01 Aa Videojet 1610 DH Service Manual Vidieo Jet

Videojet 1610
Dual Head
Service Manual
Addendum
P/N 462220-01
Revision: AA, February 2011
Copyright February 2011, 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. CLARiTY® and CLARiNET® are registered
trademarks.
Videojet Technologies Inc.

1500 Mittel Boulevard Phone: 1-800-843-3610 Offices - USA: Atlanta, Chicago
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, and The United Kingdom
www.videojet.com Distributors Worldwide
Table of Contents
Chapter 1 — Introduction
Videojet 1610 Dual Head Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
System Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
Independent Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
About the Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Related Publications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Language Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Content Presentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
The Word ‘Printer’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Chapters in the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
Chapter 2 — Safety
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
Chapter 3 — Main Parts

Printer Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
Mains Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
Connector Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
Pinout Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9
Electronics Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–22
Power Supply Unit (PSU) and Interconnect Cable Routing . . . 3–23
Double Headed Air pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23
Printer Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25
EHT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–27
Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–27
Umbilical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28
Chapter 4 — Installation
Tools and Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Typical Production Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
Unpack and Inspect the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Commission the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Inspect the Ink System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7
Inspect the Electronics System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–11
Inspect the Printheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–11
Log into UI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12
Install Ink and Make-up Cartridges . . . . . . . . . . . . . . . . . . . . . . . 4–14
Rev AA 1
Videojet 1610 Dual Head Service Manual Addendum
Configure the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–18

Prime the Ink Core Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–20
Perform System Flush Purge and Umbilical Purge. . . . . . . . . . . 4–22
Perform Ink Stream Alignment and Viscosity Calibration . . . . 4–25
Clean Stop and Clean Start the Printer . . . . . . . . . . . . . . . . . . . . . 4–28
Perform Final Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–29
Set the Speed Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–32
Stack Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–33
Chapter 5 — Printer Set up

Set up the Printheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
Set up the Product Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
How to Set up the Product Detector in S-Mode for Printer (S) . . 5–4
How to Set up the Product Detector in System Mode for a Printer (I)5–
6
How to Set up the Product Detector in Independent Mode for Printer
(I) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9
Set up the Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10
Internal Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10
External Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14
Auto Encoding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–18
Chapter 6 — Printer Operation

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
How to Select Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
Perform System Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2
Perform Full System Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2
Chapter 7 — User Interface

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
Menu Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
System Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
Calibrate Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
Data Logging Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
Chapter 8 — Replacement Instructions

Printhead Bonding during Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Bonding during Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
2 Rev AA
Chapter 9 — Maintenance
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
Perform Calibration and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2
Calibrate EHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2
Calibrate Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Chapter 10 — Troubleshooting
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1
How to Clear a Clogged Nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1
Perform a Nozzle Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2
Perform a Clean Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–3
Perform System Flush Purge (with Nozzle Attached) . . . . . . . . 10–3
Clean the Nozzle with a Syringe and Cleaning Liquid . . . . . . . 10–4
CSB Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–5
Chapter 11 — Illustrated Parts List

Videojet 1610 Dual Head Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–4
Electronics Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–5
Control System Board (CSB) with Back Plate . . . . . . . . . . . . . . . 11–6
Printer Interface Board Assembly (PIB) . . . . . . . . . . . . . . . . . . . . 11–7
Double Headed Air Pump Assembly (Dual Head Printer). . . . 11–8
EHT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–8
Connector Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–9
PCB Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–10
Ink Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–12
Gutter Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–13
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–14
Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–15
Dual Head Beacon Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–15
Dual Head Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–15
Printhead Clamp Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–16
Adjustable Alignment Dual Printhead Bracket Assembly . . . 11–17
Dual Head Air Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–18
Miscellaneous Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–20
Connectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–20
Appendix A — Clean/Quick Start and Stop Description

Clean Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2
Clean Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2
Quick Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–3
Rev AA 3
Nozzle Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–3
4 Rev AA
Introduction
1
Videojet 1610 Dual Head Printer
The Videojet 1610 Dual Head (DH) printer is a continuous ink jet printer
that can print fixed and variable codes at elevated line speeds on
consumer and industrial products.
The most important feature of the printer lies in the Dual Head
configuration which differentiates this printer from the other 1000 line
series printers. It has the same architecture and features as the Videojet
1610 printers. The printer can print text, characters, logos and graphics (up
to 34 dots high) with the help of one or both printheads independently.
There are two printers available:
• Videojet 1610 Dual Head with System Mode
• Videojet 1610 Dual Head with Independent Mode
The printer with System mode (S-Mode) is the Standard model. The
printer with Independent Mode (I-Mode) is an advanced model with the
optional I-Mode feature. Both the printers can operate in S-Mode. Only the
printer purchased with I-Mode set up, can run in independent mode.
System Mode
In System mode configuration, either one or both the printheads operate
on a single production line. It requires one product detector and one
encoder input to control both the printheads. Both the printheads print on
the same product. Each printhead can print a separate message.
Independent Mode
In Independent mode, either one or both the printheads operate on two
different production lines. The printheads can operate independently.
Thus, I-Mode configuration requires two product detectors and two
encoder inputs to support independent printing on two lines. Each
printhead can print a separate message.
Rev AA Videojet 1610 Dual Head Printer 1-1

Note: A printer with I-Mode can operate as a S-Mode printer but a S-Mode
printer cannot be operated as an I-Mode printer. In order to upgrade S-Mode
configuration to I-Mode configuration, the connector panel must be replaced.
Note: Each printhead must be set up separately before printing.
About the Manual

This addendum is written for the service technicians of Videojet 1610 DH
printer. The document describes the significant differences between the
Videojet 1610 DH printer and the Videojet 1610 printer. Therefore, this
addendum must be read in conjunction with Videojet 1610 Service Manual
(P/N 462129).
Related Publications
The following manuals is available for reference:
• Videojet 1610 Service Manual, Part Number: 462129
• Videojet 1610 Dual Head Operator Manual Addendum: 462219
• Videojet 1610 Operator Manual, Part Number: 462128
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 spanish version of
the operator manual addendum is part number 462219-04. Table 1-1 on
page 1-2 shows the list of language codes that you can use to identify the
translated versions of this manual.
Note: The availability of the Operator Manual is indicated by an asterisk (*).

Availability of the Service Manual is indicated by a plus sign (+). For more
information, contact the Videojet distributor or subsidiary.
Code Language Availability (see

note)
01 English (US) * +
02 French *
Table 1-1: Language Codes
1-2 About the Manual Rev AA

Code Language Availability (see

note)
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 *
36 Chinese (Traditional) *
Table 1-1: Language Codes (Continued)
Content Presentation
This addendum contains different types of information like safety
guidelines, additional notes, user interface (UI) terminology and so on.
Rev AA Content Presentation 1-3

Refer to Chapter 1, “Introduction” of the Videojet 1610 Service Manual (P/

N 462129) for complete information on these topics.
The Word ‘Printer’

The word ‘printer’ indicates the ‘Videojet 1610 Dual Head printer’, from
this point onwards, in this manual.
In specific, Standard printers with S-Mode will be referred to as ‘Printer
(S)’ and printers with I-Mode will be referred to as ‘Printer (I)’.
Safety Information
The safety information includes warning and caution statements.
Warning
The warning statements indicate hazards or unsafe practices that can
cause severe personal injury or death. For example:
Warning
PERSONAL INJURY. 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 cause
damage to the equipment. For example:
Warning
PERSONAL INJURY. Do not fit or remove any connector on the
printer when the power is turned on. The failure to follow this
caution can damage the printer.
1-4 Content Presentation Rev AA

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. Printhead Set up Describes the set up procedures for dual printheads, product
detector and Encoding options
6. Printer Operation Contains the information on how to set up and operate the
printer
7. User Interface Explains how to use the UI to create and save messages
8. Replacement Explains the procedures to remove and replace the parts of the
Instructions printer
9. Maintenance Contains the information on how to maintain and clean the

printer
10. Troubleshooting Contains the operator level diagnostic and troubleshooting

procedures
11. Illustrated Parts Contains the illustrated parts list of orderable parts
List
12. Appendix A Describes clean start, quick start, clean stop and quick
stop procedures
Table 1-2: List of Chapters
Rev AA Chapters in the Manual 1-5

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 potential defects and hazards in our products.
The intended use of the 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.
Refer to the Chapter 2, “Safety” of Videojet 1610 Service Manual (P/N
462129) for the following safety related information:
• General Safety Guidelines
• Electrical Safety Guidelines
• Fluid Safety Guidelines
• Compressed Air Safety Guidelines
• UI Related Safety Guidelines
• Other Important Guidelines
Caution
EQUIPMENT DAMAGE. Make sure the printer is operated with
approved fluids only.
Rev AA Introduction 2-1

Main Parts
3
This section describes the main parts of the printer. The connector panel
and electronics compartment are described in detail for Videojet 1610 DH
Printers. For other assemblies and sub-assemblies, refer to the Videojet
1610 Service Manual (P/N 462129) for complete information:
• Cabinet
- Control Panel
- Electronics Compartment Door
- Ink Compartment Door
- Ink System Filter
• Electronics Compartment
- Control System Board
- Electronics Compartment Fan
• Ink Compartment
- Ink Core Module
- Smart Cartridges
- Ink Compartment Fan
- Gutter Pump
- Condenser Assembly
• The Hydraulic System
Printer Overview
There are two printers available:
Videojet 1610 Dual Head Printer (Standard Model):
In System mode configuration, either one or both the printheads operate
on a single production line. It supports one product detector and one
encoder input to control both printheads. Both the printheads print on the
Rev AA Printer Overview 3-1

same product. Each printhead can print a separate message. Refer to

Figure 3-1 on page 3-2.
Videojet 1610 Dual Head Printer with Independent Mode (Advanced):
In Independent mode, either one or both the printheads operate on up to
two different production lines. The printheads can operate independently.
Thus, I-Mode configuration allows up to two product detectors and two
encoder inputs to support independent printing on up to two lines. Each
printhead can print a separate message. Refer to Figure 3-2 on page 3-3.
4
2
S-Mode
1. Electronics Compartment Door 5. Connector Panel (S-Mode)
2. Ink Compartment 6. Electronics Compartment*
3. Umbilical (x2) 7. Main Power Switch*
4. Printhead (x2) 8. Ink System Filter*
* The components are not shown in the picture
Figure 3-1: Main Parts of the Printer (S)
3-2 Printer Overview Rev AA

5 4
2
I-Mode
1. Electronics Compartment Door 5. Connector Panel (I-Mode)
2. Ink Compartment 6. Electronics Compartment*
3. Umbilical (x2) 7. Main Power Switch*
4. Printhead (x2) 8. Ink System Filter*
* The components are not shown in the picture

Figure 3-2: Main Parts of the Printer (I)
Note: In order to upgrade from Printer (S) to Printer (I), the connector panel
must be replaced.
Cabinet
The cabinet of the Videojet 1610 Dual Head printer is made of stainless
steel. The cabinet includes the following parts:
• Control panel
• Electronics compartment door
• Mains power switch
• Ink compartment door
• Connector panel
• Umbilical
Refer to Figure 3-3 on page 3-4 to see the parts of the cabinet.
Rev AA Cabinet 3-3

Note: The design of the printer handle has changed from the Videojet 1610
printer.
7
2
3
5
4
1. Control Panel 5. Umbilical (x2)
2. Mains Power Switch 6. Handle
3. Electronics Compartment Door 7. Connector Panel (I-Mode)
4. Ink Compartment Door 8. Ink System 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
Mains Power Switch

The mains power switch (item 1, Figure 3-4) is a green push button to turn
on or turn off the power supply to the printer. You can find the mains
power switch on the right side of the printer.
Note: The handles (item 2) are provided for easy movement of the unit.
3-4 Cabinet Rev AA

2
1. Mains Power Switch
2. Handle
Figure 3-4: Main Power Switch
Connector Panel
The connector panel is on the left side of the printer (item 5, Figure 3-1 on
page 3-2 and Figure 3-2 on page 3-3). The panel contains the connectors
shown in Figure 3-5 on page 3-7 and Figure 3-6 on page 3-8.
The number of connectors provided depends on the printer model you
select. The Printer (S) is configured with connector board PCB 7 consisting
of eight port and three blanking ports. Printer (I) is configured with
connector board PCB 6 with eleven ports. For more information on Printer
(S) and Printer (I), refer to “Printer Overview” on page 3-1.
Note: Access Print > Head Mode > System or Independent option to change from
System mode to Independent mode or vice versa. Apart from this change, you
must replace the PCB 6/7 as per your requirement.
Table 3-1 provides the connectors for the printers.
Connector Type PCB Standard Optional
COM 2 PCB 7 Videojet 1610

RS 232/485 DH (S-Mode)
PCB 6 Videojet 1610

DH (I-Mode)
COM 1 PCB 7 Videojet 1610

RS 232/485 DH (S-Mode)
PCB 6 Videojet 1610

DH (I-Mode)
Relay Switches PCB 7 Videojet 1610

DH (S-Mode)
PCB 6 Videojet 1610

DH (I-Mode)
Table 3-1: Connector Panel
Rev AA Cabinet 3-5

Connector Type PCB Standard Optional
Head 1, Beacon PCB 7 Videojet 1610

DH (S-Mode)
PCB 6 Videojet 1610

DH (I-Mode)
Head 1, Encoder PCB 7 Videojet 1610

DH (S-Mode)
PCB 6 Videojet 1610

DH (I-Mode)
Head 1, Trigger 2 PCB 7 Videojet 1610

DH (S-Mode)
PCB 6 Videojet 1610

DH (I-Mode)

DH (S-Mode)
PCB 6 Videojet 1610

DH (I-Mode)
Head 2, Beacon PCB 7 Videojet 1610

DH (S-Mode)
PCB 6 Videojet 1610

DH (I-Mode)
Head 2, Encoder PCB 6 Videojet 1610

DH (I-Mode)

DH (I-Mode)

DH (I-Mode)
Ethernet - Videojet 1610 Videojet 1610

DH (S-Mode) DH (I-Mode)
USB - Videojet 1610 Videojet 1610

I/O PCB 4 Videojet 1610 Videojet 1610

Table 3-1: Connector Panel (Continued)
3-6 Cabinet Rev AA

11
2
10 3
Cat 5e
5
7 6
1. COM 1, RS 232/ RS 485 6. USB
2. Relay Switches (Print ready 7. Ethernet
output) 8. Head 2, Beacon
3. Head 1, Trigger 2 9. Head 1, Beacon
4. Head 1, Trigger 1 10. Head 1, Shaft Encoder Input
5. I/O 25 Way 11. COM 2, RS 232/ RS 485
Note: The blanked connectors with the grommets fitted are not provided for Printer (S)
Figure 3-5: Connector Panel (S-Mode)
Rev AA Cabinet 3-7

