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AGFA, the Agfa rhombus, Anapurna L and Anapurna XL are registered trademarks of Agfa-Gevaert N.V. or its affiliates. Those names and product names not mentioned here are trademarks or registered trademarks of their respective owners. For more information about Agfa Graphics products, visit www.agfa.com or contact us at the following address:
Agfa Graphics. Septestraat 27 B-2640 Mortsel, Belgium Tel: (+)32 3 444 2111
Copyright 2007 Agfa Graphics, Belgium. All software and hardware described in this document are subject to change without notice.
1-2
Contents
About this Service Manual
............................................................................................................................. 0 - 1 1. Service Manual Overview ............................................................................................................................................. 0 - 1 2. Scope .................................................................................................................................................................................... 0 - 1 3. Related Documentation ................................................................................................................................................ 0 - 1
......................................................................................................................................... 1 - 1
1. General Description ........................................................................................................................................................ 1 - 3 1.1. System Description ............................................................................................................................................ 1 - 3 1.2. Block Diagram ...................................................................................................................................................1 - 13 2. Safety Circuits .................................................................................................................................................................1 - 14 2.1. Emergency Stop Circuit ..................................................................................................................................1 - 14 2.2. Door Open Detection ......................................................................................................................................1 - 15 3. Power Distribution ........................................................................................................................................................1 - 18 3.1. Functional Description ...................................................................................................................................1 - 18 4. Compressed Air Distribution ......................................................................................................................................1 - 20 4.1. Functional Description ...................................................................................................................................1 - 20 5. Data flow ...........................................................................................................................................................................1 - 28 5.1. Functional Description ...................................................................................................................................1 - 28 5.2. Printed Circuit Boards .....................................................................................................................................1 - 28 6. Media Transport .............................................................................................................................................................1 - 29 6.1. Functional Description ...................................................................................................................................1 - 29 6.2. Printed Circuit Boards .....................................................................................................................................1 - 44 7. Ink Supply System ........................................................................................................................................................1 - 45 7.1. Functional Description ...................................................................................................................................1 - 45 7.2. Printed Circuit Boards .....................................................................................................................................1 - 54 8. Head Carriage Movement ...........................................................................................................................................1 - 55 8.1. Functional Description ...................................................................................................................................1 - 55 8.2. Printed Circuit Boards .....................................................................................................................................1 - 60 9. Print Head .........................................................................................................................................................................1 - 61 9.1. Functional Description ...................................................................................................................................1 - 61 9.2. Printed Circuit Boards .....................................................................................................................................1 - 65 10. UV Curing .......................................................................................................................................................................1 - 66 10.1. Functional Description .................................................................................................................................1 - 66 10.2. Printed Circuit Boards ..................................................................................................................................1 - 74 11. Programmable Logic controller (PLC) .................................................................................................................1 - 75 11.1. Functional Description .................................................................................................................................1 - 75 12. Anapurna Control Program ......................................................................................................................................1 - 80 12.1. Control Program .............................................................................................................................................1 - 80 12.2. Buttons used for Maintenance Purposes ..............................................................................................1 - 81 12.3. Setup Parameters ...........................................................................................................................................1 - 81 12.4. Test Menu .........................................................................................................................................................1 - 88 13. Working with White Ink - Guidelines ..................................................................................................................1 - 90 13.1. Printing Jobs without White Ink ...............................................................................................................1 - 90 13.2. Application requires no White Ink at All ...............................................................................................1 - 90 13.3. Putting White Ink into the Circuit ...........................................................................................................1 - 91 14. Printed Circuit Boards ...............................................................................................................................................1 - 95 14.1. MAIN PCB .........................................................................................................................................................1 - 95 14.2. FPGA PCB ....................................................................................................................................................... 1 - 102 14.3. HEAD PCB ...................................................................................................................................................... 1 - 108 14.4. REFILL PCB ..................................................................................................................................................... 1 - 117 14.5. CARTRIDGE PCB .......................................................................................................................................... 1 - 123
Service Manual :Anapurna L/XL 2007 V1.0 Company Confidential i
14.6. HEAD LIFT PCB ............................................................................................................................................. 1 - 127 14.7. ITV CONTROLLER PCB ............................................................................................................................... 1 - 133 14.8. SUB PCB ......................................................................................................................................................... 1 - 136 14.9. IF PCB .............................................................................................................................................................. 1 - 140 14.10. I/O PCB ........................................................................................................................................................ 1 - 144 14.11. TAKE UP PCB .............................................................................................................................................. 1 - 148 14.12. REFILL CONTROL PCB ............................................................................................................................. 1 - 150 14.13. INDICATOR PCB ........................................................................................................................................ 1 - 153 14.14. DRIVER COMMUNICATION PCB ......................................................................................................... 1 - 156
Chapter 2
............................................................................................2 - 1
1. Overview ..............................................................................................................................................................................2 - 2 1.1. Anapurna's Print Quality ...................................................................................................................................2 - 2 1.2. Outstanding Printing Potential ......................................................................................................................2 - 2 1.3. Inspired Design ....................................................................................................................................................2 - 3 1.4. User Profile ............................................................................................................................................................2 - 3 2. Features ...............................................................................................................................................................................2 - 4 2.1. Borderless Printing .............................................................................................................................................2 - 4 2.2. Roll to Roll and Rigid Printing .......................................................................................................................2 - 4 2.3. Dual Board Printing ............................................................................................................................................2 - 4 2.4. White Color Printing ..........................................................................................................................................2 - 4 2.5. Status Signal Lamp .............................................................................................................................................2 - 4 2.6. Automatic Ink Filling System .........................................................................................................................2 - 5 2.7. UV Curing ...............................................................................................................................................................2 - 5 2.8. Changeable UV Lamps ......................................................................................................................................2 - 5 2.9. Exhausting System ..............................................................................................................................................2 - 5 2.10. Automatic Print Head Height .......................................................................................................................2 - 5 2.11. Easy and Quick Installation ..........................................................................................................................2 - 5 2.12. Simple Maintenance .......................................................................................................................................2 - 5 3. Specifications ....................................................................................................................................................................2 - 6 3.1. Print Technology ..................................................................................................................................................2 - 6 3.2. Head Technology .................................................................................................................................................2 - 6 3.3. Media .......................................................................................................................................................................2 - 7 3.4. Inks ...........................................................................................................................................................................2 - 8 3.5. Working Conditions ............................................................................................................................................2 - 9 3.6. Electricity ...............................................................................................................................................................2 - 9 3.7. RIP PC ................................................................................................................................................................... 2 - 10 3.8. Service PC ........................................................................................................................................................... 2 - 10 3.9. Anapurna L .......................................................................................................................................................... 2 - 11 3.10. Anapurna XL .................................................................................................................................................... 2 - 11
Chapter 3
....................................................................................................................................................3 - 1
1. Safety Notes .......................................................................................................................................................................3 - 2 1.1. Warning/Caution/Note ....................................................................................................................................3 - 2 1.2. Emergency Stop ...................................................................................................................................................3 - 2 1.3. Handling UV Curable Ink ..................................................................................................................................3 - 3 1.4. UV Radiation .........................................................................................................................................................3 - 3 1.5. Electricity ...............................................................................................................................................................3 - 4 1.6. Maintenance Safety Instructions ..................................................................................................................3 - 4 1.7. MSDS Contents ....................................................................................................................................................3 - 5 2. Overview Safety Labels ..................................................................................................................................................3 - 6 3. Preparing for Service .......................................................................................................................................................3 - 8 3.1. Moving Head Carriage to Home or Purge Position .................................................................................3 - 8 3.2. Putting the print Engine in Service Mode .................................................................................................3 - 8
ii
4. Disassembly/Assembly of Major Components ..................................................................................................... 3 - 9 4.1. Disassembly/Assembly of the Air Pressure Panel Components ....................................................... 3 - 9 4.2. Disassembly/Assembly of the Media Transport System Components ........................................ 3 - 13 4.3. Disassembly/Assembly of the Ink Supply System Components at Refill Unit ........................ 3 - 24 4.4. Disassembly/Assembly of the Ink Supply System Components at Head Carriage Unit ...... 3 - 46 4.5. Disassembly/assembly of the Head Carriage Movement Components ...................................... 3 - 53 4.6. Disassembly/Assembly of the Print Head Components ................................................................... 3 - 60 4.7. Disassembly/Assembly of the UV Curing System Components .................................................... 3 - 72 5. Installing the PCI I/O Card ....................................................................................................................................... 3 - 83 5.1. Location ............................................................................................................................................................... 3 - 83 5.2. Replacement of the PCI I/O Card .............................................................................................................. 3 - 84 6. Adjustment and Alignment Procedures ............................................................................................................... 3 - 89 6.1. Vacuum Blower Adjustments ...................................................................................................................... 3 - 89 6.2. Print Head Adjustments ................................................................................................................................. 3 - 91 6.3. Conveyer Belt Alignment .............................................................................................................................. 3 - 97 6.4. Head Base Alignment ..................................................................................................................................... 3 - 99 6.5. Lamp house Alignment ................................................................................................................................3 - 103
Chapter 4
Preventive Maintenance
................................................................................................................................... 4 - 1
1. Maintenance Schedule .................................................................................................................................................. 4 - 2 2. Print Media Unit Maintenance ................................................................................................................................... 4 - 5 2.1. Guidelines and Specific Safety Instruction ............................................................................................... 4 - 5 2.2. Conveyer Belt ....................................................................................................................................................... 4 - 6 2.3. Vacuum Holes ...................................................................................................................................................... 4 - 9 2.4. LM Guide ............................................................................................................................................................. 4 - 10 2.5. LM Blocks ........................................................................................................................................................... 4 - 11 2.6. Carriage Belt (S5M Belt) ................................................................................................................................ 4 - 13 2.7. S3M Belt .............................................................................................................................................................. 4 - 16 2.8. Linear Scale Encoder ...................................................................................................................................... 4 - 24 2.9. Bearings Print Media Unit ............................................................................................................................ 4 - 33 2.10. Waste Tank ...................................................................................................................................................... 4 - 35 3. Head Carriage Unit Maintenance ............................................................................................................................ 4 - 36 3.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 36 3.2. Print Head ........................................................................................................................................................... 4 - 38 3.3. UV Lamp Box / UV Lamp Box Housing .................................................................................................... 4 - 46 3.4. Head Carriage .................................................................................................................................................... 4 - 53 4. Refill Unit Maintenance ............................................................................................................................................. 4 - 54 4.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 54 4.2. Air filter 6 Color and White .......................................................................................................................... 4 - 55 4.3. Ink Filter .............................................................................................................................................................. 4 - 56 5. Purge Unit Maintenance ............................................................................................................................................ 4 - 63 5.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 63 5.2. Purge box ............................................................................................................................................................ 4 - 63 6. Home Unit Maintenance ............................................................................................................................................ 4 - 65 6.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 65 6.2. Home box ............................................................................................................................................................ 4 - 65 7. Safety Circuit .................................................................................................................................................................. 4 - 67 7.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 67 7.2. Emergency Stop Circuit ................................................................................................................................. 4 - 67 8. Air Tank Maintenance ................................................................................................................................................. 4 - 69 8.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 69 8.2. Air Tank ................................................................................................................................................................ 4 - 69 9. Air Pressure Panel Maintenance ............................................................................................................................. 4 - 70 9.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 70 9.2. Air Pressure Panel ............................................................................................................................................ 4 - 70
iii
10. Engine ............................................................................................................................................................................. 4 - 75 10.1. Guidelines and Specific Safety Instruction .......................................................................................... 4 - 75 10.2. Engine Level .................................................................................................................................................... 4 - 75
Chapter 5
Troubleshooting
............................................................................................................................................................5 - 1
1. Troubleshooting Based on Visible Problems .........................................................................................................5 - 2 1.1. Troubleshooting Based on Tower Lamp Indications ..............................................................................5 - 2 1.2. Troubleshooting Based on Mechanical and/or Electrical Problems ................................................5 - 2 2. Troubleshooting Based on UI Error Messages .................................................................................................... 5 - 13 3. Troubleshooting based on Image Quality Control ............................................................................................ 5 - 14 3.1. Encoder (MARK) Error ...................................................................................................................................... 5 - 14 3.2. Black Strips ......................................................................................................................................................... 5 - 15 3.3. Waves on the Media Surface ....................................................................................................................... 5 - 15 3.4. Only UNI MODE Output ................................................................................................................................. 5 - 16 3.5. Image Quality Failure ..................................................................................................................................... 5 - 16 3.6. Spray on your Image ....................................................................................................................................... 5 - 18 3.7. Print Length Exceeds Maximum Platen Length .................................................................................... 5 - 18 4. UV Lamp Troubleshooting .......................................................................................................................................... 5 - 20 5. Servo Motor Driver Troubleshooting ...................................................................................................................... 5 - 21
Chapter 6 Chapter 7
Glossary Annex
..................................................................................................................................................................................6 - 1
.........................................................................................................................................................................................7 - 1
1. Pneumatic Diagrams .......................................................................................................................................................7 - 3 1.1. Pneumatic Diagram ............................................................................................................................................7 - 5 2. Electrical Diagrams ..........................................................................................................................................................7 - 7 2.1. Main Power Distribution in the Electrical Circuit Panel .......................................................................7 - 9 2.2. Power Supply Distribution - 3 Phase with neutral with ground star 380V (EU) ....................... 7 - 11 2.3. Power Supply Distribution - 3 Phase no neutral with ground delta 208-240V (US) ............... 7 - 13 2.4. UV Lamp Power Box Connections .............................................................................................................. 7 - 15 2.5. UV Lamp Power Circuit .................................................................................................................................. 7 - 17 2.6. UV Lamp Head Part .......................................................................................................................................... 7 - 19 2.7. UV Lamp Power Cables .................................................................................................................................. 7 - 21 3. Programmable Logic Controller (PLC) Block Diagram .................................................................................... 7 - 23 3.1. Main PLC ............................................................................................................................................................. 7 - 25 3.2. UV Lamp PLC ...................................................................................................................................................... 7 - 27 4. Printed Circuit Boards .................................................................................................................................................. 7 - 29 4.1. Total PCB Diagram Layout ............................................................................................................................ 7 - 31 4.2. MAIN PCB ............................................................................................................................................................ 7 - 33 4.3. FPGA PCB ............................................................................................................................................................ 7 - 35 4.4. HEAD PCB ............................................................................................................................................................ 7 - 37 4.5. REFILL PCB .......................................................................................................................................................... 7 - 39 4.6. CARTRIDGE PCB ................................................................................................................................................ 7 - 41 4.7. HEAD LIFT PCB .................................................................................................................................................. 7 - 43 4.8. ITV CONTROLLER PCB ..................................................................................................................................... 7 - 45 4.9. SUB PCB ............................................................................................................................................................... 7 - 47 4.10. IF PCB ................................................................................................................................................................. 7 - 49 4.11. I/O PCB ............................................................................................................................................................. 7 - 51 4.12. TAKE UP PCB ................................................................................................................................................... 7 - 53 4.13. REFILL CONTROL PCB ................................................................................................................................... 7 - 55 4.14. INDICATOR PCB .............................................................................................................................................. 7 - 57 4.15. DRIVER COMMUNICATION PCB ............................................................................................................... 7 - 59
iv
Preventive Maintenance
This chapter describes repair and service procedures for the Anapurna L/XL.
Troubleshooting
This chapter describes how you can recognize and solve mechanical, electrical and image problems you could encounter when printing with the Anapurna L/XL.
Glossary
This chapter describes definitions and abbreviations used throughout the Service Manual which you may not be familiar with.
Annex
This chapter gives an overview of the diagrams and printed circuit boards of the Anapurna L/XL. Finally, you can find a spare parts list.
2. Scope
The Service Manual is intended to provide all necessary information for the service technician to maintain the Anapurna L/XL so that the system runs smoothly, professionally and under optimum conditions.
3. Related Documentation
The following document can be referred to for more information:
! ! !
Anapurna L/XL Pre-Site Survey Anapurna L/XL Installation Guide Anapurna L/XL Operator Manual
0-1
RELATED DOCUMENTATION
0-2
CHAPTER
Functional Description
This chapter describes how the Anapurna L/XL functions. 1. General Description ............................................................................................................................................... 1 - 3 1.1. System Description .................................................................................................................................. 1 - 3 1.2. Block Diagram ........................................................................................................................................ 1 - 13 2. Safety Circuits ....................................................................................................................................................... 1 - 14 2.1. Emergency Stop Circuit ....................................................................................................................... 1 - 14 2.2. Door Open Detection ........................................................................................................................... 1 - 15 3. Power Distribution .............................................................................................................................................. 1 - 18 3.1. Functional Description ........................................................................................................................ 1 - 18 4. Compressed Air Distribution ........................................................................................................................... 1 - 20 4.1. Functional Description ........................................................................................................................ 1 - 20 5. Data flow ................................................................................................................................................................ 1 - 28 5.1. Functional Description ........................................................................................................................ 1 - 28 5.2. Printed Circuit Boards .......................................................................................................................... 1 - 28 6. Media Transport ................................................................................................................................................... 1 - 29 6.1. Functional Description ........................................................................................................................ 1 - 29 6.2. Printed Circuit Boards .......................................................................................................................... 1 - 44 7. Ink Supply System .............................................................................................................................................. 1 - 45 7.1. Functional Description ........................................................................................................................ 1 - 45 7.2. Printed Circuit Boards .......................................................................................................................... 1 - 54 8. Head Carriage Movement ................................................................................................................................ 1 - 55 8.1. Functional Description ........................................................................................................................ 1 - 55 8.2. Printed Circuit Boards .......................................................................................................................... 1 - 60 9. Print Head .............................................................................................................................................................. 1 - 61 9.1. Functional Description ........................................................................................................................ 1 - 61 9.2. Printed Circuit Boards .......................................................................................................................... 1 - 65 10. UV Curing ............................................................................................................................................................. 1 - 66 10.1. Functional Description ...................................................................................................................... 1 - 66 10.2. Printed Circuit Boards ....................................................................................................................... 1 - 74 11. Programmable Logic controller (PLC) ....................................................................................................... 1 - 75 11.1. Functional Description ...................................................................................................................... 1 - 75 12. Anapurna Control Program ............................................................................................................................ 1 - 80 12.1. Control Program .................................................................................................................................. 1 - 80 12.2. Buttons used for Maintenance Purposes ................................................................................... 1 - 81 12.3. Setup Parameters ............................................................................................................................... 1 - 81 12.4. Test Menu .............................................................................................................................................. 1 - 88 13. Working with White Ink - Guidelines ....................................................................................................... 1 - 90 13.1. Printing Jobs without White Ink ................................................................................................... 1 - 90 13.2. Application requires no White Ink at All ................................................................................... 1 - 90 13.3. Putting White Ink into the Circuit ................................................................................................ 1 - 91 14. Printed Circuit Boards ..................................................................................................................................... 1 - 95 14.1. MAIN PCB .............................................................................................................................................. 1 - 95 14.2. FPGA PCB ............................................................................................................................................. 1 - 102 14.3. HEAD PCB ............................................................................................................................................ 1 - 108 14.4. REFILL PCB .......................................................................................................................................... 1 - 117 14.5. CARTRIDGE PCB ................................................................................................................................ 1 - 123 14.6. HEAD LIFT PCB ................................................................................................................................... 1 - 127 14.7. ITV CONTROLLER PCB ..................................................................................................................... 1 - 133 14.8. SUB PCB ............................................................................................................................................... 1 - 136 14.9. IF PCB .................................................................................................................................................... 1 - 140
1-1
FUNCTIONAL DESCRIPTION
FUNCTIONAL DESCRIPTION
I/O PCB ............................................................................................................................................. TAKE UP PCB ................................................................................................................................... REFILL CONTROL PCB ................................................................................................................... INDICATOR PCB .............................................................................................................................. DRIVER COMMUNICATION PCB ...............................................................................................
1-2
GENERAL DESCRIPTION
FUNCTIONAL DESCRIPTION
1. General Description
1.1. System Description
1.1.1. General View Of the Anapurna L/XL
The illustration below indicates the front, rear, left and right side of the Anapurna L/XL.
Figure 1.1: Notation conventions
Rear
Left
Right
Fron
The front, rear, left and right side are defined according to the opposite transport direction of the print media.
! !
The front side of the Anapurna L/XL corresponds with the print media output side. The rear side of the Anapurna L/XL corresponds with the print media input side.
Purge unit. Head carriage unit. Print media unit Home unit. Refill unit.
1-3
FUNCTIONAL DESCRIPTION
GENERAL DESCRIPTION
Ink temperature and ink vacuum control Purge unit Print media unit Conveyer belt Home unit Refill unit
Vacuum table
1-4
GENERAL DESCRIPTION
FUNCTIONAL DESCRIPTION
Purging part. Accessible via the purge front door and the purge rear door.
Main box left Located behind the main box left side door.
! !
Feed servo motor driver (1). UV lamp power box (=UV system power supply) (2).
1-5
FUNCTIONAL DESCRIPTION
GENERAL DESCRIPTION
Main power panel. Located behind the main box rear door.
1 2 3 4
5 6 7 8
Sub ink tank (6 colors) Sub ink tank (white) Head base plate Cleaning solution valve
1-6
GENERAL DESCRIPTION
FUNCTIONAL DESCRIPTION
Roll to roll. Automated winder/unwinder system to wind/unwind the print medium rolls.
Rigid table. Media transport table consisting of roller bars used to transport rigids towards the printing table. Easy to hook up to the printer.
Print table. The vacuum print table consists of a polyester woven conveyor belt driven by a servo motor and 2 adjustable vacuum blowers which hold the media during printing and transport.
10 6 9 5
1 2 3 4 5 6
!
Emergency button Vacuum control Media set (media register pins) Media fixing bar (front and rear) Air inlet + air regulators Head base temperature control
7 8 9 10 11
UV lamp control (Left and right) Monitor Take up control system Ink temperature and ink vacuum control Tower lamp
Console. Digital system that controls the Anapurna L/XL. It consists of a built-in monitor (UI) and a control PC.
Control system. Indicators and control buttons to control the head/ink quality parameters, the paper supply system, the vacuum system, the UV lamps and finally a tower light to indicate alarm conditions.
1-7
FUNCTIONAL DESCRIPTION
GENERAL DESCRIPTION
Main box right Located behind the control system cover. Accessible via the ink supply door.
! ! !
1 2 3
!
4 5
Ink supply chain / hose fixing guide(1), Shock absorber (3), Limit Switch (4), Carriage servo motor driver (2)
3 1 2
1-8
GENERAL DESCRIPTION
FUNCTIONAL DESCRIPTION
Components behind home right door: Behind a protection cover you can find the double pulley assembly with
! ! !
Carriage servo motor (1), Driver belt S3M(2), Carriage belt S5M(3),
! ! !
1-9
FUNCTIONAL DESCRIPTION
GENERAL DESCRIPTION
RED 1
YELLOW 2
GREEN 3 BLUE 4
WHITE 5
Function Power ON Air pressure below 0.3 MPa Low ink level (at main tank) Ready state -> UV lamp curing available Overheat Lamp power off Media register pins down Full waste tank (> 3.5 litre) Vacuum in use Overflow (of ink) in sub air tank
4 5
For more information about how to solve the alarm indications (flashing + beeping), refer to Troubleshooting Based on Tower Lamp Indications on page 5-2 (chapter Troubleshooting).
1 - 10
GENERAL DESCRIPTION
FUNCTIONAL DESCRIPTION
1 2 3
4 5
3 4 1
2 5
1 2 3
4 5
1 - 11
FUNCTIONAL DESCRIPTION
GENERAL DESCRIPTION
1 2
1 2
3 4
1 - 12
GENERAL DESCRIPTION
FUNCTIONAL DESCRIPTION
PRESSURE SENSOR
TAKE UP PCB
HEAD PCB
MAIN PCB
FPGA PCB
MEMORY
INTERFACE CIRCUIT
HEATING 120VDC
FPGA CIRCUIT
CONTROL CIRCUIT
RS 232
PC
I/O PCB DRIVER COMM. PCB
CARTRIDGE PCB
SUB PCB
PRINT HEAD
STEP MOTOR
FEED MOTOR
CARRIAGE MOTOR
IF PCB
P L C (K7M-DR60S)
PID CONTROLLER
PUSH ROLLER (FRONT/REAR) UV LAMP CONTROL TOWER LAMP CONTROL MEDIA STOP CONTROL
UV LAMP
1 - 13
FUNCTIONAL DESCRIPTION
SAFETY CIRCUITS
2. Safety Circuits
2.1. Emergency Stop Circuit
The system is provided with 4 emergency stops, two at the front side and two at the back side.The emergency stop circuit is activated when one of the emergency buttons is activated. When the emergency button is activated all systems are cut off from the mains, but certain parts remained powered.
3 - PHASE AC3 8 0 V, 5 0 / 6 0 Hz PE
P1 P2 P3
P1 1 P2 2 P2 3
P2 2 N
PC- SM S P 300W PC S/ W
OPERATOR PC
P2 2 N
P SM S # 8 +2 4 VDC GND
RESTART
2
E MO 1
MC #1(50A)
M -A C
E MO 2
E MO 3
E MO 4
2 5
3 - PHASE AC2 0 8 ~2 4 0 V, 5 0 / 6 0 Hz PE
P1 P2 P3
EL CB # 1 ( 3 - PHASE AC3 8 0 V, 5 0 A)
P1 1 P2 2 P2 3
( 1) ( 4)
P2 2 P1 1
PC- SM S P 300W PC S/ W
OPERATOR PC
( 5)
P1 1
( 3)
P2 3
RESTART
2
E MO 1
MC - A
E MO 2
E MO 3
E MO 4
MC #1(50A)
2 5
In case of emergency, push the emergency stop button immediately to stop the Anapurna L/XL. The emergency button cuts off the power, except for the PC and SMPS8.
By pulling the emergency button back, the emergency stop is cancelled. The Anapurna L/XL must be restarted.
1 - 14
SAFETY CIRCUITS
FUNCTIONAL DESCRIPTION
1
!
Waiting mode When the carriage is at its home or purge position and you start a print job with open front or rear cover, a door open error appears.
Printing mode For engine < V1.1: When you open the front or rear cover during printing, the head carriage will move to the home position after finishing the swath. The print will be cancelled and the UV lamps will go off and the UV lamp shutter will be closed automatically. For engines V1.1 and V1.2: When you open the front or rear cover during printing, the head carriage stops, the UV lamps will go off, the UV lamp shutter will be closed and the UV cooling will start automatically.
WARNING: Opening the covers during printing will result in a cancelled print. Only open the covers in emergency situations. Head carriage movements and printing can only be done with closed covers.
