ALE TZ Series Service Manual UK
Contents
1. SERVICE MANUAL ALE Design Print Trace 26 11 2009 Disclaimer This manual contains instructions for service operations on the ALE TZ series print heads and ink systems Read it carefully before performing any manipulation on these All service operations should be undertaken by qualified personnel only Contact us if you need training for our equipment All information written in this Service Manual was correct at the time indicated in the version table below However the continual enhancement of Our products may result in some differences existing between the information contained in this document and your equipment Copyright 2009 ALE sarl all rights reserved Reproducing this manual in whole or part without permission is expressly prohibited RiX and TraceX are registered trademarks of ALE sarl All trademarks in this document belong to their respective owners Version history Date Revision Modifications Author 12 04 2007 First version TZ72 only JR AF 17 09 2007 2 All Tzs AF 27 01 09 3 Corrections pages and chapters numbers AF 10 09 09 4 TZ 54 AF TZ series Service Manual ALE Design Print Trace 26 11 2009 Contents Disclaimer Contents li Notes IV 1 The TZ system architecture 1 1 Ink circuit 1 1 1 TZ18 ink circuit 1 1 2 TZ34 ink circuit 1 1 3 TZ54 ink circuit 1 1 4 TZ72 ink circuit 1 2 Pump function 1 3 Elec2. 2 1 1 Replacement of TZ18 or TZ34 FPGA chip To replace the driver board in a TZ18 34 follow these steps e Switch the controller OFF and disconnect the data cable e Open the ink system as shown in 2 4 Open the ink system e Remove the FPGA chip from the driver board Note you will need to use a PLCC extractor tool to remove it safely see Fig 18 Fig 18 PLCC extractor e Insert the replacement chip with care e Close the ink system 2 1 2 Replacement of TZ72 FPGA chip Proceed as follows e Refer to chapter 2 6 2 Separate TZ72 print head from ink system to separate the print head from the umbilical Then open the print head as per chapter 2 7 3 Open the TZ72 print head Remove the FPGA chip with a PLCC extractor Fig 18 Insert the replacement chip with care Close print head Re attach the umbilical 2 2 Replacing the driver board 2 2 1 Replacement of TZ18 or TZ34 driver board To replace the driver board in a TZ18 34 follow these steps e Switch the controller OFF e Open the ink system as described in 2 4 Open the ink system TZ series Service Manual Service procedures 18 ALE Design Print Trace 26 11 2009 e Disconnect all connections to the driver board gt Controller input 25 way ribbon cable with D connector gt Note the order in which the ribbon cables are fitted for later refitting gt Print engine s output s 14 way ribbon cable s gt Pump 2 way plug with black amp red wires e The
3. A01 during conveyor movement 2 Encoder working correctly problem with message e Thel o monitor shows one of the inputs not changing gt Faulty encoder Connect different encoder and spin the wheel by hand to see if inputs change Print start slipping image misalignment e Poor contact between shaft encoder wheel and conveyor gt Rectify e Encoder too far from print heads so that conveyor stretch causes problems 2 Move encoder as close to print heads as possible e Encoder mode not switched on gt Rectify e Many conveyors vibrate when stationary causing false pulses to be sent by encoder Does this occur during photocell delay 2 Minimise photocell delay e Photocell delay quite long and system line speed variable The longer the photocell delay the more chance for slippage gt Minimise photocell delay e Photocell detection unreliable gt Inspect photocell Determine a method of verification e Photocell detection inverted Use I O monitor gt Rectify TZ series Service Manual Maintenance 49 ALE Design Print Trace 26 11 2009 e Conveyor speed exceeding maximum print speed causing print stretch Max speed is approx 40m min at 100 print width 20m min at 50 and 80m min at 200 gt Change width setting or encoder wheel gt TZ34 print head half of the message is inverted e Incorrect head configuration selected This is common if CodeX files are used that were originally connected to other printer
4. large daily expansion and contraction of air in an almost empty bottle may affect print quality and or dripping from the print engine nozzle due to there being too high a level of ink in the reservoir at certain times during the day e n factories with large daily temperature fluctuations be prepared to use smaller capacity ink bottles for example 250mL or only allow bottles to become half empty it is the air in the bottle that expands not the ink e Alternatively remove the ink bottle when the system is not in use and fit the shipping cap This will prevent the reservoir level changing e When print re starts the excess ink will be taken from the reservoir first quickly restoring the correct level The worst case scenario is a system that is a in a location with a large daily A temperature variation b using a low viscosity ink c fitted with a 650mL bottle that is almost empty and d not in use there is no opportunity for the print action to take unwanted ink from the reservoir This possibility should be identified and avoided 3 4 Fault diagnosis Refer to the TZ series operators manual for basic fault diagnosis of common printing and priming problems likely to be encountered during installation and use of the system Listed below is additional information After priming print is OK for a few minutes Then progressively de primes horizontal lines appear in the image or print is grey e Insufficient prime p
