Videojet

1210/1510
Service Manual

P/N 361869-21
Rev AC, December 2008
 Copyright December 2008 , Videojet Technologies Inc. (herein referred to as Videojet). All rights
reserved.

This document is the property of Videojet Technologies Inc. and contains confidential and
proprietary information owned by Videojet. Any unauthorized copying, use or disclosure of it without
the prior written permission of Videojet is strictly prohibited.

Videojet Technologies Inc.

1500 Mittel Boulevard Phone: 1-800-843-3610 Offices - USA: Atlanta, Chicago, Los Angeles, Philadelphia
Wood Dale, IL Fax: 1-800-582-1343 INT’L: Canada, France, Germany, Ireland, Japan, Spain,
60191-1073 USA Int’l Fax: 630-616-3629 Singapore, The Netherlands, The United Kingdom
www.videojet.com Distributors Worldwide
Compliance Information
For Customers in the European Union
This equipment displays the CE mark to indicate conformance to the
following legislation.
• BS EN61000-6-4 2007 Generic Emissions Standard for industrial
environments
• BS EN55022 Class A 2006 Emissions Standard for industrial
environments
• BS EN61000-3-2 2006 Harmonic Current Fluctuations
• BS EN61000-3-3 1995 Voltage Fluctuation and Flicker
• BS EN61000-6-2 2005 Generic Immunity Standard for industrial
environments
• BS EN61000-4-2 1995 ESD Requirements
• BS EN61000-4-3 2006 Radiated Susceptibility
• BS EN61000-4-4 2004 Electrical Fast Transient Burst Requirement
• BS EN61000-4-5 2006 Surges Requirements
• BS EN61000-4-6 1996 Conducted Susceptibility
• BS EN61000-4-11 2004 Voltage Dips and Interruptions
Following the provisions of EU EMC Directive 2004/108/EC

For Customers in the U.S.A.

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

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

This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to Part 15 of the FCC Rules. These limits
are designed to provide reasonable protection against harmful
interference, when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio

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Videojet 1210/1510 Service Manual

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. 004-00-
00345-4.
This equipment has been tested and certified for compliance with U.S.
regulations regarding safety and electrical emissions by:
Electromagnetic Testing Services Limited
Pratts Fields
Lubberhedges Lane
Stebbing, Dunmow
Essex, CM6 3BT
England, UK

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:
Electromagnetic Testing Services Limited
Pratts Fields
Lubberhedges Lane
Stebbing, Dunmow
Essex, CM6 3BT
England, UK

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 Videojet 1210/1510 Service Manual

Pour la clientèle du Canada

Le present appareil numerique n’emet 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 équipement est certifié CSA.

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Support and Training
Contact Information
If you have any questions or need assistance, please contact at 1-800-843-
3610 (for all customers within the United States). Outside the U.S.,
customers should contact their 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 Total Source® Commitment
Total Source® TOTAL SERVICE PLUS RELIABILITY, is the commitment
to provide you - our customer - the complete service you deserve.

The Total Source Commitment

The Total Source® Service Program is an integral part of our business in
providing marks, codes, and images where, when, and how often
customers specify for packages, products, or printed materials. Our
commitment includes:
• Applications support
• Installation services
• Maintenance training
• Customer response center
• Technical support
• Field service
• Extended hours phone assistance
• Parts and supplies
• Repair service

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 Videojet 1210/1510 Service Manual

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

Note: The manuals are intended to be supplements to (and not replacements for)
customer training.

For more information on Customer Training Courses, call 1-800-843-3610

(within the United States only). Outside the US, customer should contact a
subsidiary office or their local distributor for further information.

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Table of Contents
For Customers in the European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
For Customers in the U.S.A.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
For Customers in Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Pour la clientèle du Canada. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Support and Training

Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Service Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Customer Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Table of Contents

Chapter 1 — Introduction
Videojet 1210/1510 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
About the Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
Related Publications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
Language Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
Content Presentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
The Word ‘Printer’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Positional References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Additional Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
User Interface Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
Chapters in the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7

Chapter 2 — Safety
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
General Safety Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
Electrical Safety Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Electrical Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Electrical Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
Fluid Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
Ink and Make-up Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
Cleaning Agent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
Compressed Air Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8

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UI Related Safety Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8

Other Important Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9

Chapter 3 — Main Parts

Printer Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
Main Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
Electronics Compartment Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
Ink Compartment Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
Umbilical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
Connector Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
Print Trigger 2 Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15
Back Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15
Electronics Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16
Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17
Control System Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–18
Electronics Compartment Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–21
Positive Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–21
Printer Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–22
EHT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23
Ink Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–24
Ink Core Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25
Ink Core Module Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–26
Smart Cartridges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28
Ink Compartment Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28
Gutter Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28
Vent Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29
Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–30
Printhead Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–31
Printhead Valve Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–31
Print Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–31
Printhead Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–32
Umbilical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–36
The Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–36

Chapter 4 — Installation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
Tools and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Typical Production Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
Commission the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4

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Inspect the Ink System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4

Inspect the Electronics System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7
Inspect the Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7
Log into UI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
Install Ink and Make-up Cartridges . . . . . . . . . . . . . . . . . . . . . . . . 4–9
Configure the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–13
Prime the Ink Core Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–15
Perform System Flush Purge and Umbilical Purge . . . . . . . . . . 4–16
Perform Ink Stream Alignment and Viscosity Calibration . . . . 4–19
Clean Stop and Clean Start the Printer . . . . . . . . . . . . . . . . . . . . . 4–20
Record the Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–21
Perform Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–21
Set the Password Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–23
Install the Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–24
Internal Encoding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–24
External Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–26
Install the Product Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–28
Install the Stack light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–30
Align the Ink Stream . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–33
Perform Calibration and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–36
Calibrate EHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–36
Calibrate Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–38

Chapter 5 — Printer Operation

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
Reset Run Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
Restore Calibration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
Perform System Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
Perform Full System Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4

Chapter 6 — User Interface

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

Chapter 7 — Replacement Instructions

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
Common Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
How to Open the Electronics Compartment Door . . . . . . . . . . . . 7–3
How to Close the Electronics Compartment Door . . . . . . . . . . . . 7–5
How to Open the Ink Compartment Door. . . . . . . . . . . . . . . . . . . 7–5
How to Close the Ink Compartment Door. . . . . . . . . . . . . . . . . . . 7–7

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Control System Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7

Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7
How to Remove the Old Control System Board . . . . . . . . . . . . . . 7–7
How to Install the New Control System Board . . . . . . . . . . . . . . . 7–8
Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9
How to Remove the Old Power Supply Unit. . . . . . . . . . . . . . . . . 7–9
How to Install the New Power Supply Unit . . . . . . . . . . . . . . . . 7–11
LCD and FIB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13
How to Remove the Old LCD and FIB Assembly . . . . . . . . . . . . 7–13
How to Install the New LCD and FIB Assembly. . . . . . . . . . . . . 7–16
Keyboard/Electronics Compartment Door . . . . . . . . . . . . . . . . . . . . 7–16
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–16
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–17
How to Remove the Old Electronics Compartment Door . . . . . 7–17
How to Install the New Electronics Compartment Door . . . . . . 7–20
Ink Core Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–21
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–21
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–22
How to Remove the Old Ink Core Module. . . . . . . . . . . . . . . . . . 7–22
How to Install the New Ink Core Module . . . . . . . . . . . . . . . . . . 7–30
Ink Core Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–35
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–35
How to Remove the Old Ink Core Pump . . . . . . . . . . . . . . . . . . . 7–36
How to Install the New Ink Core Pump . . . . . . . . . . . . . . . . . . . . 7–39
Print Engine Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41
How to Remove the Old Print Engine Assembly . . . . . . . . . . . . 7–41
How to Install the New Print Engine Assembly . . . . . . . . . . . . . 7–43
Printhead Valve Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–44
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–44
How to Remove the Old Printhead Valve Module . . . . . . . . . . . 7–44
How to Install the New Printhead Valve Module. . . . . . . . . . . . 7–47
Umbilical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–50
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–50
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–51
Umbilical Assembly (with Printhead) . . . . . . . . . . . . . . . . . . . . . . . . . 7–52
How to Remove the Umbilical Assembly (with Printhead) . . . 7–52
How to Install the Umbilical Assembly (with Printhead) . . . . . 7–59
Umbilical Assembly (with Printhead Chassis) . . . . . . . . . . . . . . . . . . 7–68
How to Remove the Umbilical Assembly (with Printhead Chassis)7–
68

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How to Install the Umbilical Assembly (with Printhead Chassis)7–71

Printer Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–74
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–74
How to Remove the Old Printer Interface Board . . . . . . . . . . . . 7–74
How to Install the New Printer Interface Board . . . . . . . . . . . . . 7–76
Power Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–77
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–77
How to Remove the Old Power Switch . . . . . . . . . . . . . . . . . . . . 7–77
How to Install the New Power Switch . . . . . . . . . . . . . . . . . . . . . 7–80
Septum Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–82
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–82
How to Remove the Old Ink and Make-up Septa. . . . . . . . . . . . 7–83
How to Install the New Ink and Make-up Septa . . . . . . . . . . . . 7–85
Electronics Compartment Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–86
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–86
How to Remove the Old Electronics Compartment Fan . . . . . . 7–86
How to Install the New Electronics Compartment Fan . . . . . . . 7–87
Ethernet Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–88
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–88
How to Remove the Old Ethernet Connector . . . . . . . . . . . . . . . 7–88
How to Install the New Ethernet Connector . . . . . . . . . . . . . . . . 7–89
Positive Air Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–90
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–90
How to Remove the Old Positive Air Kit . . . . . . . . . . . . . . . . . . . 7–91
How to Install the New Positive Air Kit. . . . . . . . . . . . . . . . . . . . 7–93
Gutter Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–94
Tools and Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–94
How to Remove the Old Gutter Pump . . . . . . . . . . . . . . . . . . . . . 7–94
How to Install the New Gutter Pump. . . . . . . . . . . . . . . . . . . . . . 7–98
Ink Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–99
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–99
How to Remove the Old Ink Door . . . . . . . . . . . . . . . . . . . . . . . 7–100
How to Install the New Ink Door . . . . . . . . . . . . . . . . . . . . . . . . 7–102
Ink System Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–104
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–104
How to Remove the Ink System Fan. . . . . . . . . . . . . . . . . . . . . . 7–105
How to Install the New Ink System Fan. . . . . . . . . . . . . . . . . . . 7–106
EHT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–106
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–106
How to Remove the Old EHT Module . . . . . . . . . . . . . . . . . . . . 7–107
How to Install the New EHT Module. . . . . . . . . . . . . . . . . . . . . 7–108
USB Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–109
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–109

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How to Remove the Old USB Connector . . . . . . . . . . . . . . . . . . 7–110

How to Install the New USB Connector . . . . . . . . . . . . . . . . . . . 7–110
Plug and Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–111
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–111
How to Remove the Old Power Cable . . . . . . . . . . . . . . . . . . . . 7–111
How to Install the New Power Cable . . . . . . . . . . . . . . . . . . . . . 7–114
CSB Lithium Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–117
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–117
How to Remove the Old CSB Lithium Battery . . . . . . . . . . . . . 7–117
How to Install the New CSB Lithium Battery . . . . . . . . . . . . . . 7–118
PCB 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–118
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–118
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–119
How to Remove the Old PCB 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 7–119
How to Install the New PCB 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–121

Chapter 8 — Maintenance
Prime the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2
Umbilical Purge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
System Flush Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6
Nozzle Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–11
Replacement of Ink System Fan Filter for IP65. . . . . . . . . . . . . . . . . . 8–12
How to Remove the Old Ink System Fan Filter for IP65 . . . . . . 8–12
How to Install the New Ink System Fan Filter . . . . . . . . . . . . . . . 8–12
Replacement of Ink System Fan Filter for IP55. . . . . . . . . . . . . . . . . . 8–13
How to Remove the Old Ink System Fan Filter for IP55 . . . . . . 8–13
How to Install the New Ink System Fan Filter for IP55 . . . . . . . 8–13
Replacement of Floor Filter for IP65. . . . . . . . . . . . . . . . . . . . . . . . . . . 8–14
How to Remove the Old Floor Filter IP65 . . . . . . . . . . . . . . . . . . 8–14
How to Install the New Floor Filter IP65 . . . . . . . . . . . . . . . . . . . 8–15
Replacement of Floor Filter for IP55. . . . . . . . . . . . . . . . . . . . . . . . . . . 8–15
How to Remove the Old Floor Filter IP55 . . . . . . . . . . . . . . . . . . 8–15
How to Install the New Floor Filter for IP55 . . . . . . . . . . . . . . . . 8–17
Windows CE Upgrade Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–17
Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–17
System Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–17
Hardware Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–18
USB Download through Serial Commands . . . . . . . . . . . . . . . . . 8–19
USB Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–21

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Chapter 9 — Troubleshooting
Read the Operator Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
Important Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
Startup Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2
Printer Fails to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2
Display Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Backlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
LCD Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Keypad Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Beacon Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Printer Status Icons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Indicator Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Fault Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–7
Warning Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–13
Voltage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–33
Jet Start and Stop Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–34
Quick Start Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–34
Clean Start Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–35
Clean Stop Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–37
CSB Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–38
Installing DNW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–56
ADC/DAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–56
Ancillary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–57
Charge Amplifier Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–57
Charge Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–57
SRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–58
EHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–58
Levels/Pressure/Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–58
Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–58
Phase Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–59
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–59
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–59
DIN Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–59
Manual Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–60

Chapter 10 — Illustrated Parts List

How to Read the IPL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1
Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–4
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–4
Videojet 1210/1510 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–5
Electronics Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–6
Control System Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–7

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Power Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–7

Electronics Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–8
Power Supply Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–9
Printer Interface Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . 10–10
Electronics Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–11
Positive Air Pump Assembly (Optional for 1210) . . . . . . . . . . . 10–11
EHT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–12
Connector Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–12
PCB 2 Assembly (Option for Videojet 1210). . . . . . . . . . . . . . . . 10–13
PCB 1 Assembly (Option for Videojet 1210). . . . . . . . . . . . . . . . 10–13
Display Door with Keypad in Different Languages . . . . . . . . . 10–16
Ink Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–17
Ink Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–17
Make-up Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–18
Ink Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–18
Septum Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–19
Ink Core Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–20
Ink Core Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–21
Gutter Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–22
Ink System Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–22
Ink System Filter Assembly - IP55 . . . . . . . . . . . . . . . . . . . . . . . . 10–23
Floor Filter IP65 (Optional for Videojet 1510 and 1510 E) . . . . 10–24
Floor Filter IP55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–25
Vent Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–25
Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–28
Printhead Valve Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–29
Print Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–30
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–31
Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–32
Beacon Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–32
Dry Air Kit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–33
Static Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–34
Mobile Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–35
Printhead Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–36
Printhead Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–36
Mounts to Printhead Holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–37
Printer Wall Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–38
Wash Station Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–39
Shaft Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–39
Product Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–40
Power Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–41
Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–42
Din Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–43

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Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–48

Miscellaneous Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–48
Connectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–48
Hydraulics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–49
Printhead and Umbilical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–49
Tools Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–50

Appendix A — Clean/Quick Start and Stop Description

Clean Start/Stop Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
Clean Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2
Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2
Clean Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–3
Quick Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–3
Nozzle Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–4

Appendix B — Encoder Information

Internal Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–1
External (Reduce Or Direct) Encoding . . . . . . . . . . . . . . . . . . . . . . . . . B–2
Auto Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–4

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Introduction
1
Videojet 1210/1510 Printer
The Videojet 1210/1510 is a continuous ink jet printer that can print fixed
and variable codes at high line speeds on consumer and industrial
products. The printer delivers superior uptime, print quality, and ease of
use to the operators.

About the Manual

The Videojet 1210/1510 Service Manual is written for the service
technician of the printer. The Service Manual contains the installation,
service, and troubleshooting procedures.

Related Publications
The Videojet 1210/1510 Operator Manual (Part Number: 361868) is
available for reference.

Language Codes
When you order these manuals, make sure to add the 2-digit language
code at the end of the part number. For example, the part number of the
Spanish version of the Operator Manual is 361868-04. Use the list of
language codes shown in Table 1-1 on page 1-2 to identify the translated
versions of the manual.
Note: Availability of the Operator Manual is indicated by an asterisk (*).
Availability of the Service Manual is indicated by a plus sign (+). Availability of
the Illustrated Parts List is indicated by the number sign (#). Contact the Videojet
distributor or subsidiary for more information.

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Videojet 1210/1510 Service Manual

Code Language Availability (see note)

01 English (US) * + #

02 French *

03 German *

04 Spanish *

05 Portuguese (Brazilian) *

06 Japanese *

07 Russian *

08 Italian *

09 Dutch *

10 Chinese (Simplified) *

11 Arabic *

12 Korean *

13 Thai *

15 Norwegian *

16 Finnish *

17 Swedish *

18 Danish *

19 Greek *

20 Hebrew *

21 English (UK) * + #

23 Polish *

24 Turkish *

25 Czech *

26 Hungarian *

33 Vietnamese *

34 Bulgarian *

35 Portuguese *

36 Chinese (Traditional) *

Table 1-1: List of Language Codes

1-2 Related Publications Rev AC

 Videojet 1210/1510 Service Manual

Content Presentation
This manual contains different types of information like safety guidelines,
additional notes, User Interface (UI) terminology and so on. To help you
identify the different types of information, different writing styles are
used. This section describes these writing styles.

The Word ‘Printer’

The word ‘printer’ indicates the Videojet 1210/1510 printer, from this
point onwards, in this manual.

Positional References
Unless stated to the contrary, positions and directions such as left, right,
front, rear, to the right and to the left are given with respect to the printer
when viewed from the front.

Units of Measurement
This manual uses metric units of measurement. The equivalent English
measures are included in parenthesis. For example, 240 mm (9.44 inches)

Safety Information
The safety information includes warning and caution statements.

Warning
The warning statements indicate hazards or unsafe practices that can
result in personal injury or death.
For example:

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

Caution
The caution statements indicate hazards or unsafe practices that can result
in damage to the equipment.
For example:

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Videojet 1210/1510 Service Manual

Caution
Do not fit or remove any connector on the printer when the power is
on, otherwise the printer may get damaged.

Additional Notes
Notes provide additional information about a particular topic.
For example:

Note: You can set the password protection for some functions to prevent any
unauthorized access.

User Interface Terminology

The user interface (UI) elements are shown in italics. For example,
Messages (see Figure 1-1).

Figure 1-1. Menu Screen

1-4 Content Presentation Rev AC

 Videojet 1210/1510 Service Manual

Keys

Key Style Used

Left arrow key

Right arrow key

Up arrow key

Down arrow key

Enter key

Esc key

F1 key

F2 key

F3 key

F4 key

Alt key

Ctrl key

Shift key

Table 1-2: Content Presentation Style for Keys

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Videojet 1210/1510 Service Manual

Abbreviations and Acronyms

Abbreviation Expansion

AC Alternating Current

CSB Control System Board

DC Direct Current

DMM Digital Multi Meter

DVM Digital Volt Meter

EHT Extra High Tension

FPGA Field Programmable Gate Array

IEC International Electrotechnical Commission

LED Light Emitting Diode

LCD Liquid Crystal Display

MOD Modulation

MS Microsoft

PC Personal Computer

PCB Printed Circuit Board

PIB Printer Interface Board

PSU Power Supply Unit

QVGA Quarter Video Graphics Array

SoC System on Chip

SRAM Static Random Access Memory

USB Universal Serial Bus

VDC Volts of Direct Current

WYSIWYG What You See Is What You Get

FIB Front Panel Interface Board

Table 1-3: Abbreviations and Acronyms

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 Videojet 1210/1510 Service Manual

Chapters in the Manual

Chapter Chapter Name Description

No.

1. Introduction Contains the information about this manual, the related

publications, and writing styles used in this manual

2. Safety Contains the safety and hazard information

3. Main Parts Describes the main parts of the printer

4. Installation Explains the installation procedures of different parts of

the printer

5. Printer Operation Contains the information on how to use the UI to setup

and operate the printer

6. User Interface Explains how to use the UI to create and store messages

7. Replacement Explains the procedures to remove and replace the parts

Instructions of the printer

8. Maintenance Provides the maintenance and cleaning procedures of the

printer.

9. Troubleshooting Contains diagnostic and troubleshooting procedures

10. IPL Contains the illustrated parts list of orderable parts

11. Appendix A Describes clean start, quick start, clean stop and quick
stop procedures

12. Appendix B Contains encoder setup information

Table 1-4: List of Chapters

Rev AC Chapters in the Manual 1-7

Safety
2
Introduction
The policy of Videojet Technologies Inc. is to manufacture non-contact
printing/coding systems and ink supplies that meet high standards of
performance and reliability. We enforce strict quality control techniques to
eliminate the potential for defects and hazards in our products.
The intended use of the Videojet 1210/1510 printer is to print information
directly onto a product. Use of this equipment in any other fashion may
lead to serious personal injury.
The safety guidelines provided in this chapter are intended to educate the
technicians on all safety issues, so that the printer is serviced and operated
in a safe manner.

General Safety Guidelines

• Always refer to the correct service manuals as per the specific Videojet
printer model.
• Only Videojet-trained personnel must carry out installation and
maintenance work. Any such work undertaken by unauthorized
personnel may damage the printer and will invalidate the warranty.
• 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.
• The printhead must be completely dry before attempting to start the
printer, otherwise the printhead may get damaged.
• To prevent nozzle clogs, always wear rubber gloves whenever the
nozzle tubing manifold is to be disconnected from the printhead valve
module.

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Videojet 1210/1510 Service Manual

Electrical Safety Guidelines

This section explains the safety guidelines related to electrical power
supply and electrical cables.

Electrical Power Supply

Warning
Make sure that the main electrical supply is within the range
indicated by the label next to the main inlet of the printer. If the
voltage ratings are different, do not use the printer and contact your
local supplier.

Warning
Lethal voltages are present within this equipment when it is
connected to the mains electrical supply. Only trained and
authorized personnel must carry out the 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. Non-adherence to this warning can result
in death or personal injury.

Warning
A high AC voltage is present at the inverter and backlight. Extreme
caution is required when diagnosing failure in these areas.

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 Videojet 1210/1510 Service Manual

Electrical Cables

Warning
Use only the main power cable supplied with the printer. The end of
this cable must have an approved, three-pole, main plug that has a
protective ground conductor.
The electrical power cables, sockets and plugs must be kept clean
and dry.
For pluggable equipment, the socket-outlet must be installed near
the equipment and must be easily accessible.

Warning
Always inspect the cables for damage, wear, corrosion, and
deterioration. Make all grounding/bonding connections void of
areas of paint, ink build-up, and corrosion.

Grounding

Warning
The printer must be connected only to an AC power supply that has
a protective ground conductor and must be according to IEC
requirements or applicable local regulations.

Warning
Do not use the printer if there is any interruption in the protective
ground conductor or if the protective ground conductor is
disconnected. The failure to follow this warning can cause an
electrical shock.

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Videojet 1210/1510 Service Manual

Warning
Always ground conductive equipment to an earthing electrode or to
the building grounding system with approved cables as per NEC
standards in order to drain all potential static discharge. For
example, a metal service tray to earth ground.

Warning
A resistance reading from the grounded service tray to the
equipment chassis or mounting bracket should be 0 to less than 1
ohm. A resistance check should be made using a safe and reliable
ohmmeter and should be done on a frequent basis

Warning
To ensure safe grounding, the resistance between the mains lead
earth wire and the test points must be less than 1Ω.

Warning
The PCBs contain static sensitive devices. A suitably grounded,
antistatic wrist strap must be worn when working on or handling
PCBs.

Bonding

Warning
Always prevent static discharge from occurring. Use proper
Grounding and Bonding methods. Only use Videojet approved
metallic service trays and ground cables.

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 Videojet 1210/1510 Service Manual

Warning
Always bond conductive equipment together with approved cables
to maintain them at the same potential and minimize static
discharge. For example, printhead to metal service tray.

Caution
Always empty the service trays frequently. Some inks and cleaning
solutions are flammable. Make sure that the waste fluids are
disposed according to HAZMAT.

Fuses

Warning
To ensure continued protection against fire hazards, replace fuses
only with the specified type and rating.

Fluid Safety Guidelines

This section describes the hazards that may occur while handling ink,
make-up fluid, and cleaning solutions, and the safety precautions that a
user must take to prevent the hazards.

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Videojet 1210/1510 Service Manual

Ink and Make-up Fluid

Warning
The ink and make-up fluid 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 make-up fluid contaminates the skin, wash immediately
with soap water. DO NOT use washdown or solvent to clean ink
stains from the skin.

Warning
The ink and make-up fluid 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 cloth that becomes
saturated with these substances. Dispose all such items in
accordance with the local regulations.
In the event that any ink or make-up fluid container is not
completely empty after use, it should be resealed. Only full bottles
are recommended for use when replenishing ink or make-up fluid;
partially filled bottles must be disposed in accordance with the local
regulations.

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

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 Videojet 1210/1510 Service Manual

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

Cleaning Agent

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

Warning
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 the cleaning agent.
If cleaning agent contaminates the skin, rinse off with running water
for at least 15 minutes.

Warning
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 cloth that becomes
saturated with cleaning agent. Dispose all such items in accordance
with local regulations.

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Videojet 1210/1510 Service Manual

Caution
Make sure that the cleaning agent is compatible with the ink used
before carrying out printhead cleaning otherwise the printhead may
get damaged.

Compressed Air Safety Guidelines

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

UI Related Safety Guidelines

Caution
To prevent unauthorized access to the software, ensure that Clear
Password is executed when exiting from a higher level password.

Caution
Ensure that the correct message name is selected for message
deletion as no message selection confirmation prompt is given. All
messages apart from the TEST MESSAGE will be deleted.

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

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 Videojet 1210/1510 Service Manual

Other Important Guidelines

1 DEGRADED PERFORMANCE. Machine functions that only Videojet-
trained personnel can access are set at password level 3 (MASTER
password). To obtain the password, do one of the following:
• Call Videojet Technologies Inc. Customer Service Department at 1-
800-843-3610 (United States only), or contact the local Videojet
Technologies Inc. representative.
• Access Service tab at www.videojet.com.
2 EXCESSIVE USE OF MAKE-UP FLUID. As solvent is used during the
stop cycle, repeatedly stopping and starting the printer can lead to
excessive use of make-up fluid or solvent and can lead to a Ink Core
Level High error.
3 QUICK STOP. After a quick stop, the machine must not be left in the
same state for any length of time as drying ink may make restarting
difficult.
4 PRINTER OVERHEATING. Report all overheating incidents to a
maintenance engineer.
5 DAMAGE TO GUTTER. Never attempt to bend the gutter. Its position
is fixed.
6 DAMAGE TO CHARGE ELECTRODE. The charge electrode is not
adjustable so, do not attempt any mechanical adjustments.
7 EQUIPMENT DAMAGE. Adhere to prescribed circuit limitations
when using any external input or output devices with the printer.
8 EQUIPMENT DAMAGE. The DIN connector for the lamp stack must
not have any inductive load placed on it as it may cause damage to the
PCB.
9 EQUIPMENT DAMAGE. Do not fit or remove any connector on the
printer when the power is on, otherwise the printer may get damaged.
10 RISK OF EXPLOSION. If the battery is replaced by an incorrect type,
it will lead to an explosion. Always dispose the used batteries
according to the instructions and local regulations.

11 HEATER. In a fault condition, heater can reach 70 oC. Do not touch

the plate on which the heater is mounted. The failure to follow this
warning can cause personal injury.

Rev AC Other Important Guidelines 2-9

Main Parts
3
Printer Overview

1510 1210

1
5
5

2
4

1. Electronics Compartment Door 5. Connector Panel

2. Ink Compartment 6. Electronics Compartment*
3. Printhead 7. Main Power Switch*
4. Umbilical
8. Back Filter*

* The components are not shown in the picture.

Note: Availability of the connectors depends on the printer
model you choose.
Figure 3-1: Main Parts of the Printer

Rev AC Printer Overview 3-1

Videojet 1210/1510 Service Manual

Figure 3-2 shows the schematic diagram of Videojet 1210/1510 printer.

PSU
LCD 0V
5V
FIB 34 way CSB
+15 V
-15 V
Keypad
24 V

50 way 50 way 50 way

Printhead Interface
PIB
Connectors

Ink and
Core Module Make-up
Cartridges

Figure 3-2: System Overview

Cabinet
The cabinet of Videojet 1210/1510 printer is constructed of stainless steel
with an inner fibre lining. The cabinet includes the following parts:
• Control panel
• Electronics compartment door
• Main power switch
• Ink compartment door
• Connector panel
• Umbilical
Refer to Figure 3-3 on page 3-3 to see the parts of the cabinet.

3-2 Cabinet Rev AC

 Videojet 1210/1510 Service Manual

7 1

6
3
4
5

1. Control Panel 5. Handle

2. Main Power Switch 6. Umbilical
3. Electronics Compartment Door 7. Connector Panel
4. Ink Compartment Door 8. Back Filter*

*The component is not shown in the figure.

Note: Availability of the connectors depends on the printer model you
choose.

Figure 3-3: Printer Cabinet

Control Panel
The control panel (Figure 3-4) provides the user interface to the printer.
Refer to Chapter 3 in the Videojet 1210/1510 Operator Manual for more
information.

Rev AC Cabinet 3-3

Videojet 1210/1510 Service Manual

6
! " £ $ % ^ & * ( )
1 2 3 4 5 6 7 8 9 0

Q W E R T Y U I O P
5 3
A S D F G H J K L

Z X C V B N M

4
1. Status LEDs 5. Display
2. Arrow Keys 6. Contrast Key (Brightness Control)
3. Keypad 7. Function Keys
4. Information Key

Figure 3-4: Control Panel

Main Power Switch

The main power switch (item 1, Figure 3-5) is a green push button to turn
on or turn off the power supply to the printer. You can find the main
power switch on the right side of the printer.

Note: The handles (item 2) are provided for easy movement of the unit.

1
2

1. Main Power Switch

2. Handle
Figure 3-5: Main Power Switch

Electronics Compartment Door

The electronics compartment door (item 3, Figure 3-3 on page 3-3) is
mounted on two hinges and its seal is water resistant when closed. The
door is closed using two M4 x 30 socket head screws. The door contains
control panel (refer to “Control Panel” on page 3-3) and front panel
interface board.

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 Videojet 1210/1510 Service Manual

See “Electronics Compartment” on page 3-16 for more information on the

electronics compartment.

LCD and Front Panel Interface Board

The front panel interface board (FIB), provides the interface between the
CSB and the LCD and keyboard. This assembly is located inside the
electronics compartment door.

LCD

Figure 3-6: LCD

1. Keypad Right 4. 34-way Ribbon to CSB

2. Touch Panel (Future Option) 5. Keypad Left
3. Program (Only Used In Production) 6. Mono LCD

Figure 3-7: FIB

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Videojet 1210/1510 Service Manual

Ink Compartment Door

The ink compartment door (item 4, Figure 3-3 on page 3-3) is mounted on
a hinge pin and is water and dust resistant, when closed. See “Ink
Compartment” on page 3-24 for more information on the contents of this
compartment.

Umbilical
The umbilical (item 6) that connects the printer cabinet to the printhead is
attached to the cabinet through a threaded fitting, secured with nuts and
washers.

Connector Panel
The connector panel (item 7) provides inputs for several types of external
devices.
Table 3-1 provides the connectors for the printer.

Connector Type Standard Optional

Print Trigger1 Videojet 1210 -

(PCB 0) Videojet 1510
(PCB 1)

COMMS RS232 - Videojet 1210

(PCB 2) Videojet 1510
(PCB 2)

COMMS RS485 - Videojet 1210

(PCB 1) Videojet 1510
(PCB 1)

Shaft Encoder - Videojet 1210

(PCB 2) Videojet 1510
(PCB 2)

Relay Switches - Videojet 1210

(PCB 1) Videojet 1510
(PCB 1)

Status Output - Videojet 1210

(PCB 2) Videojet 1510
(PCB 2)

USB Videojet 1210 -

Videojet 1510

Message A Input - Videojet 1510

Table 3-1: Connector Panel Ports

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 Videojet 1210/1510 Service Manual

Connector Type Standard Optional

Print Trigger 2 - Videojet 1510

Message B Input - Videojet 1510

Ethernet - Videojet 1510

Table 3-1: Connector Panel Ports (Continued)

Connectors Availability
• The Message A Input, Message B Input, Print Trigger 2 connectors are
optional connectors in Videojet 1510 and are not available in Videojet
1210 printer.
• The Ethernet connector is not available in Videojet 1210 printer.
• The status output, shaft encoder, COMMS RS 232, COMMS RS 485,
and relay switches are optional connectors in Videojet 1210 printer.

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Videojet 1210/1510 Service Manual

Status Output Connector

11 1
2

10 3
4

9 5
6

8
7
Cat 5e

1. Message A Input 7. USB

2. Print Trigger 2 8. Ethernet
3. Status Output 9. COMMS RS485
4. Shaft Encoder 10. COMMS RS232
5. Relay Switches 11. Message B Input
6. Print Trigger 1

Figure 3-8: Connector Panel

The printer provides an output for a set of status lights through the status
output connector (item 3, Figure 3-8). This is a 6 way DIN connector. The
pin allocation is shown in Table 3-2 and Figure 3-9.

4
2
5

1 6

Figure 3-9: Status Output Connector Pin Diagram

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 Videojet 1210/1510 Service Manual

Pin Function

DIN Pin 1 Red lamp negative supply

DIN Pin 2 Amber lamp negative supply

DIN Pin 3 Green lamp negative supply

DIN Pin 4 +24 VDC supply to the strobe/siren

Maximum Rating = 900 mA

DIN Pin 5 Strobe/siren negative supply

DIN Pin 6 +24 VDC common to the traffic lights

Table 3-2: Status Output Connector Pinouts

Shaft Encoder Connector

The printer provides a 12 V (200 mA DC total) output for use by a shaft
encoder with a maximum frequency of 100 kHz. The shaft encoder
connector (item 4) is a 4 way DIN connector. The pin allocation is shown
in Table 3-3.

2 3

1 4

Figure 3-10: Shaft Encoder Connector Pin Diagram

Pin Function

DIN Pin 1 +15 VDC supply to shaft encoder

DIN Pin 2 Shaft encoder input ‘A’

DIN Pin 3 Shaft encoder input ‘B’

Din Pin 4 0 VDC common

Table 3-3: Shaft Encoder Connector Pinouts

Note: The shaft encoder output must be of the PUSH/PULL type.

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Videojet 1210/1510 Service Manual

Relay Switches
The relay switches connector (item 5) is a 7 way DIN connector. This
connector supports the following relays:
• Relay ‘A’ duplicates the functionality of the green LED on the
keyboard, and you can use the relay to provide a ‘Print Ready’ output.
• Relay ‘B’ duplicates the functionality of the yellow LED on the
keyboard, and you can use the relay to provide a ‘warning’ output.
Electrical Rating:
1 A 30 VDC
0.3 A @ 125 VAC Maximum Switch Cap

3 4

2 5

1 6

7
Figure 3-11: Relay Switches Connector Pin Diagram

Pin Function

DIN Pin 1 Relay A - Normally open contact

DIN Pin 2 Relay A - Normally closed contact

DIN Pin 3 Relay A - Common contact

DIN Pin 4 Relay B - Normally open contact

DIN Pin 5 Relay B - Normally closed contact

DIN Pin 6 Relay B - Common contact

DIN Pin 7 Not used

Table 3-4: Relay Switches Connector Pinouts

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 Videojet 1210/1510 Service Manual

Print Trigger 1 Connector

The printer provides a 12 V, 200 mA, DC total output for use by a
photoelectric cell (PEC), inductive proximity detector or micro switch. The
print trigger 1 connector (item 6, Figure 3-8 on page 3-8) is a 3 way DIN
connector. The pin functions are shown in Table 3-5.

1
3

Figure 3-12: Print Trigger 1 Connector Pin Diagram

Pin Function

DIN Pin 1 +15 VDC supply to sensor

DIN Pin 2 Sensor output

DIN Pin 3 0 VDC common

Table 3-5: Print Trigger 1 Connector Pinouts

USB Connector
The USB Connector allows for data to be transferred to and from a
connected USB flash drive (item 7).

Figure 3-13: USB Connector

Ethernet Connector
The ethernet connector (item 8) is used to connect the printer to a remote
computer or network to import data or control the printer remotely.

Note: Ethernet Connector is not available in 1210 model.

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Videojet 1210/1510 Service Manual

Cat 5e

Figure 3-14: Ethernet Connector

COMMS RS-485 Connector

The COMMS RS-485 connector (item 9) is a 5 way DIN (180 degree or
stereo type) connector. Use this to connect the printer to an RS-485
network to import data or control the printer remotely.

5
4

1 3

Figure 3-15: COMMS RS-485 Connector

Pin Function

DIN Pin 1 Line A

DIN Pin 2 Line B

DIN Pin 3 0 VDC Common

DIN Pin 4 -

DIN Pin 5 -

Table 3-6: COMMS RS-485 Connector Pinouts

COMMS RS-232 Connector

The printer has an COMMS RS-232 communication port linked to the
COMM1 connector. The COMMS RS-232 connector (item 10, Figure 3-8 on
page 3-8) is a 5 way DIN connector. The pin allocation is shown in Table 3-
7.

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 Videojet 1210/1510 Service Manual

2 4

5
1

Figure 3-16: COMMS RS-232 Connector

Pin Function

DIN Pin 1 0 VDC common

DIN Pin 2 Transmit data out from the printer.

DIN Pin 3 Received data into the printer.

Din Pin 4 DTR output from the printer.

Din Pin 5 DCD input to the printer.

Table 3-7: COMMS RS-232 Connector Pinouts

Message A and B Input Connectors

4 5

1 8

6 3

7
Figure 3-17: Message A Input Connector

Pin Function

DIN Pin 1 MSG A1 (red)

DIN Pin 2 MSG A2 (yellow)

DIN Pin 3 MSG A3 (white)

Din Pin 4 MSG A4 (black)

Table 3-8: Message A Input Connector Pinouts

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Videojet 1210/1510 Service Manual

Pin Function

Din Pin 5 MSG A5 (blue)

Din Pin 6 MSG A6 (green)

Din Pin 7 MSG A7 (orange)

Din Pin 8 MSG A8 (brown)

Table 3-8: Message A Input Connector Pinouts (Continued)

4 5

1 8

6 3

7
Figure 3-18: Message B Input Connector

Pin Function

DIN Pin 1 MSG B1 (red)

DIN Pin 2 MSG B2 (yellow)

DIN Pin 3 MSG B3 (white)

Din Pin 4 MSG B4 (black)

Din Pin 5 MSG B5 (blue)

Din Pin 6 MSG B6 (green)

Din Pin 7 MSG B7 (orange)

Din Pin 8 MSG B8 (brown)

Table 3-9: Message B Input Connector Pinouts

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 Videojet 1210/1510 Service Manual

Print Trigger 2 Connector

1 3

Figure 3-19: Print Trigger 2 Connector

Pin Function

DIN Pin 1 15V DC

DIN Pin 2 Signal

DIN Pin 3 Ground

Table 3-10: Print Trigger 2 Connector Pinouts

Back Filter
The ink compartment draws the air from the outside atmosphere to keep
the compartment cool. The back filter removes the dust from the air that
goes inside the ink compartment (see Figure 3-20).The IP65 version back
filter is optional (see Figure 3-21 on page 3-16).