14
2
13 3
4
5
12
6
11
10 Cat 5e
7
9 8
1. COM 1, RS 232/ RS 485 7. I/O 25 Way
2. Relay Switches (Print ready 8. USB
output) 9. Ethernet
3. Head 1, Trigger 2 10. Head 2, Encoder (I-Mode)
5. Head 2, Trigger 2 (I-Mode) 12. Head 1, Beacon
6. Head 2, Trigger 1 (I-Mode) 13. Head 1, Encoder
14.COM 2, RS 232/ RS 485
Figure 3-6: Connector Panel (I-Mode)
Note: All the connectors are sealed to provide the required protection from water
and dust according to the IP67 standard.
3-8 Cabinet Rev AA

Pinout Information
Connector Pinout
COM 2 DIN 8 Pin

RS 232/485
COM 1 DIN 8 Pin

RS 232/485
Relay Switches DIN 7 Pin
Head 1, Beacon DIN 6 Pin
Head 1, Encoder DIN 4 Pin
Head 1, Trigger 2 DIN 3 Pin
Head 1, Trigger 1 DIN 3 Pin
Head 2, Beacon DIN 6 Pin
Head 2, Encoder (I-Mode only) DIN 4 Pin
Head 2, Trigger 2 (I-Mode only) DIN 3 Pin
Head 2, Trigger 1 (I-Mode only) DIN 3 Pin
Ethernet -
USB -
I/O DIN 25 Pin (Bulgin)
Table 3-2: Pinout Information
Shaft Encoder Connector

The printer provides a nominal +15 VDC, 200 mA output for use by a shaft
encoder with a maximum frequency of 100 kHz. The printer looks for
NPN open collector input for the encoder signals. The printer uses pulses
(leading and trailing edges) from both channels (Channel A and Channel
B) of the shaft encoder. So the pulses per inch (PPI) from the encoder are
multiplied by a factor of 4. See more information in the shaft encoder
setup. The shaft encoder connector (item 10, Figure 3-5 on page 3-7 and
item 10 and 13, Figure 3-6 on page 3-8) is a 4 way DIN connector. The pin
allocation is shown in Table 3-3 on page 3-10.
Rev AA Cabinet 3-9

2 3
1 4
Figure 3-7: 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 mating cable (male,4 pin DIN connector - P/N: 500-0036-581) is used
to interface other shaft encoders to the printer.
Product Detector Connector 1 (PEC1)

The product detector connector, detects the product and informs the
printer, when to print on the product. The printer provides a +15 VDC,
200mA output for use by a photoelectric cell (PEC), inductive proximity
detector. The print trigger 1 connector (item 4, Figure 3-5 on page 3-7 and
item 4 and 6, Figure 3-6 on page 3-8) is a 3 way DIN connector. The pin
functions are shown in Table 3-4 on page 3-11.
Note: Photoelectric cell (PEC) is also called as inductive proximity detector or

product detector.
The default configuration is a NPN (current sinking input). This input can
be changed to a PNP (sourcing input) with the movement of a jumper
located on the back of the control panel. If the input is configured for PNP
the maximum input voltage will be +24 VDC.
3-10 Cabinet Rev AA

1
3
Figure 3-8: Product Detector Connector 1 Pin Diagram
Pin Function
DIN Pin 1 +15 VDC supply to sensor
DIN Pin 2 Sensor output
DIN Pin 3 0 VDC common
Table 3-4: Product Detector Connector 1 Pinouts
Note: The mating cable (male, 3 pin DIN connector -P/N: 500-0036-578) is used
to interface other product detectors to the printer.
Product Detector Connector 2 (PEC2)

The product detector connector, detects the product and informs the
printer, when to print on the product. This input is the second product
detector input for the printer. This is also used for the bi-directional
(reverse print) input, used for traversing printhead applications. This
input reverses the characters and message when triggered prior to PEC1
triggered. The printer provides a +15 VDC, 200mA output for use by a
photoelectric cell (PEC). The product detector connector 2 (item 3,
Figure 3-5 on page 3-7 and item 3 and 5, Figure 3-6 on page 3-8) is a 3 way
DIN connector. The pin functions are shown in Table 3-5 on page 3-12.
The default configuration is a NPN (current sinking input). This input can
be changed to a PNP (sourcing input) with the movement of a jumper
located on the back of the control panel. If the input is configured for PNP
the maximum input voltage will be +24 VDC.
Rev AA Cabinet 3-11

1
3
Figure 3-9: Product Detector Connector 2 Pin Diagram (Female)
Note: Figure 3-9 represents the view of the connector on the side of the printer.
Pin Function
DIN Pin 1 +15 VDC supply to sensor
DIN Pin 2 Sensor output
DIN Pin 3 0 VDC common
Table 3-5: Product Detector Connector 2 Pinouts
Note: The mating cable (male, 3 pin DIN connector (P/N: 500-0036-578) is used
to interface other product detectors to the printer.
Tri-Color Alert Light Stack (Beacon)

The printer provides an output for a set of status lights through the status
output connector (item 8 and 9, Figure 3-5 on page 3-7 and item 11 and 12,
Figure 3-6 on page 3-8). This provides +24 VDC output, the printer will
switch in a ground to turn on the light. This is a 6-way DIN connector. The
pin allocation is shown in Table 3-6 on page 3-13.
Lamp color Function
Green Print Ready Output
Yellow Warning Output
Red Fault Output
Note: For 24 VDC, the maximum current rating is 900 mA.
3-12 Cabinet Rev AA

4
2
5
1
6
Figure 3-10: Status Output Connector Pin Diagram (Female)
Note: Figure 3-10 represents the view of the connector on the side of the printer.
Pin Function
DIN Pin 1 Red lamp negative supply
DIN Pin 2 Amber (Yellow) lamp negative supply
DIN Pin 3 Green lamp negative supply
DIN Pin 4 +24 VDC supply to all lamps/siren
DIN Pin 5 Siren negative supply
DIN Pin 6 +24 VDC common to the traffic lights
Table 3-6: Status Output Connector Pinouts
Note: The mating cable (male, 6 pin DIN connector - P/N: 500-0036-577).
Relay Switches
The relay switches connector (item 2, Figure 3-5 on page 3-7 and Figure 3-
6 on page 3-8) is a 7 way DIN connector. This output is a cold contact relay
with a normally open (N.O.) and normally closed (N.C.). This connector
supports the following relays:
• Relay ‘A’ contacts are for printhead 1.
• Relay ‘B’ contacts are for printhead 2.
Maximum Contact Loading
0.5A @ +30 VDC Max
These relays have electrical ratings of 1 - 30 VDC, 300 mA maximum. It is
suggested to use +24 VDC. For example, if the printer is in a print ready
state, the normally open (N.O.) contacts closes and informs the host that
the printer is in a print ready state. If the printer is removed from the print
Rev AA Cabinet 3-13

mode for any reason (removed from print), printer faults out, thus opens
the contacts. The pin allocation is shown in Table 3-7 on page 3-14.
3 4 4 3
2 5 5 2
1 6 6 1
7 7
Female Connector Male Connector
Figure 3-11: Relay Switches Connector Pin Diagram
Note: Female connector (Figure 3-11) represents the view of the connector on the
side of the printer.
Connector Pin Function Wire Color
Female Male Pin

Pin
DIN Pin 1 DIN Pin 6 Relay A - Normally open contact White

(Print Ready, Head 1)
DIN Pin 2 DIN Pin 5 Relay A - Normally closed contact Red

DIN Pin 3 DIN Pin 4 Relay A - Common contact (Print Black

Ready, Head 1)
DIN Pin 4 DIN Pin 4 Relay B - Normally open contact Green

DIN Pin 5 DIN Pin 2 Relay B - Normally closed contact Blue

DIN Pin 6 DIN Pin 1 Relay B - Common contact (Print Brown

Ready, Head 2)
DIN Pin 7 DIN Pin 7 Not used -
Table 3-7: Relay Switches Connector Pinouts
Note: The mating cable - P/N SP378810 (male, 7 pin DIN connector - P/N: 500-
0036-583).
3-14 Cabinet Rev AA

Note: A single relay connector covers both printheads, providing a single

changeover contact set for each head. Print Ready Output (mirrors Green LED)
will use the relay output (in Series or Parallel depending on N/O or N/C).
Note: These outputs are cold contact relays. It will not supply control voltage to
the host system. If the host is going to send a control voltage through these
contacts, it is suggested to use +24VDC.
RS-232 and RS-485 Communication Ports

Two communications ports are available which can be configured to RS-
232 or RS-485 by a user selectable link (item 1 and 11, Figure 3-5 on
page 3-7 and item 1 and 14, Figure 3-6 on page 3-8).
When the communication port is configured to RS-232, the software
handshaking (see Table 3-8 on page 3-16) and hardware handshaking (see
Table 3-9 on page 3-16) is available for both communication port 1 and
port 2.
The RS-485 port (see Table 3-10 on page 3-17) can only be used with WSI
interface.
RS-232 or RS-485 can be selected using the jumpers located on the back of
the PCB. By default RS-232 is connected. Three cables are available for
communication channels - I/O cable (RS 232 - 3 m), I/O cable (RS-232 -6
m) and I/O cable (RS 232 / RS 485 - 6 m).
2
4 5
6 3
7
8
Figure 3-12: RS 232 Connector (3 m)
2
4 5
6 3
8 7
Figure 3-13: RS 232 Connector (6 m)
Rev AA Cabinet 3-15

2
4 5
6 3
8 7
Figure 3-14: RS 232 and RS 485 Connector (6 m)
The Table 3-8 shows the pin connection information for RS-232 software
handshaking.
8 Pin DIN Plug DB 9 Pin Connector
DIN Pins Function DB 9 Function

Pins
1 TXD (Transmit Data) 2 Received Data
3 RXD (Received 3 Transmit Data

Data)
8 Gnd 5 System Ground
Table 3-8: RS-232 Pin Connection Information - Software Handshaking
The Table 3-9 shows the pin connection information for RS-232 hardware
handshaking.

Pins
1 TXD (Transmit Data) 2 Received Data
3 RXD (Received 3 Transmit Data

Data)
8 Gnd 5 System Ground
2 RTS (Request to 8 Clear to Send

Send)
4 CTS (Clear To Send) 7 Request to Send
1+4+6
Table 3-9: RS-232 Pin Connection Information - Hardware Handshaking
3-16 Cabinet Rev AA


Pins
1 Data Carrier
Detect
4 Data Terminal
Ready
6 Data Set Ready
Table 3-9: RS-232 Pin Connection Information - Hardware Handshaking
Note: 1+4+6 -This indicates that pins 1, 4 and 6 are connected together
internally.
The Table 3-10 shows the pin connection information for RS-485
connector.
8 Pin DIN Plug DB 9 Pin Connector Port

Pins
6 1-A (Transmit Data+) RS -485
5 1-B (Transmit Data -) RS -485
7 Gnd RS -485
Table 3-10: RS - 485 Pin Connection Information
Jumper Settings for RS-232 and RS-485

The user selectable links for RS-232 and RS-485 are available which is
located on the PCB 6 (see Figure 3-15 and Figure 3-16 on page 3-18) and
PCB 7 (see Figure 3-17 on page 3-19 and Figure 3-18 on page 3-19). Note
the positions of the jumper settings to select the required communication
protocol.
Rev AA Cabinet 3-17

RS 232
Figure 3-15: RS 232 Jumper Settings (PCB 6)
RS 485
3-18 Cabinet Rev AA

RS 232
RS 485
Rev AA Cabinet 3-19

25 Way
Connector
Figure 3-19: 25 Way Connector - PCB 6
RS-232 RS-485
J2 J3 J2 J3
Figure 3-20: RS-232 and RS-485 Jumper Settings
Note: The mating cable (male, 8 pin DIN connector - P/N: 500-0036-584).
USB Connector
The USB Connector (item 6, Figure 3-5 on page 3-7 and item 8, Figure 3-6
on page 3-8) allows you to do the following:
• Message importing and exporting
• Data logging
• Importing logos
• To update printers software.
This port is not currently used for a communication port or an external
data source.
3-20 Cabinet Rev AA

Figure 3-21: USB Connector
Ethernet Connector
The ethernet connector (item 7, Figure 3-5 on page 3-7 and item 9,
Figure 3-6 on page 3-8) is used to connect the printer to a remote computer
or network to import data or control the printer remotely.
Cat 5e
Figure 3-22: Ethernet Connector
Rev AA Cabinet 3-21

Electronics Compartment
The electronics compartment contains the parts shown in Figure 3-23 on
page 3-22.
1 3
1. Double Headed Air Pump 5. Printer Interface Board (PIB)

2. Power Supply Unit 6. Control System Board (CSB)
3. Extra High Tension (EHT) Block 7. Connector Panel Boards
4. Electronics Compartment Fan
Figure 3-23: Electronics Compartment
3-22 Electronics Compartment Rev AA

Power Supply Unit (PSU) and Interconnect Cable Routing

The charge and modulation cables from umbilical 1 and umbilical 2 are
routed from top of the PSU and connected to the CSB. For complete
information, refer to Videojet 1610 Service Manual (P/N 462129).
1. PSU Output Cable 2

2. Charge and Modulation Cable
Figure 3-24: Cable Routing
Note: Cable need to be separated for EMC.
Double Headed Air pump

The double headed air pump (with dampener) assembly provides dust
free air to the printheads and thus prevents the accumulation of dust in
the printheads and contamination of the ink.
Rev AA Electronics Compartment 3-23

1. Dampener
2. Positive Air Pump
Figure 3-25: Double Headed Air Pump
Note: When a customer orders a printer with an air dryer kit, the double headed
air pump is not fitted to the printer. The air dryer supplies positive air to the
printhead from an external air source. Air dryers are required when the printer is
operated in an environment with elevated humidity or certain water sensitive inks
are used. For more information, please contact Videojet Technologies Inc.
Customer Service Department at 800.843.3610 (United States only), or contact
the local Videojet Technologies Inc. representative.

