43s Ink Jet

Printer
Service Manual

P/N 361451-01
Revision: AC, September 2003

Copyright 2003, 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
Wood Dale, IL
60191-1073 USA
www.videojet.com

Phone: 1-800-843-3610
Fax:
1-800-582-1343
Intl Fax: 630-616-3629

Offices - USA: Atlanta, Chicago, Los Angeles, Philadelphia

INTL: Canada, France, Germany, Ireland, Japan, Spain,
Singapore, The Netherlands, The United Kingdom
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 users 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 reasonable 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 has been tested and certified for compliance with U.S.
regulations regarding safety and electrical emissions by TUV Rheinland of
North America, Inc.

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Videojet 43s Inkjet Printer Service Manual

For Customers in Canada

This digital apparatus does not exceed the Class A limits for radio noise
emissions from digital apparatus set out in the Radio Interference
Regulations of the Canadian Department of Communications.
This equipment has been tested and certified for compliance with
Canadian regulations regarding safety and electrical emissions by TUV
Rheinland of North America, Inc.

Pour la clientle du Canada

Le present appareil numerique nemet pas de bruits radioelectriques
depassant les limites applicales aux appareils numerique de las class A
prescrites dans le Reglement sur le brouillage radioelectrique edicte par le
ministere des Communications du Canada.
Cet quipement est certifi CSA.

For Customers in the European Union

This equipment displays the CE mark to indicate conformance to the
following legislation.
Applicable EMC standards:
BS EN55022 Class B 1998 Emissions standards for information
technology equipment
BS EN61000-3-2 2000 Harmonic Current Emissions
BS EN61000-3-3 1995 Voltage Fluctuation and flicker
BS EN61000-6-2 1999 Immunity standard for Industrial Environment
BS EN61000-4-2 1995 ESD Requirements
BS EN61000-4-3 1997 Radiated Susceptibility
BS EN61000-4-4 1995 Electrical Fast Transient Burst Requirement
BS EN61000-4-5 1995 Surges Requirements
BS EN61000-4-6 1996 Conducted Susceptibility
BS EN61000-4-11 1994 Voltage Dips and Interruptions

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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: 1-800-843-3610
Fax: 1-800-582-1343
International Fax: 630-616-3629
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 Tot al 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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Videojet 43s Inkjet Printer 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.

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Table of Contents
Compliance Information
For Customers in the U.S.A.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
For Customers in Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Pour la clientle du Canada. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
For Customers in the European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Support and Training
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Service Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Customer Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Table of Contents

Chapter 1 Introduction
About this Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Writing Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Associated Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mains Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hazard Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Warning Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Caution Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chapter 2 Installation
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Required Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Unpacking and Inspecting the Printer . . . . . . . . . . . . . . . . . . . . . . 22
Preparation for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Clean Start/Stop Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Jet Start and Stop Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Quick Start Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Clean Start Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Clean Stop Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Setting up Shifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Production Line Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Throw Distance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Shaft Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

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Internal Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

External Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Product Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Chapter 3 Consumables
Selecting Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Ink and Solvent Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Chapter 4 Firmware Download

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Windows 3.xx Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Checking the Communications Link . . . . . . . . . . . . . . . . . . . . . . . . 42
Using Microsoft Windows 3.xx to Download Firmware . . . . . . . 43
Windows 95/98/2000 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Checking the Communications Link . . . . . . . . . . . . . . . . . . . . . . . . 45
Using Windows 95, 98 or 2000 to Download Firmware . . . . . . . . 47
Boot Monitor Recovery Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Chapter 5 Calibration and Testing

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Earth Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Machine Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Pressure Zero Offset Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Cooling Fan Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
I/O Board LED Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Gutter Fault and Charge Error Disable . . . . . . . . . . . . . . . . . . . . . . . . . 56
Voltage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Calibrate 285 V Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Reset Run Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Set EHT Trip Level (for printhead setup only). . . . . . . . . . . . . . . . . . . 59
About the Low Fluid Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
Fill Mixer Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
Entering Fluid Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
Manually Priming the Flush Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
VMS Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
Nozzle Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
Strobe LED Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
Ink Jet Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
Head Heater Temperature and Ink Pressure . . . . . . . . . . . . . . . . . . . 520
Modulation Calibration (Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521

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Phase Profile Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524

Phase Offset Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
Print Charge Value Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
Setting EHT Tables for Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
Clean Shutdown Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
Set EHT Trip Level (Normal Operation). . . . . . . . . . . . . . . . . . . . . . . 529
EHT Trip Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
Print Height Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
Backup Calibration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
Restore Calibration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
Enable Gutter Detect and Charge Check . . . . . . . . . . . . . . . . . . . . . . 533

Chapter 6 Technical Description

Main Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Electronics System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Connector Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
Control Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614
CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622
Ink Pump Motor Driver Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 636
PSU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639
General Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639
Output Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640
Electronics Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641
Electronics Compartment Cooling Fan. . . . . . . . . . . . . . . . . . . . . 641
EHT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
Ink System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
Mains Input Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
Ink System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
Top Up and Ink Reservoirs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646
Ink System Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646
Fluid Management System (FMS) . . . . . . . . . . . . . . . . . . . . . . . . . 649
Printhead Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 652
Ink Jet Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 652
Droplet Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653
Droplet Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654
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Ink System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655

Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655
Viscosity Monitoring System Sequence . . . . . . . . . . . . . . . . . . . . 657
Clean Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658
Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 660
Clean Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661
Quick Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663
Nozzle Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664
Ink Addition to Mixer Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664
Top Up Addition to Mixer Tank . . . . . . . . . . . . . . . . . . . . . . . . . . 664

Chapter 7 System Software

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Using the Menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Messages Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Editor Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
User Fields Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Print Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Password Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
System Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Configure Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710
Calibrate Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712
Data Logging Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714

Chapter 8 Assembly / Disassembly

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
PSU Module Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
LCD and Backlight Inverter Assembly . . . . . . . . . . . . . . . . . . . . . . . . 811
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 813
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Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 813
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
Ink and Top Up Reservoir Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 816
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 816
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 816
Exchanging the Sensor and LED . . . . . . . . . . . . . . . . . . . . . . . . . . 816
Fluid Management System (FMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 818
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 818
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 820
Ink System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 821
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 821
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 822
Main Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 824
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 824
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 826
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 826
Flush Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 827
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 827
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 828
Solenoid Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 828
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 828
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 828
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 830
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 830
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 831
Fan Failure Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 832
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 832
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 833
EHT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 834
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 834
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 834
Head Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 835
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 835
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 836
Phase Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 837
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 837
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 838
EHT Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 839
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 839
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 840
Nozzle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 841
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 841
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 842

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Umbilical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 843
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 843
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 845
Positive Air Pump (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 847
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 847

Chapter 9 Maintenance Schedule

Chapter 10 Troubleshooting
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Printer Fails to Initialize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Display Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Backlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Keypad Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Display Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Mixer Tank Level High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1013

Chapter 11 Cleaning and Adjustment

Valve Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
VMS Inlet Restrictor Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
VMS Outlet Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Umbilical Purge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Printhead Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Chapter 12 Illustrated Parts List

How to Use This Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Optional Parts and Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
43s Ink Jet Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Stands and Lamp Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Encoders and Encoder Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Product Detectors and Detector Accessories . . . . . . . . . . . . . . . . . . . 124
Networking Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Other Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Major Sub-Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Keypad and LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Connector Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1210

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Electronics Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1212

Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1214
FMS Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1216
Ink Bottles and Ink System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 1219
Ink Filler Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1221
Miscellaneous Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1222

Chapter 13 Tools and Spare Part Kits

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Basic start up kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Service tool kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Other tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Spare parts kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Ink system filter kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Basic spare parts kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Comprehensive spare parts kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Appendix A Circuit Diagrams

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foldout 1: CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foldout 2: I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foldout 3: Pump Motor Control Board . . . . . . . . . . . . . . . . . . . . . . . .

