VIDEOJET Universal 37pc Service Manual

Universal 37pc

Service Manual

P/N 361518-01

Revision: AB, March 2004

Copyright 2004, Videojet Technologies Inc. (herein referred to as Videojet). All rights reserved.

This document is the property of Videojet Technologies Inc. and contains confidential and

proprietary information owned by Videojet. Any unauthorized copying, use or disclosure of it without

the prior written permission of Videojet is strictly prohibited.

Videojet Technologies Inc.

1500 Mittel Boulevard Phone: [phone] Offices - USA: Atlanta, Chicago
Wood Dale, IL Fax: [phone] INT’L: Canada, France, Germany, Ireland, Japan, Spain,
60191-1073 USA Int’l Fax: [phone] Singapore, The Netherlands,The United Kingdom

www.videojet.com Distributors Worldwide

Compliance Information

For Customers in the U.S.A.

This device complies with Part 15 of the FCC Rules. Operation is subject to
the following two conditions: 1) this device may not cause harmful
interference, and 2) this device must accept any interference received,
including interference that may cause undesired operation.

Warning

Changes or modifications to this unit not expressly approved by the
party responsible for compliance could void the user’s authority to
operate the equipment.

This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to Part 15 of the FCC Rules. These limits
are designed to provide responsible protection against harmful
interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is likely
to cause harmful interference in which case the user will be required to
correct the interference at his own expense.

Shielded cables must be used with this unit to ensure compliance with
Class A FCC limits.

The user may find the following booklet prepared by the Federal
Communications Commission helpful: How to Identify and Resolve
Radio-TV Interference Problems. This booklet is available from the U.S.
Government Printing Office, Washington, DC 20402, Stock No. 004-00­00345-4.

This equipment is UL listed.

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Universal 37pc Service Manual

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Rev AB

Support and Training

Contact Information

If you have any questions or need assistance, please contact Videojet
Technologies Inc. at 1-800-843-3610 (for all customers within the United
States). Outside the U.S., customers should contact their Videojet
Technologies Inc. distributor or subsidiary for assistance.

Videojet Technologies Inc.

1500 Mittel Boulevard

Wood Dale, IL 60191-1073 U.S.A.

Phone: [phone]
Fax: [phone]

International Fax: [phone]

Web: www.videojet.com

Service Program

About Tot al Source Commitment

Tot al Source® TOTAL SERVICE PLUS RELIABILITY, is the Videojet
Technologies Inc. commitment to provide you - our customer - the
complete service you deserve.

The Tot al Source Commitment

The Videojet Total Source® Service Program is an integral part of our
business in providing marks, codes, and images where, when, and how
often customers specify for packages, products, or printed materials. Our
commitment includes:

• Applications support.

• Installation services.

• Maintenance training.

• Customer response center.

• Technical support.

• Field service.

• Extended hours phone assistance.

• Parts and supplies.

•Repair service.

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Universal 37pc Service Manual

Customer Training

If you wish to perform your own service and maintenance on the printer,
Videojet Technologies Inc. highly recommends you complete a Customer
Training Course on the printer.

Note: The manuals are intended to be supplements to (and not replacements for)
Videojet Technologies Inc. Customer Training.

For more information on Videojet Technologies Inc. Customer Training
Courses, call 1-800-843-3610 (within the United States only). Outside the
U.S., customer should contact a Videojet subsidiary office or their local
Videojet distributor for further information.

iv

Rev AB

Table of Contents

Compliance Information

For Customers in the U.S.A.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Support and Training

Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Service Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Customer Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Table of Contents

Chapter 1 — Introduction

Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

About the Service Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Chapter 2 — Safety

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

Safety Conventions Used in the Manual. . . . . . . . . . . . . . . . . . . . . . . . 2–2

Safety Guidelines for Items in the Spare Parts Kit. . . . . . . . . . . . . . . . 2–4

Equipment Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5

Placement of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6

Using Printer Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6

Ink Safety Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7

Medical Emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11

Chapter 3 — Installation

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

Setting Up the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2

External Data Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–18

Install Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–26

Ink System Service Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–27

Prime Printer with Make-up Fluid (AUTO PRIME) . . . . . . . . . . . . . 3–30

Drain Make-up Fluid From Printer (AUTO DRAIN) . . . . . . . . . . . . 3–34

Prime Printer with Ink (AUTO PRIME) . . . . . . . . . . . . . . . . . . . . . . . 3–36

Refresh Ink System (AUTO REFRESH) . . . . . . . . . . . . . . . . . . . . . . . 3–38

Ink Stream Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–40

Set the Fluids Low Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–57

Adjust the Positive Air Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–59

Adjusting the High Voltage Plate Gap . . . . . . . . . . . . . . . . . . . . . . . . 3–60

Adjusting the Bar Code Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–62

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Universal 37pc Service Manual

Chapter 4 — Theory of Operation

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

The Ink Jet Printing Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–2

Controlling the Ink Stream . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–6

Functional Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–8

Chapter 5 — Equipment Description

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

The Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–2

The Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–3

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–4

Chapter 6 — Maintenance

Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–1

Reading the Ink On Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–2

Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–4

Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–10

Circulating Ink Through the Printer . . . . . . . . . . . . . . . . . . . . . . . . . .6–18

Preparing the Printer for Extended Shutdown. . . . . . . . . . . . . . . . . .6–20

Preparing Printer for Use After Extended Shutdown . . . . . . . . . . . .6–23

Chapter 7 — Service Mode

Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–1

Printer Ink-on time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–6

Ink System Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–8

Ink and High Voltage Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–15

Changing the Nozzle Drive and High Voltage Setting. . . . . . . . . . . 7–17

Ink System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–19

Ink System Service Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–21

Prime Printer with Fluid (AUTO PRIME). . . . . . . . . . . . . . . . . . . . . .7–24

Drain Fluid From Printer (AUTO DRAIN) . . . . . . . . . . . . . . . . . . . . .7–28

Prime Printer with Ink (AUTO PRIME) . . . . . . . . . . . . . . . . . . . . . . .7–30

Refresh Ink System (AUTO REFRESH) . . . . . . . . . . . . . . . . . . . . . . . .7–33

Ink Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–36

Ink Stream Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–38

Conduct a Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–53

Changing the Bar Code Type for Parallel Mode . . . . . . . . . . . . . . . .7–60

Adjusting the High Voltage Plate Gap . . . . . . . . . . . . . . . . . . . . . . . .7–62

Adjusting the Bar Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–64

vi

Rev AB

Chapter 8 — Troubleshooting

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

Fault Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2

Correcting a Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6

LED Printer Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–32

Electronic Test Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–42

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–55

Chapter 9 — Serial Interface

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1

Definition of the Serial Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4

Switching the Printer to Serial Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4

Serial Communications Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5

List of Commands Host Sends to Printer . . . . . . . . . . . . . . . . . . . . . . . 9–8

List of Responses Printer Sends to Host . . . . . . . . . . . . . . . . . . . . . . . 9–36

Zero-Length Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–42

Control Signal Timing Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–47

Character Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–51

Insert Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–54

Universal 37pc Service Manual

Chapter 10 — Parallel Interface

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1

Switching the Printer to Parallel Mode . . . . . . . . . . . . . . . . . . . . . . . . 10–1

Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2

Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–7

United States Postal Service Interface Information. . . . . . . . . . . . . 10–11

Chapter A — Specifications

Physical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1

Environmental Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2

Electrical Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–3

Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–3

User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–4

Printing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–5

Index

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Universal 37pc Service Manual

viii

Rev AB

Introduction

In this chapter you will find:

• a brief description of the intended use of the product

• who this manual is intended for and how it is organized

• a description of the other manuals associated with this printer

Warning

Read Chapter 2, “Safety” before attempting to install, operate,
service, or maintain the equipment.

1

Equipment Description

The Videojet Universal 37pc (postal coder) printer is a non-contact, ink jet
printer that prints at high production speeds onto almost any surface in
any direction. This equipment is typically used for printing postal bar
codes onto mail pieces.

Printer Supplies

Due to the large variety of inks available for use with this product, this
printer can print on virtually any surface, texture, contour, or shape.

Consult your Videojet Technologies sales representative if you have any
questions regarding supplies selection (inks, make-up fluids, and cleaning
solutions), or product applications.

Caution

Only Videojet supplies are recommended for use in this printer.
Non-approved supplies may damage the unit or produce inferior
printer operation or printing output.

Rev AB Equipment Description 1-1

Universal 37pc Service Manual

About the Service Manual

The Service Manual is intended for use by qualified service or
maintenance personnel only. It contains information on installing,
maintaining, troubleshooting, and servicing the printer.

Warning

Customers who intend to service and maintain the printer
themselves must only have qualified personnel perform those
procedures. Qualified personnel are considered to be 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 Universal 37pc Service Manual is intended to be a
supplement (and not a replacement) to training.

Related Documents

Two other documents are available (through Videojet Customer Service)
for the Universal 37pc:

• Operator’s Guide (P/N 361517-01)

• Illustrated Parts Breakdown (P/N 361519-01)

Universal 37pc Operator’s Guide

Refer to the Universal 37pc Operator’ Guide (also supplied with the
printer) for information on operating the printer.

Universal 37pc Illustrated Parts Breakdown

The Illustrated Parts Breakdown shows the parts of the printer and the
printer accessories that are available to order from Videojet Technologies.

1-2 About the Service Manual

Rev AB

Language Codes

When ordering manuals, be sure to add the 2-digit language code to the
end of the part number. For example, the Spanish version of this manual is
part number 361518-04.

Code Language Availability (see note)

01 English (US) * + #

02 French

03 German

04 Spanish

05 Portuguese

06 Japanese

07 Russian

08 Italian

09 Dutch

Universal 37pc Service Manual

10 Chinese (Simplified)

11 Arabic

12 Korean

13 Thai

14 Icelandic

15 Norwegian

16 Finnish

17 Swedish

18 Danish

19 Greek

20 Hebrew

21 English (UK) * + #

23 Polish

Note: Initial availability of the Operator’s Guide is indicated by an asterisk (*).
Availability of the Service Manual is indicated by a plus sign (+). Availability of
the Illustrated Parts Breakdown is indicated by the number sign (#). For more
information, consult your Videojet distributor or subsidiary.

Rev AB About the Service Manual 1-3

Universal 37pc Service Manual

1-4 About the Service Manual

Rev AB

Safety

2

In this chapter you will find:

• safety conventions used throughout this manual

• important safety guidelines to follow when operating the equipment

• important safety guidelines to follow when working with inks, make­up fluids, and cleaning solutions

• what to do in case of a medical emergency

Warning

Introduction

The policy of Videojet Technologies Inc. is to manufacture non-contact
printing/coding systems and ink supplies that meet high standards of
performance and reliability. We enforce strict quality control techniques to
eliminate the potential for defects and hazards in our products.

The intended use of this printer is to print information directly onto a
product. Use of this equipment in any other fashion may lead to serious
personal injury.

The safety guidelines provided in this chapter are intended to educate the
operator on all safety issues so the operator can operate the printer in a
safe manner.

Read this chapter thoroughly before attempting to install, operate,
service, or maintain this product.

Rev AB Introduction 2-1

Universal 37pc Service Manual

Safety Conventions Used in the Manual

Specific safety information is listed throughout this manual in the form of
Warning and Caution statements. Pay close attention to these statements
as they contain important information on avoiding potential hazards to
yourself or to the equipment.