Back Filter

Figure 3-20: Back Filter (IP55 Version)

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Videojet 1210/1510 Service Manual

Figure 3-21: Back Filter (IP65 Version)

Electronics Compartment

2
7

6
3
5

1. Electronics Compartment Fan 4. Control System Board (CSB)

2. Power Supply Unit (PSU) 5. Printer Interface Board (PIB)
3. Positive Air Pump (IP 55 and IP 65 6. EHT Module
versions)* 7. Connector Panel Boards
*Standard on Videojet 1510.
*Optional on Videojet 1210.

Figure 3-22: Electronics Compartment

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 Videojet 1210/1510 Service Manual

Power Supply Unit

The Power Supply Unit (PSU) is the main source of power to the
printer.The mains input circuit is shown in the Figure 3-23. The AC
electrical power is supplied through three core cables to the mains filter.
The line and neutral are fed to the On/Off switch. After the On/Off
switch the line and neutral are fed to TB1 connector on the PSU.

Mains Switch PSU

L L

N N

E TB1

Figure 3-23: Mains Input Circuit

TB 1 Connector

Figure 3-24: Power Supply Unit

The PSU features are as follows:

• The mains fuse (T3A 110-240 V) is located in the PSU.
• The PSU provides four DC voltage levels (+24 VDC, +15 VDC, +5
VDC, and -15 VDC) to the CSB.
• Two fuses are soldered to the PSU board. These two fuses cannot be
reset or replaced.
• The input power to the PSU ranges from 84 to 264 VAC, 50 – 60 Hz.

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Videojet 1210/1510 Service Manual

Control System Board

1. Connectors CN1, CN2 and CN3 6. CPU JTAG

2. Charge Tunnel and Modulation Signal Connector 7. USB 2 Host Device
3. Input Power Connector 8. User Interface Connector
4. LEDs 9. Ethernet Connector
5. JTAG

Figure 3-25: Control System Board

Connectors 1, 2, and 3
The ribbon cables from the PIB connect to the CSB through the connectors
1, 2 and 3 (item 1, Figure 3-25) and relay the data that reaches PIB from
different parts of the printer to the CSB.

Charge Tunnel and Modulation Signal Connector

The charge tunnel and modulation signals are generated on the CSB.
These signals are sent directly to the printhead through the umbilical. All
other input or output signals are sent through the PIB.

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 Videojet 1210/1510 Service Manual

Charge 1 MOD Connector

Pin Function

DIN Pin 1 Charge

DIN Pin 2 GND

DIN Pin 3 GND

DIN Pin 4 MOD

Table 3-11: Pin Functions for Charge 1 MOD Connector

Input Power Connector

You can check the voltages at input power connector (item 3,Figure 3-25
on page 3-18) to make sure that the power supply from the mains power
supply is of the correct value.

Pin Signal

1 +15 V

2 0V

3 +5 V

4 -15 V

5 +5 V

6 +24 V

7 0V

8 N/C

Table 3-12: Pin Connections - Input Power Connector

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LEDs

1. Power LED 3. SoC to FPGA LED

2. Print Engine LED 4. Ethernet LED

Figure 3-26: Status LEDs

LED Description

Power Indicates the status of 3.3 VDC

Print Engine Flashes when printing is in progress

SoC to FPGA Indicates the status of communications between the

processor and the FPGA

Ethernet Indicates the status of Ethernet communications

Table 3-13: Status LEDs

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Electronics Compartment Fan

A cooling fan circulates the air inside the electronics compartment. The
top-cover casting of the printer dissipates the heat.

Figure 3-27: Cooling Fan

Positive Air Pump

The positive air pump is a standard part for the 1510. The positive air
pump provides dust free air to the printhead and thus prevents the
accumulation of dust in the printhead.

Note: Positive air pump is optional in 1210 model.

Positive Air Pump

Figure 3-28: Positive Air Pump

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Printer Interface Board

7 8 9 10 1 2 3 4 5

6
1. 10-way Printhead Connector 6. CSB Ribbon Cable Connectors (x3)
2. 12-way Printhead Connector 7. USB Connector
3. EHT Cable Connector 8. PCB1 Connector/PCB0 Connector
4. Positive Air Pump Connector 9. PCB 2 Connector
5. Electronics Compartment Fan Connector 10. PCB 3 Connector

Figure 3-29: Printer Interface Board (PIB) - Electronics Compartment Side

2 1
1. 14-way Ink Door Ribbon Cable Connector 4. 20-way Ink Core Module Ribbon Cable
2. Ink Compartment Fan Connector Connector
3. 16-way Ink Core Module Ribbon Cable
Connector

Figure 3-30: Printer Interface Board (PIB) - Ink Compartment Side

The description of different connectors on the PIB is provided in the

Table 3-14.

Connector Description

10-way Printhead Connector Connection to valves, phase detector, strobe LED, heater and
12-way Printhead Connector thermistor, and gutter detect

EHT Cable Connector Input to EHT module

Positive Air Pump Connector Input to positive air pump

Table 3-14: PIB Connectors

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Connector Description

Fan Connector Input to electronics compartment fan

CSB Connectors (x3) Input to CSB

USB Connector External USB (not the USB connection on CSB)

PCB0 Connector Print Trigger 1, COMMS RS-485, and Relay Switches

PCB1 Connector Print Trigger 1, COMMS RS-485, and Relay Switches

PCB 2 Connector COMMS RS-232, Shaft Encoder, Status Output

PCB 3 Connector Message A and B Input, Print Trigger 2

Ink System Ink pump, valves, sensors, level detectors, smart chip supplies
validation system

Table 3-14: PIB Connectors (Continued)

EHT Module
The extra high tension (EHT) module (item 2, Figure 3-31) generates the
high tension voltage (0 to 8000 VDC) that is supplied to the deflector plate
in the printhead.

1
2

1. Cooling Fan
2. EHT Module

Figure 3-31: Cooling Fan and EHT Module

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Ink Compartment
The ink system provides a continuous supply of ink to the printhead at the
correct pressure, temperature and viscosity. The ink system is housed in
the printer cabinet and the different components of the system are
interconnected by PTFE tubing.

3
1. Smart Cartridges 3. Ink Core Module
2. Ink Compartment Door 4. Ink Compartment Fan*

*The component is not shown in the picture

Figure 3-32: Ink Compartment

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Ink Core Module

The ink core module maintains the pressure and viscosity of the ink in the
printer.

1. Ink Core
2. Ink Core Pump

Figure 3-33: Ink Core Module

The ink core module contains the following subsystems:

• Ink core pump
• Ink core

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Ink Core Module Connections

There are three input, three output, and one vent hydraulic connections to
the ink core module.

Connections Type of Tube

Input Hydraulic Connections • Ink addition tube (black-striped tube)

• Gutter pump discharge (blue-striped tube)
• Make-up addition tube (green-striped tube)

Output Hydraulic • Flush supply tube (red-striped tube)

Connections • Ink supply tube (clear tube)
• Ink Commissioning Tube (clear tube)

Vent Vent or breather tube (clear tube)

Table 3-15: Ink Core Module Connections

Two ribbon cables provide the electrical interface between the ink core
module and the electronic system. The cables connect directly from the ink
core module to the PIB and allow for the transfer of the following signals:
• Ink pump motor control signal
• Pressure sensing signals (2 sensors)
• Ink temperature signal
• Valve control signals
• Mixer tank level detecting signals
• Ink system smart chip information (refer to “Smart Cartridges” on
page 3-28 for additional information).

Ink Core Pump

The ink core pump is a positive displacement gear pump driven by a 24
VDC brushless motor.
The pump provides stable ink pressure to the nozzle during printing and
also provides a flow of ink to other components inside the ink core
module.

Ink Core Module Functions

The phasing and velocity fly-by sensors and supporting circuitry
contribute directly or indirectly to the performance of six critical control
functions during steady-state operation:
• Phasing
• Modulation control
• TOF measurement

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 Videojet 1210/1510 Service Manual

• Pump speed control

• Target pressure control
• Viscosity control
The functions of the ink core module are shown in Table 3-16.

Name Function Frequency

Phasing Between prints, charge transfer to test drops is measured by Performed

the LEAD fly-by sensor (phase detector) in order to approximately
synchronize drop charging to drop break-off, thereby 25 times per
optimizing print quality. second

Modulation Between prints, modulation amplitude is validated by Performed

Control performing an abbreviated auto-modulation test using the continuously
LEAD fly-by sensor (phase detector). The amplitude is
changed in small increments whilst measuring the rate of
change of the phase angle in order to verify that the amplitude
setting remains at or near the “appropriate setting”.

TOF Between prints, drop velocity is monitored by measuring the Performed

Measurement TIME OF FLIGHT of the test drops from the LEAD (phase) every TENTH
sensor to the TRAILING (velocity) sensor. The measured phasing test
result is referred to as the “actual velocity”.

Pump Speed A pressure transducer inside of the Core measures “actual Performed
Control pressure”. This pressure is compared to the “target pressure”. once per
The resultant error is used to increase or decrease the pump second
speed.

Target Pressure The “target pressure” represents the nominal pressure the Occur every
Control printer determines that it must operate at in order for the actual 10 seconds
velocity to be equal to the “velocity set point”. The printer
makes modifications to the target pressure by reviewing the
“history” of the velocity error parameter (“PID” control).
“Velocity error” refers to the difference between the actual
velocity and the set point.

Viscosity Once the printer has determined its “target pressure”, it has Occurs every
Control the means to perform viscosity adjustments. Determination 5 minutes (if
concerning viscosity is made by comparing the empirically- necessary)
determined “target pressure” to a reference pressure known
as the “temperature-compensated target pressure”. This value
is acquired indirectly from data encoded on the ink cartridge
Smart Chip. This reference pressure is mathematically
determined and represents the pressure required to acquire
the correct “actual velocity” under ideal viscosity conditions. If
the target pressure deviates from the reference pressure, the
printer attributes this to viscosity variation and responds
accordingly.

Table 3-16: Ink Core Module Functions

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Smart Cartridges
Two types of cartridges are used in the printer.
• Ink cartridge - This contains the ink.
• Make-up cartridge - This contains the make-up fluid.

Functions
The cartridge is based on smart chip technology that helps you to:
• Find the accurate level of ink and make-up fluid
• Use correct type of ink or make-up fluid
• Know the expiry date of the ink

1. Smart Chip
2. Septum

Figure 3-34: Smart Cartridges

Ink Compartment Fan

The ink compartment fan (item 1, Figure 3-35 on page 3-29) cools the ink
compartment.

Gutter Pump
The gutter pump (item 2, Figure 3-35) is fitted to the rear of the cabinet
inside the ink compartment. The functions of the gutter pump are as
follows:
• Vacuum generation for gutter suction
• Vacuum generation to assist in nozzle back flushing
• Ink delivery to the ink core module during printer installation

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 Videojet 1210/1510 Service Manual

1. Ink Compartment Fan

2. Gutter Pump

Figure 3-35: Fan and Gutter Pump

Vent Recovery System

The vent recovery system converts the solvent/air vapour created in the
mixer tank into recoverable solvent. Refer to the Figure 3-36 on page 3-30.

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Videojet 1210/1510 Service Manual

To vent pipe
on ink core

To gutter pump
manifold

Figure 3-36: Vent Recovery System

Printhead
The printhead contains the following parts:
• Printhead cover
• Print engine
• Printhead valve module

3 2
1. Printhead Cover 3. Knurled Screw
2. Print Engine 4. Printhead Valve Module

Figure 3-37: Printhead

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Printhead Cover
The printhead cover (item 1, Figure 3-37) is attached to the printhead with
a knurled screw (item 3). The cover protects the printhead components.
Removal of the cover is sensed by the printer through the cover switch.
When the cover is removed the voltage to the deflector electrodes is
turned off.

Printhead Valve Module

The printhead valve module (item 4) consists of the bleed/gutter valve,
ink feed valve, solvent feed valve, and the head heater.

Print Engine
The print engine (item 2) consists of the nozzle, charge electrodes, time of
flight sensors, deflection plate, and gutter tube.

Nozzle
The nozzle (item 8, Figure 3-38 on page 3-32) creates the ink droplets.

Charge Electrode
The charge electrode (item 9) applies an electrical charge to each ink
droplet. The charge applied to the droplet is variable and affects the
position of the droplet on the substrate.

Phase Detectors
The phase detectors (item 12) measure the ink drop velocity and perform
phasing.

Gutter Tube
The gutter tube (item 11) is the return path for the uncharged ink droplets
that are not used for printing. The gutter delivers the ink back into the ink
core.
The gutter detect senses when ink is present in the gutter. The ink feed
tubes are metallic and a signal is fed to one of them. A signal return lead is
connected to the other. When ink (which is conductive) is present, the
signal passes through it to the return lead. The gutter detect signal is then
fed, via the umbilical, to the CSB in the electronics system.

Deflection Plate
The deflection plate (item 10) is supplied with a fixed positive DC voltage
(0 - 8000 VDC) from the EHT Module. This voltage deflects the charged

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Videojet 1210/1510 Service Manual

drops over the top of the gutter, through the printhead slot, and onto the
substrate.

1
16 2

5
15 6

14 7
13 8
9

12

10

11
1. Solvent Flush Line 9. Charge Electrode
2. Bleed/Gutter Line 10. Deflection Plate
3. Bleed/Gutter Valve 11. Gutter Tube
4. Ink/Solvent Feed Valve 12. Phase Detectors (electrodes)
5. Front Manifold 13. Nozzle Cradle
6. Ink Pipe 14. Nozzle Holder
7. Ground 15. Bleed Pipe
8. Nozzle 16. Ink Feed Line

Figure 3-38: Printhead Components

Printhead Operation
The flush supply and ink supply lines merge at Pico valve V1. The ink is
heated as it flows through the manifold assembly to the nozzle. The nozzle
is outfitted with both the feed and the bleed ports. The nozzle bleed port
provides a source of vacuum, used during manual irrigation/
backflushing.

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Ink Supply
Make-up Supply
Under Vacuum

V1 V2

1. Gutter Tube 4. Nozzle

2. High Voltage/EHT Plate 5. Heater
3. Charge Electrode

Figure 3-39: Printhead Operation

The flow of ink is as follows:

1 The ink and solvent mixture flows through the feed line (item 16,
Figure 3-38 on page 3-32) into the printhead.
2 The ink enters the feed valve (item 4).
3 The valves open or close as per the print requirements.

Note: The bleed valve opens and closes as needed during flushing the nozzle
and supplying ink to the nozzle.
4 The ink flows into the nozzle.
To adjust the nozzle refer to“Align the Ink Stream” on page 4-33.
5 The piezoelectric crystal vibrate the nozzle at a frequency of around 75
KHz nominal value in the longitudinal direction.
This vibration enables the nozzle to breakup the stream of ink into
droplets.
6 The ink drops enter the charge electrode (item 9) where they are
charged at different voltage levels based on the character to be
generated.
7 The charged ink drops then pass through the EHT/ High Voltage
Field (item 2, Figure 3-39) and over the phase detectors.

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Videojet 1210/1510 Service Manual

8 The High Voltage/EHT plate deflects the charged drops of ink at

various angles depending on the charge placed on the drop at the
moment of breakoff.
9 An electrically conductive ink is supplied under pressure by the ink
core to the nozzle assembly (item 6, Figure 3-40) through the ink feed
pipe (item 1).
10 An ink stream is formed as the ink is forced out of the nozzle jet orifice
(item 5).
A modulation signal is applied to a ceramic transducer which is
clamped to the nozzle assembly. The transducer crystals (item 3 and
item 4) causes the nozzle assembly to vibrate longitudinally, breaking
up the ink stream into droplets, a small distance away (the break up
point) from the nozzle jet orifice. The frequency of modulation is 76.8
kHz (nominal value).
The ink droplets are produced at the same rate as the modulation
frequency and are uniform in size and separated by equal distances.
The nozzle orifice diameter is 70 microns.

5 2
3
4

1. Ink Feed Pipe 4. Crystal Transducer

2. Damping Mass 5. Nozzle Jet Orifice
3. Crystal Transducer 6. Nozzle Assembly

Figure 3-40: Ink Jet Formation

Droplet Charging
11 The charge electrode (item 2 in Figure 3-41) is positioned at the break
up point of the ink stream and extends for several drops either side of
it.

Note: This allows a tolerance for break up position and shields the ink stream
from the influence of the other electrostatic fields. The distance between the
nozzle assembly (item 1) and the charge electrode is 2 mm.

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1. Nozzle Assembly
2. Charge Electrode

Figure 3-41: Charge Electrode

The ink stream and the charge electrode can be considered as the two
electrodes of a capacitor. By raising the charge electrode to a specific
positive voltage (with a charge pulse) the section of the ink system within
the charge electrode will have a negative charge induced on it. When a
drop of ink then breaks from the jet it will have trapped on it a charge
directly proportional to that on the charge electrode. If the positive voltage
is then removed from the charge electrode, the negative charge on the jet
will discharge through the ink jet and nozzle assembly to ground.
However, the drop of ink which has become detached from the jet cannot
discharge as it no longer has a conductive path to ground.

Droplet Deflection
12 The droplet stream passes through an electrostatic field maintained by
the deflector electrodes that are connected to a high tension supply
(typically 6 kV).
13 The negatively charged droplets are deflected by the field towards the
high voltage deflector electrode.
The distance a drop is deflected is proportional to the charge carried.
The charge carried is proportional to the voltage applied to the charge
electrode when the drop became detached from the ink jet.
The charged droplets once deflected leave the printhead to form
characters in a dot matrix format on the substrate. Droplets which are
not required for printing are not charged and are therefore not
deflected.

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Videojet 1210/1510 Service Manual

2
1. Deflected Droplet Path 4. Droplet Path to Gutter
2. Substrate 5. Phase Detectors (Electrodes)*
3. Gutter

* The part is not shown in the figure

Figure 3-42: Droplet Deflection

Umbilical
The umbilical has the electrical wiring and ink system tubing from the
printer to the printhead.

The Hydraulic System

This section describes the combined operation of the ink system,
printhead and umbilical to print on a substrate. The Figure 3-43 on page 3-
37 shows the hydraulic system of the printer.
The hydraulic system of the printer consists of the following components:
• Ink cartridge
• Make-up cartridge
• Ink core module
• Umbilical
• Printhead

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• Gutter pump
• Condenser

VL
Nozzle
VF Flush Pump
VP VR
VG VV

Printhead

VC VT

VS VJ

VI VM
Gutter Ink Jet
Pump Pump Pump

Vent

Condensor Mixer Tank Ink Make-up

Figure 3-43: Hydraulic System Components

Rev AC The Hydraulic System 3-37

Installation
4
Introduction
This chapter describes the procedures to install Videojet 1210/1510
printer.

Caution
Only Videojet trained personnel must carry out the installation and
maintenance work. Any such work undertaken by unauthorized
personnel can damage the printer and invalidate the warranty.

Warning
Make sure that the mains electrical supply is within the range
indicated by the label adjacent to the mains inlet of the printer. If the
voltage ratings differ, do not use the printer until you consult your
Videojet 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.

Warning
The printer must be connected to an AC 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 to the protective ground
terminal may render the apparatus dangerous.

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Warning
Lethal voltages are present within this equipment when it is
connected to the mains electrical supply. 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. The failure to follow this warning can cause death or
personal injury.

Tools and Supplies

Tools
Refer to the service tool kit listed in “Tools Kit” on page 10-50 for
information on tools and supplies required to install the printer.

Supplies
Two cartridges of ink and two cartridges of make-up fluid.

Typical Production Line

A typical printer installation is shown in Figure 4-1 on page 4-3, where the
printer (item 6) is mounted on a printer stand (item 7). The printhead
(item 1) is configured to print vertically with the help of a clamp and
bracket assembly. A stack light (item 8) is fitted to the printer.

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 Videojet 1210/1510 Service Manual

2
8

3
4

5
MESSA
B INPUTGE

MESSA
A INPUTGE

COMM
PRINT
RS S TRIGG
232
ER
STATU 2
OUTPUS
T
COMM SHAFT
RS S ENCOD
485 ER
RELAY
SWITC
HES
PRINT
TRIGG
ETHER ER
1
NET

USB

1. Printhead 6. Printer
2. Shaft Encoder 7. Printer Stand
3. Shaft Encoder Cable 8. Stack light
4. Photo Cell 9. Printhead Stand
5. Photo Cell Cable

Figure 4-1: Typical Production Line Installation

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Videojet 1210/1510 Service Manual

Unpack and Inspect the Printer

1 Open the shipping box, and make sure that all the parts listed in the
packing list are present in the box. If any part is missing, contact
Videojet Technologies Inc.
• Refer to Chapter , “Support and Training” for Videojet contact
information.
• Refer to Chapter 10, “Illustrated Parts List” for part numbers.
2 Make sure that there are no damaged parts. If you find any damaged
part, contact Videojet Technologies Inc. to order a new part.

Commission the Printer

This section describes the tasks that a user must perform to commission
the printer.

Inspect the Ink System

1 Put the printer on a stand or table.

Note: The printer can be mounted on three types of stands: mobile printer
stand, static printer stand, or the wall mounting assembly. Refer to the
respective installation instructions to install the printer on a stand.
2 Turn the knob and open the ink compartment door (see Figure 4-2).

Figure 4-2: Turn the Knob

3 Push the plate (item 2, Figure 4-3 on page 4-5) in the direction shown
to open the ink compartment door (item 1) completely.

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 Videojet 1210/1510 Service Manual

1. Ink Compartment Door

2. Plate
Figure 4-3: Ink Compartment Door

4 Remove and discard the foam pads (see Figure 4-4 on page 4-5).

Figure 4-4: Foam Pads

5 Pull the ink core module out of the ink compartment (see Figure 4-5
on page 4-6).

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Videojet 1210/1510 Service Manual

1. Ink Compartment Door

2. Ink Core Module

Figure 4-5: Pull Ink Core Module

6 Make sure that the ink core manifold is connected to the ink core
module correctly (see Figure 4-6).

Ink Core Manifold

Figure 4-6: Ink Core Manifold

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7 Make sure that all the tubes are connected to the ink core manifold
(see Figure 4-7).
8 Make sure that the air vent tube is connected to the solvent recovery
system at the bottom rear of the cabinet.

1. Clear Tube (5/32 inch) 5. Blue Stripe Tube (1/8 inch)

2. Red Stripe Tube (1/8 inch) 6. Black Stripe Make-up Tube (1/8 inch)
3. Green Stripe Ink Tube (1/8 inch) 7. Clear Tube (1/8 inch)
4. Air Vent

Figure 4-7: Tubes to Ink Core Manifold

9 Push the ink core module into the ink compartment.

10 Close the ink compartment door.

Inspect the Electronics System

11 Open the electronics compartment and make sure that all the electrical
cables are fitted and routed correctly.
12 Verify that the pneumatic tube is connected between the positive air
pump and the filter (if positive air pump is fitted).
13 Record PIB and CSB revisions. You must disconnect the cables to
inspect the PIB. Reconnect the cables (refer to Figure 3-30 on page 3-
22, Figure 3-29 on page 3-22 and Table 3-14 on page 3-22 for more
information).

Inspect the Printhead

14 Remove the printhead cover and inspect for damage.
15 Check the parameters listed in Table 4-1 on page 4-8.

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Videojet 1210/1510 Service Manual

Checks Value

Check the distance between the nozzle 2.3 mm (minimum)

and the charge electrode

Visually check the charge electrode gap 0.575 to 0.675 mm

Table 4-1: Charge Electrode and Nozzle

Log into UI
16 Connect the printer to the AC power supply and turn on the printer.
The menu screen appears on the display (see Figure 4-8 on page 4-8).

Figure 4-8: Menu Screen

17 If you cannot see the display, adjust the contrast using the contrast
adjustment button .

18 Log into the user interface (UI) at level 3 password. On the Password
menu, select Enter Password. The Enter Password dialog box appears.

Figure 4-9: Menu Screen

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 Videojet 1210/1510 Service Manual

Use the password generated by the DailyPassword application. To

obtain the password, do one of the following:
• Call Videojet Technologies Inc. Customer Service Department at 1-
800-843-3610 (United States only), or contact the local Videojet
Technologies Inc. representative.
• Access Service > Videojet Password Generator tab on
www.videojet.com.

Note: The printer may display a No Ink Parameters warning and an Ink
Core Change alarm. These are normal indications that the ink core is new
and not programmed.

Install Ink and Make-up Cartridges

19 Open the ink compartment door (refer to Step 2 and Step 3 on page 4-
4).

Warning
The ink, solvent and make-up fluid are irritating to the eyes and
respiratory system. To prevent personal injury when handling these
substances follow the guidelines given below:
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 make-up fluid contaminates the skin, wash immediately
with soapy water. DO NOT use washdown or solvent to clean ink
stains from the skin.

20 Under Data Logging, record the version information for the following:
• SW Rev
• PE Rev
• WinCE
21 Perform a valve test.
22 Install one new cartridge of ink and one new cartridge of make-up
fluid in the printer.
23 Check to make sure that the printer identifies the cartridges and ‘No
ink’ message disappears

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24 If required, perform the ‘Update Ink Core’ Parameters.

To update the parameters, do these tasks:
a. Select Calibrate > Update Ink Core Parameters. The ink data is
displayed on the screen.
b. Make sure that the ink data displayed on the screen matches with
the data on the ink cartridge.
c. Press the Enter key and wait for about 4 to 5 seconds. The ink data
displayed on the screen disappears and the new ink type
information appears.
d. Make sure that the part number on the ink cartridge matches with
the part number displayed on the screen. Record the part number.
See Figure 4-10.

Figure 4-10: Ink Part Number

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25 Verify and record the ink type and expiration date. Access Calibrate >
View Ink Smart Chip Data menu (see Figure 4-11 and Figure 4-12).
26 Make sure that the ink reference matches with the number displayed
on the menu screen (see Figure 4-10 and Figure 4-12).

Figure 4-11: View Ink Smart Chip Data Option

Figure 4-12: Ink Smart Chip Data

27 Verify and record the make-up type and expiration date. Access
Calibrate > View Makeup Smart Chip Data menu (see Figure 4-13 on
page 4-12 and Figure 4-14 on page 4-12).

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Figure 4-13: View Makeup Smart Chip Data Option

Figure 4-14: View Makeup Smart Chip Data

28 Verify and record the ink core ‘Run Hours’. Access Calibrate > View Ink
Core Smart Chip Data menu (see Figure 4-15 on page 4-12).

Figure 4-15: View Ink Core Smart Chip Data

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Configure the Printer

29 Calibrate the EHT. Refer to “Calibrate EHT” on page 4-36.
30 Set date and time. Access Configure > Set Time/Date (see Figure 4-16).

Figure 4-16: Set Time/Date

31 Set the nozzle type and the conduit length. Access Configure > System
Settings.The System Settings dialog box appears (see Figure 4-17 on
page 4-14).
• Make sure that the nozzle type is set correctly for the current
configuration (70 micron).
• Make sure that the conduit length is set correctly for the current
configuration.

Printer Conduit Length

Videojet 1210 2 m (standard), 3m (optional)

Videojet 1510 3 m (standard), 6 m (optional)

Table 4-2: Conduit Length

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Figure 4-17: System Settings

32 Make sure that the current printhead elevation is zero. Access

Calibrate > Printhead Elevation. The Printhead Elevation dialog box
appears (see Figure 4-18).

Note: Keep the printhead at the same height as the point where the umbilical
is attached to the cabinet.

Figure 4-18: Printhead Elevation

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 Videojet 1210/1510 Service Manual

Prime the Ink Core Module

33 Select System > Fill Ink Core to prime the printer with the ink (see
Figure 4-19) and record the time to prime.

Figure 4-19: Fill Ink Core Menu

34 Make sure that the fluid flows through the black-striped tube (item 1,
Figure 4-20) and blue-striped tube (item 2).

1. Black Striped Tube

2. Blue Striped Tube

Figure 4-20: Prime Core

35 Monitor the Diagnostics Screen Two to track the Ink Core Level from
Empty to Low to Middle. Select Calibrate > Diagnostics Screen 2. The
Diagnostics Screen Two appears (see Figure 4-21 on page 4-16).

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Videojet 1210/1510 Service Manual

Figure 4-21: Diagnostics Screen Two

36 Continue the Fill Ink Core procedure until the middle level is reached.
Replace the ink cartridge with a new cartridge when the ink reaches
‘middle’ level.
If the ink level stalls above ‘low’ but below ‘middle’, replace the
cartridge at this time to allow the ‘Fill Ink Core’ procedure
completion.

Perform System Flush Purge and Umbilical Purge

37 Remove the printhead cover screw that fastens the printhead cover to
the printhead chassis and remove the printhead cover (see Figure 4-
22).

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 Videojet 1210/1510 Service Manual

1. Umbilical 4. Printhead Cover Screw

2. Printhead Cover 5. Printhead Valve Module
3. Print Engine
Figure 4-22: Printhead Cover Removed

Caution
Always wear a set of rubber gloves before disconnecting the nozzle
tubing manifold. This helps to prevent nozzle clogs.

38 Remove the M2 x 6 socket-head-cap screw (item 1, Figure 4-23) that

attaches the front tubing manifold to the printhead valve module.
39 Remove the 2-way manifold gasket (item 5).
40 Put the 2-way manifold gasket provided in the bypass kit on the ports
of the printhead valve module.
41 Fit the nozzle bypass manifold (that has the loop of tube) (part
Number 399247) to the printhead valve module using the M2 x 6
socket-head screw.

Rev AC Commission the Printer 4-17

Videojet 1210/1510 Service Manual

4
1. M2 x 6 Socket-head Screw 4. Quick Disconnect
2. Nozzle Bypass Manifold 5. 2 Way Manifold Gasket
3. Tubing

Figure 4-23: Bypass Manifold

42 Open the quick disconnect (item 4) in the middle of the loop and
direct the supply side into a receptacle.
43 Start System Flush Purge (select System > System Flush Purge). Refer to
“System Flush Purge” on page 8-5 to perform system flush purge.

Note: Record the time to complete the system flush purge.

44 Observe if the fluid flows through the flush supply line (red stripe)
and flows out of the loop in the end.
Make sure that the fluid that is ejected is clear (make-up, not ink).

Note: Allow the system flush procedure to stop automatically after

completion.
45 Perform umbilical purge (refer to “Umbilical Purge” on page 8-3).
This procedure will not time-out automatically, so perform a Quick
Stop to stop the umbilical purge process after a few seconds.

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 Videojet 1210/1510 Service Manual

Figure 4-24: Umbilical Purge

46 Remove the nozzle bypass manifold and the 2-way manifold gasket.
47 Fit the front tubing manifold to the printhead valve module using M2
x 6 socket-head-cap screw.

Perform Ink Stream Alignment and Viscosity Calibration

48 Remove the make-up cartridge from the make-up stall.
49 Start the jet using quick start.

Figure 4-25: Quick Start Jet

You can see the ink stream toggling at the start, because of air bubbles
that remains in the system. If the nozzle is clogged, perform nozzle

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Videojet 1210/1510 Service Manual

backflush. (System > Nozzle Flush). Limit the number of backflushes to

40.
50 Check the position of the ink stream into the gutter:
• If the ink stream is aligned into the gutter, go to Step 51. You can
make the fine adjustments to the alignment later.
• Else, perform an ink stream alignment, if necessary (refer to “Align
the Ink Stream” on page 4-33). Make sure that the adjustments are
not at either end of the adjustment ranges. If adjustments are at the
end of the ranges, there can be a nozzle partial clog even though the
ink stream is not severely misaligned. If necessary, do a nozzle
backflush (System > Nozzle Flush).
51 Make sure that the jet startup is complete. The jet running icon on the

main screen must be solid (must not flash) .

52 Make sure that the printer has reached steady state. Steady state
indicates: actual velocity = velocity set point, ±0.1m/sec.

Caution
If the viscosity calibration is not done, the viscosity high/low
warning will not disappear from the screen. This calibration step is
the most critical step in installing the printer.

53 Perform viscosity calibration (refer to “Calibrate Viscosity” on page 4-

38). Go to Calibrate > Diagnostics Screen 1 and record Target Pressure
(both the values).
54 Check the ink stream alignment and make the fine adjustments if
necessary. The ink stream must be centered horizontally and
vertically not more than 2 to 3 stream widths from the top of the
gutter. The top of the gutter is the arc opposite the EHT plate (angled
plate).
55 Reinsert the make-up fluid cartridge.

Clean Stop and Clean Start the Printer

56 Put a piece of paper under the printhead (to capture splatter) and
press the F1 key to do a clean stop.

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 Videojet 1210/1510 Service Manual

During shutdown if ink splatters inside the printhead, check the ink
stream alignment again and make sure that the flush pump is fully
primed.
57 Put another piece of paper under the printhead and press the F1 key
to do a clean start.

Record the Data

58 When the jet running icon is solid, press ‘i’ key to open the Diagnostic
Screen 1. Record the following values:
• Target Pressure (both values)
• Actual Pressure
• Velocity Set Point
• Actual Velocity
• Head Temperature
• Drop Frequency
• Modulation Voltage
• Printing Phase
• Phasing Threshold
• Phase Profile
Open Diagnostic Screen 2 and record the following values:
• Ink Temperature
• Electronics Temperature
• Pump RPM

Perform Final Checks

59 Make sure that auto modulation is enabled (Calibrate > Auto
Modulation).
60 Install the printhead cover and verify that the amber light is turned
off:
• If the amber light is turned on when with the printhead cover fitted,
check the Current Warnings screen and perform the required
troubleshooting.
61 Use a flow meter and make sure that the rate of positive air flow out of
the printhead slot is 4 SCFH.
62 Take a sample print.

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Videojet 1210/1510 Service Manual

63 Close the ink compartment door.

64 Make sure that the electronics compartment door and the ink
compartment door are closed.

Caution
Do not perform Step 65 until the system is ready for production, as it
affects the viscosity adjustments of the printer.

65 If the production printing is necessary, measure the vertical distance

between the umbilical exit point on the side of the cabinet and the
bottom of the printhead when it is fitted to the conveyor. This is the
Printhead Elevation. Enter the value (in centimeters) in the UI.

Figure 4-26: Printhead Elevation

66 Back up printer settings using a USB flash drive. Select Configure >
Backup System Settings.

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 Videojet 1210/1510 Service Manual

Figure 4-27: Backup System Settings

67 Press the Enter key to backup the settings.

68 Validate machine parameters.

Set the Password Levels

Consult the customer and find out which machine functions must be
available for different personnel and which passwords they want to use.
Set the passwords for levels 1 and 2. You can also set the password levels
for the menus. Use the DailyPassword application for the daily level 3
password.
Notes: The password levels of functions set at password Level 0, 1 or 2 can be
changed at Password Level 2. The password level of functions set at Password
Level 3 cannot be changed at any password level. Contact the Videojet
representative or access Service > Videojet Password Generator tab on
www.videojet.com to obtain the password.

Figure 4-28: Password Menu

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Videojet 1210/1510 Service Manual

Caution
Machine functions that only trained personnel can access are set at
password level 3 (master password). Contact the Videojet
representative or access Service > Videojet Password Generator tab on
www.videojet.com to obtain the password.

Install the Encoder

When the product speed is constant, the printer uses internal encoding.
When the speed of the conveyor varies, the printer uses external encoding
(that is use of shaft encoder).

Internal Encoding
An internal clock sets the stroke rate to a constant pace. Refer to “Internal
Encoding” on page B-1, for more information on internal encoding.
Do the following tasks to set encoding source to internal encoder:
1 Navigate to Configure> Shaft Encoder Source. The Print Control menu
appears (see Figure 4-29 on page 4-24).
2 Set the Shaft Encoder Source to Internal.

Figure 4-29: Internal Shaft Encoder Source

Note: A width of 1 will provide the fastest print that the printer can achieve
in each font using the Internal Shaft Encoder option (refer to Figure 4-30).
The message width is increased by approximately 3% for each increment.

4-24 Install the Encoder Rev AC

 Videojet 1210/1510 Service Manual

Figure 4-30: Message Width

Rev AC Install the Encoder 4-25

Videojet 1210/1510 Service Manual

External Encoding
If the conveyor speed varies, an external shaft encoder must be fitted in
order to maintain constant message width (refer to “External (Reduce Or
Direct) Encoding” on page B-2 for more information).
Do the following tasks to install an external shaft encoder:
1 Turn off the printer.
2 Connect the shaft encoder cable to the shaft encoder connector. See the
following pictures for connections:
• Figure 4-31 on page 4-27 - shows the shaft encoder connector on the
connector panel.
• Figure 4-1 on page 4-3 - shows the installed shaft encoder and the
related connections.
• Figure 4-32 on page 4-27 - describes the shaft encoder connector
socket pin layout.

Note: 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.

Note: Using quadrature shaft encoders to determine changes of direction

disables the width function (that is, the width must be set to 1). If width
control is required, an external divider box must be provided.

4-26 Install the Encoder Rev AC

 Videojet 1210/1510 Service Manual

Shaft Encoder Connector

Cat 5e

Note: Availability of connectors depends on the printer model you choose.

Figure 4-31: Connector Panel

2 3

1 4

Figure 4-32: Encoder - Socket Pin Layout

3 Two LEDs on the boards show the operating status of the shaft
encoder inputs. Use the LEDs to confirm that a shaft encoder is
connected correctly.
4 Set the shaft encoder source to External. Navigate to Configure> Shaft
Encoder Source in the UI. The Print Control menu appears (see Figure 4-
33 on page 4-28).

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Videojet 1210/1510 Service Manual

Figure 4-33: Print Control Menu

5 Make sure to set the physical parameters for external encoder.

Install the Product Detector

Figure 4-1 on page 4-3 shows a photocell (item 4) connected through a
cable (item 5) to print trigger 1 connector on the connector panel.

1
3

1. +15 VDC Supply to Sensor

2. Sensor Output
3. 0 VDC Common

Figure 4-34: Print Trigger 1 Connector Pin Diagram

Note: Print Trigger 2 is for reverse print and is not a product detector trigger,
but a change in state reverses the direction of print. It has an NPN and PNP
connection. The Print Trigger 2 option requires the use of non-standard system
software.

Do the following tasks to install a product detector:

1 The photocells may be either NPN or PNP devices. Set Jumper JB1 on
the CSB to match the device type (see Figure 4-35).

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 Videojet 1210/1510 Service Manual

NPN Device PNP Device

Figure 4-35: Product Detector Configuration

2 Turn on the printer.

3 Select the photocell source. Access Configure > Photocell Source. The
Print Control menu appears.
Set the relevant photocell level(s) to Active high or Active low based on
the device type (NPN = Active high: PNP = Active low). Access
Configure > Photocell Levels. The Photocell Levels menu appears.

Printhead
Product Delay Product

Product Detector
Figure 4-36: Product Delay

Rev AC Install the Product Detector 4-29

Videojet 1210/1510 Service Manual

Install the Stack light

3

4
2
5

1 6
1. Red lamp negative supply 5. Strobe/siren negative supply
2. Amber lamp negative supply 6. +24 VDC common to the traffic lights
3. Green lamp negative supply
4. +24 VDC supply to the strobe/siren
(Maximum Rating = 900 mA)

Figure 4-37: Status Output Connector Pin Diagram

Do the following tasks to install a stack light:
1 Fit the stack light (item 1, Figure 4-38) to the stack light mounting
bracket (item 3) using three M4x10 socket-head cap screws (item 2).
2 Fit the stack light mounting bracket to the printer cabinet (item 1,
Figure 4-39 on page 4-31), using three M4x10 socket-head cap screws
(item 2) and three M4 plain nylon washers (item 3).