1 - 15
FUNCTIONAL DESCRIPTION
SAFETY CIRCUITS
SENSOR CONTROLLER
2.2.2.1. Connectors
Connectors Name and Function PA10-U SENSOR CONTROLLER Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Nr. Pin Name ACI NPUT L51 OUT NC OUT COM OUT NO ACI NPUT L52 N.C N.C N.C SEN#1 DC12V SEN#1 GND IN 1 O.C OUT 1 SEN#2 DC12V SEN#2 GND IN 2 O.C OUT 2 REAR SENSOR PR12-4DN brown DC12-24V blue GND black SIGNAL OUT 1 2 3 FRONT SENSOR PR12-4DN brown DC12-24V blue GND black SIGNAL OUT 1 2 3 MAIN PCB MAIN PCB SMPS#6 J10 J10 4 5 7 PCB or Part SMPS#6 Connected to Conn. 6 Pin
1 - 16
SAFETY CIRCUITS
FUNCTIONAL DESCRIPTION
2.2.2.2. Leds
LED OUT 1 OUT 2 IN 1 IN 2 POWER Type Color red red orange red green Indication Not in use Not in use Front door Rear door 220V AC
2.2.2.3. Switches
Switch AND/OR Setting AND Description Select AND or OR for IN1 and IN2 inputs Note: Switching this dipswitch from AND to OR means that the carriage movement is enabled when only ONE door is closed (for service purposes only). NORM/INV NORM/FLANK NORM NORM Selection switch to invert the inputs. Operating in a true/false mode Selection switch for a true\false (NORM) situation or a flank trigger (FLANK). With a flank trigger a time setting is needed (TIME SET and TIME ANALOG). MODE TIME SET SA = ON SB, SC and SD = OFF T1 = ON T2 = OFF With 2 switches you can set 4 time ranges, between 0.01 - 0.1 - 1 - 10 -100s. Here the range from 0.1 - 1s is used. Fine adjustment for TIME SET switches
TIME ANALOG
1 - 17
FUNCTIONAL DESCRIPTION
POWER DISTRIBUTION
3. Power Distribution
3.1. Functional Description
3.1.1. Electrical Circuit Panel
Figure 1.10: Electrical circuit panel
4 5 6
1 7 2
1 2 3 4
Main power inlet terminal block 1st circuit breaker (MCCB #1, main circuit braker 50A) Noise filter Main MC (MC #1) - Closed by Start button - Open when activating one of the emergency stops. 2nd circuit breaker (MCCB#2 to #6) MCCB #2, Lamp MCCB #3, Ring blower 1 MCCB #4, Ring blower 2 MCCB #5, Motor driver MCCB #6, Control Rack
6 7 8 9
Ring blower #1 MC - Ring blower switch 1st step on, Circuit Close Ring blower #2 MC - Ring blower switch 2nd step on, Circuit Close SMPS8 - supply power (+24VDC) to main MC and FAN in power distribution panel Terminal block Routing emergency switch, start button and Main MC
1 - 18
POWER DISTRIBUTION
FUNCTIONAL DESCRIPTION
SYSTEM N EED P O W ER
Model : :ANAPURNA in le t p o w e r V olage: t 3P H A S E 380V f requency 50/60H z 2 S E R V O M O TO R 3P hase 380V -50H z 3 R I G B LO W E R N 3P hase 380V -60H z 3P hase 380V -50H z 3P hase 380V -60H z 3 4 5 LA M P C O M PRESSO R EXHAUST Tot al V :230V / F :50H z
:ANAPURNA L :ANAPURNA XL :ANAPURNA L :ANAPURNA XL
No
ite m
F re q u e n c y
d e ta ils PC
o u tp u t vo lta g e (V )
c u rre n t(A ) o w e r(K w ) Q 'ty P 24 120 24 24 S ub-Tot al 220 220 220 12.5 2 5 3 2 2 3.6 3.8 3.7 3.8 3.7 20 2 2 0.3 0.24 0.12 0.072 0.44 0.44 0.8 1.5 1.75 1.5 1.75 4.4 1 2 2 2 2 1 1 2 2 1
M A X (K w ) 0.3 0.48 0.24 1.5 2.5 0.88 0.44 0.8 3 3 4.4 0.44 0.44 11.66 12.02
w e ig h te d va lu e
C O N TR O L R A C K
V :230V / F :50H z
SM PS
100%
* M ot pem i bl volage: A C 200V ~ A C 240V (50H z/60H z) pre or ssi e t volage t i requi t est s red.
11.66 13.42
To check the permanent voltage, refer to Checking the Permanent Voltage on page 5-7 of the Troubleshooting chapter.
Connections in the Electric Circuit Panel For the electrical diagram (A3 format), refer to Main Power Distribution in the Electrical Circuit Panel on page 7-9 (chapter Annex).
Power Supply Distribution For the electrical diagrams EU and US version (A3 format), refer to:
!
Power Supply Distribution - 3 Phase with neutral with ground star 380V (EU) on page 7-11 (chapter Annex). Power Supply Distribution - 3 Phase no neutral with ground delta 208-240V (US) on page 713 (chapter Annex).
1 - 19
FUNCTIONAL DESCRIPTION
Compressed Air Pressure (purple flow), Carriage Part (blue rectangle), Air Tank (yellow rectangle), Lamp Shutter Left/Right Cylinders (light blue rectangle), Media Set Cylinders and Media Hold Front/Rear Cylinders (green and red rectangle).
For the pneumatic diagram (A3 format), refer to the Pneumatic Diagram on page 7-5 (chapter Annex).
Main Air Press. 0.4 - 0.8 MPa Max. Press. 2MPa Capacity 0.005M 3
Air Tank
R P A
Setting Press 0.6 MPa Waste Tank Over-flow Sig. 0.3 - 0.7 MPa Purge Sig.
Air Filter # 1
A B
4f Air Tube
EA P EB
I/O PC B Sig. I/O PC B Sig.
EA P EB
EA P EB
IN
EA P EB
Carriage Part
Air Filter # 2
A R P
E/P Regulator
SU P OU T
P R
Check valve
Check valve
SOLUTION SUB-TANK
SOLUTION BAR
MAIN WASTE INKTANK PSE531-M5 Pressure Sig. Float Sensor Float Sensor Sig. Sig.
P
VACUUM EJECTOR
R P
INK TANK
1 - 20
FUNCTIONAL DESCRIPTION
The system requires an industrial compressor working twenty-four hours a day (seven days a week) delivering a stable compressed air pressure of minimum 6 bar (range 0.4-0.8 MPa) and a flow of minimum 15 l/min. The capacity shall be over 3 HP (horsepower). The reinforced compressed air hose must have an outer diameter of 6 mm. The pressure vessel should be minimum 50l. The reinforced compressed air hose coming from the compressed air supply is connected to the air inlet pressure hose, which is located in the air pressure panel.
Figure 1.12: Air pressure panel - pneumatic flow key parts
2 3 4 5 6 7
1 2 3 4
Main air pressure inlet port Main air inlet pressure indicator Main regulator (0.4-0.8 MPa) Lamp shutter regulator (0.10 MPa0.15 MPa) Air filter #1
5 6 7 8
1st regulator at carriage div. (0.3 MPa) Air filter #2 2nd regulator at carriage div. (0.15 MPa) Water drain out
1 - 21
FUNCTIONAL DESCRIPTION
1 2 34
12
10 11
1 2 3 4 5 6
!
Sub air tank and ink overflow tank Air relief valve sub air tank (speed V/V (AS1001F-06) + air filter) Pressure sensor PSE531-M5-L Drain cock (when overflow) Solution tank Lamp shutter solenoid valves
7 8 9 10 11 12
Solution valve Electro-pneumatic regulator ITV2010 Vacuum ejector INO-4336-4 Purge air valve VT301V-025GB Purge air valve VT301-025GB ITV2010 display
Purge air valve. Operational when purging (push purge switch at the front of the head carriage unit).
! !
VT301V-025GB (Figure 1.13, item 10), range -0.1 to 1 bar. VT301-025GB (Figure 1.13, item 11), range 0 to 10 bar.
Electro-pneumatic regulator ITV2010 (Figure 1.13, item 8 and 12). The IVT controller displays the overpressure (default + 0.30 mbar or lower, in case the vacuum pressure is set to -0.032MPa) which is sent through a venturi tube to create the desired negative pressure setting in the sub air tank. The pressure sensor PSE531-M5-L (Figure 1.13, item 3) constantly measures the negative pressure in the sub air tank and the read-out is sent back to the IVT controller. Base on this read-out, the ITV controller adjusts the flow pressured air through the venturi tube to compensate.
1 - 22
FUNCTIONAL DESCRIPTION
Fluctuations in the meniscus vacuum source (negative pressure) should be minimized. The air relief (Figure 1.13, item 2) on the top of the sub air tank regulates the strength of the negative pressure inside the sub air tank. NOTE: The other items of Figure 1.13 are discussed in other paragraphs.
Purge switch
1 - 23
FUNCTIONAL DESCRIPTION
1
!
Drain cock
When the air pressure at the main air tank is lower than 0.3 MPa, the following can occur:
! ! !
Red tower lamp start flashing and beeping. Refill system stops to prevent excessive ink outlet from print head. Head carriage is forced automatically to the purge position to prevent damages on the print head.
When the air pressure at the main air tank is higher than 0.7 MPa, the system automatically ejects the pressure. Drain water from the main air tank (1) by opening the drain cock (2).
1 2
1 - 24
FUNCTIONAL DESCRIPTION
Media set cylinders The six 5/2-way valves are mounted inside the media register pins and are manually driven by means of the media set switch, located at the home rear side.
Media hold front/rear cylinders The two 5/2-way valves are mounted underneath the print table and moves the front/rear media fix bar up and down. The front media fix bar is manually driven by means of the front switch. The rear media fix bar is manually driven by means of the rear switch. There is one front and rear switch, at the home front side and one front and rear switch at the home rear side. The illustration below, shows the front media fix bar.
1 - 25
FUNCTIONAL DESCRIPTION
4.1.6.2. Functioning
The illustration below describes the functioning of the media set cylinders and the media hold front/ rear cylinders.
Figure 1.16: Functioning media set cylinders and the media hold front/rear cylinders
HOME UNIT
5 Front
Front NO
GND
Back NO
6
A1 A2 P 040 P 051 P 052 P 04E
24 Vdc Gnd
PLC
Rear
3 Level Switch Media Set NO NC
A1 A2
NO P 018 P 019
Rear
A1
A2
Front
1 - 26
FUNCTIONAL DESCRIPTION
1 - 27
FUNCTIONAL DESCRIPTION
DATA FLOW
5. Data flow
5.1. Functional Description
2
FPGA PCB
MEMORY
MAIN PCB
Anapurna PC
1
INTERFACE CIRCUIT
HEAD PCB
FPGA CIRCUIT
CONTROL CIRCUIT
RS 232
CARTRIDGE PCB
6
PRINT HEAD
FPGA PCB on page 1-102 MAIN PCB on page 1-95 HEAD PCB on page 1-108 CARTRIDGE PCB on page 1-123
1 - 28
MEDIA TRANSPORT
FUNCTIONAL DESCRIPTION
6. Media Transport
6.1. Functional Description
6.1.1. General Information
TAKE UP MOTOR
PRESSURE SENSOR
TAKE UP PCB
HEAD PCB
MAIN PCB
FPGA PCB
MEMORY
INTERFACE CIRCUIT
HEATING 120VDC
FPGA CIRCUIT
CONTROL CIRCUIT
RS 232
PC
I/O PCB DRIVER COMM. PCB
CARTRIDGE PCB
SUB PCB
PRINT HEAD
STEP MOTOR
FEED MOTOR
CARRIAGE MOTOR
IF PCB
P L C (K7M-DR60S)
PID CONTROLLER
PUSH ROLLER (FRONT/REAR) UV LAMP CONTROL TOWER LAMP CONTROL MEDIA STOP CONTROL
UV LAMP
1 - 29
FUNCTIONAL DESCRIPTION
MEDIA TRANSPORT
1 2
3 4
1 2
NOTE: When you insert the media fixing roll bar (1), make sure: the ball bearing is inside the guide (2), the media fixing roll bar is always horizontally levelled between the left and right frame when lowering the bar. NOTE: For more information about the media fixing roll bar, refer also to Media Set Cylinders and Media Hold Front/Rear Cylinders on page 1-25.
1 - 30
MEDIA TRANSPORT
FUNCTIONAL DESCRIPTION
When printing on a banner/paper type of roll media, only the right vacuum side should be used. (Even when the media width is almost the engine width). When printing on two rigid media, both vacuum tables must be used.
NOTE: Be aware that the vacuum (push) button at the home rear side is not connected (internal connection) with the vacuum (3 level) switch at the home front side (refer to Figure 1.18). the lamp in the push button (home rear side) is directly connected to the lamp tower, the lamp in the green switch (home front side) is connected to the switch. So if you switch the blowers on using the front switch, the lamp behind the switch is illuminated. If you switch on the blowers using the rear push button, the lamp behind the front switch is not illuminated.
NOTE: For more information about the vacuum blowers, refer to Vacuum on page 1-31.
6.1.3. Vacuum
6.1.3.1. Vacuum Blower - General Information
Two adjustable vacuum air pumps hold the media on the print table during printing and transport.
Figure 1.17: Vacuum air pump - parts
1 2 3
4 5
1 - 31
FUNCTIONAL DESCRIPTION
MEDIA TRANSPORT
The vacuum blower is set according to the engine configuration, star connection (Europe) or delta connection (USA).
The air relief valve is set according to the engine configuration (50 Hz or 60 Hz). Information can be found on the identification plate on top of the vacuum blower. The rated current 3.8A (50Hz engine) or 6.7A (60Hz engine).
1 - 32
MEDIA TRANSPORT
FUNCTIONAL DESCRIPTION
6.1.3.2. Functioning
The illustration below describes the functioning of the vacuum blowers.
Figure 1.18: Functioning vacuum blowers
L1 L2 L3
HOME UNIT
24Vdc Gnd
0 1 2
Front
3 Level Switch Front Panel
NO Gnd A2 A1 11 12 A1 Relay #2 24 Vdc A2 34 NC
Step 1
NC NO 0 1 2
Step 2
NC
NO 0 1 2
31
PLC
41 42 4B 04 05 Gnd
Step 3
NC NO
Rear
Push button Back Panel
Gnd
A2
A1
11 12
A1 Relay #3 A2
41
0C
24 Vdc
44
NOTE: For more information about the use of the vacuum blowers, refer to Vacuum Plate Usage on page 1-31.
1 - 33
FUNCTIONAL DESCRIPTION
MEDIA TRANSPORT
2 4
1 3
1 2
3 4
For information about mounting the roll bars of the auto feeding system, refer to the paragraph Installing the Roll Bars of the Roll to Roll System of the Installation Manual. The auto feeding system has 2 tension bars (in the form of gear type). Holding the media under a constant tension, those tension bars prevent distortion of and waves on the media, so stable and qualified print can be acquired. NOTE: When you insert the tension roll bar, make sure: the ball bearing is inside the guide, the tension roll bar is always horizontally levelled between the left and right roll bar bracket when lowering the bar.
1 - 34
MEDIA TRANSPORT
FUNCTIONAL DESCRIPTION
The rear media roll bar unwinds the printed media, with a constant tension and height, acquired from media detection sensors (2). A reflection plate (1) detects the signal coming from the media detection sensor(2) mounted on the roll bar bracket at the home unit.
The front media roll bar winds the printed media, holding a constant tension to reduce distortion. The wind direction can be reversed.
! ! ! !
(1) In Manual Mode, motor rotates CW (2) In Manual Mode, motor rotates CCW (1)+(2) You can RESET by pushing the buttons for 1 sec. (3)
! !
In Auto Mode: select motor direction (CW or CCW) In Manual Mode: select motor (Back or Front)
1 - 35
FUNCTIONAL DESCRIPTION
MEDIA TRANSPORT
When using roll to roll media, it is imperative to have a good roll to roll transportation, to ensure long print runs. The right way to load roll to roll media is dependent on the maximum printable width of the roll. References: Loading Roll to Roll Media on page 1-36.
The maximum allowed weight of the print medium roll is 50 kg (110.231 lb). The core diameter of the print medium roll must be 7.62 cm (3 inch). The maximum allowed roll diameter is 36 cm (14.17 inch). The maximum allowed print medium thickness is 50 mm.
The way to pull the print medium through the print engine is independent on the media width. But the way to load the print medium roll on the rear media roll bar is dependent on the maximum printable width of the roll. Use the table below to check whether you use the correct loading procedure:
ti
Table 1.1
Loading a print medium roll Media width Load procedure Load along the dark blue border of the printing table Load in the middle of the printing table Load along the dark blue border of the printing table Load in the middle of the printing table
Anapurna L
Anapurna XL
1 - 36
MEDIA TRANSPORT
FUNCTIONAL DESCRIPTION
2 Remove one of the movable flanges by unscrewing the black turning knob. 3 Slide the print medium roll over the rear media roll bar. 4 Mount the flange. 5 Put both flanges on the proper position according to the width of the print medium roll and mount the black turning knobs again (refer to Table 1.1).
!
If the print media roll is smaller than 20% of the maximum printable size, load the print media in the middle of the rear media roll bar and proceed with step 6. Otherwise, load the print medium roll to the far end of the rear media roll bar and proceed with step 7.
6 In case the print medium roll is positioned in the middle of the rear media roll bar, the print media is not positioned in the beam of the media detection signal sensor. 6.1 Hang a piece of media core over the tension roll bar and position the core in the beam of the media detection signal sensor. As a result the media will be detected and will provide the best tension onto the system. CAUTION: If you do not use the media core, the tension roll bar will be lifted out of its position .
1 - 37
FUNCTIONAL DESCRIPTION
MEDIA TRANSPORT
W RONG
6.2 Proceed with step 8.
OK
7 In case the print medium roll is positioned to the far end of the rear media roll bar, always use the left or right dark blue border on the conveyer belt (print table) as a reference to align the paper edge of the print medium and to define the position of one of the flanges. 8 Remove the rear tension roll bar. 9 Pull the print medium over the rubber roll bar towards the print table. 10 Pull the print medium far enough towards the front side.
1 2
1 - 38
MEDIA TRANSPORT
FUNCTIONAL DESCRIPTION
11 Mount the rear tension roll bar on top of the print medium and slowly lower the rear tension roll bar to the bottom position.
1 2 3
1 2
12 Go to the front side and remove the front tension roll bar. 13 Pull the print medium to the front media roll bar. 14 Mount some dummy cores around the front media roll bar. 15 Use the two flanges and the dummy core(s) to roll up the print medium. Tape the front edge of the print medium to the front media core(s). 16 Mount the front tension roll bar on top of the print medium and slowly lower the front tension roll bar to the bottom position. NOTE: For more information about the operating instructions, refer to the Operator Manual of the Anapurna L/XL.
1 - 39
FUNCTIONAL DESCRIPTION
MEDIA TRANSPORT
To align rigids, proceed as follows: 1 Turn the Media Set switch to position 1 or 2. When turning the Media Set switch once, all nr.1 pins will come down, allowing you to load one rigid. This rigid can be small or at full engine width. When you turn the switch once more, the nr.2 pin will also come down, allowing you to load two rigid media. While performing those actions, the blue tower lamp lights up. 2 Align/position the print media against the media register pins. 3 Turn on the vacuum using the vacuum button (home rear side) to fix the print media to the conveyer belt. For more information about how to use the vacuum button, refer to Vacuum Plate Usage on page 1-31 and Figure 1.18.
1 - 40
MEDIA TRANSPORT
FUNCTIONAL DESCRIPTION
4 Set the margin values, top and left. The "A" and "B" positions, the "o-point" at the corner of your media, are known distances. The "A" point has a Top Margin of 300 mm and 50 mm as a Left Margin. These can be entered in the Control program.
NOTE: Image placement for printing on two rigids must be done at RIP level.
5 Start printing.
Feed servo driver (type MR-J2S-40CP), located behind the main box left side door. Carriage servo driver (type MR-J2S-70CP), located behind the home rear door.
1 2 3 4
1 2
3 4
SW3: DOWN - change by descending order SW4: SET - save values, it can be considered as ENTER key
1 - 41
FUNCTIONAL DESCRIPTION
MEDIA TRANSPORT
first installation to check the machine status, wrong carriage movement, irregular media feeding.
NOTE: The parameters marked with an * before their symbols are made valid by switching power off once and then switching on again after parameter setting.
Customer setting Feed Carriage 0010 0001 0001 040B 2048 125 m rad/s r/min r/min m x10STMm r/min ms station 100 200 0004 500 10 0 0 100 100 1 0102 0100 0000 000E 0000 0002 0000 0 % mV mV pulse/rev % % pulse mV 0 0 0 4000 100 100 0 0 0410 0001 0002 0405 2048 125 100 20 0004 500 10 0 0 100 0 2 0102 0100 0000 000E 0000 0002 0000 0 0 0 0 4000 100 100 0 0
NO. Symbol Basic Parameters 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 *OP4 SIC FFC VCO TLO *ENR TL1 TL2 *BKC MO1 *STY *FTY *OP1 ATU *CMX *CDV FED PGI *ZTY ZRF CRF ZST CRP JOG *STC *SNO *BPS MOD *DMD *BLK *OP2
Initial Value
Unit
Command system/regenerative brake option selection Feeding function selection Function selection 1 Auto tuning Electronic gear numerator Electronic gear denominator Movement complete output range Position loop gain Home position return type Home position return speed Creep speed Home position shift distance For manufacturer setting JOG Jog speed S-pattern acceleration/deceleration time constant Station number setting Communication baudrate selection, alarm history clear Analog monitor output Status display selection Parameter block Function selection For manufacturer setting Function selection Serial communications time-out selection Feed forward gain Override offset Torque limit offset Encoder output pulses Internal torque limit Internal torque limit Backlash compensation Analog monitor 1 offset
0000 0000 0002 0105 1 1 100 35 0010 500 10 0 0 100 0 0 0000 0100 0000 0000 0000 0002 0000 0 0 0 0 4000 100 100 0 0
Expansion Parameters 1
1 - 42
MEDIA TRANSPORT
FUNCTIONAL DESCRIPTION
NO. Symbol 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 NH1 NH2 LPF GD2B PG2B VG2B VICB *CDP CDS CDT *OP8 *OP9 *OPA *OP6 *ZPS DCT ZTM ZTT *LMP *LMN *LPP *LNP MO2 MBR GD2 PG2 VG1 VG2 VIC VDC
Name and function Analog monitor 2 offset Electromagnetic brake sequence output Position loop gain Speed loop gain Speed loop gain Speed integral compensation Speed differential compensation JOG operation acceleration/deceleration time constant Home position return operation acceleration/deceleration time constant Home position return position data Moving distance after proximity dog Stopper type home position return stopper time Stopper type home position return torque limit value Software limit + Software limit Position range output address + Position range output address -
Unit 0
Customer setting Feed Carriage 0 100 8.0 25 1100 900 40 980 0 0 0 1000 100 15 0 0 0 0 100 1.0 250 1300 1300 5 980 0 0
0 1000 100 15 0 0 0 0
0 1000 100 15 0 0 0 0
Expansion Parameters 2 For manufacturer setting Function selection 6 For manufacturer setting Function selection 8 Function selection 9 Function selection A For manufacturer setting Machine resonance suppression filter 1 Machine resonance suppression filter 2 Low-pass filter, adaptive vibration suppression control Position control gain 2 changing ratio Speed control gain 2 changing ratio Speed integral compensation changing ratio Gain changing selection Gain changing condition Gain changing time constant For manufacturer setting OUT1 output time selection 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 1/10 Ratio % % % (Note) ms 100 100 100 0000 10 1 100 10000 10 10 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 70 100 100 100 0000 10 1 100 10 10 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 80 100 120 100 0004 10 1 100 10 10
10000 10000
1 - 43
FUNCTIONAL DESCRIPTION
MEDIA TRANSPORT
NO. Symbol 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90
Name and function OUT2 output time selection OUT3 output time selection Selected to program input polarity selection
Initial Value 100 100 100 0000 0009 080A 0706 020B 0504
Unit
Customer setting Feed Carriage 100 100 100 0000 0009 080A 0706 020B 0504 0032 0000 0005 0D04 0102 0 0 100 100 100 0000 0009 080A 0706 020B 0000 0032 0000 0005 0D04 0102 0 0
Special Parameters
1 - 44
FUNCTIONAL DESCRIPTION
PRESSURE SENSOR
TAKE UP PCB
HEAD PCB
MAIN PCB
FPGA PCB
MEMORY
INTERFACE CIRCUIT
HEATING 120VDC
FPGA CIRCUIT
CONTROL CIRCUIT
RS 232
PC
I/O PCB DRIVER COMM. PCB
CARTRIDGE PCB
SUB PCB
PRINT HEAD
STEP MOTOR
FEED MOTOR
CARRIAGE MOTOR
IF PCB
P L C (K7M-DR60S)
PID CONTROLLER
PUSH ROLLER (FRONT/REAR) UV LAMP CONTROL TOWER LAMP CONTROL MEDIA STOP CONTROL
UV LAMP
1 - 45
FUNCTIONAL DESCRIPTION
The ink flow in the machine. The different parts of the ink system.
Ink Pump
Ink Filter
Solution Tank
Ink Bottle
1 2 3
4 5 6
Ink filter Ink hose fixing (top) Ink hose fixing (bottom)
7 8 9
1 - 46
FUNCTIONAL DESCRIPTION
Ink tank
The print engine is equipped with a swinging ink supply door with 7 stainless steel ink tanks and one cleaning main solution tank. The successive colors are White (W), Light Magenta (Lm), Light Cyan (Lc), Yellow (y), Magenta (M), Cyan (C) and Black (K). The far right tank is the main solution tank. Contents: 1.6 litre per color, 4 litre for white ink tank. White ink tank has a continuous working stirring rod inside. Adjust the ON (1) and OFF (2) timer of the stirring rod to the desired value (hour scale division).
! !
The ink tank indicator panel controls the full/empty state of each ink tank. The capacity is measured by means of 2 floaters in the ink tank, one for minimum and one for maximum. Low level detection at 0.3 l (4h to print), high level detection at 1.2 l. If ink tank is empty, the yellow tower lamp starts flashing and beeping.
1 - 47
FUNCTIONAL DESCRIPTION
Refill system
! ! !
The system is provided with an automatic/manual ink refill system. Ink can be refilled in while printing.
The ink and solution is stored in bottles of 1 liter. The color is indicated on a label. When pouring ink and solution, you have to keep in mind the followings: WARNING: ONLY refill with the 1 liter bottle, when the low level alarm goes off. At that point, you can pour in a complete 1 l bottle.
WARNING: Always pour out ink bottles into the main ink tanks.
WARNING: When pouring ink into the ink tank, try to pour gently by holding the bottle so the ink does not gurgle.
WARNING: Carefully read the instructions on the warning label when handling the UV ink.