Warning Statements

• are used to indicate hazards or unsafe practices which could result in
personal injury or death

• have a triangular symbol with an exclamation point to the immediate
left of text

• are preceded by the word “Warning”

• are always found before the step or piece of information to which they
refer

For Example:

Warning

The next step, “Cleaning the Printhead,” must be performed by
service or maintenance personnel who have the proper training and
experience to work on this equipment and are aware of hazards to
which they are exposed.

Caution Statements

• are used to indicate hazards or unsafe practices which could result in
product or property damage

• have a triangular symbol with an exclamation point to the immediate
left of text

• are always preceded by the word “Caution”

• are always found before the step or piece of information to which they
refer

2-2 Safety Conventions Used in the Manual

Rev AB

Universal 37pc Service Manual

For Example:

Caution

Never turn the printer Off by switching the AC power switch to the
OFF (O) position before pressing the STOP/START key and
allowing the printer to complete the two-minute shutdown
sequence. Failure to follow this procedure properly prevents the
printer from drawing the ink in the ink return line back into the
reservoir. This may cause the ink to dry in the line, resulting in
problems when you turn the printer back On.

Rev AB Safety Conventions Used in the Manual 2-3

Universal 37pc Service Manual

Safety Guidelines for Items in the Spare Parts Kit

Reduran® Special Hand Cleaner and Latex gloves are included as part of
the printer Spare Parts Kit. The following safety precautions must be
observed when using these items.

Guidelines for using Reduran® Special

• Reduran Special is not to be used in place of a PPE (Personal
Protective Equipment), but is only to be used in cases of accidental
skin contact with dried ink.

• Keep Reduran Special away from items such as clothing. It will de­colorize clothing and other materials.

Guidelines for using Latex gloves

• Latex gloves should not be used if the user is allergic to latex.

• Latex gloves should only be used in operations where the only
concern is exposure to ink which may stain skin.

• For cases involving skin contact with VIDEOJET® fluids or organic
solvents, a more durable glove such as Butyl rubber gloves are
recommended. Latex gloves are not designed for use with organic
solvents.

• Disposable nitrile or latex gloves may be suitable for brief contact,
such as splash protection, only when the bulk of a more durable glove
would interfere with maintenance operations.

• Do not re-use disposable gloves.

• Do not use disposable gloves in operations which may tear or
puncture the glove.

2-4 Safety Guidelines for Items in the Spare Parts Kit

Rev AB

Equipment Safety Guidelines

Introduction

This section contains important safety guidelines pertaining to the
operation and handling of the printer and associated equipment.

Warning

Always observe the following safety guidelines when operating and
handling the printer and associated equipment.

Comply with Electrical Codes

All electrical wiring and connections must comply with
applicable local codes. Consult the appropriate
regulatory agency for further information.

Universal 37pc Service Manual

Avoid Breathing Exhaust Vapors

During operation, the printer exhausts material through
the printer exhaust tube. This material may be
flammable and present a health hazard. For these
reasons, do not allow the exhaust to be confined to an
area that does not have proper ventilation or be located
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.
If any of these circumstances apply, it may be necessary to vent the printer
exhaust to outside air. Consult the appropriate regulatory agency
concerning emission permitting and venting system requirements before
venting printer exhaust to outside air.

Note: A Vapor Exhaust Ducting Kit is available through Videojet.

Rev AB Equipment Safety Guidelines 2-5

Universal 37pc Service Manual

Do Not Remove Warning Labels

Do not, under any circumstances, remove or obstruct
any warning, caution, or instruction labels in the
printer.

Placement of the Printer

Do not place the printer in a hazardous location. Hazardous locations, as
defined in the United States, are those areas that may contain hazardous
materials in sufficient quantity to create an explosion. These are defined in
Article 500 of the National Electrical Code

Outside the United States, you must ensure compliance with all local
regulations regarding equipment placement in potentially hazardous
locations.

ANSI/NFPA 70–1993.

Warning

Do not place the printer in a hazardous location

Wall Mounting the Printer

To maintain regulatory approval for a wall-mounted printer, the wall
mounting structure and the customer-supplied hardware must be capable
of supporting four times the total weight of the printer and the wall
mounting structure.

Mounting the Printhead Stand

To maintain regulatory approval, the printhead stand must be bolted to
the floor, conveyor, or other stable foundation when installed.

Using Printer Accessories

To maintain regulatory approval for the printer, you must use only
Videojet approved accessories when attaching any device to the
equipment.

2-6 Placement of the Printer

Rev AB

Ink Safety Guidelines

Introduction

This section contains important safety guidelines pertaining to the use and
handling of printer supplies (inks, make-up fluids, and cleaning
solutions).

Warning

Always observe the following safety guidelines when using or
handling inks, make-up fluids, and cleaning solutions.
For continued protection against possible fire hazard, use only
Videojet supplies with a flash point no lower than -22°C (-8°F) and
boiling point no lower than 56°C (133°F).

Universal 37pc Service Manual

Figure 2-1. Ink, Make-up Fluid, and Cleaning Solution

No Smoking

Do not smoke when near the printer or printhead.
Explosion or fire may result if the printer exhaust fumes
are subjected to an ignition source.

Rev AB Ink Safety Guidelines 2-7

Universal 37pc Service Manual

Wear Safety Glasses

Avoid Skin Contact

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 physician
immediately.

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
physician if irritation persists.

Avoid Breathing in Vapors

Avoid prolonged exposure to vapors. If respiratory
protection is needed, a cartridge organic respirator is
required.

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.

2-8 Ink Safety Guidelines

Rev AB

Universal 37pc Service Manual

Read the Material Safety Data Sheets (MSDS)

Read and understand the Material Safety Data Sheet
(MSDS) before using any ink, make-up fluid, or cleaning
solution. An MSDS exists for each type of ink, make-up
fluid, and cleaning solution; the appropriate sheet or
sheets are supplied with the product when shipped

Make certain to retain all MSDSs for future reference in
the event you should need to see a physician regarding an ink-related
accident. Additional copies of MSDSs are available upon request and can
be obtained by contacting the Videojet Customer Service Department at
800–843–3610. Outside the U.S., customers should contact a subsidiary
Videojet office or their local Videojet distributor.

Electronic copies of MSDSs can be found in the support section of the
Videojet web site.

Store Inks Properly

Certain inks, make-up fluids, and cleaning solutions are
flammable and must be stored appropriately. Storage
must comply with local regulations; contact the
appropriate regulatory agency for further information.
The label on the bottle or the Material Safety Data Sheet
(MSDS) will indicate if a particular fluid is flammable.

Warning

The waste container or service tray used to ground the printhead
must be made of metal. Use of a non-metallic waste container/
service tray may result in the possibility of electrostatic discharge.

Ground the Printhead to the Service Tray

To avoid the possibility of electrostatic discharge when test printing or
discharging fluid from the printhead into the service tray. Ensure all
service tray and printhead fasteners are properly tightened. (refer
Figure 2-2). This is necessary to avoid the possibility of electrostatic
discharge that may result in fire.

Videojet highly recommends the use of the Videojet approved service
tray. Use of a non-metallic container is not recommended because it
cannot be grounded properly. Refer to Figure 2-2 for the recommended
grounding method.

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Universal 37pc Service Manual

Note: The service tray is available through Videojet. Refer to the Illustrated Parts
Breakdown for further information.

Figure 2-2. Grounding the Service Tray

2-10 Ink Safety Guidelines

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Medical Emergencies

Introduction

This section contains important medical information should an accident
occur.

Warning

In the event of a medical emergency, contact a physician
immediately.

Emergencies Involving Printer Fluids

If the incident involves an ink, make-up fluid, or cleaning solution, bring
the bottle and/or Material Safety Data Sheet (MSDS) with you to the
physician’s office. These items contain important information that the
physician may require in order to provide treatment.

Universal 37pc Service Manual

Rocky Mountain Poison Control Center

All of Videojet inks, make-up fluids, and cleaning solutions are also
registered with the Rocky Mountain Poison Control Center, located in the
United States. If the bottle or MSDS cannot be located, the physician can
contact the Rocky Mountain Poison Control Center to obtain the
information required.

Rocky Mountain Poison Control Center
[phone]

Note: Persons outside the United States requiring medical attention can have a
physician contact the Rocky Mountain Poison Control Center in the United
States or a poison control center or hospital in their own area.

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2-12 Medical Emergencies

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Installation

In this chapter you will find:

• how to install the printer and prepare it for operation

• how to connect AC power and compressed air to the printer

• how to run drain, refresh and prime procedures

• how to set up and adjust the printer for operation

3

Introduction

Inspection

If the printer has been removed from its shipping carton for the first time,
check the unit for damage. Examine the control unit, umbilical, and
printhead closely. The printer is packed carefully at the manufacturing
facility. If any damage is noted, damage claims should be filed with the
carrier.

Chapter Content

The procedures in this chapter show you how to take a printer from the
shipping carton, and install it so that the printer will print a bar code when
properly interfaced to a mail sorting system. If the printer has already
been installed, you can use the individual sections in this chapter as
reference.

Caution

It is strongly recommended that a Videojet Technologies service
engineer install the printer. This will ensure that the printer has been
installed properly, and that the system parameters have been set to
match your line application. Contact Videojet Technologies or your
local Videojet subsidiary or distributor for further information.

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Universal 37pc Service Manual

Setting Up the Printer

Tools/Supplies

The following tools/supplies are required to complete the procedures in
this section:

• small flat blade screwdriver

• Phillips screwdriver

• adjustable wrench, small

•printer stand*

• Videojet service tray*

• air input filter kit*

• factory-supplied compressed air source, or optional portable air
compressor*

• air dryer unit. (only required if using the portable air compressor or if
factory compressed air is high in water content).

• high voltage gap tool* (included in configuration kit)

• flow meter* (included in configuration kit)

• appropriate-sized tubing (enough length to route from air source to
air input filter kit, and quick disconnect fitting for the air hose. Five
feet/1.52 m of tubing are included with the printer)

• appropriate electrical source – refer to Appendix A for electrical
requirements

Items denoted by an asterisk (*) are Videojet supplies or accessories which
are available from Videojet Technologies Items can be ordered by
referring to the Accessories and Spare Parts chapter (Chapter 3) of the
Illustrated Parts Breakdown manual.

In addition, whenever Videojet accessories or spare parts are specified as
available from Videojet Technologies throughout this chapter, refer to the
Accessories and Spare Parts chapter (Chapter 3) of the Illustrated Parts
Breakdown manual for specific instructions for placing an order with
Videojet Technologies.

3-2 Setting Up the Printer

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Mount Printer to Stand

Caution

If the printer is to be located on the floor, use of the Videojet stand
(P/N 378415) is required. Failure to attach this stand to printers
placed on the floor will void the Underwriter’s Laboratories Inc.
Listing of this product.

Do not position printer upside down at any time. Tilt or hold the printer
upright as the printer stand is attached.

Make certain the printer is in a well-ventilated area. If it is not, use the
vapor and exhaust ducting kit (P/N 370089) available from Videojet
Technologies.

Universal 37pc Service Manual

Determine Printer Proximity to Conveyor

Position the printer near the mail sorting system, making certain to
consider the following guidelines:

• The area selected should be free of vibration.

• The umbilical is 10 feet in length. Make certain the printhead will
reach its final location at the conveyor.