4-30 Install the Stack light Rev AC

 Videojet 1210/1510 Service Manual

1. Stack light
2. M4x10 Socket-head cap Screws (x3)
3. Stack light Mounting Bracket

Figure 4-38: Stack light

2
3

1. Printer Cabinet
2. M4x10 Socket-head cap Screws (x3)
3. M4 Plain Nylon Washers (x3)

Figure 4-39: Stack light Installation

3 Insert the stack light connector into the status output connector on the
connector panel (see Figure 4-40 on page 4-32).

Rev AC Install the Stack light 4-31

Videojet 1210/1510 Service Manual

Status Output Connector

Cat 5e

Figure 4-40: Connector Panel

The installation of the stack light is complete.

4-32 Install the Stack light Rev AC

 Videojet 1210/1510 Service Manual

Align the Ink Stream

Two adjustments are required; nozzle vertical adjustment and nozzle
horizontal adjustment.

Warning
The ink and make-up fluid are irritating to the eyes and respiratory
system. Remember the following guidelines 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 make-up fluid contaminates the skin, wash immediately
with soap water. DO NOT use washdown or solvent to clean ink
stains from the skin.

Do the following tasks to align the ink stream:

1 Loosen the knurled screw and remove the cover from the printhead.
2 Secure the printhead vertically in a suitable stand with the nozzle
pointing downwards.
3 Put a suitable container beneath the printhead to collect the ink.
4 Disable gutter detect and charge check, as follows:
a. Open the System menu.

Figure 4-41: System Menu

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Videojet 1210/1510 Service Manual

b. Select Gutter Fault Shutdown Enable. The Gutter Fault Shutdown box
appears.
c. Toggle to set the value to Disable.
d. Press the Enter key.

Optimum jet
position, 2 to 3
times diameter of jet

Gutter
center line

First quarter
of the gutter
Figure 4-42: Ink Jet Gutter Position

5 Perform a Quick Start. When the ink jet has started, check that the ink
jet is in the correct position in the gutter (see Figure 4-42).

Note: You must perform a quick start rather than a clean start when you are
aligning the printhead during the commissioning process. However, if you
are aligning the printhead of a printer that has already been in operation for
some time, you may perform either a quick start or a clean start at this point.

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

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 Videojet 1210/1510 Service Manual

6 Adjust the ink jet position, if necessary using the horizontal

adjustment screws (item 2, Figure 4-43 on page 4-35) and vertical
adjustment screw (item 1).
When the adjustment has been made, make sure that the horizontal
adjustment screws are tight and the ink jet position is correct.

4
3 2

1. Vertical Adjustment Screw 3. Horizontal Locking Screw

2. Horizontal Adjustment Screw 4. Vertical Locking Screw

Figure 4-43: Printhead Adjustment Screw Location

7 When the ink jet position is correct in the gutter, check the ink jet is
flowing through the centre of the charge electrode slot parallel to the
sides of the slot (see Figure 4-44).

Equidistant Gap

Figure 4-44: Ink Flow through Charge Electrode

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Videojet 1210/1510 Service Manual

Caution
You must not tamper with the printhead charge electrode
components.

8 To direct the ink jet flow through the charge electrode:

a. Release the horizontal adjustment screw (item 2, Figure 4-43 on
page 4-35).
b. Move the block until the jet is in the correct position. Secure the
adjustment screw and check the jet position again.

Perform Calibration and Testing

The system calibration and test procedures must be performed when print
engine module, EHT supply, CSB, or umbilical is changed.

Calibrate EHT
Do the following tasks to calibrate the EHT:
1 Open the Calibrate menu.

Figure 4-45: Calibrate Menu

2 Select Calibrate EHT. The EHT Calibration Messages appear based on

the condition.

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 Videojet 1210/1510 Service Manual

Figure 4-46: EHT Calibration Messages

3 Press Enter. EHT Calibration Sweep occurs.Refer to Figure 4-47.

Figure 4-47: EHT Calibration Sweep

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Videojet 1210/1510 Service Manual

Calibrate Viscosity
Do the following tasks to perform viscosity calibration:

Note: Perform this procedure every time the ink core module is replaced or the
print engine module is replaced.

1 Keep the printhead at the same height as the point where the
umbilical is attached to the cabinet.
Set the printhead elevation value to zero (see Figure 4-48).

Figure 4-48: Printhead Elevation

2 Turn the knob and open the ink compartment door (see Figure 4-49).

Figure 4-49: Unlock Ink Compartment Door

4-38 Perform Calibration and Testing Rev AC

 Videojet 1210/1510 Service Manual

3 Remove the make-up fluid cartridge (see Figure 4-50).

Make-up
Fluid Cartridge

Figure 4-50: Cartridge Removal

4 Perform a Quick Start. See Figure 4-51.

Figure 4-51: Quick Start

5 Make sure that the jet startup is complete. The jet running icon on the

home screen should be solid (not blinking) .

6 Make sure that the printer has reached steady state. Steady state
means: Actual Velocity = Velocity Set Point + or -0.1 m/s
For example, see Figure 4-52 on page 4-40.

Rev AC Perform Calibration and Testing 4-39

Videojet 1210/1510 Service Manual

Figure 4-52: Steady State

7 Perform viscosity calibration. Follow the prompts provided by the

printer, assuming that the ink is known perfect ink (see Figure 4-53).

Note: Perfect ink is the ink that is pulled directly from an ink cartridge
known to be within a specific viscosity range.

Figure 4-53: Viscosity Calibration

8 Put the make-up cartridge into make-up cartridge slot.

9 Enter the correct printhead elevation in the UI. Refer to Figure 4-48 on
page 4-38.
10 Put the printhead into the printhead bracket on the conveyor.

4-40 Perform Calibration and Testing Rev AC

Printer Operation
5
Introduction
Refer to the Operator Manual for the following information:
• How to turn on the printer
• How to Clean Start and Clean Stop the printer
• How to login for the first time
• How to set the passwords for menus and levels
• How to access other password levels
• How to clear the passwords
• How to view version info
• How to reset and hide the product counter
• How to view and reset run hours
• How to configure the serial port
• How to connect to a remote device
• How to enter service information
• How to create a message
• How to print messages

Reset Run Hours

If the Service icon appears, 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 Data Logging menu >Enter Service
Information option.

Rev AC Introduction 5-1

Videojet 1210/1510 Service Manual

1 Navigate to Data Logging > Reset Run Hours.

Figure 5-1: Data Logging Menu

2 Press the Enter key. The Reset Run Hours menu appears.

Figure 5-2: Reset Run Hours Menu

3 Select Set machine alarm hours.

For example:
a. Enter the number of hours until the next ink core change is due. For
more information refer to the Table 8-1 on page 8-1 for maintenance
schedule.
b. Press the Enter key to save the settings.
4 If you want to reset the run hours, set Reset machine run hours to Yes.

Restore Calibration Parameters

The following procedure may be performed in order to recover previously
backed-up job and printer configuration information from a USB flash
drive:
1 Insert the USB flash drive into the external USB port of the printer.

5-2 Restore Calibration Parameters Rev AC

 Videojet 1210/1510 Service Manual

2 Select Configure >Restore System Settings.

Figure 5-3: Restore System Settings

3 Press the Enter key to restore the settings.

Perform System Backup

Do the following tasks to perform a complete backup of all programmable
printer files, including job and printer configuration information:
1 Press the F1 key to stop the ink jet.
2 Insert a USB flash drive into the external USB port of the printer.
3 Select Configure > Full System Backup.

Figure 5-4: Full System Backup

3) Follow the printer prompts and complete the backup.

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Videojet 1210/1510 Service Manual

Perform Full System Restore

Do the following tasks to recover previously backed-up information from
the USB flash drive:
1 Press the F1 key to stop the ink jet.
2 Insert a USB flash drive into the external USB port of the printer.
3 Select Configure > Full System Restore. The Restore Options dialog box
appears.

Figure 5-5: Full System Restore

4 Use the Right or Left arrow keys to scroll through the available options
to restore.

Figure 5-6: Restore Options

5 Press the Enter key to restore the selected option.

5-4 Perform Full System Restore Rev AC

User Interface
6
Introduction
Refer to Videojet 1210/1510 Operator Manual for information on how to
navigate in the UI, create the messages, edit the messages, save the
messages, and create the user fields.

Rev AC Introduction 6-1

Replacement
Instructions 7
Introduction
This section contains complete instructions for the replacement of the
components listed below.

Description Page No.

Replace the Control System Board 7-7

Replace the Power Supply Unit 7-9

Replace the Liquid Crystal Display (LCD) or the Front Panel 7-13
Interface Board (FIB)

Replace the Keyboard/Electronics Compartment Door 7-16

Replace the Ink Core Module 7-21

Replace the Ink Pump 7-35

Replace the Print Engine Assembly 7-41

Replace the Printhead Valve 7-44

Replace the Umbilical Assembly 7-50

Replace the Printer Interface Board (PIB) 7-74

Replace the Electronics Fan 7-86

Replace the Septum Assembly 7-82

Replace the Gutter Pump 7-94

Replace the Power Switch 7-77

Replace the Ethernet Connector 7-88

Replace the Positive Air Kit 7-90

Replace the Ink Door Assembly 7-99

Replace the Ink System Fan 7-104

Replace the EHT Module 7-106

Replace the USB Connector 7-109

Replace the Plug and Power Cable 7-111

Table 7-1: Location of the Instructions

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Videojet 1210/1510 Service Manual

Description Page No.

Replace the CSB Lithium Battery 7-117

Replace the PCB 1, 2 and 3 7-118

Table 7-1: Location of the Instructions

Safety Information

Caution
PERSONAL INJURY. Before you begin any maintenance work,
make sure that the printer is turned off and disconnected from the
AC power supply.

Warning
LETHAL VOLTAGES. Lethal voltages are present within this
equipment when it is connected to the mains electrical supply. Only
trained and authorized personnel can 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.

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.

7-2 Safety Information Rev AC

 Videojet 1210/1510 Service Manual

Caution
PERSONAL INJURY. Only trained service or maintenance
personnel must perform these installation procedures. Qualified
personnel have successfully completed the training courses, have
sufficient experience with this printer, and are aware of the potential
hazards to which they will be exposed.

Common Procedures

How to Open the Electronics Compartment Door

Do the following tasks to open the electronics compartment:
1 Turn off the main power switch of the printer.
2 Turn off the AC power supply to the printer.
3 Disconnect the mains power cord from the outlet.

Warning
Before you open the electronics compartment door, wear anti-static
wrist straps and ground yourself to the chassis of the cabinet. Failure
to follow this warning can cause both personal injury and damage to
the printer.

4 Use the 3 mm allen wrench to remove the two M4 screws (Figure 7-1
on page 7-4) that attach the electronics compartment door to the
printer cabinet.

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Videojet 1210/1510 Service Manual

M4 Screws

Figure 7-1: Electronics Compartment Door

5 Open the electronics compartment door (Figure 7-2).

Figure 7-2: Electronics Compartment Door Opened

7-4 Common Procedures Rev AC

 Videojet 1210/1510 Service Manual

6 Push the latch (item 2, Figure 7-3) downwards to open the control
system board (CSB) (item 1).

1. CSB 3. M4 x 8 Cap-head Screws (x2)

2. Latch 4. Retainer

Figure 7-3: Latch

How to Close the Electronics Compartment Door

Do the following tasks to close the electronics compartment door:
1 Close the CSB (item 1, Figure 7-3).
2 Push the latch (item 2) up and close the CSB.
3 Close the electronics compartment door with the two M4 screws (see
Figure 7-1 on page 7-4).
4 Connect the mains power cord to the electrical outlet and turn on the
power.

How to Open the Ink Compartment Door

Do the following tasks to open the ink compartment door:
1 Stop the production and remove the printer from the print mode.
2 Log into the Videojet 1210/1510 user interface (UI) as level 2 or level 3
user.
3 Press the F1 key to stop the ink jet.

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Videojet 1210/1510 Service Manual

4 Turn the knob and open the ink compartment door (see Figure 7-4).

Figure 7-4: Unlock Ink Compartment Door

5 Push the plate (item 2) in the direction shown to open the ink
compartment door (item 1, Figure 7-5) completely.

1. Ink Compartment Door

2. Plate

Figure 7-5: Ink Compartment Door Opened

7-6 Common Procedures Rev AC

 Videojet 1210/1510 Service Manual

How to Close the Ink Compartment Door

Do the following tasks to close the ink door:
1 Close the ink compartment door and turn the knob to lock the door
(see Figure 7-4 on page 7-6).
2 Connect the mains power cord to the electrical outlet.
3 Turn on the main power switch off the printer.

Control System Board

Tools and Supplies Required

Tool or Supply Quantity

3 mm Allen Wrench 1

Table 7-2:Tools and Supplies

Warning
Read the “Safety Information” on page 7-2 before you perform the
below tasks.

How to Remove the Old Control System Board

Do the following tasks to remove the old control system board (CSB):
1 Open the electronics compartment door. Refer to “How to Open the
Electronics Compartment Door” on page 7-3.
2 Remove the hinge bracket that holds the CSB.
3 Remember all the cable connections to the CSB (Figure 7-6 on page 7-
8).
4 Disconnect all the cable connectors from the CSB.

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Videojet 1210/1510 Service Manual

Figure 7-6: CSB

5 Discard the CSB according to the local regulations.

The removal of the old CSB is complete.

How to Install the New Control System Board

Do the following tasks to install the new CSB:
1 Put the new CSB in the electronics compartment, so that the pins on
the mounting plate fit in the hinge bracket.
2 Connect all the cable connectors to the CSB.
3 Push the latch up and close the CSB.
4 Put the retainer over the hinge pins of the CSB mounting plate.
5 Fit the retainer using the two M4 x 8 cap-head screws (item 3, Figure
7-3 on page 7-5).
6 Close the electronics compartment door. Refer to “How to Close the
Electronics Compartment Door” on page 7-5.
The installation of the new CSB is complete.

7-8 Control System Board Rev AC

 Videojet 1210/1510 Service Manual

Power Supply Unit

Tools and Supplies Required

Tool or Supply Quantity

3 mm Allen Wrench 1

7 mm Nut Runner 1

Table 7-3:Tools and Supplies

Warning
Read the “Safety Information” on page 7-2 before you perform the
below tasks.

How to Remove the Old Power Supply Unit

Do the following tasks to remove the old power supply unit (PSU):
1 Open the electronics compartment door. Refer to “How to Open the
Electronics Compartment Door” on page 7-3.
2 Swing open the control system board (CSB) (item 2, Figure 7-7 on
page 7-10).

Rev AC Power Supply Unit 7-9

Videojet 1210/1510 Service Manual

1. PSU
2. CSB

Figure 7-7: Control System Board

7-10 Power Supply Unit Rev AC

 Videojet 1210/1510 Service Manual

3 Remove the two M4 nyloc nuts (item 3, Figure 7-8) from the stud (item
2) inside the cabinet.

1. PSU
2. Stud
3. M4 Nyloc Nut

Figure 7-8: PSU Assembly

4 Disconnect the following cables from the PSU (item 1, Figure 7-8).
• PSU cable to the 8-way connector on the CSB
• Cable to the 3-way mains connector on the power switch
5 Discard the old PSU according to local regulations.
The removal of the old PSU is complete.

How to Install the New Power Supply Unit

Do the following tasks to install the new PSU:
1 Connect the following cables to the PSU:
• PSU cable from the 8-way connector on the CSB
• 3-way mains connector from the power switch
2 Put the PSU assembly into the lug (see Figure 7-9 on page 7-12) in the
rear of the electronics compartment and then on the two studs.

Rev AC Power Supply Unit 7-11

Videojet 1210/1510 Service Manual

3 Use the two M4 nyloc nuts to fit the PSU assembly into the lug inside
the cabinet.

Figure 7-9: Lug

4 Close the CSB.

5 Close the electronics compartment door. Refer to “How to Close the
Electronics Compartment Door” on page 7-5.
The installation of the new PSU is complete.

7-12 Power Supply Unit Rev AC

 Videojet 1210/1510 Service Manual

LCD and FIB Assembly

Introduction
The LCD and FIB are part of one assembly. Replace the FIB and LCD
together.

Tools and Supplies Required

Tool or Supply Quantity

T20 Torx Screwdriver 1

Table 7-4:Tools and Supplies

Warning
Read the “Safety Information” on page 7-2 before you perform the
below tasks.

How to Remove the Old LCD and FIB Assembly

Do the following tasks to remove the old LCD and FIB assembly:
1 Open the electronics compartment door. Refer to “How to Open the
Electronics Compartment Door” on page 7-3.

Rev AC LCD and FIB Assembly 7-13

Videojet 1210/1510 Service Manual

1. Electronics Compartment Door 4. FIB Cable

2. K40 x 10 Torx Screws (x4) 5. Ground Wire
3. Inner Display Cover

Figure 7-10: Open Electronics Compartment Door

2 Disconnect the front panel interface board (FIB) ribbon cable (item 4,
Figure 7-10) from the FIB.
3 Use a T20 Torx screwdrivers to remove the four K40 x 10 Torx screws
(item 2) at the corners of the inner display cover (item 3) on the
underside of the electronics compartment door.
4 Disconnect the ground wire (item 2, Figure 7-11 on page 7-15) from
the FIB that is connected to the keypad tag (item 3).

7-14 LCD and FIB Assembly Rev AC

 Videojet 1210/1510 Service Manual

1. Screw
2. Ground Wire
3. Keypad Tags (x2)
Figure 7-11: Ground Wire on Keypad Tag

5 Disconnect the two keyboard-to-FIB ribbon cables (item 1, Figure 7-

12) from connectors X7 and X8 on the periphery of the FIB (item 3).

1. Keyboard-to-FIB Ribbon Cable (x2) 3. FIB

2. K40x10 Torx Screws (x4)

Figure 7-12: Remove the FIB

6 Use T20 Torx driver to unscrew the four K40x10 Torx screws (item 2,
Figure 7-12) from the four corners of the FIB.
7 Remove the old LCD and FIB assembly and discard according to the
local regulations.
The removal of the old LCD and FIB assembly is complete.

Rev AC LCD and FIB Assembly 7-15

Videojet 1210/1510 Service Manual

How to Install the New LCD and FIB Assembly

Do the following tasks to install the new LCD and FIB assembly:
1 Before you install the new LCD and FIB assembly, peel the protective
film from the new LCD (see Figure 7-13).
2 Fit the new LCD and FIB assembly to the electronics compartment
door using four K4x10 Torx screws (refer to Figure 7-12 on page 7-15).
.

Figure 7-13: Peel the Protective Film

3 Connect the two keyboard to FIB ribbon cables to connectors X7 and

X8 on the periphery of the FIB (see Figure 7-12 on page 7-15).
4 Connect the ground wire to the FIB (refer to Figure 7-11 on page 7-15).
5 Fit the inner display cover and tighten the four K40 x 10 Torx screws.
Make sure that the cover fits into the gasket all the way round.
6 Connect the FIB ribbon cable to the FIB.
7 Close the electronics compartment door. Refer to “How to Close the
Electronics Compartment Door” on page 7-5.
The installation of the new LCD and FIB assembly is complete.

Keyboard/Electronics Compartment Door

Introduction
The spare electronics compartment door comes with the relevant
keyboard overlay (in language required), gasket and fixings screws.
However it does not contain liquid crystal display and front panel

7-16 Keyboard/Electronics Compartment Door Rev AC

 Videojet 1210/1510 Service Manual

interface board (LCD and FIB) assembly, cover, and leads. Hence, the
replacement instructions are same for both the keyboard and electronics
compartment door.

Tools and Supplies Required

Tools or Supplies Quantity

3 mm Allen Wrench 1

T20 Torx Screwdriver 1

7 mm Nut Spinner 1

Table 7-5:Tools and Supplies Required

Warning
Read the “Safety Information” on page 7-2 before you perform the
below tasks.

How to Remove the Old Electronics Compartment Door

Do the following tasks to remove the old electronics compartment door:
1 Open the electronics compartment door. Refer to “How to Open the
Electronics Compartment Door” on page 7-3.

Note: There is no need to open the Control System Board (CSB).

Rev AC Keyboard/Electronics Compartment Door 7-17

Videojet 1210/1510 Service Manual

1. Electronics Compartment Door 4. FIB Ribbon Cable

2. K40 x 10 Torx Screws (x4) 5. Ground Wire
3. Inner Display Cover

Figure 7-14: Open Electronics Compartment Door

2 Disconnect the front panel interface board (FIB) ribbon cable (item 4,
Figure 7-14) from the FIB.
3 Use a T20 Torx screwdriver to remove the four K40 x 10 Torx screws
(item 2, Figure 7-14) at the corners of the inner display cover (item 3)
on the underside of the electronics compartment door.
Keep the inner display cover inside electronics compartment.
4 Use a T20 Torx screwdriver to remove the six K50 x 12 Torx screws
(item 1, Figure 7-15 on page 7-19) that hold the electronics
compartment door (item 3) to the hinge bracket (item 2).

7-18 Keyboard/Electronics Compartment Door Rev AC

 Videojet 1210/1510 Service Manual

1. K50 x 12 Torx Screws (x6)

2. Hinge Bracket
3. Electronics Compartment Door
Figure 7-15: Remove the Electronics Compartment Door

5 Remove the electronics compartment door from the printer.

6 Disconnect the ground wire from the FIB (item 2, Figure 7-16) that is
connected to the keypad tag (item 3).

1. Screw
2. Ground Wire
3. Keypad Tags (x2)
Figure 7-16: Ground Wire on Keypad Tag

Rev AC Keyboard/Electronics Compartment Door 7-19

Videojet 1210/1510 Service Manual

7 Disconnect the two keyboard-to-FIB ribbon cables (item 1, Figure 7-

17) from connectors X7 and X8 on the periphery of the FIB (item 3).

1. Keyboard-to-FIB Ribbon Cable (x2) 3. FIB

2. K40x10 Torx Screws (x4)

Figure 7-17: Remove the FIB

8 Use T20 Torx driver to unscrew the four K40 x 10 Torx screws (item 2)
from the four corners of the FIB.
9 Remove the FIB and LCD assembly from the electronics compartment
door.
10 Keep the FIB and LCD assembly on an antistatic bubble sheet.
11 Discard the electronics compartment door according to the local
regulations.
The removal of the old electronics compartment door is complete.

How to Install the New Electronics Compartment Door

Do the following tasks to install the new electronics compartment door:
1 To attach the old FIB and LCD assembly to the new electronics
compartment door, do the following tasks:
a. Fit the old FIB and LCD assembly to the new electronics
compartment door using four K4 x 10 Torx screws (see Figure 7-17).
b. Connect the ground wire to the FIB (see Figure 7-16 on page 7-19).
c. Connect the two keyboard to FIB ribbon cables to connectors X7
and X8 on the periphery of the FIB (see Figure 7-17).
2 Fit the electronics compartment door to the hinge bracket using the six
K50 x 12 screws (item 1, Figure 7-15 on page 7-19).

7-20 Keyboard/Electronics Compartment Door Rev AC

 Videojet 1210/1510 Service Manual

3 Fit the inner display cover and tighten the four K40 x 10 screws. Make
sure that the cover fits into the gasket all the way round.
4 Connect the FIB ribbon cable to the FIB.
5 Close the electronics compartment door. Refer to “How to Close the
Electronics Compartment Door” on page 7-5.
The installation of the new electronics compartment door is complete.

Ink Core Module

Introduction
The ink core module comes as a single unit. The only part that you can
replace is ink core pump. This instruction sheet describes how to replace
the ink core module with and without the pump.

1. Ink Core Pump

2. Ink Module

Figure 7-18: Ink Core Module

Rev AC Ink Core Module 7-21

Videojet 1210/1510 Service Manual

Tools and Supplies Required

Tool or Supply Quantity

2.5 mm Allen Wrench 1

3 mm Allen Wrench 1

T10 Torx Screwdriver 1

7 mm Nut Spinner 1

Side Cutters 1

Table 7-6:Tools and Supplies Required

Warning
Read the “Safety Information” on page 7-2 before you perform the
below tasks.

How to Remove the Old Ink Core Module

Do the following tasks to remove the old ink core module:
1 Stop the production and remove the printer from the print mode.
2 Log into the Videojet UI as level 2 or level 3 user.
3 Press the F1 key to stop the ink jet.
4 Turn the knob and open the ink compartment door (see Figure 7-19).

Figure 7-19: Unlock Ink Compartment Door

7-22 Ink Core Module Rev AC

 Videojet 1210/1510 Service Manual

5 Remove the ink and the make-up cartridges from their slots in the
module (see Figure 7-20).

Figure 7-20: Cartridge Removal

6 Insert an empty solvent cartridge or a special cartridge into the ink

cartridge slot.

Note: A special cartridge is an empty bottle used for draining.

Note: Do not remove the special cartridge until the Empty Ink Core routine
is completed. The smart chip on the cartridge is programmed to allow for one
time insertion only.
7 Select Empty Ink Core option (see Figure 7-21 on page 7-24). The
contents of the ink core will be pumped into the special cartridge.

Note: The Empty Ink Core process can take up to 10 minutes and may
require two special cartridges.

Rev AC Ink Core Module 7-23

Videojet 1210/1510 Service Manual

Figure 7-21: Empty Ink Core

Note: Do not remove the special cartridge until the routine is completed as a
leak can occur.
8 After the Empty Ink Core routine is complete, discard the special
cartridge according to hazardous materials (HAZMAT).
9 Turn off the main power switch of the printer.
10 Disconnect the mains power cord from the electrical outlet.
11 Push the plate in the direction shown to open the ink compartment
door completely (see Figure 7-22).

Figure 7-22: Plate

7-24 Ink Core Module Rev AC

 Videojet 1210/1510 Service Manual

12 Pull the ink core module out of the ink compartment (see Figure 7-23).

Figure 7-23: Pull Ink Core Module

13 Disconnect the ink core module ribbon cable (item 1, Figure 7-24)
from the printer interface board (PIB) (see Figure 7-25 on page 7-26).

1. Ink Core Module Ribbon Cable

2. Ground Wire

Figure 7-24: Ink Core Module Ribbon Cable

Rev AC Ink Core Module 7-25

Videojet 1210/1510 Service Manual

14 Disconnect the ground wire (item 2, Figure 7-24 on page 7-25) from
the printer cabinet (see Figure 7-25).

1. Ribbon Cable Connection to PIB 3. Ring Terminal

2. Spiral Wrap 4. Ground Wire Connection

Figure 7-25: Ground Wire to the Printer Cabinet

15 Cut the ring terminal (item 3, Figure 7-25) from the ground wire and
remove the wire from the spiral wrap (item 2).
16 Loosen and remove the two M3 screws (item 1, Figure 7-26 on page 7-
27) that fasten the ink core manifold (item 2) to ink core module using
2.5 mm allen wrench.

7-26 Ink Core Module Rev AC

 Videojet 1210/1510 Service Manual

1. M3 Screws (x2)
2. Ink Core Manifold
3. Gasket

Figure 7-26: Ink Core Module Manifold

Note: You must fit the old ink core manifold to the new ink core module
immediately.
17 Remove the plate on the ink core manifold of the new ink core
module.
18 Fit the old ink core manifold to the new ink core module using the two
M3 screws and new gasket immediately (see Figure 7-26).

Note: Keep the ink core manifold clean.

19 If you need to replace the ink core module along with the pump, there
is no need to remove the pump, discard the ink core module along
with the pump, according to hazardous materials (HAZMAT).
The removal of the ink core module along with the ink core pump is
complete.
20 If you need to replace the ink core module without the pump, you
need to first remove and store the pump, and then replace only the ink
core module. Refer to “How to Remove the Ink Core Pump” on
page 7-28.

Rev AC Ink Core Module 7-27

Videojet 1210/1510 Service Manual

How to Remove the Ink Core Pump

Do the following tasks to remove the ink core pump:
21 Use a T10 Torx screwdriver to remove the two K30 x 12 Torx screws
(item 3, Figure 7-27) that fasten the ink core pump cover (item 1) to the
ink core module (item 2).

3
1

1. Ink Core Pump Cover

2. Ink Core Module
3. K30 x 12 Torx Screws (x2)

Figure 7-27: Ink Core Pump Cover

22 Slide the pump cover down the ribbon cable and remove the cover.
23 Discard the pump cover according to the local regulations.
24 Remember the method of routing the pump wire harness inside the
ink core module.
25 Disconnect the pump wire harness from JP1 connector on the ink core
module interface board.
26 Use the 3 mm allen wrench to remove the two M4 x 35 socket-head-
cap screws (item 1, Figure 7-28 on page 7-29) that hold the pump
saddle clamp (item 2) to the ink core module (item 7).
27 Remove the pump saddle clamp and keep the clamp in a safe location.
28 Disconnect the ground wire from the ink pump earth tag (item 3). See
Figure 7-29 on page 7-29 for reference.

7-28 Ink Core Module Rev AC

 Videojet 1210/1510 Service Manual

3
4

1. M4 x 35 Socket-head-cap Screw (x2) 5. O-rings

2. Pump Saddle Clamp 6. Ports on the Ink Core Module
3. Earth tag 7. Ink Core Module
4. Ink Core Pump
Figure 7-28: Ink Core Module

Ground Wire

Figure 7-29: Ground Wire

Rev AC Ink Core Module 7-29

Videojet 1210/1510 Service Manual

Note: Use tissues to absorb the spills from the pump.

29 Gently lift the ink core pump out of the ink core module.
30 Remember the location of the two O-rings (item 5, Figure 7-28 on
page 7-29) that seal the pump inlet and outlet ports and discard the O-
rings.
31 Keep the ink core pump in a safe location to use again.
32 Discard the ink core module (without the pump) according to
hazardous materials (HAZMAT).
The removal of ink core module without the ink core pump is complete.

How to Install the New Ink Core Module

Do the following tasks to install the new ink core module:
• If you have removed the ink core pump from the old ink core module,
you need to fit the old ink core pump to the new ink core module.
Refer to “How to Install the Old Ink Core Pump” to install the old ink
core pump into the new ink core module.
• If you have not removed the ink core pump from the old ink core
module, go to “How to Install the New Ink Core Module” on page 7-
31.

How to Install the Old Ink Core Pump

Do the following tasks to install the old ink core pump into the new ink
core module:
1 Remove the two K30 x 12 Torx screws (item 3, Figure 7-27 on page 7-
28) that fasten the ink core pump cover (item 1) to the ink core module
(item 2).
2 Slide the pump cover down the ribbon cables.
3 Remove the protective plate on the pump mounting block.
4 Discard the screws, plates, and O-rings.
5 Insert the new O-rings on the ports of the pump before you install the
old ink pump.
6 Install the old ink pump over the ports of the new ink core module.
Make sure that the two pins go into the two holes of the ink core
pump correctly (see Figure 7-30).

7-30 Ink Core Module Rev AC

 Videojet 1210/1510 Service Manual

Pin

Figure 7-30: Pins

7 Connect the ground wire to the pump earth tag (see Figure 7-29 on
page 7-29).
8 Fit the pump saddle clamp over the old ink core pump using M4 x 35
socket-head-cap screws (item 1, Figure 7-28 on page 7-29).
9 Connect the pump wire harness to the JP1 connector on the ink core
module interface board.
10 Feed the ink core ribbon cable and the ground wire towards the back
of the cabinet and slide the cover until it is in the correct position.
11 Fasten the ink core pump cover to the ink core module using the
K30x12 Torx screws.
12 Go to Step 13 to continue with the installation of the ink core module.

How to Install the New Ink Core Module

13 Wind the ground wire around the spiral wrap twice to retain and
reconnect to the earth point in the back.
14 Connect the ground wire to the printer cabinet (see Figure 7-25 on
page 7-26).
15 Connect the ink core module ribbon cable (item 1, Figure 7-24 on
page 7-25) to the PIB.
16 Push the ink core module back into the printer cabinet.
17 Install the smart cartridges. Make sure that the correct fluid types are
used.
18 Close the ink compartment door and turn the knob to lock the door.
19 Connect the mains power cord to the electrical outlet.
20 Turn on the main power switch of the printer.
21 Select level 2 or level 3 password as the user level to log into the UI.

Rev AC Ink Core Module 7-31

Videojet 1210/1510 Service Manual

22 Check the ink system run hours. The system must display 0 hours.

Figure 7-31: View Run Hours

23 Fill the ink core.

Note: The process takes approximately 20 minutes to complete the cycle.

Figure 7-32: Fill Ink Core Option

24 Remove the printhead cover screw that fastens the printhead cover to
the printhead chassis and remove the printhead cover (see Figure 7-
33).

7-32 Ink Core Module Rev AC

 Videojet 1210/1510 Service Manual

1. Umbilical 4. Printhead Cover Screw

2. Printhead Cover 5. Printhead Valve Module
3. Print Engine
Figure 7-33: Printhead Cover Removed

Caution
To prevent nozzle clogs, always wear rubber gloves whenever the
front tubing manifold is disconnected from the printhead valve
module.

25 Remove the M2 x 6 socket-head-cap screw that attaches the front

tubing manifold to the printhead valve module.
26 Fit the nozzle bypass manifold that has the loop of tube to the
printhead valve module using the M2 x 6 socket-head screw (see
Figure 7-34).

Rev AC Ink Core Module 7-33

Videojet 1210/1510 Service Manual

4
1. M2 x 6 Socket-head Screw 4. Quick Disconnect
2. Bypass Manifold 5. 2 Way Manifold Gasket
3. Tube

Figure 7-34: Bypass Manifold

27 Perform Umbilical Purge for 10 to 15 minutes (refer to the “Umbilical

Purge” on page 8-3 for procedure).
28 Remove the nozzle bypass manifold and the 2 way manifold gasket.
29 Loosely connect the front tubing manifold along with a new gasket
(do not tighten).
30 Put a full make-up fluid cartridge in the ink compartment.
31 Put a receptacle under the printhead to catch the make-up fluid
during flushing.
32 Perform a System Flush Purge. Refer to the “System Flush Purge” on
page 8-5 for procedure.
Make-up fluid will flow from the two way manifold into the
receptacle. Flushing will automatically stop when the purge cycle is
complete.
33 Tighten the 2 way front tubing manifold to printhead valve module.
34 Perform the quick start (see Figure 7-35 on page 7-35).

7-34 Ink Core Module Rev AC

 Videojet 1210/1510 Service Manual

Figure 7-35: Quick Start

35 Check the ink stream alignment and adjust if necessary (refer to the
“Align the Ink Stream” on page 4-33 for procedure).
36 Perform a clean stop, and then a clean start to check the performance.
Press the F1 key to perform clean start or clean stop.

Note: Put a paper towel below the printhead when you perform a clean start
and stop.
The installation of the new ink core module is complete.

Ink Core Pump

Tools and Supplies Required

Tools or Supplies Quantity

T10 Torx Screwdriver 1

3 mm Allen Wrench 1

Table 7-7:Tools and Supplies

Rev AC Ink Core Pump 7-35

Videojet 1210/1510 Service Manual

Warning
Read the “Safety Information” on page 7-2 before you perform the
below tasks.

How to Remove the Old Ink Core Pump

Do the following tasks to remove the old ink core pump:
1 Pull the ink core module out of the ink compartment (see Figure 7-36).

Figure 7-36: Ink Core Module

Figure 7-37 shows how the ink core module ribbon cable, and the
ground wire are routed through the ink pump cover.

1. Ink Core Module Ribbon Cable

2. Ground Wire
Figure 7-37: Ink Core Module Ribbon Cable

7-36 Ink Core Pump Rev AC

 Videojet 1210/1510 Service Manual

2 Use a T10 Torx screwdriver to remove the two K30 x 12 Torx screws
(item 3, Figure 7-38 on page 7-37) that fasten the ink pump cover (item
2) to the ink core module.

1. Ink Core Pump

2. Ink Core Pump Cover
3. K30 x 12 Torx Screws (x2)

Figure 7-38: Ink Core Pump Cover

3 Lift the ink pump cover and gently slide it towards the back of the
cabinet, exposing the pump.
4 Feed the ink core module ribbon cable and the ground wire through
the pump cover to allow it to be repositioned.
5 Remember the method of routing the pump wire harness inside the
ink core module.
6 Disconnect the pump wire harness from JP1 connector on the ink core
module interface board.
7 Use the 3 mm allen wrench to remove the two M4 x 35 socket-head-
cap screws (item 1, Figure 7-40 on page 7-39) that hold the pump
saddle clamp (item 2) to the ink core module (item 7).
8 Remove the pump saddle clamp.
9 Disconnect the ground wire from the ink core pump earth tag (item 3).
See Figure 7-39 on page 7-38 for reference.

Rev AC Ink Core Pump 7-37

Videojet 1210/1510 Service Manual

Ground Wire

Figure 7-39: Ground Wire

Note: Use tissues to absorb the spills from the pump.

10 Gently lift the ink core pump out of the ink core module.
11 Remember the location of the two O-rings (item 5) that seal the pump
inlet and outlet ports and discard the O-rings.

7-38 Ink Core Pump Rev AC

 Videojet 1210/1510 Service Manual

3
4

1. M4 x 35 Socket-head-cap Screws 5. O-rings

2. Pump Saddle Clamp 6. Ports on the Ink Core Module
3. Earth Tag 7. Ink Core Module
4. Ink Core Pump
Figure 7-40: Ink Core Module

12 Dispose the ink core pump as per local regulations.

The removal of the old ink core pump is complete.

How to Install the New Ink Core Pump

Do the following tasks to install the new ink core pump:
1 Insert the new O-rings (item 5, Figure 7-40 on page 7-39) on the ports
of the pump before you install the new pump.
2 Install the new ink pump onto the mounting block.
Make sure that the two pins go into the two holes of the ink core
pump correctly (see Figure 7-41).

Rev AC Ink Core Pump 7-39

Videojet 1210/1510 Service Manual

Pin

Figure 7-41: Pins

3 Connect the ground wire to the pump earth tag (see Figure 7-39 on
page 7-38).
4 Fit the pump saddle clamp over the new ink core pump using M4 x 35
socket-head-cap screws (item 1, Figure 7-40 on page 7-39).
5 Connect the pump wire harness to the JP1 connector on the ink core
module interface board.
6 Put the ink core pump cover over the ink core module in correct
position.
7 Feed the core ribbon cable and the ground wire towards the back of
the cabinet and slide the cover until it is in the correct position.
8 Fasten the ink core pump cover to the ink core module using the
K30x12 Torx screws.
9 Push the core module back into the printer cabinet.
10 Close the ink compartment door. Refer to “How to Close the Ink
Compartment Door” on page 7-7.
The installation of the new ink core pump is complete.

7-40 Ink Core Pump Rev AC

 Videojet 1210/1510 Service Manual

Print Engine Assembly

Tools and Supplies Required

Tool or Supplies Quantity

1.5 mm Allen Wrench 1

Table 7-8: Tools and Supplies

Warning
Read the “Safety Information” on page 7-2 before you perform the
below tasks.