WARNING: UV ink contains some chemicals harmful to eyes and skin. Always wear safety gloves when handling UV ink. In case of accidental contact, rinse immediately with plenty of water and consult a doctor, if required. CAUTION: Do not use ink other than the ones recommended by AGFA. Other ink may cause nozzle clogging or other serious problems to your printer.
1 - 48
FUNCTIONAL DESCRIPTION
CAUTION: Respect the color sequence of the ink buffer system. Each ink tank is fitted with a colored label indicating the color type.
CAUTION: Especially, do not confuse between Magenta and Light Magenta, or between Cyan and Light Cyan.
CAUTION: Be aware that the main solution tank is always full with solution liquids.
NOTE: Only the white ink bottle needs to be shaken before use.
When starting up the Anapurna L/XL for the first time after installation, bleed each ink filter after filling each ink tank with 1 liter of ink. If an ink tank has remained empty during too long a period and if consequently, the ink filter is dry.
After filling ink into the main ink tanks, start bleeding the ink filters. Bleeding the air from an ink filter is necessary to fill the ink circuit completely with ink. If you do not extract the air from the ink filter, overflow, leaking heads, missing nozzles can occur because the sub ink tank is filled with air. Bleeding occurs manually. The ink filter should not be exposed to fluorescent light and sunlight.
NOTE: For more information about bleeding the ink filters, refer to Bleeding the Ink Filters on page 4-56 (chapter Preventive Maintenance).
from main tank to ink pump. from ink pump to ink filter. from ink filter to hose fixing guide, located behind the home rear door. from hose fixing guide, through the upper cable trunk (chain), to the sub ink tanks.
1 - 49
FUNCTIONAL DESCRIPTION
1
!
Sub ink tank (6C) A sub ink tank for the six colors, the successive colors from left to right are: K, C, M, Y, Lc, Lm. Each sub ink tank has a content of 35 ml per color.
Sub ink tank (White) A white sub ink tank for the spot-white and pre-white print head.
! !
The level of each sub ink tank is controlled by means of a float senor connected to the Head PCB. The temperature of the 6C sub ink tank and the white sub ink tank is controlled by means of a temperature sensor build underneath an orange heater plate. The upper value on the Sub Ink Tank Temp. PID panel (1) and the White Sub Ink Tank Temp. PID panel (2) indicates the actual temperature respectively measures by the temperature sensor of the 6C sub ink tank and the white sub ink tank.
1 - 50
FUNCTIONAL DESCRIPTION
To adjust the sub ink tank temperature and the white sub ink tank temperature, use the keypad underneath the display.
1 2
PV: processing value indicator (RED) SV: setting value indicator (GREEN
Keypad
Adjusting the sub ink tank temperature (6C and/or white) will affect the orange heater plates (6c and/or white) build underneath the sub ink tank (6C and/or white).
3 4
1 2
!
Heater Plate of white sub ink tank Heater Plate of 6C sub ink tank
3 4
A head temperature sensor (safety thermostat 45C) is connected on the Magenta print head (Head 3 - black cable). The sensor in the Magenta print head controls output to the heater bars to each head. This head temperature sensor is connected to J29 on the Head PCB.
1 - 51
FUNCTIONAL DESCRIPTION
To change the set value during run, proceed as follows: 1 Press the key.
The right digit of the SV indicator is flashing red. 2 Use the key, to shift one digit to the left.
As a result the second digit of the SV indicator is flashing red now. 3 Repeat pressing the 4 Press the and key, until you reach the desired digit.
5 When the setting is completed, press the MD key. The flashing stops and the controller returns to Run status. 6 Press the AT key to close the procedure.
The level of the solution tank is controlled by means of a level senor connected to the Head PCB. The temperature of the solution tank is not controlled.
CAUTION: Be aware that the solution tank is always full with solution liquids.
1 2 3
4 5
When the print head valves (K, C, M, Y, Lc, Lm, W1 and W2) are set to the ink outlet position (I). The ink can flow to the head. In case of clogged nozzles, or misfiring nozzles, clean the print heads to unclog the missing nozzles. NOTE: For more information about cleaning the print heads, refer to Cleaning a Print Head on page 438 (chapter Preventive Maintenance).
1 - 52
FUNCTIONAL DESCRIPTION
When waste liquid comes to a certain level in the waste tank (content > 3.5 litre), the blue tower lamp starts flashing and the buzzer starts. The full detection sensor connector (2-pin), is located in the cable trunk.
!
Check waste ink tank. Use the tap underneath the waste tank to empty the waste tank.
Ink overflow Ink overflow happens when ink runs through from the sub ink tank to the sub air tank. At that time, all tower lamp start flashing and beeping. For more information, refer to Overflow (of Ink) in Sub Air Tank on page 5-5 (chapter Troubleshooting).
1 - 53
FUNCTIONAL DESCRIPTION
REFILL PCB on page 1-117 TAKE UP PCB on page 1-148 REFILL CONTROL PCB on page 1-150 INDICATOR PCB on page 1-153
1 - 54
FUNCTIONAL DESCRIPTION
PRESSURE SENSOR
TAKE UP PCB
HEAD PCB
MAIN PCB
FPGA PCB
MEMORY
INTERFACE CIRCUIT
HEATING 120VDC
FPGA CIRCUIT
CONTROL CIRCUIT
RS 232
PC
I/O PCB DRIVER COMM. PCB
CARTRIDGE PCB
SUB PCB
PRINT HEAD
STEP MOTOR
FEED MOTOR
CARRIAGE MOTOR
IF PCB
P L C (K7M-DR60S)
PID CONTROLLER
PUSH ROLLER (FRONT/REAR) UV LAMP CONTROL TOWER LAMP CONTROL MEDIA STOP CONTROL
UV LAMP
1 - 55
FUNCTIONAL DESCRIPTION
Horizontal movement from purge to home position and vice versa along 2 LM guides, also know as carriage rail.
Vertical movement head lifting along the along 2 LM guides (head lifting type).
7 8
9 10
1 2 3 4 5
UV source Print Head Head base plate Manual head height setting knob Sub ink tank (6C)
6 7 8 9 10
Sub ink tank (W) Upper LM guide Linear scale (Encoder strip) Lower LM guide S3M belt, carriage belt
1 - 56
FUNCTIONAL DESCRIPTION
Automatic head base height control. Manual head base height control
NOTE: For more information about how to set the head gap, refer to Head Gap Control on page 184.
1 3
1 Select Carriage Release Test (1) in the Test Menu window. As a result, the head carriage unit is disconnected from the motor, which allows you to move the head carriage unit manually. 2 Click Test (2).
Service Manual :Anapurna L/XL 2007 V1.0 Company Confidential 1 - 57
FUNCTIONAL DESCRIPTION
The head carriage unit can now be moved manually from right to left. 3 Push the head carriage unit to the desired position and check the head height by using a thickness measuring device underneath the head base plate.
1 2 3 4 5
4 Repeat step 3. 5 When finished, push the head carriage close to the home position. 6 Select Reset Test (3) in the Test Menu window.
NOTE: For more information about the Reference value, refer to Factory Set on page 1-86.
1 - 58
FUNCTIONAL DESCRIPTION
2 3
5 6 7
1 2 3 4
Linear scale (encoder strip) Encoder Encoder bracket Limit switch (home position)
5 6 7
The head carriage unit moves from the home to the purge along a metal linear scale encoder (1). The linear scale is divided as follows:
! !
Thick stripes every 50 mm, named MARK. Small stripes every 20 m (50/2500 steps), named ENC.
The encoder (2) is used to determine the position of the head carriage unit. The encoder is mounted on the encoder bracket (3), which is attached to the carriage bottom plate. The encoder reads the linear scale (1) in order to encode the position of the head carriage unit. Every time the encoder (2) passes a MARK and ENC stripe on the linear scale (1) during the movement of the head carriage unit from the home limit switch (4) to the purge position, the MARK LED (7) and ENC LED 6) on the Main PCB (5) lights up respectively. The encoder parameters are Max. Platen Size, Home Pos.Offset, Max. Mark Count and Carriage Gear Ratio and are defined in the Factory Data Setting window. Refer to Factory Set on page 1-86.
1 - 59
FUNCTIONAL DESCRIPTION
To measure the encoder pulses. If the encoder reads the linear scale normally, the head carriage repeatedly moves from left to right . If the encoder cannot read correctly, the error message encoder failed is displayed on the window pane.
When the head base plate temperature is too high (> 38C), run the encoder test for 5 minutes allowing the head carriage unit to move without printing. As a result temperature of the head base plate will go down. For more information about the head base plate temperature, refer to Head Base Temperature Control on page 1-63. Note that a temperature of <40C should be possible with a 2-ventilator system.
the head carriage unit is not moving, the head carriage unit is not moving smoothly, the position of the head carriage unit is shifting.
NOTE: For more information about the encoder check, refer to Encoder Checking on page 4-25 (chapter Preventive Maintenance)
HEAD LIFT PCB on page 1-127 DRIVER COMMUNICATION PCB on page 1-156
1 - 60
PRINT HEAD
FUNCTIONAL DESCRIPTION
9. Print Head
9.1. Functional Description
TAKE UP MOTOR
PRESSURE SENSOR
TAKE UP PCB
HEAD PCB
MAIN PCB
FPGA PCB
MEMORY
INTERFACE CIRCUIT
HEATING 120VDC
FPGA CIRCUIT
CONTROL CIRCUIT
RS 232
PC
I/O PCB DRIVER COMM. PCB
CARTRIDGE PCB
SUB PCB
PRINT HEAD
STEP MOTOR
FEED MOTOR
CARRIAGE MOTOR
IF PCB
P L C (K7M-DR60S)
PID CONTROLLER
PUSH ROLLER (FRONT/REAR) UV LAMP CONTROL TOWER LAMP CONTROL MEDIA STOP CONTROL
UV LAMP
1 - 61
FUNCTIONAL DESCRIPTION
PRINT HEAD
By means of negative pressure, the ink is kept in the print heads. A too high setting will cause missing ink nozzles, or no ink firing at all. When the pressure is too low, the ink will leak out of the heads. The negative pressure should be set to -.0.32 MPa. The system will adjust the setting, when the temperature on the head base plate is too high. This is an automatic function, the customer will never see a change on the display. When using White ink: It is possible that the negative pressure needs to be tuned towards approximately -0.036 MPa, to get a stable nozzle behavior for the white heads. With the white ink, a higher temperature will result in a lower viscosity (more liquid state), which can lead to ink pooling underneath the print head. Tip: Let the print heads leaking and adjust 4 units higher.
NOTE: Pooling: ink build up underneath the print head, causing nozzle failure. As the head needs to fire drops, the fired drops are not getting through the pool of ink underneath the head. An increase of negative pressure, (-0.036 MPa) will bring the ink more upwards into the meniscus of the print head, thus preventing the pooling.
2 3
1 - 62
PRINT HEAD
FUNCTIONAL DESCRIPTION
Read-out on display:
!
The upper value on the display is the actual temperature, the lower value is only an indication without meaning. The actual temperature will not change if you change the lower value. The actual temperature needs to be 32C when engine is not in use (cold engine). When printing, the temperature increase. For good printing results, the temperature indication should not exceed 38C. Make sure you print with closed engine doors all the time, especially when room temperatures are 25C and above. This will give you the best cooling inside the engine.
! !
NOTE: In case the head base temperature > 38C during printing, do the following: stop printing at the end of the current print job switch off the UV-lamps and run the Encoder Test for 5 minutes (refer to Encoder Count Test on page 1-89). The carriage will now move continuously without printing, allowing the base plate to cool down.
The temperature of the head base plate is measured by means of a temperature sensor, which is built into the PT sensor bracket. The PT sensor bracket is fixed to the head base plate. The temperature sensor is connected to J17 of the Head Lift PCB and leads through the Head Base Temp. PID panel. So this sensor only measures and indicates the actual temperature of the head base on the Head Base Temp PID display. If you disconnect J17 from the Head Lift PCB, the text "Open" appears on the Head Base Temp PID display.
1 - 63
FUNCTIONAL DESCRIPTION
PRINT HEAD
1
!
PT sensor bracket
The setting in the Head PCB is driving the heating elements of the different printing heads (heater bar - red cables). To have a temperature on the head base plate, you must heat the heater bar of each print head. Each heater bar (K, C, M, Y, Lc, Lm, W) is connected to the Head PCB.
Lc M Y Lc Lm
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PRINT HEAD
FUNCTIONAL DESCRIPTION
Head PCB
Cartridge PCBs
HEAD PCB on page 1-108 CARTRIDGE PCB on page 1-123 HEAD LIFT PCB on page 1-127 SUB PCB on page 1-136 IF PCB on page 1-140
1 - 65
FUNCTIONAL DESCRIPTION
UV CURING
10. UV Curing
10.1. Functional Description
TAKE UP MOTOR
PRESSURE SENSOR
TAKE UP PCB
HEAD PCB
MAIN PCB
FPGA PCB
MEMORY
INTERFACE CIRCUIT
HEATING 120VDC
FPGA CIRCUIT
CONTROL CIRCUIT
RS 232
PC
I/O PCB DRIVER COMM. PCB
CARTRIDGE PCB
SUB PCB
PRINT HEAD
STEP MOTOR
FEED MOTOR
CARRIAGE MOTOR
IF PCB
P L C (K7M-DR60S)
PID CONTROLLER
PUSH ROLLER (FRONT/REAR) UV LAMP CONTROL TOWER LAMP CONTROL MEDIA STOP CONTROL
UV LAMP
1 - 66
UV CURING
FUNCTIONAL DESCRIPTION
UV source (left)
UV source (right)
Two UV sources take care of the on the fly curing. They are positioned symmetrically left and right of the printing heads.
! ! ! ! ! ! !
High speed on-the-fly curing. Curing power: 120 W/cm. 2 fixed settings: full and half strength. Air cooled lamp-house. Quick and easy replacement of the UV-bulbs (always change both the lamps). Expected lifetime 1000 hours (full strength). Use of an automated shutter system.
1 - 67
FUNCTIONAL DESCRIPTION
UV CURING
Depending on the heat-resistance/thickness of your media, you can set the UV lamp power to Half or Full power. By default, Full power should be used whenever possible.
!
For Bi-directional printing, both UV lamps need to be used (curing is done on the fly in both directions). For Uni-directional printing, only the right UV lamp will be used (curing is only done when the head carriage unit is moving from right to left).
NOTE: Full power is only switched to the lamps when printing. Even if the switch is set to full power immediately, the lamp will remain at half power when on standby. NOTE: Once the lamps are switched off, it is important that both cooling fans are left on long enough to complete the cool-down cycle of the lamps.
1 - 68
UV CURING
FUNCTIONAL DESCRIPTION
2 3 3
5 6 7 8
9 10
1 2 3 4 5
Lamp power connector (4P) UV lamp box Lamp case outer air inlet AC FAN UV lamp box housing Lamp signal connector (10P) (LAMP-L-SIG label)
Lamp shutter signal connector (2P) (LAMP SHUTTER L label) 7 Lamp shutter ON pneumatic tube (yellow) 8 Lamp shutter OFF pneumatic tube (red 9 Lamp case inner air outlet DC FAN 10 UV Lamp
1 - 69
FUNCTIONAL DESCRIPTION
UV CURING
12 11
3 4 5 6
10
1 2 3 4 5 6
AC fuse DC fuse POW Lamp status indicator - Power ON (L) LOW Left UV lamp status indicator - half power (R) LOW Right UV lamp status indicator - half power (L) HI Left UV lamp status indicator - full power
7 8 9
(R) HI Right UV lamp status indicator - full power Air inhalation hole RIGHT lamp connector (7P)
10 RIGHT lamp connector (4P) 11 LEFT lamp connector (7P) 12 LEFT lamp connector (4P)
1 - 70
UV CURING
FUNCTIONAL DESCRIPTION
2 3
1 2 3 4 5
Low voltage relays Right lamp power settings Left lamp power settings AC cooling fan Power supply SMPS #6
6 7 8 9
Elcos (#6) High voltage relays UV lamp PLC, type K7M-DR40S Relays
Figure 1.23: UV lamp power box (inner description) - detail low voltage and high voltage relays
1 2 3 4
1 2 3 4
Relay ACfan (L) Relay ACfan (R) Relay SHUTTER (L) Relay SHUTTER (R)
5 6 7 8
Relay MC(R) - HIGH Relay MC(R) - LOW Relay MC(L) - HIGH (not visible) Relay MC(L) - LOW (not visible)
1 - 71
FUNCTIONAL DESCRIPTION
UV CURING
Figure 1.24: UV lamp power box (inner description) - detail Relays and UV lamp PLC
1 2 3 4
1 2 3
4 5
WARNING: Keep in mind always to plug the connector to the voltage connection equal to or larger than the effective input voltage. Possible connections are: 208/220/250V, 50/60Hz. e.g. if the input voltage is 235V (Spain), connect to the 250V connection.
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UV CURING
FUNCTIONAL DESCRIPTION
10.1.7. Diagrams
!
Connections in the UV lamp power box For the electrical diagram, refer to UV Lamp Power Box Connections on page 7-15 (chapter Annex).
Power supply distribution For the electrical diagram, refer to UV Lamp Power Circuit on page 7-17 (chapter Annex).
UV lamp head Part For the diagram, refer to UV Lamp Head Part on page 7-19 (chapter Annex).
UV lamp power cables For the diagram, refer to UV Lamp Power Cables on page 7-21 (chapter Annex). Briefly:
!
The 4P lamp connector provides voltage feed for the UV lamp (pin A and pin C) and the AC fan (pin B). The 10P (7P) connector provides the control signals for the shutter and the thermistors. If the UV lamp box is not correctly joined in the UV lamp box housing, pin J and pin K of the 10P connector are not closed.
UV Lamp Power Box
7P connector (L & R)
4P connector (L & R)
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FUNCTIONAL DESCRIPTION
UV CURING
1 - 74
FUNCTIONAL DESCRIPTION
11.1.0.2. Location
! !
The main PLC is located behind the control system cover. Accessible via the ink supply door. The UV lamp PLC is located in the UV lamp power box. Accessible via the main box left side door.
1 - 75
FUNCTIONAL DESCRIPTION
11.1.0.3. Diagrams
!
Main PLC For the diagram (A3 format), refer to Main PLC on page 7-25 (chapter Annex).
UV lamp PLC For the diagram (A3 format), refer to UV Lamp PLC on page 7-27 (chapter Annex).
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FUNCTIONAL DESCRIPTION
Connectors Name and Function Nr. 2 3 4 + 1 2 3 4 + 1 2 3 4 + 1 2 3 4 + 1 2 3 4 + N.O COM + Connectors Name and Function D-SUB 15P Nr. LAMP PLC Nr. GND 44 46 43 45 4D 1 2 3 4 5 6 Nr.
Pin Name P003 GND P007 24V+ P003 GND P006 GND P008 24V+ P003 GND P000 GND P002 24V+ P000 N.C N.C P018 GND P052 GND N.C N.C P019 GND P052 GND P0C GND P04B GND Pin Name PCB or Part PCB or Part
1 - 77
FUNCTIONAL DESCRIPTION
Connectors Name and Function Nr. 4F 9 10 Connectors Name and Function EPDB BLOWER START Nr. Nr. E066 E044 E034 Connectors Name and Function 5557-8P Nr. Nr. 1 2 3 4 5 6 7 8 Nr. 7 9
10 Pin Name GND P041 P042 Pin Name PCB or Part Connected to Conn. Pin PCB or Part Connected to Conn. Pin
SOL V/V P04E P052 P051 GND P040 GND GND GND
Connectors Name and Function SOL VT 301 Connectors Name and Function 5557 - 4P *2 Nr. TOWER LAMP Nr. P047 P048 P049 P04A P04B P04C GND 1 2 3 4 1 2 3 Nr. Nr. P015
1 - 78
FUNCTIONAL DESCRIPTION
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FUNCTIONAL DESCRIPTION
NOTE: Here only the buttons used for maintenance actions are discussed.
6 7 8 9
10
16
15
14
13
12
11
1 2 3 4 5 6 7 8
IMAGE SIZE display window To open an image file(.rtl) To access the Setup Parameters window Select pass mode To access the Test Menu window To set Top (forward) and Left Margin To select Uni-Directional printing To start printing
9 10 11 12 13 14 15 16
To indicate the printing progress STATUS Message display window To move head carriage unit to Home position To move head carriage unit to Purge position To jog the loaded media Forwards/Backwards To move the loaded media Forwards/Backwards To lift the head to highest position (>50mm) IMAGE display window
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FUNCTIONAL DESCRIPTION
1 - 81
FUNCTIONAL DESCRIPTION
You can change the value when you see that the drops are deviated from their correct position. When printing Bi-di, the dots must be aligned and need to be jetted to the same position, printing from right-to-left, and when printing from left-to-right. A deviated Bi-Dir alignment will show as un-sharp text and blurry images. For more information on how to check the Bi-Dir Alignment, refer to the Operator Manual.
Solution: Increase the Step Size value from: e.g.: 51660 to 51680
Solution: Decrease the Step Size value from: e.g.: 51660 to 51640.
2 Change the Step Size value according to what you see. 3 Click Save As and overwrite the existing .dat-file in the Data File Name text box. 4 In the Control Program, click Test. The Test Menu window appears. 5 In the Test Menu window, select Parameter Download and click Test. Now, the new value is active. NOTE: For more information about the Test Menu window, refer to Test Menu on page 1-88.
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FUNCTIONAL DESCRIPTION
! !
We consider 1230 as the default speed. When printing Uni-directional with 1230, the printing speed is 1230, and the returning speed (to home) is, by default set to 2000. As a result, you do not loose half your Bi-dir speed when printing Uni. To choose a random carriage speed, fill in a value besides *Carriage Speed.
NOTE: Changes on the carriage speed, requires a Parameter Download in the Test menu.
12.3.5. UV Options
The table below lists the parameters of the UV Options group.
Group Parameter Cont. ON Explanation lamps continuous ON Selected: the lamp stays on between 2 jobs, this is preferred (longest lifetime) Cleared: the lamp goes out between 2 jobs, you need to respect cooling down- and warm-up time Time needed to warm-up the UV-lamps after switching on. (= the time before the green tower lamp lights up). Time needed to cool-down the UV-Lamps after switching off (= the time the fans on the head carriage unit stays on after switching off the lamps). Cure (Default), Set Both
Lamp Type
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FUNCTIONAL DESCRIPTION
Check Distance
12.3.6.2. Executing a head gap control ! To set the head base height, execute a head gap control as follows:
1 Move the head carriage to the home position (front right side). WARNING: Always make sure the head carriage is positioned in the HOME position, when you perform the "Set Gap" procedure. 2 Load the media. If no media is present, position the desired blank A4 paper on the print table between the 2 red marking bullets positioned on the axle underneath the white transport belt and within the reach of the 2 marking bullets positioned on the side of the head carriage.
1 - 84
FUNCTIONAL DESCRIPTION
3 In the Control Program, click Setup. The Setup Parameters window appears. Refer to Setup Parameters on page 1-81 4 Fill out the Gap value and the Check Distance value in the UV Options group. Refer to Head gap control parameters on page 1-84. 5 Click Set Gap.
The Head Base will stay in the home position and go up to the highest limit position (> 50mm). 2 After this movement, the following message appears.
3 Click Yes to confirm that the carriage is clear to move to the "Check Distance" position. As a result, the head carriage unit will move 800mm to the left and come down to set the gap. A sensor plate will become visible underneath the Head Base, to make contact with the media surface.
1 - 85
FUNCTIONAL DESCRIPTION
4 The Head Base will lower to his "Reference" point, and the following message appears.
5 Click OK to confirm the lowering from the reference point to the desired head base height (1.5 mm). When this is done, the following message appears.
1 - 86
FUNCTIONAL DESCRIPTION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 18 17 16
1 2
No. of Colors: select color numbers to be output (default 6) Max. Platen Size: The maximum width from home position to purge position, expressed in motor encoder counts. Max plate size = max mark count x carriage gear ratio (e.g. 379000 = 49 X 7742) Left Margin Offset: The distance between the home position and the zero position (black nozzle row) from the image. Mark Center Offset: The distance extra travelled after the image Home Pos Offset: Distance between detecting Home position and real home position.
10 Uni-Speed: The return speed of the head carriage unit when printing in uni-directional mode. 11 Top Margin Feed: The feed before a new print start
4 5
Max. Mark Count: The markers counted (read by the encoder) from the home position to the purge position.
7 8 9
Weep Time (Sec): The time between 2 weep actions. Weep Amount: While weeping once, set Weep amount. Firing Pulse (mS): Weep Pulse time signal
12 Carriage Gear Ratio: The gear pulley ratio from the carriage motor (the factor between head carriage unit encoder counts and linear encoder markers) Always 7742. 13 Feed Gear Ratio: Reduction ratio at feed motor 14 Head Gap Reference: Distance where the sensing bracket recognize the position of the output material. This is also the point where the "Head Base" will wait for an onscreen confirmation, before going down to set the desired gap. 15 Head Offset: Head delay to map other colors onto black (= Software alignment of the inline heads). e.g. K CY: CY has to move to the right CY has to move to the left + 16 White Color: White Selection mode for forward/backward optional white color 17 Head Type: Spectra NOVA/GALAXY selection mode 18 Units: Metric (mm), English (Inch), decision Unit
1 - 87
FUNCTIONAL DESCRIPTION
NOTE: The Jet Test is executed between the 2 white marking bullets positioned on the axle underneath the white transport belt and within the reach of the 2 marking bullets positioned on the side of the head carriage.
1 - 88
FUNCTIONAL DESCRIPTION
WARNING: Do not push or pull on the UV-lamps. Only push on the back of the head carriage unit.
1 - 89
FUNCTIONAL DESCRIPTION
1 - 90
FUNCTIONAL DESCRIPTION
3 Disconnect the flat ribbon cable between the Spot White Cartridge PCB (J5) and the Head PCB and between the Pre White Cartridge PCB (J5) and the Head PCB, to avoid weeping of the white print heads.
HEAD PCB
K C M Y Lc Lm
CARTRIDGE PCBs
Wspot
Wpre
4 Disconnect the white ink pump from the refill PCB. NOTE: If at a certain point in time, you decide to fill your engine with white ink, refer to Putting White Ink into the Circuit on page 1-91.
Filling White Ink, Connecting the Spot White and Pre White Cartridge PCB, Setting the Temperature and Vacuum Control Settings, Aligning the White Heads.