• Allow for some slack when routing the umbilical to the products to be
printed upon. Do not kink or stretch the umbilical, or allow any
portion of it to be located near sharp objects or areas of heavy traffic.

• The I/O cables must reach the mating connectors on the rear of the
printer. Ensure the cabling is dressed properly and clear of moving
parts.

• When selecting the location, the AC power source and compressed air
source connections (unless you are using a portable air compressor)
must be accessible.

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Universal 37pc Service Manual

Connect Printer to Power Source

The printer contains a universal power supply that operates from 90 to 264
VAC without adjustment. The printer comes equipped with a Power cord
with a 120 V plug (North America).

1 If your printer requires 120 V plug (North America), plug the power

cord into the appropriate electrical source. Continue to Connect
Compressed Air on page 3-8

2 If your printer requires 230 V plug or International plug, complete the

steps in the next section Printers Requiring Plug Replacement.

Printers Requiring Plug Replacement

The 120 VAC printer is equipped with a NEMA 5-15P plug. If you want to
replace this plug, complete the steps below.

Caution

To maintain safety certification, only the plug should be replaced.
The original power cord should be used.

1 Cut off the attached plug from the end of the line cord.

2 Replace the plug with a compatible plug which will work with the

available power outlet receptacle.

3 Follow the wiring instructions included with the purchased plug.

Make certain that the green/yellow ground wire is connected to the
plug's grounding pin.

4 After the new plug is attached, plug the power cord into the

appropriate electronic source.

5 Continue to Connect Compressed Air.

3-4 Setting Up the Printer

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Connect Compressed Air

When connecting compressed air to the printer, the use of an air line filter
and regulator is mandatory. This is necessary to ensure the quality of the
air supplied to the printer. An air dryer may also be needed. An air input
filter kit can be purchased separately through Videojet Technologies.

If a non-Videojet filter/regulator package is used, a reducer fitting (P/N

208644) is available from Videojet Technologies . This 5/16-inch to 1/4­inch reducer union is used to adapt the 1/4 inch outer diameter (O.D.)
input air tube to the 8 mm metric size.

If a compressed air source is not available or within range of the printer,
you can use a portable air compressor to supply compressed air to the
printer. An air compressor is available through Videojet Technologies.

Air Requirements

Before connecting compressed air to the printer, make certain the air
source to be used is clean, dry, and free of contaminants, oil, and water,
and the following air requirements are met:

Universal 37pc Service Manual

Input Pressure: 70-100 psi (4.83-6.89 bar). However, the

recommended setting is between 70 and 80 psi.

Consumption: 0.70 SCFM (maximum)

0.36 SCFM (typical)

Quality: Instrument quality required (filtered to 0.03

micron and no more than 1 PPM oil content).
The air quality can be achieved with
commercially available twin package filters
consisting of a pre-filter, followed by a sub
micron coalescing type filter.

Pressure Dew Point: Less than 40

° F at 80 psi (4.44° C at 5.52 bar)

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Universal 37pc Service Manual

Procedure

Complete the following steps to connect compressed air to the printer.

1 Retrieve the coil of unconnected tubing from the ink compartment.

Figure 3-1. Retrieving the air tube coil

2 The ends of the coil are joined by a brass fitting. Disconnect one end of

3-6 Setting Up the Printer

the coil from this fitting.

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Universal 37pc Service Manual

3 Feed the free end of the coil through the air tube hole in the back of the

cabinet.

Figure 3-2. Sliding the air tube into the printer

Note: A small amount of alcohol applied to the outside of the tube will make
it easier to slide the tube through the hole.

4 Once the end of the air tube appears on the inside of the printer

cabinet, continue pulling the tube through until approximately 30
inches (76 cm) of tube are inside the cabinet.

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Universal 37pc Service Manual

5 Route the air tube behind the other tubes on the inside of the cabinet

door as shown in Figure 3-3. Connect the end of the tube to the elbow
fitting on the bottom of the air manifold.

Figure 3-3. Connecting the input air tube to the air manifold

6 Mount the air pressure regulator in a suitable location.

7 Trim the unconnected end of the input air tube to the length required

3-8 Setting Up the Printer

Input air tube

Note: It is not necessary to mount the regulator on the printer itself.
However, the air pressure regulator that Videojet sells for use with this
printer may be mounted on the printer as shown in Figure 3-4.

to reach the air pressure regulator. If necessary, an additional length
of tubing may be attached using the brass fitting that joined the ends
of the tube coil.

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Universal 37pc Service Manual

8 Attach the printer’s input air tube to the output of the air pressure

regulator and adjust the air flow to 70 psi. If using a third party air
regulator, consult the instructions that came with the regulator being
used. If using an air regulator provided by Videojet, follow the steps
below:

a. Connect the compressed air source to the input of the air regulator

assembly.

Compressed

Air Source

Figure 3-4. Input Air Connection to Air Pressure Regulator

b. Connect the output of the air pressure regulator to the printer’s

input air tube.

c. Adjust the air pressure regulator until 70 psi is shown on the gauge

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Universal 37pc Service Manual

Turn Printer On

1 Press the AC power switch to the ON (|) position to turn power to the

printer On (refer to Figure 3-5). The light and the display screen on the
keyboard will illuminate indicating that power is being supplied to
the printer.

Figure 3-5. Location of AC power switch

2 Continue to “Select POSTNET or I.D. Tag Use.”

3-10 Setting Up the Printer

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Select POSTNET or I.D. Tag Use

A Universal 37pc in parallel mode can function as either POSTNET or I.D.
tag printer. However, the bar code type must be selected the first time the
printer is powered on.

Note: If the printer will NEVER use parallel mode, you must still follow this
procedure in order to ensure that this screen does not reappear the next time the
printer is switched on. However, which setting you select is irrelevant.

Complete these steps to set the bar code type for parallel print mode

1 The first time a new printer is turned on, the screen shown below

appears.

SELECT BAR CODE TYPE

FOR PARALLEL MODE

POSTNET NO

Universal 37pc Service Manual

BAR NO-BAR YES

2 Press the Yes/No key on the keyboard to select <YES> for one of the

two options (<POSTNET> or <BAR-NO BAR>).

3 Press the Save key to save the option selected.

Note: Bar code type can only be selected upon initial setup. If the printer type
select screen does not appear at initial start-up, then the printer has already
been configured for a bar code type.

To change the bar code type after installation, the control board must be
manually reset. See “Changing the Bar Code Type for Parallel Mode” on
page 7-60 for instructions on how to reset the control board.

4 Once the bar code type is selected and saved, the printer displays the

message “INITIALIZATION COMPLETE.”

5 Press the Standby key to complete the printer selection and

initialization procedure.

6 Continue to “Verify Preliminary Vacuum Setting.”

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Universal 37pc Service Manual

Verify Preliminary Vacuum Setting

Vacuum must be present in the system to complete the installation
process. However, the final vacuum setting cannot be set until after the
printer has been loaded with ink. Complete these steps to confirm there is
enough vacuum to complete the installation process.

1 Press the Start/Stop key to start up the printhead. This is required to

provide air to the system to adjust the vacuum. Wait until the vacuum
gauge reaches its final setting (about 5 seconds). See Figure 3-7 for the
location of the Vacuum gauge.

Note: Check vacuum quickly. If a printer fault occurs, reset the alert and
continue with the procedure.

2 If the vacuum gauge reads between 9 and 13 inches of vacuum, press

the Start/Stop key to shut down the printhead, and skip the rest of
this procedure, and then continue with the next procedure Checking
the Pressure Tank Full Switch. If the vacuum does not read between 9
and 13 inches of vacuum, continue with step 3.

3 The vacuum adjusting needle valve is located inside the main door on

the left side of the air manifold (refer to Figure 3-6). To adjust the
vacuum, unlock the collar, and turn the small knob while watching
the vacuum gauge. Turn the needle valve counterclockwise to
increase vacuum and clockwise to decrease vacuum.

Figure 3-6. Adjusting the Vacuum

3-12 Setting Up the Printer

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Universal 37pc Service Manual

4 After vacuum is set to between 9 and 13 inches, lock the collar and

recheck the vacuum setting.

Figure 3-7. Reading the Vacuum Gauge

Note: A Trap Bottle accessory may be installed when using water based inks
due to the potential for foaming to occur in the ink reservoir. The Trap Bottle
accessory is available from Videojet Technologies.

5 Continue to Checking the Pressure Tank Full (PTFL) Switch.

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Universal 37pc Service Manual

Checking the Pressure Tank Full (PTFL) Switch

Before loading the printer with fluid for the first time, check to make
certain the pressure tank full (PTFL) switch is operating properly.

Caution

If the PTFL switch is faulty, the pressure tank will overfill when
loading fluid into the printer. This may damage many internal
printer components. DO NOT load fluid into the printer until you
have verified that the PTFL switch works.

Procedure

Complete the following steps to check the pressure tank full (PTFL) switch
in the printer:

Warning

Make certain that the air to the printer is disconnected before
starting this procedure. This is a preventive measure in case you
accidentally press an active key while performing this procedure.

1 Disconnect the air supply from the printer.

2 Disconnect the ink output line fitting and remove the pressure tank

fitting at the bottom of the ink module (refer to Figure 3-8). The
pressure tank float will fall out of the module to the bottom of the
fluid pan.

3 Use a 5/16” allen wrench to loosen the door latch screw on the front

right side of the printer fluid pan. Open the cabinet door to gain access
to the printer's electronics section.

Note: The LED bank is located on the main PCB in the electronics section of
the printer (refer to Figure 3-9).

3-14 Setting Up the Printer

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Universal 37pc Service Manual

Pressure Tank

Fitting

Ink Output

Line Fitting

Figure 3-8. Checking the PTFL Switch Connection

Caution

Do not use a hard or abrasive object to push the float into the
pressure tank as it may scratch or damage the wall causing the float
to hang up or get stuck in the pressure tank.

4 Use a soft, thin object (such as a piece of plastic tubing) to push the

float up into the pressure tank. Observe the PTLW LED on the LED
bank to verify that the PTLW LED is lit and turns off as the float is
pushed upwards.

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Universal 37pc Service Manual

Figure 3-9. LED Panel

5 Continue to push the float all the way up into the pressure tank until it

stops and observe the PTFL LED on the LED bank at the same time.

6 If the PTFL LED did light up, the pressure tank full (PTFL) switch is

operating properly. If the PTFL LED did not light, check the PTFL
switch connection located on the solenoid bank assembly. The switch
connection is #5 and is color-coded orange (refer to Figure 3-10). If the
PTFL LED still does not light when pushing the float upward, replace
the pressure tank full switch and check the PTFL LED again.

7 Install the pressure tank fitting and the ink output line fitting back

into the ink module port (refer to Figure 3-8).

Note: Verify that both ferrules are still in place on the tube. Do not over
tighten!

3-16 Setting Up the Printer

Rev AB

8 Continue to Ink System Service Preparation.

Universal 37pc Service Manual

Figure 3-10. Checking the PTFL Switch

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Universal 37pc Service Manual

External Data Connections

This section describes the external data connections for the Universal 37pc
printer. The six data connectors, numbered J1 through J6 are located on
the rear of the printer cabinet (refer to Figure 3-11).