How to Remove the Old Print Engine Assembly

3
4
11
10

5
9
6

1. M2 x 6 Socket-head-cap Long Screw (x6) 7. Print Engine Gasket

2. Nozzle Assembly 8. M2 Spring Washer
3. Charge Electrode 9. Printhead Valve Module
4. Deflector Plate 10. Front Tubing Manifold Gasket
5. Print Engine Deck 11. Front Tubing Manifold
6. Gutter Tube

Figure 7-42: Print Engine

Rev AC Print Engine Assembly 7-41

Videojet 1210/1510 Service Manual

Do the following tasks to remove the old print engine assembly:

1 Turn off the mains power switch of the printer.
2 Disconnect the mains power cord from the electrical outlet.
3 Remove the printhead cover screw that fastens the printhead cover to
the printhead chassis and remove the printhead cover (see Figure 7-
43).

1. Umbilical 4. Printhead Cover Screw

2. Printhead Cover 5. Printhead Valve Module
3. Print Engine
Figure 7-43: Printhead Cover Removed

4 Remove the six M2 x 6 socket-head-cap screws (item 1, Figure 7-42 on

page 7-41) that are used to fasten the print engine to the chassis.

Caution
To prevent nozzle clogs, always wear rubber gloves whenever the
front tubing manifold is disconnected from the printhead valve
module.

5 Remove the M2 x 6 socket-head-cap screw that fastens the front

tubing manifold (item 11) to the printhead valve module (item 9).
6 Tilt the print engine to one side carefully to access the undercarriage.
7 Remove the M2 x 6 socket-head-cap screw and M2 spring washer
(item 8) that attach the EHT/HV wire (red wire) to the undercarriage
of the print engine.
8 Apply pressure vertical to the print engine deck as the gutter slides
into the chassis.
9 Discard the old print engine, print engine gasket, and the front tubing
manifold gasket according to local regulations.

7-42 Print Engine Assembly Rev AC

 Videojet 1210/1510 Service Manual

The removal of the old print engine assembly is complete.

How to Install the New Print Engine Assembly

Do the following tasks to install the new print engine assembly:
1 Take the new print engine assembly and fit the new print engine
gasket (item 7, Figure 7-42 on page 7-41) to the print engine.
2 Put the front tubing manifold gasket (item 10) into the manifold.
3 Attach the EHT/HV wire (red wire) to the undercarriage of the print
engine using one M2 x 6 socket-head-cap screw and one M2 spring
washer (item 8).
4 Carefully fit the print engine to the chassis and make sure to align the
gutter tube with its opening in the chassis.

Note: Make sure that the gutter is installed correctly or gutter can be pushed
out of place.
5 Visually inspect that the print engine gasket is seated properly before
securing the print engine to the chassis.
6 Fit the print engine to the chassis using the six M2 x 6 socket-head-cap
screws (item 1).
7 Connect the mains power cord to the electrical outlet.
8 Turn on the main power switch of the printer.
9 Log into user interface (UI) using Level 3 password.
10 Perform a system flush purge (refer to the “System Flush Purge” on
page 8-5 for procedure).
11 Fit the front tubing manifold (item 11, Figure 7-42 on page 7-41) to the
printhead valve module (item 9) using one M2 x 6 socket-head-cap
screw.
12 Run the printer for approximately 15 minutes to let the printer
stabilize.
13 Perform viscosity calibration.
14 Turn on the inkjet and check the ink stream alignment. If required,
align the ink stream.
15 Fit the printhead cover to the printhead chassis using the printhead
cover screw.
16 Perform EHT calibration.
The installation of the new print engine assembly is complete.

Rev AC Print Engine Assembly 7-43

Videojet 1210/1510 Service Manual

Printhead Valve Module

Tools and Supplies Required

Tool or Supply Quantity

1.5 mm Allen Wrench 1

Table 7-9: Tools and Supplies

Warning
Read the “Safety Information” on page 7-2 before you perform the
below tasks.

How to Remove the Old Printhead Valve Module

Do the following tasks to remove the old printhead valve module:

Note: Make sure that the printhead is above the level of the ink core module when
performing this procedure. Otherwise, the ink in the ink core module may flow
through the umbilical and leak through the tubing manifold once it is removed.

1 Turn off the main power switch of the printer.

2 Disconnect the mains power cord from the electrical outlet.
3 Remove the printhead cover screw that fastens the printhead cover to
the printhead chassis and remove the printhead cover (see Figure 7-44
on page 7-45).

7-44 Printhead Valve Module Rev AC

 Videojet 1210/1510 Service Manual

1. Umbilical 4. Printhead Cover Screw

2. Printhead Cover 5. Printhead Valve Module
3. Print Engine

Figure 7-44: Printhead Cover Removed

Caution
To prevent nozzle clogs, always wear rubber gloves whenever the
front tubing manifold is disconnected from the printhead valve
module.

4 Remove the M2 x 6 socket-head-cap screw (item 4, Figure 7-45 on

page 7-46) that attaches the front tubing manifold (item 5) to the
printhead valve module (item 2).

Rev AC Printhead Valve Module 7-45

Videojet 1210/1510 Service Manual

2
8
3
7
4

6 5

1. M2 x 6 Socket-head-cap Screw (x6) 6. Front Tubing Manifold Gasket

2. Printhead Valve Module 7. Rear Tubing Manifold Gasket
3. Printhead Valve Module Gasket 8. 3 Way Manifold Assembly (Rear Tubing
4. M2 x 6 Socket-head-cap Screw Manifold)
5. 2 Way Manifold Assembly (Front 9. M2 x 6 Socket-head Cap Screw (x2)
Tubing Manifold)

Figure 7-45: Printhead Valve Module

5 Remove the two M2 x 6 socket-head-cap screws (item 9, Figure 7-45)

that attach the rear tubing manifold (item 8) to the printhead valve
module.
6 Remove the six M2 x 6 socket-head-cap screws (item 1) that attach the
printhead valve module to the chassis.
7 Lift the front and rear tubing manifolds away from the printhead
valve module.

Note: Prevent the bending of the tubing to avoid the damage to the tubing.
8 Carefully lift and remove the printhead valve module from the
chassis.
9 When the printhead valve module is removed from the chassis,
carefully rotate the printhead valve module to one side to access the
undercarriage.
10 Detach the gutter tube from the gutter return pipe (item 2, Figure 7-46
on page 7-47) carefully.

Note: Replace the gutter tube if found damaged.

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 Videojet 1210/1510 Service Manual

11 Discard the old printhead valve module gasket (item 3, Figure 7-45 on
page 7-46), front tubing manifold gasket (item 6) and rear tubing
manifold gasket (item 7) according to the local regulations.
The removal of the old printhead valve module is complete.

1. Printhead Valve Module

2. Gutter Return Pipe

Figure 7-46: Gutter Return Pipe

How to Install the New Printhead Valve Module

Do the following tasks to install the new printhead valve module:
1 Fit the new rectangular printhead valve module gasket onto the
chassis.

Note: Make sure that the tab on gasket is aligned to the notch on chassis.
2 Tilt the new printhead valve module to one side and insert the gutter
tube into the gutter return pipe.
3 Press the printhead valve module into the chassis.

Note: Make sure that the printhead valve module gasket is seated correctly.

Rev AC Printhead Valve Module 7-47

Videojet 1210/1510 Service Manual

4 Fit the printhead valve module using M2 x 6 socket-head-cap screws

in the order given below:
a. Fit the first screw, facing the module with the printhead pointing to
the right (see Figure 7-47).

Figure 7-47: Order of Placing Screws - First Screw

b. Fit the second screw (see Figure 7-48).

.

Figure 7-48: Order of Placing Screws - Second Screw

5 Fit the remaining four screws in any order.

6 Fit the rear tubing manifold to the printhead valve module using the
two M2 x 6 socket-head screws and the new rear tubing manifold
gasket.
7 Put the 2 way manifold gasket provided in the bypass kit on the ports
of the printhead valve module.
8 Fit the nozzle bypass manifold (that has the loop of tube) to the
printhead valve module using the M2 x 6 socket-head screw (see
Figure 7-49 on page 7-49).

7-48 Printhead Valve Module Rev AC

 Videojet 1210/1510 Service Manual

4
1. M2 x 6 Socket-head Screw 4. Quick Disconnect
2. Nozzle Bypass Manifold 5. 2 way Manifold Gasket
3. Tube

Figure 7-49: Bypass Manifold

9 Connect the mains power cord to the electrical outlet.

10 Turn on the main power switch of the printer.
11 Log into the User Interface (UI).
12 Perform umbilical purge (refer to the “Umbilical Purge” on page 8-3).
13 Perform system flush purge (refer to the“System Flush Purge” on
page 8-5).
14 Remove the nozzle bypass manifold and the 2-way manifold gasket.
15 Put the new front tubing manifold gasket on the ports.
16 Fit the front tubing manifold to the printhead valve module using a
M2 x 6 socket-head screw.
17 Fit the printhead cover to the printhead chassis using the printhead
cover screw.
The installation of the new printhead valve module is complete.

Rev AC Printhead Valve Module 7-49

Videojet 1210/1510 Service Manual

Umbilical Assembly

Introduction
The umbilical assembly with printhead (see Figure 7-50) contains new
print engine and new printhead valve module attached to a new
printhead chassis. Refer to “Umbilical Assembly (with Printhead)” on
page 7-52.

Figure 7-50: Umbilical with Printhead

The umbilical assembly with printhead chassis (see Figure 7-51 on page 7-
51) comes without the print engine and printhead valve module. So, you
have to remove the old print engine and printhead valve module from the
old printhead chassis and attach the modules to the new printhead
chassis. Refer to “Umbilical Assembly (with Printhead Chassis)” on
page 7-68.

7-50 Umbilical Assembly Rev AC

 Videojet 1210/1510 Service Manual

Figure 7-51: Umbilical with Printhead Chassis

Tools and Supplies Required

Tools or Supplies Quantity

7 mm Nut Driver 1

T10 TORX Screwdriver 1

Pozi-drive Screwdriver 1

Side Cutters 1

1.5 mm Allen Wrench (for print engine and 1

printhead valve module replacement)

2.5 mm Allen Wrench 1

3 mm Allen Wrench 1

Crimp Pliers 1

Sharp Knife 1

Bypass Kit (Part Number 399247) 1

Table 7-10:Tools and Supplies

Warning
Read the “Safety Information” on page 7-2 before you perform the
below tasks.

Rev AC Umbilical Assembly 7-51

Videojet 1210/1510 Service Manual

Umbilical Assembly (with Printhead)

How to Remove the Umbilical Assembly (with Printhead)

Do the following tasks to remove the umbilical assembly along with
printhead:
1 Open the ink compartment door. Refer to “How to Open the Ink
Compartment Door” on page 7-5.
2 Loosen and remove the two M3 screws that fasten the ink core
manifold to the ink core module using 2.5-mm allen wrench (see
Figure 7-53 on page 7-53).

1. Ink Core Module Ribbon Cable

2. Ground Wire

Figure 7-52: Ink Core Module Manifold

7-52 Umbilical Assembly (with Printhead) Rev AC

 Videojet 1210/1510 Service Manual

1. M3 Screws (x2)
2. Ink Core Manifold
3. Gasket
Figure 7-53: Ink Core Manifold

3 Remove the P-clip that holds all the tubes. You can find the P-clip in
the back of the cabinet.
4 Remove the spiral wrap that holds the tubes that connect to the ink
core manifold (see Figure 7-52 on page 7-52).
5 Cut the tubes shown in Figure 7-54 on page 7-54 with a sharp knife 16
mm away from the face of the ink core manifold.

Caution
Do not remove the ground wire (item 5, Figure 7-52 on page 7-52)
that is connected to ink core.

Note: Keep the tubes to use again during the installation.

Note: Use tissues to absorb the spills.

Rev AC Umbilical Assembly (with Printhead) 7-53

Videojet 1210/1510 Service Manual

1. Clear Tube (5/32”) 4. Blue Stripe Tube (1/8”)

2. Green Stripe Ink Tube (1/8”) 5. Black Stripe Make-up Tube (1/8”)
3. Air Vent

Figure 7-54: Cut Tubes

6 Cut the 5/32 inch tube from the gutter pump manifold with a sharp
knife, 16 mm away from the face of the gutter pump manifold.
7 Pull the tubes out of the p-clips and make sure that the blue and
brown sleeved tubes are kept.
8 Cut the tube that is left on the gutter pump manifold barb vertically
down with a knife and remove the tube.

Warning
Before you open the electronics compartment door, wear anti-static
wrist straps and ground yourself to the chassis of the cabinet. Failure
to follow this warning can cause both personal injury and damage to
the printer.

9 Use the 3-mm allen wrench to remove the two M4 screws (see Figure
7-55 on page 7-55) that fasten the electronics compartment door to the
printer cabinet.

7-54 Umbilical Assembly (with Printhead) Rev AC

 Videojet 1210/1510 Service Manual

M4 Screws

Figure 7-55: Electronics Compartment Door

10 Open the electronics compartment door (see Figure 7-56).

Figure 7-56: Electronics Compartment Opened

11 Push the latch down to open the control system board (CSB) (see
Figure 7-57 on page 7-56).

Rev AC Umbilical Assembly (with Printhead) 7-55

Videojet 1210/1510 Service Manual

1. CSB
2. Latch
Figure 7-57: Latch

12 If the positive air kit is fitted, disconnect and discard the silicon tubes
that are connected to the inlet and outlet of the positive air pump.
Discard the O-clip also.

Note: The positive air kit is available only in Videojet 1510 printers.
13 Remove the four K30 x 10 pan-head torx screw (item 2, Figure 7-58)
that attach the tube interface (item 1) to the dividing floor (item 3)
inside the electronics compartment.

1. Tube Interface
2. K30 x 10 Pan-head Torx Screw (x4)
3. Dividing Floor
Figure 7-58: Remove Tube Interface

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 Videojet 1210/1510 Service Manual

14 Release the P-clips that hold the following cables:

• 21 core (connects to the PHEAD1 and PHEAD2 connectors) and
other cables
• Red EHT plug, the EHT cable and the fan cable
• PSU cable and other cables

Note: Remember the connections to connect the cables again during the
installation.
15 Disconnect the connectors PHEAD1 and PHEAD2 connectors from
the printer interface board (PIB).

Note: The RF clamp holds the 21 core cable.

16 Remove and keep the two nuts that attach RF clamp to the cabinet (see
Figure 7-59).
17 Disconnect the red EHT plug from the EHT.

RF Clamp

Figure 7-59: RF Clamp

18 Cut the ty-raps that hold the charge tunnel cable along with the PSU
cable.
19 Disconnect the 4-way charge tunnel wire connector from the control
system board (CSB).
20 Disconnect the printhead ground wires that are connected inside the
electronics compartment.
21 Remove the four M4 x 8 counter-sunk screws (item 1, Figure 7-60 on
page 7-58) that attach the conduit assembly (item 2) to the printer
cabinet.

Rev AC Umbilical Assembly (with Printhead) 7-57

Videojet 1210/1510 Service Manual

1. M4 x 8 Counter-sunk Screw (x4)

2. Conduit Assembly
3. Elbow Gasket

Figure 7-60: Remove the Conduit

22 Pull the wires and tubes along with the ink core manifold and tube
interface out of the opening on the side of the cabinet.
23 Discard the old umbilical assembly along with the printhead
according to local regulations.
The removal of the umbilical assembly with the complete printhead is
complete.

7-58 Umbilical Assembly (with Printhead) Rev AC

 Videojet 1210/1510 Service Manual

How to Install the Umbilical Assembly (with Printhead)

Do the following tasks to install the umbilical assembly along with the
printhead:
1 Route the tubes and cables of the new umbilical through the opening
on the side of the cabinet, along with the ink core manifold and the
tube interface, into the electronics compartment.
2 Route the ink core manifold and the yellow stripe tube through the
hole in the dividing floor.
3 Put the elbow gasket in the correct position on the opening on the side
of the cabinet.
4 Tighten the four M4 x 8 counter-sunk screws to fasten the conduit
assembly to the printer cabinet (see Figure 7-60 on page 7-58).
5 Connect the printhead ground wires inside the electronics
compartment.
6 Reconnect the PHEAD1 and PHEAD2 connectors to the printer
interface board (PIB).
7 Group the following cables into the p-clips:
• 21 core (connects to the PHEAD1 and PHEAD2 connectors) and
other cables
• Red EHT plug, the EHT cable and the fan cable
• PSU cable and other cables
8 Refit all the p-clips to the cabinet.
9 Wrap the three ty-raps around the charge tunnel cable along with the
PSU cable.
10 Connect the red EHT plug to EHT.
11 Reconnect the 4-way charge tunnel wire connector to the CSB.
12 Fit RF cable clamp over the 21 core cable in area where braid is
exposed.

Caution
Make sure that the RF clamp is seated over the exposed braid so that
the braid is grounded to the cabinet.

13 Fit the RF clamp using the two nuts (see Figure 7-59 on page 7-57).

Rev AC Umbilical Assembly (with Printhead) 7-59

Videojet 1210/1510 Service Manual

14 Tighten the four K30 x 10 pan-head torx screws to fasten the tube
interface on the dividing floor inside the electronics compartment (see
Figure 7-58 on page 7-56).
15 If the positive air kit is fitted, do the following tasks:

Note: The positive air kit is available only in Videojet 1510 printers.
a. Fit the 40-mm silicon tube to the outlet of the positive air pump.
b. Slide the O-clip over the silicon tube.
c. Remove the sealing cap from the yellow striped printhead tube.
d. Push the printhead tube into the silicon tube approximately 25mm
(0.98 inches).
e. Crimp the O-clip in position to retain the silicon tube and the
printhead tube.
f. Connect the 200-mm silicon tube to the inlet of the positive air
pump.

Hole for
Yellow Striped Tube

Figure 7-61: Position of Yellow Stripe Tube

g. Remove the sealing caps from the two ends of other yellow stripe
tube.
h. Position 40-mm yellow stripe pipe equally through tube interface
plate (see Figure 7-61).
i. Connect the other end of the 200-mm silicon tube to the yellow
stripe tube located in the tube interface.

7-60 Umbilical Assembly (with Printhead) Rev AC

 Videojet 1210/1510 Service Manual

Caution
If the positive air kit is not fitted in the printer, ensure that the
orange hole plug is fitted into the hole for yellow stripe tube (see
Figure 7-61). The hole must not be left open.

16 Close the CSB.

17 Fasten the electronics compartment door to the printer cabinet using
the two M4 screws.
18 Route the 5/32 inch tube through the p-clip and connect the tube to
the barb on the gutter pump manifold.
19 Group the following tubes using the spiral wrap:
• Black stripe tube
• Green stripe tube
• Blue stripe tube
• 5/32 inch clear tube
• 1/8 inch clear tube and red stripe tube from the new printhead
20 Connect all the tubes to the correct ports on the ink core manifold (see
Figure 7-62).

1. Clear Tube (5/32 inch) 5. Blue Stripe Tube (1/8 inch)

2. Red Stripe Tube (1/8 inch) 6. Black Stripe Make-up Tube (1/8 inch)
3. Green Strip Ink Tube (1/8 inch) 7. Clear Tube (1/8 inch)
4. Air Vent

Figure 7-62: Tubes to Ink Core Manifold

21 Use the two M3 screws to fasten the ink core manifold to ink core
module (see Figure 7-53 on page 7-53).

Rev AC Umbilical Assembly (with Printhead) 7-61

Videojet 1210/1510 Service Manual

22 Take all the tubes except the vent tube and the ground wire to the ink
core and wrap the spiral wrap.
23 Fit the P-clip at the rear of the cabinet to hold the tubes.
24 Push the ink core module into the ink compartment.
25 Close the ink compartment door.

7-62 Umbilical Assembly (with Printhead) Rev AC

 Videojet 1210/1510 Service Manual

26 Remove the printhead cover screw that fastens the printhead cover to
the printhead chassis and remove the printhead cover (see Figure 7-
63).

1. Umbilical 4. Printhead Cover Screw

2. Printhead Cover 5. Printhead Valve Module
3. Print Engine

Figure 7-63: Printhead Cover Removed

Caution
To prevent nozzle clogs, always wear rubber gloves whenever the
front tubing manifold is disconnected from the printhead valve
module.

27 Remove the M2 x 6 socket-head-cap screw that fastens the front

tubing manifold (item 11, Figure 7-64 on page 7-64) to the printhead
valve module (item 9).

Rev AC Umbilical Assembly (with Printhead) 7-63

Videojet 1210/1510 Service Manual

3
4
11
10

5
9
6

1. M2 x 6 Socket-head-cap Screw (x6) 6. Gutter Tube

2. Nozzle Assembly 7. Print Engine Gasket
3. Charge Electrode 8. M2 Spring Washer
4. Deflector Plate 9. Printhead Valve Module
5. Print Engine Deck 10. Front Tubing Manifold Gasket
11. Front Tubing Manifold
Figure 7-64: Print Engine

28 Remove the front tubing manifold gasket (item 10, Figure 7-64) and
keep it in a safe location to use again.
29 Put the 2-way manifold gasket provided in the bypass kit on the ports
of the printhead valve module.
30 Fit the nozzle bypass manifold (that has the loop of tube) to the
printhead valve module using the M2 x 6 socket-head screw (see
Figure 7-65 on page 7-65).
31 Reconnect the mains power cord from the electrical outlet.

7-64 Umbilical Assembly (with Printhead) Rev AC

 Videojet 1210/1510 Service Manual

32 Turn on the main power switch of the printer.

4
1. M2 x 6 Socket-head Screw 4. Quick Disconnect
2. Bypass Manifold 5. 2 Way Manifold Gasket
3. Tubing

Figure 7-65: Bypass Manifold

33 Log into the User Interface (UI).

34 Put a receptacle under the printhead to catch the make-up fluid
during flushing.
35 Perform an umbilical purge to prime the ink supply system (see
Figure 7-66 on page 7-66).

Rev AC Umbilical Assembly (with Printhead) 7-65

Videojet 1210/1510 Service Manual

Figure 7-66: Umbilical Purge

36 Perform a system flush purge (see Figure 7-67).

Make-up fluid will flow from the two way manifold into the
receptacle. Flushing will automatically stop when the purge cycle is
complete.
37 Remove the nozzle bypass manifold and the 2-way manifold gasket.
38 Put the new front tubing manifold gasket on the ports.
39 Fit the front tubing manifold to the printhead valve module using a
M2 x 6 socket-head screw.

Figure 7-67: System Flush Purge

40 Perform EHT calibration (see Figure 7-68).

7-66 Umbilical Assembly (with Printhead) Rev AC

 Videojet 1210/1510 Service Manual

Figure 7-68: Calibrate EHT

41 Run the printer for approximately 15 minutes to let the printer

stabilize.
42 Perform viscosity calibration (refer to Figure 7-69 on page 7-68).

Rev AC Umbilical Assembly (with Printhead) 7-67

Videojet 1210/1510 Service Manual

Figure 7-69: Viscosity Calibration

43 Turn on the inkjet and check the ink stream alignment.

44 Fit the printhead cover to the printhead chassis using the printhead
cover screw.
The installation of umbilical assembly with complete printhead is
complete.

Umbilical Assembly (with Printhead Chassis)

How to Remove the Umbilical Assembly (with Printhead Chassis)

Do the following tasks to remove the umbilical assembly (with printhead
chassis):

How to Remove the Print Engine from Old Printhead

Do the following tasks to remove the print engine:
1 Turn off the main power switch of the printer.
2 Disconnect the mains power cord from the electrical outlet.
3 Remove the printhead cover screw that fastens the printhead cover to
the printhead chassis and remove the printhead cover (see Figure 7-63
on page 7-63).
4 Remove the six M2 x 6 socket-head-cap screws (item 1, Figure 7-64 on
page 7-64) that are used to fasten the print engine to the chassis.

7-68 Umbilical Assembly (with Printhead Chassis) Rev AC

 Videojet 1210/1510 Service Manual

Caution
To prevent nozzle clogs, always wear rubber gloves whenever the
front tubing manifold is disconnected from the printhead valve
module.

5 Remove the M2 x 6 socket-head-cap screw that fastens the front

tubing manifold (item 11) to the printhead valve module (item 9).
6 Apply pressure vertical to the print engine deck as the gutter slides
into the chassis.
7 Tilt the print engine to one side carefully to access the undercarriage.
8 Remove the M2 x 6 socket-head-cap screw and M2 spring washer
(item 8) that attach the EHT/HV wire (red wire) to the undercarriage
of the print engine.
9 Discard the print engine gasket, and the front tubing manifold gasket
according to the local regulations.
The print engine removal is complete.

Rev AC Umbilical Assembly (with Printhead Chassis) 7-69

Videojet 1210/1510 Service Manual

How to Remove the Printhead Valve Module from Old Printhead

Do the following tasks to remove the printhead valve module:

Note: Make sure that the printhead is above the level of the ink core module when
you do this procedure. Else, the ink in the ink core module can flow through the
umbilical and leak through the tubing manifold after it is removed.

2
8
3
7
4

6 5
1. M2 x 6 Socket-head-cap Screw (x6) 6. Front Tubing Manifold Gasket
2. Printhead Valve Module 7. Rear Tubing Manifold Gasket
3. Printhead Valve Module Gasket 8. 3 Way Manifold Assembly (Rear Tubing
4. M2 x 6 Socket-head-cap Screw Manifold)
5. 2 Way Manifold Assembly (Front 9. M2 x 6 Socket-head Cap Screws (x2)
Tubing Manifold)

Figure 7-70: Printhead Valve Module

10 Remove the two M2 x 6 socket-head-cap screws (item 9, Figure 7-70)

that attach the rear tubing manifold (item 8) to the printhead valve
module.
11 Keep the rear tubing manifold in the old printhead chassis.
12 Remove the six M2 x 6 socket-head-cap screws (item 1) that attach the
printhead valve module to the chassis.
13 Lift the front and rear tubing manifold away from the printhead valve
module.

Note: Prevent the bending of the tubing, because the tubing can get
damaged.
14 Carefully lift the printhead valve module from the chassis.

7-70 Umbilical Assembly (with Printhead Chassis) Rev AC

 Videojet 1210/1510 Service Manual

15 When the printhead valve module is removed from the chassis,

carefully rotate the printhead valve module to one side to access the
undercarriage.
16 Detach the gutter tube from the gutter return pipe (item 2, Figure 7-
71) carefully.
17 Discard the old printhead valve module gasket (item 3, Figure 7-70),
and rear manifold tubing gasket (item 7) according to the local
regulations.

1. Printhead Valve Module

2. Gutter Return Pipe

Figure 7-71: Gutter Return Pipe

The printhead valve module removal is complete.

18 Follow Step 1 on page 7-52 till Step 22 on page 7-58 under “How to
Remove the Umbilical Assembly (with Printhead)” on page 7-52.
19 Discard the old umbilical assembly and the printhead chassis
according to the local regulations.
The removal of the umbilical assembly with printhead chassis is complete.

How to Install the Umbilical Assembly (with Printhead Chassis)

Do the following tasks to install the umbilical assembly:
1 Follow Step 1 on page 7-59 till Step 25 on page 7-62 under “How to
Install the Umbilical Assembly (with Printhead)” on page 7-59.

Rev AC Umbilical Assembly (with Printhead Chassis) 7-71

Videojet 1210/1510 Service Manual

How to Install the Printhead Valve Module

Do the following tasks to install the printhead valve module:
2 Fit the new rectangular printhead valve module gasket onto the
chassis.

Note: Make sure that the tab on gasket is aligned to the notch on chassis.
3 Tilt the printhead valve module to one side and insert the gutter tube
into the gutter return pipe.

Note: Replace the gutter return tube if the tube is damaged.

4 Press the printhead valve module into the chassis.

Note: Make sure that the printhead valve module gasket is seated correctly.
5 Attach the printhead valve module using M2 x 6 socket-head-cap
screws in the order given below:
a. Fit the first screw, facing the module with the printhead pointing to
the right (see Figure 7-72).

Figure 7-72: Order of Placing Screws- First Screw

b. Fit the second screw (see Figure 7-73)

.

Figure 7-73: Order of Placing Screws- Second Screw

6 Fit the remaining four screws in any order.

7 Remove the cap attached to the rear manifold on the new chassis. The
gasket comes out.
8 Put the rear manifold gasket on the ports of the old printhead valve.

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 Videojet 1210/1510 Service Manual

9 Fit the old rear tubing manifold to the printhead valve module using
the two M2 x 6 socket-head screws.
The printhead valve module installation is complete.

How to Install the Old Print Engine

Do the following tasks to install the old print engine:
10 Take the old print engine assembly and fit the new print engine gasket
(item 7, Figure 7-64 on page 7-64) to the print engine.
11 Attach the EHT wire (red wire) to the undercarriage of the print
engine using one M2 x 6 socket-head-cap screw and one M2 spring
washer (item 7).
12 Fit the new print engine gasket.
13 Carefully fit the print engine to the chassis and make sure to align the
gutter tube with its opening in the chassis.

Note: Make sure that the gutter is installed correctly or gutter can be pushed
out of place.
14 Visually inspect that the print engine gasket is seated properly before
securing the print engine to the chassis.
15 Fit the print engine to the chassis using the six M2 x 6 socket-head-cap
screws (item 1).
The print engine installation is complete.
16 Follow the steps from Step 29 on page 7-64 to Step 38 on page 7-66.
17 Fit the front tubing manifold to the printhead valve module using a
M2 x 6 socket-head screw.
18 Follow the steps from Step 40 on page 7-66 to Step 44 on page 7-68.
The installation of the umbilical assembly with printhead chassis is
complete.

Rev AC Umbilical Assembly (with Printhead Chassis) 7-73

Videojet 1210/1510 Service Manual

Printer Interface Board

Tools and Supplies Required

Tool or Supply Quantity

3 mm Allen Wrench 1

Table 7-11:Tools and Supplies

Warning
Read the “Safety Information” on page 7-2 before you perform the
below tasks.

How to Remove the Old Printer Interface Board

Do the following tasks to remove the old printer interface board (PIB):
1 Open the electronics compartment door (refer to “How to Open the
Electronics Compartment Door” on page 7-3).

Note: Before removal, remember the connectors connected to the PIB.

2 Disconnect all the connectors from the PIB on the electronics
compartment side (see Figure 7-74 on page 7-75).
3 Open the ink compartment door (refer to “How to Open the Ink
Compartment Door” on page 7-5) and pull the ink core module out to
access the PIB connectors.
4 Disconnect all the connectors from the PIB on the ink compartment
side (see Figure 7-75 on page 7-75).

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 Videojet 1210/1510 Service Manual

7 8 9 10 1 2 3 4 5

6
1. 10-way Printhead Connector 6. CSB Ribbon Cable Connectors (x3)
2. 12-way Printhead Connector 7. USB Connector
3. EHT Cable Connector 8. PCB1 Connector
4. Positive Air Pump Connector 9. PCB 2 Connector
5. Electronics Compartment Fan Connector 10. PCB 3 Connector

Figure 7-74: PIB Connectors - Electronics Compartment Side

2 1
1. Ribbon Cable Connector from Ink Door 4. 20-way Ink Core Module Ribbon Cable
2. Ink Compartment Fan Connector Connector
3. 16-way Ink Core Module Ribbon Cable
Connector

Figure 7-75: PIB Connectors - Ink Compartment Side

5 Remove the six M4 screws (item 1, Figure 7-76 on page 7-76) and M4
ET washers (item 2) to detach the PIB (item 3) from inside the cabinet.
6 Remove the gasket (item 4).
7 Discard the PIB, M4 screws, washers and gasket according to the local
regulations.

Rev AC Printer Interface Board 7-75

Videojet 1210/1510 Service Manual

1. M4 Screws (x6) 3. PIB

2. ET Washers (x6) 4. Gasket

Figure 7-76: PIB Inside the Cabinet

The removal of the old PIB is complete.

How to Install the New Printer Interface Board

Do the following tasks to install the new PIB:
1 Put the gasket on the dividing floor over the six upstanding threaded
bushes in the electronics compartment.
2 Put the new PIB on the gasket.
3 Fit the new PIB to the cabinet with M4 screws and M4 ET washers.
4 Reconnect all the cables and connectors above and below the new PIB.
5 Close the CSB.
6 Close the electronics compartment door. Refer to “How to Close the
Electronics Compartment Door” on page 7-5.
7 Close the ink compartment door. Refer to “How to Close the Ink
Compartment Door” on page 7-7.
The installation of the new PIB is complete.

7-76 Printer Interface Board Rev AC

 Videojet 1210/1510 Service Manual

Power Switch

Tools and Supplies Required

Tool or Supply Quantity

Screwdriver 1

Nr.1 pozidrive 1

3 mm Allen Wrench 1

7 mm Nut Spinner 1

Adjustable Pipe Pliers (to hold and 1

tighten the ring nut on switch)

Table 7-12:Tools and Supplies

Warning
Read the “Safety Information” on page 7-2 before you perform the
below tasks.

How to Remove the Old Power Switch

Do the following tasks to remove the old power switch:
1 Open the electronics compartment door (refer to “How to Open the
Electronics Compartment Door” on page 7-3).
2 Do the following tasks to detach the power supply unit (PSU) (item 1,
Figure 7-77 on page 7-78) assembly from the electronics compartment:
a. Disconnect the following cables from the PSU:
• Cable to the 8-way connector on the CSB
• Cable to the 3-way mains connector on the power switch.
b. Release the PSU cable from the p-clips.

Rev AC Power Switch 7-77

Videojet 1210/1510 Service Manual

1. PSU
2. Studs
3. M4 Nyloc Nut
Figure 7-77: PSU Assembly

c. Remove the two M4 nyloc nuts (item 3) from the studs (item 2)
inside the electronics compartment.
d. Keep the PSU in a safe location.
3 Pull the contact block (item 3, Figure 7-78 on page 7-79) covered by the
sleeve (item 4) upwards to disconnect the claws. Or, use a screwdriver
to release the claws.
4 Push the sleeve backwards away from the contact block.

Caution
Do not unbend the terminals, the terminals can break.

Note: Remember the positions of the terminals.

5 Loosen the four screws (item 1) and remove the terminals (item 2)
using Nr.1 pozidrive.
6 Disconnect the terminals from the contact block.

7-78 Power Switch Rev AC

 Videojet 1210/1510 Service Manual

4
3

1. Screws 3. Contact Block

2. Terminals 4. Sleeve

Figure 7-78: Remove Terminals

7 Use a large pair of mole grips or adjustable pipe pliers to grip the
contact block holder (item 3, Figure 7-79) and twist backwards.
The contact block holder comes out or breaks. The lock ring (item 2) is
released.

Note: Apply considerable force to separate the two portions of the power
switch.
8 Extract the actuator body (item 1) of the switch out of the handle.

2 1
1. Actuator Body
2. Lock Ring
3. Contact Block Holder

Figure 7-79: Power Switch Disassembled

Rev AC Power Switch 7-79

Videojet 1210/1510 Service Manual

9 Discard all the parts of the power switch according to the local
regulations.
The removal of old power switch is complete.

How to Install the New Power Switch

Do the following tasks to install a new power switch:
1 Remove the lock ring from the actuator of the new power switch.
2 Do not remove the rubber gasket.
3 Insert the actuator body into the printer handle.
The key on actuator body must align with the key in the handle.
4 Fit the lock ring from inside the electronics compartment.
5 Align and fix the contact block holder to the switch actuator.

Note: The black legs on the actuator align with the rectangular hole in the
contact block holder and this can be fitted in two different orientations.
6 Connect the terminals to the rear of the new contact block.
7 Cover the terminals with the sleeve.
8 Do the following tasks to fit the PSU:
a. Connect the contact block to the contact block holder of the power
switch.
b. Put the PSU assembly into the lug (see Figure 7-80 on page 7-81) in
the rear of the electronics compartment and then on the two studs.
c. Use the two M4 nyloc nuts to fit the PSU assembly to the studs.

7-80 Power Switch Rev AC

 Videojet 1210/1510 Service Manual

Figure 7-80: Lug

d. Connect the 3-way connector from the switch to the PSU.

Figure 7-81: Power Switch Installed

9 Close the CSB.

10 Close the electronics compartment door. Refer to “How to Close the
Electronics Compartment Door” on page 7-5.
The installation of the new power switch is complete.

Rev AC Power Switch 7-81

Videojet 1210/1510 Service Manual

Power Switch Wiring Information

The Figure 7-82 shows the power switch connections for both US and
Europe. Refer to Table 7-13 for more information.

Figure 7-82: Power Switch

Connection Europe USA

1A Mains Cable Live (brown) Mains Cable Live (black)

1B Wire to 3-way Connector Wire to 3-way Connector

(brown) (brown)

2B Mains Cable Neutral Mains Cable Neutral

(blue) (white)

2A Wire to 3-way Connector Wire to 3-way Connector

(blue) (blue)

Table 7-13:Power Switch Wiring Information

Septum Assembly

Tools and Supplies Required

Tool or Supply Quantity

T10 Torx Screwdriver 1

Side Cutters 1

3 mm Allen Wrench 1

7 mm Nut Spinner 1

2.5 diameter x 100 mm pin 1

Light Hammer 1

Sharp Knife 1

Table 7-14:Tools and Supplies

7-82 Septum Assembly Rev AC

 Videojet 1210/1510 Service Manual

Warning
Read the “Safety Information” on page 7-2 before you perform the
below tasks.

How to Remove the Old Ink and Make-up Septa

Do the following tasks to remove the old ink and make-up septa:
1 Open the ink compartment door (refer to “How to Open the Ink
Compartment Door” on page 7-5).
2 Remove the smart cartridges, so that the ink and make-up septa are
seen (see Figure 7-83).

2 1

1. Ink Septum
2. Make-up Septum

Figure 7-83: Ink and Make-up Septa

3 Use the 2.5 mm pin and hammer to knock out the hinge pin (item 2,
Figure 7-84 on page 7-84) from the right hand side hole of the door.
The pin comes out of the hole on the left side of the door.
4 Pull the hinge completely, so that the door is released.

Rev AC Septum Assembly 7-83

Videojet 1210/1510 Service Manual

Note: Take care not to bend the hinge pin. Keep the hinge pin to use again.

1. Lug
2. Hinge Pin
Figure 7-84: Hinge Pin

5 Cut the ink tube (item 1, Figure 7-86 on page 7-85) and the make-up
tube (item 6) 16 mm from the face of the ink and make-up septa (item
4) using a sharp knife.
6 Remove the two K30 x 12 screws (item 2) to release the clamp (item 5).
7 Is the length of the ink and make-up tubes enough to use again during
the installation of new septa?
• If Yes, proceed to Step 8.
• If No, disconnect the other end of the ink and make-up tubes from
the ink core manifold (see Figure 7-85). Discard the pipes according
to the local regulations.

1. Ink Tube (Green Stripe)

2. Make-up Tube (Black Stripe)

Figure 7-85: Ink Core Manifold

7-84 Septum Assembly Rev AC

 Videojet 1210/1510 Service Manual

8 Remove the three K30 x 8 screws (item 3) on each septum to remove

the two septa.
9 Discard the septa according to the local regulations.