5. Print Trace 26 11 2009 ae Fig 61 unscrew the two M5 shoulder SCrews Fig 62 unscrew the M3 button head screw e With a tool push the valve switch inside the tube and rotate the tube with respect to the back plate to hold the switch inside Fig 63 push the valve switch inside the tube e Pull the tube backwards and remove it from the print head Fig 64 and Fig 65 TZ series Service Manual Service procedures 38 ALE Design Print Trace 26 11 2009 Fig 64 pull the tube backwards Fig 65 remove the tube from the print head 2 9 3 Open the TZ54 TZ72 print head Follow this procedure e Fora TZ 54 separate the print head from the rest of the system by following the steps in chapter 2 7 2 Separate TZ54 print head from ink system e Fora TZ 72 separate the print head from the rest of the system by following the steps in chapter 2 6 2 Separate TZ72 print head from ink system e Remove the two M4 dome nuts at the back of the print head Fig 66 TZ series Service Manual Service procedures 39 ALE Design Print Trace 26 11 2009 E E E i Fig 67 unscrew the M5 shoulder screws amp E Fig 66 remove M4 dome nuts e Remove mounting M5 shoulder screws from the print head body These screws can be placed either on top or on the side of the enclosure Fig 67 e Carefully extract the print engine assembly from the enclosure Fig 68 Carefull
6. Print Head CON14 FROM K series controller FireWire Ink Low potentiometer Print Head FireWire nk Low alarm LED Fig 8 TZDB driver board 1 3 3 TZ72 driver board The driver board for TZ72 is called ET7DBO2 and is not located in the ink system but in the print head close to the print engine This driver board is also used in all ET7 print heads in a different configuration This is the reason why only one of the two pump connectors is used TZ series Service Manual The TZ system architecture 9 ALE Design Print Trace 26 11 2009 d PRINT ENGINE Fig 9 ET7DBO2 driver board If you need to replace the FPGA chip the reference is ACTET780OPL solvent version or ACTET735PL oil version Note TraceX9 levels may be added to the FPGA chips references to enable optional features like EntriX VerifiX They are called TAC2 TZ series Service Manual The TZ system architecture 10 ALE Design Print Trace 26 11 2009 1 4 Hydraulic architecture 1 4 1 TZ18 hydraulic architecture Below are graphics describing the ink circuit in the ink system Fig 11 and the print head Fig 12 The shut off valve is made of a flexible tube clamped by a Fig 10 Oil version clamp valve switch and a spring Fig 10 Note that depending on the version Oil or Solvent the valve tube is not the same Always replace tubes and fittings with those supplied by ALE TUBE4X25C DOWM
7. clamp valve tube for leaks or damage cracks Replace if needed by a new tube of the same material ask ALE for the reference of the tube e Prime the engine and print a black pad test in the prime menu of the controller see controller manual for details to make sure all dots are printing TZ series Service Manual Maintenance 44 ALE Design Print Trace 26 11 2009 3 1 4 Ink system The following actions should be taken during the periodic service e Open the pump compartment as in 2 4 Open the ink system e Open the reservoir see 2 3 Access to the ink reservoir and empty it with a syringe Do not turn the ink system upside down e Inspect tubes and fittings for leaks e Inspect circuit board for cleanliness e Clean interior and exterior surfaces pm Fig 73 Gauze filter replacement e Replace the filter ref FILTGAUZE at the bottom of the reservoir remove the clip holding the filter replace the filter put back the clip e Replace the o rings in the reservoir if needed please contact ALE for dimensions and materials e Reassemble the entire printer prime it and check print quality TZ series Service Manual Maintenance 45 ALE Design Print Trace 26 11 2009 3 2 Transport 3 2 1 Empty the ink circuit It is recommended to clean and empty the printer before transport To flush out the printer e Remove the ink bottle e Switch the controller ON e Put the print head in this configurat
8. driver board is attached to the back plate with a square bracket gt Undo the nut and screw gt Put the replacement driver board in place e Re assemble the system by following the previous steps in reverse order 2 2 2 Replacement of TZ54 driver board To replace the driver board in a TZ54 follow these steps e Switch the controller OFF e Open the ink system as described in 2 4 Open the ink system e Disconnect all connections to the driver board Note the order in which the ribbon cables are fitted for later refitting gt Print engine output FireWire cable gt Pump 2 way plug with black amp red wires gt Ink low detection 3 way plug with black blue and white wires e Thedriver board is attached to the back plate with 2 pillars gt Unscrew the pillars gt Put the replacement driver board in place e Re assemble the system by following the previous steps in reverse order 2 2 3 Replacement of TZ72 driver board As it contains many fragile parts replacing the TZ72 driver board is a factory operation If the driver board replacement is needed it is recommended to send us the TZ72 print head See chapter 2 6 2 Separate TZ72 print head from ink system for instructions on separating the print head from the rest of the printer 2 3 Access to the ink reservoir Access to the contents of the ink reservoir is needed for replacing the filter at the bottom of the reservoir e Unscrew the ink tray 2 M5 button head screws on the p