Figure 3-11. Printer Connectors

Output Power

The total current available at J1, J2, J3 and J6 is as follows:

• 24V DC at 225ma Max

• 12V DC at 250ma Max

• 5V DC at 150ma Max

3-18 External Data Connections

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Universal 37pc Service Manual

J1, J2 and J3 — Product Detect / Encoder / Alert Light

These three ports are provided for the connection of product detectors,
shaft encoders and alert lights. The design allows all three devices to be
connected to the same port or each device to be connected to a separate
port.

Pinouts for connectors J1, J2 and J3
(external view)

J1, J2 and J3 (DB9 Male) Pin Description

Pin Signal Name Description

1 PROD_IN Product detect input. Signals the printer of a product

detect when connected to GND. An open collector,
drain, etc. may be used to accomplish this. The open
collector should be rated for a minimum of 15 V and a
maximum of 0.4 Vce (sat) @ 10 ma. The minimum
pulse width when connected to GND or not con-

nected to GND should be 65
tact type relays should not be used.

µsec. Mechanical con-

The printer may be configured to trigger on the lead­ing edge or on the trailing edge of the pulse. See
“Selecting the product detector edge trigger” on
page 3-20.

2 ENC_IN Encoder input. Signals the printer of an encoder

pulse by connecting to GND and then releasing. An
open collector, drain, etc. may be used to accomplish
this. The open collector should rated for a minimum
of 15 V and a maximum of 0.4 Vce (sat) @ 10 ma.
The internal circuitry is capable of responding to a 1
MHz clock, however, this would not be practical
because of transmission line effects. The encoder
pulses are divided down internally. See Chapter 9,
“Serial Interface” for more information.

3 RED Red Alert Light. This output signals an attached alert

light to switch the red lamp on or off. The lamp should
be on when the signal is low, off when the signal is
high. Output is open collector rated at 24 VDC Max
and 75ma Max.

4 YELLOW Yellow Alert Light. This output signals an attached

alert light to switch the yellow lamp on or off. The
lamp should be on when the signal is low, off when
the signal is high. Output is open collector rated at 24
VDC Max and 75ma Max.

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Universal 37pc Service Manual

J1, J2 and J3 (DB9 Male) Pin Description

Pin Signal Name Description

5 GREEN Green Alert Light. This output signals an attached

6+24V DC

7+12V DC

8+5V DC

9 GND Ground

Selecting the product detector edge trigger

1 With the printer in the Standby mode, press the F1 key to select

<SETUP/STATUS> and then the F2 key to select <SETUP>. The
screen shown below should now be displayed.

alert light to switch the green lamp on or off. The lamp
should be on when the signal is low, off when the sig­nal is high. Output is open collector rated at 24 VDC
Max and 75ma Max.

BAUD RATE ⇐ ⇒ 19200

DETECT POS EDGE NO

2 Press the down arrow key once to place the cursor in the <DETECT

POS EDGE> field.

3 Press the YES/NO key to select whether to trigger the printer with the

positive or negative edge of the product detector signal.

3-20 External Data Connections

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J4 — RS-232 Serial Interface

This standard DB9 RS-232 serial interface is used to connect the printer to
a host computer that will direct printing operations. See Chapter 9, “Serial
Interface” for more in depth information on this interface.

J4 (DB9 Female) Pin Description

Pin Signal Name Description

1 - No connection

2 Tx Transmit data from the printer

3 Rx Receive data from the computer

Universal 37pc Service Manual

Pinouts for connector J4
(external view)

4 DSR Data Set Ready

5 GND Ground

6 DTR Data Terminal Ready

7 CTS Clear To Send

8 RTS Request To Send

9

Note: Although the printer supports all of the signals in the table above, it is
possible to form a connection with only the signals on pins 2, 3 and 5
implemented on the host computer. However, if the host computer does not
provide DSR and DTR signalling, it is necessary to form a loopback connection
between pins 4 and 6 of the printer’s serial interface.

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Universal 37pc Service Manual

Setting the baud rate

The Baud Rate is the speed at which data is received and transmitted. Use
the following procedure to set the Baud Rate.

1 With the printer in the Standby mode, press the F1 key to select

<SETUP/STATUS> and then the F2 key to select <SETUP>.The screen
below appears.

BAUD RATE ⇐ ⇒ 19200

DETECT POS EDGE NO

2 View the current setting in the <BAUD RATE> field. If desired, use

the left and right arrow keys to change the setting. (Settings: 1200,
2400, 4800, 9600, 19200, 38400, 57600, and 115200.)

Note: The baud rate must be high enough so that data is supplied to the
printer faster than the printer prints the messages. Otherwise, the host-sent
data will not arrive in time to be printed.

3-22 External Data Connections

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J5 — Parallel Interface

Connects the printer to a host computer that will direct printing
operations. See Chapter 10, “Parallel Interface” for an in depth description
of this connector’s functions.

J5 (DB15 HD Female) Pin Description

Pin Signal Name Description

1 Data 3 Data lines are used to transfer print data to

2Data 6

Universal 37pc Service Manual

Pinouts for connector J5
(external view)

the printer.

3 Data Strobe The printer reads the data contained on

Data1 – Data7 and starts the print cycle
based on the data received when the data
strobe line is pulsed.

4 Data Strobe Flag Set by DATA STROBE pulse. DATA

STROBE FLAG is cleared when data is
read by the printer.

5Ground

6Data 1

7Data 4

8Data 7

9 Data Request High indicates printer is ready to receive

data, on the DATA lines. Low indicates that
it is not.

10 - No Connection

11 Data 2

12 Data 5

13 Data 8

14 Printer Ready Low when printer is ready to print data.

High when a printer fault occurs.

15 - No Connection

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Universal 37pc Service Manual

J6 — I/O

This connector contains auxiliary inputs and outputs that are not included
in the primary interfaces. All inputs can be driven using an open collector,
drain, etc. configuration. The open collector should be rated for a
minimum of 15V and a maximum of V
outputs are open collector rated at 24 VDC Max and 10ma Max.

ce (SAT) of 0.4V @ 10ma. All

Pinouts for connector J6
(external view)

J6 (DB25 Male) Pin Description

Pin Signal Name Description

1 SHUT_DWN Remote Shutdown. The purpose of this active low

input is to allow an external switch to be con­nected to the printer via an external cable which
will allow an operator to shut down the printhead
remotely. Once the operator activates this switch,
the printer reacts exactly the same as it would had
it received a serial port Printer Control command
(see Chapter 9, “Serial Interface”) to shut the print­head down. This switch input has a 25msec
debounce incorporated.

2 PRINT_INHIBIT Print Inhibit. The purpose of this active low input is

to prevent the printer from printing when a product
detect occurs. While this input is held low, any
product detect signals are ignored regardless of
the active printer mode. This function is available
only when the printer is operating in serial mode.

3 REV_CHR Print Direction. The purpose of this active low

input is to reverse the orientation of alpha charac­ters. While this input is held low, every stroke of
every alpha character will be printed in reverse.
This function is available only when the printer is
operating in parallel mode.

4 Input 4 (Reserved for future expansion)

3-24 External Data Connections

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Universal 37pc Service Manual

J6 (DB25 Male) Pin Description

Pin Signal Name Description

5 FLUID_LOW Fluid Low Warning. This active high output will

indicate when the fluid in either the ink or makeup
bottle is low. After 30 minutes of a fluids low warn­ing, an ink out fault will occur and printing stops.

6PRINTER_NOT_

READY

Printer Not Ready. This active high output indi­cates whether or not the printer is ready to print
(while in the Print Mode with no existing faults.).

7 Output 3 (Reserved for future expansion)

8 Output 4 (Reserved for future expansion)

9 Output 5 (Reserved for future expansion)

10 Output 6 (Reserved for future expansion)

11 Output 7 (Reserved for future expansion)

12 Output 8 (Reserved for future expansion)

13 +24 VDC

14 Ground

15 +5 VDC

16 Ground

17 +5 VDC

18 Ground

19 +12 VDC

20 Ground

21 +12 VDC

22 Ground

23 +24 VDC

24 Ground

25 +24 VDC

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Universal 37pc Service Manual

Install Printer

After the printer compressed air and AC power is connected, the printer is
ready to be loaded with ink and prepared for operation.

Shown below are the steps necessary to load the printer with ink and
prepare it for operation. To complete the necessary procedures, it is
important to review and understand the keyboard operation section of the
service manual located in Chapter 7.

Ink loading procedures should be completed in the order shown below as
one continuous task, which will take approximately two hours.

1 Ink System Service Preparation

2 Prime Printer with Make-up Fluid (AUTO PRIME)

3 Drain Make-up Fluid from Printer (AUTO DRAIN)

4 Prime Printer with Ink (AUTO PRIME)

5 Complete an Auto Refresh (AUTO REFRESH)

6 Calibrate the Ink Stream

7 Conduct a Test Print

8 Set the Fluids Low Adjustment

9 Adjust the Positive Air Flow

10 Adjust the High Voltage Plate Gap

11 Adjust the Bar Height

3-26 Install Printer

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Ink System Service Preparation

Ground the Service Tray

When working with flammable fluids (make-up or ink) there exists the
possibility of fire due to static discharge that may ignite the fluids. To
avoid any possibility of static discharge, the service tray used to collect
fluid must be properly grounded.

Complete these steps to ground the service tray to the printer.

1 Ensure the printer is connected to an earth ground through the AC

power cord.

2 Use a screwdriver to loosen the screw on the printhead, then slide the

printhead out of the cover (refer to Figure 3-12).

Universal 37pc Service Manual

Figure 3-12. Removing the Printhead Cover

3 Always use a metal grounded tray to collect flammable fluids. A

metal service tray is available through Videojet Technologies. Place
the service tray on a flat surface such as the floor. Then, position the
printhead in the holder as shown in Figure 3-13.

4 Attach the service tray grounding clip to either the printhead screw as

shown or to the metal wire mesh around the base of the printhead
umbilical.

5 Remove the internal cover over the ink valve.

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Universal 37pc Service Manual

6 Install the printhead chassis into the holder on the service tray as

shown.

Figure 3-13. Grounding the Service Tray

Install Bleed Tube

A bleed tube must be attached to the ink valve bleed port when
performing certain ink maintenance procedure.

Attach the bleed tube to the appropriate port, then loosen the bleed screw
to allow the fluids to drip from the bleed tube directly into the stainless
steel service tray. This prevents fluids from entering the nozzle, which
may damage the nozzle if dust or debris is present in the empty ink
system.

Tools/Supplies Required

You will need the following items (included with the printer) to attach the
bleed tube to the ink valve:

• Bleed tube (provided with printer)

• 0.050 allen wrench

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Universal 37pc Service Manual

Procedure

Complete these steps to attach a bleed tube.

1 Locate the bleed port on the ink valve. Attach the bleed tube securely

to the port and route the tube through the hole in the printhead face
plate (refer to Figure 3-14). Make sure the tube is directed into the
grounded metal service tray.

2 Connect the allen wrench to the matching set screw. During the ink

maintenance procedures, you will turn the set screw to drain the
fluids through the bleed port.

Allen
Wrench

Bleed

Tub e

Ink Valve

Bleed Port

Figure 3-14. Attaching the Bleed Tube

3 Continue to Prime Printer with Make-up Fluid.

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Universal 37pc Service Manual

Prime Printer with Make-up Fluid (AUTO PRIME)

Priming the printer with make-up fluid flushes an empty ink system and
prepares it for loading with ink. Complete these steps to prime the printer
with make-up fluid.