6 1

2
3

1. Ink Tube (Green Stripe) 4. Ink/Make-up Septum (x2)

2. K30 x 12 Screw (x2) 5. Clamp
3. K30 x 8 Screw (x6) 6. Make-up Tube (Black Stripe)

Figure 7-86: Cartridge Stall Rear Side

The removal of the old ink and make-up septa is complete.

How to Install the New Ink and Make-up Septa

Do the following tasks to install the new ink and make-up septa:
1 Fit the ink and make-up septa to the smart cartridge stalls using the
six K30 x 8 screws (item 3, Figure 7-86).
2 If you have discarded the ink and make-up tubes during the removal
procedure, connect one end of the ink and make-up tubes to the ink
core manifold (see Figure 7-85 on page 7-84).
3 Put the clamp in the position shown in Figure 7-86.
4 Guide the ink tube, make-up tube, ribbon cable, gutter pump cable,
and the valve cable through the clamp, and fit the clamp to the ink
and make-up septa using the two K30 x 12 screws.
5 Connect the other end of the ink and make-up tubes to the ink and
make-up septa.

Rev AC Septum Assembly 7-85

Videojet 1210/1510 Service Manual

6 Fit the smart cartridges.

7 To fit the ink compartment door into the hinge, do the following tasks:
a. Reinsert the hinge pin to the left side of the door with the lug on the
left side of the hinge pin.
b. The hinge pin is hammered with the 2.5 mm pin until resistance is
felt. The hinge pin is locked.

Note: Make sure that the pipes and cables move freely when the door is
opened and closed. Adjust the clamp if necessary.
8 Close the ink compartment door. Refer to “How to Close the Ink
Compartment Door” on page 7-7.
The installation of the new ink and make-up septa is complete.

Electronics Compartment Fan

Tools and Supplies Required

Tool or Supply Quantity

3 mm Allen Wrench 1

Nr.2 Posidrive 1

7 mm Spanner 1

7 mm Nut Spinner 1

Table 7-15:Tools and Supplies

Warning
Read the “Safety Information” on page 7-2 before you perform the
below tasks.

How to Remove the Old Electronics Compartment Fan

Do the following tasks to remove the old electronics compartment fan:
1 Open the electronics compartment door. Refer to “How to Open the
Electronics Compartment Door” on page 7-3.

7-86 Electronics Compartment Fan Rev AC

 Videojet 1210/1510 Service Manual

2 Before you continue to remove the fan, remember the location where
the fan cable is connected on the printer interface board (PIB).
3 Disconnect the fan connector (item 7, Figure 7-87) from the PIB.
4 Release the P-clips. The fan wiring drops down through the P-clips.
5 Use Nr.2 pozidrive and 7 mm spanner to remove the two M4 x 16
counter-sunk screws (item 6) and two M4 nyloc nuts (item 5) and
remove the finger guard (item 4).
6 Use the 3 mm allen wrench to remove the four M4 x 10 cap-head
screws (item 3) and four M4 ET washers (item 2) that hold the fan
(item 1) to the printer cabinet.
7 Discard the fan according to the local regulations.
The removal of the old electronics compartment fan is complete.
.

7
1

2
3

1. Fan 5. M4 Nyloc Nut (x2)

2. M4 ET Washer (x4) 6. M4 x 16 Counter-sunk Screw (x2)
3. M4 x 10 Cap-head Screw (x4) 7. Fan Connector
4. Finger Guard

Figure 7-87: Remove Fan

How to Install the New Electronics Compartment Fan

Do the following tasks to install the new electronics compartment fan:
1 Fit the new fan to the printer cabinet using the four M4 x 10 cap-head
screws and four M4 ET washers.

Rev AC Electronics Compartment Fan 7-87

Videojet 1210/1510 Service Manual

2 Fit the finger guard using the two M4 x 16 counter-sunk screws and
two M4 nyloc nuts.
3 Guide the fan connector through the P-clips and connect to the PIB.
4 Close the electronics compartment door. Refer to “How to Close the
Electronics Compartment Door” on page 7-5.
The installation of the new electronics compartment fan is complete.

Ethernet Connector
The ethernet connector is available only in Videojet 1510 printers.

Tools and Supplies Required

Tool or Supply Quantity

3 mm Allen Wrench 1

Adjustable spanner or pipe pliers to give 1

minimum 33A/F

Table 7-16:Tools and Supplies

Warning
Read the “Safety Information” on page 7-2 before you perform the
below tasks.

How to Remove the Old Ethernet Connector

Do the following tasks to remove the old ethernet connector:
1 Open the electronics compartment door (refer to “How to Open the
Electronics Compartment Door” on page 7-3).
2 Disconnect the Ethernet cable (a special 90 degrees cable) between the
Ethernet connector (item 8, Figure 7-88 on page 7-89) and the CSB
Ethernet connection.

7-88 Ethernet Connector Rev AC

 Videojet 1210/1510 Service Manual

1 2

8
7

6 5
1. Stud 5. Ground Cable
2. Ring Terminal 6. Lock Nut
3. M4 ET washer 7. Rubber Washer
4. M4 Nyloc Nut 8. Ethernet Connector

Figure 7-88: Ethernet Connector

3 Remove the M4 nyloc nut (item 4) and M4 ET washer (item 3) on the

M4 ring terminal (item 2) attached to the stud (item 1) on the printer
cabinet.
4 Disconnect the ground cable (item 5).
5 Loosen and remove the lock nut (item 6).
6 Detach the old ethernet connector from the printer cabinet.
7 Remove the rubber washer (item 7).
8 Discard the old ethernet connector, lock nut and the rubber washer.
The removal of the old ethernet connector is complete.

How to Install the New Ethernet Connector

Do the following tasks to install the new ethernet connector:
1 Make sure that the rubber washer is on the ethernet connector.
2 Align the key feature in the washer with the key feature on the
connector body.
3 Insert the ethernet connector into the hole in the printer cabinet.
Make sure that the key on the ethernet connector aligns with the key
in the cabinet hole.
4 Fit the ethernet connector with the lock nut inside the printer cabinet.

Rev AC Ethernet Connector 7-89

Videojet 1210/1510 Service Manual

5 Connect one end of the ground cable to the ethernet connector.

6 Connect the M4 ring terminal end of the ground cable to the stud
using the M4 nyloc nut and M4 ET washer.
7 Connect the ethernet cable between the ethernet connector and the
CSB ethernet connection. The 90 degree end must be fitted to the
connector on the side panel.
8 Close the electronics compartment door. Refer to “How to Close the
Electronics Compartment Door” on page 7-5.
9 Fit the dust cap to the connector.
The strap on the dust cap has a small hole at the free end. Push it over
the pin at the side of the connector body.
The installation of the new ethernet connector is complete.

Positive Air Kit

The positive air kit is available in Videojet 1510 printers. It is optional in
1210 model.

Tools and Supplies Required

Tool or Supply Quantity

3 mm Allen Wrench 1

7 mm Nut Driver 1

Crimp Pliers 1

Table 7-17:Tools and Supplies

Warning
Read the “Safety Information” on page 7-2 before you perform the
below tasks.

7-90 Positive Air Kit Rev AC

 Videojet 1210/1510 Service Manual

How to Remove the Old Positive Air Kit

Do the following tasks to remove the old positive air kit:
1 Open the electronics compartment door. Refer to “How to Open the
Ink Compartment Door” on page 7-5.
2 Disconnect the printhead tube (yellow stripe tube, silicon tube and the
O-clip) (item 2, Figure 7-89) from the outlet of the positive air pump
(item 1).
3 Remove the O-clip and the silicon tube from the yellow stripe tube.
4 Disconnect the silicon tube (item 3) from the inlet of the positive air
pump.
5 Disconnect the other end of the silicon tube from the yellow stripe
tube located in the tube interface.

3 2 1
1. Positive Air Pump
2. Printhead Tube
3. Silicon Tube
Figure 7-89: Positive Air Pump

6 Remove the M4 nyloc nut (item 3, Figure 7-90 on page 7-92) that
attaches the P-clip (item 2) to the rear of the printer cabinet.
7 Release the 5-way connector cable out of the P-clip, and keep the P-
clip in a safe location to use again.
8 Use a nut driver to remove the other M4 nyloc nut (item 4) from the
positive air pump bracket.

Rev AC Positive Air Kit 7-91

Videojet 1210/1510 Service Manual

4 3 2 1
1. Positive Air Pump Bracket 3. M4 Nyloc Nut
2. P-clip 4. M4 Nyloc Nut

Figure 7-90: Remove Positive Air Pump

9 Disconnect the 5-way connector cable (see Figure 7-91) from the
printer interface board (PIB).

5-way Connector
Cable

Figure 7-91: 5-way Connector Cable

10 Discard the positive air pump, silicon tubes and O-clip according to
the local regulations.

7-92 Positive Air Kit Rev AC

 Videojet 1210/1510 Service Manual

The removal of the old positive air kit is complete.

How to Install the New Positive Air Kit

Do the following tasks to install the new positive air kit:
1 Put the new positive air pump assembly on the studs inside the
electronics compartment.
2 Put the P-clip on the top stud.
3 Route the 5-way connector cable through the P-clip.
4 Fit the P-clip to the rear of the printer cabinet with M4 nyloc nut using
7-mm nut driver.
5 Tighten the other M4 nyloc nut using 7-mm nut driver.
6 Connect the 5-way connector cable to the connection labeled A_PUMP
on the PIB.
7 Cut the 240-mm silicon tube into two lengths, 200-mm tube and 40-
mm tube.
8 Fit the 40-mm silicon tube to outlet of the positive air pump.
9 Slide the O-clip over the silicon tube.
10 Push the yellow stripe printhead tube into the silicon tube
approximately 25 mm (0.98 inches).
11 Crimp the O-clip in position to retain the silicon tube and the yellow
stripe tube.
12 Fit the 200-mm silicon tube to the inlet of the positive air pump.
13 Fit the other end of the 200-mm silicon tube to the yellow stripe tube
located in the tube interface.
14 Close the CSB.
15 Use the two M4 screws to fit the electronics compartment door to the
printer cabinet.
16 Connect the mains power cord to the electrical outlet.
17 Turn on the main power switch of the printer.
The installation of the new positive air kit is complete.

Rev AC Positive Air Kit 7-93

Videojet 1210/1510 Service Manual

Gutter Pump

Tools and Supplies

Tools or Supplies Quantity

7 mm Nut Spinner 1

2.5 mm Allen Wrench 1

T10 Torx Driver 1

Light Hammer 1

Sharp Knife 1

Side Cutter 1

2.5 D x 100 mm Long Pin (to 1

knock the hinge pin out)

Table 7-18:Tools and Supplies

How to Remove the Old Gutter Pump

Do the following tasks to remove the old gutter pump:
1 Open the ink compartment door. Refer to “How to Open the Ink
Compartment Door” on page 7-5.
2 Use the 2.5 mm pin and hammer to knock out the hinge pin (item 2,
Figure 7-92) from the right hand side hole of the door.
The pin comes out of the hole on the left side of the door.
3 Pull the hinge completely, so that the door is released.

7-94 Gutter Pump Rev AC

 Videojet 1210/1510 Service Manual

1. Lug
2. Hinge Pin

Figure 7-92: Hinge Pin

4 Pull the ink core module from the ink compartment.

5 Disconnect the ground wire that is connected to the ink compartment
door from the stud inside the ink compartment.
6 Disconnect the 4-way gutter pump connector (item 5, Figure 7-93 on
page 7-96) and 2-way valve connector (item 1) from the PCBs on the
cartridge holders. Both components connect to connectors labeled J2.

Rev AC Gutter Pump 7-95

Videojet 1210/1510 Service Manual

The gutter pump connector has four colored wires. The valve
connector has two black wires.

5 1

2
4

3
1. 2-way valve Connector 4. Cartridge Holder
2. K30 x 12 Pan-head Torx Screw (2) 5. 4-way Gutter Pump Connector
3. Cable Clamp

Figure 7-93: Cartridge Holders

7 Use the T10 torx driver to remove the K30 x 12 pan-head screws (item
2, Figure 7-93 on page 7-96) and release the cable clamp (item 3) that
holds the gutter pump cables, valve cables, green stripe ink tube,
black stripe make-up tube, and the ribbon cables.
8 Use the 7 mm nut spinner to remove the two nuts that attach the P-
clips (item 6, Figure 7-94 on page 7-97) to the floor of the ink
compartment.
9 Detach the black cables from the cable bundle (this wire contains the
wires for the gutter pump and the valve).
10 Push the blue and brown sleeves up the pipes on the gutter pump
manifold to access the tubes.

Note: Use tissues to retain spill from the tubes.

11 Cut the following tubes approximately 16 mm (0.63 inch) away from
the face of the gutter pump manifold with a sharp knife.
a. Clear tube connected to the front right port
b. Clear tube connected to the front left port
c. Blue striped tube connected to the rear port

7-96 Gutter Pump Rev AC

 Videojet 1210/1510 Service Manual

12 Using the 7 mm nut spinner, remove the two M4 nyloc nuts (item 3,
Figure 7-94) that attach the gutter pump bracket (item 4) to the rear
wall of the ink compartment.

2
3

5
7 6
1. Blue Stripe Pipe with Blue Sleeve 5. Clear Pipe
2. Clear Pipe with Brown Sleeve 6. P-clip
3. M4 Nyloc Nut (x2) 7. Commissioning Valve
4. Gutter Pump Bracket

Figure 7-94: Gutter Pump Assembly

13 Remove the gutter pump assembly from the ink compartment.

The removal of the old gutter pump is complete.

Rev AC Gutter Pump 7-97

Videojet 1210/1510 Service Manual

How to Install the New Gutter Pump

Do the following tasks to install the new gutter pump:
1 Put the new gutter pump in the ink compartment. Fit the three tubes
to the pump manifold according to the following instructions:
• Clear tube (item 2, Figure 7-95) to the front right port
• Clear tube (item 3) with brown sleeve to the front left port
• Blue striped tube (item 1) with blue sleeve to the rear port

3 1

1. Blue Stripe Tube with Blue Sleeve

2. Clear Tube
3. Clear Tube with Brown Sleeve

Figure 7-95: Gutter Pump Tubes

2 Using the 7 mm nut spinner, fit the two M4 nyloc nuts that attach the
gutter pump assembly to the rear wall of the ink compartment (see
Figure 7-94 on page 7-97).
3 Add the two black cables to the cable bundle and route the bundle
through the P-clips.
4 Using the 7 mm nut spinner, secure the P-clips to the floor of the ink
compartment.
5 Route the cable bundle, green stripe ink tube, black stripe make-up
tube, and the ribbon cable through the cable clamp (see Figure 7-93 on
page 7-96).
6 Connect the 2-way valve connector and 4-way gutter pump connector
to the PCBs.
• The connector with the two black wires (2-way) plugs into J2 on the
PCB on make-up cartridge holder.
• The connector with the four colored wires (4-way) plugs into J2 on
the PCB on the ink cartridge holder.

7-98 Gutter Pump Rev AC

 Videojet 1210/1510 Service Manual

7 To fit the ink compartment door into the hinge, do the following tasks:
a. Reinsert the hinge pin to the left side of the door with the lug on the
left side of the hinge pin.
b. The hinge pin is hammered with the 2.5 mm pin until resistance is
felt. The hinge pin is locked.
8 Connect the ground wire to the stud inside the ink compartment. Use
the 7 mm nut spinner.

Note: When the door is fitted, check that the cables and tubes can move freely
when the door is closed and opened. The cables and tubes must not be
strained.
9 Close the ink compartment door. Refer to “How to Close the Ink
Compartment Door” on page 7-7.
The installation of the new gutter pump is complete.

Ink Door Assembly

Tools and Supplies Required

Tool or Supply Quantity

2.5 D x 100 mm Long Pin (to 1

knock the hinge pin out)

Light Hammer 1

7 mm Nut Spinner 1

10 mm Spanner 1

T10 Torx Driver 1

Sharp Knife (to cut tubes) 1

Table 7-19:Tools and Supplies

Rev AC Ink Door Assembly 7-99

Videojet 1210/1510 Service Manual

How to Remove the Old Ink Door

Do the following tasks to remove the old ink door:
1 Open the ink compartment door. Refer to “How to Open the Ink
Compartment Door” on page 7-5.
2 Use the 2.5 mm pin and hammer to knock out the hinge pin (item 2,
Figure 7-96) from the right hand side hole of the ink door assembly.

1. Lug
2. Hinge Pin

Figure 7-96: Hinge Pin

3 The pin comes out of the hole on the left side of the door.
4 Pull the hinge completely, so that the door is released.
5 Use the 7 mm nut spinner to disconnect the ground wire that is
connected to the ink compartment door from the stud inside the ink
compartment.
6 Disconnect the 4-way gutter pump connector (item 7, Figure 7-97 on
page 7-101) and 2-way valve connector (item 1) from the PCBs on the
cartridge holder (item 5). Both components connect to connectors
labeled J2.

7-100 Ink Door Assembly Rev AC

 Videojet 1210/1510 Service Manual

7 1

2
6
3
5

4
1. 2-way valve Connector 5. Cartridge Holder
2. Ink Tube (Green Stripe) 6. Make-up Tube (Black Stripe)
3. K30 x 12 Pan-head Torx Screw (2) 7. 4-way Gutter Pump Connector
4. Cable Clamp

Figure 7-97: Cartridge Holder

7 Use the T10 torx driver to remove the K30 x 12 pan-head screws (item
3, Figure 7-97) and release the cable clamp (item 4) that holds the
gutter pump cables, valve cables, the 14 way ribbon cable, the black
stripe (item 6) and green stripe tubes (item 2).
8 If you want to keep the old 14-way ribbon cable, disconnect the 14-
way headers from the PCBs on the cartridge holder. Else, go to Step 9.
9 If the ribbon cable must be replaced, do the following tasks:
a. Release the P-clips that retain the 14-way ribbon cable in the ink
system.
b. Disconnect the 14-way ribbon cable from the underside of the
printer interface board (PIB).
c. Remove and discard the 14-way ribbon cable.
10 If you must reuse the black and green stripe tubes then do the
following tasks. Else, go to Step 11.
a. Pull out the ink core module from the ink compartment.
b. Disconnect the ink core manifold.

Rev AC Ink Door Assembly 7-101

Videojet 1210/1510 Service Manual

c. Cut the green striped tube and black striped tube (item 1 and item
2, Figure 7-98) with a sharp knife 16 mm from the face of ink core
manifold.
d. Cut the tubes left on the barb fittings vertically downwards and
remove the tubes.
e. The black and green stripe tubes are pulled back through the spirol
wrap and the P-clips.

1. Ink Tube (Green Stripe)

2. Make-up Tube (Black Stripe)

Figure 7-98: Ink Core Manifold

11 If the pipes are not short on the existing door, then pull the tubes off
or cut with a sharp knife from the septum tubes.
12 Discard the old door according to local regulations.
The removal of the old ink door assembly is complete.

How to Install the New Ink Door

Do the following tasks to install the new ink door assembly:
1 Align the new ink door assembly carefully.
2 Reinsert the hinge pin to the left side of the ink door assembly with
the lug (item 1, Figure 7-96 on page 7-100) on the left side of the hinge
pin.
3 The hinge pin is hammered with the 2.5 mm pin until resistance is felt.
The hinge pin is locked.

7-102 Ink Door Assembly Rev AC

 Videojet 1210/1510 Service Manual

4 If the old door tubes are used, insert the tubes into the septum
connections. If new pipes are used do the following tasks:
a. Route the new black and green stripe tubes through all the p-clips
and the spirol wrap.
b. Connect the pipes to the ink core manifold.
c. Push the ink core module into the ink compartment.
5 If the old 14-way cable is used, reconnect the 14-way headers to the
relevant PCBs. If you want to install a new 14-way cable, do the
following tasks:
a. Route the ribbon cable through all the P-clips
b. Connect the ribbon cable to the PIB.
6 Connect the 4-way gutter pump connector and 2-way valve connector
to the PCBs on the cartridge holder. Both the connectors connect to J2
connectors on the PCB. Refer to Figure 7-99.
7 Use the T10 torx driver to attach the cable clamp with the K30 x 12
pan-head screws that holds the gutter pump cables, valve cables,
green stripe ink tube, black stripe make-up tube and the 14-way
ribbon cable. Refer to Figure 7-99.

Figure 7-99: Septum Connections

8 Tighten all the p-clips.

9 Connect the ground wire that is connected to the ink compartment
door from the stud inside the ink compartment.

Rev AC Ink Door Assembly 7-103

Videojet 1210/1510 Service Manual

Note: After the door is fitted, check that the cables and tubes can move freely
when the door is closed and opened. The cables and tubes must not be
strained.
10 Adjust the two M6 nuts (item 5, Figure 7-100) and two M6 washers
(item 4) on the stud (item 2) to give the required compression to the
door gasket (item 1).

1
2

3
4

5
1. Door Gasket 4. M6 Washer (x2)
2. Stud 5. M6 Nut (x2)
3. Latch

Figure 7-100: Latch

11 Close the ink compartment door. Refer to “How to Close the Ink
Compartment Door” on page 7-7.
The installation of the new ink door assembly is complete.

Ink System Fan

Tools and Supplies Required

Tool or Supply Quantity

3 mm Allen Wrench 1

Table 7-20: Tools and Supplies

7-104 Ink System Fan Rev AC

 Videojet 1210/1510 Service Manual

How to Remove the Ink System Fan

Do the following to remove the ink system fan:
1 Open the ink compartment door. Refer to “How to Open the Ink
Compartment Door” on page 7-5.
2 Pull the ink core module (item 3, Figure 7-101) out of the ink
compartment.

1. Cartridges
2. Ink Compartment Door
3. Ink Core Module
Figure 7-101: Pull Ink Core Module

3 Detach the fan guard (item 4, Figure 7-102) from the fan housing (item
2).

4 3
1. M4 ET Washer (x4) 3. M4 x 10 Cap Head Screw (x4)
2. Fan Housing 4. Fan Guard

Figure 7-102: Ink Fan Assembly

4 Disconnect the fan cable from the printer interface board (PIB).

Rev AC Ink System Fan 7-105

Videojet 1210/1510 Service Manual

5 Remove the four M4 x 10 cap-head screws (item 3) and four M4 ET

washers (item 1) to detach the fan housing from the raised mounting
box located at the back of the ink compartment.
Keep the four M4 x 10 cap-head screws and the four M4 ET washers to
use again.
6 Discard the ink system fan as per the local regulations.
The removal of the old ink system fan is complete.

How to Install the New Ink System Fan

Do the following tasks to install the new ink system fan:
1 Attach the new fan housing to the raised mounting box located at the
back of the ink compartment using the four M4 x 10 cap-head screws
and four M4 ET washers.
2 Connect the fan cable to the PIB.
3 Attach the fan guard to the fan housing.
4 Push the ink core module into the ink compartment.
5 Close the ink compartment door. Refer to “How to Close the Ink
Compartment Door” on page 7-7.
The installation of the new ink system fan is complete.

EHT Module

Tools and Supplies Required

Tool or Supply Quantity

3 mm Allen Wrench 1

7 mm Nut Driver 1

Table 7-21:Tools and Supplies

7-106 EHT Module Rev AC

 Videojet 1210/1510 Service Manual

How to Remove the Old EHT Module

Do the following tasks to remove the old EHT Module:
1 Open the electronics compartment door. Refer to “How to Open the
Electronics Compartment Door” on page 7-3.
2 Disconnect the EHT cable (item 3, Figure 7-103 on page 7-107) from
the PIB.
3 Disconnect the EHT plug (item 1) from the EHT module.

1
2
3

1. EHT Plug
2. P-Clip
3. EHT Cable

Figure 7-103: EHT Plug and Cable

4 Release p-clips (item 2) that hold the EHT cable.

5 Use the 7 mm nut driver to remove the two M4 Nyloc nuts (item 2,
Figure 7-104 on page 7-108) that attach the EHT Module (item 1) to the
cabinet.
6 Dispose the old EHT Module according to the local regulations.

Rev AC EHT Module 7-107

Videojet 1210/1510 Service Manual

1. EHT Module
2. M4 Nyloc Nuts (x2)

Figure 7-104: Removal of EHT Module

The removal of old EHT Module is complete.

How to Install the New EHT Module

Do the following tasks to install the new EHT Module:
1 Place the new EHT Module on the cabinet.
2 Use the 7 mm nut driver to tighten the two M4 nyloc nuts to attach the
EHT Module to the cabinet.
3 Connect the EHT cable from the new EHT Module to the PIB.
4 Reconnect the EHT plug.
5 Position the new EHT cable in the p-clips and fit the cable.
6 Close the CSB assembly.
7 Close the electronics compartment door. Refer to “How to Close the
Electronics Compartment Door” on page 7-5.
8 Perform EHT Calibration (see Figure 7-105)

7-108 EHT Module Rev AC

 Videojet 1210/1510 Service Manual

Figure 7-105: Calibrate EHT

The installation of the new EHT Module is complete.

USB Connector

Tools and Supplies Required

Tool or Supply Quantity

3 mm Allen Wrench 1

Adjustable spanner or pipe pliers 1

to give minimum 33A/F

Table 7-22:Tools and Supplies

Rev AC USB Connector 7-109

Videojet 1210/1510 Service Manual

How to Remove the Old USB Connector

Do the following tasks to remove the old USB connector:
1 Open the electronics compartment door. Refer to “How to Open the
Electronics Compartment Door” on page 7-3.
2 Disconnect the USB cable (item 2, Figure 7-106) from the USB 2 on the
printer interface board (PIB).

3 1

1. Lock Nut 3. Rubber Washer

2. USB Cable 4. USB Connector

Figure 7-106: USB Connector

3 Loosen and remove the lock nut (item 1, Figure 7-106).

4 Detach the old USB connector (item 4) from the printer cabinet.
5 Remove the rubber washer (item 3).
6 Discard the old USB connector, locknut and rubber washer.
The removal of the old USB connector is complete.

How to Install the New USB Connector

Do the following tasks to install the new USB connector:
1 Make sure rubber washer is on connector body. Align the key feature
in the washer with the key feature on the connector body.
2 Insert the USB connector into the hole in the printer cabinet.

7-110 USB Connector Rev AC

 Videojet 1210/1510 Service Manual

Make sure that the key on the connector body aligns with the key in
the cabinet hole.
3 Fit the lock nut (with the USB cable) inside the printer cabinet.
4 Connect the other end of the USB cable to USB 2 on the PIB.
5 Close the CSB.
6 Fit the dust cap to the connector.
The strap on the dust cap has a small hole at the free end. Push it over
the pin at the side of the connector body.
7 Close the electronics compartment door. Refer to “How to Close the
Electronics Compartment Door” on page 7-5.
The installation of the new USB connector is complete.

Plug and Power Cable

Tools and Supplies Required

Tool or Supply Quantity

Nr.1 Posidrive 1

3 mm Allen Wrench 1

24mm Spanner 1

Table 7-23: Tools and Supplies

How to Remove the Old Power Cable

Do the following tasks to remove the old power cable:
1 Open the electronics compartment door (refer to “How to Open the
Electronics Compartment Door” on page 7-3).
2 Do the following tasks to detach the power supply unit (PSU)
assembly from the electronics compartment:
a. Remove the two M4 nyloc nuts (item 3, Figure 7-107 on page 7-112)
from the studs (item 2) inside the electronics compartment.
b. Disconnect the following cables from the PSU:
• PSU cable from the 8-way connector on the CSB.

Rev AC Plug and Power Cable 7-111

Videojet 1210/1510 Service Manual

• 3-way mains connector from the power switch.

c. Disconnect the ty-raps securing the charge/modulation cable to the
PSU cable.

1. PSU
2. Studs
3. M4 Nyloc Nut
Figure 7-107: PSU Assembly

d. Keep the PSU in a safe location.

3 Pull the contact block (item 3, Figure 7-108 on page 7-113) covered by
the sleeve (item 4) upwards to disconnect the claws, or use a
screwdriver to release the claws.
4 Push the sleeve backwards off the contact block.

Caution
Do not unbend the terminals, the terminals can break.

Note: Remember the positions of the terminals.

5 Loosen the four screws (item 1) and remove the terminals (item 2)
using Nr.1 pozidrive.
6 Disconnect the terminals from the contact block.

7-112 Plug and Power Cable Rev AC

 Videojet 1210/1510 Service Manual

4
3

1. Screws 3. Contact Block

2. Terminals 4. Sleeve

Figure 7-108: Remove Terminals

7 Remove the M4 nyloc nut (item 3, Figure 7-109 on page 7-114) and M4
ET washer (item 1) and disconnect the ground wire from the ground
stud (item 5).
8 Remove the M20 x 1.5p lock nut (item 2).

Rev AC Plug and Power Cable 7-113

Videojet 1210/1510 Service Manual

1. M4 ET Washer 4. Cable Gland

2. M20 x 1.5p Nut 5. Ground Stud
3. M4 Nyloc Nut

Figure 7-109: Remove Cable Gland

9 Disconnect the plug from power cable.

10 Release the cable-strain-relief-clamp nut on the cable gland.
11 Open the cable gland by inserting a screwdriver on either side.
12 Hinge open the gland and slide the gland from the cable.
13 Pull the disconnected power cable through the hole in the electronics
compartment.
14 Discard the power cable with the plug according to local regulations.
The removal of the old power cable is complete.

How to Install the New Power Cable

Do the following tasks to install the new power cable:
1 Slide the M20 x 1.5p lock nut over the free end of the new power cable
(see Figure 7-110 on page 7-115).

7-114 Plug and Power Cable Rev AC

 Videojet 1210/1510 Service Manual

Figure 7-110: Power Cable

2 Insert this free end of the power cable through the hole in the cabinet
from inside the electronics compartment.
3 Connect the power cable to the switch contact block at the correct
terminals with the four screws using Nr.1 pozidrive (see Figure 7-111
and Table 7-24).

Figure 7-111: Power Switch - US and Europe

Table 7-24 shows the wiring details of the power switch.

Connection Europe USA

1A Mains Cable Live (brown) Mains Cable Live (black)

1B Wire to 3-way connector Wire to 3-way connector

(brown) (brown)

2B Mains Cable Neutral (blue) Mains Cable Neutral (white)

2A Wire to 3-way Connector Wire to 3-way Connector (blue)

(blue)

Table 7-24:Wiring Information

4 Pull the sleeve back on the contact block.

5 Connect the contact block to the mains switch assembly.
6 Reconnect the ground wire to the ground stud with the M4 nyloc nut
and M4 ET washer.
7 Slide the new cable gland over the free end of the power cable
towards the hole in the cabinet from outside.

Rev AC Plug and Power Cable 7-115

Videojet 1210/1510 Service Manual

Do not close the cable gland at this stage.

8 Push any excess cable in the electronics compartments out through
the hole.
9 Locate the gland in the hole and on the support bracket below this
hole. Close the cable gland near the hole.
10 Tighten the M20 x 1.5p lock nut.
11 Tighten the cable strain relief nut on the cable gland to retain the
cable.
12 Do the following tasks to fit the PSU:
a. Connect the below cables:
• Connect the 8-way cable to the CSB.
• Connect the 3-way connector from the switch to the PSU.
b. Put the PSU assembly into the lug (see Figure 7-112) in the rear of
the electronics compartment and then on the two studs.
c. Use the two M4 nyloc nuts to fit the PSU assembly to the studs.

Figure 7-112: Lug

d. Ty-rap the charge/modulation cable to the PSU cable.

13 Connect the new plug to the power cable.
14 Close the CSB.
15 Close the electronics compartment door. Refer to “How to Close the
Electronics Compartment Door” on page 7-5.
The installation of the new power cable is complete.

7-116 Plug and Power Cable Rev AC

 Videojet 1210/1510 Service Manual

CSB Lithium Battery

Tools and Supplies Required

Tool or Supply Quantity

3 mm Allen Wrench 1

Table 7-25:Tools and Supplies

How to Remove the Old CSB Lithium Battery

Do the following tasks to remove the old CSB lithium battery:
1 Open the electronics compartment door. Refer to “How to Open the
Electronics Compartment Door” on page 7-3.
2 Use the 3 mm allen wrench to remove the two M4 x 8 cap-head screws
(item 3, Figure 7-113) that hold the retainer (item 4).
3 Push the latch (item 1) down to open the control system board (CSB)
(item 2).

1. Latch 3. M4 x 8 Cap-head Screws (x2)

2. Control System Board 4. Retainer

Figure 7-113: Latch

4 Locate the CSB lithium battery (see Figure 7-114 on page 7-118).
5 Lift the battery clamp and remove the old CSB lithium battery.

Rev AC CSB Lithium Battery 7-117

Videojet 1210/1510 Service Manual

2 1

1. Battery Clamp
2. Lithium Battery

Figure 7-114: Control System Board

6 Dispose the old CSB lithium battery according to local regulations.

The removal of the old CSB lithium battery is complete.

How to Install the New CSB Lithium Battery

Do the following tasks to install the new CSB lithium battery:
1 Push the new CSB lithium battery under the battery clamp.
2 Swing the CSB assembly into closed position.
3 Attach the retainer with the two M4 x 8 cap-head screws. Use the 3
mm allen wrench.
4 Close the electronics compartment door. Refer to “How to Close the
Electronics Compartment Door” on page 7-5.
The installation of the new CSB lithium battery is complete.

PCB 1, 2 and 3

Introduction
The printer is provided with PCB 1 and PCB 2 on the connector panel.
There are three standard connectors on each PCB. PCB 3 is optional for
1510 printer. PCB 0 is standard for 1210 printer.

7-118 PCB 1, 2 and 3 Rev AC

 Videojet 1210/1510 Service Manual

The instructions given below are for PCB 2 only. You must follow the
same instructions for PCB 0, PCB 1 and PCB 3.

Tools and Supplies Required

Tool or Supply Quantity

3 mm Allen Wrench 1

7mm Nut Spinner 1

Special Din Spanner 1

(P/N 234657)

Table 7-26:Tools and Supplies

How to Remove the Old PCB 2

Do the following tasks to remove the old PCB 2:
1 Open the electronics compartment door. Refer to “How to Close the
Electronics Compartment Door” on page 7-5.
2 Remove and keep the connector plugs that are fitted to the connectors
on PCB 2.
3 Push the latch and open the control system board.
4 Disconnect the 14-way ribbon cable from PCB 2 from the printer
interface board (PIB).
5 If you must replace PCB 1 and PCB 3, disconnect the following ribbon
cables form the PIB:
• 20-way ribbon cable connected to the PCB 1
• 16-way ribbon cable connected to the PCB 3

Rev AC PCB 1, 2 and 3 7-119

Videojet 1210/1510 Service Manual

4 3 2 1
1. PCB 2 4. Earthing Tab
2. M4 Nyloc Nut 5. PCB 1
3. M4 ET Washer

Figure 7-115: PCB 2

6 Remove and discard the M4 nyloc screw (item 2, Figure 7-115) and M4
ET washer (item 3) that attach the earthing tab (item 4) to the cabinet.
7 Use the special din spanner to detach the lock nut (item 4, Figure 7-116
on page 7-121) from the connectors on the PCBs.
8 Remove and discard PCB 2 (item 1, Figure 7-115 on page 7-120)
according to local regulations.

7-120 PCB 1, 2 and 3 Rev AC

 Videojet 1210/1510 Service Manual

4
3

Cat 5e

1. PCB 3 3. PCB 1/PCB 0

2. PCB 2 4. Lock Nut

Figure 7-116: Connector Panel

9 Discard the old PCB 2 as per local regulations.

The removal of the old PCB 2 is complete.

How to Install the New PCB 2

Caution
PCB 1,2, and 3 must be fitted in the correct position (see Figure 7-
116). Do not fit them in the wrong row.

Do the following tasks to install the new PCB 2:

1 Insert the new PCB 2 into its correct position from inside the
electronics compartment.
2 Fit the PCB with the lock nut from outside.
3 Fit the earthing tab to the cabinet with the M4 nyloc screw and M4 ET
washer.
4 Connect the 14-way ribbon cable from PCB 2 to the PIB.

Rev AC PCB 1, 2 and 3 7-121

Videojet 1210/1510 Service Manual

5 Close the control system board.

6 Fit the dust caps to all the connectors.
7 Close the electronics compartment door. Refer to “How to Close the
Electronics Compartment Door” on page 7-5.
The installation of the new PCB 2 is complete.

7-122 PCB 1, 2 and 3 Rev AC

Maintenance
8
The preventative maintenance schedules mentioned in this chapter must
be carried out by a trained and authorized personnel.
Actual intervals depend on machine running hours. The figures below are
based on eight hours usage per day. If the actual usage is higher, the
intervals should be reduced.

Task Medium

Clean the Printhead Weekly

Replace the Core Module 9,000 hours (for 1510)

6000 hours (for 1210)

Replace the Ink pump 18,000 hours for 1510 (for every other ink
core change)
18,000 hours for 1210 (after 3 core
changes)

Replace the Fan Filter (IP55) 2,000 hours

Replace the Floor Filter (IP55) Must be replaced with the ink core module

Replace the Fan Filter (IP65) 2,000 hours

Replace the Floor Filter (IP65) Must be replaced with the ink core module

Replace the Stealth Air Dryer 2,000 hours

Table 8-1: Preventative Maintenance Schedule

Warning
It is possible that in a fault condition the heater can reach 70 °C. Do
not touch the plate on which heater is mounted. The failure to follow
this warning can cause personal injury.

Rev AC 8-1
Videojet 1210/1510 Service Manual

Prime the Printer

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.

1 Select System > Fill Ink Core. This process primes the printer with ink.
Record the prime time.

Figure 8-1. Fill Ink Core Command

2 Observe if the ink is going through the black-striped and blue-striped

tubes. During this process, it should take approximately 22 minutes
for the ink core to change status from empty to middle.

Note: Make sure that there are no leaks in tubing and fittings.
3 Check the ink cartridge. If empty, replace with a new cartridge.

8-2 Prime the Printer Rev AC

 Videojet 1210/1510 Service Manual

Umbilical Purge
The umbilical purge option is used to flush the ink core module before
fitting the nozzle.

Caution
Do not fit the nozzle before you perform this procedure.

Perform umbilical purge in the following conditions:

• To prevent debris from blocking the nozzle if the printer has not been
used for a long time
• If contamination of the umbilical is suspected
• If a new umbilical has been fitted
• If the ink color or type is to be changed
Do the following tasks to perform umbilical purge:
1 Turn off the main power switch of the printer.
2 Disconnect the mains power cord from the electrical outlet.
3 Remove the printhead cover screw that fastens the printhead cover to
the printhead chassis and remove the printhead cover (see Figure 8-2).
.

1. Umbilical 4. Printhead Cover Screw

2. Printhead Cover 5. Printhead Valve Module
3. Print Engine
Figure 8-2: Printhead Cover Removed

Rev AC Umbilical Purge 8-3

Videojet 1210/1510 Service Manual

Caution
To prevent nozzle clogs, always wear rubber gloves whenever the
nozzle tubing manifold is to be disconnected from the printhead
valve module.

4 Remove the M2 x 6 socket-head-cap screw that attaches the front

tubing manifold to the printhead valve module.
5 Put the 2-way manifold gasket provided in the bypass kit on the ports
of the printhead valve module.
6 Fit the nozzle bypass manifold that has the loop of tube to the
printhead valve module using the M2 x 6 socket-head screw (see
Figure 8-3).