Printer Interface Board
12 13 14 15 1 2 3 4 5 6 7
9
10
11
1. EHT Printhead 2 Cable Connector 9. 10-way Printhead 1 Connector
2. 12-way Printhead 2 Connector 10. 34-Way Connector
3. 10-way Printhead 2 Connector 11 CSB Ribbon Cable Connectors (x3)
4. EHT Printhead 1 Cable Connector 12. USB 2 Connector
5. Positive Air Pump 2 Connector 13. PCB-M Connector
6. Positive Air Pump 1 Connector 14. PCB 4 Connector
7. Electronics Compartment Fan Connector 15. PCB 6 Connector
8. 12-way Printhead 1 Connector
Figure 3-26: Printer Interface Board (PIB) - Electronics Compartment Side
4
3
2 1
1. 14-Way Ink Door Ribbon Cable Connector
2. Ink Compartment Fan Connector
3. 16-Way Ink Core Module Ribbon Cable Connector
4. 20-Way Ink Core Module Ribbon Cable Connector
Figure 3-27: Printer Interface Board (PIB) - Ink Compartment Side

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

Table 3-11 on page 3-26.
Connector Description
10-way Printhead 1 Connector Connection to valves, phase detector,

12-way Printhead 1 Connector strobe LED, heater and thermistor, and
10-way Printhead 2 Connector gutter detect
12-way Printhead 2 Connector
EHT Printhead 1 Cable Connector Input to EHT module

EHT Printhead 2 Cable Connector
Positive Air Pump 1 Connector Input to double headed positive air

Positive Air Pump 2 Connector pump
Electronics Compartment Fan Con- Input to electronics compartment fan

nector
CSB Connectors Input to CSB
USB 2 Connector External USB (not the USB connection

on CSB)
PCB 6 Connector (I-Mode) • COM 1, RS 232/ RS 485

• Relay Switches
• Head 1, Trigger 2
• Head 2, Encoder
• Head 2, Beacon
• Head 1, Beacon
• Head 1, Encoder
• COM 2, RS 232/ RS 485
PCB 7 Connector (S-Mode) • COM 1,RS 232/ RS 485

• Relay Switches
• Head 2, Beacon
• Head 1, Beacon
• Head 1, Encoder
• COM 2, RS 232/ RS 485
PCB 4 Connector I/O 25 Pin Connector
PCB-M Connector Expansion
Ink System Ink pump, valves, sensors, level detec-

tors, smart chip supplies
validation system
Table 3-11: PIB Connectors

EHT Module
The extra high tension (EHT) module (Figure 3-28) generates the high
tension voltage (0 to 8000 VDC) that is supplied to the deflector plate in
the printhead.
The printer has two cables (head specific) for the EHT module.
4 2
1. EHT Module
2. P-Clip*
3. EHT Cable (Head 1)*
3. EHT Cable (Head 2)
* - Item is not shown in the figure
Figure 3-28: EHT Module
Printhead
The printhead uses the ink supplied by the ink core module to print text
and graphic characters on a product. The control signals and ink are sent
to the printhead through the umbilical.
In Dual Head configuration, both the printheads have the same design.
The printheads operate at an offset of up to two meters relative to each
other. The two printheads are independently controllable. Each printhead
must be set up separately.
The printheads can operate in the two modes:
• System Mode (standard configuration)
• Independent Mode
Rev AA Printhead 3-27

Refer to “Videojet 1610 Dual Head Printer” on page 1-1 for more
information.
System Mode
Both the printheads print on a product with one external product detect
and/or shaft encoder (for example, on a single line). Each printhead can
print a separate messages.
Note: Printer (S) cannot operate in I-Mode.
Independent Mode
Each printhead operates independently on upto two lines. Each printhead
can print different messages.
1 2
3
1. Umbilical 4. Printhead Screw
2. Printhead Cover 5. Printhead Valve Module
3. Printhead Engine
Figure 3-29: Printhead
For more information on printhead, refer to the Videojet 1610 Service

Manual (P/N 462129).
Umbilical
The umbilical has the electrical wiring and ink system tubing from the
printer to the printhead. In Dual Head configuration, both the printheads
have separate umbilical.
Note: The printhead and umbilical should be isolated from external vibrations.
3-28 Umbilical Rev AA

Installation
4
This section describes the procedures to install Videojet 1610 DH printer.
Refer to Videojet 1610 Service Manual (P/N: 462129) for more information
on following topics:
• Nozzle Adjustment
• Set the Password Levels
• Set the Throw Distance
Caution
EQUIPMENT DAMAGE. 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.
Caution
EQUIPMENT DAMAGE. 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.
Rev AA 4-1
Caution
EQUIPMENT DAMAGE. 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.
Warning
PERSONAL INJURY. 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 Chapter 10, Illustrated Parts List of the
Videojet 1610 Service Manual (P/N 462129) for information on tools and
supplies required to install the printer.
Supplies
• Two cartridges of ink
• Three cartridges of make-up fluid
• Wash bottle
• Wash solution
• Gloves
• Tissue
4-2 Rev AA
Typical Production Line

A typical printer installation is shown in Figure 4-1 on page 4-4 where the
printer (item 6) is mounted on a printer stand (item 1). The two printheads
(item 9 and item 10) is configured to print vertically with the help of a
clamp and bracket assembly. A stack light (item 8) is fitted to the printer.
Rev AA 4-3
1
10
8
6
Figure 4-1: Typical Production Line Installation (System Mode)
4-4 Rev AA
10
1
9
tem
S ys m
ing y ste
vers gS
Tra in 2
v ers
Tra
3
8
6
Figure 4-2: Typical Production Line Installation (Independent Mode)
Rev AA 4-5
Item No. Description
1 Printhead Stand
2 Shaft Encoder
3 Shaft Encoder
Cable
4 Photocell
5 Photocell Cable
6 Printer
7 Printer Stand
8 Stack Light
9 Printhead 1
10 Printhead 2
Table 4-1: Typical Production Line Parts
Unpack and Inspect the Printer

Do the following tasks to 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 Videojet 1610 Service Manual (P/N 462129) for below topics:
• Compliance Chapter, “Support and Training” for Videojet contact
information.
• 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.
4-6 Unpack and Inspect the Printer Rev AA

Inspect the Ink System

3 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.
4 Turn the knob and open the ink compartment door (see Figure 4-3).
Figure 4-3: Turn the Knob
5 Push the plate (item 2, Figure 4-4 on page 4-8) in the direction shown
to open the ink compartment door completely.
Rev AA Commission the Printer 4-7

1. Ink Compartment Door

2. Plate
Figure 4-4: Ink Compartment Door

6 Remove and discard the foam pads (see Figure 4-5).
Figure 4-5: Foam Pads Removal
7 Remove and discard the foam pads that are attached to the CSB in the
electronics compartment.
4-8 Commission the Printer Rev AA

8 Pull the ink core module out of the ink compartment (see Figure 4-6).
Inspect the ink core for shipping damages such as cracks.
1. Ink Compartment Door

2. Ink Core Module
Figure 4-6: Pull Ink Core Module
9 Make sure that the ink core manifold is connected to the ink core
module correctly (see Figure 4-7).
Ink Core Manifold
Figure 4-7: Ink Core Manifold
10 Make sure that all the tubes (seven) are connected to the ink core
manifold. Refer to Table 4-2 on page 4-10 for the colour code of the
sleeves.

Also, make sure that the quick disconnect Y pieces are correctly
connected.
1. Brown Stripe Clear Tube (5/32 inch) 5. Blue Stripe Tube (1/8 inch)
2. Red Stripe Tube (1/8 inch) 6. Black Stripe Ink Tube (1/8 inch)
3. Green Stripe Make-up Tube (1/8 inch) 7.Yellow Stripe Clear Tube (1/8 inch)
4. Clear Pipe (6 mm)
Figure 4-8: Tubes to Ink Core Manifold
Tube Colour Code of the Functions

Number Sleeve
1 Brown (Gutter pump) It carries ink and solvent back from

the gutter pump.
2 Red (Printhead) It carries solvent to the printhead.
3 Green (Make up) It carries solvent to the ink core.
4 Clear Pipe (Condensor) It is used for air venting.
5 Blue (Gutter pump) It carries ink and solvent back from

the gutter pump.
6 Black (Ink Line) It carries ink to the ink core.
7 Yellow (Printhead) It carries ink to the printhead
Table 4-2: Ink Core Manifold Tubes
11 Make sure that the core vent tube is connected to the hydraulics
compartment fan.
12 Push the ink core module into the ink compartment.
13 Close the ink compartment door.

Inspect the Electronics System

14 Open the electronics compartment and make sure that all the electrical
cables are fitted and routed correctly.
15 Make sure that the pneumatic tube that connects to positive air pump
and dampener is connected correctly.
1. Cables
2. Pneumatic Tube
Figure 4-9: Air Pump and Dampener
16 Record PIB and CSB revisions. You will need to disconnect the cables
to inspect the PIB. Replace these cables.
Inspect the Printheads

17 Remove the printhead cover for both the printheads (see Figure 4-10
on page 4-12) and inspect for damages like:
• Loose tubing, decks, screws and manifolds
• Damage to printhead sleeve
• Scratches to printhead assembly
• Loose fitting of the umbilical on the back of the printhead
• Cracks and abrasions on the black umbilical rubber jacket

18 Check the distance between the nozzle and the charge electrode
(Table 4-3).
Microns Charge Electrode Distance
60 Microns 1 mm
70 Microns 2.3 mm
Table 4-3: Charge Electrode Distance
19 Visually check the charge electrode gap.

Gap = 0.575-0.675 mm
20 Replace the printhead cover for both the printheads.
1 2
3
1. Umbilical 4. Printhead Cover Screw
3. Printhead Engine
Figure 4-10: Printhead Cover Removed
Log into UI
21 Connect the printer to the AC power supply and turn on the printer.
The menu screen appears on the display. (see Figure 4-11).

Figure 4-11: Menu Screen
22 If you cannot see the display, adjust the contrast using the contrast
adjustment button .
Log into the user interface (UI) at level 3 password. On the Password
menu, select Enter Password. The Enter Password dialog box
appears.Note: Make a note of the Ink Part No. displayed on the menu
screen.
Figure 4-12: Password Menu
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.

23 Navigate to Print > Head Mode. Select System or Independent using the
arrow keys.
Refer to “Printer Overview” on page 3-1 for more information on the
head mode.
Figure 4-13: Head Mode
Note: The head mode selected depends on the model purchased.
Install Ink and Make-up Cartridges

24 Open the ink compartment door (refer to Step 4 and Step 5 on page 7).
Warning
PERSONAL INJURY. 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.

Warning
PERSONAL INJURY. Read and understand the Material Safety Data
Sheet (MSDS) before using any ink, make-up fluid, or cleaning
solution. An MSDS exists for each type of ink, make-up fluid, and
cleaning solution. For more information, visit www.videojet.com and
navigate to Documentation > Material Safety Data Sheets.
25 Access Data Logging > Version Info menu to view the version
information. Record the following:
• SW Version
• PE Firmware Version
• CE Image Version
Confirm that the CSB/Ink Core "utilisation" are set at High/High for
1610.
26 Perform valve test.Access System > Valve Test (Figure 4-14)
Figure 4-14: Valve Test
27 Install one new cartridge of ink and one new cartridge of make-up
fluid in the printer (Figure 4-15).
28 Make sure that the ink out and make-up out icons disappear.

1
2
1. Ink Receptacle
2. Make-up Receptacle
Figure 4-15: Ink and Makeup Cartridge Holder
29 If unknown ink and unknown make-up icons are displayed, perform

the Update Ink Core Parameters.
Note: Make sure that the ink and make-up cartridges are inserted into the
correct slots.
To update the parameters, do the following tasks:
a. Select Calibrate > Update Ink Core Parameters. The ink data is
displayed on the screen(Figure 4-16 on page 4-17).
b. Make sure that the part number on the ink cartridge matches with
the part number displayed on the screen. Record the part number.
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.

Figure 4-16: Ink Part Number
30 Verify and record the ink type and expiration date. Access Calibrate >
View Ink Smart Chip Data menu (see Figure 4-17).
Make sure that the ink reference matches with the number displayed
on the menu screen (see Figure 4-17).
Figure 4-17: View Ink Smart Chip Data Option
31 Verify and record the make-up type and expiration date. Access
Calibrate > View Makeup Smart Chip Data menu (see Figure 4-18 on
page 4-18).

Figure 4-18: View Makeup Smart Chip Data Option
32 Verify and record the ink core ‘Run Hours’. Access Calibrate > View Ink
Core Smart Chip Data menu.
Figure 4-19: View Ink Core Smart Chip Data
Configure the Printer

33 Please make sure printhead is clean and dry. Calibrate both the EHT 1
and EHT 2. Refer to “Calibrate EHT” on page 4-39.
34 Set date and time. Access Configure > Set Time/Date (see Figure 4-20 on
page 4-19).

Figure 4-20: Set Time/Date
35 Set the nozzle type and the conduit length.

• Access Configure > System Settings. The System Settings dialog box
appears (see Figure 4-21). Make sure you select the correct nozzle
type for the current configuration (60 micron).
Figure 4-21: System Settings
• Access Calibrate > Printhead Elevation. The Printhead Elevation dialog

box appears (see Figure 4-22 on page 4-20). Make sure that the
conduit length is set correctly for the current configuration (see
Table 4-4 on page 4-20).
Note: During the installation procedure, keep the printheads at the same
height as the point where the umbilicals is attached to the cabinet.
Note: Make sure that the printhead elevation is ‘0’ for each printhead.
Note: If the printhead is below cabinet level, the printhead elevation is a

negative number.

Printer Conduit Length
Videojet 1610 3 m (standard), 6m (optional)
Table 4-4: Conduit Length
Figure 4-22: Printhead Elevation
Prime the Ink Core Module

36 Select System > Fill Ink Core to prime the printer with the ink (see
Figure 4-23) and record the time to prime.
Figure 4-23: Fill Ink Core Menu
37 Make sure that the fluid flows through the black-striped tube (item 1,
Figure 4-24) and blue-striped tube (item 2).

1. Black Striped Tube

2. Blue Striped Tube
Figure 4-24: Prime Core
38 Monitor the flow of fluid as it is pulled toward the ink core. As the ink
core reaches a low level, the red LED is turned off and is replaced with
a Ink Core low icon.
Note: When ink core is empty, the red LED is illuminated.
Note: Make sure to see that the ink is being pulled from the cartridge to the
gutter pump and then sent to the ink core. If the ink is not flowing, the
system shows the cartridge empty icon even though no fluid was pulled from
it.
39 The Fill Ink Core procedure stops automatically when the ink core
level reaches middle level.
If the ink level stalls above ‘low’ but below ‘middle’, replace the
cartridge when prompted to allow the completion of the ‘Prime Core’
procedure.
Note: The printer indicates if another cartridge is required to complete the

procedure.
Note: 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 4-25 on page 4-22).

Figure 4-25: Diagnostics Screen Two
Perform System Flush Purge and Umbilical Purge
Note: The following procedure needs to be performed on each printhead

separately.
Caution
Always wear a set of rubber gloves before removing the printhead
covers and disconnecting the nozzle tubing manifold. This helps to
prevent nozzle clogs.
40 Remove the printhead cover screw that fastens the printhead cover to
the printhead chassis and remove the printhead covers (see Figure 4-
26).

1 2
3
3. Printhead Engine
41 Remove the M2 x 6 socket-head-cap screw (item 1, Figure 4-27 on

page 4-24) that attaches the front tubing manifold to the printhead
valve module.
42 Remove the 2-way manifold gasket (item 5).
43 Put the 2-way manifold gasket provided in the bypass kit on the ports
of the printhead valve module.
44 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.