1 Remove the two empty bottles in the fluid pan portion of the printer.

2 Install two bottles of the correct type of make-up fluid into the fluid

pan (refer to Figure 3-15).

Figure 3-15. Installing the Make-up Fluid Bottles

3 Place the AC power switch to the On (I) position.

3-30 Prime Printer with Make-up Fluid (AUTO PRIME)

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Universal 37pc Service Manual

4 Press the Service key to enter the Service mode.

37 PC/UI ID#

PRINT INK

HEAD SYSTEM

5 Press the F2 key to select <INK SYSTEM>.

INK SYSTEM

INK INK

CONTROL UPKEEP

6 Press the F2 key to select <INK UPKEEP>.

7 Press the Down Arrow key twice to move the cursor to the <YES/

NO> field next to <AUTO PRIME>.

SET PRESSURE NO

AUTO REFRESH NO

AUTO PRIME NO

MORE OPTIONS NO

8 Press the Yes/No key to select <YES>. The message “FOR PRIMING

SYSTEM WITH NEW FLUIDS” appears on the display screen.

FOR PRIMING SYSTEM

WITH NEW FLUIDS.

START PRIMING NO

9 With the cursor in the <YES/NO> field next to <START PRIMING>,

press the Yes/No key to start priming the printer. The message
“AUTO PRIME RUNNING” appears on the display screen.

Rev AB Prime Printer with Make-up Fluid (AUTO PRIME) 3-31

Universal 37pc Service Manual

10 Wait two minutes and confirm that the ink pressure regulator is set to

5 psi (refer to Figure 3-14). If it does not read 5 psi, adjust the ink
pressure regulator until the gauge reads 5 psi.

Note: It will take two or three minutes before the printer sends pressure to
the ink pressure gauge once AUTO PRIME is started. The NVAL LED
indicates pressure will be available to the gauge.

Ink Pressure

Gauge

Ink Pressure

Regulator

Figure 3-16. Adjusting the Ink Pressure

11 Open the bleed valve using the 0.050” allen wrench one full turn and

wait until fluid drips from the bleed tube.

12 Adjust the bleed valve for a fluid flow rate of about 2 drips per

second.

3-32 Prime Printer with Make-up Fluid (AUTO PRIME)

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Universal 37pc Service Manual

13 Note: If the fluid drip rate is not set correctly, the printer may display an

ALERT and priming will stop. If this occurs, reset the alert and restart the
AUTO PRIME procedure. A “FILL TIME TOO LONG” alert indicates a
too fast drip rate. An “EMPTY TIME TOO LONG” alert indicates a too
slow drip rate.

14 When the message “AUTO PRIME COMPLETE” appears on the

display screen, the make-up priming procedure is complete.

15 Close the bleed valve but don’t remove the allen wrench from the set

screw.

16 Press the Exit key.

17 Continue to Drain Make-Up Fluid From Printer.

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Universal 37pc Service Manual

Drain Make-up Fluid From Printer (AUTO DRAIN)

The make-up must be completely drained from the ink system before it
can be loaded with ink. Complete these steps to drain the make-up fluid
from the printer.

1 Press the Down Arrow key three times to move the cursor to the

<YES/NO> field next to <MORE OPTIONS>.

SET PRESSURE NO

AUTO REFRESH NO

AUTO PRIME NO

MORE OPTIONS NO

2 Press the Yes/No key to select <YES>.

AUTO DRAIN NO

3 Press the Yes/No key to select <YES>. The message “FOR

DRAINING FLUIDS FROM THE SYSTEM” appears on the display
screen.

FOR DRAINING FLUIDS

FROM THE SYSTEM.

START DRAINING NO

4 With the cursor in the <YES/NO> field next to <START DRAINING>,

press the Yes/No key to begin draining the printer. The message
“AUTO DRAIN RUNNING” appears on the display screen.

5 Open the bleed valve using the 0.050” allen wrench one full turn.

6 When the “AUTO DRAIN COMPLETE” message appears on the

display screen, the make-up draining procedure is complete.

7 Press the Exit key.

3-34 Drain Make-up Fluid From Printer (AUTO DRAIN)

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Universal 37pc Service Manual

8 Close the bleed valve, but don’t remove the allen wrench from the set

screw.

9 Continue to Prime Printer with Ink.

Rev AB Drain Make-up Fluid From Printer (AUTO DRAIN) 3-35

Universal 37pc Service Manual

Prime Printer with Ink (AUTO PRIME)

Complete the following steps to load (prime) the printer with ink and
prepare it for operation.

1 Remove the previously installed bottle of make-up fluid on the right

side of the fluid pan.

2 Install a new bottle of the correct type of ink into the right side of the

fluid pan as shown in Figure 3-17. (The bottle filter is marked with an
ink bottle label for reference).

Figure 3-17. Installing the Ink Bottle

3-36 Prime Printer with Ink (AUTO PRIME)

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Universal 37pc Service Manual

3 Press the Down Arrow key twice to move the cursor to the <YES/

NO> field next to <AUTO PRIME>.

SET PRESSURE NO

AUTO REFRESH NO

AUTO PRIME NO

MORE OPTIONS

4 Press the Yes/No key to select <YES>. The message “FOR PRIMING

SYSTEM WITH NEW FLUIDS.” appears on the display screen.

FOR PRIMING SYSTEM

WITH NEW FLUIDS.

START PRIMING NO

5 With the cursor in the <YES/NO> field next to <START PRIMING>,

press the Yes/No key to begin priming the printer. The message
“AUTO PRIME RUNNING” appears on the display screen.

6 Ensure the bleed valve is still open one full turn Wait until fluid drips

from the bleed tube (about 2 to 3 minutes).

7 View the ink pressure regulator to confirm that the ink pressure

regulator is still set to 5 psi (refer to Figure 3-16 on page 3-32). If it is
not, adjust the ink pressure regulator to 5 psi.

8 As ink is being expelled from the bleed tube adjust the bleed valve for

a fluid flow rate of about 2 drips per second.

Note: If the fluid drip rate is not set correctly, the printer may display an
ALERT and priming will stop. If this occurs, reset the alert and restart the
AUTO PRIME procedure. A “FILL TIME TOO LONG” alert indicates a
too fast drip rate. An “EMPTY TIME TOO LONG” alert indicates a too
slow drip rate.

9 When the message “AUTO PRIME COMPLETE” appears on the

display screen, the priming with ink procedure is complete.

10 Close the bleed valve and remove the bleed tube.

11 Press the Exit key.

12 Continue to Refresh Ink System.

Rev AB Prime Printer with Ink (AUTO PRIME) 3-37

Universal 37pc Service Manual

Refresh Ink System (AUTO REFRESH)

The Auto Refresh procedure removes all of the ink currently in the ink
system, and replaces it with fresh ink from the ink bottle.

The Auto Refresh procedure takes approximately 15 minutes once it has
been started. Complete these steps to refresh the ink system.

1 Remove the printhead from the printhead holder in the service tray

but ensure that the grounding clip remains attached to the printhead.

2 Turn the vertical adjustment screw one turn counterclockwise to raise

the ink stream over the ink return block; note its original position
(refer to Figure 3-18).

3 Return the printhead to the printhead holder in the service tray.

Vertical Adjustment

Screw

Figure 3-18. Location of vertical adjustment screw

4 Press the Down Arrow key once to move the cursor to the <YES/NO>

field next to <AUTO REFRESH>.

SET PRESSURE NO

AUTO REFRESH NO

AUTO PRIME NO

MORE OPTIONS NO

5 Press the Yes/No key to select <YES>. The message “FOR

REPLACING FLUID INSIDE THE MODULE” appears on the screen.

FOR REPLACING FLUID

INSIDE THE MODULE.

START REFRESH NO

3-38 Refresh Ink System (AUTO REFRESH)

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Universal 37pc Service Manual

Warning

When the <YES> key is pressed, ink will spray from the printhead.
Ensure the printhead is aimed into the service tray.

6 With the cursor in the <YES/NO> field next to <START REFRESH>,

press the Yes/No key to begin the Refresh procedure. The message
“AUTO REFRESH RUNNING REFER TO MANUAL” appears on the
display screen.

Note: The ink refresh procedure requires an ink pressure of greater than 30
psi. If the ink pressure is set below 30 psi, ink may not spray from the nozzle.

7 Increase the ink pressure to 40 psi by adjusting the ink pressure

regulator and watching the ink pressure gauge (refer to Figure 3-16 on
page 3-32).

8 Ensure the ink is spraying over the ink return block. If not, adjust the

ink stream vertical alignment screw counterclockwise until the ink
stream completely clears the top of the ink return block. The ink must
spray into the service tray for the entire refresh cycle.

9 The printer will now remove the ink currently in the ink system, and

replace it with fresh ink from the ink bottle. When “AUTO REFRESH
COMPLETE” appears in the display, the Auto Refresh cycle is
complete.

Note: The ink will turn off four minutes prior to the completion of the ink
refresh cycle.

10 Turn the vertical adjustment screw clockwise to return the vertical

alignment to its original position.

11 Press the Exit key three times to return to the initial service mode

screen.

12 Press the Standby key to exit the service mode.

13 Continue to Ink Stream Calibration.

Rev AB Refresh Ink System (AUTO REFRESH) 3-39

Universal 37pc Service Manual

Ink Stream Calibration

The ink stream calibration procedure ensures that the following
conditions are met: the ink is aligned into the ink return block properly,
the ink drop break-off occurs at the proper location in the charge tunnel,
the ink pressure is adjusted to the correct setting, the set point time to
maintain the correct ink viscosity is established, and the optimal nozzle
drive setting is established.

If any of these conditions are not set properly, the printer may provide
poor print quality or experience printer faults.

The ink stream calibration procedure is completed only when there is new
ink in the system.

Procedure

To calibrate the ink stream, complete the following sections in the order
shown:

• Align the Ink Stream

• Set the Final Vacuum Adjustment

• Center the Ink Drop Break-off

• Set the Ink Pressure

• Re-Center the Ink Drop Break-Off - If break-off has shifted
significantly from the center of the charge tunnel, re-do the ink
pressure setting.

• Complete the Nozzle Drive Setting

Align the Ink Stream

Complete the following steps to align the ink stream into the ink return
block:

1 Aim the printhead into the service tray. If the printhead is located in

the printhead holder, remove it from the printhead holder so that you
can view the ink stream. However, ensure that the grounding clip
remains attached to the printhead.

3-40 Ink Stream Calibration

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Press the Service key to enter the Service mode.

37 PC/UI ID#

PRINT INK

HEAD SYSTEM

2 Press the F1 key to select <PRINT HEAD>.

INK ON NO

HIGH VOLTAGE ON NO

TEST PRINT ON NO

CHANGE SETTINGS NO

Universal 37pc Service Manual

Warning

Ink may spray out of the printhead when completing the next step ­turning the Ink On.

3 With the cursor in the <INK ON> field, press the Yes/No key to select

<YES> to turn the printhead On.

Note: No Signal and /or Phasing faults may occur during the ink stream
calibration causing the ALERT light to flash. This is normal, ignore these
alerts and continue with calibration.

4 View the ink pressure gauge to confirm that it shows a pressure

setting of 40-psi (2.76 bar). If it does not, adjust the ink pressure
regulator to 40-psi (2.76 bar) (refer to Figure 3-16 on page 3-32).