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Introduction

About this Guide

Welcome to the Service Manual for the Videojet 43s Inkjet printer.
This manual is intended as a reference guide for trained service personnel
and contains the following information:
installation and calibration instructions;
disassembly and reassembly instructions for field-replaceable
components;
a technical description of the principles of operation of the printer;
a troubleshooting guide;
a quick reference guide to the control software which describes the
function of each menu item.

Writing Conventions
Positional References
Unless stated to the contrary, positions and directions such as left, right,
front, rear, clockwise and counter-clockwise are given with respect to the
printer when viewed from the front.
Units of Measurement
This handbook uses metric units of measurement. The equivalent English
measures are included in parenthesis.

Associated Publications
The following publications are related to this document:
Videojet 43S Ink Jet Printer Instructions for Use, Part Number: 361450.

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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 361451-04.
Code

Language

Availability (see note)

01

English (US)

02

French

03

German

04

Spanish

05

Portuguese

06

Japanese

07

Russian

08

Italian

09

Dutch

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 Instructions for Use is indicated by an asterisk (*).
Availability of the Service Manual is indicated by a plus sign (+). For more
information, consult your Videojet distributor or subsidiary.

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Installation and Inspection

The equipment described in this handbook must be installed and
subsequently inspected at the recommended intervals by qualified service
and maintenance personnel.

Mains Power Supply

Ensure that the mains electrical supply is within the range indicated by the
label adjacent to the mains inlet on the printer. If the voltage ratings differ,
do not use the printer until you have consulted your local supplier.
Use only the mains power cable supplied with the printer. This cable must
terminate in an approved, three-pole, mains plug which has a protective
ground conductor.
Keep electrical power cables, sockets and plugs clean and dry at all times.

Grounding
The equipment must be connected only to an a.c. power supply, which has
a protective ground conductor in accordance with IEC requirements or
applicable local regulations. Any interruption of the protective ground
conductor or disconnection of the protective ground terminal may render
the apparatus dangerous.

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Hazard Information
This section contains important hazard notices. You must read these
notices before using the printer.
The hazard information is prioritized into typographically distinct
warning and caution notices as follows:

Warning
Warning notices denote a potential hazard to the health and safety of
users. These notices clearly state the nature of the respective hazard
and the means by which it can be avoided.
Warning notices, together with the warning symbol shown on the
left, appear in full in the preliminary pages and at their points of
application in the manual. They are presented in the typographical
style of this notice.

Caution
Cautionary notices denote a potential hazard to the physical
integrity of equipment/software but not a danger to personnel.
These notices clearly state the nature of the hazard and the means by
which it can be avoided.
Cautionary notices appear in full in the preliminary pages and at
their points of application in the manual. They are presented in the
typographical style of this notice.

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Warning Notices
Warning
LETHAL VOLTAGES. Lethal voltages are present within this
equipment when it is connected to the mains electrical supply. Only
trained and authorized personnel may carry out maintenance work.
Observe all statutory electrical safety codes and practices. Unless it is
necessary to run the printer, disconnect the printer from the mains
electrical supply before removing the covers or attempting any
service or repair activity, otherwise death or personal injury may
result.

Warning
HANDLING INK, SOLVENT AND TOP-UP. The ink, solvent and
top-up are irritating to the eyes and respiratory system. To prevent
personal injury when handling these substances:
Always wear protective clothing and rubber gloves.
Always wear goggles with side-shields or a face mask. It is also
advisable to wear safety glasses when carrying out maintenance.
Apply barrier hand cream before handling ink.
If ink or top-up contaminates the skin, wash immediately with soapy
water. DO NOT use washdown or solvent to clean ink stains from
the skin.

Warning
RISK OF PERSONAL INJURY. To avoid spillage of ink or top-up, do
not remove the foil seal from the bottle prior to replenishing the ink
or top-up reservoir.

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Warning
FIRE AND HEALTH HAZARD. The ink, solvent and top-up are
volatile and flammable. They must be stored and handled in
accordance with local regulations.
Do not smoke or use a naked flame in the vicinity of these
substances.
Immediately after use remove any tissue or cloths that become
saturated with these substances. Dispose of all such items in
accordance with local regulations.
In the event that any ink, solvent or top-up container is not
completely empty after use, it should be resealed. Only full bottles
are recommended for use when replenishing ink or top ups;
partially filled bottles should be disposed of in accordance with local
regulations.

Warning
WASTE INK. When setting up the nozzle, direct the ink stream into
a beaker or suitable container. To avoid contamination of the ink
supply in the printer, do not re-use any ink collected in this way.
Dispose of all waste ink in accordance with local regulations.

Warning
VAPOUR HAZARD. Prolonged breathing of top-up or cleaning
fluid vapor may cause drowsiness and/or effects similar to alcoholic
intoxication. Use only in open, well-ventilated areas.

Warning
FUSES FIRE HAZARD. To ensure continued protection against the
risk of fire, replace fuses only with the specified type and rating.

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Warning
TOXIC HAZARD. The cleaning agent is poisonous if taken
internally. Do not drink. Seek medical attention immediately if
ingested.

Warning
HANDLING CLEANING AGENT. The cleaning agent is irritating to
the eyes and respiratory system. To prevent personal injury when
handling this substance:
Always wear protective rubber gloves and clothing.
Always wear goggles with side-shields or a face mask. It is also
advisable to wear safety glasses when carrying out maintenance.
Apply barrier hand cream before handling ink.
If cleaning agent contaminates the skin, rinse off with running water
for at least 15 minutes.

Warning
FIRE AND HEALTH HAZARD. The cleaning agent is volatile and
flammable. It must be stored and handled in accordance with local
regulations.
Do not smoke or use a naked flame in the vicinity of the cleaning
agent.
Immediately after use remove any tissue or cloths that become
saturated with cleaning agent. Dispose of all such items in
accordance with local regulations.

