DirectJet 1024UV Service Manual

The DirectJet 1024UV is a professional-grade UV digital printing system designed for high-volume production environments. This service manual covers technical specifications, maintenance procedures, troubleshooting guidelines, and safety protocols for qualified service technicians. The system features UV-curable ink technology, precision print heads, advanced media handling, and industrial-grade components for reliable operation.

1. Technical Specifications 2. System Overview 3. Installation Procedures 4. Maintenance Schedule 5. Print Head Maintenance 6. UV Curing System 7. Electrical System 8. Mechanical Components 9. Software Configuration 10. Error Codes & Diagnostics 11. Troubleshooting Guide

Technical Specifications

Key technical parameters and performance characteristics of the DirectJet 1024UV printing system.

Specification	Description
Print Technology	Piezo-electric Drop-on-Demand UV Inkjet
Maximum Print Width	1024mm (40.3 inches)
Print Resolution	Up to 1440 x 1440 dpi
Print Speed	Up to 75 m²/hour in production mode
Ink System	8-color UV curable ink (CMYK + LcLm + White + Varnish)
Media Thickness	0.1mm to 50mm
UV Curing System	LED UV lamps with adjustable intensity
Power Requirements	220-240V AC, 50/60Hz, 15A
Operating Environment	15-30°C, 40-60% humidity
Dimensions	2500mm (L) x 1500mm (W) x 1400mm (H)

System Overview

Major components and functional description of the DirectJet 1024UV printing system.

Print Head Assembly: 8 independent piezo print heads with automatic maintenance system
Ink Delivery System: Pressure-regulated ink supply with filtration and degassing
UV Curing Unit: LED-based curing system with temperature monitoring
Media Handling: Precision roller system with tension control and alignment
Control Electronics: Main controller board, motor drivers, and interface modules
Software Interface: RIP software with color management and job queuing

WARNING! Only qualified technicians should perform service procedures. Disconnect power before servicing.

Installation Procedures

Step-by-step installation guide for the DirectJet 1024UV system.

Site Preparation: Ensure level floor, adequate ventilation, and proper electrical supply
Unpacking: Remove shipping restraints and protective materials
Assembly: Install media roll holders and output stacker
Electrical Connection: Connect to dedicated 220V circuit with proper grounding
Ink System Setup: Prime ink lines and initialize print heads
Software Installation: Install RIP software and device drivers
Calibration: Perform initial print head alignment and media calibration

CAUTION! Use proper lifting equipment; system weight exceeds 300kg.

Maintenance Schedule

Daily: Clean print heads, check ink levels, inspect media path
Weekly: Clean encoder strip, lubricate guide rails, check UV lamp output
Monthly: Replace ink filters, clean cap station, calibrate sensors
Quarterly: Replace wiper blades, clean ink supply system, full system calibration
Annually: Replace UV lamps, service motors and drives, comprehensive system check

Print Head Maintenance

Procedures for maintaining and servicing print head components.

Cleaning Procedures: Manual cleaning via service menu, nozzle check patterns, head soaking procedure.

Replacement: Head alignment after replacement, electrical connectivity check, firmware update if required. Performance Verification: Print test patterns, check droplet formation, verify firing frequency.

UV Curing System

Maintenance and service procedures for the UV curing subsystem.

Lamp Inspection: Check LED array for damage or degradation
Power Supply: Verify output voltage and current specifications
Cooling System: Clean fans and heat sinks, check airflow
Intensity Calibration: Use UV meter to verify curing energy
Safety Interlocks: Test door switches and emergency stops

Tip: Always wear UV-protective eyewear when servicing curing system.

Electrical System

Power distribution, control circuits, and safety systems.

Main Power Supply: 220V AC input, DC power distribution
Motor Drivers: Stepper and servo motor control circuits
Sensor Systems: Optical, mechanical, and proximity sensors
Safety Circuits: Emergency stop, interlock switches, thermal protection
Communication: Ethernet, USB, and serial interfaces

WARNING! High voltage present in power supply units. Disconnect power before servicing.

Mechanical Components

Maintenance procedures for mechanical systems and moving parts.

Carriage Assembly: Guide rails, bearings, and belt tension adjustment
Media Transport: Roller alignment, tension settings, drive gear maintenance
Ink System: Pump maintenance, valve operation, tube connections
Frame Structure: Bolt torque verification, alignment checks

Software Configuration

System software settings, calibration procedures, and diagnostic tools.

RIP Settings: Color profiles, resolution settings, print modes. System Configuration: Media settings, ink limits, curing parameters. Diagnostic Tools: System logs, error history, performance monitoring.

Error Codes & Diagnostics

Comprehensive list of system error codes and diagnostic procedures.

Error Code	Description	Diagnostic Procedure
E001	Print Head Communication	Check head cables, replace interface board
E012	Ink Supply Pressure	Check pumps, valves, and pressure sensors
E025	Media Transport	Inspect rollers, encoders, and drive motors
E038	UV System Fault	Test lamps, power supply, cooling system
E101	Main Controller	Reset system, update firmware, replace board

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Banding in prints	Clogged nozzles, misalignment	Perform head cleaning, run alignment procedure
Poor curing	UV lamp failure, incorrect settings	Check lamp output, adjust curing parameters
Media feeding issues	Roller wear, tension problems	Adjust tension, replace worn rollers
Ink starvation	Clogged filters, pump failure	Replace filters, service ink pumps
Communication errors	Cable damage, interface issues	Check cables, reset interfaces

Reset Procedure: Service menu > System > Factory Reset (use with caution).

Technical Support: 1-800-DIRECTJET; www.directjet-support.com