1 - 91
FUNCTIONAL DESCRIPTION
1 - 92
FUNCTIONAL DESCRIPTION
2 Make sure that print head valves (K, C, M, Y, Lc, Lm, W1 and W2) are still in the solution outlet position (S) and the solution valve in the ink outlet position (I). 3 Shear the tubes of each ink drain valve. Take care to make no kinks into the tubes. 4 Place a receiving bin underneath the valves and repeat for every valve, one after the other the following: 4.1 Set the valve to the ink outlet position (I) for some seconds until you drained the content of the sub ink tank. 4.2 Then close the valve (set to S position) and wait 10 seconds until the sub-ink tank is refilled. 4.3 Repeat this a second time. 5 Wipe off the ink drop from the valve using a fiber free cloth and reconnect the tube (hand fasten). The easiest way to reconnect the tube onto the valve is to use a piece of paper or cloth around the tube. By doing so, you have more grip onto the tube without making a bend. Now you can put the vacuum pressure to the initial value (range -0.032 MPa to -0.038 MPa) and continue with flushing the heads with cleaning solution.
13.3.2. Connecting the Spot White and Pre White Cartridge PCB
1 Power off the engine using the emergency stop button. 2 Connect the flat ribbon cable between the Spot White Cartridge PCB (J5) and the Head PCB and between the Pre White Cartridge PCB (J5) and the Head PCB. 3 Restart the engine.
NOTE: Be aware that a new head requires the first hour a slightly lower vacuum pressure to wet the head nozzles and to get nozzles open. Ones all nozzles are sufficient wetted, put the vacuum to a higher final value to get reliable printing (see table above).
1 - 93
FUNCTIONAL DESCRIPTION
1 - 94
FUNCTIONAL DESCRIPTION
1 2 3
13
4 5
12
11 10
1 2 3 4 5 6 7
Connection to home limit switch Connection to Driver Comm. PCB Connection to door interlock module Connection to Driver Comm. PCB To ENCODER To SMPS #3 Connection to Driver Comm. PCB
8 9 10 11 12 13
Connection to I/O PCB Connection to PC COM1 (D-SUB 9P) Connection to I/O PCB Connection to Refill PCB Connection to Head PCB Connection to FPGA board
14.1.1.2. Location
The main PCB is located in the control box of the Home unit.
1 - 95
FUNCTIONAL DESCRIPTION
MAIN PCB
14.1.1.3. Function
1 (J7) Connected to PC, execute Users command. 2 (J16) Connected to FPGA Board, collect output data (= image data). 3 (J15) Connected to Head PCB, control output data and collect signals from sub ink tank. 4 (J5, J12) Control feed and carriage motor driver. 5 (J14) Collect information from linear scale encoder. 6 (J11) Connected to Refill PCB, control Refill. 7 (J17, J18) Connected to I/O PCB, collect and control lamp-on, lamp shutter, media set, feed limit signal. 8 (J8) Connected to limit, and control initial position.
1 - 96
FUNCTIONAL DESCRIPTION
1 - 97
FUNCTIONAL DESCRIPTION
Connectors Name and Function Nr. 43 44 45 46 47 48 49 50 Connectors Name and Function D-SUB26P Nr. J15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Connectors Name and Function 5267-5P Nr. J10 1 2 Nr. Nr. Nr.
Pin Name GND GND GND GND GND GND DC3.3V+ DC3.3V+ Pin Name DATA AB1 DATA CD1 DATA AB2 DATA CD2 DATE AB3 DATA CD3 DATA AB4 DATA CD4 DATA AB5 DATA CD5 DATA AB6 DATA CD6 DATA AB7 DATA CD7 DATA AB8 DATA CD8 MEDIA SHIFT_CK RX1_TTL TX1_TTL HV_CK ERROR_OUT HT_CNTRL S.GND S.GND S.GND Pin Name GND DC5V+ PCB or Part INTERLOCK MODULE PCB or Part HEAD PCB PCB or Part
1 - 98
FUNCTIONAL DESCRIPTION
Connectors Name and Function 5267-6P Nr. J11 1 2 3 4 5 6 Connectors Name and Function 5267-3P J7 Nr. 1 2 3 Connectors Name and Function 5267-6P J5 Nr. 1 2 3 4 5 6 Connectors Name and Function 2P J4 Nr. 1 2 Connectors Name and Function 5267-8P Nr. J12 1 2 3 4 5 6 7 8 Nr. Nr. Nr. Nr. Nr.
Pin Name GND N.C N.C TXD N.C N.C Pin Name GND TX RX Pin Name GND TX N.C. RX N.C. N.C. Pin Name GND DC24V+ Pin Name GND MOTOR_RX_IN GND MOTOR_STOP DC24V+ N.C PCB or Part DRIVER COMM. PCB PCB or Part PCB or Part DRIVER COMM. PCB PCB or Part PC - COM1 PCB or Part REFILL PCB
1 - 99
FUNCTIONAL DESCRIPTION
Connectors Name and Function 5267-4P J9 Nr. 1 2 3 4 Connectors Name and Function 5267-3P J8 Nr. 1 2 3 Connectors Name and Function 5267-3P Nr. J17 1 2 3 4 5 6 7 8 Connectors Name and Function 5267-5P Nr. J18 1 2 3 4 5 Connectors Name and Function Nr. J14 1 2 3 4 5 6 Nr. Nr. Nr. Nr. Nr.
Pin Name GND N.C N.C DC5V+ Pin Name GND HOME SENSOR DC5V+ Pin Name DC5V+ MEDIA SET 1 MEDIA SET 2 MEDIA SET 3 FEED LIMIT LEFT SHTTER RIGHT SHTTER GND Pin Name GND EXT8 EXT7 DC24V+ DC5V+ Pin Name CHASSIS GND GND ENCA+ ENCAENCB+ GND PCB or Part PCB or Part I/O PCB PCB or Part I/O PCB PCB or Part HOME LIMIT S/W PCB or Part DRIVER COMM. PCB
1 - 100
FUNCTIONAL DESCRIPTION
Connectors Name and Function Nr. 7 8 9 10 11 12 Connectors Name and Function RESET Nr. 1 2 Nr. Nr.
Pin Name ENCRI+ ENCRIGND DC5V+ ENCBDC5V+ Pin Name 24V+ GND PCB or Part PCB or Part
14.1.2.2. Leds
LED D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 Color Green Green Green Green Green Green Green Green Green Green Green Green Indication 5V MOVE-L MOVE-R MEDIA WEEP SERV-R/S HV ERROR ENC MARK TEST TRAVEL
14.1.2.3. Switches
Switch RUN FEED STOP Setting Description
14.1.2.4. Measurements
J10 - To interlock module Pin 1 (white) Pin 2 (black) +0Vdc +5Vdc 0V Ground when door open, alarm on when door closed, alarm off
1 - 101
FUNCTIONAL DESCRIPTION
3 1 2
1 2
(J10) Connection to MAIN PCB (J8) Connection to PCI I/O card CN1
1 - 102
FUNCTIONAL DESCRIPTION
14.2.1.2. Location
The FPGA PCB is located in the control box of the Home unit.
FGPA PCB
14.2.1.3. Function
The main functions of the FPGA PCB are: 1 Dividing the image data stream in different colors. 2 Collecting output data from the PCI I/O card. The PCI I/O card is fixed on the PC Main board. 3 Transferring output data to the Main PCB.
1 - 103
FUNCTIONAL DESCRIPTION
1 - 104
FUNCTIONAL DESCRIPTION
Connectors Name and Function Nr. 43 44 45 46 47 48 49 50 Connectors Name and Function PC1 J7 Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Nr. Nr.
Pin Name GND GND GND GND GND GND DC3.3V+ DC3.3V+ Pin Name N.C N.C N.C N.C N.C N.C GND N.C PCD15 N.C PCD14 N.C PCD13 N.C PCD12 N.C PCD11 N.C PCD10 N.C PCD9 N.C PCD8 N.C PCD7 N.C PCD6 N.C PCD5 N.C PCD4 N.C PCD3 PCB or Part PCI CARD PCB or Part
1 - 105
FUNCTIONAL DESCRIPTION
Connectors Name and Function Nr. 34 35 36 37 38 39 40 Connectors Name and Function PCN2 J8 Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Nr. Nr.
Pin Name N.C PCD2 N.C PCD1 N.C PCD0 N.C Pin Name N.C PCSELA N.C PCSELB N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C GND PCB or Part PCI CARD PCB or Part
1 - 106
FUNCTIONAL DESCRIPTION
Pin Name N.C N.C O_REQ N.C N.C N.C PCB or Part
1 - 107
FUNCTIONAL DESCRIPTION
1 2 3 4
Connection to MAIN PCB Level sensor connectors (K, C, M, Y, Lc, Lm, S, W) Connection to cartridge PCBs (incoming data) Head temperature potentiometer
5 6 7
Connection to head temperature sensor (2 black wires to the Magenta print head) Connection to each head heating device 220V connector
1 - 108
FUNCTIONAL DESCRIPTION
14.3.1.2. Location
The HEAD PCB is located at the back side of the head carriage unit, underneath the HEAD LIFT PCB.
HEAD PCB
K C M Y Lc Lm Wspot Wpre
14.3.1.3. Function
The main functions of the HEAD PCB are: 1 Connected to MAIN PCB, collect output data and ink supplying signals from sub ink tank. 2 Connected to each CARTRIDGE PCBs, and transfer output data. 3 Collect floating signals from each ink tank. 4 Connect each head heating device. This is the connection to the heater bar of each print head (K, C, M, Y, Lc, lm, W, W) 5 Connect the head temperature sensor. Is this the black thermostat cable connected to the thermistor of the Magenta Print head (see Temperature detection components and setting components on page 1-63).
1 - 109
FUNCTIONAL DESCRIPTION
1 - 110
FUNCTIONAL DESCRIPTION
Connectors Name and Function 5267-2P Nr. INK8 1 2 Connectors Name and Function 3951-2P 1 2 3 4 5 6 7 8 Nr. 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 Connectors Name and Function J1 Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Nr. Nr. Nr.
Pin Name INK8 GND Pin Name HV2 HEATER #1 HV2 HEATER #2 HV2 HEATER #3 HV2 HEATER #4 HV2 HEATER #5 HV2 HEATER #6 HV2 HEATER #7 HV2 HEATER #8 Pin Name GND_SIGNAL GND_SIGNAL HV_ERR HV_CK1 SHIFT_CK1 DATA_CDH1 DATA_ABH1 N.C 12V 12V GND_POWER GND_POWER N.C N.C HV1 HV1 PCB or Part HEAD CARTRIDGE PCB J5 (black) HEAD HEATER #8 HEAD HEATER #7 HEAD HEATER #6 HEAD HEATER #5 HEAD HEATER #4 HEAD HEATER #3 HEAD HEATER #2 PCB or Part HEAD HEATER #1 PCB or Part LEVEL SENSOR WHITE
1 - 111
FUNCTIONAL DESCRIPTION
Connectors Name and Function J2 Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Connectors Name and Function J3 Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Nr. Nr.
Pin Name GND_SIGNAL GND_SIGNAL HV_ERR HV_CK2 SHIFT_CK2 DATA_CDH2 DATA_ABH2 N.C 12V 12V GND_POWER GND_POWER N.C N.C HV1 HV1 Pin Name GND_SIGNAL GND_SIGNAL HV_ERR HV_CK3 SHIFT_CK3 DATA_CDH3 DATA_ABH3 N.C 12V 12V GND_POWER GND_POWER N.C N.C HV1 HV1 PCB or Part HEAD CARTRIDGE PCB J5 (Magenta) PCB or Part HEAD CARTRIDGE PCB J5 (Cyan)
1 - 112
FUNCTIONAL DESCRIPTION
Connectors Name and Function J4 Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Connectors Name and Function J5 Nr. 1 Nr. Nr.
Pin Name GND_SIGNAL GND_SIGNAL HV_ERR HV_CK4 SHIFT_CK4 DATA_CDH4 DATA_ABH4 N.C 12V 12V GND_POWER GND_POWER N.C N.C HV1 HV1 Pin Name GND_SIGNAL PCB or Part HEAD CARTRIDGE PCB J5 (Light Cyan) PCB or Part HEAD CARTRIDGE PCB J5 (Yellow)
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
GND_SIGNAL HV_ERR HV_CK5 SHIFT_CK5 DATA_CDH5 DATA_ABH5 N.C 12V 12V GND_POWER GND_POWER N.C N.C HV1 HV1
1 - 113
FUNCTIONAL DESCRIPTION
Pin Name GND_SIGNAL PCB or Part HEAD CARTRIDGE PCB J5 (Light Magenta)
GND_SIGNAL HV_ERR HV_CK6 SHIFT_CK6 DATA_CDH6 DATA_ABH6 N.C 12V 12V GND_POWER GND_POWER N.C N.C HV1 HV1 Pin Name GND_SIGNAL PCB or Part HEAD CARTRIDGE PCB J5 (Spot White) Connected to Conn. Pin
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
GND_SIGNAL HV_ERR HV_CK7 SHIFT_CK7 DATA_CDH7 DATA_ABH7 N.C 12V 12V GND_POWER GND_POWER N.C N.C HV1 HV1
1 - 114
FUNCTIONAL DESCRIPTION
Connectors Name and Function J8 Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Connectors Name and Function J9 Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Nr. Nr.
Pin Name GND_SIGNAL GND_SIGNAL HV_ERR HV_CK8 SHIFT_CK8 DATA_CDH8 DATA_ABH8 N.C 12V 12V GND_POWER GND_POWER N.C N.C HV1 HV1 Pin Name DATA AB1 DATA CD1 DATA AB2 DATA CD2 DATA AB3 DATA CD3 DATA AB4 DATA CD4 DATA AB5 DATA CD5 DATA AB6 DATA CD6 DATA AB7 DATA CD7 DATA AB8 DATA CD8 MEDIA SHIFT_CK RX1_TTL TX1_TTL HV_CK ERROR_OUT HT_CNTRL PCB or Part MAIN PCB J15 PCB or Part
1 - 115
FUNCTIONAL DESCRIPTION
Connectors Name and Function Nr. 24 25 26 Connectors Name and Function 5267-2P Nr. J29 1 2 Connectors Name and Function STL950 Nr. J13 1 2 3 4 5 6 7 8 Nr. Nr. Nr.
Pin Name S.GND S.GND S.GND Pin Name SIGNAL GND Pin Name HV2 GND HV1 GND 5V+ GND 24V+ GND PCB or Part PCB or Part PCB or Part
14.3.2.2. Leds
LED D1 Color Indication the first 8 INK LEDs are related to the status of the sub ink tank (LED ON means sub ink tank empty and as a result a signal is sent to the pumps) HV_ERR (High Voltage) HT_ERR (Heather Error) INK_OVF (Ink Overflow)
D2 D4 D6
14.3.2.3. Adjustments
Refer to Head Base Temperature Control on page 1-63.
1 - 116
FUNCTIONAL DESCRIPTION
2 11 3 4
10
1 2 3 4 5 6 7
Connection to Indicator PCB Connection to Main PCB Connection to air tank Connection to SMPS #3 Connection to Front media detection sensor Connection to Front gear motor Connection to sub tank flow sensor
8 9 10 11 12 13
Connection to Refill Control PCB Connection to Rear media detection sensor Connection to Rear gear motor Connection to Indicator PCB Connection to Take Up PCB Connection to Ink pumps (C, M, Y, K, Lm, Lc, W and S)
14.4.1.2. Location
The REFILL PCB is located behind the swinging ink supply door.
1 - 117
FUNCTIONAL DESCRIPTION
14.4.1.3. Function
The main functions of the REFILL PCB are: 1 The main PCB controls the Refill PCB (serial cable between MAIN and REFILL) 2 Controlling each ink pump (C, M, Y, K, Lm, Lc, W and S). 3 Transferring the state signals of each ink supply to the CONTROL PCB. 4 Collecting ink empty signal coming from the INDICATOR PCB. 5 Connected to the TAKE UP PCB. 6 Collecting media detection sensor signals (See Auto Feeding System on page 1-34). 7 Collecting signals coming from the air tank.
1 - 118
FUNCTIONAL DESCRIPTION
Connectors Name and Function 5267-2P Nr. J11 1 2 Connectors Name and Function 3191-3P Nr. J16 1 Nr. Nr.
Pin Name MOTOR REAR+ MOTOR REARPin Name DC24V+ PCB or Part TAKE UP REAR MEDIA DETECTION SENSOR PCB or Part REAR TAKE UP MOTOR
2 3 Connectors Name and Function 5557-2P Nr. J10 1 2 Connectors Name and Function Apr-57 Nr. J15 1 Nr. Nr.
REAR-SENSE GND Pin Name MOTOR FRONT+ MOTOR FRONTPin Name F_SEN PCB or Part TAKE UP FRONT MEDIA DETECTION SENSOR Connected to Conn. Pin PCB or Part FRONT TAKE UP MOTOR Connected to Conn. Pin
2 3 4 Connectors Name and Function Mar-45 Nr. J17-1 1 2 3 Connectors Name and Function 5267-3P Nr. J17 1 2 3 Nr. Nr.
GND N.C DC24V+ Pin Name DC5V+ N.C GND Pin Name RX N.C (TX) GND PCB or Part MAIN PCB J11 Connected to Conn. Pin PCB or Part INDICATOR PCB J11 Connected to Conn. 3 2 1 Pin
1 - 119
FUNCTIONAL DESCRIPTION
Connectors Name and Function 5267-4P Nr. BZ1 1 2 3 4 Connectors Name and Function Nr. J20 1 2 J27 1 2 J24 J1 J25 J3 J26 J5 1 2 1 2 1 2 1 2 1 2 1 2 Connectors Name and Function IDC-30P Nr. J 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Nr. Nr. Nr.
Pin Name GND N.C N.C BUZZER+ Pin Name PUMP_S DC24V+ PUMP_W DC24V+ PUMP_LM DC24V+ PUMP_LC DC24V+ PUMP_Y DC24V+ PUMP_M DC24V+ PUMP_C DC24V+ PUMP_K DC24V+ Pin Name SW_Y SW_M SW_C SW_K SW_LM SW_LC SW_WHITE SW_S +5V GND S_LED_Y S_LED_M S_LED_C S_LED_K PCB or Part REFILL CONTROL PCB KNF MOTOR K KNF MOTOR C KNF MOTOR M KNF MOTOR Y KNF MOTOR LC KNF MOTOR LM KNF MOTOR WHITE PCB or Part KNF MOTOR SOLUTION PCB or Part
1 - 120
FUNCTIONAL DESCRIPTION
Connectors Name and Function Nr. 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Connectors Name and Function 5267-2P Nr. J13 1 2 Connectors Name and Function 5267-3P Nr. J34 1 2 3 Connectors Name and Function 5267-6P Nr. J32 1 2 3 4 5 6 Nr. Nr. Nr. Nr.
Pin Name S_LED_LM S_LED_LC S_LED_WHITE S_LED_S +5V GND P_LED_Y P_LED_M P_LED_C P_LED_K P_LED_LM P_LED_LC P_LED_WHITE P_LED_S +24V GND Pin Name LAMP ON 24V+ Pin Name LAMP ON N.C GND Pin Name 5V N.C PRESSURE_LOW N.C N.C N.C PCB or Part Air tank PCB or Part PCB or Part Main PLC PCB or Part
1 - 121
FUNCTIONAL DESCRIPTION
14.4.2.2. Leds
LED D12 Color Indication Status ink pumps + 1 communication LED with Indicator PCB
14.4.2.3. Switches
Switch SW1 Setting Description RESET
14.4.2.4. Measurements
J32 - Connection to air pressure sensor main air tank Pin 6 (black) Pin 4 (white) +5Vdc +5Vdc 0V Permanent above 3 bar, alarm off below 3 bar, alarm on
1 - 122
FUNCTIONAL DESCRIPTION
1 2
(J1 - J4) connection with the 4 data cables of one print head (J5) connection to HEAD PCB
1 - 123
FUNCTIONAL DESCRIPTION
14.5.1.2. Location
The eight CARTRIDGE PCBs are located at the back side of the head carriage unit, underneath the HEAD PCB. The CARTRIDGE PCB for white is positioned a little to the back.
K C M Y Lc Lm
CARTRIDGE PCBs
Wspot
Wpre
14.5.1.3. Function
The CARTRIDGE PCB controls the head and the connected head ink jet function (ink drop).
1 - 124
FUNCTIONAL DESCRIPTION
1 - 125
FUNCTIONAL DESCRIPTION
Pin Name HVPULSE N.C N.C GND CLK DATA OUT1 DATA IN DC12V+ GND PCB or Part HEAD #1 FLAT CABLE #8
14.5.2.2. Leds
LED D4 Type Color Indication LEDG-SM 12V
1 - 126
FUNCTIONAL DESCRIPTION
1 2 3
4 5 6
Connection to IF PCB Connection to heater plate of white sub ink tank Connection to heater plate of 6C sub ink tank
1 - 127
FUNCTIONAL DESCRIPTION
14.6.1.2. Location
The HEAD LIFT PCB is located at the back side of the head carriage unit.
14.6.1.3. Function
The main functions of the HEAD LIFT PCB are: 1 Controlling the head carriage lift step motor. 2 Connected to ITV PCB (J13), control ITV. 3 Connected to IF PCB, 4 Control head base (J17) and sub ink tank temp (J10). The temperature sensor which is connected to J17 of the Head Lift PCB leads through the Head Base Temp. PID panel. So this sensor only measures and indicates the actual temperature of the head base on the Head Base Temp PID display. If you disconnect J17 from the Head Lift PCB, the text "Open" appears on the Head Base Temp PID display (See Temperature detection components and setting components on page 1-63). 5 Connect heating device to white sub ink tank (J25) and 6C sub ink tank (J14). 6 Controlling the head gap sensor. 7 Controlling the purge solenoid of the purge switch (J12).
1 - 128
FUNCTIONAL DESCRIPTION
1 - 129
FUNCTIONAL DESCRIPTION
Connectors Name and Function 3951-6P J8 Nr. 1 2 3 4 5 6 Connectors Name and Function 5267-3P Nr. J10 1 2 3 Connectors Name and Function 5045-3P Nr. J11 1 Nr. Nr. Nr.
Pin Name DC24V+ DC24V+ GND GND BASE_HEATER SUB_HEATER Pin Name SUB_B SUB_B SUB_A Pin Name IN+ PCB or Part SUB AIR TANK PRESSURE SENSOR PCB or Part PT SENSOR SUB INK TANK PCB or Part I/F PCB
2 3 Connectors Name and Function 3951-2P Nr. J12 1 2 Connectors Name and Function 5045-4P Nr. J13 1 2 3 4 Nr. Nr.
DC24V+ GND Pin Name DC24V+ SOL(1), SOL(2) Pin Name OUT+ N.C DC24V+ GND PCB or Part ITV2010 Connected to Conn. Pin PCB or Part PURGING S/W (PUSH BUTTON) Connected to Conn. Pin
1 - 130
FUNCTIONAL DESCRIPTION
Connectors Name and Function 3951-3P Nr. J14 1 2 3 Connectors Name and Function Nr. J25 1 2 Nr. Nr.
Pin Name GND GND SUB_HEATER Pin Name GND SUB_HEATER PCB or Part 6C SUB INK HEATER PCB or Part WHITE SUB INK HEATER
Connectors Name and Function 5045-7P Nr. J15 1 2 3 4 5 6 7 Connectors Name and Function 5045-10P Nr. J16 1 2 3 4 5 6 7 8 9 10 Nr. Nr. A
GND A~ B GND B~ N.C Pin Name OUT+ OUT+ IN+ IN+ GND GND GND DC24V+ DC24V+ DC24V+ PCB or Part ITV CONTROLLER CN1 Connected to Conn. 4 4 3 3 2 2 2 1 1 1 Pin
1 - 131
FUNCTIONAL DESCRIPTION
Connectors Name and Function 5267-4P Nr. J17 1 2 3 4 Connectors Name and Function 3951-4P Nr. J18 1 2 3 4 Connectors Name and Function 3951-7P Nr. J23 1 2 3 4 5 Nr. Nr. Nr.
Pin Name BASE_B BASE_B N.C BASE_A Pin Name GND DC5V+ GND DC24V+ Pin Name DC24V+ N.C SOLA N.C DC24V+ PLATEN SENSING B/K LOCK SOLENOID PCB or Part PCB or Part SMPS #6 PCB or Part PT SENSOR HEAD BASE
Connected to Conn. CH1 DC5V+ GND CH2 DC24V+ GND Connected to Conn. Pin Pin
6 7
N.C SOLB
14.6.2.2. Leds
LED LED 1 LED 2 Color Indication
14.6.2.3. Switches
Switch SW1 RESET Setting Description
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FUNCTIONAL DESCRIPTION
14.7.1.2. Location
The ITV CONTROLLER PCB is located behind the control system cover underneath the PID panel. To get access to the ITV CONTROL PCB, open the ink supply door.
14.7.1.3. Function
The main functions of the ITV CONTROL PCB are: 1 Collecting the control signals from PSE200. 2 Connected to Head Lift PCB and control ITV. 3 Minus (-) pressure setting control.
1 - 133
FUNCTIONAL DESCRIPTION
1 - 134
FUNCTIONAL DESCRIPTION
Connectors Name and Function CH-1 J2 Nr. 1 2 3 4 Connectors Name and Function J3 Nr. 1 2 3 4 Connectors Name and Function J4 Nr. 1 2 3 4 Connectors Name and Function J5 Nr. 1 2 3 4 Nr. Nr. Nr. Nr.
Pin Name BROWN BLUE BLACK Pin Name BROWN BLUE BLACK Pin Name BROWN BLUE BLACK Pin Name BROWN BLUE BLACK PCB or Part IVT CONTROL PCB or Part IVT CONTROL PCB or Part IVT CONTROL PCB or Part IVT CONTROL
Connected to Conn. 1 2 4 9 3 Connected to Conn. 1 2 4 9 3 Connected to Conn. 1 2 4 9 3 Connected to Conn. 1 2 4 9 3 Pin Pin Pin Pin
14.7.2.2. Switches
Switch SW2 ON Setting Description Factory setting
14.7.2.3. Adjustments
It is not necessary to tune the variable resistors GAIN and ZERO. Both resistors are factory set.
1 - 135
FUNCTIONAL DESCRIPTION
1 2
1 - 136
FUNCTIONAL DESCRIPTION
14.8.1.2. Location
The SUB PCB is located in the control box of the Home unit.
SUB PCB
14.8.1.3. Function
The main functions of the SUB PCB are: 1 Collecting the tower lamp signals air Low, ink low, lamp on, media set on, blower on coming from the PLC. 2 Transferring the signals air Low, lamp shutter L/R and UV lamp on to the I/O PCB. 3 Distributing the 5V and 24 V DC voltages coming from the SMPS (DC5V/24). SMPS is an acronym for Switch Mode Power Supply.
1 - 137
FUNCTIONAL DESCRIPTION
1 - 138
FUNCTIONAL DESCRIPTION
Connectors Name and Function 3951-6P J4 Nr. 1 2 3 4 5 6 Connectors Name and Function 5267-2P Nr. J48 1 2 Connectors Name and Function 5557-2P Nr. J44 1 2 Nr. Nr. Nr.