9. ink circuit in the ink system Fig 14 the umbilical Fig 16 and the print head Fig 17 Always replace tubes and fittings with those supplied by ALE TZ series Service Manual The TZ system architecture 15 ALE Design Print Trace 26 11 2009 72mm print head hydraulic components OIL OD4xIDZ OIL valve tub double shut off valve BARECPCF ODG6xID3 SOLYANT valve tube HS double shut off valve BARBARA BARBCPCF i Fig 17 TZ72 print head tubes and fittings TZ series Service Manual The TZ system architecture 16 ALE Design Print Trace 26 11 2009 1 5 Colour codes and ink compatibility WARNING Never change the ink type in a printer and use only ALE supplied fluids Mixing different inks causes catastrophic damage Components of the hydraulic circuit can be damaged by inappropriate ink or solvent The ink reservoirs and pumps are coded with colour tie wraps The pumps are coded with a tie wrap around the gear head Ink reservoir and pump colour codes e RED means compatible with ALE supplied solvent based inks e YELLOW means compatible with ALE supplied oil based inks e NONE means compatible with ALE supplied oil based inks Other ink types please contact ALE for further compatibility information TZ series Service Manual The TZ system architecture 17 ALE Design Print Trace 26 11 2009 2 Service procedures 2 1 Replacing the FPGA chip on a driver board
10. the shut off valve is open the ink will go through the print engine When the pump is active the ball in the direct prime module blocks the way and the ink cannot go back to the reservoir When the pump is inactive the balls goes out of the way and the ink can pass through the direct prime module see Fig 6 Printing mode the print engine takes ink from the reservoir through the direct prime module through the 6X4 tube the valves and the filter The ink is ejected by the print engine nozzles TZ series Service Manual The TZ system architecture 3 ALE Design Print Trace 26 11 2009 1 1 2 TZ34 ink circuit Below is a schematic describing the TZ34 ink circuit Fig 3 It includes a reservoir a direct prime module a pump two ink tubes and a shut off valve for the print head with a syringe connection The shut off valve allows to close the ink circuit between the ink reservoir and the print engines Because the syringe connection is located between the valve and the print engines it is possible to use a syringe to flush the print engines only the valve is closed for that operation see 2 8 Flushing a TZ1 8 34 print head with a syringe 8 RESERVOIR 4X25 tube CLOSED OPEN XAAR 128mm PRINT ENGINE Shut off valve XAAR 128mm PRINT ENGINE j Luer for syringe 16 05 07 Fig 3 TZ34 ink circuit Priming mode the pump sucks ink from the reservoir and
11. 0 mount the new filter in the good flowing direction tightly fasten e Inspect the clamp valve tube for leaks or damage cracks Replace if needed by a new tube of the same material ask A for the reference of the tube e Prime the engine and print a black pad test in the prime menu of the controller see controller manual for details to make sure all dots are printing 3 1 3 TZ72 print head The following actions should be taken during the periodic service TZ series Service Manual Maintenance 42 ALE Design Print Trace 26 11 2009 e Open the print head by following instructions given in 2 7 3 Open the TZ72 print head Inspect tubes and fittings for leaks Inspect circuit board for cleanliness Clean interior and exterior surfaces Replace the filter FILTPAPER as follows gt Put tissue paper under the filter 2 Disconnect it on each side Fig 71 2 Replace it with a new one The filter has a flow direction indicated by an arrow that needs to be respected 2 Tightly fasten the conical fittings around the filter as they ensure the sealing Fig 72 TZ series Service Manual Maintenance 43 ALE Design Print Trace 26 11 2009 n gm m 5 LI Fig 71 protect the electronics with cleaning tissue and extract the filter ET pJas Fig 72 mount the new filter in the good flowing direction tightly fasten e Inspect the
12. 34 print head with a syringe 34 2 9 Opening the print head 35 2 9 Open the TZ18 print head 35 2 9 2 Open the TZ34 print head 37 2 9 3 Open the TZ54 TZ72 print head 40 3 Maintenance 42 3 1 Periodic service 42 3 1 1 TZ18 and TZ34 print heads 42 3 1 2 TZ54 print head 42 3 1 3 TZ72 print head 43 3 1 4 Ink system 46 3 2 Transport 47 3 2 Empty the ink circuit 47 3 2 2 Pack the printer 47 3 3 Managing effects of large temperature changes 47 3 4 Fault diagnosis 48 TZ series Service Manual iii ALE Design Print Trace 26 11 2009 Notes TZ series Service Manual ALE Design Print Trace 26 11 2009 1 The TZ system architecture The TZ series systems are designed to be connected to one of the ALE controllers Each TZ consists of an ink system connected to a print head with an umbilical of 1m length Each TZ contains hydraulics and electronics e Hydraulics allow the ink flow from the reservoir ink system to the print engine print head e Electronics are used to transmit the printing data from the J series controller to the print engine to control the pump and in the communications between the TZ and the controller ink low spit Both the ink system and the print head are enclosed in stainless steel at least 1 2mm thick 1 1 Ink circuit The TZ series printing systems introduce a single reservoir design with automatic level control and pump assisted priming The bottle is compatible with th