Warning
PERSONAL INJURY. Airborne particles and substances are a health
hazard. Do not use high pressure compressed air for cleaning
purposes.

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Warning
EARTH CONTINUITY. To ensure safe earthing the resistance
between the mains lead earth wire and the test points must be less
than 1.

Warning
HANDLING INK, SOLVENT AND TOP-UP. A high ac voltage is
present at the inverter and backlight.
Extreme caution is required when diagnosing failure in these areas.

Caution Notices
Caution
EQUIPMENT DAMAGE. Only Videojet-trained personnel my carry
out installation and maintenance work. Any such work undertaken
by unauthorized personnel may damage the printer and will
invalidate the warranty.

Caution
DEGRADED PERFORMANCE. Machine functions that only
Videojet-trained personnel can access are set at Password Level 3
(MASTER password), these functions must not be given as customer
options.

Caution
ELECTROSTATIC SENSITIVE DEVICES. The printed circuit boards
contain static sensitive devices. A suitably grounded, antistatic wrist
strap must be worn when working on or handling printed circuit
boards.

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Caution
FALSE READINGS. To avoid the risk of false readings, the pump
zero offset should only be calibrated when there is no ink in the
system and the pump is off.

Caution
PRINT QUALITY. To ensure high print quality, ink viscosity must
be checked and must be correct prior to attempting modulation
calibration.

Caution
INCORRECT MEASUREMENT. If the temperature compensation
factor is not used, the end result could be incorrect by as much as
40%.

Caution
EQUIPMENT DAMAGE. Never attempt to bend the gutter. Its
position is fixed.

Caution
DAMAGE TO CHARGE ELECTRODE. Take care not to deform the
charge electrode slot when rotating the charge electrode.

Caution
CHARGE CABLE. Ensure that the charge cable is not pulled out of
its position in the rear face of the deflector block assembly.

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Caution
EQUIPMENT DAMAGE. Never attempt to bend the gutter. It is in a
fixed position.

Caution
EQUIPMENT DAMAGE. The I/O Board LEDS connector must not
be used to drive anything other than LEDs as specified otherwise
damage may occur.

Caution
EXCESSIVE USE OF TOP-UP OR SOLVENT. As solvent is used
during the stop cycle, repeatedly stopping and starting the printer
can lead to excessive use of top-up or solvent and may lead to a
Mixer Tank High error.

Caution
QUICK STOP. After a Quick Stop machine should not be left in this
state for any length of time as drying ink may make restarting
difficult.

Caution
EQUIPMENT DAMAGE. To avoid the risk of overfilling or spillage,
never replenish ink or top-up unless the relevant low icon is shown.
Ensure that ink bottle is completely empty before removing.

Caution
EQUIPMENT DAMAGE. Do not fit or remove any connector on the
printer whilst power is on, otherwise the printer may be damaged.

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Caution
CLEANING MATERIALS. To avoid damage to the printer
components use only soft brushes and lint free cloths for cleaning.
Do not use high pressure air, cotton waste or abrasive materials.

Caution
EQUIPMENT DAMAGE. Ensure that the cleaning agent is
compatible with the ink used before carrying out printhead cleaning
otherwise the printhead may be damaged.

Caution
EQUIPMENT DAMAGE. The printhead must be completely dry
before attempting to start the printer otherwise the printhead may
be damaged.

Caution
PRINTER OVERHEATING. Report all overheating incidents to a
maintenance engineer.

Caution
RISK OF DATA LOSS. Ensure the correct message name is selected
for message deletion as no message selection confirmation prompt is
given.

Caution
RISK OF DATA LOSS. All messages apart from the TEST MESSAGE
will be deleted.

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Caution
RISK OF DATA LOSS. The Clear Message option, when selected,
does not ask for confirmation to clear the message.

Caution
RISK OF DATA LOSS. The Delete user field option does not ask for
confirmation to delete a User Field.

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Hazard Information

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Installation

Introduction
The printer is tested prior to dispatch to the customer. The
Commissioning section in this chapter contains the necessary
instructions for setup and additional testing at the customer site.
Each installation must be approached on an individual basis due to
variations in production line build specifications. Supposedly identical
production lines can vary significantly due to customer requirements or
modifications.
Each installation must be preceded by a site survey to establish the
necessary information relevant to the production line and printer. In some
cases it may be impossible to install a printer; it is therefore of vital
importance that all the installation criteria are met before attempting
installation. The site survey form must be completed as fully as possible by
the sales engineer.
Missing or ambiguous information should be clarified by telephone or fax
prior to the installation procedure.

Warning
LETHAL VOLTAGES. Lethal voltages are present within this
equipment when it is connected to the mains electrical supply. Only
trained and authorized personnel may carry out maintenance work.
Observe all statutory electrical safety codes and practices. Unless it is
necessary to run the printer, disconnect the printer from the mains
electrical supply before removing the covers or attempting any
service or repair activity, otherwise death or personal injury may
result.

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Caution
EQUIPMENT DAMAGE. Only Videojet-trained personnel may
carry out installation and maintenance work. Any such work
undertaken by unauthorized personnel may damage the printer and
will invalidate the warranty.

Required Items
You will need the following items to complete this procedure:
the Service Tool Kit listed in Chapter 13
1 liter of ink
1 liter of suitable top-up
1 liter of suitable wash down

Commissioning
Unpacking and Inspecting the Printer
1 Open the box and visually inspect the machine for transit damage.
2 Check the contents of the box against the packing list.
3 Verify that the correct type of nozzle is fitted to the printhead tray and
that the nozzle is mechanically and electrically fitted. A 60-micron
nozzle for the 43s (P/N 200-0430-141) should have orange and black
wires. Its serial number should begin with an S.
If the incorrect nozzle is fitted or the nozzle needs replacing, refer to
Nozzle Assembly on page 8-41 for instructions on installing a new
nozzle.
Important: Ensure that the nozzle tubes are not yet connected.

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Required Items

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Preparation for Use

(1) Mains power button
(2) Mains power cord
(3) FMS tray
(4) Retainer screw
(5) Breather tube

Figure 2-1. Beginning the commissioning process

Fitting the breather tube
1 Open the ink compartment door as shown in Figure 2-1.
2 Remove the retaining screw (Item 4 in Figure 2-1) and lift the FMS
tray (3) forwards and out of the printer.
3 Remove the blue bulkhead fitting from the end of the breather tube (5)
and attach the fitting to the round hole in the floor of the ink
compartment (near the back wall, just to the left of the ink reservoir).
4 Reattach the breather tube to the newly-mounted fitting.