Pin Name AIR-LOW INK LOW LAMP ON MEDIA SET BLOWER ON N.C Pin Name SUC-LEVEL DC5V+ Pin Name MOTOR+ MOTORPCB or Part PCB or Part not used PCB or Part PLC
1 - 139
FUNCTIONAL DESCRIPTION
14.9. IF PCB
14.9.1. IF PCB Layout
14.9.1.1. Figure
14.9.1.2. Location
The IF PCB is located behind the control system cover underneath the PID panel. To get access to the IF PCB, open the ink supply door.
IF BCB
14.9.1.3. Function
The main functions of the IF PCB are: 1 Distributing the 24 V DC voltages. 2 Connected to IF PCB, head base and sub ink tank temp. 3 Connected to the head base temperature, sub ink tank temperature and white sub ink tank temperature PID controller.
1 - 140
FUNCTIONAL DESCRIPTION
1 - 141
FUNCTIONAL DESCRIPTION
Connectors Name and Function 3951-2P J6 Nr. 1 2 Connectors Name and Function 3951-2P J7 Nr. 1 2 Connectors Name and Function 5267-3P J8 Nr. 1 2 3 Connectors Name and Function 3951-3P J9 Nr. 1 2 3 Connectors Name and Function 5267-4P Nr. J10 1 2 3 4 Connectors Name and Function 3951-2P Nr. J11 1 2 Nr. Nr. Nr. Nr. Nr. Nr.
Pin Name DC24V GND Pin Name DC24V GND Pin Name SUB-A SUB-B SUB-B Pin Name SUB-HEATER N.C GND Pin Name BASE-B BASE-B N.C BASE-A Pin Name BASE HEATER GND PCB or Part PCB or Part PCB or Part PCB or Part PCB or Part PCB or Part
1 - 142
FUNCTIONAL DESCRIPTION
Connectors Name and Function 5045-9P Nr. J12 1 2 3 4 5 6 7 8 9 Connectors Name and Function 5045-5P Nr. J13 1 2 3 4 5 Connectors Name and Function PID Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Nr. Nr. Nr.
Pin Name GND N.C N.C N.C N.C N.C N.C N.C DC24V Pin Name PSE N.C N.C GND DC24V Pin Name SV2 IN SV2-COM CA SENSOR EV2-OUT2 EV2-OUT1 N.C EV1-OUT2 EV1-OUT1 ACIN ACIN N.C COM N.O PCB or Part PCB or Part PCB or Part
1 - 143
FUNCTIONAL DESCRIPTION
1 5
1 2 3
(J2) Connection to feed limit and media sensor (J3) Connection to SUB PCB (J6) Connection to SUB PCB
4 5
1 - 144
FUNCTIONAL DESCRIPTION
14.10.1.2. Location
The I/O PCB is located in the control box of the Home unit.
I/O PCB
14.10.1.3. Function
The main functions of the I/O PCB are: 1 (J3, J6) Indicating the signals of the lamp shutter L/R and the UV lamp on coming from the SUB PCB. 2 (J2) Collecting and transferring the signals of feed limit and media sensors. 3 (J1, J4) Indicating and transferring the signals UV lamp on, lamp shutter L/R, media sensors and feed limit to the MAIN PCB.
1 - 145
FUNCTIONAL DESCRIPTION
1 - 146
FUNCTIONAL DESCRIPTION
Pin Name N.C UV LAMP ON N.C N.C PCB or Part MAIN PCB
14.10.2.2. Leds
LED LED1 LED2 LED3 LED4 LED5 LED6 LED7 Type ON/OFF signals Color green green green green green green green Indication Media sensor 1 Media sensor 2 Media sensor 3 Feed Limit Left shutter Right shutter UV lamp on
1 - 147
FUNCTIONAL DESCRIPTION
14.11.1.2. Location
The TAKE UP PCB is located behind the control system cover at the bottom of the PID panel. To get access to the TAKE UP PCB, open the ink supply door.
TAKE UP BCB
14.11.1.3. Function
The TAKE UP PCB is connected with the REFILL PCB and control the motor rotation of the take-up motor and displays the state signals.
1 - 148
FUNCTIONAL DESCRIPTION
14.11.2.2. Leds
LED D1 D2 D3 D4 D5 Type red green green red green Color Indication auto/manual indicator CW led CCW led Auto led Error led
14.11.2.3. Switches
Switch SW1 CW switch SW2 C switch SW3 SW4 in out in out in out in out Setting Description rotate motor CW rotate motor CCW FRONT REAR AUTO mode MANUAL mode
1 - 149
FUNCTIONAL DESCRIPTION
1 2
(D1-D8) Empty Ink refill status LED indications (D9-D16) Feeding Ink refill status LED indications
3 4
14.12.1.2. Location
The REFILL CONTROL PCB is located behind the refill system panel. To get access to the REFILL CONTROL PCB, unscrew the 4 screws of the refill system panel.
14.12.1.3. Function
The REFILL CONTROL PCB is connected to REFILL PCB. The REFILL CONTROL PCB indicates each ink refill status (empty, feeding) and the status of the manual feeding switches.
1 - 150
FUNCTIONAL DESCRIPTION
14.12.2.2. Leds
LED D1 D2 D3 D4 D5 D6 D7 D8 D9 red red red red red red red red green Color Indication
1 - 151
FUNCTIONAL DESCRIPTION
Indication
14.12.2.3. Switches
Switch SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 Setting Description Manual feeding of white ink Manual feeding of Lm ink Manual feeding of Lc ink Manual feeding of Y ink Manual feeding of M ink Manual feeding of C ink Manual feeding of K ink Manual feeding of solution
1 - 152
FUNCTIONAL DESCRIPTION
1 2
(J13) Transferring Ink empty signal to REFILL PCB (J11) +5VDC coming from REFILL PCB
3 4
(J1-J8) Connection to ink tank flow sensor (D1-D16) Ink Full/Empty LED indications
14.13.1.2. Location
The INDICATOR PCB is located behind the ink tank indicator panel. To get access to the INDICATOR PCB, unscrew the 4 screws of the ink tank indicator system panel.
14.13.1.3. Function
The main functions of the INDICATOR PCB are: 1 Connecting the flow sensor to each main ink tank. 2 Indicating the ink full or empty status. 3 Transferring the ink empty signal to the REFILL PCB.
1 - 153
FUNCTIONAL DESCRIPTION
1 - 154
FUNCTIONAL DESCRIPTION
14.13.2.2. Leds
LED D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 D16 red green red green red green red green red green red green red green red Color green Indication white ink tank full white ink tank empty Lm ink tank full Lm ink tank empty Lc ink tank full Lc ink tank empty Y ink tank full Y ink tank empty C ink tank full White ink tank empty M ink tank full M ink tank empty K ink tank full K ink tank empty Solution tank full Solution tank empty
14.13.2.3. Measurements
J13 - Connection to REFILL PCB J4 Pin 1 (green) Pin 2 (red) +5Vdc 0V +5Vdc empty alarm on empty alarm off Permanent
J1 / J8 - Connection to level sensor ink tank Pin 1 (black) Pin 2 (red) Pin 3 (yellow) +5Vdc +5Vdc 0V +5Vdc 0V Permanent empty detection on empty detection off full detection on full detection off
1 - 155
FUNCTIONAL DESCRIPTION
2 5
1 2 3
(J7) +5VDC coming from MAIN PCB (J4) Connection to feed servo motor driver (J3) Connection to carriage servo motor driver
4 5
1 - 156
FUNCTIONAL DESCRIPTION
14.14.1.2. Location
The DRIVER COMM PCB is located in the control box of the Home unit.
14.14.1.3. Function
The main functions of the DRIVER COMMUNICATION PCB are: 1 Connected to the carriage and feed servo motor driver. 2 Receiving the carriage and feed motor driver signals from the MAIN PCB.
1 - 157
FUNCTIONAL DESCRIPTION
1 - 158
CHAPTER
2-1
OVERVIEW
1. Overview
The Anapurna L/XL are wide format industrial inkjet printers for indoor and outdoor sign and displays. Theses UV-curable engines stand for quality printing on uncoated rigids as well as on roll media.
! ! !
Print resolution: 363 x 725 dpi. Prints up to 250 cm wide. Choice of media.
Rigid media
2-2
OVERVIEW
posters billboards fleet displays POS & POP displays exhibition panels stage graphics construction announcements ad panels etc.
2-3
FEATURES
2. Features
2.1. Borderless Printing
Borderless printing means:
! ! ! !
No loss of time cutting. Less manpower. No wasted material. Print exactly what your customers order.
Reduce your costs. Make your business more profitable. Make it easier for you to offer your customers more attractive price quotations.
2-4
FEATURES
2.7. UV Curing
According to your requirements you can set the strength of the UV-lamps to "full" or "half", thus saving on life cycle of the lamps.
Anapurna L and Anapurna XL: 2 extraction units, consisting of an exhaust tube and the blower.
2-5
SPECIFICATIONS
3. Specifications
NOTE: For detailed information about the Anapurna L/XL Specifications, refer to the User Manual.
Piezo drop-on demand inkjet A piezoelectric inkjet head uses mechanical force to transfer the ink onto the substrate. Pixel information is transformed into an electric signal applied to the ceramic piezo material of the inkjet nozzle. This generates pressure on the ink in the nozzle, pushing the ink out. The drop on demand technology only jets ink droplets when they are needed. There is no unnecessary ink flow or ink waste during printing or standstill.
! !
256 addressable jetting nozzles with spacing of 279 microns (0.011) intrinsic resolution of 91 dpi.
2-6
SPECIFICATIONS
7 heads in line (1). 1 head mounted in front of the other heads, used for Pre-White (2).
1 1 2
3.3. Media
3.3.1. Thickness
Material Rigids Roll material 1 to 50 mm min. 0.1 mm (max. roll diameter 36 cm) Thickness max 28 kg/m up to 50 kg
2
Weight
3.3.2. Type
! ! ! ! ! ! !
2-7
SPECIFICATIONS
3.4. Inks
3.4.1. General Information UV Curable Ink
Ink colors: Cyan, Magenta, Yellow, Black, Light cyan, Light magenta, White. Ink package: 1 liter bottle, packed per 2. One ink tank is used for cleaning solution
The Anapurna UV curable ink is specially developed for best performance on the Anapurna engine. Sharp printing, vibrant colors on a wide range of media. Ensures dry and instant ready prints with excellent outdoor durability. Curing system:
! !
! !
Enhances apparent output resolution by using Light Cyan and Light Magenta. Results in smooth highlights.
2-8
SPECIFICATIONS
Agfa inks tuned towards the ISO Standard 12647 (2004). Calculated number of colors (Volume calculated within Monaco CMS).
! !
ISO Standard 12647: 770000 colors. Anapurna ink on Anapurna printing in: 4 pass: 6 pass: 830000 colors. 8 pass: 850000 colors. 12 pass: 1080000 colors. 16 pass:
3.6. Electricity
Voltage (V) Europe 3 phase with neutral with ground star 380 V-10% - 415 V+6% 3 phase no neutral with ground 208 V-10% - 240 V+6% Frequency (Hz) 50 Hz Maximum Fuse protection Current rating (A) 40 A 50 A
US
60 Hz
36 A
50 A
2-9
SPECIFICATIONS
3.7. RIP PC
The Wasatch SoftRIP is provided for ripping images. Install the Wasatch SoftRIP on a separate PC that fulfils the following platform specifications.
Pentium 1 GHz CPU. 512 MB RAM. 8 GB Hard Drive. Windows 2000, XP or Vista.
Recommended:
! ! ! !
Pentium IV 3.06 GHz CPU or faster. 1 GB RAM. 80 GB or larger Hard Drive. Windows 2000, XP or Vista.
NOTE: The faster the CPU, the faster the software will process your images. It is therefore advisable to buy the fastest available computer you can. While more RAM will also help speed up the processing, it is the speed of the CPU that directly affects how fast SoftRIP runs. If you are processing large files over 100 MB in size, it is also advisable to upgrade to at least 1 GB of memory. NOTE: Wasatch SoftRIP can process more than one image at a time and takes advantage of multiple CPUs for this purpose. For every additional processor in your computer, it is recommended you double the amount of RAM, up to a maximum of 512 MB per processor. It is important to use multigigabyte disk drives on computers that are intended for use in high resolution printing, especially if you plan to keep the RIPped images available in the Wasatch Print Queue.
3.8. Service PC
If you want to connect a service PC to the Anapurna L/XL provide the following:
!
2 - 10
SPECIFICATIONS
3.9. Anapurna L
!
Dimensions
Unit Width 3700 mm 146 inch 1750 mm 68.9 inch Height 1660 mm* 65 inch 970 mm ** 38.2 inch Depth 2360 mm*** 93 inch 1000 mm**** 43 inch Weight 1700 kg 3748 lbs -
* height without tower light (tower light = 670 mm) ** adjustable to the height of the printing table *** depth with mounted roll bar brackets (without brackets = 2075 mm) **** length without coupling
! ! !
Printing speed up to 22 boards/hr (70 x 100 cm) (= poster quality) Floor space 700 x 700 cm (276" x 276") Maximum media width 160 cm (62,9")
3.10. Anapurna XL
!
Dimensions
Unit Width 4750 mm 187 inch 2650 mm 104 inch Height 1660 mm* 65 inch 970 mm ** 38.2 inch Depth 2360 mm*** 93 inch 1000 mm**** 43 inch Weight 2300 kg 5071 lbs -
* height without tower light (tower light = 670 mm) ** adjustable to the height of the printing table *** depth with mounted roll bar brackets (without brackets = 2075 mm) **** length without coupling
! ! !
Printing speed up to 30 boards/hr (70 x 100 cm) (= poster quality) Floor space 700 x 800 cm (276" x 316") Maximum media width 250 cm (98,4")
2 - 11
SPECIFICATIONS
2 - 12
CHAPTER
3-1
SAFETY NOTES
1. Safety Notes
The purpose of this paragraph is to provide you with guidelines on the use and safety of the Anapurna L/XL during repair and service to avoid personal injury or damage to the printer.
1.1. Warning/Caution/Note
Three types of safety terms are used to attract your attention to specific information. The meaning of each safety term is described below:
!
Warning
WARNING: Warnings are directions which, if not followed, can cause fatal or serious injuries to the operator or engineer. Caution
CAUTION: A caution is used when there is a possible danger due to incorrect manipulation. As a result, you could damage the equipment, lose data or obtain an unexpected result. Note
NOTE: A note contains additional information which may be useful to you but which is not vitally important to work safely.
3-2
SAFETY NOTES
WARNING: The Anapurna L/XL has an airing system to carry away harmful gases (ozone gas which is built up by the curing process). Before performing any operations involving ink, consult the MSDS. CAUTION: Do not use ink other than the ones recommended by AGFA. Other ink may cause nozzle clogging or other serious problems to your printer.
CAUTION: Respect the color sequence of the ink buffer system. Each ink tank is fitted with a colored label indicating the color type. From left to right: (W), Lm, Lc, Y, M, C, K and Solution.
1.4. UV Radiation
Ultraviolet radiation (UV) has a high photon energy range and is particularly hazardous because there are usually no immediate symptoms of excessive exposure. Always wear UV protective (tinted) glasses while working with an open front cover or while working on the head carriage.
WARNING: UV light can cause harmful damage to eyes and skin. Therefore never look into UV light without wearing protective glasses. Never exposure your skin to UV light.
3-3
SAFETY NOTES
1.5. Electricity
WARNING: Do not touch the Anapurna L/XL or any electrical components when your hands are wet.
CAUTION: Avoid other electrical equipment near the printer. Electronic waves can cause wrong operation or can shorten the life span of the printer.
WARNING: Do not touch the print head during printing or maintenance actions. Do not place any obstacle on the print table which can hinder the head carriage during movement.
CAUTION: Regular inspecting and cleaning of the Anapurna L/XL is required to help to prevent machine damage and printing difficulties.
CAUTION: The print table is not to be used as a worktable. Never lean on the printer and do not place anything on the printer.
CAUTION: Always clean the print head using cleaning fluid after printing and before turning off the system.
CAUTION: Avoid direct light on inner parts such as sensors. Direct light can cause malfunctions that lead to a reduced image quality.
CAUTION: Never shutdown the PC of the engine. A shut down of the PC also stops the stirring of the white ink which can lead to white ink supply problems.
3-4
SAFETY NOTES
CAUTION: Never turn off the compressed air during idle periods. If it is needed to do this, execute the following actions before shutting down the engine:
! ! !
put all ink valves in the solution (S) outlet position, mount the capping plate underneath the head base plate, disconnect the 2 cables of the carriage servo motor to avoid that after power-up the engine again, the carriage accidentally moves after reset while the capping plate is still mounted.
Identification of the product, Composition/data on components, Hazard identification, First aid measures, Fire fighting measures, Accidental release measures, Handling and storage, Exposure controls and personal protection, Physical and chemical properties, Information on stability and reactivity, Toxicological information, Ecological information, Disposal considerations, Transport information, Regulatory information.
3-5
Meaning Before attempting to work with the Anapurna L/XL, the operator must read and understand the Anapurna L/XL Operator manual.
WARNING
Moving parts can crush and cut. Do not operate with guard removed. Lockout/tagout before servicing
This label is located on panels that enclose gears and rollers that could potentially harm fingers and hands.
WARNING
HAZARDOUS VOLTAGE
Contact may cause Electric shock or burn Turn off and lock out System before servicing
Shock hazard. Make sure the power is switched off before opening areas marked with the flashing arrow.
Make sure the Anapurna L/XL is not in printing mode before opening doors provided with this label.
3-6
Label
CAUTION Loud noise hazard. Ear protection must be worn
UV LIGHT.
Do not look directly at light.
2006-05
Made in Korea This device complies with FCC PART 15 SUB PART 15 CLASS A
3-7
To move the head carriage to purge position (front left side), click the Purge button in the Anapurna Control Program.
To move the head carriage to home position (front right side), click the Purge button in the Anapurna Control Program.
3-8
Replacement of the Regulators, Replacement of the Air Filter, Replacement of the Solenoid.
put all ink valves in the solution (S) outlet position, mount the capping plate underneath the head base plate, disconnect the 2 cables of the carriage servo motor to avoid that after power-up the engine again, the carriage accidentally moves after reset while the capping plate is still mounted.
2 3
1 2 3
4 5
3-9
B. MANPOWER
Qualification Service engineer Number of people 1 Man-hours Execution time
C. SPECIAL TOOLS
Description Code
E. PROCEDURE 1 Set all print head valves (K, C, M, Y, Lc, Lm, W1 and W2) to the solution outlet position (S). 2 Set the solution valve to the ink outlet position (I).
1 2 3
4 5
3 Switch off the engine. 4 Turn off the compressed air supply. 5 Locate the regulator (AW20-02BCG) (6), (IR-1020-01BG (7) and (IR-1000-01BG (8).
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Regulator AW20-02BCG
Regulator IR-1020-01BG
Regulator IR-1000-01BG
6.1 Unscrew the 2 cross-slotted screws. 6.2 Disconnect the air hoses. 6.3 Mount a new regulator, tighten the 2 cross-slotted screws and reconnect the air hoses. 7 Restore the compressed air supply. 8 Check the positive pressure.
2 3 4 5
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8.1 Check the incoming compressed air pressure with a pressure gauge (1). 8.2 The main regulator (2) should indicate 0.6 MPa. 8.3 Check the pressure of the other regulators with a pressure gauge. The UV lamp regulator (3) should indicate 0.1-0.15 MPa. The first carriage regulator should indicate 0.3 MPa (4), the second 0.15 MPa (5). 9 Restart the engine. 10 Set all print head valves and the solution valve to the proper outlet position. 11 Verify the printing conditions and if necessary clean the print heads. Refer to Cleaning a Print Head on page 4-38.
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Replacement of the Conveyer Belt, Replacement of the Feed Servo Motor, Replacement of the Winder/Unwinder Drive Motor, Replacement of a Media Register Pin, Replacement of the Limit Switch and Shock Absorber, Replacement of a Vacuum Pump.
B. MANPOWER
Qualification Service engineer Operator Number of people 1 1 Man-hours Execution time
C. SPECIAL TOOLS
Description Allen key no.12 Conveyer belt wire D2+2509266 Code
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E. PROCEDURE 1 Move the conveyer belt until the belts joint is positioned in the middle (1) on top of the printing table. To move the conveyer belt, use Media Feed buttons in the Anapurna Control Program.
2.1 Remove the metal black cover on the left and right rear side. 2.2 Unscrew the left and right tension bolt (rotate CCW) to loosen the tension. 3 Remove the pin out of the conveyer belt and put the old conveyer belt aside.
4 Place a new conveyer belt on the table. NOTE: There is no difference between the bottom and top side of the conveyer belt
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5.1 Start the concatenation link by link. 5.2 if you notice a bulb (2), adjust the concatenation (3)(e.g. relation 2 hook against 1 hook) so the bulb disappears.
6 Secure the concatenation by means of two paperclips (or two pieces from the old needle) and slightly tighten the conveyer belt to remove the bulb. 7 Drive the conveyer belt a complete turn, to verify if the belt remains flat during movement. 7.1 If the belt remains flat during movement, use the conveyer belt tool to re-insert the needle and proceed with step 8.
7.2 If the belt is not flat during movement, repeat steps 5 to 7. 8 Finally, establish the conveyer belt alignment. Refer to Adjustment and Alignment Procedures on page 3-89.
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B. MANPOWER
Qualification Number of people Man-hours Execution time
C. SPECIAL TOOLS
Description Code
E. PROCEDURE
1 2
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B. MANPOWER
Qualification Service technician Number of people 1 Man-hours Execution time
E. PROCEDURE For both front right side and rear right side: 1 Remove the cover (1) of the motor by unscrewing the 2 cross-slotted screws.
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2 Cut the tie wrap (2) around the motor and the 2 connectors and disconnect the 2-pin connector and the 4-pin connector (3).
3 Remove the drive motor and replace by a new one. 4 Connect the 2-pin connector and the 4-pin connector. 5 Strap the 2 connectors around the motor using a wide tie wrap. 6 Mount the cover of the motor using the 2 cross-slotted screws.
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B. MANPOWER
Qualification Number of people Man-hours Execution time
C. SPECIAL TOOLS
Description Code
E. PROCEDURE
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B. MANPOWER
Qualification Number of people Man-hours Execution time
C. SPECIAL TOOLS
Description Code
E. PROCEDURE
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B. MANPOWER
Qualification Service technician Number of people 1 Man-hours Execution time
C. SPECIAL TOOLS
Description Teflon tape Code
E. PROCEDURE
! Disassemble
1 Disconnect the electrical connections and the compressed air connections.
1.1 Disconnect the electrical connection (1) 1.2 Open the clamping bracket at the air cylinder input (2). 1.3 Remove the grey flexible hose of the air cylinder input (2).
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! Assemble
1 Take the following items:
1 2
! !
Silencer
vacuum pump, marked with a color dot. silencers and air controller, marked with the same color dot.
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2.1 Mount the silencer to the OUT side. 2.2 Mount the air controller to the IN side. 3 Establish the electrical connection. 4 Establish the compressed air connection. 4.1 Connect the grey flexible hose to the air cylinder input. NOTE: To avoid leakage, wind isolation tape around the cylinder input before attaching the hose.
4.2 Take a clamping bracket and put it over the hose. 4.3 Tie up the clamping bracket and tighten the crosshead screw.
5 Establish or check the following adjustments for the new vacuum blower. 5.1 Adjust the vacuum blower settings according to the engine configuration, star connection (Europe) or delta connection (USA). 5.2 Adjust the air relief valve according to the engine configuration (50 Hz or 60 Hz). Refer to Vacuum Blower Adjustments on page 3-89. 6 Finally, position the vacuum pump underneath the print table with the silencers directed to the side (roll bar bracket) of the print engine. Be aware that the vacuum pump is not positioned in the beam of the media detection signal sensor.
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Replacement of the Printed Circuit Boards (PCB), Replacement of the Main Ink Tank (Color and White) Components, Replacement of the Ink Pump, Replacement of the Ink Filter, Replacement of the Ink Tubes Located in the Ink Supply Door, Replacement of the Ink Tubes in the Chain.
IN OUT IN OUT
Ink Pump
Ink Filter
Solution Tank
Ink Bottle
CAUTION: Regular inspecting and cleaning of the Anapurna L/XL is required to help to prevent machine damage and printing difficulties.
CAUTION: Avoid direct light on inner parts such as sensors. Direct light can cause malfunctions that lead to a reduced image quality.
CAUTION: The ink filter should not be exposed to fluorescent light and sunlight.
CAUTION: Never shutdown the PC of the engine. A shut down of the PC also stops the stirring
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A. PRELIMINARY ACTIVITIES
Operation Move the head carriage to the purge position. Put the print engine in service mode. Reference Chapter 3 3.1. Chapter 3 3.2.
B. MANPOWER
Qualification Service technician 1 Number of people Man-hours Execution time
E. PROCEDURE Briefly: 1 Locate the PCB that needs to be replaced. 1.1 Indicator PCB, refer to INDICATOR PCB on page 1-153. 1.2 Refill control PCB, refer to REFILL CONTROL PCB on page 1-150. 1.3 Refill PCB, refer to REFILL PCB on page 1-117. 2 Disconnect all connectors. 3 Remove the PCB and replace by a new one. NOTE: When you replace a PCB board, replace all fixing screws to assure a correct working of the PCB/ engine. Some fixing screws fulfill the function of earth connection 4 Reconnect all connectors.
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4.3.3. Replacement of the Main Ink Tank (Color and White) Components
The following ink tank components are discussed:
! ! ! ! !
Air filter (6C and W), Refill float sensor (6C and W), Circling motor (White), Twin Timer, Main Ink tank.
A. PRELIMINARY ACTIVITIES
Operation Move the head carriage to the purge position. Put the print engine in service mode. Reference Chapter 3 3.1. Chapter 3 3.2.
B. MANPOWER
Qualification Service technician 1 Number of people Man-hours Execution time
E. PROCEDURE
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2 Disconnect the level sensor (2) of the appropriate main ink tank (color or white). One side of the 3-pin connector is connected with the refill float sensor of the main ink tank. The other side of the 3-pin connector is connected to the Indicator PCB, located behind the ink tank indicator panel.
3 Unscrew the nut (3) on top of the refill float sensor to remove the refill float sensor from the main ink tank (4).
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5 Insert the new refill float sensor and tighten the nut. Note that the new refill float sensor (5) contains a refill float sensor cover (6) and a nut (7).
67 8 5
6 Guide the 3-pin connector through the nearest hole (8) in the ink supply door and reconnect the level sensor (step 2).
2 Disconnect the stirrer drive connector (2) of the main white ink tank. The 2-pin connector with the red/blue wire is connected with the circling motor of the white main ink tank. The 2-pin connector with the black/white wire leads through the stirrer timer, also know as Twin Timer (3).
