to the ink when
ink becomes too dense.
5. Support Tray
The support tray carries the whole hydraulic system, ink and
Makeup tank, which can be pulled out in order to check the
hydraulic system.
Note: Please loose the support tray lock before pulling out the
tray.
6. Viscosimeter
The viscosimeter includes a metal float and a sensor to monitor
the viscosity coefficient of the ink.
7. Main Ink Filter
The main ink filter is installed at the right side of the bracket
(Figure 3-6). It filtrates and cushions the ink going to hydraulic
system.
8. Makeup Filter
The Makeup filter filtrates the Makeup ink going to flush pipe in
the printhead (Figure 3-6), and prevents dust into printhead.
9. Churn Filter
The churn filter filtrates the ink going to the viscosimeter (Figure
3-6), and prevents dust into viscosimeter.
10. Recovery Filter
The recovery filter filtrates un-used ink from gutter (Figure 3-6),
and prevents dust into ink tank.
3-9
Equipment Description and Component Identification
Makeup
Filter
Valves Board
Churn Filter
11
12
Figure 3-6. Hydraulics Compartment-2
11. Ink Supply Pump
The ink supply pump transfers ink to printhead and generates a
pressure to spurt out the ink through printhead.
12. Makeup Pump
The makeup pump transfers the makeup ink to the printhead and
generates a pressure to spurt out the Makeup ink to clean the
printhead.
13. Circulation Pump
The circulation pump absorbs ink from viscosimeter and also
absorbs ink from printhead and returns ink to ink tank.
14. Recovery Pump
The recovery pump returns un-used ink from printhead to ink
tank.
Recovery Filter
1413
Solenoid Electric Valves
Main Ink Filter
11 Ink Supply Pump
12 Makeup Pump
13 Circulation Pump
14 Recovery Pump
3-10
Equipment Description and Component Identification
Figure 3-7 Hydraulic System
3-11
Equipment Description and Component Identification
Figure 3-8 Perspective Drawing for Valves Board
3-12
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