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Start up calibration and testing

5 Disconnect the electrical connectors from V1 (top-up add valve).
6 If the customer has ordered the positive air pump option, the pump
should be installed now (before the power is switched on). See
Positive Air Pump (optional) on page 8-47 for instructions.
7 If the mains power cord does not already have an AC plug attached,
attach the proper plug now according to the following table:
Wire Color

Description

Brown

Blue

Green/Yellow

Ground

8 Insert the mains power cord in an appropriate electrical outlet and

press the mains power button (1) to switch the printer on. The printer
PSU will automatically detect and adjust to the mains voltage.
The quick screen is displayed on the LCD panel.
9 If nothing is visible on the LCD display, press f3 , then press ctrl
and L. This will cause the LCD to repeatedly cycle through the
complete range of contrast values. Press any key when the LCD is at
the most visible point in the cycle. This locks the contrast at the chosen
value.
10 Select Enter Password from the Password menu (or press Alt + W) and
enter the Master password.
11 Perform a full system reset to clear any erroneous configuration
information. To do this, select Full System Reset from the Configure
menu. Select All Messages Deleted.
12 Re-enter the master password (as in step 10).
13 Perform the following checks and calibration procedures located in
Chapter 5:
a. Pressure Zero Offset Calibration on page 5-4
b. Cooling Fan Check on page 5-4
c. I/O Board LED Check on page 5-5
d. Gutter Fault and Charge Error Disable on page 5-6
e. Reset Run Hours on page 5-8
f. Set EHT Trip Level (for printhead setup only) on page 5-9
Be sure to follow these procedures in the order listed above.
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14 Select Set Time/Date from the Configure menu. Enter the correct details
and then press the Enter key.
Filling the ink system
15 Remove the filler plug (Item 2 in Figure 2-2).
16 Prime the mixer bowl (3) with approximately 250 ml of the correct ink
using a syringe and a length of 40 mm x 6 mm tube. The Mixer Tank
Low icon will cease to be displayed when approximately 250 ml has
been added to the mixer bowl.
(1) FMS tray
(2) Filler plug
(3) Mixer tank

Figure 2-2. Ink Mixer Tank and Filler Plug Location

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Warning
HANDLING INK, SOLVENT AND TOP-UP. The ink, solvent and
top-up are irritating to the eyes and respiratory system. To prevent
personal injury when handling these substances:
Always wear protective clothing and rubber gloves.
Always wear goggles with side-shields or a face mask. It is also
advisable to wear safety glasses when carrying out maintenance.
Apply barrier hand cream before handling ink.
If ink or top-up contaminates the skin, wash immediately with soapy
water. DO NOT use washdown or solvent to clean ink stains from
the skin.

17 Ensure that the complete 250 ml is added before proceeding.

18 Refit the filler plug (2) to the top of the FMS. Then, replace the FMS
tray (1) and the retainer screw.

Caution
INCORRECT CALIBRATION. Do not forget to re-insert the FMS
tray in the printer. Leaving the FMS tray out will cause the
calibrations performed later to be incorrect (the FMS must be level).

19 Pour the remaining ink into the ink reservoir (black cap on top of the
printer). Verify that the ink low icon on the LCD is no longer present
and that the yellow LED near the filler cap is extinguished.
20 Fill the top-up reservoir (white cap on top of the printer) with one liter
of the appropriate top-up solvent. Verify that the top-up low icon on
the LCD is no longer present and that the yellow LED near the filler
cap is extinguished.
21 From the System menu, select Fill Mixer Tank and press enter
. The
pump will start and the mixer tank will fill. The pump will stop
automatically when the ink level is satisfactory.
22 Enter the appropriate information about the ink and top-up being
used (see Entering Fluid Information on page 5-14).

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Removing trapped air

23 Remove the front and rear printhead covers and the nozzle seal (retain
the seal for refitting if the machine has to be transported).
24 Slacken the jet valve (V11) screws.
25 Place tissue paper around the printhead and jet valve to absorb
solvent when the priming procedure commences.

Warning
HANDLING CLEANING AGENT. The cleaning agent is irritating to
the eyes and respiratory system. To prevent personal injury when
handling this substance:
Always wear protective rubber gloves and clothing.
Always wear goggles with side-shields or a face mask. It is also
advisable to wear safety glasses when carrying out maintenance.
Apply barrier hand cream before handling ink.
If cleaning agent contaminates the skin, rinse off with running water
for at least 15 minutes.

26 From the System menu, select System Flush Purge.

27 Press

enter

28 Press Y to confirm or N to cancel the operation.

The machine starts and the flush pump is actuated. During the
actuation of the flush pump, solvent is ejected from beneath the jet
valve.

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29 Allow the machine to run for approximately 30 seconds before

pressing F1 (Abort Flush.).
30 Tighten the jet valve (V11) screws and dry the printhead.
Note: The majority of air should now have been removed. However, if a
significant amount of air remains trapped in the flush system, you can
remove it by manually priming the flush pump. See Manually Priming the
Flush Pump on page 5-15 for instructions.
31 Select Umbilical Purge from the System menu. Enable the purge using
the right arrow key.
32 Leave the machine running and check for leaking tubing and fittings.
33 Disable the umbilical purge by using the right arrow key.
Verifying functionality of the gutter detect system
34 Perform an EHT trip test. See EHT Trip Test on page 5-32.
35 Start the jet by selecting Quick Start from the System menu. Once
running, enable gutter detect by selecting Gutter Detect from the
System menu and then using the right arrow key to select Enable. Press
the Enter key when you are finished. After a few seconds, the machine
should shut down with a gutter error. Verify that the gutter error icon
is showing on the display.
36 Disable gutter detect by selecting Gutter Detect from the System menu
and then using the right arrow key to select Disable. Press Enter.
Restart the jet by selecting Quick Start from the System menu. When
the machine is in running mode, shut it down by selecting Clean Stop
from the System menu or by Pressing F1. Verify that the machine
indicates that it cannot do a clean stop because of a charge error or a
gutter fault and carries out a quick stop instead.

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Connecting the nozzle

37 Extend the nozzle PTFE tubes forwards across the head heater as
shown below. Cut the tubes off at the length required to reach the rear
end of the head heater. It is best if the tubes are cut exactly at the edge
of the manifold.
(1) Nozzle PTFE tube
(2) Bleed barb
(3) Feed barb
(4) Cut line

Figure 2-3. Connecting the nozzle tubes

38 Connect the nozzle tubes to the print head heater as follows:
a. Fit the clear PTFE tube (last chance filter fitted) to the feed barb
(Item 3 in Figure 2-3).
b. Fit the black line PTFE tube to the bleed barb (2).
39 Perform a nozzle flush operation to clean any debris out of the print
head (see Nozzle Flush on page 5-18).
40 Align the printhead (see Printhead Alignment on page 11-7).
VMS calibration
41 Wait 20 minutes to allow the system temperature to stabilize.
42 Press the information key

on the bottom left of the keypad.