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3 Unscrew the circling motor (4) from the main ink tank.
.
4 Insert the new circling motor (5) and guide the 2-pin connector through the nearest hole (6) in the ink supply door and reconnect the stirrer drive connector (7).
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! Twin Timer
1 Open the ink supply door to get access to the twin timer. 2 Remove the old twin timer (1). Press the two blue buttons (2) to unlock the twin timer from the bracket.
4 2 3
3 Clamp the new twin timer on the bracket. 4 Adjust the ON (4) and OFF (3) timer of the stirring rod to the desired value (hour scale division).
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B. MANPOWER
Qualification Service technician 1 Number of people Man-hours Execution time
E. PROCEDURE
! Disassemble:
1 Open the ink supply door and lift out the refill case cover (1) on the right-hand side.
2 Disconnect the appropriate ink pump connector (2) from the Refill PCB.
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3 Remove the cable protection wrapped around the ink pump cables (3).
4 Detach the cable from the fixing bracket (4). 5 Cut the tie wrap around the ink pump cables (5). Use a wire-cutter, but be aware not to cut any cables.
OUT IN 6 7
6.1 Disconnect the tube from the ink pump IN connection (7) and close the tube to avoid leakage. The ink pump IN connection tube is connected with the corresponding main ink tank. 6.2 Disconnect the tube from ink pump OUT connection(6) and close the tube to avoid leakage. The ink pump OUT connection tube is connected with the bottom of the corresponding ink filter. 6.3 Unscrew the 2 cross-slotted screws (8) and remove the old ink pump.
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! Assemble:
1 Take out the new ink pump.
OUT IN
2 2
2.1 Mount the new ink tube to the pump fixing bracket (1). 2.2 Slide a clamping ring (2) over the two ink pump connections (IN and OUT). 2.3 Position the cable behind the tubes (3). 2.4 Attach the cable to the other cables using a tie wrap (4). 2.5 Wrap cable protection around the ink pump cables (5). 3 Reconnect the appropriate pump connector (6) to the Refill PCB.
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OUT
IN
4.1 Connect the tube coming from the bottom of the appropriate ink filter (IN) to the ink pump OUT connection (6). 4.2 Slide the clamping ring over the tube and clamp using a pincer. 4.3 Connect the tube coming from the appropriate main ink tank to the ink pump IN connection (7) 4.4 Slide the clamping ring over the tube and clamp using a pincer. 5 Close the refill case cover (8) and close the ink supply door.
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B. MANPOWER
Qualification Service technician 1 Number of people Man-hours Execution time
E. PROCEDURE
! Disassemble:
1 Unscrew the four screws to remove the refill system panel. Place the panel against the right cover.
2 Put a receiving bin and some absorbent lint free cleaning tissues underneath the appropriate ink filters to catch possible spilled ink.
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3 Get access to the refill PCB and disconnect the following connectors.
3.1 Connector J17 (power supply to the sub ink tank). 3.2 The appropriate ink pump connector. 4 Open the two caps of the appropriate ink filter. Venting cap at the top (1) and drain cap at the bottom (2).
5 Wait until the ink content of the ink filter is dripped out.
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IN 4
6.1 Unscrew the tube on top (OUT) of the ink filter (3) and close the tube. The tube on top of the ink filter (OUT) leads to the hose fixing guide. To close the tube, use a closing cap from the new ink filter (the black flexible cap that fits over the tube connector) and put it on the open tube connector of the installed filter. 6.2 Unscrew the tube on the bottom (IN) of the ink filter (4) and close the tube. The tube at the bottom of the ink filter (IN) is coming from the corresponding ink pump OUT connection. To close the tube, use the second closing cap of the new ink filter. 7 Loosen the filter fixing bracket (5) and remove the old ink filter.
! Assemble
1 Take out the new ink filter. 2 Connect the tube coming from the ink pump OUT connection to the bottom of the new ink filter (IN). 3 Attach the new ink filter using the filter fixing bracket. 4 Connect the tube coming from the hose fixing guide to the top of the new ink filter (OUT). 5 Bleed the new ink filter. Refer to Bleeding the Ink Filters on page 4-56 (chapter Preventive Maintenance).
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4.3.6. Replacement of the Ink Tubes Located in the Ink Supply Door
! ! !
from main tank to ink pump. from ink pump to ink filter. from ink filter to hose fixing guide, located behind the home rear door.
A. PRELIMINARY ACTIVITIES
Operation Move the head carriage to the purge position. Put the print engine in service mode. Reference Chapter 3 3.1.. Chapter 3 3.2.
B. MANPOWER
Qualification Service engineer. Number of people Man-hours Execution time
C. SPECIAL TOOLS
Description open-end wrench cross head screwdriver wire-cutter pincer Code
E. PROCEDURE NOTE: When replacing the ink tubes of a certain color located in the ink supply door, it is recommended to install a new ink filter and a new ink pump for that color. NOTE: The replacement procedure only discuss the replacement of the ink tubes. For the replacement of the ink pump and the ink filter, refer to Replacement of the Ink Pump on page 3-31 and Replacement of the Ink Filter on page 3-35. NOTE: The replacement procedure is written for one ink tube (e.g. of the white main ink tank). Repeat the procedure for the other ink tubes.
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! Disassemble:
Remove the ink tube between the main tank and the ink pump IN connection: 1 Open the ink supply door and remove the cover (1) above the main ink tanks.
2 Disconnect the ink outlet tube (2). To disconnect the ink outlet tube from the ink outlet pipe of the main ink tank, unscrew the brass M6 pipe bolt. 3 Close the ink outlet tube (3), with a cap, to avoid any leakage.
4 Pull the ink outlet tube out at the rear side of the ink supply door.
5 Disconnect the ink tube from the ink pump IN connection. 6 Put away the ink tube. Remove the ink tube between the ink filter OUT connection and the hose fixing guide: 7 Disconnect the ink tube from the hose fixing guide: 7.1 Remove the hose fixing bracket (5). 7.2 Disconnect the ink tube (6) and close the tube to avoid ink leakage.
Service Manual :Anapurna L/XL 2007 V1.0 Company Confidential 3 - 39
7.3 Close the ink tube coming from the hose fixing guide (7).
8 Remove the tube protection (8). 9 Pull the tube out of the refill case cover (9). 10 Take the ink tube out of the pump hose fixing bracket (10).
10
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11 Disconnect the ink tube from the ink filter OUT connection (top of the ink filter) (11). Close the filter cap to avoid leakage.
11
OUT
IN
12 Put away the ink tube. Remove the ink tube between the ink pump OUT connection and the ink filter IN connection: 13 Disconnect the ink tube from the ink pump OUT connection. 14 Disconnect the ink tube from the ink filter IN connection (bottom ink filter) and close it (1). Close the filter connection cap to avoid leakage (2).
15 Put away the ink tube. 16 Remove the ink filter. Refer to the disassemble procedure of Replacement of the Ink Filter on page 3-35. 17 Remove the ink pump. Refer to the disassemble procedure of Replacement of the Ink Pump on page 3-31.
! Assemble:
1 Mount a new ink filter. But use new ink tubes. Refer to the assemble procedure of the Replacement of the Ink Filter on page 3-35. 1.1 Connect a new ink tube from the top of the ink filter (OUT) to the corresponding ink hose (1). 1.2 Mount the hose fixing bracket (2).
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2 Mount the new ink pump. But use new ink tubes. Refer to the assemble procedure of Replacement of the Ink Pump on page 3-31. 2.1 Put a new ink tube through the ink supply door from top to bottom (4). 2.2 Connect the top end of ink tube with the main ink tank (5). 2.3 Guide the bottom end of the ink tube through the pump hose fixing bracket (6). 2.4 Connect the bottom end of the tube to the ink pump IN connection (7). 2.5 Connect a new ink tube from the ink pump OUT connection to the bottom of the appropriate ink filter (IN connection).
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B. MANPOWER
Qualification Service technician Number of people 1 Man-hours Execution time
C. SPECIAL TOOLS
Description open-end wrench wire-cutter Code
E. PROCEDURE NOTE: The replacement procedure is written for one ink tube. Repeat the procedure for the other ink tubes. 1 Get access to the hose fixing guide (1).
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2 Remove the nut (2) of the ink tube with an open-end wrench.
3 Take the nut (3) and the ink tube (4) out.
4 Remove the nut from the ink tube. 5 Tape the new tube over a certain length to the old tube. Be aware that both tubes are tightly connected.
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6 Go to the purge side and open all purge doors to get access to the sub ink tank.
6.1 Disconnect the corresponding ink tube from the sub ink tank. 6.2 Cut the tie wrap that keep all ink tubes together at sub ink tank side. 6.3 Pull the old tube gently out of the chain until the new tube become visible. 6.4 Remove the old ink tube from the new ink tube. 7 Connect both sides of the new ink tube. One side to the sub ink tank, the other side to the hose fixing guide.
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4.4. Disassembly/Assembly of the Ink Supply System Components at Head Carriage Unit
This section describes the following replacement procedures:
! ! ! ! ! !
Replacement of the Sub Ink Tank (Color and White) Components, Replacement of the Solution Tank, Replacement of the Sub Air Tank Components, Replacement of a 2-Way Valve, Replacement of the Carriage Assembly Components, Replacement of the Waste Tank.
IN OUT IN OUT
Ink Pump
Ink Filter
Solution Tank
Ink Bottle
Print Head
Components Head Carriage Unit
Ink
4.4.1. Replacement of the Sub Ink Tank (Color and White) Components
The following sub ink tank components are discussed:
! !
Float sensor (6C and W), Temperature sensor (6C and W).
A. PRELIMINARY ACTIVITIES
Operation Move the head carriage to the purge position. Put the print engine in service mode. Reference Chapter 3 3.1. Chapter 3 3.2.
B. MANPOWER
Qualification Service technician 1 Number of people Man-hours Execution time
3 - 46
E. PROCEDURE
Float sensor, Pressure sensor (PSE531-M5-L), Air filter, Speed V/V (AS1001F-06).
1
1 2
3 - 47
A. PRELIMINARY ACTIVITIES
Operation Move the head carriage to the purge position. Put the print engine in service mode. Reference Chapter 3 3.1. Chapter 3 3.2.
B. MANPOWER
Qualification Service technician 1 Number of people Man-hours Execution time
E. PROCEDURE
! Float sensor
-.- Not Available Yet -.To adjust the speed V/V: The underpressure setting (-0.032MPa) are influenced by the air relief valve, called Speed V/V (AS1001F-06) mounted on the sub air tank. In case of problems with the vacuum, you can regulate the strength of the negative pressure inside the sub air tank by tuning the air relief valve, speed V/V (AS1001F-06). This is an extra regulating
3 - 48
mechanism in relation to the atmosphere air pressure (leakage air). If you open the air relief valve, the system is aggressive.
1 Unscrew the locker nut. 2 Turn the tuning screw (1) clockwise till it is closed completely. 3 Turn the screw 1 complete turn counterclockwise. 4 Lock this screw again with the locker nut.
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Electro-pneumatic regulator ITV2010, Air purge valve VT301V-025GB and VT301-025GB, Vacuum ejector (INO-4336-4) INO-4336-4, Encoder
A. PRELIMINARY ACTIVITIES
Operation Move the head carriage to the purge position. Put the print engine in service mode. Reference Chapter 3 3.1. Chapter 3 3.2.
B. MANPOWER
Qualification Service technician 1 Number of people Man-hours Execution time
C. SPECIAL TOOLS
Description Code
E. PROCEDURE
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! Encoder
3 - 51
B. MANPOWER
Qualification Service technician 1 Number of people Man-hours Execution time
E. PROCEDURE 1 Disconnect the full detection sensor connector (2-pin), located in the cable trunk.
2 Unscrew the nut on top of the waste tank to remove the refill float sensor. 3 Remove the old refill float sensor. 4 Insert the new refill float sensor and tighten the nut. Note that the new refill float sensor contains a refill float sensor cover and a nut. 5 Connect the full detection sensor connector (2-pin) and close the cable trunk.
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Replacement of the Ball Screw Assy, Replacement of the Head Base Components, Replacement of the Head Base Lifting Assembly, Replacement of the Printed Circuit Boards (PCB).
1 2
3 - 53
A. PRELIMINARY ACTIVITIES
Operation Move the head carriage to the purge position. Put the print engine in service mode. Reference Chapter 3 3.1. Chapter 3 3.2.
B. MANPOWER
Qualification Service technician Number of people 1 Man-hours Execution time
E. PROCEDURE A head crash can lead to bending of the lifting bar and as a result the bearings of the ball screw will be damaged after some time. The procedure below explains how to remove the ball screw.
! Disassemble
1 Lower the head carriage unit using the manual head height setting knob until the bolts (1) are in front of the service hole. The service hole is situated in the back plate of the liftable part of the head carriage unit.
2 Support the head carriage unit so the ball screw does not carry the head carriage unit. Use the head transport protection plate to support the head carriage unit on top off the ink tray.
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3 4 3 2
3.1 Loosen the screws of the coupling (3). 3.2 Remove the four bolts that fix the support bracket (4). 4 Remove the ball screw upper unit (5).
5 5
4.1 Remove the 4 screws. 4.2 Lift the ball screw unit over the shaft.
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5 Remove the aluminium motor fixing plate (support bracket) (6) by unscrewing the 4 screws.
6 6
6 Release the moving plate fixing block (7). This plate is attached with 4 screws to the moving plate.
7 Release the ball screw lower unit (8) by unscrewing the 2 bolts (9). Those 2 bolts are in front of the service hole (refer to step 1).
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10
11
8.1 Tilt the complete ball screw pen, with all surrounding components, out off the engine. 8.2 Disassemble this part and replace the broken part by new ones. NOTE: Be aware of the ball screw spring, it is still loaded. To unload, move the ball screw completely up. 8.3 To remove the moving plate fixing block (11), unlock and unscrew the lock nut () at the bottom. CAUTION: Do not remove the bearing from the shaft. The ball is not fixed.
! Assemble
To assemble, proceed in the opposite way.
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B. MANPOWER
Qualification Service technician Number of people 1 Man-hours Execution time
C. SPECIAL TOOLS
Description Code
E. PROCEDURE
3 - 58
A. PRELIMINARY ACTIVITIES
Operation Move the head carriage to the purge position. Put the print engine in service mode. Reference Chapter 3 3.1. Chapter 3 3.2.
B. MANPOWER
Qualification Service technician 1 Number of people Man-hours Execution time
E. PROCEDURE Briefly: 1 Locate the PCB that needs to be replaced. 1.1 Head Lift PCB, refer to HEAD LIFT PCB on page 1-127. 1.2 Head PCB, refer to HEAD PCB on page 1-108. 1.3 Cartridge PCB, refer to CARTRIDGE PCB on page 1-123. 2 Disconnect all connectors. 3 Remove the PCB and replace by a new one. NOTE: When you replace a PCB board, replace all fixing screws to assure a correct working of the PCB/ engine. Some fixing screws fulfill the function of earth connection 4 Reconnect all connectors.
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Replacement of a Print Head, Replacement of the Heater Bar and the Thermistor, Replacement of the Temperature Sensor.
CAUTION: Always clean the print head using cleaning fluid after printing and before turning off the system.
CAUTION: Avoid direct light on inner parts such as sensors. Direct light can cause malfunctions that lead to a reduced image quality.
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K C M Y Lc Lm W spot W pre
A. PRELIMINARY ACTIVITIES
Operation Move the head carriage to the purge position. Put the print engine in service mode. Put the print head valve of the heads that need to be replaced, to the solution outlet position (S). Put the solution valve on the ink outlet position (I). Reference Chapter 3 3.1. Chapter 3 3.2.
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Operation Open all purge doors (front, rear, left and top), to get full access to the head carriage unit. Remove the head cover of the head carriage unit by unscrewing the two crosshead screws on each side and the three crosshead screws on the front side. Place some towels in front of the purge grid to keep the working area clean.
Reference
B. MANPOWER
Qualification Service technician Number of people 1 Man-hours Execution time
C. SPECIAL TOOLS
Description Allen Key no.1.5 and no.2.5 Crosshead screwdriver Long Philips screwdriver Spanner no.10 Long nose plier Code
3 - 62
E. PROCEDURE NOTE: The replacement procedure is written for the replacement of one print head (complete disassembly/assembly of the Magenta print head). Repeat the procedure if more than one print head has to be replaced.
! Disassemble:
1 Detach the following cables: 1.1 Detach the 4 data cables of the print head (1) from the CARTRIDGE PCB (2) using a plier.
Lc
2
1.2 Detach the black thermostat cable (3) which is connected to J29 of the HEAD PCB. NOTE: Only applicable for the Magenta head.
1.3 Detach the red heater cable (4) which is connected to the HEAD PCB.
Lc M Y Lc Lm
3, 4
3 - 63
2 Detach the metal head PCB frame from the head base plate by unscrewing the 5 bolts on top of the head carriage unit. Use a long Philips screwdriver.
3 Raise the complete assembly (5) (head PCB frame) on 2 foam blocks (6).
4 Loosen the head fixing (13) from the head base plate (12). 4.1 Unlock the Eccentric nut (11) using an Allen key no. 1.5. 4.2 Remove the nut (11) using spanner no.10. 4.3 Remove the teflon washer (8), eccentric bushing (7), wave washer (9) and the 2 black washers (10).
7 8
13
12
11
10
3 - 64
5 Remove head adjusting springs (14) in front and side using an Allen key no. 2.5.
14
15
14, 15, 16
16
6 Loosen the head adjusting bolt at the rear side of the print head until you are able to pull out the print head easily. Use a screwdriver. NOTE: The head adjusting bolts are the bolts which allows you to do the front/back alignment of the print head. 7 Loosen the ink tube (18) on of the print head valve.
17 18
7.1 Unscrew the locknut (17) underneath the print head valve. 7.2 Shear the tube (18) of each valve. 8 Remove the print head.
NOTE: Place the head always on the black side on the table. Not on the Aluminum side.
3 - 65
9 Remove the print head (19) from the head fixing (Aluminum block) (20). Unscrew the 2 screws underneath the head.
19 20
! Assemble:
10 Take the new print head.
11 Change (renew) O rings (21) if head is removed from aluminum block. New O-rings are delivered with the new print head.
21
21
3 - 66
13 Reconnect the tube of the print head valve and manually tighten the locknut.
14 Place the print head into the head base plate. 15 Mount the head adjusting springs in front and side as illustrated. Use an Allen key no. 2.5. NOTE: Mind the order: socket screw, spring fixing pipe (22), teflon washer (23), head adjusting spring (24) and teflon washer (23).
24
23
22
16 Attach the head fixing (25) to the head base plate (26). 16.1 Mind the order: eccentric nut (27), teflon washer (28), eccentric bushing (29), wave washer (30) and the 2 black washers (31) with the smooth sides to each other. 16.2 Tighten the nut (27) finger tight.
25
26
27
28
29
30
31
31
3 - 67
17 Remove the 2 foam blocks and lower the complete metal head PCB frame.
18 Attach the metal head PCB frame from the head base plate by screwing the 5 bolts on top of the head carriage unit. 19 Reconnect the following cables: 19.1 Connect the red heater cable to the Head PCB. 19.2 Connect the black thermostat cable to J29 of the Head PCB. NOTE: Only applicable for the Magenta head.
19.3 Connect the 4 data cables of the print head to the corresponding Cartridge PCB. 20 Finally, establish the following adjustments and alignment procedures for the new print head: 20.1 Adjusting the Head Base Temperature on page 3-91, 20.2 Adjusting the Head Voltage on page 3-92, 20.3 Hardware Alignment of the Print Head on page 3-94, 20.4 Software Alignment of the Print Head on page 3-95
3 - 68
Each print head has a heater bar (2), which is connected to the Head PCB. Only the Magenta print head has a thermistor (1), also called head temperature sensor, which is connected to the Head PCB.
For more information about the heater bar and the thermistor of the Magenta print head, refer to Temperature detection components and setting components on page 1-63 (chapter Functional Description).
1 2 2 1 2
Heater bar
A. PRELIMINARY ACTIVITIES
Operation Disassemble the print head. Reference 3 4.6.2., step 1 to 9.
B. MANPOWER
Qualification Service technician Number of people Man-hours Execution time
C. SPECIAL TOOLS
Description Code
3 - 69
E. PROCEDURE 1 Put the head fixing on his side and remove the head heather fixing plate (1). 2 Remove the heater bar (2) and the thermistor (3).
1 2 3
3 Replace the thermistor and the heater bar by a new one. 3.1 Make sure that the head heater fixing plate (4) fits with the head fixing (5) without crushing the thermistor and heater bar cable.
3.2 When mounting the print head on the head fixing, make sure the thermistor and heater bar are correctly positioned into the print head.
4 Assemble the print head back into the head base plate. For more information, refer to Replacement of a Print Head on page 3-61, step 11 to 20.
3 - 70 2007 V1.0 Company Confidential Service Manual :Anapurna L/XL
B. MANPOWER
Qualification Service technician Number of people 1 Man-hours Execution time
C. SPECIAL TOOLS
Description cross-slotted screwdriver Code
E. PROCEDURE
1 Disconnect the 4-pins connector J17 on the Head Lift PCB. 2 Remove the PT sensor bracket (1) by unscrewing the two cross-slotted screws. 3 Pull out the temperature senor cable (2). 4 Replace the temperature sensor by a new one. 5 Assemble the temperature sensor back. 6 Establish the head base plate temperature adjustment. Refer to Print Head Adjustments on page 3-91.
Service Manual :Anapurna L/XL 2007 V1.0 Company Confidential 3 - 71
Replacement of the UV Lamp Box, Replacement of the UV Lamp Box Housing, Replacement of the Air Inlet AC Fan, Replacement of the Air Oulet DC Fan, Replacement of the Ignitor, Replacement of the UV Lamp, Replacement of the UV Lamp Shutter, Replacement of the Thermistor.
2 1 3
4 6
5 8 6
1 2 3 4
UV lamp box (left) UV lamp box (right) Lamp case outer air inlet AC fan UV Lamp fixing
5 6 7 8
Lamp shutter UV lamp box housing Lamp case inner air outlet DC fan Lamp (190 mm)
3 - 72
Chapter 3 3.2.
B. MANPOWER
Qualification Service technician 1 Number of people Man-hours Execution time
C. SPECIAL TOOLS
Description Allen Key no. Crosshead screwdriver Code
E. PROCEDURE NOTE: The replacement procedure is written for the left UV lamp box. If you want to remove the right UV lamp box, move the head carriage to the home position (front right side) and execute the same procedure as for the left UV lamp box. 1 Detach the UV lamp box from the UV lamp box housing by unscrewing the two head screws (1). 2 Disconnect the lamp power connector (4-pin) (2).
3 - 73
Chapter 3 3.2.
B. MANPOWER
Qualification Service technician 1 Number of people Man-hours Execution time
3 - 74
C. SPECIAL TOOLS
Description Allen Key no. Crosshead screwdriver Code
E. PROCEDURE NOTE: The replacement procedure is written for the left UV lamp box. If you want to remove the right UV lamp box, move the head carriage to the home position (front right side) and execute the same procedure as for the left UV lamp box. 1 Disconnect the following electrical connections:
3 1 2
1.1 Disconnect the yellow lamp shutter on pneumatic connector (1). 1.2 Disconnect the red lamp shutter off pneumatic connector (3). 1.3 Disconnect the lamp signal connector (label = LAMP-L-SIG) (2). 1.4 Disconnect the lamp shutter signal connector (label = LAMP SHUTTER L) (4). 2 Dismount the UV lamp box housing by unscrewing the four head screws.
3 - 75
4 Establish the UV lamp Adjustment Refer to Lamp house Alignment on page 3-103.
B. MANPOWER
Qualification Service technician Number of people 1 Man-hours Execution time
C. SPECIAL TOOLS
Description Allen Key no. Crosshead screwdriver Code
E. PROCEDURE 1 Unscrew the following screws: 1.1 2 x 4 screws of the fan grid (1). 1.2 4 screws of the 4 pin lamp power connector (2).
3 - 76
1.3 Screws at the front (3) and rear (4) side of the UV lamp box cover.
2 Remove the reflector bracket from the cover as illustrated in the four steps below.
step 1
step 2
step 3
step 4
3 Replace the AC fan(s) by a new one. Be careful with the electrical connections.
3 - 77
4 Mount the reflector bracket back into the cover as illustrated in the five steps below.
step 1
step 2
step 3
step 4
step 5
4.1 First, slide the reflector bracket partly into the cover. 4.2 Mount the 4 pin power connector and tighten the screws. 4.3 Then pull the reflector bracket completely into the cover. This to be sure not to touch the reflector surface.
3 - 78
5 Reassemble the AC fans and the grids as illustrated in the three steps below.
step 1
step 2
step 3
6 Mount the UV lamp box back into the UV lamp box housing. Refer to Replacement of the UV Lamp Box on page 3-73.
B. MANPOWER
Qualification Service technician Number of people 1 Man-hours Execution time
C. SPECIAL TOOLS
Description Allen Key no. Crosshead screwdriver Code
3 - 79
E. PROCEDURE 1 Remove the reflector bracket from the UV lamp box cover. Refer to Replacement of the Air Inlet AC Fan on page 3-76, step 1 to 2. 2 Remove the old ignitor and replace by a new one as illustrated in the three steps below. NOTE: There are two ignitor types available. The way how to connect the electrical wires depends on the ignitor type. (See step 3 in the illustration below).
step 1
step 2
step 3
4 Mount the reflector bracket back into the UV lamp box cover. Refer to Replacement of the Air Inlet AC Fan on page 3-76, step 4 to 6.
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B. MANPOWER
Qualification Number of people Man-hours Execution time
C. SPECIAL TOOLS
Description cross-slotted screwdriver Code
E. PROCEDURE
4 Mount the new thermistor on the bracket. 5 Reconnect the electrical connectors. 6 Close the cover.
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! Replacement of the thermistor mounted on the reflection cap of the UV lamp box
3 - 82
FPGA PCB
PC Main Board
3 - 83
B. MANPOWER
Qualification Service technician Number of people 1 Man-hours Execution time
E. PROCEDURE
! Mechanical
3 - 84
4 Select PCI-7200.
3 - 85
Fill in the fields Name and Company. 8 Click next. The Program directory selection screen is displayed:
Click the Browse button, if you want to modify the default program destination.
3 - 86 2007 V1.0 Company Confidential Service Manual :Anapurna L/XL
9 Click Next. The next window show the setup type, where you are asked to set the type of setup you prefer.
This screen summarizes the settings you have entered. If you are not satisfied with them, click the Back button and repeat the previous steps. 11 Click Next. After a while the installation is completed.
3 - 87
Select PCI 7200 card, and then select DI:1, DO:17000. 13 Click Apply (input completed).