3
4
1. M2 x 6 Socket-head Screw 4. Quick Disconnect
2. Nozzle Bypass Manifold 5. 2 Way Manifold Gasket
3. Tubing
Figure 4-27: Bypass Manifold
45 Open the quick disconnect (item 4) in the middle of the loop and
direct the supply side into a receptacle.
46 Start System Flush Purge (select System > System Flush Purge >Select
Head > Head 1 OR Head 2).
Figure 4-28: System Flush Purge

47 Record the time to complete the procedure. 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. The procedure takes 15 minutes.
48 Connect the quick disconnect in the middle of the loop connector and
perform Umbilical Purge (select System > Umbilical Purge > Select Head
> Head 1 OR Head 2).
This procedure will not finish automatically, so perform a quick stop
to stop the umbilical purge process after a few seconds.
Figure 4-29: Umbilical Purge
49 Remove the nozzle bypass manifold and the 2-way manifold gasket.
50 Fit the front tubing manifold to the printhead valve module using M2
x 6 socket-head-cap screw. Make sure to fit the gasket under the
manifold.
Replace the make-up cartridge with a fresh cartridge.
Repeat the steps Step 40 to Step 50 for the second printhead.
Perform Ink Stream Alignment and Viscosity Calibration

51 Remove the make-up cartridge from the make-up stall.
Note: The following procedure needs to be performed for Head 1 first and
then for Head 2.
52 Start jet 1 using quick start (System > Quick Start Jet > Select Head >
Head 1).

Figure 4-30: Quick Start Jet
You can see the ink stream toggling at the start, because of air bubbles
that remain in the system. If the nozzle is clogged, perform nozzle
back flush. Refer to Chapter 9 in the Videojet 1610 Service Manual (P/
N 462129) for more information.
Note: Limit the total number of back flush to 40 for both the heads.
53 Check the position of the ink stream in the gutter:
• If the ink stream is aligned to the gutter, go to Step 54.
• Else, do mechanical adjustments to the nozzle (refer to “Nozzle
Adjustment” in the Videojet 1610 Service Manual (P/N 462129)).
Note: Inspect the nozzle orifice and charge electrode to make sure that the
stream travels through the center of the electrode and runs parallel to the
walls of the electrode/charge tunnel.
If adjustments are at either end of the ranges, there can be a nozzle partial
clog even though the ink stream is not severely misaligned.
Perform nozzle back flush if required.
While in some cases, an ink stream can be misaligned, you can adjust the ink
stream to flow correctly into the gutter. But a misaligned ink stream leads to
incorrect pressure setting as the printer needs more than normal pressure to
get the correct velocity with a slightly clogged nozzle.
54 Make sure that the jet startup is complete. The jet running icon on the
main screen must be solid (must not flash) .

55 Allow 30 minutes and make sure that the printer has reached steady
state. Steady state indicates: actual velocity = velocity set point,
±0.1m/second (check these parameters on Diagnostics Screen One).
Note: The software will not allow the Viscosity Calibration until 30 minutes.
Caution
EQUIPMENT DAMAGE. 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.
Note: The calibration needs to carried out on both the printheads

individually to make sure that each printhead is capable of independent
viscosity control.
56 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 closest to the EHT plate (angled
plate).
Note: The printer may take 30 minutes to reach the steady state.
57 After a period of 30 minutes where the printhead needs to be settled,
perform viscosity calibration. Select Calibrate > Viscosity Calibration.
(see Figure 4-31 on page 4-27).
Figure 4-31: Viscosity Calibration
58 Record Target Pressure (both the values). To record the pressure, access
Calibrate > Diagnostics Screen 1. (see Figure 4-32 on page 4-28).

If you are calibrating for Head 1, go to Step 57. If you are calibrating
for Head 2, go to Step 59.
Figure 4-32: Diagnostic Screen One
59 Once the viscosity calibration is completed for jet 1, start jet 2 using
quick start (System > Quick Start Jet - Select Head > Head 2).
60 Once jet 2 is started, stop jet 1 using quick stop (System > Quick Stop Jet
- Select Head > Head 1) and return to Step 53.
61 Once the viscosity calibration is completed for jet 2, stop jet 2 using
quick stop (System > Quick Stop Jet - Select Head > Head 2). Now insert a
fresh make-up fluid cartridge.
Clean Stop and Clean Start the Printer
Note: The following procedure needs to be performed on each printhead

separately.
62 Put a piece of paper under the printheads (to capture splatter) and
press the F1 key to do a clean stop of both the printheads.
During shutdown if ink splatters inside the printhead, check the ink
stream alignment again and make sure that the flush pump is fully
primed.
Note: The flush pump is a controlled diaphragm inside the ink core module.
63 Put another piece of paper under the printheads and press the F1 key
to do a clean start of both the printheads.
During startup, perform clean start if the ink splatters inside the
printhead, check the ink stream alignment again and make sure that
the flush pump is fully primed.

Perform Final Checks

64 Make sure that the auto modulation is enabled (Calibrate > Auto
Modulation).
Figure 4-33: Auto Modulation
65 Make sure that the correct Head Mode (Print > Head Mode> Independent
OR System) is selected depending on the printer configuration.
Figure 4-34: Select Head Mode

66 Install the printhead cover and verify that the amber light is turned
off:
If the amber light is turned on with the printhead cover fitted, check
the Current Warnings screen and perform the required
troubleshooting. Access System > Warnings Screen.
67 Install the printhead caps.
68 Use a flow meter and make sure that the rate of positive air flow out of
the printhead slot is 14 SCFH.
69 Take a sample print.
70 Close the ink compartment door.

71 Make sure that the electronics compartment and the ink compartment
doors are closed and locked.
Caution
EQUIPMENT DAMAGE. Do not perform Step 72 until the system is
ready for production, as it affects the viscosity adjustments of the
printer.
72 Backup printer settings using a USB flash drive. Select Configure >
Backup System Settings.
Figure 4-35: Backup System Settings
73 If 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.
74 Press the Enter key to backup the settings.

75 Validate machine parameters (refer to Table 4-5 on page 4-31).
Machine Parameter Typical Value (see Note above)
Diagnostic Screen One
Target pressure (both values) 2.6 (2.6)

Note: Target Pressure is for
HEAD1 only.
Actual Pressure 2.6

Note: Actual Pressure is for
HEAD1 only.
Velocity Set Point 20.000
Actual Velocity 20.000
Head Temperature (both values) 35 °C
Drop Frequency 75 to 77 Hertz
Modulation Voltage (both values) Variable (auto sets on jet start)
Printing Phase Variable (auto controls)
Phasing Threshold (both values) 200 (auto controls after setup

170 - 250 nominally)
Phase Profile Variable combinations of 1 and

0: For every 16 digits there
should always be between 7 and
9 consecutive ones. The rest of
the digits should be zeros. For
example:
• 1111111110000000
• 0001111111000000
• 0000011111111100
Note: The ones can also be
wrapped around:
1111110000000111
Diagnostic Screen Two
Ink Temperature Typically 10 °C - 35 °C, subject

to the environmental
temperature (Higher and lower
temperatures may be seen when
running at environmental
extremes of 5 °C or 45 °C)
Table 4-5: Typical Diagnostics Screen Values

Machine Parameter Typical Value (see Note above)
Electronics Temperature Typically 15 °C to 50 °C

This is subject to the
environmental temperature.
Note: Electronics Temperature is
for HEAD1 only.
Pump rpm 1200-1800

Note: Pump rpm is for HEAD1
only.
Makeup Vacuum Variable

Subject to the amount of make-
up fluid available in the cartridge.
Heater Power Variable

Relative to the environmental
temperature. Zero above 35 °C
Gutter Detect Status In Gutter - When Ink Jet is

running normally
Ink Core Level Mid level (High and Low level

causes an icon to appear on the
screen, but it does not stop the
operation)
EHT Voltage 4 KV to 8 KV
% EHT Trip 85%
Traffic Light • Green - Printing (no

warnings or errors)
• Green and Yellow - Printing,
but with alarm or warning
• Yellow - Not printing,
warnings or errors present
• Red - Failure state
Table 4-5: Typical Diagnostics Screen Values (Continued)
Set the Speed Compensation

Speed compensation enables the printer to print a message in the same
position on a product as the product speed changes. This feature can be
useful if the conveyor speed is very high and the product is relatively
small. The printer computes a variable stroke delay for each product. As
the product speed is reduced, the variable stroke delay increases. The
correct print distance must be entered. The nominal value is 12 mm and
the range is 5 mm to 15 mm.
4-32 Set the Speed Compensation Rev AA

Note: When speed compensation is ON, the print delay is increased by 60 strokes
(approximately one inch, or 25.4 mm). Therefore, one inch must be subtracted
from the existing delay in order for the printed code to remain in the same position
on the product.
Enter the throw distance (access Print > Head Settings). See Figure 4-37.
Figure 4-37: Throw Distance
Stack Light
The stack light is an accessory used to provide the printer status to the
user. If the printer configuration and printing application requires two
beacons, then use the dual head beacon (see Figure 4-38 on page 4-33).
The connector panel has two status output connectors (see Figure 4-39 on
page 4-34) provided for connecting the stack light.
1. Stack Lights
2. M4 X 10 Socket-head Screws (x6)
3. Stack light Mounting Bracket
Figure 4-38: Stack Light
Rev AA Stack Light 4-33

Cat 5e
1. Beacon, Head 2 Connector

2. Beacon, Head 1 Connector
Figure 4-39: Connector Panel
4-34 Stack Light Rev AA

Printer Set up
5
This section describes the following topics while commissioning the dual
head printer.
• Printheads Set up
• Product Detector Set up (S-Mode and I-Mode)
• Encoder Set up
Set up the Printheads

To set up the two printheads, do the following:
1 Navigate to Print > Line Configuration. Select Display Units of Measure
as either Inches or Metric (Figure 5-1).
Figure 5-1: Line Configuration
2 Install the printheads onto the conveyors.

3 Press F1 key for the Select Head dialog box to appear (Figure 5-2 on
page 5-2).
Note: Press F3 to toggle between the two heads when on a menu.
Rev AA Set up the Printheads 5-1

Figure 5-2: Select Head
4 Navigate to Calibrate > Printhead Elevation (Figure 5-3). Enter the

correct Printhead Elevation for each printhead.
Note: During the installation procedure, keep the printhead at the same
height as the point where the umbilical is attached to the cabinet.
Note: If the printhead is below cabinet level, the printhead elevation is a

negative number.
5 Navigate to Print > Head Settings. The Head Settings dialog box appears
(Figure 5-4 on page 5-3).
a. Enter the correct Throw Distance for each printhead.
Throw distance = distance from printhead faceplate to the substrate.
b. Set the Invert and Reverse for each printhead. Refer Figure 5-5 on
page 5-3 and Figure 5-6 on page 5-3 for print samples depicting the
various combinations of settings.
5-2 Set up the Printheads Rev AA

Figure 5-4: Head Settings
BELT DIRECTION
Right-to-Left Travel
INVERT = OFF INVERT = OFF INVERT = ON INVERT = ON

REVERSE = OFF REVERSE = ON REVERSE = OFF REVERSE = ON
Figure 5-5: Effects of Invert/Reverse Parameters - R to L
BELT DIRECTION
Left-to-Right Travel
INVERT = OFF INVERT = OFF INVERT = ON INVERT = ON

REVERSE = OFF REVERSE = ON REVERSE = OFF REVERSE = ON
Figure 5-6: Effects of Invert/Reverse Parameters - L to R
Rev AA Set up the Printheads 5-3

Set up the Product Detector

The section describes how to set up the product detector in three
scenarios:
• Standard Printer (S-Mode) - Printer (S)
• Printer (I) in S-Mode
• Printer (I) in I-Mode
Note: Press F1 key for the Select Head dialog box to appear. Select the required
printhead.
Note: Press F3 to toggle between the two heads when on a menu.
How to Set up the Product Detector in S-Mode for Printer (S)

1 Set the photocell jumpers on PCB 7 as required for NPN or PNP (see
Figure 5-7 and Figure 5-8 on page 5-5).
Jumpers
Figure 5-7: PCB 7 NPN Setting
5-4 Set up the Product Detector Rev AA

Jumpers
Figure 5-8: PCB 7 PNP Setting
2 Connect the photocell to the Head 1, Trigger 1 connector port on the

cabinet (Figure 5-9).
Head 1, Trigger 1
Cat 5e
Figure 5-9: Head 1, Trigger 1 Connector - S-Mode
3 Navigate to Configure > Photocell Levels (Figure 5-10). Determine the

Active state of the photocell as follows:
a. Block the photocell (set to Active).
Rev AA Set up the Product Detector 5-5

b. Check LED D2 on PCB 7. If the LED is ON while the photocell is

blocked, set Photocell 1 Level to Active High. If the LED is OFF while
the photocell is blocked, set Photocell 1 Level to Active Low.
Figure 5-10: Photocell Levels
How to Set up the Product Detector in System Mode for a Printer (I)
1 Make sure the Printer (I) is set to S-Mode (Figure 5-11). Navigate to
Print > Head Mode. Select System using the arrow keys.
Figure 5-11: System Mode
Figure 5-12 on page 5-7 and Figure 5-13 on page 5-7).

Jumpers
Figure 5-12: PCB 6 NPN Settings
Jumpers
Figure 5-13: PCB 6 PNP Settings
3 Connect the photocell to the Head 1, Trigger 1 connector port on the

cabinet (Figure 5-14 on page 5-8).

Head 1, Trigger 1
Cat 5e
Figure 5-14: Head 1, Trigger 1 Connector
4 Navigate to Configure > Photocell Levels (Figure 5-10 on page 5-6).

Determine the Active state of the photocell as follows:
a. Block the photocell (set to Active).
blocked, set Photocell 1 Level to Active High. If the LED is OFF while
the photocell is blocked, set Photocell 1 Level to Active Low.