43 Observe visc set and visc actual. If these two numbers are more
than three seconds apart, wait until the difference drops to three
seconds (or less).
44 Once visc set and visc actual are within +/- 3 seconds of one
another, select VMS chamber calibration from the Calibration menu.
45 Ensure that Automatic is selected and press enter.
46 Wait for the printer to confirm that calibration of the VMS has been
completed.

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47 Press the information key again and verify that visc set and visc
actual are now identical.
48 Replace the connectors removed from valve V1.
Final configuration and testing
49 Set the throw distance for the clean start/stop, modulation and charge
tests to 14mm.
50 Place a clean sheet of paper under the printhead.
51 Press F1 to stop the jet.
52 When the jet has completely stopped, press F1 to start the jet again.
53 Compare the ink left on the sheet of paper to the pass and fail criteria
shown in Clean Start/Stop Standards on page 2-13. If the sample
does not pass this criteria, refer to Jet Start and Stop Diagnostics on
page 2-14 for help in troubleshooting the problem.
54 Perform the following checks and calibration procedures located in
Chapter 5:
a. Strobe LED Check on page 5-18
b. Modulation Calibration (Manual) on page 5-21
c. Phase Profile Adjustment on page 5-24
d. Phase Offset Calibration on page 5-25
e. Select Auto Modulate from the Calibrate menu and then wait until
the printer informs you that it has finished
f. Print Charge Value Calibration on page 5-26
g. Setting EHT Tables for Printing on page 5-27
h. Set EHT Trip Level (Normal Operation) on page 5-29
i. Print Height Test on page 5-31
j. Enable Gutter Detect and Charge Check on page 5-33
These procedures must be done in the order shown above.

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Test print
55 Input a message. The message must contain a six-digit incrementing
counter.
56 Place an earthed print collector dish under the printhead.
57 Select the created message for printing.
58 Select Continuous Print mode:
a. From the Print menu, select Continuous Print.
b. From the Continuous print sub-menu, set Continuous mode to Time
Mode and Time Mode Delay to 50.

59 From the Configure menu, select Photocell Levels and set the state of the
photocell 1 level to Active High or Active Low as required.

60 The printer should now be printing continuously. Let the printer

complete a minimum of 250,000 prints. Use the counter to monitor the
number of messages printed. Monitor the printer to ensure that the
system functions correctly.
61 At regular intervals access the Calibrate menu and select the
Diagnostics Screen. Monitor the machine parameters and check that
they remain stable. Typical Diagnostics Screen values are shown in
Table 2-1.
Note: The values provided are typical. The exact figures will vary slightly for
each machine depending on the model, ink type and ambient conditions.

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Machine Parameter

Typical Value (see Note above)

Dependency

Ink Pressure

32

Ink type, Pressure set value.

Cabinet Temperature

25

Ambient temperature.

Viscosity Set Point

34

Ink type, Ambient temperature.

Phase Angle

Any value (must be stable)

Correct Jet Break-up.

Ink Temperature

25

Ambient temperature

Head Temperature

35

Ink type, heater set point.

Viscosity Actual

34

Indicated value 1 compared to

Viscosity Set Point = correct
viscosity.

Phase Profile

08-09 (Ideal)

Phase charge, charge value,

Phase pick-up position

Ink (Reservoir Tank)

Covered

Level Detect covered - OK

Level Detect uncovered - LOW

Covered

Level Detect covered - OK

Level Detect uncovered - LOW
or EMPTY

Low
Sol (Top-up Reservoir)
Low

Full

Filling
Emptying Empty

VMS
Mix

Low

On
Empty

High

VMS chamber Sequence

MIXER TANK CONDITION
High - Tank level too High
On - Tank level OK
Low - Tank level too Low

Table 2-1: Typical diagnostics screen values

62 After 250,000 prints have been satisfactorily completed, press f1
and ensure that the printer performs a clean shutdown.
Note: If the machine does not provide an adequate clean start-up or
shutdown during these procedures, refer to Jet Start and Stop Diagnostics
on page 2-14.
63 Once you are satisfied with the current configuration of the printer,
save it as a known good configuration (see Backup Calibration
Parameters on page 5-32).

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Clean Start/Stop Standards

The following illustrations show the minimum acceptable standards for
clean start and clean stop. Compare these to samples obtained by placing a
sheet of blank paper directly under the printhead.
(samples are shown
actual size)

Typical clean
start-up/shutdown

Typical dirty
start-up/shutdown

Minimum standard
required

Figure 2-1. Clean start/stop test illustrations

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Videojet 43s Inkjet Printer Service Manual

Jet Start and Stop Diagnostics

Use the flow charts in this section to diagnose problems with dirty jet
starts and stops.

Quick Start Diagnostics

Figure 2-2. Quick start diagnostics flowchart

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Jet Start and Stop Diagnostics

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Clean Start Diagnostics

Figure 2-3. Clean start diagnostic flowchart, sheet 1

(Continued on next page)

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Videojet 43s Inkjet Printer Service Manual

Figure 2-4. Clean start diagnostics flowchart, sheet 2

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Jet Start and Stop Diagnostics

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Clean Stop Diagnostics

Figure 2-5. Clean stop diagnostics

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Passwords
Liase with the customer and find out which machine functions they want
available to relevant personnel and which passwords they want to use. Set
the Passwords for Levels 1 and 2.

Caution
DEGRADED PEFORMANCE. Machine functions that only Videojettrained personnel can access are set at Password Level 3 (MASTER
password), these functions must not be given as customer options.

Notes: You must be at Password Level 3 to set Password Levels. Do not divulge
the master password to the customer.

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Passwords

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Setting up Shifts
Liase with the customer to confirm shift requirements (if any). The
example below show how to set a shift system where the day is split into
three shifts with each shift numbered from 1 and shift 1 starting at 0700.
1 From the Configure menu, select Set Shifts. The Set Shifts sub-menu is
displayed.

2 Set the shift parameters as follows:

Start hour of shift 1 = 7
Start minutes of shift 1 = 0
Character for shift 1 = 1
Shift length (hours) = 8
Shift length (minutes) = 0
Notes: You must delete the Character for shift 1 using the Backspace or
Delete key before entering a new value.
Once you enter a start time and length, the other shifts are calculated
automatically.
3 Using the Shift criteria defined above, the insertion of a shift at
approximately 15:00 would provide a shift number of 2.
07:00+8=15:00

07:00

07:00+8+8=23:00

SHIFT 1
SHIFT 2
SHIFT 3
00h

08:00

16:00

23:59

Figure 2-4. Shift Setting Diagram

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Production Line Setup

Typical Installation
A typical installation is shown in Figure 2-5, where the printer (6) is
mounted on a printer stand (5). The printhead (4) is configured to print
vertically via a clamp (2) and bracket (3) assembly. A lamp stack (1) is
fitted to the printer stand.