14 Reboot the PC. (Driver installation completed) 15 Turn off the PC power and put the PCI card into the PCI slot of the PC Main Board. 16 Turn on the PC power, select auto driver setting click (it requires one minute). 17 Installation completed.
3 - 88
6.1.2. Procedure
1 Adjust the vacuum blower settings according to the engine configuration, star connection (Europe) or delta connection (USA). 1.1 Remove the top cover of the box on top of the vacuum blower. 1.2 Check the contact bridges (star or delta) and adjust if necessary as illustrated below.
2 Adjust the air relief valve according to the engine configuration (50 Hz or 60 Hz). 2.1 Refer to the identification plate on top of the vacuum blower. 2.2 Check the rated current 3.8A (50Hz engine) or 6.7A (60Hz engine) on the identification plate.
3 - 89
2.3 Close the air inlet by holding a piece of foam in front of the inlet tube of a running blower. 2.4 Remove the cover of the air controller.
2.5 Check if the rotation direction of the vacuum pump corresponds with the arrow indication on the vacuum pump. If not, switch two phases (e.g. L1 and L2). 2.6 Measure the current around the vacuum blowers power cable. 2.7 Adjust the spring tension, by turning the head screw, until you measure the rated current indicated on the identification plate. NOTE: Turn the head screw clock wise to increase the current.
If the spring is at its end position and you can still measure a current lower then the nominal current, screw the spring back approximately 5 turns until the current lowers, in order to have a little bit of spurious air for cooling.
Vacuum blower 1
Vacuum blower 2
3 - 90
NOTE: Refer to Head Base Temperature Control on page 1-63 of the chapter Functional Description.
6.2.1.2. Procedure
To adjust the head base temperature: 1 Adjust the head PCB voltage of the head PCB by turning the blue VR temperature potentiometer clock wise (CW) or counter clock wise (CCW). The head PCB is positioned underneath the sub ink tank. 2 Turn CCW to lower the temperature. Note that a voltage of approximately 1.6 V can be seen as guidance and corresponds with a temperature of 32C on most engine configurations. The higher the voltage value, the lower the temperature value.
Head PCB
Cartridge PCBs
3 - 91
6.2.2.2. Procedure
To adjust the head voltage of each print head: 1 Take out the sheet with the spectra recommended voltage value of the manufacturer delivered together with the new print head.
2 Adjust the head voltage of the head that has been replaced (e.g. Cyan) and calculate the corresponding Agfa voltage using the correction table below.
Drive voltage Anapurna heads Spectra recommended voltage for Nova head : Correction factor for Anapurna G1 at 35C: Corrected voltages for Anapurna G1Inks: Black 92 Cyan 92 Magenta Yellow 93 92 Li. Cyan 90 Li Mag. white 1 white 2 91 94 92
0,0
0,0
1 2 3
2.1 Fill in the recommended value (1), which you can find on the paper of the manufacturer (e.g. Magenta 92) 2.2 Multiply the value with the correction factor (2) for that color (e.g. Cyan 0.911702) to become the correct voltage (3) for the Anapurna head (e.g. 83.9).
3 - 92
3 Adjust the head voltage on the Cartridge PCB of that color (e.g. Cyan). 3.1 Measure the current voltage (4). 3.2 Adjust the head voltage (5) by turning CW or CCW.
! !
6 6 Cartridge PCB
3 - 93
micro porous paper, print without UV-curing, use the rtl test file Headslant_all_spotwhite printed in 8-pass unidirectional. Location rtl testfiles: C:\Anapurna\Reference\
6.2.3.2. Procedure
Execute the following two hardware corrections:
! !
! Slant correction
The print head is skewed in the hole. Adjust by means of the eccentric nut (1) at the front side of the print head.
3 - 94
! Front/back correction
The print head is positioned too far to the front or the back. Adjust by means of the screw at the back side of the print head.
micro porous paper, print without UV-curing, use the rtl test file Headslant_all_spotwhite printed in 8-pass unidirectional. Location rtl testfiles: C:\Anapurna\Reference\
6.2.4.2. Procedure
To execute an electronic calibration for every color, proceed as follows: 1 In the Control Program, click Setup.
The Setup Parameters window appears. 2 In the Setup Parameters window, click Factory Set (3).
3 Enter the password (4) and click OK. The Factory Data Setting window appears.
3 - 95
4 Change the Head Offset values (e.g. K CY) 4.1 If CY has to move to the right: decrease the current value. 4.2 If CY has to move to the left: increase the current value.
f
5 After changing the values, Click Save. The Setup Parameters window appears. 6 Click Save As and create a new .dat file, or overwrite the old one.
use the rtl test file Headslant_all_prewhite printed in 8-pass unidirectional. the front/back alignment can only be done after the media feed correction.
3 - 96
C. SPECIAL TOOLS
Description Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Loosen the tension on the belt:
NOTE: In case you have mounted a new conveyer belt, skip step 1.
1.1 Remove the metal black cover on the left and right rear side.
1.2 Completely unscrew the left and right tension bolt (rotate CCW) to loosen the tension.
2 Position the conveyer belt 2.1 Move the conveyer belt until the belts joint is positioned in the middle at the underside of the printing table.
3 - 97
2.2 Go to the rear side of the print engine and measure the distance from the left/right side of the printing table to the conveyer belt. Do the same at the front side of the print engine. This measured distance should be equal, on front side as well as on rear side of the engine. 3 Tighten the conveyer belt. Alternately tighten the left and right tension bold. Only tighten maximal one complete turn a time. 4 Execute a transport test. 4.1 Mark the position of the belt regard to the printing table. 4.2 Move the conveyer belt for at least 10 minutes. 4.3 Mark the position of the belt regard to the printing table and measure the difference regard to the measurement before moving the conveyer belt.
5 Eliminate the measured difference by adjusting the belt tension. 5.1 Loosen the conveyer belt completely. 5.2 Reposition the conveyer belt and use the same marking technique as in step 2 and 4. 5.3 Tighten the conveyer belt taking the measured difference into consideration.
t
Measured distance < 0,5 cm increase the tension with the same amount on the side where the belt was moving to.
Measured distance > 0,5 cm increase the tension with half of the measured difference on the side where the belt was moving to. reduce the tension with half of the measured difference on the side where the belt was moving from.
6 Execute a transport test: 6.1 Move the conveyer belt for at least 10 minutes. 6.2 Check the markings on the conveyer belt and printing table.
3 - 98
NOTE: The position of the belt should not move more than 2 mm.
6.3 If necessary, adjust the position of the belt. Rotate the left and/or right tension bolt CW or CCW to control the tension while the conveyer belt is moving. NOTE: The position of the conveyer belt can still move slightly during daily production. Those small shifts can be removed by rotating the left and/or right tension bolt CW or CCW. For more information, refer to Inspecting and Adjusting the Conveyer Belt Tension on page 4-7of the Preventive Maintenance chapter.
C. SPECIAL TOOLS
Description Code
! Preceding measurements
1 Measure the distance between the head carriage unit and the print table with Messkeil kon 1:10 ruler. 2 Measure the gap between the head base plate and print table using a rigid (2mm Dibond plate) as reference on top of the vacuum table. 3 Execute the head gap control. The distance between the dibond plate and base plate is around 5 mm. Refer to Executing a head gap control on page 1-84 (chapter Functional Description). 4 Push one of the emergency buttons to cut off the power. 5 Disconnect the connector between the carriage servo motor and carriage servo driver.
3 - 99
As a result, the head carriage unit can be moved easily by hand. 6 Lower the head carriage unit using the manual head height setting knob until the gap between dibond plate and base plate is around 2mm. Refer to Manual head height setting knob on page 1-58 (chapter Functional Description). 6.1 Measure the gap left right, front back. 6.2 Check if the max deviation of the four measurements is within tolerance. (maximum deviation is <0.5mm). 6.3 If the parallelism of the base plate is out of tolerance an adjustment of the base plate is advisable. 7 Reconnect the connector between the carriage servo motor and servo carriage driver.
1 2 2
Base plate
1 Locate the right-hand mounting hook (3). 2 Loosen the 2 fixing screws (2) of mounting hook (3). 3 Adjust the parallelism within tolerance by using the top screw (1). 4 Fasten the fixing screws again (2). 5 Repeat step 2 to 4 for the left-hand mounting hook (4). 6 Check if the tolerances are within the tolerances. Repeat if necessary.
3 - 100
Reference Blocks
1 1
Jig
1 Execute the head gap control partly. Click OK and the head carriage unit will move above the print table Refer to Executing a head gap control on page 1-84 (chapter Functional Description). 2 Push one of the emergency buttons to cut off the power. 3 On top of the fixed back panel of the head carriage unit you will find 2 reference blocks (1),this are the zero points.This is the reference to adjust the head carriage unit and is set in the factory. NOTE: Never loose the bolts of the reference blocks.
3 - 101
4 To check the evenness of the head carriage unit use the 2 jigs (2) which are delivered with the engine as showed in the Figure 3.2. 5 Place the jigs on top of the back panel and the reference blocks using the manual head height setting knob. 6 If there is a difference release the adjustment screws (3) marked green as showed in the Figure 3.2. 7 Once an adjustment is done, put the jigs back in to see whether the position of the back plate is the same left to right. 8 Tighten the adjustment bolts if the back plate is leveled against the zero points. 9 Double check the level of the base plate by measuring the gap between base plate and print table.
3 - 102
B. MANPOWER
Qualification Service technician Number of people Man-hours Execution time
C. SPECIAL TOOLS
Description Code
Left alignment
Right alignment
3 - 103
3 - 104
CHAPTER
Preventive Maintenance
This chapter describes the preventive maintenance procedures for the Anapurna L/XL. 1. Maintenance Schedule ........................................................................................................................................ 4 - 2 2. Print Media Unit Maintenance .......................................................................................................................... 4 - 5 2.1. Guidelines and Specific Safety Instruction ..................................................................................... 4 - 5 2.2. Conveyer Belt ............................................................................................................................................ 4 - 6 2.3. Vacuum Holes ............................................................................................................................................ 4 - 9 2.4. LM Guide .................................................................................................................................................. 4 - 10 2.5. LM Blocks ................................................................................................................................................. 4 - 11 2.6. Carriage Belt (S5M Belt) ..................................................................................................................... 4 - 13 2.7. S3M Belt ................................................................................................................................................... 4 - 16 2.8. Linear Scale Encoder ............................................................................................................................ 4 - 24 2.9. Bearings Print Media Unit .................................................................................................................. 4 - 33 2.10. Waste Tank ............................................................................................................................................ 4 - 35 3. Head Carriage Unit Maintenance .................................................................................................................. 4 - 36 3.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 36 3.2. Print Head ................................................................................................................................................. 4 - 38 3.3. UV Lamp Box / UV Lamp Box Housing ......................................................................................... 4 - 46 3.4. Head Carriage ......................................................................................................................................... 4 - 53 4. Refill Unit Maintenance .................................................................................................................................... 4 - 54 4.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 54 4.2. Air filter 6 Color and White ............................................................................................................... 4 - 55 4.3. Ink Filter .................................................................................................................................................... 4 - 56 5. Purge Unit Maintenance ................................................................................................................................... 4 - 63 5.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 63 5.2. Purge box .................................................................................................................................................. 4 - 63 6. Home Unit Maintenance .................................................................................................................................. 4 - 65 6.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 65 6.2. Home box ................................................................................................................................................. 4 - 65 7. Safety Circuit ......................................................................................................................................................... 4 - 67 7.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 67 7.2. Emergency Stop Circuit ....................................................................................................................... 4 - 67 8. Air Tank Maintenance ........................................................................................................................................ 4 - 69 8.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 69 8.2. Air Tank ..................................................................................................................................................... 4 - 69 9. Air Pressure Panel Maintenance .................................................................................................................... 4 - 70 9.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 70 9.2. Air Pressure Panel ................................................................................................................................. 4 - 70 10. Engine ................................................................................................................................................................... 4 - 75 10.1. Guidelines and Specific Safety Instruction ............................................................................... 4 - 75 10.2. Engine Level ......................................................................................................................................... 4 - 75
4-1
PREVENTIVE MAINTENANCE
MAINTENANCE SCHEDULE
1. Maintenance Schedule
Unit Head Carriage unit Component Print head Print head Frequency Daily Daily Activity Clean Nozzle Check and purge or clean the failed heads if necessary Clean Cleaning solution Crystal Plate (190)(8C) D2+2509166 Operator Inspect and clean lint-free cloth if necessary with isopropyl alcohol (IPA) Check for printing print outs and curing quality Check for printing and curing quality and replace both UV lamp if necessary Replace lamp 190 mm D2+2509221 Required Tools lint-free cloth Spare Part Name Spare Part Order Code Operator/ Service See ... Engineer Operator Operator 4 3.2.1. 4 3.2.1.
Print head Crystal Glass plate (UV lamp box housing left and right)
Weekly 1 Month
4 3.2.1. 4 3.3.1.
Print Head / UV lamp 1 Month box Print Head / UV lamp 3 Month box
6 Month
4 3.3.3.
1 Year
Inspect shutter functionality and replace if malfunctioning Inspect and clean Acetone if necessary Grease AFB lubricating grease
LM guide (Head Carriage) LM blocks (Head Carriage) Head PCB (Head Carriage) Head base plate (Head Carriage)
1 Month
6 Month
4 2.5.1.
1 Year
Inspect the head voltage Inspect the head base plate parallelism
1 Year
4-2
MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE
Unit
Component
Frequency 1 Month
Activity
Required Tools
Print Media LM guide unit (Frame Assembly Box Beam) LM blocks (Frame Assembly Box Beam)
6 Month
Grease
4 2.5.1.
Linear scale encoder 1 Month (Frame Assembly Box Beam) S5M belt (15 mm) (= carriage belt) S3M belt (564 mm) 6 Month 6 Month
Inspect and clean Acetone or isoif necessary propyl alcohol (IPA) Inspect the tension and re tension if necessary Replace Inspect the position and re position if necessary Replace S3M BELT (564mm), black Bearing UFL004 D2+2959024 S5M BELT (15mm), grey D2+2959029
Operator
4 2.8.1.
4 2.6.1.
4 2.6.2. 4 2.7.1.
1 Year
4 2.7.2.
Bearing UFL004 (Double Pulley Assembly) Idle pulley bearing (Idle Pulley Assembly)
6 Month
D2+2509194
4 2.9.1.
6 Month
4 2.9.1.
Tension Roll Bearings 6 Month Bearings Rigid Table Bearing UFL diameter 40 (Frame Assembly) Conveyer belt Weekly 6 Month 6 Month
Clean, inspect and re tension if necessary Inspect the position and adjust if necessary Replace Conveyer belt D2+2503014 XL Conveyer belt D2+2503015 L
Operator
4 2.2.1.
1 Month
Operator
4 2.2.2.
6 Month
Vacuum holes
6 Month
Inspect vacuum holes and clean if necessary Inspect and empty if necessary
Waste tank
Weekly
4 2.10.1.
4-3
PREVENTIVE MAINTENANCE
MAINTENANCE SCHEDULE
Unit
Component
Frequency
Activity Inspect the functionality Grease assy Inspect for any moisture and replace if necessary Bleed ink filters Replace if necessary
Required Tools
Print Media Media thickness sen- 6 Month unit sor 6 Month Refill unit Air filter (6C) Air filter (W) Daily
4 4.2.1.
Ink Filter
6 Month 1 Year
Purge unit
Grid (Ink fixing upholder #1 and #2) Ink receiving bin (Purge fixing upholder #3)
Weekly
Inspect and clean Filling knife or if necessary screw driver. Solution. Inspect waste Filling knife or barrel and pierce screw driver hole. Clean if necessary Inspect and clean Filling knife or if necessary screw driver. Solution. Drain Drain Replace Inspect all four emergency stops Inspect the functionality Door sensor (Front/Rear) Door sensor controller (PA10-U) D2+2509239 D2+2509238 Air filter AF20-01BG Air filter AF20-01BG D2+2509015
1 Year
Operator
4 5.2.2.
Home unit
Weekly
Operator
4 6.2.1.
Air tank
Air tank
Safety circuit
1 Year
Engine
1 Year
4 10.2.1.
4-4
PREVENTIVE MAINTENANCE
WARNING: Be aware of the waste disposal and regulations that bear on UV curable ink. Always follow the instructions on the label of the ink cartridge. UV radiation
Ultraviolet radiation (UV) has a high photon energy range and is particularly hazardous because there are usually no immediate symptoms of excessive exposure. Always wear UV protective (tinted) glasses while working with an open front cover or while working on the head carriage.
WARNING: UV light can cause harmful damage to eyes and skin. Therefore never look into UV light without wearing protective glasses. Never exposure your skin to UV light. Maintenance safety instructions
WARNING: Do not touch the print head during printing or maintenance actions. Do not place any obstacle on the print table which can hinder the head carriage during movement.
CAUTION: Regular inspecting and cleaning of the Anapurna L/XL is required to help to prevent machine damage and printing difficulties.
CAUTION: The print table is not to be used as a worktable. Never lean on the printer and do not place anything on the printer.
4-5
PREVENTIVE MAINTENANCE
E. PROCEDURE 1 Remove the ink using a cloth moistened with cleaning solution. 2 Check the proper functioning of the two vacuum zones. Test the two vacuum zones by using the vacuum switch/button located at the home unit (respectively front/rear) and in the meantime verify the correct functioning of the white tower lamp and measure the PLC outputs P041, P042 and P048. For more information refer to Vacuum Plate Usage on page 1-31 (chapter Functional Description). NOTE: When the belt is completely printed, vacuum can become insufficient.
3 If cleaning does not result in a proper vacuum functioning you need either to:
!
clean the vacuum holes. For more information about cleaning the vacuum holes, refer to Inspecting and Cleaning the Vacuum Holes on page 4-9.
or
!
replace the conveyer belt. For more information about replacing the conveyer belt, refer to Replacement of the Conveyer Belt on page 3-13 of the chapter Repair and Service.
4-6
PREVENTIVE MAINTENANCE
B. MANPOWER
Qualification Operator 1 Number of people Man-hours Execution time
C. SPECIAL TOOLS
Description Allen Key no. 12 Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Do the following two checks: 1 Manually check the tension of the belt.
2 Check if the belt is touching the left and right guide narrowly.
4-7
PREVENTIVE MAINTENANCE
2 If the belt tension is sufficiently and the belt is touching the left and right side narrowly, adjustments are not necessary. 3 In case of a too low belt tension or a belt bending near the left and/or right guide, adjust the belt tensioning. Proceed with step 4.
4 Remove the metal black cover on the left and right rear side.
5 Rotate the left and/or right tension bolt CW or CCW to adjust the tension (that implies adjusting the position). NOTE: These small adjustments can be done while the conveyer belt is moving.
4-8
PREVENTIVE MAINTENANCE
C. SPECIAL TOOLS
Description Syringe needle Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Remove the conveyer belt. Refer to Replacement of the Conveyer Belt on page 3-13, step 1 to 3 (chapter Repair and Service). 2 Puncture all holes of the vacuum table using a syringe needle. This to open the points where the vacuum holes interfere with the honeycomb structure inside the table. CAUTION: Do not use a drill to puncture the holes.
3 Fit the old conveyer belt. Refer to Replacement of the Conveyer Belt on page 3-13, step 3 to 8 (chapter Repair and Service). NOTE: Refitting the old belt is not always possible.
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PREVENTIVE MAINTENANCE
2.4. LM Guide
The head carriage unit can move in two directions:
!
Horizontal movement from purge to home position and vice versa along 2 LM guides, also know as carriage rail.
1 2
3 4
1 2
!
3 4
Vertical movement head lifting along the along 2 LM guides (head lifting type).
B. MANPOWER
Qualification Operator 1 Number of people Man-hours Execution time
E. PROCEDURE 1 Visually check the condition of the LM guide. 2 Move the head carriage several times from the purge side to the home side and verify whether the movement occurs smoothly (Mind the sound). 3 If necessary clean the LM guides and grease the LM blocks. Cleaning means removing dust and removing accumulated grease with acetone.
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PREVENTIVE MAINTENANCE
2.5. LM Blocks
There are 4 LM blocks at the back side of the head carriage unit, which guide the head carriage unit along the upper and lower LM guide. Greasing the LM blocks should be done regularly, in particular every 6 Months or depending on the operating conditions. Insufficient grease causes noise sounds of the head carriage unit, printing quality deterioration, and can reduce the Anapurnas life expectancy.
B. MANPOWER
Qualification Service technician 1 Number of people Man-hours 10 10 Execution time
C. SPECIAL TOOLS
Description Spray gun MG70 Code
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PREVENTIVE MAINTENANCE
E. PROCEDURE 1 Open the purge top and rear door. 2 Open the head cover door of the head carriage unit to get access to the top side of the head carriage unit. 3 Locate the greasing nipples of the 4 LM blocks.
4 Grease each LM block. 4.1 Insert the spray gun into the grease nipple.
4.2 Carefully spray approximately 10-30 ml. CAUTION: An overdose of grease can contaminate the printing conditions.
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PREVENTIVE MAINTENANCE
B. MANPOWER
Qualification Service technician 1 Number of people Man-hours Execution time
C. SPECIAL TOOLS None D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Manually inspect the tension of the carriage belt (no belt sag?) (1) and re tension if necessary. 1.1 Open the purge left side door to get access to the idle pulley assembly. 1.2 Tighten the two socket screws (2) to re tension the carriage belt (1).
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PREVENTIVE MAINTENANCE
2 Inspect the position of the carriage belt. 2.1 Open the home right side door to get access to the double pulley assembly. 2.2 Remove the double pulley protection cover (3) by unscrewing 5 screws.
2.3 Inspect the position of the carriage belt (4) on the double pulley. 2.4 If the carriage belt is not centered, align the carriage belt by adjusting the 2 lateral bearing height adjusting blocks (5) as illustrated in the figure below.
2.5 Replace and fix the double pulley protection cover. 3 Inspect the state (worn out?) of the carriage belt and replace if necessary. Refer to Replacing the Carriage Belt (S5M) on page 4-15.
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PREVENTIVE MAINTENANCE
B. MANPOWER
Qualification Service technician 1 Number of people Man-hours 60 60 Execution time
E. PROCEDURE
Idle pulley
Bearing
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PREVENTIVE MAINTENANCE
C. SPECIAL TOOLS
Description Jig Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Open the home right side door to get access to the double pulley assembly. 2 Remove the double pulley protection cover (1) by unscrewing 5 screws.
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4 If the S3M belt is not centered, align the S3M belt as follows: 4.1 Take out the jig.
4.3 Adjust the position of the 2 bottom bearing height adjusting blocks (4) until the wing of the motor pulley (5) touches the lower panel of the jig (5).
5 6
NOTE: The tension of the S3M belt is determined by the distance between the double pulley and the motor pulley 5 Replace and fix the double pulley protection cover.
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PREVENTIVE MAINTENANCE
Double pulley
S5M belt
Bearing ULF004
A. PRELIMINARY ACTIVITIES
Operation Move the head carriage to the purge position. Put the print engine in service mode. Reference Chapter 3 3.1. Chapter 3 3.2.
B. MANPOWER
Qualification Service technician Number of people Man-hours Execution time
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PREVENTIVE MAINTENANCE
E. PROCEDURE 1 Open the home right side door and the home rear door to get access to the double pulley assembly. 2 Remove the double pulley protection cover (1) by unscrewing 5 screws.
4 Remove the carriage servo motor (3) by unscrewing the 4 socket-head screws (4).
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6 Loosen the ULF004 bearing at carriage servo motor side 6.1 First remove the ring (6) using an Allen Key. 6.2 Loosen the ULF bearing (7) by removing the 2 socket-head screws (8).
7 Remove the ring (9) of the ULF Bearing at the opposite side.
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8 Loosen 2 screw bolt (10) of the 2 bearing height adjusting blocks (11) at carriage servo motor side and remove the ULF004 bearing (12).
10
11 10 11
12
13
NOTE: For convenience's sake, you can loosen the tension of the carriage belt (S5M) (14) by unscrewing the 2 socket screws (15) of the idle pulley assembly (purge side).
15
14
15
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10 Insert (wriggle) the new S3M belt along the right double pulley fixing bracket (16).
16
11 Remount the ULF004 bearing (17) and the ring (18) at carriage servo motor side.
17
18
12 Remount the ring (19) of the ULF Bearing at the opposite side.
19
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20
14 Remount the carriage driver motor (21) using the 4 socket-head screws.
21
NOTE: If you have loosen the tension of the carriage belt (S5M) in step 9, re tension the carriage belt. Refer to Inspecting the Carriage Belt (S5M) on page 4-13, step 1. 15 Finally, establish the following two belt alignments:
!
Aligning the S3M belt. Refer to Inspecting the Position of the S3M Belt on page 4-16. Aligning the S5M belt. Refer to Inspecting the Carriage Belt (S5M) on page 4-13, step 2.
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PREVENTIVE MAINTENANCE
E. PROCEDURE 1 Visually inspect the linear scale (encoder strip) for dust and grease.
2 Clean the linear scale using a cloth moistened with isopropyl alcohol to remove grease and dust. When stained, clean with acetone.
3 Execute the Encoder Test (Enc. Count Test in Test Menu window). Refer to the procedure Encoder Checking on page 4-25, step 1 and 2.
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PREVENTIVE MAINTENANCE
the head carriage unit is not moving, the head carriage unit is not moving smoothly, the position of the head carriage unit is shifting.
C. SPECIAL TOOLS None D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 In the Control Program, click Test.
The Test Menu window appears. 2 In the Test Menu window, select Enc. Count Test (1) and click Test (2).
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PREVENTIVE MAINTENANCE
If the encoder reads the linear scale normally, the head carriage repeatedly moves from left to right. Proceed with step 6. If the encoder cannot read correctly, the error message encoder failed is displayed on the window pane. Proceed with step 3.
3 Check the encoder parameters. 3.1 In the Control Program, click Setup.
The Setup Parameters window appears. 3.2 In the Setup Parameters window, click Factory Set (3).
3.3 Enter the password (4) and click OK. The Factory Data Setting window appears. 3.4 Note down the following regulated values submitted by the manufacturer when the machine is shipped out. Max. Platen Size (5), Home Pos.Offset (6), Max. Mark Count (7) and Carriage Gear Ratio (8). NOTE: The default set value for the Carriage Gear Ratio (8) is always 7742.