4
1. M2 x 6 Socket-head Screw 4. Quick Disconnect
2. Bypass Manifold 5. 2-way Manifold Gasket
3. Tube Loop

Figure 8-3. Nozzle Bypass Manifold

7 Connect the mains power cord to the electrical outlet.

8 Turn on the main power switch of the printer.

8-4 Umbilical Purge Rev AC

 Videojet 1210/1510 Service Manual

9 Log into the User Interface (UI).

10 Select Umbilical Purge (see Figure 8-4).

Note: Make sure that there are no leaks in tubing and fittings.

Figure 8-4. Umbilical Purge Command

11 The purge option runs for 15 minutes.

12 Remove the nozzle bypass manifold and the 2-way manifold gasket.
13 Put the new front tubing manifold gasket on the ports.
14 Fit the front tubing manifold to the printhead valve module using a
M2 x 6 socket-head screw.
15 Fit the printhead cover to the printhead chassis using the printhead
cover screw.

System Flush Purge

The system flush purge procedure is usually performed during the
commissioning of the printer.

Tools and Supplies Required

Tool or Supply Quantity

Nozzle bypass manifold 1

Table 8-2: Tools and Supplies Required

Rev AC System Flush Purge 8-5

Videojet 1210/1510 Service Manual

Tool or Supply Quantity

Cartridges of clear solvent 5

(appropriate to ink base)

Ink cartridge case with a smart chip 1

programmed for ink

Empty container for recovered ink Minimum 1 liter capacity

1.5-mm ball driver 1

Syringe or Wash Bottle 1

Clean solvent 1 liter

Safety glasses 1

Table 8-2: Tools and Supplies Required

Procedure
Do the following tasks to perform system flush purge:
1 Turn off the main power switch of the printer.
2 Disconnect the mains power cord from the electrical outlet.
3 Make sure that the printhead is installed on a correct mounting
bracket and is directed into a suitable container.
4 Turn the knob and open the ink compartment door.
5 Remove the ink and the make-up fluid cartridges from the cartridge
holders.
6 Remove the printhead cover screw that fastens the printhead cover to
the printhead chassis, and remove the printhead cover (see Figure 8-2
on page 8-3).

Caution
To prevent nozzle clogs, always wear rubber gloves whenever the
nozzle tubing manifold is to be disconnected from the printhead
valve module.

7 Remove the M2 x 6 socket-head-cap screw that attaches the front

tubing manifold to the printhead valve module.
8 Manually flush the nozzle assembly with a clean solvent. Use a
syringe or wash bottle to do this task.

8-6 System Flush Purge Rev AC

 Videojet 1210/1510 Service Manual

9 Fit the nozzle bypass manifold and the 2-way manifold gasket to the
printhead valve module (refer to Figure 8-3 on page 8-4).
10 Open the quick disconnect (item 4, Figure 8-3 on page 8-4).
11 Put the container for recovered ink under the nozzle bypass manifold.
12 Connect the mains power cord to the electrical outlet.
13 Turn on the main power switch of the printer. The menu screen
appears on the display.
14 Navigate to Password menu The menu shown in Figure 8-5 appears.

Figure 8-5. Password Menu

15 Select Enter Password submenu. The Enter Password dialog box appears
(see Figure 8-6).

Figure 8-6. Enter Password Dialog Box

16 Enter the Level 3 password and press the Enter key. The system allows
you now to access all the menus in the UI.
17 Navigate to System menu and disable the Gutter Fault Shutdown.

Rev AC System Flush Purge 8-7

Videojet 1210/1510 Service Manual

Figure 8-7. Gutter Fault Shutdown Command

18 Select System > Quick Start Jet

Figure 8-8. Quick Start Jet Command

The ink flows from the nozzle bypass manifold until the ink core
empty level is reached.
19 When the ink flows from the nozzle bypass manifold, introduce
solvent into the gutter for 30 seconds.
20 Put the recovered ink aside for re-use if required (it is not required
again during this procedure).
21 Close the quick disconnect in the nozzle bypass manifold.
22 Fit one of the solvent cartridges into the ink cartridge stall (with the
smart chip programmed for ink).

8-8 System Flush Purge Rev AC

 Videojet 1210/1510 Service Manual

23 Select System > Fill Ink Core. The ink core pump should stop when the
middle level is reached.

Figure 8-9. Fill Ink Core Command

24 If the pump does not stop within 4 minutes, do the following tasks:
This condition occurs when the fluid is not conductive because of
dilution in ink.
a. Remove the cartridge from the stall and check if the cartridge is
empty.
b. If the cartridge is empty, proceed to Step 25.
c. If there is still some fluid in the cartridge, return it to the stall and
allow the pump to run for a further minute, before checking again.
25 Select System > Umbilical Purge and allow the printer to purge the
umbilical with solvent for a minimum of 5 minutes (refer to
“Umbilical Purge” on page 8-3).
26 After 5 minutes, stop the umbilical purge using Quick Stop.
27 Select System > System Flush Purge.

Rev AC System Flush Purge 8-9

Videojet 1210/1510 Service Manual

Figure 8-10. System Flush Purge Command

28 Observe if fluid is going through the red-striped tube (flush supply
line). This process will take about 44 cycles.

Note: Make sure that there are no leaks in tubing and fittings.
29 Press the Enter key.
30 Press Y to confirm, or N to cancel the operation.
• Make sure that a receptacle is placed beneath the printhead to
collect the used make-up fluid.
• The make-up fluid must be removed from the printhead to
complete the procedure.
• If make-up fluid is not visible, repeat the procedure.
• If air is visible in the effluent, repeat the procedure.The procedure
will take approximately 10 - 15 minutes
31 The printer takes between 3 and 4 minutes to empty the ink core. At
about this time, listen for the sound of the pump changing, as it begins
to race when the level of fluid in the ink core drops below the pick-up
tube. At this point, stop the printer by switching it off at the mains.
32 Repeat instructions for the remaining solvent cartridges (Step 22 to
Step 31).
33 Remove the final empty solvent cartridge and the nozzle bypass
manifold.
34 Refit the front tubing manifold of the nozzle.
35 Disconnect the 3-way manifold from the printhead valve module and
disconnect the 3 printhead tubes from the ink system in the cabinet
(clear tube, red-striped tube and larger gutter tube).

8-10 System Flush Purge Rev AC

 Videojet 1210/1510 Service Manual

36 Expel fluid from the printhead tubes with clean air.

37 Reconnect the printhead tubes to the ink system tubes and refit the 3-
way manifold to the heater manifold.
38 Close the ink compartment door.
39 Fit the printhead cover to the printhead.

Nozzle Flush
Perform the nozzle flush in the following conditions:
• If a nozzle has been clogged with dried ink
• If the jet break up is asymmetric
Do the following tasks to perform nozzle flush:
1 Remove the printhead cover screw that fastens the printhead cover to
the printhead chassis and remove the printhead cover (see Figure 8-2
on page 8-3).
2 Support the printhead in a suitable stand and place a container
underneath to catch any extra solvent.
3 If the nozzle is clogged, initiate System > Nozzle Flush.

Figure 8-11. Nozzle Flush Option

If nozzle does not clear, seek assistance to have nozzle inspected by

engineering.
4 Press the Enter key. The nozzle orifice should be irrigated with
washdown to clear any blockages.

Rev AC Nozzle Flush 8-11

Videojet 1210/1510 Service Manual

5 The nozzle flush remains active for 2 minutes, but can be stopped at
any time by pressing the F1 key.

Replacement of Ink System Fan Filter for IP65

How to Remove the Old Ink System Fan Filter for IP65
Do the following tasks to remove the old ink system fan filter:
1 Turn the knob and open the ink system fan filter cover (item 2,
Figure 8-12).
2 Remove the fan filter element (item 1) from the fan filter cover.

1. Fan Filter Element

2. Fan Filter Cover

Figure 8-12. Ink System Fan Filter - IP65

3 Discard the fan filter element according to the local regulations.

The removal of ink system fan filter for IP65 is complete.

How to Install the New Ink System Fan Filter

Do the following tasks to install the new ink system fan filter:
1 Insert the new ink system fan filter element inside the fan filter cover.
2 Close the ink system fan filter cover carefully.
The installation of ink system fan filter for IP65 is complete.

8-12 Replacement of Ink System Fan Filter for IP65 Rev AC

 Videojet 1210/1510 Service Manual

Replacement of Ink System Fan Filter for IP55

How to Remove the Old Ink System Fan Filter for IP55
Do the following tasks to remove the old ink system fan filter:
1 Turn the knob and open the ink system fan filter cover (item 2,
Figure 8-13).
2 Remove the fan filter element (item 1) from the fan filter cover.

1. Fan Filter Element IP55

2. Fan Filter Cover

Figure 8-13. Ink System Fan Filter - IP55

3 Discard the old fan filter according to the local regulations.

The removal of old ink system fan filter for IP55 is complete.

How to Install the New Ink System Fan Filter for IP55
Do the following tasks to install the new ink system fan filter:
1 Insert the new ink system fan filter element inside the fan filter cover.
2 Close the ink system fan filter cover carefully.
The installation of new ink system fan filter for IP55 is complete.

Rev AC Replacement of Ink System Fan Filter for IP55 8-13

Videojet 1210/1510 Service Manual

Replacement of Floor Filter for IP65

How to Remove the Old Floor Filter IP65

Do the following tasks to remove the old floor filter:
1 Loosen the four M4 x 40 cap-head screws (item 1, Figure 8-14) and
remove the screws.
2 Detach the ink core support channel (item 2).
3 Remove the six screws, and lift the filter clamp (item 4).
4 Remove the filter element (item 5) from the filter tray.

1. M4 x 40 Cap-head Screw (x4) 4. Filter Clamp

2. Ink Core Support Channel 5. Filter Element
3. M4 x 8 Cap-head Screw (x6) 6. Filter Tray

Figure 8-14. Floor Filter - IP65

5 Discard the old floor filter element according to the local regulation.
The removal of old floor filter for IP65 is complete.

8-14 Replacement of Floor Filter for IP65 Rev AC

 Videojet 1210/1510 Service Manual

How to Install the New Floor Filter IP65

Do the following tasks to install the new floor filter:
1 Insert the new floor filter element on the filter tray.
2 Fit the filter clamp to the filter tray using the six screws.
3 Attach the ink core support channel.
4 Tighten the M4 x 40 cap-head screws.
The installation of new floor filter for IP65 is complete.

Replacement of Floor Filter for IP55

How to Remove the Old Floor Filter IP55

Do the following tasks to remove the old floor filter:
1 Loosen the four M4 x 40 cap-head screws (item 1, Figure 8-15) and
remove the screws.
2 Detach the ink core support channel (item 2).
3 Detach the ink side filter top (item 3) and ink side filter base (item 4).
4 Remove the floor filter element (item 5) from the cabinet base.

Rev AC Replacement of Floor Filter for IP55 8-15

Videojet 1210/1510 Service Manual

3
4
5

1. M4 x 40 Cap-head Screw (x4) 4. Ink Side Filter Base

2. Ink Core Support Channel 5. Floor Filter Element
3. Ink Side Filter Top

Figure 8-15. Floor Filter - IP55

5 Discard the old floor filter element according to the local regulations.
The removal of old floor filter for IP55 is complete.

8-16 Replacement of Floor Filter for IP55 Rev AC

 Videojet 1210/1510 Service Manual

How to Install the New Floor Filter for IP55

Do the following tasks to install the new floor filter:
1 Insert the new floor filter element on the cabinet base.
2 Attach the ink side filter base and ink side filter top above the floor
filter element.
3 Attach the ink core support channel.
4 Tighten the M4 x 40 cap-head screws.
The installation of new floor filter for IP55 is complete.

Windows CE Upgrade Procedure

Tools and Supplies Required

Equipment Quantity

“A to A” USB Cable 1

Serial Cable (MS1227 or 80200258) 1

Laptop 1

CSB Pack (bundled software files) 1

Table 8-3: Tools and Supplies Required

System Backup
You must perform a full system backup in order to safeguard the existing
data of the customers, as the subsequent steps that you will be performing
will erase all existing data. Refer to “Perform System Backup” on page 5-3.

Rev AC Windows CE Upgrade Procedure 8-17

Videojet 1210/1510 Service Manual

Hardware Connections
Do the following tasks to establish hardware connections:
1 Turn off the power supply to the printer.

Warning
Before you open the electronics compartment door, wear anti-static
wrist straps and ground yourself to the chassis of the cabinet. Failure
to follow this warning can cause both personal injury and damage to
the printer.

2 Open the electronics compartment.

3 Connect the "A to A" USB cable from the USB connection of the laptop
to the USB connection on the left side of the CSB.
4 Configure SW2 as follows:

1 OFF

2 OFF

3 OFF

4 ON

5 ON

6 OFF

This ensures that the CSB is set to the USB device mode.
5 Connect the serial cable from the DB-9 port on the laptop to the 5-pin
DIN connector on the side of the printer.
6 Turn on the printer.

WINDOWS XP
Laptop should establish USB connection with the printer, and prompt for
a new hardware device and look for a suitable driver. Guide it to the
secbulk.sys and secbulk.inf files in the USB directory of the CSB Pack bundle.

WINDOWS 2000
7 Do the following tasks to install the driver for windows 2000:
a. Navigate to Start> Settings> Control Panel.
b. Select Add/Remove Hardware.

8-18 Windows CE Upgrade Procedure Rev AC

 Videojet 1210/1510 Service Manual

c. Navigate through the associated Wizard and Troubleshooter.

When prompted to identify the needed driver, select the secbulk.sys
and secbulk.inf files in the USB directory of the CSB Pack bundle.
8 Turn off the printer.

USB Download through Serial Commands

Do the following tasks to initiate USB download through serial
commands:
1 Configure Hyper terminal on the laptop with the following
specifications:
• 115,200 baud
• 8 data bits
• No parity
• 1 Stop Bit
• No flow control
2 Turn on the printer.
3 Monitor the terminal software display. You must press the space bar
on the laptop within 5 seconds.
The code that appears on the terminal display is shown in Figure 8-16.

Figure 8-16.Terminal Display

You can see a countdown to Initiating image launch.

Rev AC Windows CE Upgrade Procedure 8-19

Videojet 1210/1510 Service Manual

You have 5 seconds from power-up in which to press the space bar. If
you miss it, turn off the printer and try again.
4 The "EBoot menu" should be provided through Hyper terminal (see
Figure 8-17).

Figure 8-17.Eboot Menu

5 Go through the following sequence of steps to prepare for USB (or

Ethernet) download on the laptop, and to ensure that the downloaded
image is programmed to NAND (thereby making the board
standalone bootable).

Note: The first four steps can be modified as necessary.

a. Press '4' to show (Reset to factory default configuration)
b. Press '8' until Kernel Debugger shows DISABLED
c. Press '5' until Startup Image: shows LAUNCH EXISTING
d. Press '6' until Program disk image into SmartMedia card shows
ENABLED
e. Press 'T' (Clear the sector info for steploader and Eboot)
f. Press 'S' (Protect the StepLoader)
g. Press '9' (Format Boot Media for BinFS)
h. Press 'W' (Write Configuration Right Now)
i. Finally, press 'U' to initiate USB Download

8-20 Windows CE Upgrade Procedure Rev AC

 Videojet 1210/1510 Service Manual

USB Download
Do the following tasks for USB download:
1 Run dnw.exe software. This application is located in the USB folder of
the CSB Pack bundle.
2 Make sure that USB:OK is displayed (see Figure 8-18).

Figure 8-18.USB: OK

3 Select USB Port > UBOOT(WINCE500) > UBOOT and the screen
shown in Figure 8-19 appears.

Figure 8-19.USB Port Menu

Rev AC Windows CE Upgrade Procedure 8-21

Videojet 1210/1510 Service Manual

4 Navigate to the required location and select the appropriate.bin file.

Click the Open button (see Figure 8-20).

Figure 8-20..bin File

5 The USB download gets initiated.

8-22 Windows CE Upgrade Procedure Rev AC

 Videojet 1210/1510 Service Manual

6 Once the download is complete you should see the image (see
Figure 8-21) appear in the Hyper terminal display and this is the
image being committed to NAND Flash.

Figure 8-21.Terminal Window Display

7 The following code should appear in Hyper terminal (and WinCE and
then the UI will start on the printer) (see Figure 8-22).

Figure 8-22.Terminal Window Display

8 The printer will prompt the user to load the 43s interface. Make the
appropriate selection.

Rev AC Windows CE Upgrade Procedure 8-23

Videojet 1210/1510 Service Manual

9 Once the printer has booted, it will automatically go into the EHT
Calibration procedure.

Note: These settings (EHT Calibration) were erased during the upgrade.
10 Enter the Level 3 password.
11 The printer will have loaded a software version and a firmware
version as part of the CE upgrade process.
12 You can check the version information under Data Logging.
13 Additional changes to the software and firmware versions may be
accomplished by using the normal process and the USB flash drive.

8-24 Windows CE Upgrade Procedure Rev AC

Troubleshooting
9
Read the Operator Manual
The Videojet 1210/1510 Operator Manual (Part Number 361868) contains
the troubleshooting procedures that an operator is allowed to perform.
Refer to the operator manual for these procedures.
This chapter contains the troubleshooting procedures that only a service
technician is allowed to perform.

Warning
It is possible that in a fault condition the heater can reach 70° C
temperature. Do not touch the plate on which heater is installed. The
failure to follow this warning can cause personal injury.

Important Guidelines
• Before you perform fault diagnosis or do any repairs described in this
section, Videojet recommends to shift the printer from the production
line to a clean environment.
• When a fault condition occurs, the first step to locate the cause must
be to check the following:
• The fault and status icons displayed on the display (refer to “Printer
Status Icons” on page 9-6).
• The status LEDs on the CSB.
• Table 9-6 on page 9-6 through Table 9-8 on page 9-13 list the possible
printer status icons. These tables contain either remedial action or a
reference to more detailed fault finding information.

Rev AC Read the Operator Manual 9-1

Videojet 1210/1510 Service Manual

Startup Problems

Printer Fails to Start

Possible Cause Remedial Action

No main power supply Make sure that the main power supply is turned on.
To turn on the printer, press the green push button.

Main power supply input cable 1. Make sure that the main power supply cable is connected.
disconnected or defective 2. Check the continuity of the cable. If the cable is defective,
repair or replace the cable.

Printer main power supply fuse Check the F1 fuse in the PSU. Replace the fuse if necessary.
failed

Mains switch is faulty Check mains switch. Replace the switch if faulty.

Cable between mains switch and 1. Check the cable connections. Reconnect if necessary.
PSU is disconnected or faulty 2. Check the cable for continuity. Replace if faulty.

PSU output not reaching the Check LEDs 2, 3, 4 and 5 on CSB (see Figure 9-1 on
CSB page 9-3).

Cable between PSU and CSB is 1. Check if the cable between PSU and CSB is connected.
faulty or disconnected Reconnect if necessary.
2. Check the cable for continuity, replace if faulty.

PSU fuse failed Check the fuse, replace if necessary.

PSU faulty Replace the PSU (see “Power Supply Unit” on page 7-9).

CSB failed 1. Make sure that LEDs 2, 3, 4 and 5 on CSB are illuminated
(see Figure 9-1 on page 9-3).
2. Change the CSB (see “Control System Board” on page 7-7).

Table 9-1: Printer Startup Problem and Remedies

9-2 Startup Problems Rev AC

 Videojet 1210/1510 Service Manual

5 4 3 2
1. CSB 4. SoC to FPGA LED
2. Power LED 5. Ethernet LED
3. Print Engine LED

Figure 9-1: Status LEDs

Display Faults

Backlight

Warning
LETHAL VOLTAGES. A high AC voltage is present at the inverter
and backlight. Extreme caution is required when diagnosing failure
in these areas.

Rev AC Display Faults 9-3

Videojet 1210/1510 Service Manual

Note: Some DVMs may not show the 1000 VAC correctly. Use an oscilloscope
fitted with a high voltage probe to measure the voltage.

Possible Cause Remedial Action

Backlight inverter faulty 1. Check for 24 VDC at 3 way input connector on backlight converter
(Pins 1 and 2 on CSB B/LIGHT connector).
2. Check for 1000 VAC at output leads from backlight inverter (Pins 3
and 5).
3. If 24 VDC is present but 1000 VAC is missing, replace the LCD/
backlight assembly (refer to “LCD and FIB Assembly” on page 7-13).

Cable between CSB 1. If 24 VDC is not present at backlight inverter but is present at Pins 1
and backlight is and 3 of B/LIGHT connector on CSB, make sure that the cable is
disconnected or faulty connected between the CSB and the backlight.
2. Check the cable for continuity, replace if faulty.

Backlight faulty If 1000 VAC is present at output of backlight inverter but backlight is not
illuminated, replace the LCD/Backlight assembly (refer to “LCD and FIB
Assembly” on page 7-13).

CSB faulty Check for 24 VDC on pins 1 and 3 of B/LIGHT connector on CSB. If 24
VDC is not present, replace the CSB (refer to “Control System Board” on
page 7-7).

Table 9-2: Display Backlight Failure

LCD Faults

Possible Cause Remedial Action

LCD contrast not set

Press to set the contrast.
correctly

Ribbon cable between CSB Check the cable for continuity. Replace if faulty.
and LCD is faulty

CSB faulty Replace the CSB (see “Control System Board” on page 7-7).

LCD faulty Replace the LCD assembly (see “LCD and FIB Assembly” on
page 7-13).

Table 9-3: LCD Failure

9-4 Display Faults Rev AC

 Videojet 1210/1510 Service Manual

Keypad Faults

Possible Cause Remedial Action

Ribbon cable between CSB and 1. Make sure that the ribbon cable between CSB and the
keypad is disconnected or faulty keypad is connected.
2. Replace the cable for continuity, replace if faulty.

CSB faulty Replace the CSB

(refer to “Control System Board” on page 7-7).

Keyboard faulty Replace the keyboard.

(refer to “Keyboard/Electronics Compartment Door” on
page 7-16).

Table 9-4: Keypad Failure

Beacon Indication

Beacon Description
Color

Red Jet off, No warnings. All Relays off

Amber Jet on, Warning present, Print not enabled and Relay 2 set

Green Print enabled, No Warnings and Relay 1 set

Green and Print enabled, Warning Present, Relay 1 and 2 set

Amber

Red and Jet off, Warning Present and Relay 2 set

Amber

No Lights Jet Running, No Warnings, and Print disabled. All Relays are
off in this mode

Table 9-5: Alarm Light Conditions

Rev AC Beacon Indication 9-5

Videojet 1210/1510 Service Manual

Printer Status Icons

The printer status icons are divided into three groups:
• The indicator icons - These icons show the status of the ink jet.
• The fault icons - These icons indicate a fault condition. During a fault
condition, the printer stops printing.
• The warning icons - These icons indicate a warning condition. The
printer continues to print until the warning condition becomes a fault
condition.

Indicator Icons

Icon Name Description

Jet Running The ink jet is running and the machine is

ready to print. When the machine starts, this
icon flashes.

Jet Stopped Indicates that the ink jet has stopped. When
the machine stops, this icon flashes.

Table 9-6: Indicator Icons

9-6 Printer Status Icons Rev AC

 Videojet 1210/1510 Service Manual

Fault Icons

Fault Reason Causes Action

Charge Error The Temperature of 1. Check the electronics compartment

temperature the electronics temperature on diagnostics screen.
of the charge compartment is 2. Ensure that the electronics compartment fan
amplifier is more than the is working.
above the specified limit. 3. Keep electronics compartment door open
specified limit and see if the compartment temperature
OR drops; attempt restart.
invalid charge 4. If fault occurs again, reduce the print rate
data. and monitor electronics compartment
temperature.

Defective CSB 1. Check test points related to charge amplifier;

TP50, TP72, and CHG (refer to “CSB Test
Points” on page 9-38).
2. Replace the CSB (see “Control System
Board” on page 7-7).

EHT Trip Excessive The printhead 1. Clean and dry the printhead.
current in the is dirty or wet 2. Restart the inkjet; monitor for ink buildup on
EHT circuit as the printhead during the printing operations,
measured by if possible.
the CSB.
The EHT circuit 1. Stop the ink jet.
is not 2. Calibrate EHT (refer to “Calibrate EHT” on
calibrated page 4-36).
3. Restart the inkjet and monitor the system
performance.

Short in 1. Stop the inkjet and turn off the printer.

umbilical or 2. Unplug the EHT wire from the EHT power
EHT resistor supply.
3. Measure the resistance between the EHT
wire and the EHT plate.
4. If open or short circuit exists, remove the
print engine and inspect the EHT resistor.
5. Replace the umbilical (refer to “Umbilical
Assembly” on page 7-50).

Defective EHT Replace the EHT power supply (refer to “EHT

power supply Module” on page 7-106).

Defective CSB Replace the CSB (refer to “Control System

Board” on page 7-7).

Table 9-7: Fault Icons

Rev AC Printer Status Icons 9-7

Videojet 1210/1510 Service Manual

Fault Reason Causes Action

Gutter Fault Ink jet is on, Nozzle is 1. Perform a nozzle back flush.
but ink stream clogged 2. Restart the inkjet and make sure that the ink
is not stream is entering the gutter.
detected in
the gutter for Inadequate ink 1. Check for the presence of pump fault (refer
more than 5 pressure to “Pump Fault” on page 9-9)
seconds 2. Check the actual pressure using diagnostics
screens.

Ink stream is 1. Perform a nozzle flush.

misaligned 2. Restart the inkjet and make sure that the ink
stream is entering the gutter.
3. Perform an ink stream alignment (refer to
“Align the Ink Stream” on page 4-33).

No vacuum 1. Clean the printhead.

2. Perform a nozzle flush and check for flow in
the return line to make sure the proper
operation of the vacuum system.
3. Remove the print engine and inspect the
length of tubing between the gutter and the
printhead valve module for clogs (refer to
“How to Remove the Old Print Engine
Assembly” on page 7-41).
4. Loosen and clean valve V2 (VP and VG).

The gutter 1. Remove the print engine and inspect the

sense chamber gutter sense chamber (refer to “How to
is defective Remove the Old Print Engine Assembly” on
page 7-41).
2. Check CSB test point 45 for the gutter sense
signal.
3. Check umbilical wires related to the gutter
sense signal.
4. Replace the umbilical if required (refer to
“Umbilical Assembly” on page 7-50).

Ink Core The low level New Perform "Fill Ink Core" procedure to maintain
Empty sensor in the installation correct level in ink core module.
ink core
module is not Ink Core Level Refer to “Ink Core Level Low” on page 9-25.
covered. Low warning
has occurred,
and the printer
is unable to
add ink.

Table 9-7: Fault Icons (Continued)

9-8 Printer Status Icons Rev AC

 Videojet 1210/1510 Service Manual

Fault Reason Causes Action

Pump Fault The pump Presence of 1. Inspect the ink compartment, electronics
speed is leaks in the ink compartment, and umbilical for leaks.
greater than compartment, 2. Repair if possible.
98% of the electronics
maximum compartment
value and the or umbilical
actual
pressure is Erroneous 1. Inspect the electrical connections between
greater than pressure the ink core module and the PIB, and
0.2 bar below indication between the PIB and the CSB.
the target 2. Check and compare the voltage readings at
pressure. the test points related to pump and
pressure: TP20, TP21, TP22, and TP47
(refer to “CSB Test Points” on page 9-38).
Also, remove the top cover of the ink core
module and measure the voltage between
points + Press and - Press.

Defective pump 1. Inspect the electrical connections between

the ink core module and the PIB, and
between the PIB and the CSB.
2. Open the pump compartment, and inspect
the pump.
3. Replace the pump, if required (refer to “How
to Remove the Old Ink Core Pump” on
page 7-36 and “How to Install the New Ink
Core Pump” on page 7-39).

Ink too thin 1. Check the Diagnostics Screen One.

2. Compare the target pressure with the
temperature-compensated target pressure.
3. If the target pressure is significantly less
than (1 bar) the temperature-compensated
target pressure, the ink is too thin.
4. Recover the viscosity by allowing the jet to
run continuously, or by draining and re-
priming the system.

Erroneous 1. Clean the printhead.

velocity 2. Check the Diagnostics Screen One.
indication 3. Compare the Actual Velocity with the
Velocity Set Point.
4. Remove the print engine and measure the
resistances between the copper pads on the
underside of the print engine; compare to
the expected values (refer to “How to
Remove the Old Print Engine Assembly” on
page 7-41).
5. With an oscilloscope, check the waveforms
at the CSB test points related to velocity:
"PHA", TP69, TP58, TP59, TP60, and TP61
(refer to “CSB Test Points” on page 9-38).

Table 9-7: Fault Icons (Continued)

Rev AC Printer Status Icons 9-9

Videojet 1210/1510 Service Manual

Fault Reason Causes Action

Cabinet Too The cabinet The electronics 1. Open the electronics compartment.
Hot temperature compartment is 2. Inspect the electronics compartment
measured by overheated. components for any damage or overheating.
the CSB is 3. If possible, operate the printer with the
above 80° C. electronics compartment door open and
monitor the Cabinet Temperature through
the Diagnostics Screen Two.

The ambient 1. Move the printer to a location where the

temperature is ambient temperature is lower, or attempt to
too high. lower the temperature at the current
location.
2. Monitor the Cabinet Temperature through
the Diagnostics Screen Two.

The heat sink is Remove the insulation/obstruction from the

insulated or surroundings of the heat sink.
obstructed.

The mains 1. Check the voltage levels of the mains power

power supply is supply being supplied to the CSB.
defective. 2. Replace the mains power supply.

The CSB is Replace the CSB (refer to “Control System

defective. Board” on page 7-7).

Ink System Ink core

Service module is in
Overdue use for more
than 8000
hours

Table 9-7: Fault Icons (Continued)

9-10 Printer Status Icons Rev AC

 Videojet 1210/1510 Service Manual

Fault Reason Causes Action

Unable to The printer Presence of Ink Refer to “Ink Core Level High” on page 9-24.
Control has been Core Level
Viscosity unable to High warning,
perform and target
automatic pressure has
viscosity been greater
control for 30 than 0.1 bar
minutes or above
more. temperature-
compensated
target pressure
for 1 hour.

No make-up Refer to “No Make-up Cartridge” on page 9-22.

cartridge, or
invalid make-
up cartridge,
and target
pressure has
been greater
than 0.1 bar
above
temperature-
compensated
target pressure
for 1 hour.

Printer is Refer to “Phase Threshold Error” on page 9-16.

unable to
obtain a phase
profile for half
an hour (½
hour).

Printer is Refer to “No Time for TOF” on page 9-29.

unable to
measure
velocity for half
an hour (½
hour).

Mod Driver Mod amplifier Mod amplifier

Chip Over hardware has temperature is
Temperatur shutdown. more than the
e specified limit.

Table 9-7: Fault Icons (Continued)

Rev AC Printer Status Icons 9-11

Videojet 1210/1510 Service Manual

Fault Reason Causes Action

Rasters Not enough

Memory memory to
Overflow store all
Detected requested
raster tables.

Valve Error - Hardware

Contact the error in valve
Service hit / hold drive
Department circuit.

Bad Unable to
Phasing obtain phase
data during
startup.

Modulation Hardware
Readback error, ADC
Failed readback
invalid.

Table 9-7: Fault Icons (Continued)

9-12 Printer Status Icons Rev AC

 Videojet 1210/1510 Service Manual

Warning Icons

Warning Reason Causes Action

Printhead The printhead The printhead Allow the inkjet to run. The printhead
Temperature temperature is is (temporarily) temperature should correct itself.
Too High 3° C more than overheated.
the setpoint,
with head heater The ambient If print quality or performance issues are
enabled. temperature is noted, consider operating the printer in a
too high. cooler environment.

Defective 1. Check the voltages from the mains

power supply power supply that is being supplied to
the CSB.
2. Replace the mains power supply.

Defective 1. Inspect the electrical connections

temperature between the CSB and the PIB, and
control circuit between the PIB and the umbilical.
(short) 2. Remove the printhead valve module
(refer to “Printhead Valve Module” on
page 7-44).
3. Inspect the electrical connections
between the printhead valve module and
the deck.
4. Measure the resistance between the
copper pads on the underside of the
printhead valve module and compare
these values to the expected values.
5. Check the umbilical wires for continuity.

Incorrect Requested
Raster or raster table not
Raster loaded into the
Family Name system.Warning
appears
immediately.

Table 9-8: Warning Icons

Rev AC Printer Status Icons 9-13

Videojet 1210/1510 Service Manual

Warning Reason Causes Action

Printhead The printhead The printhead Allow the inkjet to continue to run. The
Temperature temperature is has not yet printhead temperature should correct itself.
Too Low more than 3° C reached
below the target operational
temperature. temperature.
Error duration
before warning
is 30 seconds The ambient If print quality or performance issues are
temperature is noted, consider operating the printer in a
too low. warmer environment.

Defective 1. Check the voltages from the mains

power supply power supply being supplied to the CSB.
2. Replace the mains power supply.

Defective 1. Inspect the electrical connections

temperature between the CSB and the PIB, and
control circuit between the PIB and the umbilical.
(open) 2. Remove the printhead valve module
(refer to “Printhead Valve Module” on
page 7-44).
3. Inspect the electrical connections
between the printhead valve module and
the deck.
4. Reset the printhead valve module, start
the printer and monitor printhead
temperature.
5. If problem persists, measure the
resistance between the copper pads on
the underside of the printhead valve
module and compare these values to the
expected values.
6. Check the umbilical wires for continuity

TOF Too Measured jet

High velocity is more
than 10% above
target velocity.

TOF Too Low Measured jet

velocity is more
than 10% below
target velocity.

Charge Error Operator has

Shutdown disabled
Disabled machine
shutdown on
charge error

Table 9-8: Warning Icons

9-14 Printer Status Icons Rev AC

 Videojet 1210/1510 Service Manual

Warning Reason Causes Action

Gutter Fault Operator has

Shutdown disabled
Disabled machine
shutdown on
gutter fault.
Warning
appears
immediately

Printhead Lid switch circuit The printhead Replace the printhead cover.
Cover is open cover is
Removed removed

Open circuit Inspect the cabling from the umbilical to the

PIB and from the PIB to the CSB.

Defective lid 1. Stop the inkjet and turn off the printer.
switch 2. Remove the print engine and inspect the
lid switch (refer to “How to Remove the
Old Print Engine Assembly” on page 7-
41).
3. Measure the resistance between the
copper pads on the underside of the print
engine and compare readings to the
expected values.
4. Check umbilical wires for continuity.

Defective CSB Check measurement at TP56 on the CSB.

Table 9-8: Warning Icons

Rev AC Printer Status Icons 9-15

Videojet 1210/1510 Service Manual

Warning Reason Causes Action

Phase The printer is The printhead Clean and dry the printhead.
Threshold unable to is dirty
Error acquire a phase
profile with the The ink stream 1. Perform a nozzle backflush.
phase threshold is misaligned 2. Restart the inkjet.
set to the 3. If the ink stream is still misaligned,
minimum value. perform ink stream alignment (refer to
“Align the Ink Stream” on page 4-33).

No break-off 1. Perform a visual inspection to verify

break-off.
2. If break-off does not exist, check
electrical connections on the print engine
and in the electronics compartment.
3. Attempt to set the modulation manually
to obtain break-off.
4. If break-off cannot be obtained, check
the modulation signal on the CSB. If the
modulation signal does not exist, refer to
“CSB failed” on page 9-17.
5. If the modulation signal is present on the
CSB, check for the modulation signal in
the printhead.
6. Remove the print engine and check its
electrical connections (refer to “How to
Remove the Old Print Engine Assembly”
on page 7-41).
7. Replace the print engine (refer to “How
to Install the New Print Engine
Assembly” on page 7-43).

Phase Charge 1. Check the Phase Charge setting.

incorrectly set 2. Adjust the Phase Charge setting to
recover the phase profile.

Electrical 1. Check the electrical connections

malfunction in between the CSB and the PIB, and
TOF circuit between the PIB and the umbilical.
2. Remove the print engine and check the
electrical connections (refer to “How to
Remove the Old Print Engine Assembly”
on page 7-41).
3. Check the resistance between the
copper pads on the underside of the
printhead engine, and compare the
readings with the expected values.
4. Check for continuity in the umbilical
wires.

Table 9-8: Warning Icons

9-16 Printer Status Icons Rev AC

 Videojet 1210/1510 Service Manual

Warning Reason Causes Action

No charge 1. With the ink jet running but the printer not
pulses printing, check for the presence of
charge pulses at the charge tunnel.
2. If pulses are not present, check for the
presence of charge pulses at TP "CHG"
on the CSB
3. Check for continuity in the umbilical
wires.

CSB failed With test equipment, check for presence of

all related signals on CSB: TP38, CHG, and
PHA.

Table 9-8: Warning Icons

Rev AC Printer Status Icons 9-17

Videojet 1210/1510 Service Manual

Warning Reason Causes Action

Ink Viscosity The target The ink is too 1. The printer should add make-up fluid to
Too High pressure is >.1 thick. correct the ink viscosity.
bar above the 2. Monitor the progress of make-up
temperature- additions using Diagnostics Screen Two.
compensated If the printer does not appear to be
target pressure attempting to add make-up (allow at
least five minutes for a make-up addition
to be attempted), see causes below.
3. If make-up addition capability is
confirmed but printer operations are
impaired by thick ink, consider flushing
the system.

The make-up 1. Install or reset the make-up cartridge.

cartridge is 2. Make sure that the No Make-up icon
removed or disappears.
seated
improperly.

The make-up 1. Install a cartridge of the correct make-up

cartridge is of type.
the wrong type. 2. Make sure that the Wrong Make-up icon
disappears.

The make-up 1. Open the ink compartment door and

add line is gently pull the ink core module out.
disconnected 2. Locate the green-striped tube behind the
or leaks. ink core module.
3. Make sure that the quick disconnect in
this line is secure and that the line is not
leaking.

The ink core 1. Confirm the condition by checking icons

module level is on display screen.
high. 2. To clear the condition, perform the
following steps:
• Direct the printhead into a service tray.
• Disable the gutter fault.
• Raise the ink stream above the catcher.
• Allow the ink stream to flow into the
service tray until the ink core module
level is restored to normal.

The ink core Replace the ink core module (refer to “Ink
module level is Core Module” on page 7-21).
defective

Table 9-8: Warning Icons

9-18 Printer Status Icons Rev AC

 Videojet 1210/1510 Service Manual

Warning Reason Causes Action

Ink Viscosity The target The ink is too 1. Allow the inkjet to run so that the excess
Too low pressure is >.1 thin. make-up fluid evaporates. The following
bar below the actions will help to recover the viscosity:
temperature- • Avoid nozzle backflushing and improper
compensated printhead cleaning (with the vacuum
target pressure. applied).
• Use the Quick Start and Quick Stop
options whenever possible.
• Run Gutter Pump at maximum speed.
• Check for flow in the green-striped tube
to make sure that make-up is not being
unnecessarily added.
2. If printer operations are affected by thin
ink, flush the system. Perform the
following steps:
• Direct the printhead into a service tray.
• Disable the gutter fault.
• Raise the ink stream above the catcher.
• Allow the ink stream to flow into the
service tray until the viscosity is
restored (the printer will add fresh ink to
compensate for system losses).