How to Set up the Product Detector in Independent Mode for Printer (I)
1 Make sure that the Printer (I) is set to I-Mode (Figure 5-15). Navigate
to Print > Head Mode. Select Independent.
Figure 5-15: Independent Mode
Figure 5-12 on page 5-7 and Figure 5-13 on page 5-7).
3 Connect the photocell for Printhead 1 to the Head 1, Trigger 1
connector port on the cabinet (Figure 5-16).
4 Connect the photocell for Printhead 2 to the Head 2, Trigger 1
connector port on the cabinet (Figure 5-16).
Cat 5e
1. Head 1, Trigger 1
2. Head 2, Trigger 1
Figure 5-16: Head 1, Trigger 1 and Head 2, Trigger 1 Connector - I Mode

5 Navigate to Configure > Photocell Levels (Figure 5-10 on page 5-6).

Determine the Active state of the photocell as follows:
Note: Use the F3 key to toggle between the two printheads.

a. Block Head 1 photocell (set to Active).
blocked, set Photocell 1 Level for Head 1 to Active High. If the LED is
OFF while the photocell is blocked, set Photocell 1 Level to Active
Low.
c. Block Head 2 photocell (set to Active).
d. Check LED D1 on PCB 6. If the LED is ON while the photocell is
blocked, set Photocell 1 Level for Head 2 to Active High. If the LED is
OFF while the photocell is blocked, set Photocell 1 Level to Active
Low.
Set up the Encoding

The section describes the three types of encoding available.
• Internal
• External
• Auto Encoding
Note: If the printer is functioning in the I-Mode with each printhead operating on
a separate conveyor system, then the procedure described below must be
performed separately for each printhead.
Internal Encoding
Message Configuration Set to Divider/Strokes

1 Navigate to Print > Line Configuration. Set Message Configuration to
Divider / Strokes (Figure 5-17 on page 5-11).
5-10 Set up the Encoding Rev AA

Figure 5-17: Message Configuration - Divider/Strokes
2 Navigate to Print > Head Settings. Enter the Head Offset (in strokes) for
each printhead.
Figure 5-18: Head Offset
Note: In S-Mode, a single photocell is used and the Head Offset will establish
the position of each printhead with respect to this single photocell. In I-Mode,
each printhead will be fitted with its own photocell and the Head Offset will
establish the position of the printhead with respect to its own photocell.
3 Navigate to Print > Print Control. Set the Shaft Encoder Source to
Internal (Figure 5-19).
Note: If printer is in I-Mode, set Shaft Encoder Source for the correct
printhead.
Figure 5-19: Internal Shaft Encoder
4 Create and save a new message of a known width. Refer to Videojet

1610 Operator Manual on how to create a new message.
For Example:
Rev AA Set up the Encoding 5-11

• Using a 7-high font, create a 10-character message - it should be 1

inch (2.54 cm) in width.
5 Select this message for the required printhead and print the message.
6 Navigate to Messages > Message Parameters. Adjust the Width Divider
Factor until the correct code width is achieved (Figure 5-20).
7 Adjust the Product Delay (strokes) in order to attain perfect placement
of the code on the substrate (Figure 5-20).
Figure 5-20: Message Parameters
Note: If necessary, enter the determined ‘Width Divider Factor’ and

‘Product Delay’ as defaults in Messages > Default Parameters. All messages
subsequently created will open with these parameters.
Message Configuration Set to Linear Units

Linear Units (Figure 5-21).
2 Enter the Estimated Line Speed (m/min).
Figure 5-21: Linear Units and Estimated Line Speed
3 Navigate to Print > Head Settings. Enter the Head Offset (mm) for each
printhead (Figure 5-22 on page 5-13).

Figure 5-22: Head Offset (mm)
Note: In S-Mode, a single photocell is used and the Head Offset will establish
the position of each printhead with respect to this single photocell. In I-Mode,
each printhead will be fitted with its own photocell and the Head Offset will
establish the position of the printhead with respect to its own photocell.
Internal (Figure 5-19 on page 5-11).
printhead.
1610 Operator Manual on how to create a new message.
For Example:
Edit the Message Parameters for this new message and set the Width to
this desired value.
7 Adjust the Estimated Line Speed until the correct code width is achieved
8 Navigate to Message > Message Parameters (Figure 5-23 on page 5-14).
Adjust the Product Delay in order to attain perfect placement of the
code on the substrate.

Figure 5-23: Product Delay
Note: If necessary, enter the determined ‘Product Delay’ as default in

Messages > Default Parameters. All messages subsequently created will open
with this delay.
For all the subsequently created messages, use the Width in order to attain
the required code appearance.
External Encoding
Connect the Shaft Encoder as per the requirement.
• Printer (S) - Connect the shaft encoder to the Head 1 Encoder connector
port.
• Printer (I) in S-Mode - Connect the shaft encoder to the Head 1 Encoder
connector port.
• Printer (I) in I-Mode - Connect the two shaft encoders for the respective
printheads to the correct connector ports.

14
2
13 3
4
5
12
6
11
10 Cat 5e
7
9 8
1. COM 1, RS 232/ RS 485 8. USB

2. Relay Switches 9. Ethernet
3. Head 1, Trigger 2 10. Head 2, Encoder (I-Mode)
5. Head 2, Trigger 2 (I-Mode) 12. Head 1, Beacon
6. Head 2, Trigger 1 (I-Mode) 13. Head 1, Encoder
7. I/O 25 Way 14.COM 2, RS 232/ RS 485
Figure 5-24: Connector Panel (I-Mode)
Message Configuration Set to Divider/Strokes

1 Navigate to Print > Line Configuration. Set the Message Configuration to
Divider/Strokes (see Figure 5-17 on page 5-11).
each printhead (Figure 5-18 on page 5-11).
Note: In S-Mode, a single photocell will be used and the Head Offset will
establish the position of each printhead with respect to this single photocell.
In I-Mode, each printhead will be fitted with its own photocell and the Head
Offset will establish the position of the printhead with respect to its own
photocell.
3 Go to Print > Print Control (Figure 5-25 on page 5-16). Set the Shaft
Encoder Source to External.

printhead.
Figure 5-25: External

1610 Operator manual on how to create a message.
For example:
6 Navigate to Messages > Message Parameters (Figure 5-26). Adjust the
Width Divider Factor until the correct code width is achieved.
of the code on the substrate.
Note: If necessary, enter the determined ‘Width Divider Factor’ and

‘Product Delay’ as defaults in Messages > Default Parameters. All messages
Message Configuration Set to Linear Units

Linear Units (Figure 5-27 on page 5-17).

2 Enter the Encoder Resolution (ppi). To calculate PPI, refer Appendix B

of 1610 Service Manual (P/N - 462129).
Figure 5-27: Linear Units and Estimated Line Speed
printhead. Refer to Figure 5-22 on page 5-13.
photocell.
External. Refer to Figure 5-25 on page 5-16.
printhead.
For example:
this desired value.
7 Adjust the Encoder Resolution (Figure 5-27) until the correct code width
is achieved.
8 Adjust the Product Delay in order to attain perfect placement of the
code on the substrate (Figure 5-23 on page 5-14).


with this delay.
Auto Encoding
In an Auto Encoding, the Product Delay entered must be greater than the
Product Length.
Message Configuration Set to Divider / Strokes

1 Navigate to Print > Line Configuration. Set the Message Configuration is
set to Divider/Strokes (see Figure 5-17 on page 5-11).
2 Enter the Product Length.
each printhead (Figure 5-18 on page 5-11).
Enter the Head Offset as follows:
In S-Mode, for the leading printhead (the one closer to the photocell),
enter ‘0’ for the Head Offset. Use the Product Delay to control the
placement of the code on the product. Make sure that the Product
Delay is greater than the Product Length. For the trailing printhead (the
one further from the photocell), enter the distance between the
printheads for the Head Offset.
In I-Mode, each photocell must be at least one product length
upstream of the respective printhead. If the photocells are at different
distances from their respective printheads, then enter ‘0’ as the Head
Offset for the printhead whose photocell is closer, and enter the
difference between the respective photocell distances as the Head
Offset for the printhead whose photocell is further away.
photocell.
4 Go to Print > Print Control. Set the Shaft Encoder Source to Auto Encoder.
printhead.

Figure 5-28: External

For example:
6 Enter Strokes per inch (Message Parameters) as 60.
8 Navigate to Print > Line Configuration. Adjust the Product Length until
the correct code width is achieved.
of the code on the substrate. Make sure that this value is greater than
the Product Length.
Note: If necessary, enter the determined ‘Strokes per inch’ and ‘Product
Delay’ as defaults in Messages > Default Parameters. All messages
Message Configuration set to Linear Strokes

In an Auto Encoding, the Product Delay entered must be greater than the
Product Length.
1 Navigate to Print > Line Configuration. Set the Message Configuration is
set to Linear Units (see Figure 5-27 on page 5-17).

2 Enter the Product Length (mm).

printhead (Figure 5-22 on page 5-13).
Enter the Head Offset as follows:
In S-Mode, for the leading printhead (the one closer to the photocell),
enter ‘0’ for the Head Offset. Use the Product Delay to control the
placement of the code on the product. Make sure that the Product
Delay is greater than the Product Length. For the trailing printhead (the
one further from the photocell), enter the distance between the
printheads for the Head Offset.
In I-Mode, each photocell must be at least one product length
upstream of the respective printhead. If the photocells are at different
distances from their respective printheads, then enter ‘0’ as the Head
Offset for the printhead whose photocell is closer, and enter the
difference between the respective photocell distances as the Head
Offset for the printhead whose photocell is further away.
photocell.
4 Navigate to Print > Print Control (Figure 5-30). Set the Shaft Encoder
Source to Auto Encoder.
printhead.
Figure 5-30: Auto Encoder

1610 Operator manual on how to create a new message.
For example:


this desired value.
7 Adjust the Product Length until the correct code width is achieved
8 Adjust the Product Delay in order to attain perfect placement of the
code on the substrate (Figure 5-23 on page 5-14). Make sure that this
value is greater than the Product Length.

with this delay.

Printer Operation
6
Introduction
This chapter describes the procedures you can perform at level 3. Refer to
Videojet 1610 Service Manual (462129)
For information on other tasks, refer to the Videojet 1610 DH Operator
Manual Addendum (P/N 462219) and Videojet 1610 Operator Manual (P/
N 462128).
How to Select Head

Do the following tasks to select the required head for the operation:
1 Press F1 key for the Select Head dialog box to appear.
2 Select the required head from the options available using the Left and
Right arrow keys. The options are:
• Head 1
• Head 2
• Both Heads
3 Select the required head and press the Enter key to perform the
required sequence.
Note: Make sure you select the correct head while on a menu.

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 and select Both Heads to stop the ink jet for both the
heads.
2 Insert a USB flash drive into the external USB port of the printer.
3 Select Configure > Full System Backup.
Figure 6-2: Full System Backup
4 Follow the printer prompts and complete the backup.
Perform Full System Restore

Do the following tasks to recover previously backed-up information from
the USB flash drive:
1 Press the F1 key and select Both Heads to stop the ink jet for both the
heads.
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.
6-2 Perform System Backup Rev AA

Figure 6-3: Full System Restore
4 Use the Right or Left arrow keys to scroll through the available options
to restore.
Figure 6-4: Restore Options
5 Press the Enter key to restore the selected option.
Rev AA Perform Full System Restore 6-3

User Interface
7
Introduction
Refer to Videojet 1610 Operator Manual (P/N 462128) for information on
how to navigate in the UI, create the messages, edit the messages, save the
messages, and create the user fields.
Menu Description
Refer to the Videojet 1610 Operator Manual (P/N 462128) and Videojet
1610 DH Operator Manual Addendum (P/N 462219) for information on
Messages, Editor, User Fields, Print, Password, System, and Configure menus.
Refer to the Videojet 1610 Service Manual (P/N 462129) for sections on
Calibrate and Data Logging menus.
This section describes System, Calibrate and Data Logging Menus.
Note: Press F1 to select the required Head (Head 1, Head 2 or Both Heads).

System Menu
System Menu Command Function
Production The ink core is cleaned by the application of

System Flush solvent and suction action. The system prompts
the user to add solvent to the ink core.
After adding the solvent, the system performs

the flushing operation.
After performing flush, add ink to the ink core to

start the printing.
Table 7-1: System Menu and Commands
7-2 Menu Description Rev AA

System Menu Command Function
Valve Test Opens the Valve Test dialog box. You can
toggle the Test Type between Open/Close and
Continuity. You can toggle the Valve Selection
between Ink Add, Makeup Add, Gutter,
Jet-pump 1, Jet-pump 2, Solvent Recovery, Ink
Commissioning, Head Feed, Head Purge, Head
Flush, Flush-pump Vacuum, and Flush-pump
Pressure. You can toggle the Head between
Head 1 and Head 2.
List Raster Displays the list of raster files in the printer.

Files
Cover Detect Allows the printer to enable/disable the feature.

Enable
Phase Testing Allows the printer to enable/disable the feature.

Enable
Table 7-1: System Menu and Commands (Continued)
Rev AA Menu Description 7-3

Calibrate Menu
Calibrate Menu Commands Function
Diagnostics Screen 3 Opens the Diagnostics Screen

Three and displays information on
the ink system status, which can
be useful when diagnosing printer
faults.
For information on Diagnostics

Screen One, Two and Three, refer
Videojet 1610 Service Manual (P/
N 462129).
PEC Screen Displays PEC Status (ON/OFF) of

Head 1 and Head 2.
Calibrate EHT Use this option to calibrate the

EHT for Head 1 and Head 2.
Set Manual Phase Use this option to enable or

disable manual phasing for
Head 1 and Head 2.
Viscosity Calibration Use this option to calibrate the

viscosity of the ink in Head 1 and
Head 2.
Print Head Elevation Use this option to set the print

head elevation for Head 1 and
Head 2.
Table 7-2: Calibrate Menu and Commands

Calibrate Menu Commands Function
Input Line Configuration Opens the Input Line Setup dialog

box.
Output Line Opens the Output Line Setup

Configuration dialog box.
Table 7-2: Calibrate Menu and Commands (Continued)
Data Logging Menu
Data Logging Menu Commands Function
Version Info Displays version number of

software, firmware, CE Image,
CSB issue and utilization.
Table 7-3: Data Logging Menu and Commands
Rev AA Menu Description 7-5

Data Logging Menu Commands Function
Product Counter Opens the Product counter

dialogue with “Reset Counter for
Head 1, Head 2 and Display
Counters?” fields. Select Yes or
No for each field.
View Run Hours Displays the Pump run hours and

Machine run hours.
Reset Run Hours Opens a dialogue with the

following options:
• Set machine alarm hours,
range 0-65535
• Reset machine run hours, Yes
or No
• Reset pump run hours, Yes or
No
The running hours should be reset
only under exceptional
circumstances by trained service
personnel.
Table 7-3: Data Logging Menu and Commands (Continued)

Replacement
Instructions 8
When you order a spare part kit, the replacement instructions of the
respective spare part are provided along with the kit. For more
information, contact Videojet Technologies Inc. Refer to Chapter,
“Support and Training” of the Videojet 1610 Service Manual (P/N 462129)
for the contact information.
The replacement instructions are available for the parts included in the
following table.
Spare Part
Control System Board
Power Supply Unit
Liquid Crystal Display (LCD) or the Front Panel Interface Board

(FIB)
Keyboard/Electronics Compartment Door
Ink Core Module
Ink Pump
Printhead Engine Assembly
Printhead Valve Module Assembly
Umbilical Assembly
Printer Interface Board (PIB)
Electronics Compartment Fan
Septum Assembly
Gutter Pump
Gutter Pump (Videojet 1610 DH)
Power Switch
Ethernet Connector
Positive Air Kit
Table 8-1: Available Instructions
Rev AA 8-1
Spare Part
Double Headed Positive Air Pump (Videojet 1610 DH)
Ink Door Assembly
Ink System Fan
EHT Module
USB Connector
Plug and Power Cable
CSB Lithium Battery
PCB 1, 2 and 3
PCB 6 and 7 (Videojet 1610 DH)
Pressure Vacuum Test Tool
Printhead Bonding
Encoder and Adaptor Cable
Print Ready and Warning Output Cable
Beacon Installation
Air Dryer Installation
Air Dryer Installation (Videojet 1610 DH)
Photocell Mounting Plate
Ink Core Sample
Mobile Printer Stand
Adapter Plate
Wall Mounting
Printhead Stand
Static Printer Stand
Wash Station
Wash Station Upgrade
Table 8-1: Available Instructions
8-2 Rev AA
Printhead Bonding during Printing

Do the following tasks to establish bonding for the printhead and
receptacle:
1 Make sure that the printhead cover (item 6, Figure 8-1 on page 8-3) is
attached.
Note: The printhead is ground through the printhead screw (item 3) and
umbilical (item 1). If there is no screw, you must provide the printhead with
the path to the electrical ground.
3
7
1. Umbilical 5. Receptacle
2. Earth Bond Strap 6. Printhead Cover
3. Printhead Screw 7. Printhead
4. Crocodile Clip
Figure 8-1. Printhead and Receptacle
2 Use a metal or other conducting receptacle (item 5, Figure 8-1) to

collect the printhead fluid.
3 Connect one end of the earth bond strap (item 2) using crocodile clip
(item 4) to the receptacle. Make sure that the connection is rigid.
4 Connect the other end of the earth bond strap to the printhead cover
screw. Make sure that the connection is rigid.
Rev AA Printhead Bonding during Printing 8-3

5 Check the path from the electrical ground to the main printer cabinet
using a multi-meter or a similar device to make sure that the earth
loop is closed.
6 After the checks are completed, continue the printing operation.
Bonding during Servicing
Warning
PERSONAL INJURY. This operation must be carried out by a
trained service technician only.
1 Remove the printhead cover (see Figure 8-1 on page 8-3).