13. 3X6 LI I I E I Za A TS A038 Direct Prime H S 2 ce 2 BARBLAM AS i BARBAX25RA 7 L SS d BARB4X25 pA Fig 11 TZ18 ink system tubes and fittings TZ series Service Manual The TZ system architecture 11 ALE Design Print Trace 26 11 2009 18R hydraulic components OIL ee BARB25Y BARBL25M6F E TUBE4X25C 1m umbilical BARB25 ODAXxID2 versinic tube 18R hydraulic components SOLVENT BARBL25M6F TUBE4X25C BARBL25F EU f eA ae I II aerO Pei A TI 1m umbilical BARB4X25 OD6xID4 tygon tube Fig 12 18R print head tubes and fittings TZ series Service Manual The TZ system architecture 12 ALE Design Print Trace 26 11 2009 1 4 2 1234 hydraulic architecture Below are graphics describing the ink circuit in the ink system Fig 14 and the print head Fig 13 Note that depending on the version Oil or Solvent the valve tube is not the same Always replace tubes and fittings with those supplied by ALE BARB3PF220 BARBL25M6F a dri id BARBCAP risen BARBLAF TUBEAX25C E BARBL25M 1m umbilical BARB4X25RA OD4xID2 valve tube BARB25RA 34R hydraulic components OIL BARBARAT25 BARB3PF230 BARBL25M6F 5 BARBCAP TUBE
14. SXIC BARBLAF a TUBE4X25C ESI a d do P 7 BARBL25M 1m umbilical BARB4X25 BARB4RA OD6xID4 valve tube BARB4X25RA 34R hydraulic components SOLVENT Fig 13 34R TZ 34 print head tubes and fittings A038 Direct Prime BARBL25F TUBE4X25C 1 9 BARBL4M BARB4X25 PUMPA Fig 14 TZ34 TZ54 and TZ72 Ink system tubes and fittings TZ series Service Manual The TZ system architecture 13 ALE Design Print Trace 26 11 2009 1 4 3 TZ54 hydraulic architecture Below are graphics describing the ink circuit in the ink system Fig 14 the umbilical Fig 16 and the print head Fig 15 Always replace tubes and fittings with those supplied by ALE 54R hydraulic components OIL al Ss BARB4RA CHL O BARBL4M OIL valve n i tube HRHD Xaar 54mm HU _ J print engine double shut off T BARBARA valve BARBCPCF Fig 15 54R TZ 54 Print head barbs and fittings TZ series Service Manual The TZ system architecture 14 ALE Design Print Trace 26 11 2009 BARB4X25 in m P E 1 m umbilical z Mni s in d BARB3PF230 DR BARBL25M um jm y BARBL4F ij B double shut off uc valve BARBCPCM Fig 16 TZ54 and TZ72 Umbilical tubes and fittings 1 1 4 4 TZ72 hydraulic architecture Below are graphics describing the
15. ble to flush the print head with a syringe see 2 8 Flushing a TZ18 34 print head with a syringe If the nozzles remain blocked contact your distributor Engine not printing or exactly half of engine not printing e Loose connection check ribbon cables in print head gt Replace connector or use silicone paste as necessary No print photocell does not work e Installation uses a shaft encoder and line is stationary TZ series Service Manual Maintenance 48 ALE Design Print Trace 26 11 2009 gt Line must be moving for photocell to be detected when controller set in shaft encoder mode e When using the I O monitor function on controller other functions menu the display changes to P10 during photocell activation 2 Photocell is OK problem with message e O monitor normally shows and changes to POO when photocell is activated 2 Detection is inverted change photocell or change the detection setting in the controller e O monitor always shows 2 Fault in photocell connector or controller First try an alternative photocell to verify that controller is OK e O monitor always shows P10 2 Fault in photocell connector or controller First try an alternative photocell to verify that controller is OK No print shaft encoder does not work e When using the I O monitor function on controller other functions menu the display A00 changes rapidly to A10 A11
16. e entire range of ALE ink systems containing a valve which is automatically sealed during bottle removal and fitting TZ series Service Manual The TZ system architecture ALE Design Print Trace 26 11 2009 The reservoir is normally open to air via the air vent hole Fig 1 When the bottle or shipping cap is fitted the reservoir is completely sealed except at the print engine nozzles and the air vent Fig 1 Reservoir air vent 1 1 1 TZI18 ink circuit Below is a schematic describing the TZ18 ink circuit It includes a reservoir a direct prime module a pump an ink tube and a shut off valve for the print head with a syringe connection The shut off valve allows to close the ink circuit between the ink reservoir and the print engines Because the syringe connection is located between the valve and the print engines it is possible to use a syringe to flush the print engines only the valve is closed for that operation see 2 8 Flushing a 1218 34 print head with a syringe TZ series Service Manual The TZ system architecture 2 ALE Design Print Trace 26 11 2009 6X4 tube RESERVOIR CLOSED OPEN Shut off valve XAAR 128mm PRINT ENGINE Luer for syringe connection 16 05 07 AF Fig 2 TZ18 ink circuit Priming mode the pump sucks ink from the reservoir and sends it towards the print engine through the umbilical If the shut off valve is closed nothing happens If
17. e pump can operate at two pressure rates e Norm normal power priming used to remove small air bubbles from the circuit or to clean the nozzles plate The pump is only activated for a few seconds at a time e Jet high power priming used to fill an empty ink circuit The pump is connected to the driver board and is activated by the controller using a Pulse Width Modulated PWM signal 1 3 Electronic components driver boards The function of the driver board is the transmission of the data sent by the controller to the relevant equipment It is involved in all operations of the printing system The TZ18 and TZ34 driver boards are quite similar as they are printing with 18mm print engines 1 for the TZ18 2 for the TZ34 The TZ54 has a visually close but technologically very different driver board from TZ18 and 34 b4mm print band instead of 1x or 2x 18mm different protocol The TZ72 is driven by a special driver board as the Seiko print engine has a different print height and a different protocol from 18 34 and 54mm Xaar print engines TZ series Service Manual The TZ system architecture 7 ALE Design Print Trace 26 11 2009 Note TZ18 34 and 54 driver board is located in the ink system whereas 72mm driver board is located in the print head enclosure 1 3 1 TZ18 and TZ34 driver board The driver board for TZ18 and TZ34 systems is the same It is called ETXDBO2 and is located in the ink system next to the pu