(1) Lamp stack

(2) Clamp
(3) Bracket
(4) Printhead
(5) Printer stand
(6) Printer
(7) Photocell cable
(8) Photocell
(9) Shaft encoder cable
(10) Shaft encoder

Figure 2-5. Typical Production Line Installation

Throw Distance
The optimum throw distance from the printhead to the product is 8 mm.

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Production Line Setup

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Shaft Encoder
Internal Source
If no external shaft encoder is to be fitted then set the Shaft Encoder Source
to Internal, via the Configure menu. However, if the line speed varies then a
shaft encoder must be fitted in order to maintain constant message width.
A Width (Message Parameters) of 1 will provide the fastest print that the
printer can achieve in each font using the Internal Shaft Encoder option.
The message width is increased by approximately 3% for each increment.

External Source
If an external shaft encoder is fitted then set the Shaft Encoder Source to
External, via the Configure menu.
Figure 2-5 shows an external shaft encoder (10) connected via a cable (9) to
the SHAFT ENCODER connector on the connector panel.
The printer can be configured to accept two shaft encoder (quadrature)
outputs. This allows the printer to compensate for changes in direction of
the production line.

Caution
ELECTROSTATIC SENSITIVE DEVICES. The printed circuit boards
contain static sensitive devices. A suitably grounded, antistatic wrist
strap must be worn when working on or handling printed circuit
boards.

If a quadrature shaft encoder is to be used you must do the following:

1 Set jumper JB2 (Item 2 in Figure 2-6) to position B.
2 Download the appropriate special software to the printer.
3 Set the Width Value to 1.
4 Disable Print Trigger 2.
Note: Using quadrature shaft encoders to determine changes of direction disables
the width function (i.e. it must be set to 1). If width control is required, an
external divider box must be provided.

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Product Sensors
Figure 2-5 shows a photocell (8) connected via a cable (7) to PRINT
TRIGGER 1 on the connector panel.
The printer can be configured to use two product sensors (PRINT
TRIGGER 1 and PRINT TRIGGER 2).
Note: The PRINT TRIGGER 2 option requires the use of non-standard system
software.

(1) Input/Output board

(2) Sensor 2/Quadrature shaft encoder jumper JB2
(3) Print trigger 1 and 2 jumper JB1

Figure 2-6. I/O Board, Product Sensor and Shaft Encoder Jumper Location
1 The photocells may be either NPN or PNP devices. Set Jumper JB1
(Item 3 in Figure 2-6) on the I/O board to match the device type.

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Product Sensors

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Table 2-2 lists the settings for jumper JB1.

Print trigger

Device type

Jumper 1

Pins

Jumper 2

Pins

NPN

1-2

3-4

PNP

2-3

4-5

NPN

6-7

8-9

PNP

7-8

9-10

Table 2-2: Jumper JB1 Settings

2 Connect the printer to the mains supply and then press the mains
power button to switch the printer on.
3 Select the Photocell Setup option from the Configure menu.
4 Set the relevant Photocell level(s) to Active high or Active low
dependant upon the device type. (NPN = Active high: PNP = Active
low).

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2-24

Product Sensors

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Consumables

Selecting Fluids
A complete range of inks, top-up fluids and cleaning solutions for the 43s
are available from Videojet. These fluids can be ordered either as
individual bottles or as kits that contain several bottles of ink, as well as
the corresponding top-up fluid and cleaning solution.
See the current 43s ink catalog for more information on currently-available
fluids.

Ink and Solvent Storage

You must follow the precautions listed below for ink and solvent storage:
All inks and solvents should be stored and used in a well-ventilated
area and protected in case of fire.
Store and ship the inks and solvents out of direct sunlight within the
temperature range 5 C to 50 C.
When shipping inks or solvents, comply with the local laws and
regulations.
The risk of fire is an important consideration when storing/shipping
inks and solvents. Aqueous inks and solvents present a low fire risk as
they will not burn or support combustion. Inks based on water/
alcohol mixtures may burn if sufficient alcohol is present. Solventbased inks pose a greater fire risk. Consult the appropriate product
data sheet on the exact nature of the ink/solvent.
Use powder or dry foam to extinguish fires and ensure electrical
supply is turned off. A fire blanket may be used to smother small local
fires. If in doubt consult the local fire authority.
Wipe up any spillage immediately with absorbent material and
dispose of safely. If spillage is large, ventilate the area.
Dispose of ink and solvents in accordance with the local regulations.
Do not dispose of inks and solvents into the local drains.

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Videojet 43s Inkjet Printer Service Manual

Warning
HANDLING INK, SOLVENT AND TOP-UP. The ink, solvent and
top-up are irritating to the eyes and respiratory system. To prevent
personal injury when handling these substances:
Always wear protective clothing and rubber gloves.
Always wear goggles with side-shields or a face mask. It is also
advisable to wear safety glasses when carrying out maintenance.
Apply barrier hand cream before handling ink.
If ink or top-up contaminates the skin, wash immediately with soapy
water. DO NOT use washdown or solvent to clean ink stains from
the skin.

Warning
FIRE AND HEALTH HAZARD. The ink, solvent and top-up are
volatile and flammable. They must be stored and handled in
accordance with local regulations.
Do not smoke or use a naked flame in the vicinity of these
substances.
Immediately after use remove any tissue or cloths that become
saturated with these substances. Dispose of all such items in
accordance with local regulations.
In the event that any ink, solvent or top-up container is not
completely empty after use, it should be resealed. Only full bottles
are recommended for use when replenishing ink or top ups;
partially filled bottles should be disposed of in accordance with local
regulations.

Warning
VAPOUR HAZARD. Prolonged breathing of top-up or cleaning
fluid vapor may cause drowsiness and/or effects similar to alcoholic
intoxication. Use only in open, well-ventilated areas.

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Ink and Solvent Storage

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Firmware Download

Introduction
To download new operating software to the flash memory in the printer
use either:
Microsoft Windows version 3.xx Terminal mode in conjunction with
the Debug Monitor option from the System menu.
Microsoft Windows version 95/98/2000 HyperTerminal mode in
conjunction with LCD option from the System menu.
Notes: It is possible to download new versions of the same software, but it is not
possible to install firmware from a different machine variant. A security feature of
the 43s prevents the download of any firmware other than an upgrade of the
firmware which was originally supplied.

Requirements
The following equipment is required:
An IBM compatible PC (with Microsoft Windows version 3.xx, 95, 98
or 2000 installed).
A copy of the new operating software on disk.
A suitable serial communications cable to connect between the PC and
printer connector COMM1.