2 Locate the printhead screw into the printhead (Figure 8-2) and make
sure that the screw is in contact with the earth wire in the umbilical.
Printhead
Screw
Figure 8-2. Printhead Screw
3 Follow Step 2 to Step 5 under “Printhead Bonding during Printing” on

page 8-3.
8-4 Bonding during Servicing Rev AA

4 Perform the required maintenance operation. Refer to Chapter 8,

‘Maintenance’ from Videojet 1610 Service Manual (P/N: 462129) and
Chapter 9, “Maintenance” for more information on maintenance
procedures.
5 Remove the printhead screw.
6 Refit the printhead cover.
The printhead bonding instructions is complete.
Rev AA Bonding during Servicing 8-5

Maintenance
9
Introduction
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.
Task Frequency
Clean the Printhead As required
Replace the Core Module 12000 hours
Replace the Ink pump 24000 hours
Replace the Fan Filter 2,000 hours
Replace the Floor Filter Must be replaced with the ink core module
Replace the Air Dryer Filter (if 2,000 hours

fitted)
Table 9-1: Preventative Maintenance Schedule
Warning
PERSONAL INJURY. It is possible that in a fault condition the heater
can reach 70° C. Do not touch the plate on which heater is installed.
The failure to follow this warning can cause the personal injury.
Refer to the Chapter 8, “Maintenance” of the Videojet 1610 Service

Manual (P/N 462129) for complete information on following
maintenance procedures.
• Replacement of Ink System Fan Filter for IP65
• Replacement of Floor Filter for IP65
• Preparation for Long-term Shutdown (Storage) or Transportation
• Ink Change Procedure

Perform Calibration and Testing

The system calibration and test procedures must be performed when
printhead engine module, EHT supply, CSB, or umbilical is changed.
Calibrate EHT
Do the following tasks to calibrate the EHT:
Note: Please make sure printheads is clean and dry.
1 Open the Calibrate menu.
Figure 9-1: Calibrate Menu
2 Select the printhead which requires calibration.
3 Select Calibrate EHT. The EHT Calibration Message appear based on

the condition.
Figure 9-3: EHT Calibration Message
4 Press Enter. EHT Calibration Sweep occurs. Refer to Figure 9-4 on

page 9-3.
9-2 Perform Calibration and Testing Rev AA

Figure 9-4: Calibration Sweep
Calibrate Viscosity
Do the following tasks to perform viscosity calibration:
Note: Perform this procedure every time the following are replaced
• Ink core module

• Printhead engine
• CSB
Note: Perform the viscosity calibration when the viscosity of the ink in the core
known to be correct. The viscosity is correct if target pressure and the
temperature-compensated target pressure were equal before the components were
replaced. If the ink viscosity is uncertain, then replace the ink inside the core with
the fresh ink before viscosity calibration.
1 Keep the printhead at the same height as the umbilical during

installation, this height is later adjusted when moved to the
production line.
Set the printhead elevation value to zero for the required printhead.
Navigate to Calibrate > Printhead Elevation (see Figure 9-5 on
page 9-3).

2 Turn the knob and open the ink compartment door (see Figure 9-6 on
page 9-4).
Rev AA Perform Calibration and Testing 9-3

Figure 9-6: Unlock Ink Compartment Door
3 Remove the make-up fluid cartridge (see Figure 9-7 on page 9-4).
Make-up
Fluid Cartridge
Figure 9-7: Cartridge Removal

4 Perform a Quick Start. See Figure 9-8.
Figure 9-8: Quick Start
9-4 Perform Calibration and Testing Rev AA

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 -0.01 m/s
The printer does not allow the viscosity calibration process to be
initiated until the ink starts flowing without interruption for at least
30 minutes.
For example,
Target Pressure 2.6
Actual Pressure 2.62
Velocity Set Point 20.000
Actual Velocity 20.03
Table 9-2:
7 Perform viscosity calibration. Follow the prompts provided by the

printer, assuming that the ink is known perfect ink (see Figure 9-9).
Note: Perfect ink is the ink that is pulled directly from an ink cartridge
known to be within a specific viscosity range.
Figure 9-9: 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 9-5 on
page 9-3.
10 Put the printhead into the printhead bracket on the conveyor.
Rev AA Perform Calibration and Testing 9-5

Troubleshooting
10
Introduction
The Videojet 1610 Operator Manual (Part Number: 462128 contains the
troubleshooting procedures that an operator is allowed to perform. Refer
to the Operator Manual (P/N 462128) for these procedures.
This chapter contains the troubleshooting procedures that only trained
personnel or a service technician is allowed to perform.
Warning
PERSONAL INJURY. It is possible that in a fault condition the heater
can reach 70° C (158° F) temperature. Do not touch the plate on
which heater is installed. The failure to follow this warning can
cause personal injury.
Refer to Chapter 9, ‘Troubleshooting’ of the Videojet 1610 Service Manual

(P/N 462129) for complete information on following troubleshooting
procedures:
• Startup Problems
• Display Faults
• Beacon Indication
• Printer Status Icons
• Voltage Checks
• Jet Start and Stop Diagnostics
How to Clear a Clogged Nozzle

To clear the blockage in the nozzle, you require to do the procedures
described in this section. A blockage in the nozzle can be present if the
printhead engine module is showing signs of a misaligned ink stream/
loss of ink stream.

Perform a Nozzle Flush

Do the following tasks to perform a nozzle flush:
the printhead chassis and remove the printhead cover (see Figure 10-3
on page 10-4).
2 Support the printhead in a suitable stand and place a container
underneath to collect any extra solvent.
3 Make sure the container is connected to the electrical ground.
4 Initiate System > Nozzle Flush.
Figure 10-1. Nozzle Flush
5 Select Head dialog box appears. Select the required head.
Note: You can also select head by pressing F1.

6 Press the Enter key. The nozzle orifice must be washed with wisdom
to clear any blockages while nozzle flush is running.
Note: Make sure that the purge tube and return tube going up the umbilical
is observed to be clearing and that the flow of solvent is seen while running
the nozzle flush procedure.
7 If the problem is not resolved even after five nozzle flushes, perform a
clean start (refer to “Perform a Clean Start” on page 10-3).
10-2 How to Clear a Clogged Nozzle Rev AA

Perform a Clean Start

For information on how to perform a clean start, refer to Clean Stop and
Clean Start of the Printer of the Videojet 1610 Service Manual (P/N
462129).
A clean start will clean the nozzle with a higher operating pressure.
You can perform the Clean Start procedure for three times. If the ink jet
remains misaligned, perform system flush purge (refer to next procedure).
Perform System Flush Purge (with Nozzle Attached)

Do the following tasks to perform a system flush purge with the nozzle
attached:
1 Start System Flush Purge (select System > System Flush Purge).
Figure 10-2: System Flush Purge
2 Select Head dialog box appears. Select the required head.
Note: You can also select head by pressing F1.

3 Allow the system flush purge to run completely. Do not stop the
purge prematurely.
4 After system flush purge is completed, perform a clean start (refer to
“Clean Stop and Clean Start of the Printer” of the Videojet 1610
Service Manual (P/N 462129)).
5 If the ink stream is still misaligned, clean the nozzle with a syringe
and cleaning liquid (refer to the next procedure).
Rev AA How to Clear a Clogged Nozzle 10-3

Clean the Nozzle with a Syringe and Cleaning Liquid

Do the following tasks to clean the nozzle with a syringe and cleaning
liquid:
1 Turn Off the mains power switch of the printer.
2 Turn Off the AC power supply to the printer.
3 Disconnect the mains power cord from the electrical outlet.
the printhead chassis and remove the printhead cover (see Figure 10-
3).
1 2
3
3. Printhead Engine
Caution
EQUIPMENT DAMAGE. Always wear a set of rubber gloves before
disconnecting the nozzle tubing manifold. This helps to prevent
nozzle clogs.
5 Remove the M2 x 6 socket-head-cap screw that attaches the front

tubing manifold to the printhead valve module.
6 Use a syringe to flush the nozzle with 50 ml of cleaning liquid:
a. Inject the solvent through the feed side of the manifold. You must
see a stream of cleaning liquid that flows out of the nozzle.
b. Use an empty syringe to push air through the nozzle. You can
repeat the process any number of times as it does not add any fluid
to the system.
10-4 How to Clear a Clogged Nozzle Rev AA

7 If the ink stream is still misaligned, contact Videojet Technologies Inc.

Refer to “Support and Training” of the Videojet 1610 Service Manual
(P/N 462129) for Videojet contact information.
Note: When the nozzle misalignment clears after a clean start, the ink stream
goes out of alignment in the gutter and the system identifies a drop in target
pressure that can result in the system erroneously detecting low viscosity
fluid. So, it is critical that the nozzle orifice and charge electrode are inspected
to verify that a slight misalignment is not present.
CSB Test Points
Test Name Test Equipment Measurement

Point Required
TP1 -
TP4
TP1 - TP4
TP1 CPU RD Oscilloscope
Table 10-1: CSB Test Points
Rev AA CSB Test Points 10-5


Point Required
TP2 CPU WR Oscilloscope
TP3 CPU CS Oscilloscope
TP4 CPU IRQ Oscilloscope
10-6 CSB Test Points Rev AA


Point Required
TPV4 -
TPV27
TPV4 LDATA0 Oscilloscope


Point Required


Point Required


Point Required


Point Required


Point Required
TPV20 BA1 Oscilloscope


Point Required


Point Required
TP24 BA5 Oscilloscope


Point Required
TPV27 ADDR11 Oscilloscope
TP29,
TP30,
TP31
TP30-TP31
TP29
TP29 CPU RSTOUT Voltmeter Reading: 3.3 VDC
TP30 CPU RSTIN Voltmeter Reading: 3.3 VDC
TP31 EINT0 Voltmeter Reading: 3.3 VDC
TP32 -
TP33
TP33
TP32


Point Required
TP32 3.3 VDC - Voltmeter Reading: 3.3 VDC

fused - for LCD
TP33 Backlight Voltmeter Reading: 26.17 VDC

Power - fused -
to LCD
TP53
TP53 Charge Amp Voltmeter Plus 300VDC - used to measure +300 VDC
supply used in the Charge Amplifier circuit
Reading:+312 VDC
TP37
TP37 EHT 1 Drive Voltmeter 1. Used to measure the input of 28 VDC

Power voltage to the EHT1 drive circuit.
2. Use voltmeter to measure the DC voltage
at TP37.
3. The voltage measured will be
up to 28 VDC


Point Required
TPV43
TPV43 EHT1 Voltmeter Used to measure output of the EHT 1 drive

circuit.
1. With Print enabled, use a voltmeter to
measure the DC voltage at TPV43.
2. The voltage measured will be up to 24
VDC, depending on current EHT setting
for head 1.
Note: This test point is not accessible during
normal operation.
TP39
TPV39 Strobe LED 1 Oscilloscope 1. Measure the signal at TPV39.

2. Represents the digital signal used to
drive the printhead strobe led for print-
head 1
3. The following output is
considered to be good.
Note: This test point is not accessible during

normal operation.


Point Required
TPV40
TPV40 STROBE LED Oscilloscope 1. Used to measure the signal at TPV40.

2 2. Represents the digital signal used to
drive the printhead strobe LED for print-
head 2.
considered to be good.
:
TPV41
TPV41 Printhead Voltmeter 1. Used to measure the signal at TPV41.

Temperature 2. Represents the analog output of the print-
Head 1 head temperature sensor.
0.055 VDC = 1° Celsius.


Point Required
TPV47

Temperature 2. Represents the analog output of the print-
Head 2 head temperature sensor for printhead 2.
3. Measurement:
0.055 VDC = 1° Celsius.
TPV42 Ink Not used -

Temperature
TPV44,
TPV45,
TPV46
TPV44 Head Heater Voltmeter 1. Used to measure the input to the head
Drive heater drive circuit on chip U25.
2. Used to measure the signal at TPV44.
3. Measured voltage should be approxi-
mately 0.6 VDC.
TPV45 Head Heater Voltmeter 1. Used to measure the signal at TPV45.

Head 1 2. Represents the output of chip at U25
(Head Heater Drive) for printhead 1.
3. The measured voltage should approxi-
mately be 20 VDC and the voltage will
decrease (from 20 VDC) as the heater
power increases.


Point Required
TPV46 Head Heater Voltmeter Used to measure the signal at TPV46.

Head 2 1. Represents the output of chip U25 (Head
Heater Drive) for
printhead 2.
2. The measured voltage should approxi-
mately be 20 VDC and will decrease
(from 20 VDC) as the heater power
increases.
TPV37
and
TPV38

Cover 2. If the printhead cover is removed, the
measured voltage should be 3.3 VDC.
3. If the printhead cover is fitted, the mea-
sured voltage should be < 0.5VDC

Cover 2 2. If the printhead cover (for printhead 2) is
removed, the measured voltage should
be 3.3 VDC.
3. If the printhead cover is fitted, the mea-
sured voltage should be < 0.5VDC.
Lid
Switch
Circuit
(TPV37 -
TPV 38)


Point Required
TP45,
TP46
and
TP44
TP44 Modulation Voltmeter 1. The “Modulation Voltage

Head Monitor Monitor” is an output of the
modulation circuit used by the CSB to
track modulation voltage.
2. Measure the voltage at “MODV”.
3. Measured voltage should be less than 2
VDC, and the voltage will change as the
auto modulation routine is
performed.
TP45 Modulation Oscilloscope 1. Allows the measuring the modulation of

Transformer sine wave on the primary side of the
Primary modulation power amplifier transformer.
2. Measure the signal at TP45 with an oscil-
loscope.
3. The following output is considered to be
good:


Point Required
TP46 Modulation Oscilloscope 1. Used to verify output modulation signal

Drive Nozzle 1 supplied by the CSB to the nozzle.
2. With ink jet running, measure signal at
TP46. The following output is considered
to be good:
TP47,
TP49,
TP50
TP47 Modulation 2 Voltmeter 1. The “Modulation Voltage Monitor” is an

Voltage output of the modulation circuit used by
Monitor the CSB to track modulation voltage for
head 2.
2. Measure the voltage at “MODV”. Mea-
sured voltage should be less than 2 VDC,
and the voltage will change as the auto
modulation routine is performed.