5 Make sure the ink stream is aligned correctly into the ink return block.

If it is not, use the ink stream adjustment screws to align the ink
stream in the ink return block (refer to Figure 3-19 and Figure 3-20). If
the alignment is OK, continue to the next section Set Final Vacuum
Adjustment. If the alignment needs adjustment, continue this
procedure.

• Turn the horizontal locking screw ½ turn to loosen the adjustment
screws to adjust the nozzle. Once adjustments are made, tighten the
horizontal locking screw to prevent the nozzle from moving.

• Turn the horizontal adjustment screw to move the ink stream
horizontally (side to side).

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Universal 37pc Service Manual

• Turn the vertical adjustment screw to move the ink stream
vertically (up and down).

Horizontal

Locking Screw

Vertical Adjustment

Screw

Horizontal
Adjustment Screw

Figure 3-19. Adjustment Screws on Bottom of Printhead

6 Align the ink stream so that it enters the ink return block horizontally

centered and slightly above the vertical center, as shown in Figure 3-

20.

Figure 3-20. Aligning the Ink Stream into Ink Return Block

7 If the ink stream was not properly aligned in the ink return block,

there may be ink spray on the printhead components. Check to see if
the printhead has ink on the components. If it does, turn printer off,
clean the printhead components with cleaning solution, dry with
compressed air, and then turn the printer back On.

8 Continue to Set Final Vacuum Adjustment.

3-42 Ink Stream Calibration

Rev AB

Set Final Vacuum Adjustment

The final vacuum adjustment must be made with the ink On. The
preliminary vacuum adjustment was a rough adjustment. The final
vacuum adjustment is needed to fine tune the amount of vacuum in the
system, after ink is introduced into the printer.

1 With the ink On continuously for a minimum of two minutes (<INK

ON> field set to <YES>), set the system vacuum adjustment to
between 12 and 13 inches of vacuum as read on the vacuum gauge
(refer to Figure 3-22).

• Use the vacuum adjusting needle valve located on the left side of
the air manifold (refer to Figure 3-21) to adjust the vacuum. To
adjust the vacuum, unlock the collar and turn the small knob. Turn
the needle valve counterclockwise to increase vacuum and
clockwise to decrease vacuum.

• View the vacuum setting at the vacuum gauge located next to the
ink module (refer to Figure 3-22).

Universal 37pc Service Manual

2 After vacuum is set, lock the collar. Recheck the vacuum reading after

the collar has been locked.

Figure 3-21. Adjusting the Vacuum

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Universal 37pc Service Manual

Vacuum

Gauge

Figure 3-22. Viewing the Vacuum Gauge

3 Continue to Center the Ink Drop Break Off.

3-44 Ink Stream Calibration

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Center the Ink Drop Break-off

Complete these steps to center the ink drop break-off in the charge tunnel:

1 With the ink stream On (ink stream spraying from the nozzle into the

ink return block), press the Down Arrow key on the keyboard three
times to move the cursor to the <YES/NO> field next to <CHANGE
SETTINGS>.

INK ON YES

HIGH VOLTAGE ON NO

TEST PRINT ON NO

CHANGE SETTINGS NO

2 Press the Yes/No key to select <YES>.

Universal 37pc Service Manual

TEST PRINT ON NO

_______________________

NOZZLE DRIVE 100

3 Press the F1 key to select <NOZZLE DRIVE> to make the nozzle drive

setting.

4 Hold the magnifier over the charge tunnel on the printhead (as shown

in Figure 3-23) to view the ink stream.

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Universal 37pc Service Manual

Figure 3-23. Positioning Magnifier over the Charge Tunnel

Note: A magnifier holder used to hold the magnifier lens to the printhead is
available. Refer to chapter 3, “Accessories and Spare Parts” in the Illustrated
Parts Breakdown for further information.

5 Use the Arrow keys to adjust the nozzle drive setting until the ink

drop break-off point is in the center of the charge tunnel as shown in
Figure 3-24.

Pressing the Arrow keys will increase or decrease the current nozzle
drive setting by the following increments:

• Press the Up Arrow key to increase value by 1.

• Press the Down Arrow key to decrease value by 1.

• Press the Right Arrow key to increase value by 25.

3-46 Ink Stream Calibration

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Universal 37pc Service Manual

• Press the Left Arrow key to decrease value by 25.

Breakoff centered in

charge tunnel

Charge

Nozzle

Tun nel

Figure 3-24. Centering Ink Drop Break-off in Charge tunnel

6 Press the Save key to establish the new nozzle drive setting.

7 Continue to Set the Ink Pressure.

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Universal 37pc Service Manual

Set the Ink Pressure

Complete the following steps to set the ink pressure in the system:

Note: Make certain the printhead is clean and dry before performing this
procedure. If it is not, the printer will not allow you to set the ink pressure.

1 With the ink On and the printhead clean, slide the printhead back into

the printhead cover (refer to Figure 3-25). If this is not done, the
printer may make an incorrect setting due to outside (electrical) noise.
You do not need to tighten the printhead screw to secure the cover at
this point.

2 Make sure the printhead is positioned at approximately the same

elevation as it will be positioned during printing. This is important
because printhead elevation will affect pressure and may cause an
incorrect reading.

Figure 3-25. Sliding the Printhead into the Cover

3 Press the Exit key three to access the initial Service Mode screen.

3-48 Ink Stream Calibration

37 PC/UI ID#

PRINT INK

HEAD SYSTEM

Rev AB

4 Press the F2 key to select <INK SYSTEM>.

INK SYSTEM

INK INK

CONTROL UPKEEP

5 Press the F2 key to select <INK UPKEEP>.

SET PRESSURE NO

AUTO REFRESH NO

AUTO PRIME NO

MORE OPTIONS

Universal 37pc Service Manual

6 With the cursor in the <SET PRESSURE> field, press the Yes/No key

to select <YES>. (After a 10 second delay), the Set Pressure Bars will
appear.

LOW SET HIGH

NOZZLE DRIVE 100

7 Adjust the ink pressure regulator until the right side of the bar lines

up directly below the arrow as shown below.

LOW SET HIGH

NOZZLE DRIVE 100

8 Check to confirm the point of breakoff is still centered inside the

charge tunnel. If the ink pressure is changed more than about 2 psi,
you may need to re-center the ink drop breakoff in the charge tunnel
using the Arrow Keys on the keyboard (refer to Figure 3-24). The ink
pressure display must show SET, and the point of breakoff must be

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Universal 37pc Service Manual

centered inside the charge tunnel simultaneously before pressing the
Save key.

9 Press the Save key to set the ink pressure. The following screen will

appear.

Note: If the Save key is not pressed after the SET was achieved, the printer
will not establish a new set point.

10 Leave the ink On (allow the printer to run) for at least 5 minutes so

that the printer can establish the correct set point. When the printer
has completed the process, the following screen will appear.

WAIT FOR THE SET POINT

TO BE ESTABLISHED

(APPROX 5 MINUTES)

PRESSURE SET DONE

---------------------------------------

SET POINT

ESTABLISHED

11 Press the Exit key.

12 Press the Standby key; the ink will turn OFF.

Note: If you turn the ink Off before allowing it to run for approximately 5
minutes, you must repeat the procedure to set the ink pressure.

13 Remove the printhead from the printhead cover.

14 Continue to Setting the Nozzle Drive.

3-50 Ink Stream Calibration

Rev AB

Setting the Nozzle Drive

In this procedure, you will set the nozzle drive to obtain the correct drop
breakoff pattern for printing. This adjustment will provide good print
quality in typical environments under most circumstances.

If a more precise setting is required, the nozzle drive setting may be
further optimized by following the procedure “Find the Optimal Nozzle
Drive Setting” on page 7-54.

Complete the following steps to set the nozzle drive:

1 Press the Service key to enter the Service mode.

37 PC/UI ID#

PRINT INK

HEAD SYSTEM

Universal 37pc Service Manual

2 Press the F1 key to select <PRINT HEAD>.

INK ON NO

HIGH VOLTAGE ON NO

TEST PRINT ON NO

CHANGE SETTINGS NO

3 With the cursor in the <YES/NO> field next to <INK ON>, press the

Yes/No key to turn the ink On.

4 Press the Down Arrow key three times to move the cursor to the

<YES/NO> field next to <CHANGE SETTINGS>.

5 Press the Yes/No key to select <YES>.

PRINTHEAD SETTINGS

NOZZLE PRINT

DRIVE HEIGHT

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Universal 37pc Service Manual

6 Press the F1 key to select <NOZZLE DRIVE>.

TEST PRINT ON NO

NOZZLE DRIVE 100

7 Use the Arrow keys to decrease the nozzle drive value to 0.

Note: No Signal and /or Phasing faults may occur during the ink stream
calibration causing the ALERT light to flash. This is normal, ignore these
alerts and continue with calibration.

8 Hold the magnifier over the charge tunnel or install the magnifier lens

holder on the printhead to view the ink stream (refer to Figure 3-26).

_______________________

Figure 3-26. Positioning Magnifier over the Charge Tunnel

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Universal 37pc Service Manual

9 Use the Arrow keys to increase the nozzle drive setting until the ink

drop break-off pattern looks similar to the one shown in Figure 3-27.

Pressing the Arrow keys will increase or decrease the current nozzle
drive setting by the following increments.

• Press the Up Arrow key to increase value by 1.

• Press the Down Arrow key to decrease value by 1.

• Press the Right Arrow key to increase value by 25.

• Press the Left Arrow key to decrease value by 25.

NOTE:To achieve good print quality, the ink drop break-off does not need to
be in the middle of the charge tunnel when the break-off pattern is adjusted.
The important requirement is that the break-off be inside the charge tunnel,
and that the satellites have merged with the main drop before leaving the
charge tunnel.

A) Minimum Drive

B) Low Drive

C) Correct Drive

Acceptable

Breakoff

Slow Satellites

Fast Satellites

Note: For proper breakoff
pattern, refer to the
specifications sheet supplied
with your Videojet ink.

Figure 3-27. Correct Ink Drop Break-off Pattern

10 Press the Save key to establish the new nozzle drive setting.

11 Press the Standby key to exit the Service mode.

12 Continue to Conduct a Test Print.

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Universal 37pc Service Manual

Conduct a Test Print

The test print feature is used to confirm good print quality and to ensure
correct ink stream alignment into the ink return block.

Test Print Guidelines

These guidelines apply to the test print procedure:

• A test print can only be generated when the ink is on. Test print will
automatically turn on the high voltage but only during the 60-second
test print cycle.

• The test print cycle lasts for 60 seconds. The sample of print must be
taken before this time expires. At the end of 60 seconds, the printer
will automatically turn both the test print and the high voltage Off.

• When adjusting nozzle drive or print height, a test print can be
activated from either screen by pressing the Yes/No key.

• You can stop the test print cycle at anytime while it is active by
pressing the Yes/No key to change <YES> to <NO>. Keep in mind
that this will automatically turn the high voltage Off.

Test Print Message

During test print, a standard barcode is printed.

Tools/Supplies Required

You will need paper (or other substrate) to print on for this procedure.

Procedure

Complete the following steps to check the current print quality:

1 From the Standby mode, press the Service key to enter the Service

mode.

Note: If the printer is already in the <NOZZLE DRIVE> adjustment screen,
press Exit and skip to step 5.