Pressure too The actual Printer Printer will correct itself

High pressure is more transient
than 0.2 bar
above the target Erroneous 1. Inspect electrical connections between
pressure. pressure the ink core module and the PIB, and
indication between the PIB and the CSB.
2. Replace the ink core module. Check and
compare the voltage readings at the test
points related to pump and pressure:
TP20, TP21, TP22, and TP47 (refer to
“CSB Test Points” on page 9-38). Also,
remove the top cover of the ink core
module and measure the voltage
between points + Press and - Press.

Table 9-8: Warning Icons

Rev AC Printer Status Icons 9-19

Videojet 1210/1510 Service Manual

Warning Reason Causes Action

Pressure Too The actual Printer Printer will correct itself.

Low pressure is > 0.2 transient.
bar below the
target pressure. Leak in the ink 1. Inspect the ink compartment, electronics
compartment, compartment, and umbilical for leaks.
electronics 2. Repair if possible.
compartment,
or umbilical.

Erroneous 1. Inspect the electrical connections

pressure between the ink core module and the
indication. PIB, and between the PIB and the CSB.
2. Check and compare the voltage
readings at the test points related to
pump and pressure: TP20, TP21, TP22,
and TP47 (refer to “CSB Test Points” on
page 9-38). Also, remove the top cover
of the ink core module and measure the
voltage between points + Press and -
Press.

Defective pump 1. Inspect electrical connections between

the ink core module and the PIB, and
between the PIB and the CSB.
2. Open the pump compartment, and
inspect the pump.
3. Replace the pump.

No Ink No ink available No ink Insert an ink cartridge into the proper
Cartridge for addition to cartridge is cartridge holder.
the ink core present
module
The ink Remove the empty cartridge and insert a
cartridge is new ink cartridge.
empty

The printer is 1. Ensure that the ink cartridge is seated

unable to read correctly in its receptacle.
the ink 2. Remove the ink cartridge. Check if the
cartridge smart smart chip is present and is clean.
chip 3. If another ink cartridge is available, insert
it into the printer and see if the printer
can read its smart chip.
4. Check if the smart chip reader (inside the
receptacle) is positioned correctly and is
clean.
5. Check the electrical connections
between the smart chip reader and the
PIB board, and between the PIB board
and the CSB.

Table 9-8: Warning Icons

9-20 Printer Status Icons Rev AC

 Videojet 1210/1510 Service Manual

Warning Reason Causes Action

Wrong Ink Ink type in A cartridge 1. Remove the ink cartridge.

Cartridge cartridge containing the 2. Check the label on the ink cartridge to
incompatible wrong ink type confirm the ink type.
with ink core has been 3. Insert a cartridge of the correct ink type
module. inserted into into the printer.
fluid reference the printer
and fluid type
must match ink A make-up 1. Remove the cartridge.
core module. cartridge has 2. Check the label on the cartridge to
been confirm fluid type.
accidentally 3. Insert a cartridge of the correct ink type
inserted into into the printer.
the ink
cartridge holder

The smart chip 1. Remove the cartridge.

on the ink 2. Check the label on the cartridge to
cartridge is confirm fluid type.
programmed 3. Insert a cartridge of the correct ink type
incorrectly or into the printer.
does not match
the label.

Ink Cartridge Ink past expiry

Expired date

Ink Cartridge Less than 5% of Ink used for Insert a new ink cartridge into the proper
Low the required ink printing cartridge holder after ink cartridge becomes
remains in the empty.
ink cartridge.

Ink Cartridge Ink cartridge

Empty smart chip data
shows 0%.

Ink This ink

Insertions cartridge is
Exceeded inserted more
than 10 times.

Table 9-8: Warning Icons

Rev AC Printer Status Icons 9-21

Videojet 1210/1510 Service Manual

Warning Reason Causes Action

No Make-up No make-up Make-up Insert a make-up cartridge into the proper

Cartridge fluid available cartridge is not cartridge holder.
for addition to present
the ink core
module The Remove the empty cartridge and insert a
make-up new make-up cartridge.
cartridge is
empty

The printer is 1. Ensure that the make-up cartridge is

unable to read seated correctly in its receptacle.
the make-up 2. Remove the make-up cartridge. Make
cartridge smart sure that the smart chip is present and is
chip. clean.
3. If another make-up cartridge is available,
insert it into the printer and see if the
printer can read its smart chip.
4. Check that the smart chip reader (inside
the receptacle) is positioned correctly
and is clean.
5. Check the electrical connections
between the smart chip reader and the
PIB, and between the PIB and the CSB.

Wrong Make- The cartridge A cartridge 1. Remove the make-up cartridge.

up Cartridge inserted into the containing the 2. Check the label on the make-up
make-up wrong make-up cartridge to confirm the make-up type.
cartridge holder type has been 3. Insert a cartridge of the correct make-up
contains the inserted into type into the printer.
wrong make-up the printer
type.
An ink cartridge 1. Remove the cartridge.
was 2. Check the label on the cartridge to
accidentally confirm fluid type.
inserted into 3. Insert a cartridge of the correct make-up
the make-up type into the printer.
cartridge
holder.

The smart chip 1. Remove the make-up cartridge.

on the make-up 2. Check the label on the make-up
cartridge is cartridge to confirm the make-up type.
programmed 3. Insert a cartridge of the correct make-up
incorrectly or type into the printer.
does not match
the label.

Table 9-8: Warning Icons

9-22 Printer Status Icons Rev AC

 Videojet 1210/1510 Service Manual

Warning Reason Causes Action

Makeup Less than 5% of Make-up used Make preparations to insert a fresh make-
Cartridge the make-up in during jet on up cartridge into the proper cartridge holder.
Low the make-up operations. Replace the cartridge following Make-up
cartridge Out indication.
remains.

Clean Start / Viscosity is too

Stop low, so clean
Inhibited start / stop
inhibited to
prevent solvent
addition

Makeup This make-up

Insertions cartridge is
Exceeded inserted more
than 10 times

Table 9-8: Warning Icons

Rev AC Printer Status Icons 9-23

Videojet 1210/1510 Service Manual

Warning Reason Causes Action

Ink Core The high level Excessive 1. Use Quick Start and Quick Stop options
Level High sensor in the ink clean start and until ink core module level is restored.
core module is stops. 2. Keep jet running to use excess make-up.
covered. 3. If printer operation is impaired by high
ink core module level (presence of
Unable to Control Viscosity warning),
raise the ink stream above the catcher to
restore the ink core module level to
normal.

Excessive 1. Use Quick Start and Quick Stop options

nozzle until ink core module level is restored.
backflushing 2. Keep jet running to use excess make-up.
3. If printer operation is impaired by high
ink core module level (presence of
Unable to Control Viscosity warning),
raise the ink stream above the catcher to
restore the ink core module level to
normal.

Improper 1. Use Quick Start and Quick Stop options

printhead until ink core module level is restored.
cleaning 2. Keep the jet running to use excess
make-up.
3. If printer operation is impaired by high
ink core module level (presence of
Unable to Control Viscosity warning),
raise the ink stream above the catcher to
restore the ink core module level to
normal.

Leak 1. Check for flow in the black or green

striped tubing (ink and make-up add
line).
2. If flow is present continuously,
disconnect the line and check for
presence of vacuum.
3. Replace the ink core module, if required
(refer to “Ink Core Module” on page 7-
21).

Table 9-8: Warning Icons

9-24 Printer Status Icons Rev AC

 Videojet 1210/1510 Service Manual

Warning Reason Causes Action

Ink Core The middle level Ink usage The printer should add ink to restore ink
Level Low sensor in the ink during printing core module level to middle. However, if the
core module is printer is attempting to add ink, but the level
uncovered. is not restored, perform the following:
1. Confirm that the printer is attempting to
add ink by monitoring the ink add valve
on the Valves Screen. The screen
should indicate that the valve is opening.
2. If the printer is not attempting to add ink,
check if a valid cartridge of the correct
ink type is inserted into the ink cartridge
receptacle.
3. If the printer is attempting to add ink, but
the level is not restoring, troubleshoot
the ink addition system as follows:
1. Ensure that the ink cartridge is not
actually empty.
2. Stop the jet and perform a valve test.
Make sure that the ink add valve is
operational. If it is not operational,
remove and clean the valve.
3. Inspect the black-striped tubing and
the ink receptacle septum needle for
obstruction.
4. Troubleshoot the venturi system - use
the temporary gauge manifold to
check the venturi vacuum.
5. Replace the ink core module, if
required (refer to “Ink Core Module”
on page 7-21).

Table 9-8: Warning Icons

Rev AC Printer Status Icons 9-25

Videojet 1210/1510 Service Manual

Warning Reason Causes Action

Cabinet Hot The cabinet The electronics 1. Open the electronics compartment.
temperature compartment is 2. Inspect the electronics compartment
measured by overheating. components for damage or overheating.
the CSB is 3. If possible, operate the printer with the
greater than 70º electronics compartment door open and
C. monitor the Cabinet Temperature using
the Diagnostics Screen Two.

The ambient 1. Move the printer to a location where the

temperature is ambient temperature is lower, or attempt
too high. to lower the temperature at the current
location.
2. Monitor the Cabinet Temperature using
the Diagnostics Screen Two.

The heat sink is Remove the insulation / obstruction from the

insulated or vicinity of the heat sink.
obstructed.

The mains 1. Check the voltages from the mains

power supply is power supply being supplied to the CSB.
defective. 2. Replace the mains power supply if found
faulty.

The CSB is Replace the CSB (refer to “Control System

defective. Board” on page 7-7).

Ink Core The ink core

Insertions module has
Exceeded been
disconnected /
reconnected
more than 10
times

Table 9-8: Warning Icons

9-26 Printer Status Icons Rev AC

 Videojet 1210/1510 Service Manual

Warning Reason Causes Action

Pump RPM The pump Leak 1. Inspect the ink compartment, electronics
Near Max speed is >98% compartment, and umbilical for leaks.
of the maximum 2. Repair if possible.
value.
Defective pump 1. Inspect electrical connections between
the ink core module and the PIB, and
between the PIB and the CSB.
2. Open the pump cover, and inspect the
pump.
3. Replace the pump.

Ink too thin 1. Check the Diagnostics Screen One.

2. Compare the Target Pressure with the
temperature-compensated target
pressure.
3. If the Target Pressure is significantly less
than (1 bar) than the temperature-
compensated target pressure, the ink is
too thin.
4. Recover the viscosity by allowing the jet
to run continuously, or by flushing and
priming the system.

Defective pump 1. Inspect electrical connections between

the ink core module and the PIB, and
between the PIB and the CSB.
2. Open the pump cover, and inspect the
pump.
3. Replace the pump.

Erroneous 1. Clean the printhead.

velocity 2. Check the Diagnostics Screen One.
indication 3. Compare the Actual Velocity with the
Velocity Set Point.
4. Replace the print engine (refer to “Print
Engine Assembly” on page 7-41).

Ink Core Ink core module

Empty low probe is
uncovered -
tank close to
empty or empty.

Pump Fault Pump near max

RPM and
pressure low.

No Ink Core No data from ink

core smart chip -
ink core not
plugged in.

Table 9-8: Warning Icons

Rev AC Printer Status Icons 9-27

Videojet 1210/1510 Service Manual

Warning Reason Causes Action

Ink Core Ink core module 40 hours Make preparations to replace the ink core
Service Soon is very near the remaining on module (refer to “Ink Core Module” on
(0.5% Left). end of service the ink core page 7-21).
life. smart chip.

Ink Core Ink core module 160 hours Make preparations to replace the ink core
Service Soon nearing the end remaining on module (refer to “Ink Core Module” on
(2% Left) of service life. the ink core page 7-21).
smart chip.

Ink Core Ink core module 400 hours Make preparations to replace the ink core
Service Soon nearing the end remaining on module (refer to “Ink Core Module” on
(5% Left) of service life. the ink core page 7-21).
smart chip.

Product Compile time

Delay Too greater than
Short product delay.

Inter-print Insufficient time

Gap Too to compile
Short between prints.

Print Queue Too many

Too Deep products
between PEC
and printhead.

Print Overlap Print starts

before end of
current print.

Table 9-8: Warning Icons

9-28 Printer Status Icons Rev AC

 Videojet 1210/1510 Service Manual

Warning Reason Causes Action

No Time to Less than 10 The line speed Reduce the line speed, if possible.
Phase milliseconds is too fast
from the end of
one print to the The distance Increase the distance between adjacent
beginning of the between products, if possible.
next. adjacent
products is too
short.

The message Reduce the message length, if possible.

is too long.

The selected Enter the message again using a smaller

font is too big. font, if possible.

No Time for The printer is No phase 1. Observe Diagnostics Screen One. Note
TOF unable to profile. the Phase Profile.
acquire an 2. If phase profile is not present (all
actual velocity zeroes), allow the printer to adjust the
and thus cannot phase threshold to attempt and acquire a
perform TOF phase profile.
velocity control. 3. If the phase threshold is reduced to the
minimum value and a phase profile still
has not been acquired, see causes and
perform actions under “Phase Threshold
Error” on page 9-16".

The printer is 1. Observe Diagnostics Screen One. Note

unable to set the Phase Profile.
the modulation 2. If the phase profile is erratic (1's and 0's
automatically. present, but randomly), the modulation
value acquired automatically by the
printer may be erroneous.
3. Perform a visual inspection of the
printhead to confirm incorrect modulation
value.
4. Attempt to manually set the modulation
to restore break-off; monitor diagnostics
screen to assess status of automated
controls.
5. If modulation cannot be restored
manually, see causes and actions under
“Phase Threshold Error” on page 9-16.

Table 9-8: Warning Icons

Rev AC Printer Status Icons 9-29

Videojet 1210/1510 Service Manual

Warning Reason Causes Action

Overspeed The message The current line 1. Reduce the line speed.
cannot be speed is too 2. If the encoder source is Internal, adjust
printed at the fast. the width to obtain the desired
required width characters per inch.

The current 1. Increase the width setting.

width setting is 2. Test the print to see if the warning
too low. condition gets cleared.

The max 1. Edit the current message; examine the

printed dots max printed dots parameter.
parameter is 2. Reduce the max printed dots to the
too high minimum allowable value.

The selected Create a new message - use a smaller font

font is too if this is feasible. Ensure that the max
large. printed dots is set to the minimum allowable
value.

Maximum Current print go

Print Rate received less
Exceeded than one
millisecond from
last print go

No Valid Ink Ink core module

Parameters not programmed
or invalid values
in smart chip

Possible Ink Ink cartridge

Coefficient coefficients do
Update not match ink
core module
coefficients

USB External USB Defective, or Use a different USB flash drive.

Connection device drawing improper USB
Is Over excessive flash drive.
Current current

Suspected Heater set to

Head Heater 100% for more
Failure than one minute
to achieve set
temperature.

Table 9-8: Warning Icons

9-30 Printer Status Icons Rev AC

 Videojet 1210/1510 Service Manual

Warning Reason Causes Action

Creating Software busy.

Raster Raster being
Catalog replaced.
Cannot print.

Bad Nozzle!!! Nozzle taking

Please excessive
Replace Or current -
Repair possible short
circuit.

Tank Not Ink core module

Filling still LOW after 5
attempts to add
ink to increase
the level.

DAC Charge DAC not

Overflow operating
correctly - CSB
hardware fault.

DAC Comms Charge DAC not

Error operating
correctly - CSB
hardware fault.

Tuning Nozzle tuning is Modulation Enable Auto tuning.

Required required and the voltage about
Auto Tuning to adjust itself
function is outside the
disabled. control range
(0 - 200 VAC)

TOF Warning The Actual Erroneous TOF Clean and dry the printhead.
Velocity measurement.
deviates from
the Velocity Set Nozzle partially Perform a nozzle backflush.
Point by +/- 1%. obstructed.

Improper See actions above for “The printer is unable

modulation to set the modulation automatically.” on
setting. page 9-29.

Pump or See causes and actions described in

pressure “Pressure Too Low” on page 9-20.
problem.

Table 9-8: Warning Icons

Rev AC Printer Status Icons 9-31

Videojet 1210/1510 Service Manual

Warning Reason Causes Action

Service Due Printer requires The life of ink Replace the ink core module (refer to “Ink
servicing. core module is Core Module” on page 7-21).
over.

Valve error 1. Run a Valve Test and a Hardware Self

Test to determine which valve is
defective.
2. If a valve (or valves) is not functioning,
check electrical connections. Attempt to
clear any clogged valves.
3. If all the valves are functioning, check
CSB test points related to valves to
identify potential electrical issues. They
are: TP 1 through TP16, TP30, and
TP68 (refer to “CSB Test Points” on
page 9-38).

Table 9-8: Warning Icons

9-32 Printer Status Icons Rev AC

 Videojet 1210/1510 Service Manual

Voltage Checks
Table 9-9 is a representation of the power connector with the voltages
shown for each pin. Use Pin 2 as the 0 V reference.

Power
Connector

Figure 9-2: CSB Power Connectors

Note: Allow ± 5% tolerance on all voltages except -24V which is allowed at

±10% tolerance. The power connector must be connected to the CSB to carry out
this check.

PIN 4 PIN 8
-15V -24V

PIN 3 PIN 7
+5 V 0V

PIN 2 PIN 6
0V +24 V

PIN 1 PIN 5
+15 V +5 V

Table 9-9: CSB Power Connector Voltage Check

Rev AC Voltage Checks 9-33

Videojet 1210/1510 Service Manual

Jet Start and Stop Diagnostics

Use the following flow charts to diagnose problems that occur because of
dirty inkjet starts and stops.

Quick Start Diagnostics

Visually inspect
nozzle alignment

print engine
and l

when the ink valve

I I
l
l l
I I l
l

Figure 9-3: Quick Start Diagnostics Flowchart

9-34 Jet Start and Stop Diagnostics Rev AC

 Videojet 1210/1510 Service Manual

Clean Start Diagnostics

l l

l
l
make-up l l
l

Clean the make-up Replace the PH

valve in the PH valve module

I
l l I
I I
l l Back flush the nozzle
I

System flush prime

Refer to........

Sheet 1

Rev AC Jet Start and Stop Diagnostics 9-35

Videojet 1210/1510 Service Manual

I
l
print engine

No

Is Break-up Yes
Back flush the nozzle Symmetrical Go to sheet 1

Is the ink No
drawn into the
l
gutter

Yes

I ll
l
print engine

Sheet 2
Figure 9-4: Clean Start Diagnostic Flowchart

9-36 Jet Start and Stop Diagnostics Rev AC

 Videojet 1210/1510 Service Manual

Clean Stop Diagnostic

l l

l
I l l l
l
l

make-up?

l l
l
l
l

Flush the nozzle valve

I
ll l

PH valve module

Figure 9-5: Clean Stop Diagnostics

Rev AC Jet Start and Stop Diagnostics 9-37

Videojet 1210/1510 Service Manual

CSB Test Points

Figure 9-6: Test Points 1 to 16

9-38 CSB Test Points Rev AC

 Videojet 1210/1510 Service Manual

The CSB test points are described in Table 9-10.

Test Name Test Equip- Measurement

Point ment Required

TP1 Valve Control Voltmeter Measure the voltage at TP1.

Common The voltmeter must read approximately 5 VDC.

TP3 Valve 0 (Make- Voltmeter Measure the voltage at TP3.

up add valve • A reading > 4 VDC indicates that the valve is
monitor (VM)) currently de-energized (shut).
• A reading < 1 VDC indicates that the valve is
currently energized (open).

TP4 Valve 1 (Jet Voltmeter Measure the voltage at TP4.

pump #2 valve • A reading > 4 VDC indicates that the valve is
monitor (VT)) currently de-energized (shut).
• A reading < 1 VDC indicates that the valve is
currently energized (open).

TP5 Valve 2 (Jet Voltmeter Measure the voltage at TP5.

pump #1 valve • A reading > 4 VDC indicates that the valve is
monitor (VJ)) currently de-energized (shut).
• A reading < 1 VDC indicates that the valve is
currently energized (open).

TP6 Valve 3 (Flush Voltmeter Measure the voltage at TP6.

Pump Vacuum • A reading > 4 VDC indicates that the valve is
Valve Monitor currently de-energized (shut).
(VV)) • A reading < 1 VDC indicates that the valve is
currently energized (open).

TP7 Valve 4 (Flush Voltmeter Measure the voltage at TP7.

pump pressure • A reading > 4 VDC indicates that the valve is
valve monitor currently de-energized (shut).
(VR)) • A reading < 1 VDC indicates that the valve is
currently energized (open).

TP8 Valve 5 (Ink Add Voltmeter Measure the voltage at TP8.

Valve Monitor • A reading > 4 VDC indicates that the valve is
(VI)) currently de-energized (shut).
• A reading < 1 VDC indicates that the valve is
currently energized (open).

TP9 Valve 6 (Head Voltmeter Measure the voltage at TP9.

feed valve • A reading > 4 VDC indicates that the valve is
monitor (VF)) currently de-energized (shut).
• A reading < 1 VDC indicates that the valve is
currently energized (open).

TP10 Valve 7 (Head Voltmeter Measure the voltage at TP10.

flush valve • A reading > 4 VDC indicates that the valve is
monitor (VL)) currently de-energized (shut).
• A reading < 1 VDC indicates that the valve is
currently energized (open).

Table 9-10: CSB Test Points

Rev AC CSB Test Points 9-39

Videojet 1210/1510 Service Manual

Test Name Test Equip- Measurement

Point ment Required

TP11 Valve 8 (Head Voltmeter Measure the voltage at TP11.

gutter valve • A reading > 4 VDC indicates that the valve is
monitor (VG)) currently de-energized (shut).
• A reading < 1 VDC indicates that the valve is
currently energized (open).

TP12 Valve 9 (Head Voltmeter Measure the voltage at TP12.

purge valve • A reading > 4 VDC indicates that the valve is
monitor (VP)) currently de-energized (shut).
• A reading < 1 VDC indicates that the valve is
currently energized (open).

TP13 Valve 10 Voltmeter Measure the voltage at TP13.

(Solvent • A reading > 4 VDC indicates that the valve is
Recovery Valve currently de-energized (shut).
Monitor (VS)) • A reading < 1 VDC indicates that the valve is
currently energized (open).

TP14 Valve 11 Voltmeter Measure the voltage at TP14.

(Commissioning • A reading > 4 VDC indicates that the valve is
Valve Monitor currently de-energized (shut).
(VC)) • A reading < 1 VDC indicates that the valve is
currently energized (open).

TP15 Valve 12 - Not used

TP16 Valve 13 - Not used

Table 9-10: CSB Test Points (Continued)

9-40 CSB Test Points Rev AC

 Videojet 1210/1510 Service Manual

Figure 9-7: Test Point 17, 18, 19, and 63

Test Name Test Equipment Measurement

Point Required

TP17 Photocell one Voltmeter Used to determine the active state of photocell.
Block the photocell with a product and measure
the voltage at TP17.
• A reading > 3 VDC indicates that the
photocell is ACTIVE HIGH.
• A reading < 0.5VDC indicates that the
photocell is ACTIVE LOW.

Table 9-11: CSB Test Points

Rev AC CSB Test Points 9-41

Videojet 1210/1510 Service Manual

Test Name Test Equipment Measurement

Point Required

TP18 Shaft encoder Oscilloscope Used to verify if the shaft encoder is supplying
one pulses to the printer.
1. Make sure that the encoder is connected to
the printer and start the conveyor.
2. Measure the signal at TP18. The following
output is considered to be good.

TP19 Shaft encoder Oscilloscope Used to verify if the shaft encoder is supplying
two pulses to the printer.
1. Make sure that the encoder is connected to
the printer and start the conveyor.
2. Measure the signal at TP19.
Note: A signal will be present only if a
quadrature (two-phase) encoder is in use.

Table 9-11: CSB Test Points (Continued)

9-42 CSB Test Points Rev AC

 Videojet 1210/1510 Service Manual

Figure 9-8: Test Point 20 and 21

Test Name Test Equipment Measurement

Point Required

TP20 Pump tacho Oscilloscope Used to verify if the ink pump is working when
the ink pump is energized.
The following output is considered to be good.

TP21 Pump set Voltmeter Used to verify the analog signal provided by the
point FPGA to the pump driver circuit, to set the
target pressure. 1 bar = 0.28 VDC.

TP22 Pump Voltmeter Measure the voltage at TP22 with a voltmeter.

enable A reading of 3.3 VDC indicates that the CSB is
providing an ON signal to the pump motor
driver.

Table 9-12: CSB Test Points

Rev AC CSB Test Points 9-43

Videojet 1210/1510 Service Manual

Test Name Test Equipment Measurement

Point Required

+5 V 5 VDC Voltmeter Used to verify if the filtered 5 VDC level on the

(TP23) CSB.
Measure the voltage at TP23. Measured
voltage should be +5 VDC.

VCORE FPGA core Voltmeter Used to verify the FPGA core voltage on the
(TP25) voltage CSB. Measure the voltage at TP25. Measured
voltage should be +1.5 VDC.

+12 V +12 VDC Voltmeter Used to verify the regulated +12 VDC produced
ANAL on the CSB. Measure the voltage at TP26.
(TP26) Measured voltage should be +12 VDC.

-12 V -12 VDC Voltmeter Used to verify regulated -12 VDC produced on
(TP27) the CSB. Measure the voltage at TP27.
Measured voltage should be -12 VDC.

+24 V +24 VDC Voltmeter Used to verify unfiltered +24 VDC provided to
(TP28) the CSB from the mains power supply. Measure
the voltage at TP28. Measured voltage should
be +24VDC.

-24 V -24 VDC Voltmeter Used to verify unfiltered -24 VDC provided to
(TP29) the CSB from the mains power supply. Measure
the voltage at TP29. Measured voltage should
be -24VDC.

+22 V 22 V Pump Voltmeter Used to verify 22 VDC produced for the pump
(TP31) driver circuit. Measure the voltage at TP31.
Measured voltage should be 22 VDC.

TP38 Modulation Oscilloscope Used to verify output modulation signal supplied

MOD by the CSB to the nozzle. With inkjet running,
measure the signal at TP38. The following
picture shows a good signal.

Table 9-12: CSB Test Points (Continued)

9-44 CSB Test Points Rev AC

 Videojet 1210/1510 Service Manual

Test Name Test Equipment Measurement

Point Required

TP41 Level probe Voltmeter or Used to verify the common electrical drive signal in
common Oscilloscope the CORE (mixer tank) level detection circuit.
• If a voltmeter is used, the voltage should read
1.6 VDC.
• If an oscilloscope is used, a good signal will
look like the signal shown in the following
figure.

TP42 Level probe Voltmeter or Used to confirm whether the high sensor in the
0 (mixer Oscilloscope mixer tank module is covered or uncovered.
tank high) • If a voltmeter is used and the sensor is
covered, a voltage of 1.6 VDC indicates that
the sensor is uncovered.
• A voltage < 0.7 VDC indicates that the sensor
is covered.
• If an oscilloscope is used, the following signal
indicates that the sensor is uncovered.

Table 9-13: CSB Test Points

Rev AC CSB Test Points 9-45

Videojet 1210/1510 Service Manual

Test Name Test Equipment Measurement

Point Required

TP43 Level probe Voltmeter or Used to confirm whether the middle sensor in the
1 (mixer Oscilloscope mixer tank module is covered or uncovered.
tank middle) • If a voltmeter is used and the sensor is
covered, a voltage of 1.6 VDC indicates that
the sensor is uncovered.
• A voltage < 0.7 VDC indicates that the sensor
is covered.
• If an oscilloscope is used, the following signal
indicates that the sensor is uncovered.

TP44 Level probe Voltmeter or Used to confirm whether the low sensor in the
2 (mixer Oscilloscope mixer tank is covered or uncovered.
tank low) • If a voltmeter is used and the sensor is
covered, a voltage of 1.6 VDC indicates that
the sensor is uncovered.
• A voltage < 0.7 VDC indicates that the sensor
is covered.
• If an oscilloscope is used, the following signal
indicates that the sensor is uncovered.

Table 9-13: CSB Test Points (Continued)

9-46 CSB Test Points Rev AC

 Videojet 1210/1510 Service Manual

Test Name Test Equipment Measurement

Point Required

TP45 Gutter Voltmeter or Used to confirm the status of the gutter detect
sense Oscilloscope circuit.
• If a voltmeter is used and ink is present in the
gutter, voltage should read < 0.7 VDC.
• A voltage of 1.6 VDC indicates that the gutter
detect chamber is empty.
• If an oscilloscope is used, the following signal
is indicates that the gutter detect chamber is
empty.

TP47 Ink Voltmeter Used to verify the electrical output of the pressure
pressure transducer that monitors the ink pump output in the
core. 1 bar = 0.8 VDC.

TP48 Vacuum Voltmeter Used to verify the electrical output of the pressure
VPWR transducer that monitors the vacuum in the make-
up addition system in the core.

Table 9-13: CSB Test Points (Continued)

Rev AC CSB Test Points 9-47

Videojet 1210/1510 Service Manual

Test Name Test Equipment Measurement

Point Required

CHG Charge Amplifier Oscilloscope Use the oscilloscope to measure the signal
(TP51) at TP51.
When the ink stream is ON, and the printer
is not printing, the following signal indicates
that the charge amplifier circuit is
functioning properly.

HEADT Printhead Voltmeter Use the voltmeter to measure the signal at

(TP53) Temperature TP53. This represents the analog output of
the printhead temperature sensor.
0.055 VDC = 1° Celsius.

INKT Ink temperature Voltmeter Use the voltmeter to measure the signal at
(TP54) TP54. This represents the analog output of
the core temperature sensor.
0.055 VDC = 1° Celsius.

TP55 Strobe Oscilloscope Use the oscilloscope to measure the signal

at TP55. This represents the digital signal
used to drive the printhead strobe LED. A
good signal will look as follows.

Table 9-14: CSB Test Points

9-48 CSB Test Points Rev AC

 Videojet 1210/1510 Service Manual

Test Name Test Equipment Measurement

Point Required

TP56 Printhead cover Voltmeter Use the voltmeter to measure the signal at
TP56.
• If the printhead cover is removed, the
measured voltage should be 3.3 VDC.
• If the printhead cover is fitted, the
measured voltage should be < 0.5
VDC.

PHA Phasing Oscilloscope Use the oscilloscope to measure the signal

(TP57) at TP57. This represents the analog signal
being detected by the first TOF sensor in
the printhead. A good signal will look as
follows.

Table 9-14: CSB Test Points (Continued)

Test Name Test Equipment Measurement

Point Required

3V3 3.3 VDC Voltmeter Used to verify the output of the 3.3 VDC
(TP62) voltage regulator (chip U44) on the CSB.
Measure the voltage at TP62. Measured
voltage should be 3.3 VDC.

TP63 Photocell two Voltmeter Used to determine Active state of

photocell #2 (Reverse Print Input).
Block the photocell with a product and
measure the voltage at TP17.
• A reading > 3 VDC indicates that the
photocell is ACTIVE HIGH.
• A reading < 0.5VDC indicates that the
photocell is ACTIVE LOW.

TP68 Valve common Voltmeter Monitor during start-up sequence or valve

monitor test procedure to verify application of hit
voltage by valve driver circuit.

Table 9-15: CSB Test Points

Rev AC CSB Test Points 9-49

Videojet 1210/1510 Service Manual

Test Name Test Equipment Measurement

Point Required

TP69 Velocity Oscilloscope Use the oscilloscope to measure the

VEL signal at TP69. This represents the analog
signal is being detected by the second
TOF sensor in the printhead. A good
signal will look as follows.

Table 9-15: CSB Test Points (Continued)

Test Name Test Equipment Measurement

Point Required

+15 V +15 VDC Voltmeter Used to verify if unfiltered +15 VDC is being
provided to the CSB from the Mains power
supply.
Measure the voltage at +15 V. Measured
voltage should be +15 VDC.

-15 V -15 VDC Voltmeter Used to verify if unfiltered -15 VDC is

provided to the CSB from the Mains power
supply.
Measure the voltage at -15V. Measured
voltage should be -15 VDC.

TP30 V Valve drive hold Voltmeter Used to verify the onboard voltage
HOLD voltage generated and used to hold solenoid valves
open, following actuation. Measure the
voltage at TP30. Measured voltage should
be approximately +6 VDC.

TP72 Charge supply Voltmeter Used to verify the negative output voltage
negative supplied by the charge amplifier supply to
the charge amplifier.
Measure the voltage at TP72. Measured
voltage should be approximately -24 VDC.

Table 9-16: CSB Test Points

9-50 CSB Test Points Rev AC

 Videojet 1210/1510 Service Manual

Test Name Test Equipment Measurement

Point Required

TP2 Hit drive Voltmeter Used to verify that the valve drive circuit is
being supplied with the correct electronic
signal to enable the application of hit voltage
when solenoid valves are actuated.
Measure the voltage at TP2.
• If the measured voltage is +3.3 VDC,
the hit circuit is turned off (this is the
steady-state condition).
• If measured voltage is 0 VDC, the hit
circuit is turned on (indicating that
valves are being opened).

TP76 Voltage Reference Voltmeter Used to measure the positive reference

VREFP Positive voltage provided to the DAC on the CSB.
Measure the voltage at TP76. Measured
voltage should be +4.08 VDC.

TP77 DAC OUTPUT 6 Voltmeter

TP39 Modulation first Oscilloscope This test point allows for the measuring of
stage the first-stage modulation signal at the
output of chip U45. Measure the signal at
TP39 using an oscilloscope. A good signal
will look as follows.

VREFN Voltage reference Voltmeter Used to measure the negative reference

negative voltage provided to the DAC on the CSB.
Measure the voltage at VREFN. Measured
voltage should be -4.08 VDC.

TP71 DAC OUTPUT 7 Voltmeter

MODV Modulation voltage Voltmeter The modulation voltage monitor is an output

monitor of the modulation circuit used by the CSB to
track modulation voltage. Measure the
voltage at MODV. Measured voltage should
be less than 2 VDC, and should change as
the automodulation routine is performed.

Table 9-16: CSB Test Points (Continued)

Rev AC CSB Test Points 9-51

Videojet 1210/1510 Service Manual

Test Name Test Equipment Measurement

Point Required

TP67 Modulation Power Oscilloscope TP67 allows the measuring of the

Amplifier modulation sine wave on the primary side of
Transformer the modulation power amplifier transformer.
Primary Measure the signal at TP67 with an
oscilloscope. A good signal will look as
follows.

TP37 Modulation Power Oscilloscope Same as TP67, except TP37 is located on

Amplifier the opposite side of the transformer.
Transformer Measure the signal at TP37 with an
Primary oscilloscope. A good signal will look as
follows.

TP24 EHT Setpoint Voltmeter Allows the measurement of the signal being
provided to the EHT circuit to establish the
EHT voltage.
Measure the voltage at TP24.
1. A voltage between 0 and +24 VDC will
be measured, depending upon the
current character height.
2. Vary the character height and check to
make sure that the voltage at TP24
varies accordingly.

Table 9-16: CSB Test Points (Continued)

9-52 CSB Test Points Rev AC

 Videojet 1210/1510 Service Manual

Test Name Test Equipment Measurement

Point Required

TP 40 Modulation Current Voltmeter The modulation current monitor is an output

MODI Monitor of the modulation circuit used by the CSB to
track modulation current. Measure the
voltage at TP40. Measured voltage should
be less than 1 VDC, and will change as the
automodulation routine is performed.

TP65 Modulation Data Oscilloscope TP65 allows the monitoring of the data
signal supplied by the FPGA to the
modulation circuit. Measure the signal at
TP65 with an oscilloscope. A good signal
will look like this.

TP66 Modulation Clock Oscilloscope TP66 allows the monitoring of the clock
signal supplied by the FPGA to the
modulation control circuit.
Measure the signal at TP66 with an
oscilloscope. A good signal will look like the
following figure.

Table 9-16: CSB Test Points (Continued)

Rev AC CSB Test Points 9-53

Videojet 1210/1510 Service Manual

Test Name Test Equipment Measurement

Point Required

TP58 Phasing Signal Oscilloscope This test point allows the monitoring of the
Amplified processed phasing signal downstream of
chip U14 on the CSB. Measure the signal at
TP58 with an oscilloscope. A good signal
will look like the following figure.

TP59 Velocity Signal Oscilloscope This test point allows the monitoring of the
Amplified processed velocity signal downstream of
chip U15 on the CSB.
Measure the signal at TP59 with an
oscilloscope. A good signal will look like the
signal shown in the following figure.

Table 9-16: CSB Test Points (Continued)

9-54 CSB Test Points Rev AC

 Videojet 1210/1510 Service Manual

Test Name Test Equipment Measurement

Point Required

TP60 Phasing trigger 'A' Oscilloscope This test point allows the monitoring of the
trigger signal supplied by chip U16 to the
FPGA. Measure the signal at TP60 with an
oscilloscope. A good signal will look like the
following figure.

TP61 Phasing trigger 'B' Oscilloscope This test point allows the monitoring of the
trigger signal supplied by chip U16 to the
FPGA. Measure the signal at TP61 with an
oscilloscope. A good signal looks like the
following figure.

TP50 HV Charge Supply Voltmeter Used to verify the positive output voltage
Positive supplied by the charge amplifier supply to
the charge amplifier. Measure the voltage at
TP50. Measured voltage should be +312
VDC.

Table 9-16: CSB Test Points (Continued)

Rev AC CSB Test Points 9-55

Videojet 1210/1510 Service Manual

Installing DNW
1 When the CSB device is connected to a PC for the first time, you will
be prompted to install drivers. Choose C:\500051\Installers\USB
Driver\secbulk.inf.
2 To configure the software, select Options in the Configuration menu
(see Figure 9-9). The UART/USB Options dialog box appears (see
Figure 9-10 on page 9-56)

Figure 9-9: Configure Menu

3 Change the download address to 0x3020000.

Figure 9-10: UART/USB Dialog Box

4 Click the OK button.

ADC/DAC
This test checks if the ADC device can be accessed and the cabinet
temperature is less than 60 ºC.

9-56 Installing DNW Rev AC

 Videojet 1210/1510 Service Manual

Ancillary
This test does the following:
• Checks a standing current through the beacon current input is in
range.
• Checks the current drawn when switching dummy loads with the
ancillary switch (head heater, cabinet fan, and air pump outputs).
• Checks for fixed voltages on the head temperature [2.47, 2.90] and ink
temperature [1.93, 2.34] sensors.
• Turns the LED strobe off and checks the gutter is dry (square wave
present).
• Turns the LED strobe on and checks the gutter is wet (square wave
not always present).
• Turns VALVEDRIVE_5 off and checks the cover switch is open (input
high).
• Turns VALVEDRIVE_5 on and checks the cover switch is closed
(input low).
• Checks the ink bottle smart chip memory starts with the string “INK”.
• Checks the solvent bottle smart chip memory starts with the string
“SOL”.
• Checks the ink core module smart chip memory starts with the string
“MIX”.
• Checks the CSB smart chip is present.