Point Required
TP49 Modulation 2 Oscilloscope 1. Allows the measuring of the modulation

Transformer sine wave on the primary side of the
Primary modulation power amplifier transformer
for head 2.
2. Measure the signal at TP49 with an oscil-
loscope.
The following output is considered to be
good:
TP50 Modulation Oscilloscope Used to verify output modulation signal sup-

Drive Nozzle 2 plied by the CSB to the nozzle. With ink jet
running, measure signal at TP50.
good:


Point Required
TP52,
TP54
TP52 Modulation Voltmeter 1. Allows the measurement of the pro-

Current cessed signal used by the CSB to deter-
Monitor mine the nozzle current.
2. Measure the voltage at TP52.
3. 1 VDC indicates approximately 300 milli
amps of nozzle current.
TP54 Modulation 2 Voltmeter 1. Allows the measurement of the pro-

Current Moni- cessed signal used by the CSB to deter-
tor mine the nozzle current for printhead 2.
2. Measure the voltage at TP54.
3. 1 VDC indicates approximately 300 milli
amps of nozzle current.
TP63


Point Required
TP63 Modulation 2 Oscilloscope 1. This test point allows the measurement of

Clock the modulation clock signal (output of
chip U48) provide d to the modulation 2
drive circuit.
2. Measure the signal at TP63.
good:
TPV150 -
TPV154
TPV150 Modulation Din Oscilloscope Data input to Modulation DACs (chips U33
and U76).
TPV151 Modulation Voltmeter 3.3VDC

NCS


Point Required
TPV152 Modulation Oscilloscope

SCLK

(U33 - SDO
print-
head
one)

SDO
(U76 -
Printhead 2)


Point Required
TP55
TP55 Charge Oscilloscope Used to measure the signal at TP55. When

Amplifier out the ink stream is “On”, and the printer is not
printing, the following signal indicates that
the charge amplifier circuit is functioning
properly:
TPV100 QDAC RNW Oscilloscope


Point Required
TPV101 QDAC NCS Oscilloscope
TPV102 QDAC BNA Voltmeter 3.3 VDC
TPV103 RFBA Oscilloscope
TPV104 Oscilloscope


Point Required
TPV105 Oscilloscope
TPV111 Charge Amp Voltmeter 1. Allows the measurement of the analog

Out output of the charge amplifier circuitry,
that is fed back to the CSB's analog-to-
digital converter.
2. Measure the voltage at TPV111. With the
inkjet
running, the voltage should be 2.3 VDC.
3. If the inkjet is Off, the voltage should be
2.048 VDC.
TP56


Point Required
TP56 Charge Oscilloscope Used to measure the signal at TP56. When

Amplifier out the ink stream is “On”, and the printer is not
printing, the following signal
indicates that the charge amplifier
circuit is functioning properly:
TP106,
TP107,
TP108,
TP109
and
TP114
TPV106 QDAC RNW Oscilloscope


Point Required
TPV107 QDAC NCS Oscilloscope
TPV108 QDAC BNA Oscilloscope 3.3 VDC
TPV109 RFBA Oscilloscope
TPV114 Charge Amp Voltmeter 1. Allows the measurement of the analog

Out output of the charge amplifier circuitry
that is fed back to the CSB's analog-to-
digital converter.
2. Measure the voltage at TPV114. With the
inkjet running, the voltage should be 2.3
VDC.
3. If the inkjet is Off, the voltage should be
2.048 VDC.
TP112
TP113


Point Required
TPV112 Oscilloscope
TPV113 Oscilloscope


Point Required
TPV50 -
TPV61
TPV50 Print Engine Oscilloscope

Clock


Point Required

MOS

MIS
TPV53 SPI SSN Voltmeter 3.3 VDC
TPV54 NP TRIG Oscilloscope


Point Required
TPV55 Interrupt Oscilloscope
TPV56 SPI NSS Oscilloscope
TPV57 SPI MOS Oscilloscope


Point Required
TPV58 SPI MIS Oscilloscope
TPV59 SPI CLK Oscilloscope
TPV60 SC Drive Mix Voltmeter 3.0 VDC
TPV61 Pump Enable Voltmeter 1. If the ink pump is running, reading of 3.25
VDC is expected.
2. If the ink pump is idle, reading of 0 VDC
is expected.
TPV65,
TPV66


Point Required
TPV65 Shaft Encoder Oscilloscope 1. Used to verify the shaft encoder (phase B
Two in a quadrature encoder) is supplying
pulses to the printer.
2. Make sure that the encoder is connected
to the printer and start the conveyor,
measure the signal at TPV65.
Note: The signal will be present only if a
“quadrature” (two-phase) encoder is in use.
good:
TPV66 Shaft Encoder Oscilloscope 1. Used to verify that the shaft encoder is
one supplying pulses to the printer.
2. Make sure that the encoder is connected
to the printer and start the conveyor;
measure the signal at TPV66.
good:


Point Required
Power
Supplies
- TP71 -
TP73,
TP75 - 1. -12v tp75
2. +12V(TP72)
TP78,
3. +13V
TP80 1
4. +24V(TP77)
2
5. IV2(TP80)
3
6. +15V(TP73)
4
7. 3V3(TP71)
5
8. 3.3 VDC
6
TP78 5 VDC Voltmeter 1. Used to verify the filtered 5VDC level on

(+5VD) (Filtered) the CSB.
2. Measure the voltage at “+5VD”.
3. Measured voltage should be +5VDC.
TP80 FPGA core Voltmeter 1. Used to verify the FPGA core Voltage on
(+1V2) VOLTAGE the CSB.
2. Measure the voltage at “+1V2”.
3. Measured voltage should be +1.2VDC.
TP75 -12VDC Voltmeter Used to verify regulated -12 VDC produced

(-12V) on the CSB. Measure the voltage at "-12V".
Measured voltage should be -12VDC
TP72 +12VDC Voltmeter 1. Used to verify regulated +12 VDC pro-

(+12V) duced on the CSB.
2. Measure the voltage at “+12V”.
TP77 +24VDC Voltmeter 1. Used to verify unfiltered +24 VDC pro-

(+24DC) vided to the CSB from the Mains power
supply.
TP71 3.3 VDC Voltmeter 1. Used to verify the output of the 3.3 VDC
(3V3) voltage regulator (chip U54) on the CSB.
2. Measure the voltage at “3V3”.
3. Measured voltage should be 3.3VDC.
TP76 -15VDC Voltmeter 1. Used to verify unfiltered -15 VDC pro-

(-15V) vided to the CSB from the Mains power
supply.
2. Measure the voltage at “-15V”.
3. Measured voltage should be
-15VDC.


Point Required
TP73 +15V Voltmeter 1. Used to verify unfiltered +15 VDC pro-

(+15V) vided to the CSB from the Mains power
supply.
TP87,
TP89 -
TP91,
TP95 -
TP96
TP87 Velocity Oscilloscope 1. Used to measure the signal at TP87.

2. Represents the analog signal being
detected by the second TOF sensor in
the printhead.
considered to be good:


Point Required
TP89 Phasing Oscilloscope 1. Used to measure the signal at TP89.

detected by the first TOF sensor in the
printhead.
TP90 Phasing Signal Oscilloscope 1. Allows the monitoring of the processed

Amplified phasing signal
downstream of chip U63 on the CSB.
2. Measure the signal at TP90. The follow-
ing output is


Point Required
TP91 Velocity Signal Oscilloscope 1. Allows the monitoring of the processed

Amplified velocity signal
TPV30 Phasing Oscilloscope 1. Allows the monitoring of the trigger signal

Trigger A supplied by chip U61 to the FPGA.


Point Required

Trigger B supplied by chip U61 to the FPGA.
TP99,
TP100,
TP102,
TPV32 -
34
TP102 Velocity 2 Oscilloscope 1. Used to measure the signal at TP102.

detected by the second TOF sensor in
the printhead.
good:


Point Required
TP99 Phasing 2 Oscilloscope 1. Used to measure the signal at TP99.

detected by the first TOF sensor in the
printhead.
good:
TP100 Phasing Signal Oscilloscope 1. Allows the monitoring of the processed

Amplified phasing signal downstream of chip U70
on the CSB.
good:


Point Required
TPV33 Velocity Signal Oscilloscope 1. Allows the monitoring of the processed

Amplified velocity signal
2. Measure the signal at TPV33.
good:

Trigger A2 supplied by chip U66 to the FPGA.
good:


Point Required

Trigger B2 supplied by chip U66 to the FPGA.
3. The following output is considered to be
good:
TP92,
TPV155 -
TPV159


Point Required
TP92 Probes Drive Voltmeter or Oscillo- 1. Used to verify the common electrical
scope drive signal in the core (mixer tank) level
detection circuit.
2. If a voltmeter is used, the voltage shall
read 1.6 VDC. If an oscilloscope is used,
the following output is considered to be
good:
TPV155 Level Probe 0 Oscilloscope Used to confirm the “high” sensor in the
(Mixer Tank mixer tank is covered or uncovered.
High) 1. A voltage of 0 VDC indicates that the sen-
sor is covered.
2. A voltage of 0.8 VDC indicates that the
sensor is uncovered.
3. The following signal indicates that the
sensor is uncovered.


Point Required
TPV156 Level Probe 1 Voltmeter Or Oscillo- Used to confirm whether the “middle” sensor
(Mixer Tank scope in the mixer tank is covered or uncovered.
Middle) 1. If a voltmeter is used and the sensor is
covered, voltage of 0.8 VDC indicates
that the sensor is uncovered.
2. A voltage of 0 VDC indicates that the sen-
sor is covered.
3. In an oscilloscope, the following signal
indicates that the sensor is uncovered:
TPV157 Level Probe 2 Voltmeter or Oscillo- 1. If a voltmeter is used and the sensor is
(Mixer Tank scope covered, a voltage of 0.8 VDC indicates
Low) that the sensor is uncovered.
2. A voltage of 0 VDC indicates that the sen-
sor is covered.
3. The following signal indicates that the
sensor is uncovered:


Point Required
TPV158 Gutter Sense Voltmeter or Oscillo- Used to confirm the status of the “gutter
scope detect” circuit.
1. If a voltmeter is used and ink is present in
the gutter, voltage should read 0VDC.
2. A voltage of.6 VDC indicates that the gut-
ter detect chamber is empty.
3. The following signal is expected if the
gutter detect chamber is empty:
TPV159 Gutter Sense Voltmeter or Oscillo- Used to confirm the status of the “gutter
Head 2 scope detect” circuit for printhead 2.
1. If a voltmeter is used and ink is present in
the gutter, voltage should read 0 VDC.
2. A voltage of 0.6 VDC indicates that the
gutter detect chamber is empty.
3. The following signal is expected if the
gutter detect chamber is empty:


Point Required
TPV89,
TPV90
TPV89 Ink Pressure Voltmeter Used to verify the electrical output of the
pressure transducer monitoring ink pump
output in the core.
Measurement:1 VDC = 1.23 bar.
TPV90 Vacuum Voltmeter Used to verify the electrical output of the

pressure transducer
monitoring vacuum in the make-up addition
system in the core.
Measurement: 1 VDC = 208 millibars vac-
uum.
TPV80 -
TPV83,
TPV171 -
TPV180


Point Required
TPV80 Pump Voltmeter 1. Used to verify the digital signal provided

Forward/ by the FPGA to the pump driver chip
Reverse U82.
2. Voltage measured will be 3.3 VDC (pump
“forward” direction), except when the
1710 ink pump is being operated in the
“reverse” direction during the Ink core mix
cycle - the voltage measured will be 0
VDC.
TPV81 Pump Tacho Oscilloscope When Pump is running
TPV82 Pump Setpoint Voltmeter Used to verify the analogue signal provided
by the FPGA to the pump driver chip U82.
Measure the voltage when the pump is run-
ning.
1. For the 1710 (narrow-gear ink pump), 1
VDC equates to approximately 0.8 bar.
2. For non-1710 printers,1 VDC = 0.7 bar
approximately.
TPV83 Pump Current Voltmeter Measure the voltage when the pump is run-
Sense ning. Voltage
measured will normally be less than 0.1
VDC.


Point Required
TPV171 Oscilloscope
TPV172 Oscilloscope
TPV173 Oscilloscope


Point Required
TPV174 Oscilloscope
TPV175 Oscilloscope
TPV176 Oscilloscope


Point Required
TPV177 Oscilloscope
TPV178 Oscilloscope
TPV179 Oscilloscope
TPV180 REF Voltmeter Reference: Voltage used by chip is U82. the

voltage measured will be 6.4 VDC.