37 PC/UI ID#

PRINT INK

HEAD SYSTEM

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Universal 37pc Service Manual

2 Press the F1 key to select <PRINT HEAD>.

INK ON NO

HIGH VOLTAGE ON NO

TEST PRINT ON NO

CHANGE SETTINGS NO

3 Ensure that the <INK ON> field is set to <YES>. If it is not set to

<YES>, press the Yes/No key to set this field to <YES>.

4 Press the Down Arrow key three times to move the cursor to the

<YES/NO> field next to <CHANGE SETTINGS>.

5 Press the Yes/No key to select <YES>.

PRINTHEAD SETTINGS

NOZZLE PRINT

DRIVE HEIGHT

6 Press the F1 key to select <NOZZLE DRIVE>.

TEST PRINT ON NO

_______________________

NOZZLE DRIVE 100

7 With the cursor in the <TEST PRINT ON> field, press the Yes/No key

to initiate the test print mode.

8 Slide a test sample past the printhead orifice to receive a sample of the

current print quality. The sample paper should be moved across the
front of the printhead at the correct distance of about ¼ inch.

9 Check the print quality. Also check for ink buildup on the printhead

components. If no ink buildup is seen and the print quality is ok,
continue with the next step. If ink is building up on the internal
printhead components or if the print quality is poor, recheck the
nozzle and ink stream alignment adjustments.

10 Press the Standby key to exit the Service mode.

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Universal 37pc Service Manual

11 You have completed the Calibrate the Ink Stream procedure.

Continue to Set the Fluids Low Adjustment.

3-56 Ink Stream Calibration

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Set the Fluids Low Adjustment

Air passes through the fluids low needle valve to supply the fluids low
switch and replenishment bottles. This air is used to monitor the fluid
level within the bottles.

Use a screwdriver to adjust the fluids low needle valve (see Figure 3-28).

1 When adjusting the fluids low needle valve (identified as “B” for

bubbler), look in the make-up replenishment bottle. The make-up
fluid bottle should be nearly full. The ink bottle must be at least half
full.

Universal 37pc Service Manual

Fluids Low

Needle Valve

Positive Air

Needle Valve

Figure 3-28. Adjusting the Needle Valves

2 Hold the dip tube about 1/2 inch below the liquid surface (refer to

Figure 3-29).

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Universal 37pc Service Manual

3 Adjust the needle valve for approximately one to two bubble(s) per

second. This procedure adjusts the fluids alert for both replenishment
bottles.

Figure 3-29. Setting the Fluids Low Adjustment

Note: Do not hold the Dip Tube more than 1/2 inch below the liquid surface,
or you will not see any bubbles. This is due to a bypass “design” around the
switch to reduce evaporation.

4 Continue to Adjust the Positive Air Flow.

3-58 Set the Fluids Low Adjustment

Rev AB

Adjust the Positive Air Flow

Positive air supplies a slight air pressure to the printhead, which helps,
keep contaminants out of the printhead. Adjust the positive air setting at
the positive air needle valve (refer to Figure 3-28).

Use a screwdriver and a flow meter (Videojet P/N 365230) for this
adjustment. The air flow is measured at the printhead with the ink On.

Note: Cover must be on printhead, and ensure that ink is On for at least 2
minutes.

1 Hold the flow meter to the printhead (refer to Figure 3-30). The flow

meter must be held vertical to obtain an accurate reading.

2 Adjust the positive air needle valve (identified as “P” for positive air)

to 1.5–2.0 SCFH measured at the printhead.

Universal 37pc Service Manual

Figure 3-30. Flow Meter held to the Printhead

3 Turn the ink and high voltage Off.

4 Continue to Adjusting the High Voltage Plate Gap.

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Adjusting the High Voltage Plate Gap

Introduction

The physical distance between the high voltage deflection plate and
opposing ground plate must correct. This procedure confirms the correct
gap exists.

Warning

Ink and High Voltage must be Off during this procedure.

1 Make sure the ink and high voltage are Off. Either press the Start/

Stop key when in the Print or Standby mode to shut down the
printhead. Or, change the <INK ON> and <HIGH VOLTAGE ON>
fields to <NO> when in the Service mode.

2 Press the Standby key to place the printer into the Standby mode

3 Turn the main AC power switch to the OFF position.

4 Slide the high voltage gap tool between the high voltage plate and the

High Voltage

Plate

when the ink has been Off for at least two minutes.

ground plate. The gap tool should slide smoothly (no drag) between
the components.

High Voltage Plate

Mounting Screws

Gap Gauge

Figure 3-31. Gap Gauge held to the Printhead

3-60 Adjusting the High Voltage Plate Gap

Charge Tunnel

Mounting Screws

Rev AB

Adjust the High Voltage Gap

The physical distance between the high voltage deflection plate and
opposing ground plate must be correct. This procedure confirms the
correct gap exists.

1 Loosen the four screws holding the high voltage arm.

2 Place the high voltage gap tool into position.

3 Lightly press on the high voltage plate and tighten the screws.

4 Recheck the gap after tightening the screws.

5 Continue to Adjusting the Bar Height Adjustment.

Universal 37pc Service Manual

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Universal 37pc Service Manual

Adjusting the Bar Code Height

The physical height of the bar code can be adjusted. Print height is
measured in percent; the default is 50%. The print height can be set
between 1 and 100%.

Adjusting the Bar Height

Complete these steps to adjust the bar code height:

1 Ensure the printer is operational and has been interfaced to a mail

sorting system, and calibrated correctly.

2 Confirm the printhead is mounted at the correct distance from the

printing surface. This distance must be between 3/16 inch (4.76 mm)
and 5/16 inch (7.94 mm).

3 Take print samples. If the bars are too short, the high voltage setting

must be increased; and conversely if the bars are too tall, the setting
must be reduced.

Note: If the bars are the correct height, this procedure is finished and the
printer installation is complete!

4 To change the print height setting, enter the Service mode by pressing

the Service key.

5 Press the F1 key to select <PRINTHEAD>.

6 Press the Down Arrow key three times to move the cursor to the

<YES/NO> field next to <CHANGE SETTINGS>.

7 Press the Yes/No key to select <YES>.

8 Press the F2 key to select <PRINT HEIGHT>. The current print height

value is shown in the lower right corner of the display.

9 Adjust the print height setting using the Arrow keys.

Pressing the Arrow keys will increase or decrease the current print
height setting by the following increments:

• Press the Up Arrow key to increase value by 1.

• Press the Down Arrow key to decrease value by 1.

• Press the Right Arrow key to increase value by 10.

• Press the Left Arrow key to decrease value by 10.

10 Go back to step 3 to recheck the print height.

The printer installation is now complete.

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Theory of Operation

In this chapter you will find:

• a description of the ink jet printing process, including the ultrasonic,
electrostatic, and pressure effects on the ink stream

• an explanation of the two factors that control the ink stream: ink
pressure and nozzle drive

• a functional analysis of the printer and printhead start-up and
shutdown procedures, the fresh ink add subsystem, the make-up fluid
add subsystem, ink recycling (the transfer process), and the fluids low
alert subsystem

4

Introduction

This chapter describes the ink jet printing process and how the printer
applies that process.

Understanding how the printer works helps you to diagnose printer
problems more easily. Read this chapter before troubleshooting the
printer and refer to Chapter 8, “Troubleshooting” for further information
on diagnosing printer problems.

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The Ink Jet Printing Process

The ink jet printing process is based on the physical behavior of a fluid ink
stream under the influence of pressure, ultrasonic vibration, and
electrostatic forces.

Read the following sections in this order to better understand the ink jet
printing process:

• Ultrasonic Effects on the Ink Stream

• Electrostatic Effects on the Ink Stream

• Pressure Effects on the Ink Stream

Ultrasonic Effects on the Ink Stream

The printer uses ultrasonic vibration to break a pressurized, solid ink
stream into small droplets as it leaves the nozzle.

The ultrasonic vibration is produced by a ceramic crystal within the
nozzle assembly (refer to Figure 4-1). The crystal is energized by an
oscillating circuit on the controller PCB. The level of this signal is
determined by a keyboard-selectable voltage known as “nozzle drive”.
This signal causes the ink chamber within the nozzle to vibrate.

The resulting action is conducted to the ink chamber within the nozzle as a
vibration. The vibration is then transduced to the pressurized ink stream,
causing it to break off into tiny, uniform drops. These drops form within
the field of the charge tunnel (after the ink stream leaves the nozzle
orifice).

Ink Drops

Breaking Off

Nozzle Crystal

Figure 4-1. Ink Drop Break-off

4-2 The Ink Jet Printing Process

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Electrostatic Effects on the Ink Stream

The charge tunnel is an in-line electrode that charges the drops for
printing. Just before each drop forms, a positive electrical pulse is applied
to the charge tunnel at the same ultrasonic rate as the signal to the nozzle
(refer to Figure 4-2). This positive pulse induces a negative charge on the
drop as it is formed in the charge tunnel; it does this by pulling the
negatively charged electrons through the grounded ink stream and to the
surface of the drop.

Figure 4-2. Charge Tunnel Operation

Universal 37pc Service Manual

Although many drops are in the charge tunnel, the positive pulse (at the
tunnel) produces a negative charge only on the drop breaking off at that
particular time. This allows each drop to be individually controlled.

The Amount of Charge on the Drop

The amount of charge applied to a drop depends on the intended location
of that drop on the print surface. Drops located at the “top” of a character
receive a greater charge than drops located at the “bottom” of a character.
Voltage range is between 100-250 depending on the matrix or font.

The character generating microprocessor and the charging circuit on the
controller PCB determines the amount of charge placed on every drop.
Predetermined charge levels exist for all possible print characters. When a
message is entered, the PCB automatically calculates the charge for each
drop in the code.

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The High Voltage Plate

After passing through the charge tunnel, the ink stream enters the electric
field of the high voltage deflection plate, where each charged drop is
deflected from its path. This deflection changes the drop’s trajectory and
places the drop at a precise location on the print surface (see Figure 4-3).

High

Vol tag e

Plate

Full Stroke “Staircase”

Pulse Train from Electronics

Nozzle

Charge Tunnel

Figure 4-3. Drop Deflection/Character Formation

Printing
Media

Ink Return
Block

Ground
Plate

The deflection from the ink stream results from the drop being attracted to
the positive deflection field created at the deflection plate. Since unlike
charges attract, the negatively charged drops are pulled towards the
strong positive charge of the deflection plate.

Drops which receive a larger negative charge, due to a larger positive
pulse at the charge tunnel at break-off, are deflected more than drops
receiving a lesser negative charge. As explained earlier, this varying
charge level precisely controls the drop pattern as the ink lands on the
print surface.

Not every drop in the ink stream is used for printing a character; drops
which are not used for printing are left uncharged. Uncharged ink drops
are not deflected and maintain a straight trajectory into the ink return
block (located at the end of the printhead). Vacuum draws unused ink
back into the ink module where it is cycled through the ink system.

4-4 The Ink Jet Printing Process

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Pressure Effects on the Ink Stream

The only true variable in the printing process that is beyond the operator’s
control is the pulsed voltage amplitude at the charge tunnel. Recall that
this voltage is predetermined by the controller PCB. Changes in internal
printer ink pressure, however, can also affect character formation.