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Windows 3.xx Procedure

Checking the Communications Link
Before attempting to download new software check the communications
link between the PC and the printer.
1 Using a pre-configured connection cable, connect Com1 of the PC to
COMM1 of the 43s Printer.
2 On the PC, run the Terminal program (Windows Accessories Group).
3 Select the Communications option from the Settings menu and set the
following options:
Baud Rate:

9600

Data Bits:

Stop Bits:

Parity:

None

Flow Control:

None

Connector:

Com1 (assuming Com1 is the port to be used)

4 Click OK to confirm the settings.

5 If required, this set up can be saved for future use by selecting Save As
from the File menu and saving the communications set up as, for
example, 43S.trm.
6 Ensure that port COMM1 on the printer is set to corresponding baud
rate, data bits, stop bits and parity settings.
7 From the Data Logging menu, select the Serial Port Functionality option.
8 Set Status to Disable and press.
9 From the System menu select Debug Monitor.
10 Set Com1 to the active port. The prompt MON> should appear in the
PC Terminal Window.
11 To confirm that the communications link is effective press enter
on the PC. The prompt MON> should appear a second time, e.g.:
MON>
MON>
12 Press X and then
control.

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Windows 3.xx Procedure

enter

on the PC to return the printer to normal

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13 From the Data Logging menu, select the Serial Port Functionality
option.
14 Reset Status to Enable.

Using Microsoft Windows 3.xx to Download Firmware

1 Connect the serial communications cable between the serial port of the
PC and printer connector COMM1.
2 From the System menu select Debug Monitor.
3 Select LCD and press

enter

. The printer screen displays MON>.

4 On the PC, double-click on Terminal (normally located in Accessories

group).

Figure 4-1. Windows 3.xx Accessories Group

5 Type BO on the printer keypad and press

enter

6 Press the Y key to confirm. The screen display becomes blank and the
Terminal Window displays MON>.
7 On the PC, type ER and press
EEPROM.

enter

to erase the printer flash

8 The PC Terminal Window displays the message; Blank check failed,

Erasing Flash.
9 After approximately 10 seconds the Terminal Window displays the
message, Blank check passed.
10 The PC Terminal Window then displays MON>.

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11 On the PC type DU<SPACE>1 and press

displayed in the Terminal Window.
12 On the PC press
press
.

alt

enter

. 0 (zero) is

+ T (Transfers menu), select Send Text File and

enter

13 To select the new operating software file from the Send Text File
Window, proceed as follows:
a. From the Drives: menu, select a:.
b. From the List Files of Type menu, select All files [*.*].
c. Select the relevant file e.g. 4601.fla and press
downloads to the printer.

enter

. The file

An indicator at the bottom on the Terminal Window displays the

progress of the download.
14 After approximately 20 minutes the Terminal Window displays
MON>.
15 At the terminal MON> prompt, type: SET#4000#3ffff#0 and press
enter

16 At the terminal MON> prompt, type: SET#1000#37ff#0 and press

enter

17 At the terminal MON> prompt, type: SET#200#400#0 and press

enter

18 Type RUN on the PC keyboard and press

run the new operating software.

enter

to activate and

19 Carry out a full system reset (see Configure Menu, page 105).

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Windows 3.xx Procedure

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Windows 95/98/2000 Procedure

Checking the Communications Link
1 Before attempting to download new software check the
communications link between the PC and the printer.
2 Using a pre-configured connection cable, connect COM1 of the PC to
COMM1 of the 43s Printer.
3 On the PC run the HyperTerminal program.
The Connection Description window opens requesting a title and an
icon for the new connection.
4 Enter the details and click OK.

Figure 4-2. New Connection Menu (Windows 2000)

The Connect To dialog box appears.

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Windows 95/98/2000 Procedure

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5 Change the Connect Using edit box to Com1.

Figure 4-3. Connect To Menu (Windows 2000)

6 When the COM1 properties menu is displayed, ensure the settings are
as follows:
Baud Rate:
Data Bits:
Stop Bits:
Parity:
Flow Control:
Connector:

9600
8
1
None
None
Com1 (assuming Com1 is the port to be used)

7 Click OK to confirm the settings.

8 If required, this set up can be saved for future use by selecting Save As
from the File menu and saving the communications set up as, for
example, 43S.trm.
9 Ensure that port COMM1 on the printer is set to corresponding baud
rate, data bits, stop bits and parity settings.
10 From the Data Logging menu, select the Serial Port Functionality option
and set Status to Disable.
11 From the System menu select Debug Monitor.
12 Set Com1 to the active port. The prompt MON> should appear in the
PC HyperTerminal Window.
13 To confirm that the communications link is effective press enter
on the PC. The prompt MON> should appear a second time, e.g.:

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Windows 95/98/2000 Procedure

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MON>
MON>
14 Press X and then
control.

on the PC to return the printer to normal

enter

15 From the Data Logging menu, select the Serial Port Functionality option
and reset Status to Enable.

Using Windows 95, 98 or 2000 to Download Firmware

To use Microsoft Windows 95, 98 or 2000 for a firmware download,
proceed as follows:
1 Connect the serial communications cable between the serial port of the
PC and printer connector COMM1.
2 Select the System menu.
3 Select LCD and press

enter

. The printer screen displays MON>.

4 Access Windows HyperTerminal

(normally located by clicking Start/Programs/Accessories/
Communications/HyperTerminal).
5 Follow the instructions for establishing a connection (see Preparation
for Use on page 2-3).
6 Type BO on the printer keypad and press

enter

7 Press the Y key to confirm. The screen display becomes blank and the
HyperTerminal Window displays MON>.
8 On the PC, type ER and press
EEPROM.

enter

to erase the printer flash

9 The PC HyperTerminal Window displays the message: Blank check

failed, Erasing Flash.
10 After approximately 10 seconds the HyperTerminal Windows
displays the message, Blank check passed.
11 The PC HyperTerminal Window displays MON>.
12 On the PC type DU<SPACE>1 and press enter
displayed in the HyperTerminal Window.

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. 0 (zero) is

Windows 95/98/2000 Procedure

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13 On the PC press
press
.

alt

+ T (Transfer menu), select Send Text File and

enter

14 To select the new operating software file from the Send Text File
Window, proceed as follows:
a. From the Look in field, select A.
b. From the Files of Type box, select All files [*.*].
c. Select the relevant file e.g. 4701.fla and click Open. The file
downloads to the printer.
An indicator at the bottom on the Terminal Window displays the
progress of the download.
15 After approximately 20 minutes the Terminal Window displays
MON>.
16 At the terminal MON> prompt, type: SET#4000#3ffff#0 and press
enter

17 At the terminal MON> prompt, type: SET#1000#37ff#0 and press

enter

18 At the terminal MON> prompt, type: SET#200#400#0 and press

enter

19 Type RUN on the PC keyboard and press

run the new operating software.

enter

to activate and

20 Carry out a full system reset (see Configure Menu on page 7-10).

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Windows 95/98/2000 Procedure

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Boot Monitor Recovery Procedure

If a data communications error occurs whilst downloading a new software
Flash File or the system memory becomes corrupted, the system may
lock-up. If this situation occurs, use the following recovery procedure:
1 Switch off the 43s unit.
2 Remove the I/O board to allow access to the CPU.
3 Connect test point TMR1 to the chassis (0 V) with a test lead. TMR1 is
the test point closest to R12.