18. ervice Manual Service procedures 34 ALE Design Print Trace 26 11 2009 e Unscrew the two M4 dome nuts from the back of the print head with a 7mm key Fig 54 Fig 54 remove M4 dome nuts e Push the valve switch inside the tube and rotate the tube with respect to the back plate to hold the switch inside Fig 55 Fig 55 push the switch inside the tube e Move the tube backwards and remove it from the print head Fig 56 and Fig 57 TZ series Service Manual Service procedures 35 ALE Design Print Trace 26 11 2009 Fig 57 tube removed from the print head 2 9 2 Open the TZ34 print head Follow this procedure e Completely flush the print head first Remove the ink bottle and purge the ink circuit until nothing comes out of the print engines see controller instruction for purging e Unscrew and remove the two M4 dome nuts from the back plate Fig 58 TZ series Service Manual Service procedures 36 ALE Design Print Trace 26 11 2009 Fig 58 Unscrew the two M4 dome nuts e Remove the syringe plug Fig 59 and the back plate Fig 60 TIT THAI RE ju v T ae 1 TR r ra lt A E f Fig 59 remove the Syringe plug e OUE Fig 60 remove the back plate e Unscrew the two M5 shoulder screws 3mm Allen key Fig 61 and the M3 button head screw 2mm Allen key Fig 62 from the tube TZ series Service Manual Service procedures 37 ALE Design
19. flows back to the reservoir through the 4x25 tube This is particularly useful to get rid of air in the umbilical e g when the system is dry without losing ink the pump will force the air back into the reservoir where it can escape through the air cap hole When there is no air left in the umbilical only ink is sent back to the reservoir If the shut off valve is open most of the ink will go through the filter and then the print engine A small part of the ink will still go back to the reservoir through the 4x25 tube When the pump is active the ball in the direct prime module blocks the way and the ink cannot go back to the reservoir When the pump is inactive the balls goes out of the way and the ink can pass through the direct prime module see Fig 6 Printing mode the print engine takes ink from the reservoir through the direct prime module through the 6X4 tube the valves and the filter The ink is ejected by the print engine nozzles TZ series Service Manual The TZ system architecture 6 ALE Design Print Trace 26 11 2009 yeseeceseopecoe 09090040980900500000200098 90200020009 80 lg E a a a O89 PIDLODO IO AEPOCIHCRPPOPOADO CG s RESERVOIR III IIIA PUMP PRIMING MODE PUMP ACTIVE PRINTING MODE PUMP IDLE Fig 6 Direct prime 1 2 Pump function The pump only function is to prime the ink circuit It is not used to refill the reservoir this is done automatically by gravity Th
20. g 25 disconnect and extract the print engine replace the print engine assembly and reassemble the print head by following the steps in reverse order 2 5 2 Changing a TZ34 print engine To change the TZ34 print engine follow these steps TZ series Service Manual Service procedures 22 ALE Design Print Trace 26 11 2009 open the print head by following the instructions given in 2 9 2 the 1434 print head Disconnect the print engine electronic connectors Fig 26 q M E EUN ivan iem E MEN ALL 2 _ 185 471 aig M AM 1 UM DO y i P 3 A 1 aX e M E c 1 ae d a a gt de 4 EN rv is T Y Fig 26 unplug the electronic connectors Disconnect the ink tubes from the print engines Fig 27 and extract the print engines assembly Fig 28 Fig 27 disconnect ink tubes Ex Fig 28 extract the print engine assembly Remove the ink tubes left Fig 29 TZ series Service Manual Service procedures 23 ALE Design Print Trace 26 11 2009 _ 3 Fig 29 remove the old ink tubes Unscrew the flat head screw holding the defective print engine Fig 30 and remove the print engine Fig 31 Fig 31 remove deficient print engine Fig 30 unscrew M2 5 flat head screw Fit the
21. int head enclosure When disconnected both ends will shut off automatically This allows to separate the print head from the umbilical e g for servicing See chapter 2 7 2 Separate TZ54 print head from ink system for instructions on this operation RESERVOIR DIRECT PRIME 4X25 tube Xaar 54mm PRINT ENGINE Shut off valve 03 03 09 AF Fig 4 TZ 54 ink circuit 1 1 4 TZ72 ink circuit Below is a schematic describing the TZ72 ink circuit It includes a reservoir a direct prime module a pump two ink tubes a CPC connector more details below a shut off valve for the print head and a filter The CPC shut off valve is a special disconnectable valve at the back of the print head enclosure When disconnected both ends will shut off automatically This allows to separate the print head from the umbilical e g for servicing See chapter 2 7 3 Separate TZ72 print head from ink system for instructions on this operation TZ series Service Manual The TZ system architecture D ALE Design Print Trace 26 11 2009 RESERVOIR 4X25 tube double shut off valve SEIKO 72mm PRINT ENGINE Shut off valve 10 04 07 AF Fig 5 TZ72 Ink circuit The ink circuit works in two modes priming and printing Priming mode the pump sucks ink from the reservoir and sends it towards the print engine through the umbilical If the shut off valve is closed or the CPC is disconnected all the ink
