Dover Markem-Imaje 5200

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SECTION 5 Troubleshooting

5–12 0855855eng 6/08

Main Page

Table of Contents5
General Information13
Welcome to the Model 5200/540015
What's in this Guide15
Glossary16
Specifications17
Dimensional Drawing18
Safety Information19
Certification19
Automatic Startup20
Safety Labels21
Location of Safety Labels21
Foreseen Use23
Misuse23
Training Programs23
Label and Symbol Identification24
Removal from Service27
Basic Operation29
Basic Components31
The Power Switch33
Powering on the Coder33
Powering off the Coder34
The User Interface Module35
LED Indicators36
Navigation37
Menu Functions37
Function Keys37
ENTER and EXIT Keys37
START and STOP Keys37
Directional Arrow Keys37
Select Characters Dialog Box39
Using the Keyboard40
The Printhead41
Care and Cleaning43
Reliability Centered Maintenance45
Daily Cleaning of the Printhead46
Purging47
Purging Printheads in the down Jetting Position47
Auto Purge Spacing Guidelines48
Jet Testing49
Wiping50
Cleanup51
Cleaning the Bottle Sensor and Reflective Tape52
Stuck Bottle Removal53
Diagnostic Tools55
Diagnostic Guidelines57
Signal Lights57
LED Indicators on the Print Station57
Signal Tower Lights58
LED Indicator on the Printhead59
LED Indicator on the Control Board60
Switch Pack SW2 Settings on the Control Board60
Machine Diagnostics Menu61
Access Level62
Version Information Menu62
Ink System63
Melt Temperature64
Hold Temperature64
Upper Float Sensor64
Lower Float Sensor64
Printhead 1 - 4 Array Temperature65
Printhead 1 - 4 Reservoir Temperature65
Printhead 1 - 4 Ink Level65
Ink Line 1 - 465
Ink Pump66
Printhead 1 - 4 Low Vacuum66
Printhead 1-467
State67
Ink67
Temperature67
Array Thermistor67
Reservoir Thermistor68
Array Heater68
Reservoir Heater68
Ink Level Sense68
Ink Line Heater69
Ink Line Current69
Ink Line Status69
Printhead Voltage69
Printhead Lamp70
Encoder Speed70
Purge Button70
Purge Count70
Jet Test Button70
Ink Delivery Module71
State71
Bottle Sensor71
Melt Thermal State71
Melt Thermistor72
Melt Heater72
Fan72
Hold Thermal State72
Hold Thermistor73
Hold Heater73
Upper Float73
Lower Float73
Pump Motor74
Pump Cycle Time74
Pump Home Switch74
Current Pump Count74
Filter Usage Count75
Print Station75
Ink Door Switch75
Ink Door Solenoid75
Line Voltage75
Enclosure Temperature76
Product Sensor 1 and 2 (PS1 and PS2)76
Remote Purge (PS4)76
Encoder 1 and 276
Fault Relay76
Busy Relay76
VPC 1-2 and 3-477
High Vacuum Pump77
High Vacuum Duty Cycle77
High Vacuum Minimum Run Time78
Low Vacuum Duty Cycle 1 and 378
Purge Solenoid 1 and 378
Low Vacuum Duty Cycle 2 and 479
Purge Solenoid 2 and 479
User Interface79
Contrast79
Beeper80
Status Lights80
Ink Lights80
Fault Lights80
Key Pressed80
Ocu81
Reject Relay81
Reader Sensor (1 and 2)82
Reader Scan Enable (1 and 2)82
Reader Data (1 and 2)82
Product ID Sensor83
Product ID Scan Enable83
Product ID Data83
Ink Usage84
Job Prints Per Bottle84
Printhead (1-4) Number of Pixels84
Printhead (1-4) Image Density84
Printhead (1-4) Prints/Bottle84
Imaging/Printing85
Activate Timing85
Label Rendering85
Print Cycle85
Printing (Head 1-4)86
Time Fields86
Incremental Fields86
Remote Select86
Remote Variable Fields87
State Logger88
Action Logger88
MCU Logger88
Statistics88
Troubleshooting89
Troubleshooting Guidelines91
Error and Warning Messages91
Troubleshooting Chart92
Not Printing93
Printing Poorly93
Cannot Purge Printhead95
Cannot Jet Test Printhead96
Jets Fire Continuously96
Image Prints Continuously (in Print Mode)96
Enclosure Ink Leak97
Cannot Read Display98
Machine will Not Power up100
Machine Resets100
Machine Locks up100
Communications Are Lost100
Job Not Found101
Field Replaceable Parts103
Proper Handling of a Circuit Board105
Replacing the VPC Module105
What You will Need105
Preparation105
Removal105
Replacement106
Final Steps106
Replacing the User Interface Module (UIM)107
What You will Need110
Preparation110
Removal110
Replacement110
Replacing the Printhead110
What You will Need112
Preparation112
Removal112
Replacing the Ink Delivery Module (IDM)112
What You will Need114
Preparation114
Removal114
Replacing the Ink Level Sensor (ILS) in the IDM114
What You will Need118
Preparation118
Removal118
Replacing the Ink Pump Motor and Ink Pump Piston118
Replacement121
Final Steps121
Replacing the IDM Filter122
What You will Need122
Preparation122
Removal122
Replacement123
Final Steps123
Replacing the Ink Line124
What You will Need124
Preparation124
Removal124
Replacement124
Final Steps125
Replacing the Control Board126
What You will Need126
Preparation126
Removal126
Replacement126
Final Steps127
Replacing the Printhead Volt Board128
What You will Need128
Preparation128
Removal128
Replacement130
Final Steps130
Replacing the I/O Panel Assembly131
What You will Need131
Preparation131
Removal131
Replacement134
Final Steps134
Replacing the Transformer(S)135
What You will Need135
Preparation135
Removal135
Replacement136
Final Steps136
Replacing the Soft Start Board137
What You will Need137
Preparation137
Removal137
Replacement138
Final Steps138
Replacing the Vacuum/Ground Line139
What You will Need139
Preparation139
Removal139
Replacement139
Final Steps139
Replacing the Printhead Data Cable140
What You will Need140
Preparation140
Removal140
Replacement140
Final Steps140
Spare Parts Kit141
4-40 Pan Head Phillips Screws141
M4 Pan Head Phillips Screws141
Thermistor141
Holding Chamber Thermistor141
Melt Chamber Thermistor142
Cartridge Heater with Thermostat143
Holding Chamber Cartridge Heater with Thermostat (400W)143
Melt Chamber Cartridge Heater with Thermostat (200W)144
Limit Switch144
Replacing the Ink Door Lock Limit Switch144
Replacing the Pump Stroke Counter Limit Switch145
Reflective Tape on Bottle Guide145
Fuse Kit146
Fuses on Backplane Board146
Fuses on Printhead Volt Board147
Fuse on VPC Board148
Replacing the Low Vacuum Diaphragm Pump148
Printhead Soak Kit149

Dover Markem-Imaje 5200 - Page 102

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