Charge Amplifier Supply

This test does the following checks:
• Checks that the charge amplifier supply (test point HV+) is initially
about 20 V and the switching FET (Q8) is inactive.
• Turns on the charge amplifier supply (sets a charge scale not equal to
zero) and checks the supply is now about 310 V and the switching FET
is active.

Charge Amplifier
This test does the following checks:
• Writes and reads all bits of the charge DAC to test the interface
between it and the FPGA.
• Sets the charge scale to full (0x3FF would give 409.6 V output, if the
supply were that high).

Rev AC Installing DNW 9-57

Videojet 1210/1510 Service Manual

• Attempts to move the charge output up and down using the charge
and phase offset registers (one bit of charge offset = 0.4 V positive,
phase offset same but negative) until it is within the range ±1 V.
• Checks that increasing the phase offset moves the output negative by
0.4 V.
• Checks that increasing the charge offset moves the output positive by
0.4 V.
• Halves the charge scale.
• Re-establishes the charge output within the range ±1 V.
• Checks that the output moves by 0.2 V when the charge offset is
increased by one bit.

SRAM
This test checks writes sixteen random values to the SRAM at each single
address bit transition (0, 16, 32, 64, 128...) then reads and checks all values
are correct.

EHT
This test does the following:
• Checks for a fixed voltage on EHTVMON [2.41, 3.04].
• Checks for a fixed voltage on EHTIMON [1.83, 2,61].
• Ramps the EHT setpoint into a fixed load and checks the measured
current is correct.

Levels/Pressure/Vacuum
This test does the following:
• Checks for a fixed voltage on the pressure signal [2.15, 2.63].
• Checks for a fixed voltage on the vacuum signal [2.68, 4.10].
• Switches on only VALVEDRIVE_6, 7 and 8 in turn and checks that
only level sensor INK1, 2 then 3 is shorted respectively.

Modulation
This test ramps the modulation into a fixed load and checks the measured
voltage and current are correct.

9-58 Installing DNW Rev AC

 Videojet 1210/1510 Service Manual

Phase Detector
This test does the following:
• Checks for a fixed voltage on the phase detector input [2.75, 3.85].
• Checks for a fixed voltage on the velocity detector input [0.91, 2.15].
• Sweeps the phase and velocity thresholds from below to above these
fixed voltages to check the comparators work.

Pump
This test runs the pump driver (using the RELAY4-6 outputs to emulate
rotation on the Hall sensor inputs) into a dummy load and checks the
current drawn is correct and the TACHO output matches the Hall sensor
inputs.

Valves
Turns on VALVEDRIVE_9 to VALVEDRIVE_13 only in turn and checks
the valve driver current is within range.

DIN Interface
This test does the following:
• Checks for connections between the following beacon drive and PEC/
SENC signals.

Beacon Drive PEC/SENC Signals

Green PEC1

Amber SENC2

Red SENC1

Strobe PEC2

• Checks for connections between the following relays, valves and

message select signals.

VALVEDRIVE_0 MSEL0

VALVEDRIVE_1 MSEL1

VALVEDRIVE_2 MSEL2

VALVEDRIVE_3 MSEL3

Rev AC Installing DNW 9-59

Videojet 1210/1510 Service Manual

VALVEDRIVE_4 MSEL4

RELAY1 MSEL5

RELAY2 MSEL6

RELAY3 MSEL7

• Checks for connections between the following signals.

RELAY1 RELAY7

RELAY2 PELTEMP_D

RELAY3 PELTEMP_C

Manual Tests
This test sets the modulation up as a 250Vpp 76.8kHz sine wave and a
300V high staircase waveform on the charge and prompts the user to
check them on the oscilloscope.
The user is then prompted to turn the board off and check the bleed valve
holdup circuit works by checking the brightness of the bleed LED on the
test box.

9-60 Installing DNW Rev AC

Illustrated Parts List
10
The Illustrated Part List (IPL) contains the illustrations and the parts lists
for the different assemblies in the printer. The parts lists give the part
numbers, description and quantity of all the items and the modules in the
printer. You can order the items and the modules for which the part
numbers are given.

How to Read the IPL

This section describes how the higher assemblies are broken down to their
related sub assemblies and other separate parts.

Illustrations
Table 10-1 on page 10-2 shows the symbols used to indicate the different
levels of main assemblies in a printer, and the sub assemblies under the
main assembly.

Rev AC How to Read the IPL 10-1

Videojet 1210/1510 Service Manual

Assembly Symbol

Main Assembly

Sub Assembly 1

Sub Assembly 2

Sub Assembly 3

Sub Assembly 4

Table 10-1: Symbols Representation - Assemblies

Indicates further explosion.

Alphabets
• An alphabet is assigned to the main assemblies of a printer and each
sub assembly under the main assembly. See Figure 10-1 on page 10-3.
For example: If A, B, C and D identify the main assemblies of a
printer, then the alphabets E,F, and so on identify sub assemblies
below each main assembly in a sequence.
• The alphabets assigned to main assemblies are used only for one time.
• The alphabets “I” and “O” are not used because they look like the
numbers 1 and 0.

10-2 How to Read the IPL Rev AC

 Videojet 1210/1510 Service Manual

Numbers
A natural number (1,2,3.....) is assigned to the stand alone parts (in
ascending order) through out the breakdown of main assemblies. See
Figure 10-1.

Note: The numbers assigned to main assemblies can be used only for one time.

Printer

A B C D

E F 1 E F G E F G 1 2 3

G H J 1 2 3

2 3 4 5
Figure 10-1: Graphical Representation of the Different Subassemblies and Parts

Rev AC How to Read the IPL 10-3

Videojet 1210/1510 Service Manual

Tables
Figure 10-2 describes the styles used to show the explosion of the main
assemblies in parts lists.

Main Assembly

Subassembly 1

Subassembly 2

Parts under the

Subassembly OR
Stand-alone Part

Figure 10-2: Representation of the different Subassemblies and parts

in the Table

Notes
Notes provide useful information. Some examples for note are as follows:
Note: To order this item, use part number of item 9 in this table.

Note: This screw is a part of Core Module.

Note: This item can be ordered separately.

10-4 How to Read the IPL Rev AC

 Videojet 1210/1510 Service Manual

Videojet 1210/1510 Printer

Figure 10-3: Main Parts of the Printer

Table 10-2 shows the sub assemblies of the printer.

Item Descriptions

A Electronics Compartment
B Ink Compartment
C Umbilical
D Printhead
Table 10-2: Videojet 1210/1510 Printer Assemblies

Rev AC Videojet 1210/1510 Printer 10-5

Videojet 1210/1510 Service Manual

Electronics Compartment

A
1510 E 1210

F
View A

1
L
L

View A

H
K
J G

Figure 10-4: Electronics Compartment

10-6 Electronics Compartment Rev AC

 Videojet 1210/1510 Service Manual

Control System Board

Figure 10-5: Control System Board Assembly

Power Switch

2
Figure 10-6: Power Switch

Rev AC Electronics Compartment 10-7

Videojet 1210/1510 Service Manual

Electronics Door Assembly

E M

N 6
3
4
5 7
8
9

10

11

12

Figure 10-7: Electronics Door Assembly

Display Door

Figure 10-8: Display Door

10-8 Electronics Compartment Rev AC

 Videojet 1210/1510 Service Manual

LCD and FIB Assembly

13

N
14

Figure 10-9: LCD and FIB

Power Supply Unit Assembly

F 15

16
17
18

19

Figure 10-10: Power Supply Unit Assembly

Rev AC Electronics Compartment 10-9

Videojet 1210/1510 Service Manual

Printer Interface Board Assembly

G 20

21

22

23

Figure 10-11: Printer Interface Board Assembly

10-10 Electronics Compartment Rev AC

 Videojet 1210/1510 Service Manual

Electronics Fan Assembly

H
24

25
26

27

28

29

Figure 10-12: Electronics Fan Assembly

Positive Air Pump Assembly (Optional for 1210)

J
30

31

32
Figure 10-13: Positive Air Pump Assembly

Rev AC Electronics Compartment 10-11

Videojet 1210/1510 Service Manual

EHT Module

K
33

34

Figure 10-14: EHT Module

Connector Panel

L
1510

35 1210

36

37

39 38

Figure 10-15: Connector Panel

10-12 Electronics Compartment Rev AC

 Videojet 1210/1510 Service Manual

PCB 2 Assembly (Option for Videojet 1210)

36

Figure 10-16: PCB 2 Assembly

PCB 1 Assembly (Option for Videojet 1210)

37

Figure 10-17: PCB 1 Assembly

Rev AC Electronics Compartment 10-13

Videojet 1210/1510 Service Manual

Item Number P/N Description Qty

A Electronics Compartment

1 SP500074 Control System Board (CSB) 1

(Videojet 1510)
2 219041 Power Switch 1

E Electronics Door Assembly

3 Membrane Ground Wire 1

4 M4 Nyloc Nut 1
5 M4 ET Washer 2
6 Display Ground Wire 1
7 Display Rear Cover 1
8 Display Ribbon Connector Clamp 1
9 M4 ET Washer 2
10 M4 x 8 Cap-head Screw 2
11 M4 x 10 Cap-head Screw 1
12 K40 x 10 Pan-head Torx Screw 4

M 399116 to 399129 Display Door with Keypad

(Videojet 1510) (See Table 10-4 on page 10-16 for part
numbers of different languages)

N 399091 Liquid Crystal Display and Front Panel

Interface Board Assembly
13 K40 x 10 Pan-head Torx Screw 4
14 LCD and FIB Assembly 1

F 399077 Power Supply Unit (PSU)

15 PSU 1
16 PSU Mounting Plate 1
17 M3 ET Washer 4
18 M3 x 5 Cap-head Screw 4
Table 10-3: Electronics Compartment

10-14 Electronics Compartment Rev AC

 Videojet 1210/1510 Service Manual

Item Number P/N Description Qty

19 M4 Nyloc Nut 2
6

G 399078 Printer Interface Board (PIB) Assembly

20 M4 x 8 Cap-head Screw 6
21 M4 ET Washer 6
22 PIB 1
23 PIB Gasket 1

H 399079 Electronics Fan Assembly

24 Fan, 60 mm 1
25 M4 ET Washer 2
26 M4 x 10 Cap-head Screw 2
27 Finger guard, 60 mm 1
28 M4 Nyloc Nut 2
29 M4 x 16 Counter Sunk Screw 2

J 500084 Positive Air Pump Assembly

Note: Available only in Videojet 1510
printers as Standard.
30 Positive Air Pump 1
31 P-Clip 1
32 M4 Nyloc Nut 2

K 399081 EHT Module Assembly

33 M4 Nyloc Nut 2
34 EHT Module 1

L Connector Panel

35 SP500096 PCB 3 Assembly (Optional for Videojet 1

(Videojet 1510) 1510)
36 SP500097 PCB 2 Assembly (Standard for Videojet 1510 1
and optional for Videojet 1210)
PCB 1 Assembly (Standard for Videojet 1510
and optional for Videojet 1210)
Table 10-3: Electronics Compartment (Continued)

Rev AC Electronics Compartment 10-15

Videojet 1210/1510 Service Manual

Item Number P/N Description Qty

37 SP500095 PCB 1 Assembly (Videojet 1510) 1

(Videojet 1510)
SP500098 PCB 0 Assembly (Videojet 1210)
(Videojet 1210)
38 399084 USB Connector 1
39 399083 Ethernet Connector (Videojet 1510) 1
Table 10-3: Electronics Compartment (Continued)

Display Door with Keypad in Different Languages

Part Number Display Door with Keypad

399116 Display door with keypad English

399117 Display door with keypad European
399118 Display door with keypad Chinese
399119 Display door with keypad Turkish
399120 Display door with keypad Russian
399121 Display door with keypad Polish
399122 Display door with keypad Korean
399123 Display door with keypad Greek
399124 Display door with keypad Katakana
399125 Display door with keypad Bulgarian
399126 Display door with keypad Czech
399127 Display door with keypad Arabic
399128 Display door with keypad Hebrew
399129 Display door with keypad Thai
Table 10-4: Display Door with Keypad

10-16 Electronics Compartment Rev AC

 Videojet 1210/1510 Service Manual

Ink Compartment

F
Figure 10-18: Ink System

Ink Cartridge

Figure 10-19: Ink Cartridge

Rev AC Ink Compartment 10-17

Videojet 1210/1510 Service Manual

Make-up Cartridge

Figure 10-20: Make-up Cartridge

Ink Door Assembly

Figure 10-21: Ink Door Assembly

10-18 Ink Compartment Rev AC

 Videojet 1210/1510 Service Manual

Septum Assembly

N
10
9
8

6
5
4

Figure 10-22: Septum Assembly

Rev AC Ink Compartment 10-19

Videojet 1210/1510 Service Manual

Ink Core Module Assembly

12
F 11

Figure 10-23: Core Module

10-20 Ink Compartment Rev AC

 Videojet 1210/1510 Service Manual

Ink Core Pump

L 13

14

15

Figure 10-24: Ink Core Pump Assembly

M
19
18
17
16

Figure 10-25: Ink Core Module Without Pump

Rev AC Ink Compartment 10-21

Videojet 1210/1510 Service Manual

Gutter Pump Assembly

20

21

Figure 10-26: Gutter Pump Assembly

Ink System Fan

H
22

23

24

25

Figure 10-27: Ink System Fan Assembly

10-22 Ink Compartment Rev AC

 Videojet 1210/1510 Service Manual

Ink System Filter Assembly - IP65 (Optional for Videojet 1510

and 1510 E)

26

27

Figure 10-28: Ink System Filter Assembly - IP65

Ink System Filter Assembly - IP55

J
28

29

Figure 10-29: Ink System Filter Assembly - IP55

Rev AC Ink Compartment 10-23

Videojet 1210/1510 Service Manual

Floor Filter IP65 (Optional for Videojet 1510 and 1510 E)

K 30

31

32

33

34

35

Figure 10-30: Floor Filter IP65

10-24 Ink Compartment Rev AC

 Videojet 1210/1510 Service Manual

Floor Filter IP55

K 36

37

38

39
40

Figure 10-31: Floor Filter IP55

Vent Recovery System

41

Figure 10-32: Vent Recovery System

Rev AC Ink Compartment 10-25

Videojet 1210/1510 Service Manual

Item Number P/N Description Qty

1 Ink Cartridge 1
2 Make-up Cartridge 1

E 399071 Ink Door Assembly

3 Hinge Pin 1

N 399073 Septum Assembly

4 K30 x 12 Pan-head Torx Screw 2

5 M3 ET Washer 2
6 Tube and Ribbon Cable Clamp 1
7 K30 x 8 Pan-head Torx Screw 6
8 Black Stripe Tube (Ink System) 1
9 Septum 2
10 Green Stripe Tube (Make-up System) 1

F 399069 Ink Core with Pump

11 Ink Core Pump Cover 1

12 K30 x 12 Pan-head Torx Screw 2

L 399076 (Videojet 1510 Ink Core Pump

and 1510E)
399306 (Videojet 1210)
13 M4 x 35 Cap-head Screw 2
14 Saddle Clamp 1
15 Ink Core Pump 1

M 399070(Videojet 1510 Ink Core Module without Pump

and 1510E)
399307 (Videojet 1210)
16 M3 x 7 Manifold Screw 2
17 Ink Core Manifold (Male) 1
18 Ink Core Manifold Gasket 1
19 Ink Core Manifold (Female) 1
Table 10-5: Ink Compartment

10-26 Ink Compartment Rev AC

 Videojet 1210/1510 Service Manual

Item Number P/N Description Qty

G 399171 Gutter Pump Assembly

20 M4 Nyloc Nut 2
21 Gutter Pump and Valve 1

H 399080 Ink System Fan Assembly

22 M4 ET Washer 4
23 M4 x 10 Cap-head Screw 4
24 Fan 1
25 Fan Guard 1

J Ink System Filter Assembly

399238 IP65 (Optional for 1510)

26 234502 Filter Element 1
27 SP399195 Filter Cover 1
399239 IP55
28 Filter Element 1
29 SP399029 Filter Cover 1

K Floor Filter Assembly

Refer to Ink System IP65 (Optional for 1510)

Filter Assembly - IP65
30 M4 x 40 Cap-head Screw 4
31 Ink Core Support Channel 1
32 M4 x 8 Cap-head Screw 6
33 Filter Clamp 1
34 234496 Filter Element 1
35 Drip Tray 1
Refer to Ink System IP55
Filter Assembly - IP55
36 M4 x 40 Cap-head Screw 4
37 Ink Core Support Channel 1
Table 10-5: Ink Compartment

Rev AC Ink Compartment 10-27

Videojet 1210/1510 Service Manual

Item Number P/N Description Qty

38 Ink Side Filter Top 1

39 Ink Side Filter Base 1
40 Filter Element 1
41 399281 Vent Recovery System 1
Table 10-5: Ink Compartment

Printhead

D E

Figure 10-33: Printhead

10-28 Printhead Rev AC

 Videojet 1210/1510 Service Manual

Printhead Valve Module

E
2

7 4

Figure 10-34: Printhead Valve Module

Rev AC Printhead 10-29

Videojet 1210/1510 Service Manual

Print Engine

8
F
9

10
11
15

14

12

13

Figure 10-35: Print Engine

Item Number P/N Description Qty

D Printhead

E 399181 Printhead Valve Module

1 M2 x 6 Cap-head Screw 9

2 Gutter Valve 1

3 Printhead Valve Module Deck 1

4 Printhead Valve Module Gasket 1

5 Feed Valve 1

6 Rear Manifold Gasket 1

7 3 Way Manifold Assembly (Rear Tubing 1

Manifold)

F 399180 Print Engine

Table 10-6: Printhead Assembly

10-30 Printhead Rev AC

 Videojet 1210/1510 Service Manual

Item Number P/N Description Qty

8 M2 x 6 Cap-head Screw 8

9 Nozzle Assembly 1

10 Charge Electrode 1

11 Deflector Plate 1

12 Print Engine Deck 1

13 Print Engine Gasket 1

14 Front Tubing Manifold Gasket 1

15 2 Way Manifold Assembly (Front Tubing 1

Manifold)

Table 10-6: Printhead Assembly

Cables
3

Figure 10-36: Cables

Item Number P/N Description Qty

1 500072 Ribbon Cable Assembly Display 1

2 399052 Ribbon Cable Assembly Smart Chip and Pump 14 Way 1

3 500078 50 Way Ribbon Cables 3

Table 10-7: Cables

Rev AC Cables 10-31

Videojet 1210/1510 Service Manual

Optional Accessories

Beacon Kit

Figure 10-37: Beacon Kit

10-32 Optional Accessories Rev AC

 Videojet 1210/1510 Service Manual

Dry Air Kit Assembly

4
5
6

Figure 10-38: Dry Air Kit Assembly

Rev AC Optional Accessories 10-33

Videojet 1210/1510 Service Manual

Static Stand

9
10
11
12

13
14
15

16

17

18

19
20
21
22
23

Figure 10-39: Static Stand

10-34 Optional Accessories Rev AC

 Videojet 1210/1510 Service Manual

Mobile Stand

24

25
26
27

28
37

36

35

29

30

31

32
33
34

Figure 10-40: Mobile Stand

Rev AC Optional Accessories 10-35

Videojet 1210/1510 Service Manual

Printhead Stand

38

39

49
40

41

42
43
44
48 45

47
46
Figure 10-41: Printhead Stand

Printhead Holder

50

Figure 10-42: Printhead Photocell Holder - 8 mm

10-36 Optional Accessories Rev AC

 Videojet 1210/1510 Service Manual

51

Figure 10-43: Printhead Photocell Holder - 18 mm

Mounts to Printhead Holder

52

Figure 10-44: Mounts to Printhead Photocell Holder -8 mm

53

Figure 10-45: Mounts to Printhead Photocell Holder - 18mm

Rev AC Optional Accessories 10-37

Videojet 1210/1510 Service Manual

Printer Wall Mount

54

55

56

57
Figure 10-46: Printer Wall Mount

10-38 Optional Accessories Rev AC

 Videojet 1210/1510 Service Manual

Wash Station Assembly

58

59

Figure 10-47: Wash Station Assembly

Shaft Encoder

Figure 10-48: Shaft Encoder

Rev AC Optional Accessories 10-39

Videojet 1210/1510 Service Manual

Shaft Encoder Accessories

61

Figure 10-49: Circular Wheel

62

Figure 10-50: Shaft Cable

Figure 10-51: Spring Bracket

Product Detectors

Figure 10-52: Detector EZ

10-40 Optional Accessories Rev AC

 Videojet 1210/1510 Service Manual

Figure 10-53: Detector Retro Smart

Figure 10-54: Detector Label Eye

Power Accessories

Figure 10-55: Power Conditioner

Rev AC Optional Accessories 10-41

Videojet 1210/1510 Service Manual

Figure 10-56: Uninterrupted Power Supply

Power Cord

70
Figure 10-57: Power Cord

10-42 Optional Accessories Rev AC

 Videojet 1210/1510 Service Manual

Din Plugs

Figure 10-58: 3 Way DIN Plug

Figure 10-59: 7 Way DIN Plug

Rev AC Optional Accessories 10-43

Videojet 1210/1510 Service Manual

Item Number P/N Description Qty

399089 Beacon Assembly

1 Beacon 1

2 M4x10 Socket-head Cap Screw 3

3 Beacon Mounting Bracket 1

399090 Stealth Air Dryer Assembly

4 Stealth Air Dryer Mounting Bracket 1

5 M4 Nylon Washers 2

6 M4 x 10 Socket-head Cap Screw 3

7 Stealth Air Dryer 1

8 1/4 inch-20 x 1 inch Socket-head Screw 2

399099 Static Stand

9 M6 x 16 Long Flat Socket-head Screw 4

10 234116 Adapter Plate 1

11 M5 Flat Washers 4

12 M5 Spring Lock Washers 4

13 M5 x 20 Long Socket-head Screw for IP55 Print- 4

ers (or) M5 x 30 Long Socket-head Screw for
IP65 printers

14 Column Top Plate 1

15 M6 Flat Washer 4

16 M6 Spring Lock Washer 4

17 M6 Hex Nut 4

18 Column 1

19 Cap-head Hex Screw, 1/4” x 20 UNC x 0.625 4

20 Flat Washer 4

21 Column Bottom Plate 1

22 Floor Plate 1

Table 10-8: Accessories

10-44 Optional Accessories Rev AC

 Videojet 1210/1510 Service Manual

Item Number P/N Description Qty

23 3/8” - 16 Flat Point Socket-head, 1” Long 4

399100 Mobile Stand

24 M6 x 16 Long Flat Socket-head Screw 4

25 234116 Adapter Plate 1

26 M5 Flat Washer 4

27 M5 Spring Lock Washer 4

28 M5 x 20 Long Socket-head Screw for IP55 Print- 4

ers (or) M5 x 30 Long Socket-head Screw for
IP65 Printers

29 Column 1

30 Acorn Hex Nut 2

31 Flat Washer 4

32 Castors 4

33 Legs 2

34 Hex-head Bolt 2

35 M6 Hex Nut 4

36 M6 Spring Lock Washer 4

37 M6 Plain Washer 4

399086 Printhead Stand

38 Clamp Assembly 1

39 Vertical Tube 1

40 Printhead Cross Tube 1

41 Printhead Mount Assembly 1

42 M6 x 8 Grub Screw 2

43 M10 Nut 8

44 M10 Washer 8

45 Stand Base Plate 1

46 M16 X 40 Hex Bolt 1

47 Adjustable Foot 4

Table 10-8: Accessories (Continued)

Rev AC Optional Accessories 10-45

Videojet 1210/1510 Service Manual

Item Number P/N Description Qty

48 399093 Anti-vibration Mounting 4

49 Umbilical Clamp Assembly 1

50 399248 Printhead Photocell Holder 8 mm 1

51 399278 Printhead Photocell Holder 18 mm 1

52 399293 Printhead Mount Photocell Holder 8mm 1

53 399294 Printhead Mount Photocell Holder 18mm 1

399201 Printer Wall Mount (Stainless Steel)

54 Wall Mounting Stand 1

55 Stand Cups 4

56 Clamp Washer 4

57 M5 x 30 Socket-head Screw or M5 x 20 Socket- 4

head Screw

58 399085 Wash Station Assembly 1

59 301-0007-005 Empty 1 Liter Bottle 1

60 Shaft Encoder

Encoders

41000255 2500 PPR 1

377530 3600 PPR (use with 21000217) 1

41000256 5000 PPR 1

Encoder Kits

378815 1800 PPR kit (encoder, 25ft cable) 1

40331750 2500 PPR kit (encoder, mounting bracket, wheel) 1

378821 3600 PPR kit (encoder, 25ft cable) 1

80200266 5000 PPR kit (encoder, mounting bracket, wheel) 1

61 21000217 12 inch Circular Wheel 1

377529 12 inch Circular Wheel (With replaceable ring) 1

377523 Replaceable ring for part 377529 1

Table 10-8: Accessories (Continued)

10-46 Optional Accessories Rev AC

 Videojet 1210/1510 Service Manual

Item Number P/N Description Qty

62 378192 3 m Shaft Cable 1

378193 6 m Shaft Cable 1

378985 Encoder Adapter Cable (1210/1510) 1

63 377519 Spring Bracket 1

64 234211 Detector EZ-Pro Proximity Fiber 1

234212 Detector EZ-Pro Through Beam fiber 1

65 234215 Detector Retro Smart (Clear Materials) 1

66 234213 Detector Label Eye (Web Printing) 1

234214 Detector Mark Eye (Web Registration Mark) 1

67* 378981 Product Detector Adapter Cable (1210/1510) 1

68 356841-02 120 V Power Conditioner 1

234597 240 V Power Conditioner 1

69 80000008 Uninterrupted Power Supply (240 V Version) 1

70 Power Cord 1
(Refer to Table 10-9 on page 10-48)

71 500-0036-578 3 Way DIN Plug (Photo Cell) 1

72 500-0036-583 7 Way DIN Plug (Relays) 1

73* 500-0036-577 6 Way DIN Plug (Alert Beacon) 1

74* 500-0036-581 4 Way DIN Plug (Shaft Encoder) 1

75* 500-0036-584 8 Way DIN Plug (Message Select A/B) 1

76* 500-0076-141 DIN Plug Dust Cap 1

77* 399133 Exhaust Kit 1

78* 399093 Anti Vibration Kit Stand 1

79* 399068 Printhead Mounting Universal 1

Table 10-8: Accessories (Continued)

*- Items are not shown in the figure

Rev AC Optional Accessories 10-47

Videojet 1210/1510 Service Manual

Power Cord
Part Number Description

SP399205 Mains Power Cable EUROPEAN

SP399204 Mains Power Cable US CAN
399251 US 120V Molded Plug Power Cord (Type B)
399252 European Union Molded Plug Power Cord (Type F)
399253 Danish Molded Plug Power Cord (Type K)
399254 Italian Molded Plug Power Cord (Type C)
399255 Swiss Molded Plug Power Cord (Type J)
399256 UK Molded Plug Power Cord (Type G)
399257 China Molded Plug Power Cord (Type I)
399258 India Molded Plug Power Cord (Type D)
399261 Swedish Molded Plug Power Cord
399262 Finnish Molded Plug Power Cord
399263 Norwegian Molded Plug Power Cord
Table 10-9: Power Cord

Miscellaneous Accessories

Connectivity

Part Number Description

399186 Extension Cables 3 m RS485

399062 Extension Cables 6 m RS232
399279 Lampstack Extension Cable Beacon 6m
223213 External Ethernet Connector Cable 5 m
SP399083 Ethernet Connector Kit Spares
Table 10-10: Connectivity

10-48 Miscellaneous Accessories Rev AC

 Videojet 1210/1510 Service Manual

Part Number Description

SP399084 USB Connector Kit Spares

Table 10-10: Connectivity

Hydraulics

Part Number Description

399071 Ink Door Spare

399171 Gutter Pump Spare
399072 Tubing kit Spare
Table 10-11: Hydraulics

Printhead and Umbilical

Part Number Description

399173 Printhead and Umbilical Complete (3 m) (Standard for

Videojet 1510 and optional for Videojet 1210)
399175 Printhead and Umbilical Complete (6 m) (For Videojet
1510)
399172 Printhead and Conduit Complete (2 m, 70 microns)
(For Videojet 1210)
399178 Printhead Chassis and Umbilical (3 m) (Standard for
Videojet 1510 and optional for Videojet 1210)
399179 Printhead Chassis and Umbilical (6 m) (Standard for
Videojet 1510 and 1510E)
399177 Printhead Chassis Assembly (2 m) (Standard for
Videojet 1210)
399182 Printhead Sleeve and Screw
223277 Printhead Screw Only
Table 10-12: Printhead and Umbilical

Rev AC Miscellaneous Accessories 10-49

Videojet 1210/1510 Service Manual

Tools Kit
There are several tools in the tool kit for normal maintenance of the
printer.

The Service Tool Kit (TL399250)

Table 10-13 lists the tool kit items and their part numbers.

Part Number Description

234639 Allen/Hex Key, 0.035 inch, Set of 5

234638 M4 Nut Spinner (7mm)

234642 Ball Driver 2mm

234643 Ball Driver 2.5mm

234644 Ball Driver 3mm

234645 Ball Driver 4mm

234650 Side Cutters

234640 Allen/Hex Key 1.27mm, Set of 5

234641 Allen/Hex Key 1.5mm, Set of 5

234651 Folding Knife

234652 Knife Blades

234653 Spanner/Wrench 7mm

234654 Spanner/Wrench 1/2 inch

234655 Screwdriver Flat Blade 2.5mm

234657 DIN Spanner/Wrench

234658 Tube Cutter

355269 Loupe Magnifying Glass

234494 USB A to USB A Cable

399280 System Manifold Pressure Test Tool

399247 Nozzle Bypass Manifold Kit

234646 Torx Driver T10

234647 Torx Driver T20

234632 USB Memory Stick 2GB

234638 M4 Nut Spinner (7mm)

234648 No.1 Pozidrive

Table 10-13: TL399250 Tool Kit Parts List

10-50 Tools Kit Rev AC

 Videojet 1210/1510 Service Manual

Part Number Description

234649 No.2 Pozidrive

Table 10-13: TL399250 Tool Kit Parts List (Continued)

Rev AC Tools Kit 10-51

Clean/Quick Start and
Stop Description A
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/stop

Typical dirty
start/stop

Minimum standard
required

Figure A-1: Clean Start/Stop Test Illustrations

Rev AC Clean Start/Stop Standards A-1

Videojet 1210/1510 Service Manual

Clean Start
The Clean Start sequence is as follows:
1 The solvent from the filter is forced through the umbilical connection
into the printhead.
2 At the printhead, the solvent enters the heater manifold and passes
into the main fluid path between the jet valve and the nozzle.
3 The jet starts when the nozzle becomes pressurized by the solvent
flow.
4 If the previous stop was a clean stop, the jet will consist of almost pure
solvent. The flow of solvent quickly removes any ink residues in the
jet orifice.
5 Fluid in the jet is caught by the gutter and directed to the ink core.
6 Once the solvent flows through the jet, the jet valve opens, merging
ink with the solvent.
7 The bleed valve then opens to increase the fluid flow through the
nozzle, removing any trapped air bubbles from the nozzle body.
8 Once the bleed valve opens, the flush pump valve (V7) turns off,
preventing further solvent from being pumped into the nozzle.
9 The flush pump returns to its priming stroke and the non-return
valves in the pump prevent fluid from the printhead returning to the
umbilical connection.
10 Approximately ten seconds after the flush pump turns off, the bleed
valve closes and ink continues to flow through the jet at 4 bar.
11 Modulation is switched on and the ink pressure changes to give the
correct jet velocity.
12 Heater manifold temperature is allowed to reach the correct value
before enabling the phasing checks on the jet.

Quick Start
This method starts without a flushing sequence, and uses the ink supply
to bleed the air from the nozzle.

A-2 Clean Start Rev AC

Clean Stop
The Clean Stop sequence is as follows:
1 Deflector plate voltages are switched off before beginning this
sequence.
2 The ink pressure is set to 4 bar and the modulation voltage switches
off.
3 To increase the ink flow through the nozzle body, the bleed valve
turns on.
4 The flush pump valve turns on applying solvent pressure to the
printhead.
5 Pure solvent is forced through the filter to the printhead, mixing
solvent into the ink stream in the heater manifold.
6 Approximately one second after the solvent starts to mix with the ink,
the feed valve (V6) in the cabinet turns off, removing ink pressure
from the printhead.
7 Ink ceases to flow into the heater manifold and the solvent flushes ink
from the nozzle body.
8 Five seconds later the bleed valve turns off and then turns on again,
introducing solvent into the jet valve, which inhibits the formation of
ink residues when the printer is turned off.
9 The jet valve (on the heater manifold) turns off, ensuring that no ink
diffuses into the solvent. At this point, no ink should be present in the
nozzle body.
10 The gutter valve switches off, increasing the suction on the bleed
system. After a short pause, the bleed valve turns off.
11 After another short pause, the gutter valve turns on to clear any fluid
from the gutter.
12 Once the gutter valve turns off, the main ink pump also turns off.

Quick Stop
Note: This sequence is used to manually stop the jet for a short period, or to
automatically stop the jet during instances like EHT trip and charge error.

This method switches off the ink without flushing the nozzle or manifold.
Hence the manifold and the nozzle are full of ink when the jet stops. The
machine must not be left in this state for long periods, as dry ink in the jet
orifice may make restarting difficult. This procedure is primarily intended

Rev AC Clean Stop A-3

Videojet 1210/1510 Service Manual

for situations where the machine may be stopped and restarted several
times in quick succession. Under these conditions, the use of solvent may
become excessive and cause dilution of the ink.

Nozzle Flush
When nozzle flush is selected, the vacuum from the venturi is applied to
the return side of the nozzle, creating suction at the nozzle orifice. Solvent
is applied to the nozzle orifice to clear any blockage.
Nozzle flush automatically times out after 2 minutes but can be stopped at
any time before that by pressing F1 key Abort Flush.
A nozzle flush can be started with the jet running or stopped. If the jet is
running, selecting nozzle flush will first turn off the feed valve V6 to stop
the flow of ink to the nozzle.

A-4 Nozzle Flush Rev AC

Encoder Information
B
Internal Encoding
Internal encoding is used when product speed is constant. An internal
clock sets the stroke-rate to a constant pace.
Internal encoding is used when the product speed is constant. The internal
clock of the printer is set to the speed of the product in feet per minute
(FPM) or meters per minute (MPM)

Note: Internal encoding is also used when test printing a sample message. For
information on test printing a sample message, refer to Operator Manual.

To use internal encoding, it is necessary to determine the product speed.

This section describes four methods that can be used to determine the
product speed.

Method 1
Use a handheld tachometer that is calibrated to measure linear surface
speed in FPM or measure the revolutions per minute of the pulley.
Convert RPM to surface speed by using the following formula:
Surface speed (FPM) = [Πd x (RPM)]/12
where Π = 3.14 and d = pulley diameter in inches.

Method 2
Establish a reference mark on the conveyor belt and measure how many
inches (one inch equals 25.4 mm) this mark moves in 5 seconds. This
number is equal to the conveyor speed in FPM.

Rev AC Internal Encoding B-1

Videojet 1210/1510 Service Manual

Method 3
If you know the number of products produced per minute on the line, the
size of the product, and the gap between each product, you can calculate
the product speed.
For example:
1200 products per minute are produced on the line, each product is 2.5
inches wide, and there is a one inch gap between each product.
Conveyor speed = [(products per minute) x (size + gap)]/12
where size and gap are in inches.

Method 4
It is also possible to use the printer’s product counter to determine the
number of products per minute, and then calculate the line speed as
described in “Method 3” on page B-2.

External (Reduce Or Direct) Encoding

External encoding is used when the speed of the conveyor varies. A shaft
encoder measures the conveyor speed, and transmits the data to the
printer. This data enables the printer to vary the stroke rate according to
the variation in the speed of the conveyor. Two types of shaft encoders
namely, direct coupled or divided-down can be used:
• A direct shaft encoder maintains a 1:1 ratio between the encoder
pulses and print strokes.
• A divided-down shaft encoder is used when the conveyor speed
requires fewer pulses than the actual output of the shaft encoder.

d = distance of conveyor (product) travel per revolution of shaft

Figure B-1: Product Distance

B-2 External (Reduce Or Direct) Encoding Rev AC

 Videojet 1210/1510 Service Manual

Required shaft encoder:

Pulses per Revolution (PPR) = d x (strokes per inch)
Where strokes per inch = (strokes per character) x (characters per inch)

Example 1
Given information:
d = 23 inches
5 x 7 matrix
10 characters per inch
6 strokes per character
(five printed strokes from the 5 x 7 character, plus one “guard” stroke that
leaves a space between the characters.)
23 inches per revolution x 60 strokes per inch = 1380 PPR

Example 2
If the standard 1800 PPR shaft encoder is to be used as shown in Example
1, it will be necessary to provide some type of gearing to supply the
required 60 pulses per inch as shown in Figure B-2.

Figure B-2: External Shaft Encoder

Rev AC External (Reduce Or Direct) Encoding B-3

Videojet 1210/1510 Service Manual

To determine the required gearing, the following method is used.

1800 PPR/1380 PPR = 1.3 or 1:3:1 gear ratio

2 1

1. Pulley b
2. Pulley a

Figure B-3: External Shaft Encoder - With Pulley

If the diameter of “a” = 2.0 inches, then the diameter of “b” is 2.6 inches
(2.0 inches x 1.3 = 2.6 inches). For one rotation of “a”, 1380 pulses are
produced from the 1800 PPR shaft encoder.
If that same 1800 PPR shaft encoder is connected directly to the shaft on
the conveyor, the calculation would be as follows:
(1800 pulses per revolution)/(23 inches per revolution) = 78 pulses per
inch
(78 pulses per inch) / (6 strokes per character) = 13 characters per inch
Since the standard calls for 10 characters per inch (refer to Example 1), the
message would be compressed on the product.

Auto Encoding
Auto encoding is used when the product speed and the conveyor speed
are different (product slippage) or when the product is allowed to fall
through guides from one level to another. When auto encoding is selected,
the signal from the product detector is used to determine the product
speed, and code the product at a set stroke rate. The requirements for auto
encoding are the following:
• A product detector
• The length of the detect area (the amount which the detector senses).
This value must be entered into the printer.
• The distance between the printhead and the product detector must be
set such that, both the leading and trailing edges of the product are
sensed by the product detector before the printer starts printing the
message.

B-4 Auto Encoding Rev AC

 Videojet 1210/1510 Service Manual

Product
Motion

Product Detect Jumper Set

for Negative Edge Trigger
Product

No Product

{
Pulse Width = Product Speed
Detector Signal
Figure B-4: Auto Encoding

Example
Given information:
Detect area = 5 inches (127 mm)
Pulse width of this product = 0.1 seconds
Then, Product speed = 5 inches/0.1 second = 50 inches per second (127.0
mm/0.1 s = 1270.0 mm/s)
(50 inches per second x 60 seconds per minute)/(12 inches per foot) = 250
FPM
(1270 mm/s x 60 s/minute)/1000 mm/m = 76.2 MPM

Rev AC Auto Encoding B-5