22. ion print down with a collecting bucket Fig 74 Fig 74 ink collection configuration e Use the pump in jet mode see controller user manual for details as many times as necessary to empty the system from ink e When ink is out replace the air cap and the shipping cap on the reservoir e Flush the print head TZ18 34 with air see 2 8 Flushing a TZ1 8 34 print head with a syringe to expel the remaining ink 3 2 2 the printer Pack with care Make sure the nozzle plate cannot be damaged during transport a protection cap is delivered with each TZ1 8 34 3 3 Managing effects of large temperature changes Inks are sensitive to the temperature of the environment The temperature range that is acceptable will depend on the type of ink used and the application TZ series Service Manual Maintenance 46 ALE Design Print Trace 26 11 2009 It is important to establish that the inks in use will be appropriate for all seasons of the year e If the factory is very hot in summer and very cold in winter the ink may give different print results e Do not install the system near a window where direct sunlight can affect it Large almost empty ink bottles are sensitive to significant temperature variations in a short period of time for example between day and night The air in an empty bottle will expand and contract with temperature and cause the reservoir level to move up and down Depending on the ink types
23. models 2 Open all CodeX files change the head configuration to 1x34mm etc save and close Fig 75 Horizontal print errors due to depriming 4 Fig 76 Vertical print errors due to electronic problem or interference Leak from lowest print engine e Bottle is almost empty together with large temperature changes 2 Use smaller bottles or fit shipping cap e Reservoir level too high gt Alter level Pump will not prime the sound of the pump is too high e Air leak in tubes or fittings gt If leak is not obvious return for repair e Kinked tube gt Inspect for kinks in pump tube TZ series Service Manual Maintenance 50 ALE Design Print Trace 26 11 2009 e Direct prime module is blocked gt Return for repair Pump runs continuously e FPGA is damaged perhaps due to incorrect use of internal photocell option gt Replace FPGA chip e Pump wire is shorted somewhere gt Inspect and repair TZ series Service Manual Maintenance 5
24. mp This driver board is also used in ET systems in the same way FROM CONTROLLER PRINT ENGINES 12V e Fig 7 ETXDBO2 driver board With TZ18 only J2 is connected to the only one print engine contained in the print head In TZ34 J2 is connected to the top print engine and J3 is connected to the bottom one In case you need to change the driver board or the FPGA chip that is fitted on it the ALE references are the following e ETXDBO2 driver board for TZ18 or TZ34 system PCB TZX e FPGAchip for TZ18 or TZ34 ACTTZX 1 3 2 TZ54 driver board The driver board for TZ54 has approximately the same shape as the TZ18 34 driver board but uses a different technology It is called TzDB and it is located in the ink system next to the pump TZ series Service Manual The TZ system architecture 8 ALE Design Print Trace 26 11 2009 It features an IEEE1394 aka FireWire connector to plug the print head whereas ETXDBO2 uses 1 or 2 14 pin connectors Another change compared to ETXDBO2 is that the ink low detection circuit is integrated on the driver board The potentiometer to adjust the ink low detection which is located on the TzDB driver board is accessible from outside without having to open the ink system see TZ 54 user manual The FPGA of the TzDB is soldered and does not need to be replaced In case of replacement the reference of the TZ54 driver board is PCB TZDB FROM J series controller To
25. nt head from ink system for instructions on separating the print head from the rest of the printer 2 6 Adjusting the ink low detection In Tz18 34 and 72 the ink low detection PCB is mounted onto the pump plate on the same side as the pump In Tz54 the ink low detection circuit is integrated on the driverboard PCB and adjustable from outside Ink low detection has been specifically adjusted in ALE factory and should not be changed there is a risk of running the printer dry or to have a too frequent ink low signal on the controller 2 6 1 Tz 18 34 and 72 ink low detection adjustment Proceed as follows if you still wish to adjust ink low detection e Switch the controller OFF e Open the ink system as in 2 4 Open the ink system e Use a long and thin cross head screwdriver to reach the potentiometer on the ink low PCB Fig 36 e Switch the controller ON TZ series Service Manual Service procedures 27 ALE Design Print Trace 26 11 2009 e Adjust the potentiometer as necessary Don t forget that ink low detections have a latency ink takes a bit of time to drip from the detection tubes n Y Fig 36 Ink low adjusting 2 6 2 Tz 54 Ink low adjustment On Tz54 the ink low detection potentiometer is accessible from outside Fig 37 gt Fig 37 Tz 54 Ink low adjustment Fig 38 Tz 54 ink low adjustment e Usea long and thin cross head screwdriver to reach the potentiometer on the ink lo
26. oller power OFF and remove the data cable e Undo the 4xM4 button head screws at the back of the print head Fig 44 E Fig 44 screws Fig 45 Pull the back plate e Pull the back plate Fig 45 TZ series Service Manual Service procedures 30 ALE Design Print Trace 26 11 2009 e Disconnect the prime switch wiresFig 46 Fig 46 Disconnect prime switch wires Fig 47 Disconnect ink shut off valve e Disconnect the ink shut off valve Fig 47 e Disconnect the earth cable Fig 48 e pe ccm m E E E ES E Li E LI E Fig 49 Disconnect the 10 pin connector Fig 48 Disconnect the Earth wire TZ series Service Manual Service procedures 31 ALE Design Print Trace 26 11 2009 e Disconnect the 10pin connector coming from the umbilical Fig 49 e Unscrew with a 5mm key and disconnect the 25pin connector Fig 50 Fig 50 Unscrew and disconnect the 25pin connector To reassemble the print head and the umbilical follow the same steps in reverse order TZ series Service Manual Service procedures 32 ALE Design Print Trace 26 11 2009 2 8 Flushing a TZ18 34 print head with a syringe By connecting a syringe at the back of the print head it is possible to flush only the print engines and not the rest of the circuit Fig 51 flushing the TZ18 34 print head with a syringe To empty the print head for transportation