Point Required
TP109, TPV91 - TPV93, TPV95, TPV96 = Valves


Point Required
TPV91 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” volt-
age, when solenoid valves are actuated.
1. Measure the voltage at TPV91.
2. If measured voltage = +3.3 VDC, the “hit”
circuit is “Off” (this is the steady-state
condition).
3. If measured voltage = 0 VDC, the “hit” cir-
cuit is on (this indicates that the valves
are opened).
TPV92 HIT Drive 2 Voltmeter Refer to TPV91 - only used on the 1610
Dual Head (parallel circuit)
TPV93 Valve Common Voltmeter Measure the voltage at TPV93. The voltage
should read 5VDC, Unless “hit” voltage is
being supplied during the opening of any
valve - the measured voltage will temporarily
reach +24VDC.
TPV95 Valve Voltmeter Measure the voltage at TPV95. The mea-

Common sured voltage will read 0 VDC unless “hit”
Monitor voltage is being supplied during the opening
of any valve - the measured voltage will tem-
porarily reach approximately 3.3 VDC.
TPV96 Valve Current Voltmeter 1. Measure the voltage at TPV96; if zero

Monitor valves are open, then the measured
voltage will read approximately 0 volts.
2. The measured voltage will increase by
0.1 VDC for each valve that is opened.
3. For 1710 printer, the measured voltage
will increase by 0.15 volts when VT valve
is opened.
4. The measured voltage will increase by
0.07 volts when VV, VR, VS, VI, or VM
valves are opened.
TP108
TP108 VDDIARM Voltmeter 1.4 VDC


Point Required
TPV120 -
TPV124
TPV120 ADC EOC Voltmeter 0 VDC
TPV121 ADC DOUT Oscilloscope
TPV122 ADC DIN Oscilloscope


Point Required
TPV123 ADC NCS Oscilloscope
TPV124 ADC NCS Oscilloscope
TPV126,
TPV125
TPV125 EXP SA Voltmeter 0 VDC
TPV126 EXP SB Voltmeter 0 VDC


Point Required
TPV127 -
TPV131
TPV127 DAC SCLK Voltmeter 3.3 VDC
TPV128 DAC DIN Voltmeter 0 VDC
TPV129 DAC NLDAC Voltmeter 3.3 VDC
TPV130 DAC NCLR Voltmeter 3.3 VDC
TPV131 DAC NCS Voltmeter 3.3 VDC
TPV132
TPV132 REF P (10-Bit Voltmeter Used to measure the reference voltage in

DAC circuit) 10-bit 8-channel DAC circuit.
1. Used to measure the DC
voltage at TPV132.
2. The measured voltage should be 4.096
VDC.
TPV133 -
TPV134


Point Required
TPV133 EHT2 SETV Voltmeter 1. Used to measure the input to the EHT 2
drive circuit.
2. With Print enabled, use a
voltmeter to measure the DC voltage at
TPV133.
3. Measured voltage will be up to 4 VDC,
depending upon the current EHT setting
for head 2.
TPV134 EHT2 Voltmeter 1. Used to measure the output of the EHT 2

drive circuit.
2. With Print enabled, use a
voltmeter to measure the DC voltage at
TPV134.
3. Measured voltage will be up to 24 VDC,
depending upon the
current EHT setting for head 2.
TP34
TP34 +300VDC Voltmeter 1. Used to measure the “Rail Voltage” for

(Channel 2) head head2.
2. Used to measure the DC
voltage at TP34.
3. The voltage measured should be 285
VDC +/- 2 VDC.
TPV136,
TPV135
TPV135 Voltmeter 0.28 VDC


Point Required
TPV136 CHAN2 COM Voltmeter 1. Measurement = for the 1610 Dual Head,
this test point may be used to measure
the input to chip U22, which in turn pro-
vides the "-300 VDC Monitor" signal to
the FPGA.
2. Use a voltmeter to measure the DC volt-
age at TPV136. Measured voltage should
be .39 VDC.
TPV137 -
TPV138
TPV137 EHT2 Current Voltmeter 1. Used to measure the leakage current

Sense detected in head 2's EHT circuit.
2. Enable print for head 2 and use voltmeter
to measure the DC voltage at TPV137.
3. Represents the raw analog voltage input
to chip U83
(fitted on the 1610DH printer).
4. The voltage measured will be less than
0.05 VDC. The
voltage measured will increase as the
EHT voltage is increased.
TPV138 EHT Current Voltmeter 1. Used to measure the leakage current

Head 2 detected in head 2's EHT circuit.
2. Enable print for head 2 and use a voltme-
ter to measure the DC voltage at
TPV138.
3. The voltage measured
represents the amplified output of chip
U83 (fitted on the 1610DH printer). The
voltage measured will be between 0.5
VDC and 2.5 VDC, depending upon the
EHT voltage setting.
4. The voltage measured will increase as
the EHT voltage is increased.


Point Required
TPV63,
TPV67 -
TPV75,
TPV77 -
TPV78
Note: Do not use these test points as these test points are not accessible during normal
printer operation.
TPV63 PEC2
TPV67 PEC1
TPV68 Message
Select Bit 0
TPV69 Message
Select Bit 1
TPV70 Message
Select Bit 2
TPV71 Message
Select Bit 3
TPV72 Message
Select Bit 4
TPV73 Message
Select Bit 5
TPV74 Message
Select Bit 6
TPV75 Message
Select Bit 7
TPV77 Spare
TPV78

Illustrated Parts List
11
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.
The chapter lists the following sub-assemblies, which are different from
the standard Videojet 1610.
- Control System Board (CSB) with Back Plate
- Printer Interface Board
- Double Headed Air Pump
- EHT Module
- Connector Panel
• Ink Compartment
- Gutter Pump Assembly
• Cables
• Optional Accessories
- Beacon Kit
- Dual Head Bracket
- Printhead Clamp Assembly
- Adjustable Alignment Dual Printhead Bracket Assembly
- Dual Head Air Dryer
- Printhead Air Flow Kit
• Miscellaneous Accessories
- Connectivity
Rev AA 11-1
For information on the following assemblies and sub-assemblies, refer to

the Videojet 1610 Service Manual (P/N 462129):
- Power Switch
- Electronics Door Assembly
- Display Door
- LCD and FIB Assembly
- Power Supply Unit Assembly
- Electronics Fan Assembly
• Ink Compartment
- Ink Cartridge
- Make-up Cartridge
- Ink Door Assembly
- Septum Assembly
- Ink Core Module Assembly
- Ink Core Pump
- Ink System Fan
- Condenser Assembly
- Ink System Filter Assembly
- Floor Filter
- Cabinet Foot
• Printhead
- Printhead Valve Module
- Printhead Engine
• Optional Accessories
- Dry Air Kit Assembly
- Static Stand
- Mobile Stand
- Printhead Holder
- Mounts to Printhead Holder
- Wash Station Assembly
- Shaft Encoder
- Product Detectors
11-2 Rev AA
- Power Accessories
- Power Cord
- Din Plugs
- Power Cord
• Miscellaneous Accessories
- Hydraulics
- Printhead and Umbilical
• Tools Kit
Rev AA 11-3
Videojet 1610 Dual Head Printer
B
D
Figure 11-1: Main Parts of the Printer
Table 11-1 shows the sub assemblies of the printer.
Item Descriptions
A Electronics Compartment
B Ink Compartment
C Umbilical
D Printhead
Table 11-1: Videojet 1610 DH Printer Assemblies
11-4 Videojet 1610 Dual Head Printer Rev AA

Electronics Compartment
E
A
F
View A
View A
H
K
G
J
Figure 11-2: Electronics Compartment

Control System Board (CSB) with Back Plate
Figure 11-3: Control System Board Assembly with Back Plate

Printer Interface Board Assembly (PIB)
G 3
Figure 11-4: Printer Interface Board Assembly

Double Headed Air Pump Assembly (Dual Head Printer)
J
7
Figure 11-5: Double Headed Air Pump Assembly
EHT Module
10
11
Figure 11-6: EHT Module

Connector Panel
L S-Mode
COM 2 COM 1
RS232/485
RELAY
SWITCHES
RS232/485
12
HEAD 1 HEAD 1 HEAD 1 HEAD 1
BEACON ENCODER TRIGGER 2 TRIGGER 1
HEAD 2
BEACON
Cat 5e
13
15 14
I-Mode
COM 2 COM 1 RELAY
RS232/485 RS232/485 SWITCHES

12

Cat 5e
13
15 14
Figure 11-7: Connector Panel (S- Mode and I-Mode))

PCB Assemblies
12
13
Figure 11-8: PCB Assembly
Item Number P/N Description Qty
A Electronics Compartment
1 SP399597W Control System Board (CSB) with Back Plate 1
2 Power Switch 1
G SP399754 Printer Interface Board (PIB) Assembly
3 M4 x 8 Cap-head Screw 6
4 M4 ET Washer 6
5 PIB 1
6 PIB Gasket 1
J SP395612 Double Headed Air Pump Assembly (Dual

head Printer)
395639* Positive Air Tubing Kit
7 Dampener 1
8 Double Head Positive Air Pump 1
9 M4 Nyloc Nut 3
Table 11-2: Electronics Compartment

K SP239229 EHT Module Assembly (1610 DH)
SP500083* EHT Cable Assembly Spare
10 EHT Module 1
11 M4 Nyloc Nut 2
L Connector Panel
12 SP399764 PCB 6 Assembly (I-Mode) 1
SP399959 PCB 7 Assembly (S-Mode) 1
13 399475 PCB 4 Assembly 1
14 399084 USB Connector 1
15 399083 Ethernet Connector 1
Table 11-2: Electronics Compartment (Continued)
*- Items are not shown in the figure

Ink Compartment
Figure 11-9: Ink System
11-12 Ink Compartment Rev AA

Gutter Pump Assembly
G
3
4
5
Figure 11-10: Gutter Pump Assembly
B Ink Compartment
1 Ink Cartridge 1
2 Make-up Cartridge 1
G 395633 Gutter Pump Assembly
395656* Gutter Pump Spares Kit FG
3 Gutter Pump 1
4 M4 Nyloc Nut 2
5 3 Way Valve 1
Table 11-3: Ink Compartment
*- Item is not shown in the figure
Rev AA Ink Compartment 11-13

Cables
Figure 11-11: Cables
395634 Ribbon Cable Spare 1610 DH
1 Spare Ribbon Cable Assembly (Display) 1
2 Spare Ribbon Cable Assembly (Pump and 1

Smart chip - 14 way)
3 Spare Ribbon Cable Assembly 3

(CSB to PIB - 50 way)
4 Ribbon Cable Assembly (CSB to PIB - 34 Way) 1
Table 11-4: Cables
11-14 Cables Rev AA

Optional Accessories
Dual Head Beacon Kit
Figure 11-12: Dual Head Beacon Kit
Dual Head Bracket
4 5
Figure 11-13: Dual Head Bracket
Rev AA Optional Accessories 11-15

Printhead Clamp Assembly
Figure 11-14: Printhead Clamp Assembly
11-16 Optional Accessories Rev AA

Adjustable Alignment Dual Printhead Bracket Assembly
17
16
10
15
14
10
13
11
12
Figure 11-15: Adjustable Alignment Dual Printhead Bracket Assembly

Dual Head Air Dryer
31
21
30
23 22
24
25
29
28
26
27
Figure 11-16: Dual Head Air Dryer
395631 Dual Head Beacon Kit
1 Beacon 2
2 M4 x 10 Socket-head Cap Screw 6
3 Beacon Mounting Bracket 1
395632 Offsettable Dual Head Bracket 1
4 M6 x 8 Cup Grub Screw 4
5 Dual Head Bracket
SP395700 Printhead Clamp Assembly
Table 11-5: Accessories
11-18 Optional Accessories Rev AA

6 M5 Plastic Knob 1
7 Printhead Clamp Bracket 1
8 Printhead Clamp 1
395709 Adjustable Alignment Dual Printhead Bracket

Assembly
9 Fixed Printhead Holder 1
10 Printhead Carrier 2
11 Printhead Carrier Housing Pivot 1
12 M8 X 40 Knob 1
13 M3 x 16 Socket Head Cap Screw 2
14 M10 X 1P Locknut 2
15 Indexing Pin 2
16 Adjustable Printhead Holder 1
17 M6 x 25 Socket Head Cap Screw 2
18* M8 (003M8) Insert Headed Threaded Tappex 1
19* M3 Trisert (336M3) Insert Headed Tappex 2
20* M6 x 8 Cup Point Grub Screw 2
SP395696 Dual Head Air Dryer Spare
21 Air Dryer Mounting Bracket 2
22 Plain Nylon Washer 4
23 M4 x 10 Socket-head Screw 5
24 Air Dryer 2
25 Outlet Tube 2
26 Air Regulator 2
27 Pressure Gauge 2
28 Rubber Tube 2
29 Filter 2
30 1/4"-20 x 1" Socket-head Screw 4
Table 11-5: Accessories (Continued)

31 Inlet Tube 2
395642* Printhead Air Flow Kit 1610
Table 11-5: Accessories (Continued)
Miscellaneous Accessories
Connectivity
I/O Cables (RS 232/RS 485)
4 2
1 3
Figure 11-17: Serial Adaptor Cable RS 232 - 3 m
4 1 2 3
Figure 11-18: Serial Extension Cable RS 232 - 6 m
4
1
Figure 11-19: I/O Cable RS 485/RS 232 - 6 m
11-20 Miscellaneous Accessories Rev AA

395640 Serial Adaptor Cable RS 232 3m
395641 Serial Extension Cable RS 232 6m
395670 I/O Cable RS 232/RS 485 6m
1 Cable, 8-core, 24 AWG, Shielded (3 m or 6 m)
2 Back Shell 9 Way D
3 Connector Socket 9 Way D Solder Bucket
4 8 Pin DIN Plug, Silver, 4-6mm, Cable Exit
5* SP399909 Dual Head Printhead Interconnect Cable 1
6* 395638 Handles Spare 1
Table 11-6: Miscellaneous Accessories
Rev AA Miscellaneous Accessories 11-21

Clean/Quick Start and
Stop Description A
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.
Rev AA Clean Start A-1

Quick Start
This method starts without a flushing sequence, and uses the ink supply
to bleed the air from the nozzle.
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.
A-2 Quick Start Rev AA

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
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.
Rev AA Quick Stop A-3

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Videojet 1610

Videojet Technologies Inc.

Chapter 3 — Main Parts

Configure the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–18

Chapter 5 — Printer Set up

Chapter 6 — Printer Operation

Chapter 7 — User Interface

Chapter 8 — Replacement Instructions

Chapter 11 — Illustrated Parts List

Appendix A — Clean/Quick Start and Stop Description

Nozzle Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–3

Rev AA Videojet 1610 Dual Head Printer 1-1

Note: Each printhead must be set up separately before printing.

About the Manual

Note: The availability of the Operator Manual is indicated by an asterisk (*).

Code Language Availability (see

Table 1-1: Language Codes

1-2 About the Manual Rev AA

Code Language Availability (see

Table 1-1: Language Codes (Continued)

Rev AA Content Presentation 1-3

Refer to Chapter 1, “Introduction” of the Videojet 1610 Service Manual (P/

The Word ‘Printer’

1-4 Content Presentation Rev AA

Chapters in the Manual

Chapter Chapter Name Description

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

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

9. Maintenance Contains the information on how to maintain and clean the

10. Troubleshooting Contains the operator level diagnostic and troubleshooting

Table 1-2: List of Chapters

Rev AA Chapters in the Manual 1-5

Rev AA Introduction 2-1

Rev AA Printer Overview 3-1

same product. Each printhead can print a separate message. Refer to

* The components are not shown in the picture

Figure 3-1: Main Parts of the Printer (S)

3-2 Printer Overview Rev AA

* The components are not shown in the picture

Rev AA Cabinet 3-3

* - The Component is not shown in the figure

Mains Power Switch

3-4 Cabinet Rev AA

Figure 3-4: Main Power Switch

Table 3-1 provides the connectors for the printers.

Connector Type PCB Standard Optional

COM 2 PCB 7 Videojet 1610

PCB 6 Videojet 1610

COM 1 PCB 7 Videojet 1610

PCB 6 Videojet 1610

Relay Switches PCB 7 Videojet 1610

PCB 6 Videojet 1610

Table 3-1: Connector Panel

Rev AA Cabinet 3-5

Connector Type PCB Standard Optional

Head 1, Beacon PCB 7 Videojet 1610

PCB 6 Videojet 1610

Head 1, Encoder PCB 7 Videojet 1610

PCB 6 Videojet 1610

Head 1, Trigger 2 PCB 7 Videojet 1610

PCB 6 Videojet 1610