Ink Pressure

Ink pressure, which is the pressure applied to the inside of the pressure
tank (where ink is pushed out to the printhead), determines the speed or
velocity at which the ink travels through the printhead components. This
affects the spacing between drops as well as satellite formation.

Important: Ink pressure is controlled by the ink pressure regulator and should
never be adjusted during normal operation.

To summarize the effects of changing the ink pressure, a higher ink
pressure would result in smaller characters because the drops move more
quickly, spending less time in the field of the deflection plate. Similarly, a
decrease in ink pressure would cause a larger character printout because
the slower drops are deflected further out of their path.

Universal 37pc Service Manual

Flow Time

It is important to understand that the ink pressure setting also directly
affects flow time. Flow time is the amount of time it takes for the pressure
tank to empty. Therefore, arbitrarily changing ink pressure will upset
printer operation.

Caution

DO NOT adjust ink pressure to change bar height. Instead, adjust
the amount of high voltage applied at the printhead. See “Adjusting
the Bar Height” on page 7-64 for instructions.

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Controlling the Ink Stream

Two different printer adjustments control the ink stream: ink pressure and
nozzle drive. These adjustments are typically made during initial
installation, after changing ink types, and after servicing certain printer
components.

Adjusting the Ink Pressure

As discussed on page 4-5, the ink pressure controls the ink stream velocity
and, as a result, print quality. Keep in mind that the ink pressure
adjustment also directly affects flow time. Once initially set, this setting
must be left alone until the printer requires recalibration.

Adjusting the Nozzle Drive

The nozzle drive adjustment compensates for variations in crystal
sensitivity and ink viscosity. Changing the nozzle drive setting at the
keyboard moves the position of the ink break-off drop within the charge
tunnel. This adjustment is very precise and must be done in conjunction
with viewing the ink stream through a magnifier lens.

An LED strobe located behind the charge tunnel viewing window allows
the technician using the magnifier to view the ink stream as if it were
stationary. See Chapter 7, “Service Mode” for more information on using
the magnifier.

Adjusting the nozzle drive at the keyboard changes the voltage applied to
the crystal in the nozzle. As the nozzle drive is advanced from the
minimum value, the ink stream changes from a solid ink stream to a
stream with an ink drop break-off and individual drops. The actual
voltage level applied to the nozzle will vary depending on the ink type
used and the crystal sensitivity.

A correct ink drop break-off should be similar to that shown in Figure 4-4.
Notice in this example that the tail of the drop breaks off and forms a
separate, smaller drop called a satellite. When adjusted properly, the
satellite should “catch up” and merge with the parent drop within the
next five additional drops. It is important to note that the break-off
formation will vary depending on the ink type.

4-6 Controlling the Ink Stream

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A) Minimum Drive

Universal 37pc Service Manual

B) Low Drive

C) Correct Drive

Acceptable

Breakoff

Slow Satellites

Fast Satellites

Note: For proper break-off
pattern, refer to the
specifications sheet supplied
with your Videojet ink.

Figure 4-4. Effect of Nozzle Drive Adjustment

If the satellite is allowed to lag behind and merge with the following drop,
erratic charge distribution occurs because the satellite carries away a
portion of the parent drop charge. This causes distorted printing because
both drops are improperly deflected. This condition is typically caused by
a nozzle drive setting that is too high or too low. Look for a minimum of
three to four complete drops prior to exiting the charge tunnel.

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Universal 37pc Service Manual

Functional Analysis

Understanding how the printer operates will aid in troubleshooting the
system. The following sections contain a complete breakdown and
analysis of both the hydraulic/pneumatic functions of the printer and the
sequence of events that happen during various modes of operation. All
sequences are controlled by the microprocessors on the controller printed
circuit board (PCB).

Printer Start-up Sequence

When the AC power switch is switched to the ON (|) position, AC power
is supplied to the printer, causing the keyboard to become active.

Printer Shutdown Sequence

When the AC power switch is changed to the OFF (O) position, AC power
to the printer is disconnected. This causes the keyboard to become
inactive.

Note: Never turn the AC power switch Off while the printhead is still active.
Always shutdown the printhead (by pressing the Start/Stop key) and allow the
printer to complete its two-minute shutdown sequence before turning the AC
power Off. If you turn the AC power Off before shutting down the printhead, the
ink in the ink return line will not be drawn back into the printer. This would
result in dried ink forming in the ink return line and on the ink return block, thus
causing problems at the next printhead start-up

Printhead Start-up Sequence

The printer is able to print a message only when the printhead is fully
active (meaning that both the ink and high voltage are On). The Start/Stop
key is used to begin the printhead start-up sequence and make the
printhead active.

When the Start/Stop key is pressed, the controller PCB activates the air
control solenoid. The air control valve provides system air (via a relief
valve and input filter) to the transfer solenoid, the nozzle solenoid, and a
vacuum generator.

Creating Vacuum

When air pressure is applied to the vacuum generator (which operates on
the venturi principle to develop a vacuum at the side port), it creates
vacuum. The operation of the vacuum generator is very similar to the
operation of the carburetor in an internal combustion engine. In a

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Universal 37pc Service Manual

carburetor, the passage of air through the throat develops a low pressure
at the side port, drawing fuel into the venturi.

In the printer, the rush of air through the venturi, or throat, of the vacuum
generator causes a comparable low pressure at the side port. This port is
connected to the make-up and fresh ink add solenoids and to the top of
the ink module via the vacuum filter. A vacuum line (known as the ink
return line) extends from the ink module to the ink return block (in the
printhead) and serves to draw unused ink back into the ink module. This
process is continuous during operation. Vacuum operates the fresh ink
and make-up add valves (located in the ink module) and is also used in
the suction stroke of the transfer pump.

Energizing the Nozzle Solenoid

When the nozzle solenoid is energized, two functions occur:

• The nozzle solenoid valve opens, allowing system operating air
pressure to be applied to the ink pressure regulator. The ink pressure
regulator sets the ink pressure to the pressure tank at a pre-specified
pressure. As the ink pressure increases, the ink valve (located in the
printhead) opens (the valve should open well before pressure reaches
30 psi/2.07 bar). This causes ink to flow from the pressure tank,
through the ink valve and nozzle assembly into the ink return block
(where the ink is returned to the ink module and reused).

• The printer software energizes the transfer solenoid when a magnetic
float in the pressure tank closes a magnetic reed (PTLW) switch and
immediately fills the pressure tank. This allows the system to compare
the first current ink time (flow time) to the set point time, maintaining
a well-balanced control of fluid viscosity within the ink module
reservoir and pressure tank.

Set Point: The set point time is a reference point established during the ink
stream calibration procedure. It refers to the time it takes the float in the
pressure tank to travel from the pressure tank full (PTFL) switch (open
position) to the pressure tank low (PTLW) switch (closed position), using
fresh fluids in the printer. These are sense switches and they have
corresponding LEDs on the Printer Circuit Board. (Refer to Figure 4-5 on
page 4-10).

Flow Time: The flow time is the subsequent measurements taken each time
the fluid in the pressure tank flows from the PTFL switch (open position)
to the PTLW switch (closed position).

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The software compares the flow time to the set point time to measure the
ink viscosity. As a result, various actions may be taken depending upon
the printer mode of operation.

Figure 4-5. LED Panel on the Printer Circuit Board (PCB)

Automatic Phase Control

The first 30 seconds of the printhead start-up sequence allow the ink
stream to stabilize. In order for the printer to determine when each drop of
ink is being formed, a test signal is applied to the charge tunnel. This test
signal, known as Automatic Phase Control (APC), tests the ink stream to
ensure that drop formation and drop charging remain in sync with each
other. Following this group of drops, an identical group of drops receives
no charge.

The APC signal consists of four such groups; each group of drops is
charged at a different time, known as phases. Phase 0 starts at the same
time with the nozzle drive signal. The result is that the group of drops that

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Universal 37pc Service Manual

forms at the right time in relation to the charging signal will receive the
best total charge.

This APC signal is sensed in the ink return block and monitored by a
sensing circuit on the controller PCB to determine which of the four
phases provides a signal where the amplitude is greater than a fixed
threshold. These “good phase” signals are sent to the microprocessor to be
used to determine the best charging time during product coding.

Although the drop charge frequency is controlled by the same electronic
clock as drop formation, the dynamics of the fluid ink stream may vary
with temperature and other external factors, such as ink contamination.

If the circuit cannot lock onto a phase, a phasing fault occurs and the
control board initiates a two-minute shutdown sequence. If the start-up
procedure is completed, the phasing sequence continues for the entire
time the Start/Stop key is active, except during the time a message is
actually being printed (from when a product detect is received until when
the printed message is complete).

Once the Start/Stop Key is Pressed:

Step Figure Ref.

1. The air control solenoid (AVAL) turns on (opens).

• this allows system air pressure to be applied to the vac­uum generator, nozzle solenoid (NVAL), and transfer
solenoid (TVAL).

• when air flows through the vacuum generator, vacuum is
created and applied to the fresh ink add solenoid, make­up add solenoid, through the vacuum filter and inside the
reservoir, inside the ink return line (leading from the print­head), and to the transfer solenoid (TVAL).

Figure 4-6

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Universal 37pc Service Manual

2. When the transfer solenoid valve is closed (de-energized),
vacuum is applied to the transfer pump. Vacuum helps pull
the diaphragm backward, causing fluid to be drawn into the
pump from the reservoir. As fluid is transferred from the res­ervoir to the pump, the fluid level and the float in the reser­voir begin to drop. When the fluid level drops to a point
where the magnet on the float reaches the reservoir low
switch, the reservoir low switch closes (RLOW).

This causes either the make-up add (MVAL) or the fresh ink
add solenoid (IVAL) to energize, allowing system vacuum to
open the corresponding adder valve. The adder valve cho­sen depends on the difference between the set point time
and the current flow time and other fluid-related factors
(Figure 4-7 shows the fresh ink adder valve energized).
Once this occurs, vacuum from the reservoir draws fluid (ink
or make-up) into the reservoir from the appropriate bottle
(for the example shown in Figure 4-7, it would be the fresh
ink bottle). As fluid is added to the reservoir, the fluid level
and float begin to rise.

3. When the fluid level rises to a point where the magnet in the
float rises above the reservoir low switch, the reservoir low
switch opens. This causes the fresh ink or make-up add
solenoid (whichever was open) to de-energize, thus closing
the adder valve and stopping the addition of fluid into the
reservoir. (For the example shown in Figure 4-8, it would be
the fresh ink adder valve).

4. After six seconds, the air pressure and vacuum stabilize,
and the nozzle solenoid is energized (this allows air pres­sure to the ink pressure regulator). The ink pressure regula­tor allows a pre-specified amount of air pressure (referred to
as “ink pressure”) into the pressure tank.

Figure 4-7

Figure 4-8

4-12 Functional Analysis

As the pressure on the fluid increases, the ink valve (located
in the printhead) opens (the valve should open well before
pressure reaches 30 psi/2.07 bar). This allows fluid to flow
through the nozzle. The nozzle breaks the fluid stream into
drops. These drops enter the ink return block and are drawn
back (by vacuum) through the ink return line and into the ink
module reservoir.

At the same time, the controller PCB energizes the transfer
solenoid applying air pressure to the diaphragm of the trans­fer pump. This action fills the cylinder with fluid until the
Pressure Tank Full Switch (PTFL) closes.

Figure 4-9

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