27. replacement tube on the remaining print engine given with the replacement print engine Fig 32 TZ series Service Manual Service procedures 24 ALE Design Print Trace 26 11 2009 pa Fig 32 fit replacement tube Put the new print engine in place Fig 33 Fig 33 put the new print engine Re screw the M2 5 flat head screw TZ series Service Manual Service procedures 25 ALE Design Print Trace 26 11 2009 Fig 34 re screw the M2 5 screw Connect the ink tubes coming from the print engines to the ink circuit Si 5 na 35 re uy he Becton connectors Re connect the print engines electronic connectors Fig 35 reassemble the rest of the print head by following the steps given in 2 9 2 0pen the TZ34 print head in reverse order TZ series Service Manual Service procedures 26 ALE Design Print Trace 26 11 2009 2 5 3 Changing the TZ54 print engine Due to the fragility of the 54mm Xaar print engine and the complexity of the print head the print head should be sent back to ALE for this operation See chapter 2 7 2 Separate TZ54 print head from ink system for instructions on separating the print head from the rest of the printer 2 5 4 Changing the TZ72 print engine Due to the fragility of the 72mm Seiko print engine and the complexity of the print head the print head should be sent back to ALE for this operation See chapter 2 7 3 Separate TZ72 pri
28. ressure to clear air from the tubes in new systems or in systems that have run dry gt Temporarily set the prime pressure to HIGH and prime TZ series Service Manual Maintenance 47 ALE Design Print Trace 26 11 2009 e Print heads are being lifted by the customer during priming so air flows back in to the engines due to incorrect level gt Print heads should not be moved during priming e Shocks to umbilicals or print heads gt Isolate from source of vibration e Pump has failed gt Prime while checking for a good flow of ink from print engine s e Tubes kinked a kink occurs when a tube bends too much gt Prime while checking for a good flow of ink from print engine s With TZ34 system check for the same flow from both engines e Bottle valve is not opening properly or worn out due to the same bottle being re used gt Don t re use bottles Bottom of print missing on an engine e Needs priming gt Prime e Ink reservoir level too high causing an ink bubble on nozzles gt Adjust levels gt Reservoir level too high due to empty bottle together with large daily temperature changes gt Air leak in tubes or seals of reservoir pump or badly fitted bottle Top of print missing on an engine e Needs priming gt Prime Random dots missing e Nozzles blocked by a particle or by drying solvent version gt Purge the print head use the Jet position If the problem remains on a TZ18 34 it is possi
29. sends it towards the print engine through the umbilical If the shut off valve is closed all the ink flows back to the reservoir through the 4x25 tube This is particularly useful to get rid of air in the umbilical e g when the system is dry without losing ink the pump will force the air back into the reservoir where it can escape through the air cap hole When there is no air left in the umbilical only ink is sent back to the reservoir If the shut off valve is open most of the ink will go through the print engines A small part of the ink will still go back to the reservoir through the 4x25 tube When the pump is active the ball in the direct prime module blocks the way and the ink cannot go back to the reservoir When the pump is inactive the balls goes out of the way and the ink can pass through the direct prime module see Fig 6 TZ series Service Manual The TZ system architecture 4 ALE Design Print Trace 26 11 2009 Printing mode the print engines take ink from the reservoir through the direct prime module through the 6X4 tube the valves and the filter The ink is ejected by the print engines nozzles 1 1 3 TZ54 ink circuit Below is a schematic describing the TZ54 ink circuit It includes a reservoir a direct prime module a pump two ink tubes a CPC connector more details below a shut off valve for the print head and a filter The CPC shut off valve is a special disconnectable valve at the back of the pr
30. tronic components driver boards 1 3 1 TZ18 and TZ34 driver board 1 3 2 TZ54 driver board 1 3 3 TZ72 driver board J VU A N 1 4 Hydraulic architecture 1 4 1 TZ18 hydraulic architecture 1 4 2 TZ34 hydraulic architecture 1 4 3 TZ54 hydraulic architecture 1 4 4 TZ72 hydraulic architecture 1 5 Colour codes and ink compatibility 2 Service procedures 2 1 Replacing the FPGA chip on a driver board 2 1 1 Replacement of TZ18 or TZ34 FPGA chip 2 1 2 Replacement of TZ72 FPGA chip 2 2 Replacing the driver board 2 2 1 Replacement of TZ18 or TZ34 driver board 2 2 2 Replacement of TZ54 driver board 2 2 3 Replacement of TZ72 driver board 2 3 Access to the ink reservoir N XO co co co co OO Ui HR UU 2 4 Open the ink system TZ series Service Manual ALE Design Print Trace 26 11 2009 2 5 Changing a print engine 22 2 5 1 Changing the TZ18 print engine 22 2 5 2 Changing a TZ34 print engine 23 2 5 3 Changing the TZ54 print engine 28 2 5 4 Changing the TZ72 print engine 28 2 6 Adjusting the ink low detection 28 2 6 1 Tz 18 34 and 72 ink low detection adjustment 28 2 6 2 Tz 54 Ink low adjustment 29 2 7 Separating the print head from the ink system 30 2 7 1 Separate TZ18 or TZ34 print head from ink system 30 2 7 2 Separate TZ54 print head from ink system 30 2 7 3 Separate TZ72 print head from ink system 31 2 8 Flushing a TZ1 8