(1) CPU board

(2) Test lead
(3) Pillar (0 V)

Figure 4-4. Connection of TMR1 to chassis

4 Replace the I/O board and connections.
5 Connect a PC to the Comms port.
6 Switch on the printer.
7 Run the PC in Windows Terminal Mode and establish
communication.
8 At the PC type ER.
9 Switch off the printer and remove the test lead from the CPU.

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Videojet 43s Inkjet Printer Service Manual

10 Switch on the printer and download new software using the

download procedure.
The printer will now be operational.

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Boot Monitor Recovery Procedure

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Calibration and Testing

Introduction
The system calibration and test procedures described below should be
performed as necessary to commission the machine after repairs have
been carried out. All or part of the procedure may be required, as
indicated in the failure diagnosis and repair instructions at the beginning
of this section. The procedures may also be used as an aid to fault finding.

Earth Continuity Test

Warning
EARTH CONTINUITY. To ensure safe earthing the resistance
between the mains lead earth wire and the test points must be less
than 1.

Using the multimeter, test between the mains lead earth wire (Item 1 in
Figure 5-1) and the following points:
PSU cover (2)
PCB mounting bracket (3)
LCD cover plate (4)
Electronics compartment door (5)
Ink system compartment door (6)
FMS tray (see Item 1 in Figure 2-2. on page 2-5)
Earth point on printhead (located under the rear cover).

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Videojet 43s Inkjet Printer Service Manual

(1)
(2)
(3)
(4)
(5)

Mains lead earth wire

PSU cover
PCB mounting bracket
LCD cover plate
Electronics
compartment door
(6) Ink system
compartment door

Figure 5-1. Earth Continuity Test Points

5-2

Earth Continuity Test

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Machine Power-Up
1 Connect the printer to the mains power supply and press the mains
power button.
2 Ensure that the machine initializes correctly.
3 If the LCD is not visible, press f3 , and then ctrl
LCD is readable, press any key to set the contrast.

+ L. When the

4 If there is no ink in the system, verify that the Mixer Tank Low icon is
displayed.

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Machine Power-Up

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Videojet 43s Inkjet Printer Service Manual

Pressure Zero Offset Calibration

Caution
FALSE READINGS. To avoid the risk of false readings, the pressure
zero offset should only be calibrated when there is no ink in the
system and the pump is off.

Calibrate the pressure zero offset as follows:

1 From the Calibrate menu select the Pressure Zero Offset option.

2 Press

enter

3 Press Y to confirm or N to cancel the operation.

The ink system pressure is automatically set to zero relative to local

atmospheric pressure. There is no visual indication that the calibration has
been performed.
Note: If you want to confirm that the operation was carried out correctly, check
the Ink Pressure setting in the Diagnostics screen. It should now read 000.

Cooling Fan Check

Check that the electronics compartment cooling fan is operating correctly
(i.e. blowing air through the electronics compartment).

5-4

Pressure Zero Offset Calibration

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I/O Board LED Check

Check that LEDs 1, 3, 4 and 5 on the I/O board are illuminated and that
LED2 is dimly illuminated. The LEDs represent the following voltage
rails:
LED 1 (green)

+12 V customer's isolated supply for

shaft encoder/photocell.

LED 2 (clear/illuminates red)

285 V (+15 V = dim with printhead

cover off, +285 V = bright with
printhead cover on and jet running).

LED 3 (yellow)

-24 V supply.

LED 4 (red)

-15 V supply.

LED 5 (green)

+24 V valve/pump/heater supply.

(1) LED 1 (green); +10 V

(2) LED 2 (red); +285 V
(3) LED 3 (yellow); -24 V

(4) LED 4 (red); -15 V

(5) LED 5 (green); +24 V

Figure 5-2. I/O Board Status LED Location

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I/O Board LED Check

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Videojet 43s Inkjet Printer Service Manual

Gutter Fault and Charge Error Disable

1 From the System menu select Charge Error Shutdown Disable.

2 Press

enter

3 Select Charge error and toggle to Disable.

4 Select Gutter fault and toggle to Disable.

5 Press

5-6

enter

Gutter Fault and Charge Error Disable

to disable both functions.

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Voltage Checks
Check the voltages on the POWER connector, situated at the bottom lefthand corner of the I/O board. Use Pin 2 as the 0 V reference. Figure 5-3 is
a representation of the POWER connector with the voltages shown for
each pin.
Notes: Allow 5% tolerance on all voltages except -24V which is allowed at
!0%. The power connector must be connected to the I/O board to carry out this
check.
PIN 4
-15V

PIN 8
-24V

PIN 3
+5 V

PIN 7
0V

PIN 2
0V

PIN 6
+24 V

PIN 1
+15 V

PIN 5
+5 V

Figure 5-3. I/O board POWER connector

Calibrate 285 V Rail

To calibrate the 285 V supply, proceed as follows:
1 Remove the electrical connectors to the Ink Feed Valve (V6) on the
FMS and the Top-up Addition Valve (V1) on the top-up reservoir.
2 Ensure the printhead cover is fitted and press f1

to start the Jet.

Notes: An inkjet will not be produced at the printhead as Valve V6 has been
disabled. The machine will shut down if disable charge and gutter detect
errors are not disabled.
3 On the I/O card connect a DVM, set to measure 285 V, between TP2
(+ve) and TP1 (0 V).
4 Set the 285 V rail to 285 V 1 by adjusting VR1 on the I/O board.
Disconnect the multimeter.
Seal VR1 adjustment screw using a suitable sealing compound. Refit the
electrical connectors to valves V6 and V1.

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Voltage Checks

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Videojet 43s Inkjet Printer Service Manual

Reset Run Hours

If the Service icon is displayed, the time until the next service is due must
be entered to remove it.
Note: the contact information that is displayed
on screen when this icon appears can be
configured by selecting Enter Service
Information in the Data Logging menu.

Proceed as follows:
1 From the Data Logging menu select Reset Run Hours.

2 Press

enter

3 Select Set pump alarm hours. Enter the number of hours until the next
main ink filter change is due. For a new filter, the recommended
interval is 6 months (4368 hours) of continuous use.
4 Set Reset pump run hours to Yes.

5 Configure Set machine alarm hours to the number of hours until the
next air filter inspection is due. The recommended interval is roughly
once a week (168 hours), but that interval should be decreased if
environmental conditions are poor and may be increased in
exceptionally clean environments.
6 Set Reset machine run hours to Yes.
7 Press

5-8

Reset Run Hours

enter

to save the settings.

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