31. ump plate and 4 M4 button head screws through the ink tray Remove the ink tray Be careful that a small o ring from the reservoir lid doesn t stick to it TZ series Service Manual Service procedures 19 ALE Design Print Trace 26 11 2009 Fig 19 remove M4 and M5 screws from the ink tray LS Fig 21 Remove the side panels assembly from the pump plate e Remove the lid of the reservoir You now have access to the contents of the reservoir TZ series Service Manual Service procedures 20 ALE Design Print Trace 26 11 2009 2 4 Open the ink system e Unscrew the 3x M4 button head screws shown in Fig 23 and move the back plate backwards M4 button head screws Fig 23 Open ink system 2 5 Changing a print engine 2 5 1 Changing the TZ18 print engine To change the TZ18 print engine follow these steps open the print head by following the instructions given in 2 9 1 Open the TZ18 print head Disconnect the ink tube between the print engine and the valve Fig 24 TZ series Service Manual Service procedures 21 ALE Design Print Trace 26 11 2009 Fig 24 disconnect the ink tube Disconnect the print engine connector and extract the print engine assembly Fig 25 1 2 PLA W LX ud 4 t mts TEC cow J M l es Jm j ETE s e h 1 p a WE F M Fi
32. use the syringe without any fluid The syringe will be used to expel the fluid from the print engines To recover a missing dot fill the syringe with ALE SSBX solvent if the machine is for BSBNPX ink FDFLUSH if the machine is for BODNPM ink or with A SOB if the machine is for A BOB ink Disconnect the print head from its bracket and put it over a collecting tray To connect the syringe to the print head remove the syringe cap from the back of the print head and screw the syringe luer not too tightly the thread is conical and may be very hard to unscrew Flush the print head as desired remove the syringe and plug the syringe cap back After flushing to recover missing dots it will be necessary to go again through the priming procedure to refill the print engines with ink TZ series Service Manual Service procedures 33 ALE Design Print Trace 26 11 2009 2 9 Opening the print head 2 9 1 Open the TZ18 print head e Completely empty the print head first Remove the ink bottle and purge the ink circuit until nothing comes out of the print engines see controller instruction for purging e Unscrew the M4 grub screw from the tube with a 2 mm Allen key Fig 52 F Fig 52 unscrew the grub screw from the tube e Unscrew the two M5 shoulder screw from the tube with a 3 mm Allen key Fig 53 f PY m Fig 53 unscrew the shoulder screws from the tube TZ series S
33. w PCB Fig 38 e Switch the controller ON e Adjust the potentiometer as necessary Don t forget that ink low detections have a latency ink takes a bit of time to drip from the detection tubes TZ series Service Manual Service procedures 28 ALE Design Print Trace 26 11 2009 2 7 Separating the print head from the ink system 2 7 1 Separate TZ18 or TZ34 print head from ink system e Empty the ink circuit remove the ink bottle use the jet function of the purge menu of the controller to empty the ink circuitOpen the ink system as in 2 4 Open the ink system Disconnect the ink tube s between the back plate and the ink system If possible close the tubes with caps to protect the ink circuit from the dust 2 7 2 Separate TZ54 print head from ink system Follow these steps e Switch controller power OFF and remove the data cable e Undo the 4xM4 button head screws at the back of the print head Fig 39 e Pull the back plate Fig 40 Fig 39 Unscrew the 4 M4 screws Fig 40 Pull the back plate e Disconnect the double shut off valve Fig 41 e Disconnect the FireWire cable coming from the umbilical into the print head Fig 42 e Disconnect the earth connector Fig 43 TZ series Service Manual Service procedures 29 ALE Design Print Trace 26 11 2009 j Fig 42 FireWire cable Fig 41 double shut off valve 2 7 3 Separate TZ72 print head from ink system Proceed like this e Switch contr
34. y extract the print engine assembly from enclosure To reassemble the print head follow this procedure in reverse order TZ series Service Manual Service procedures 40 ALE Design Print Trace 26 11 2009 3 Maintenance 3 1 Periodic service You can contact A for a service kit containing all the necessary filters o rings and tubes 3 1 1 TZ18 and TZ34 print heads The following actions should be taken during the periodic service e Open the print head by following the instructions given in 2 7 1 Open the TZ18 print head or 2 7 2 Open the TZ34 print head e Inspect tubes and fittings for leaks e Inspect ribbon cables for possible damage e clean interior and exterior surfaces 3 1 2 TZ54 print head The following actions should be taken during the periodic service e Open the print head by following instructions given in 2 9 3 the TZ54 TZ72 print head e Inspect tubes and fittings for leaks Clean interior and exterior surfaces Replace the filter ALE ref FILTPAPER as follows gt Put tissue paper under the filter gt Disconnect it on each side Fig 69 TZ series Service Manual Maintenance 41 ALE Design Print Trace 26 11 2009 Fig 69 Disconnect 54R ink filter 2 Replace it with a new one The filter has a flow direction indicated by an arrow that needs to be respected gt Tightly fasten the conical fittings around the filter as they ensure the sealing Fig 70 Fig 7
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