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PREVENTIVE MAINTENANCE
6 7
4 Execute a field-test to determine the Max. Platen Size (5), Home Pos.Offset (6) and Max. Mark Count (7) values. This field-test involves three tests to be executed one after another: 4.1 Manually determine the number of marks (Max. Mark Count value) on the linear scale. Refer to Determining the number of marks on the linear scale on page 4-28. 4.2 Define the Home Pos.Offset value. Refer to Defining the Home Position Offset on page 4-29. 4.3 Test the number of pulses the encoder reader counts. Refer to Testing the number of pulses the encoder reader counts on page 4-30. 5 If necessary, adjust the values Max. Platen Size (5), Home Pos.Offset (6), Max. Mark Count (7) in the Factory Data Setting window. NOTE: When you change one of the three parameters, do not forget to download the parameters to validate the new values. See option Parameter Download in the Test Menu window. For more information about downloading parameters, refer to Parameter Download on page 1-89 (chapter Functional Description). 6 In the Control Program, click Test and select Jet Test to check the condition of the nozzle. Refer to Nozzle Check on page 4-40. 7 Print a sample and check the printing quality. 8 Clean the linear scale with acetone. Refer to Inspecting and Cleaning the Encoder Strip on page 4-24.
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PREVENTIVE MAINTENANCE
The Test Menu window appears. 2 In the Test Menu window, select Carriage Release Test (1) and click Test (2).
As a result, the head carriage unit can be moved manually from home side to purge side. 3 First, push the head carriage unit to the limit switch (3), located in the home unit.
4 Secondly, slowly push the head carriage unit to the purge side (left) until you encounter the first MARK. Note this mark as the first mark. NOTE: MARK = 1 thick stripe every 50 mm.
5 Then, manually move the head carriage unit towards the purge side (left), while counting the number of MARKs the head carriage unit passes during the movement. Stop pushing the head carriage unit just before the head carriage unit touches the purge shock absorber.
4 - 28 2007 V1.0 Company Confidential Service Manual :Anapurna L/XL
PREVENTIVE MAINTENANCE
The last MARK the head carriage unit passes, is noted as last MARK. 6 Note down the total number of MARKs counted (= Max. Mark Count).
NOTE: Make sure that the head carriage unit is in home position (front right side)
To define the home position offset, proceed as follows: 1 Execute a Carriage Release Test. For more information on how to execute a Carriage Release Test, refer to Determining the number of marks on the linear scale on page 4-28, step 1 and 2. 2 First, push the head carriage unit to the limit switch (1), located in the home unit (= Detected home position).
3 Secondly, slowly push the head carriage unit towards the purge side and stop the head carriage unit just before you can see the first MARK (= real home position). 4 Measure the distance the head carriage unit has travelled between those 2 positions (step 2 and step 3). 5 Calculate the home position offset. Home Pos. Offset = measured distance in mm (step 4) x 154 and round down to the nearest 1000 (thousands). 6 Execute the following verification test to determine whether you need to fine-tune the calculated Home Pos. Offset of step 5. 6.1 Fill in the calculated Home Pos. Offset value in the Factory Data Setting window. 6.2 Execute a parameter download. In the Control Program, click Test to open the Test Menu window. In the Test Menu window, select Parameter Download and click Test.
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PREVENTIVE MAINTENANCE
6.3 Verify whether the center of the encoder reader stops just before the MARK. Execute a carriage release, move the head carriage unit by means of the double pulley (2) (gear of black S3M belt) while checking the MARK LED at the MAIN PCB. The MARK LED lights up when the encoder passes the MARK on the encoder scale.
Do not select one of the pre-defined carriage speed values (2). 3 Execute a parameter download. In the Control Program, click Test to open the Test Menu window. In the Test Menu window, select Parameter Download and click Test. 4 Prepare the head carriage unit for moving to purge position.
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PREVENTIVE MAINTENANCE
4.1 In the Control Program, click Purge (1). 4.2 The message "Carriage Clear to Move..?" appears. 4.3 Hold your PC mouse on the Yes button. 5 Press the Enter key on your keyboard and count how many times the MARK LED (5) flashes at the Main PCB (3) while the head carriage unit is moving towards the purge side.
3 4 5
3 4
Mark LED
NOTE: The number of pulses should be the same as the value filled in the Max. Mark Count field in the Factory Data Setting window. 6 Count how many times the MARK LED (5) flashes at the Main PCB (3) while the head carriage unit is moving from home to purge. The number of counted pulses should be the same as from purge to home (see step 5). If not the encoder head is slanting or the distance encoder head/encoder scale is incorrect. Adjust the depth between the encoder head and the encoder scale. See d. 7 Finally, execute the encoder test (Enc. Count Test in the Test Menu window) at low carriage speed (6) and afterwards at normal carriage speed (7). Normally there should be no error message and the ENC and Mark LED at the MAIN PCB are flashing.
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3 Place the plastic 0.5 mm gap gauge between the encoder head (1) and the linear scale (2)
1 2
3 4
Encoder bracket (view: home right side door side) Encoder bracket (view: purge top door)
4 Adjust the distance between the encoder head (1) and the linear scale (2) by unscrewing/ screwing the two bolts on top of the encoder bracket (3). NOTE: If you are not able to reach the two bolts when the head carriage is in the home position, execute the procedure at the purge position, where you can easily reach the two bolts of the encoder bracket (4) via the purge top door. 5 Make sure that you can remove the plastic 0.5 mm gap gauge. When the distance is OK, there will be no error message while executing the encoder test (Enc. Count Test in the Test Menu window).
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PREVENTIVE MAINTENANCE
2 1
1.1 Two UFL004 bearings (1). 1.2 Four bearing height adjusting blocks (2), 2 Lubricate the idle pulley bearing (3).
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PREVENTIVE MAINTENANCE
3 Lubricate the 2 bearings ULF diameter 40 (4), located behind the shaft cover (5).
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PREVENTIVE MAINTENANCE
E. PROCEDURE 1 Inspect the following connections: Drain hose (thick), venturi hose (thin) and full detection sensor connector (2-pin) which is located in the cable trunk.
2 Place a black snap-on lid Polyethylene container underneath the waste tank. 3 Open the drain cock underneath the waste tank to empty the waste tank.
WARNING: Be aware of the waste disposal and regulations that bear on UV curable ink.
NOTE: The full detection sensor is activated when the contents of the waste tank reaches 3.5 litre. The signal P01 on the PLC, illuminates when the waste tank is full (3.5 litre).
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PREVENTIVE MAINTENANCE
WARNING: Consult the appropriate Material Safety Data Sheets (MSDS) before handling UV curable ink. WARNING: UV ink contains some chemicals harmful to eyes and skin. Always wear safety gloves when handling UV ink. In case of accidental contact, rinse immediately with plenty of water and consult a doctor, if required. WARNING: UV ink contains chemicals harmful to eyes and skin. 1. Always wear splash-resistant nitril safety gloves when handling UV ink. (Only safety gloves for single use are allowed). 2. Always wear protective glasses when refilling or changing the ink. 3. Avoid inhalation of the ink. WARNING: Be aware of the waste disposal and regulations that bear on UV curable ink. Always follow the instructions on the label of the ink cartridge.
UV radiation
Ultraviolet radiation (UV) has a high photon energy range and is particularly hazardous because there are usually no immediate symptoms of excessive exposure. Always wear UV protective (tinted) glasses while working with an open front cover or while working on the head carriage.
WARNING: UV light can cause harmful damage to eyes and skin. Therefore never look into UV light without wearing protective glasses. Never exposure your skin to UV light. Maintenance safety instructions
WARNING: Do not touch the print head during printing or maintenance actions. Do not place any obstacle on the print table which can hinder the head carriage during movement.
CAUTION: Regular inspecting and cleaning of the Anapurna L/XL is required to help to prevent machine damage and printing difficulties.
CAUTION: The print table is not to be used as a worktable. Never lean on the printer and do not place anything on the printer.
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PREVENTIVE MAINTENANCE
NOTE: At the end of the day, and when you stop printing, the head carriage unit needs to be placed in the purge position. For overnight or longer standstill times, the grid underneath the head carriage unit must be pushed to the back.
NOTE: A default "Weeping" time is set in the engine software to keep the heads open, this small amount of ink is collected in the underneath waste box, which leads to a waste tank underneath the engine. NOTE: Place some towels in front of the purge grid, this will help to keep the area clean, it is advisable to replace them weekly
NOTE: The purge grid must be placed forward again when you start to print.It prevents the ink in the underneath waste box from getting cured by the UV lamps during the printing stage. It also prevents the UV lamps from curing the ink onto the heads.
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PREVENTIVE MAINTENANCE
Manual Clean Up, Automatic Weeping, Manual Weeping, Little Purge, Large Purge, Cleaning with solution (flushing).
NOTE: The manual weeping, the little purge and the large purge cleaning procedures mention the use of the purge switch button, located at the front side of the print heads. NOTE: By pushing the purge switch button you are applying positive pressure to the ink column inside the sub ink tank, forcing ink through the nozzles. When using the purge switch button, keep in mind that: The contents of a sub ink tank is limited to 35 ml per color. The ink supply hoses going to the sub ink tanks have a very narrow diameter and it takes some time to refill the tanks. For the white ink note that one sub ink tank is feeding both white print heads when purging. When we hit the purge switch button the ink volume flowing away through the nozzles is larger than the ink supplied into the sub ink tank. NOTE: If we keep the button pushed during too long a period the sub ink tank will be drained completely since refill rate is slower than purge rate. As a result, air enters into the ink flow which causes even more missing nozzles. Give the sub ink tanks time to refill and be moderate on the use of the purge switch button.
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PREVENTIVE MAINTENANCE
A. PRELIMINARY ACTIVITIES
Operation Move the head carriage to the purge position. Reference Chapter 3 3.1.
B. MANPOWER
Qualification Operator 1 Number of people Man-hours Execution time
C. SPECIAL TOOLS
Description Cleaning stick Code
E. PROCEDURE
! Manual Clean Up
Clean the heads with a fiber-free cloth or cleaning stick, by wiping from back to front on each head separately. Use backside of cloth, or a new cloth for every next head.
NOTE: To order the cleaning stick, order D2+2161113 (cleaning stick rubber) and D2+2161115 (cleaning stick bracket).
! Automatic Weeping
A default "Weeping" time is set in the engine software to keep the heads open. To capture an automatic weeping, proceed as follows: 1 Move the head carriage to the purge position (front left side). 2 Hold a white A4-paper underneath the base plate to check the nozzles. 3 Capture the ink when the heads are weeping during approximately 10 seconds. As a result, vertical lines appears on the sheet. 4 Check them on interruption.
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PREVENTIVE MAINTENANCE
! Manual Weeping
To execute a manual weeping, proceed as follows: 1 Move the head carriage to the purge position (front left side). 2 Set the vacuum pressure to zero during 2 minutes, by turning the pressure control adjustment knob.
3 Set the vacuum pressure by turning the pressure control adjustment knob to the desired pressure (range -0.032 MPa to -0.038 MPa).
! Nozzle Check
To execute a nozzle check, proceed as follows: 1 Move the head carriage to the home position (front right side).
2 Execute the head gap control. Refer to Executing a head gap control on page 1-84 (chapter Functional Description). 3 Position a blank A4 paper on the print table as follows: Between the 2 marking bullets positioned on the axle underneath the white transport belt and within the reach of the 2 marking bullets positioned on the side of the head carriage.
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PREVENTIVE MAINTENANCE
4 Switch on the vacuum. 5 In the Control Program, click Test. The Test Menu window appears.
6 Select Jet Test and click Test to start the test print which checks the condition of the nozzles. The nozzle check will be printed between the 4 white marking bullets. NOTE: Use a black or colored paper to see the Spot- and Pre-white. The red area in the figure below shows the placement of the Spot- and Pre-white if it's turned on.
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PREVENTIVE MAINTENANCE
7 Evaluate the nozzle check for missing nozzles. For example, the nozzle condition is not good for black in the illustration below.
8 In case of nozzle failure: 8.1 Move the head carriage unit to purge position. 8.2 Push the grid backwards. 8.3 Execute a little and/or large purge. Refer to Little Purge on page 4-42 and Large Purge on page 4-43.
! Little Purge
1 2 3
4 5
1 Close the print heads valves of the print heads that are OK. Set them to the solution outlet positions (S). 2 Push the purge switch button at very short intervals.
3 Open all print head valves again. Set them to the ink outlet positions (I).
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PREVENTIVE MAINTENANCE
4 Clean the print heads with a fiber-free cloth. Refer to Manual Clean Up on page 4-39. NOTE: Clean the heads with a fiber-free cloth, by wiping from back to front on each head separately. (Use backside of cloth, or a new cloth for every next head) 5 Check on weeping Refer to Automatic Weeping on page 4-39.
! Large Purge
1 2 3
4 5
1 Set all print head valves to the ink outlet position (I). 2 Push and hold the purge switch button during approximately 2 seconds and complete the procedure by pushing the purge switch button again, but now frequent, at very short intervals.
3 Clean the print heads with a fiber-free cloth. Refer to Manual Clean Up on page 4-39. NOTE: Clean the heads with a fiber-free cloth, by wiping from back to front on each head separately. (Use backside of cloth, or a new cloth for every next head) 4 Check on weeping Refer to Automatic Weeping on page 4-39.
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PREVENTIVE MAINTENANCE
5 If nozzle failure still exists, proceed as follows: 5.1 Set the vacuum pressure to zero by turning the pressure control adjustment knob.
5.2 Leave the system for 1 to 2 minutes. Ink will starts dripping out the heads. 5.3 Restore the vacuum pressure to -0.034 MPa. 5.4 Clean the print heads with a fiber-free cloth. Refer to Manual Clean Up on page 4-39. 5.5 Check on weeping Refer to Automatic Weeping on page 4-39.
1 2 3
4 5
To clean the failing heads with solution, proceed as follows: 1 Set the print head valves of the failing print heads to the solution outlet position (S). 2 Set the solution valve to solution outlet position (S).
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PREVENTIVE MAINTENANCE
3 Push the solution valve button until you see a full solution-curtain, then stop pushing. As a result, the solution runs from the refill system to the sub ink tank, mounted at the rear of the head carriage. Note that the solution valve button is located at the back side of the print heads.
4 Leave the print heads in this condition for at least 5 minutes. 5 Put all ink valves and the solution valve in the ink outlet (I) position and set the vacuum pressure to zero. 6 Wait till the ink drops out of the heads (a few minutes). 7 Set the vacuum pressure by turning the pressure control adjustment knob to the desired pressure (range -0.032 MPa to -0.038 MPa). 8 Clean the print heads with a fiber-free cloth. Refer to Manual Clean Up on page 4-39. NOTE: Clean the heads with a fiber-free cloth, by wiping from back to front on each head separately. (Use backside of cloth, or a new cloth for every next head) 9 Check on weeping Refer to Automatic Weeping on page 4-39.
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PREVENTIVE MAINTENANCE
B. MANPOWER
Qualification Service technician 1 Number of people Man-hours Execution time
E. PROCEDURE 1 Look into the UV lamp box housing. The lamp shutter (1) is closed.
Connect the lamp shutter OFF pneumatic tube (red) (3)to the lamp shutter ON connection (2) and leave the lamp shutter ON pneumatic tube (yellow) (4) open as illustrated below.
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PREVENTIVE MAINTENANCE
or
!
Switch the connections on the corresponding lamp shutter solenoid valve (5,6). To get access the lamp shutter solenoid valves, open the purge top door and then open the head cover door of the head carriage unit.
3 Hold a white paper underneath the glass plate of the UV lamp box housing to inspect the state of the glass plate.
4 If the glass plate is dirty, do one of the following: 4.1 Clean using a lint-free cloth moistened with isopropyl alcohol (IPA). Proceed with step 9 4.2 Replace the crystal glass plate. Proceed with step 5. 5 Raise the head carriage unit to the maximum height for easy access.
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PREVENTIVE MAINTENANCE
6 Remove at the bottom side the metallic blinking frame (4) that holds the glass plate, by unscrewing the four screws (5).
5 4
8 Restore the lamp shutter ON/OFF pneumatic tube connections, to close the shutter. Procedure: opposite step 2. 9 Remount the UV lamp box. Refer to Replacement of the UV Lamp Box on page 3-73 (chapter Repair and Service).
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PREVENTIVE MAINTENANCE
A. PRELIMINARY ACTIVITIES
Operation Move the head carriage to the purge position. Put the print engine in service mode. Open the front and left purge door to get full access to the left UV lamp box. Remove the UV lamp box. Move the head carriage to the home position. Put the print engine in service mode. Open the home right side door to get full access to the right UV lamp box. Remove the UV lamp box. Chapter 3 4.7.2. Chapter 3 4.7.2. Chapter 3 3.1. Chapter 3 3.2. Reference Chapter 3 3.1. Chapter 3 3.2.
B. MANPOWER
Qualification Operator 1 Number of people Man-hours Execution time
E. PROCEDURE 1 Turn the UV lamp box upside down. 2 Unscrew the two wires out of the connector blocs (1). 3 Lift the UV lamp (2) out of the brackets (3) without touching.
1 3
4 Take the new UV lamp out of the foil. CAUTION: Do not touch the glass part of the UV lamp with your bare hands. Wear gloves when necessary. If grease of your hands gets on the glass, it can reduce the lifetime of the UV lamp significantly.
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PREVENTIVE MAINTENANCE
NOTE: Make sure that the nipple of the UV lamp is positioned towards the reflection shield (metallic plate) of the lamp housing.
6 Reconnect the 2 wires to the connector blocs. 7 Remount the UV lamp box. Refer to Replacement of the UV Lamp Box on page 3-73 (chapter Repair and Service).
B. MANPOWER
Qualification Service technician 1 Number of people Man-hours 10 10 Execution time
C. SPECIAL TOOLS None D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Open the purge top and rear door. 2 Open the head cover door of the head carriage unit to get access to the top side of the head carriage unit.
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PREVENTIVE MAINTENANCE
12
4 Check the lamp shutter functionality by pressing the blue points, of the lamp shutter solenoid valves, using a pointed object.
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C. SPECIAL TOOLS
Description Code
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WARNING: Consult the appropriate Material Safety Data Sheets (MSDS) before handling UV curable ink. WARNING: UV ink contains some chemicals harmful to eyes and skin. Always wear safety gloves when handling UV ink. In case of accidental contact, rinse immediately with plenty of water and consult a doctor, if required. WARNING: UV ink contains chemicals harmful to eyes and skin. 1. Always wear splash-resistant nitril safety gloves when handling UV ink. (Only safety gloves for single use are allowed). 2. Always wear protective glasses when refilling or changing the ink. 3. Avoid inhalation of the ink. WARNING: Be aware of the waste disposal and regulations that bear on UV curable ink. Always follow the instructions on the label of the ink cartridge.
UV radiation
WARNING: UV light can cause harmful damage to eyes and skin. Therefore never look into UV light without wearing protective glasses. Never exposure your skin to UV light.
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PREVENTIVE MAINTENANCE
E. PROCEDURE 1 Inspect the air filter (1) for any moisture. 2 If saturated, remove and replace the air filter.
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PREVENTIVE MAINTENANCE
When starting up the Anapurna L/XL for the first time after installation, bleed each ink filter after filling each ink tank with 1 liter of ink. If an ink tank has remained empty during too long a period and if consequently, the ink filter is dry.
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PREVENTIVE MAINTENANCE
E. PROCEDURE 1 Get access to the refill PCB and reconnect all pump connectors. The connector J17 should remain disconnected.
2 Unscrew the four screws to remove the refill system panel. Place the panel against the right cover.
3 Put some absorbent lint free cleaning tissues underneath the ink filters to catch possible spilled ink 4 Open the cap on top of the filter (e.g. Lm).
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PREVENTIVE MAINTENANCE
5 Hold an absorbent lint free cleaning tissue against the filter opening.
6 Press and hold the priming switch of the corresponding color until the ink flows upwards and is spilled. Use a 5 second on/off sequence (leave 5 seconds on, then 5 seconds off), in order to fill up both chambers of the filter.
7 Repeat the bleeding procedure a second and a third time to be sure that all air is extracted from the ink filter (reason: filter has a compartment that fills with a certain delay). NOTE: Wait some seconds in between the bleeds and reduce the sequence time when bleeding the second (e.g. 3 seconds on/off sequence) and third (e.g. 2 seconds on/off sequence) time. 8 Screw the cap on top of the ink filter and clean the ink filter with a cleaning tissue.
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4.3.2. Draining the First Ink from the Sub Ink Tanks
When all filters have been bled, you need to drain the first ink from the sub ink tanks (approx. 30 ml). A. PRELIMINARY ACTIVITIES None B. MANPOWER
Qualification Service technician 1 Number of people Man-hours Execution time
C. SPECIAL TOOLS None D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Unscrew the locknut underneath each print head valve (K, C, M, Y, Lc, Lm, W1 and W2).
NOTE: All print head valves are still set to the solution outlet position (S)!
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PREVENTIVE MAINTENANCE
1 2
Locknut
Tube
2 Shear the tube of each valve. 3 Open the drain cock of the sub air tank. The sub air tank is located behind the purge rear door.
Drain cock
4 Connect the connector J17 on the refill PCB to pump ink from the main ink tanks to the sub ink tanks and wait until all pumps are idle. All refill leds on the refill system indicator go out when all pumps are idle.
5 As soon as all pumps are idle, close the drain cock of the sub air tank. NOTE: The first time you drain the first ink, there is also air in the ink tubes between the main ink tanks and the sub ink tanks. The air can leave the tubes through the drain cock of the sub air tank.
4 - 60
PREVENTIVE MAINTENANCE
6 Drain the seven ink channels (K, C, M, Y, Lc, Lm, W1, W2) one after the other. To drain one ink channel, proceed as follows: 6.1 Place a receiving bin underneath the valve (e.g. K valve). 6.2 Put some absorbent lint free cleaning tissues near the receiving bin to catch possible spilled ink. 6.3 Set the valve to the ink outlet position (I).
6.4 Let the ink drop out completely (approx. 30 ml). 6.5 Wait a few seconds and let the ink drop out again (approx. 30 ml). 6.6 Set the valve to the solution outlet position (S).
7 Repeat steps 6. When draining the first ink from the sub ink tank a second time, the drained ink volume increases. 8 Repeat step 6 once again (third time) and then proceed with step 9. 9 Reconnect the tube of each print head valve and manually tighten the locknut.
1 2
Locknut
Tube
4 - 61
PREVENTIVE MAINTENANCE
10 Adjust the vacuum pressure by turning the pressure control adjustment knob until you reach the desired pressure (range -0.032 MPa to -0.038 MPa).
The old ink has drained out sufficiently. Now you can start flushing the heads with cleaning solution.
4 - 62
PREVENTIVE MAINTENANCE
WARNING: Consult the appropriate Material Safety Data Sheets (MSDS) before handling UV curable ink. WARNING: UV ink contains some chemicals harmful to eyes and skin. Always wear safety gloves when handling UV ink. In case of accidental contact, rinse immediately with plenty of water and consult a doctor, if required. WARNING: UV ink contains chemicals harmful to eyes and skin. 1. Always wear splash-resistant nitril safety gloves when handling UV ink. (Only safety gloves for single use are allowed). 2. Always wear protective glasses when refilling or changing the ink. 3. Avoid inhalation of the ink. WARNING: Be aware of the waste disposal and regulations that bear on UV curable ink. Always follow the instructions on the label of the ink cartridge.
UV radiation
WARNING: UV light can cause harmful damage to eyes and skin. Therefore never look into UV light without wearing protective glasses. Never exposure your skin to UV light.
B. MANPOWER
Qualification Operator 1 Number of people Man-hours Execution time
C. SPECIAL TOOLS
Description filling-knife or a wide screwdriver Code
4 - 63
PREVENTIVE MAINTENANCE
E. PROCEDURE 1 Visually check the state of the purge grid. 2 If cured ink is accumulated on the grid, use a filling-knife or a wide screwdriver to cut off the cured ink on the ribs.
B. MANPOWER
Qualification Operator 1 Number of people Man-hours Execution time
C. SPECIAL TOOLS
Description filling-knife or a wide screwdriver Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Push the grid to the back. 2 Use a filling-knife or a wide screwdriver to cut off the cured ink in the receiving bin.
4 - 64
PREVENTIVE MAINTENANCE
WARNING: Consult the appropriate Material Safety Data Sheets (MSDS) before handling UV curable ink. WARNING: UV ink contains some chemicals harmful to eyes and skin. Always wear safety gloves when handling UV ink. In case of accidental contact, rinse immediately with plenty of water and consult a doctor, if required. WARNING: UV ink contains chemicals harmful to eyes and skin. 1. Always wear splash-resistant nitril safety gloves when handling UV ink. (Only safety gloves for single use are allowed). 2. Always wear protective glasses when refilling or changing the ink. 3. Avoid inhalation of the ink. WARNING: Be aware of the waste disposal and regulations that bear on UV curable ink. Always follow the instructions on the label of the ink cartridge.
UV radiation
WARNING: UV light can cause harmful damage to eyes and skin. Therefore never look into UV light without wearing protective glasses. Never exposure your skin to UV light.
B. MANPOWER
Qualification Operator 1 Number of people Man-hours Execution time
C. SPECIAL TOOLS
Description filling-knife or a wide screwdriver Code
4 - 65
PREVENTIVE MAINTENANCE
E. PROCEDURE 1 Visually check the state of the home grid. 2 If cured ink is accumulated on the grid, take out the grid (1). 3 Use a filling-knife or a wide screwdriver to cut off the cured ink on the ribs.
B. MANPOWER
Qualification Operator 1 Number of people Man-hours Execution time
C. SPECIAL TOOLS
Description filling-knife or a wide screwdriver Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Take out the grid (1).
2 Use a filling-knife or a wide screwdriver to cut off the cured ink in the receiving bin (2).
4 - 66
SAFETY CIRCUIT
PREVENTIVE MAINTENANCE
7. Safety Circuit
7.1. Guidelines and Specific Safety Instruction
None
C. SPECIAL TOOLS None D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE NOTE: The system is provided with 4 emergency stops, two at the front side and two at the back side. The inspecting procedure is written for one emergency stop. Repeat the procedure for all four emergency stops. 1 Push the emergency stop button.
2 Verify whether the emergency button cuts off the power, except for the PC and SMPS8. 3 Pull the emergency button back. The emergency stop is cancelled.
4 - 67
PREVENTIVE MAINTENANCE
SAFETY CIRCUIT
NOTE: For more information about the emergency stop circuit, refer to Emergency Stop Circuit on page 1-14 (chapter Functional Description)
4 - 68
PREVENTIVE MAINTENANCE
B. MANPOWER
Qualification Service technician 1 Number of people 5 Man-hours 5 Execution time
C. SPECIAL TOOLS None D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Open the drain cock (2) to eliminate the water of the air tank (1).
4 - 69
PREVENTIVE MAINTENANCE
put all ink valves in the solution (S) outlet position, mount the capping plate underneath the head base plate, disconnect the 2 cables of the carriage servo motor to avoid that after power-up the engine again, the carriage accidentally moves after reset while the capping plate is still mounted.
B. MANPOWER
Qualification Service technician 1 Number of people 5 Man-hours 5 Execution time
C. SPECIAL TOOLS
Description Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Remove the air pressure panel (1).
4 - 70
PREVENTIVE MAINTENANCE
3 Locate the two air filters (AF20-01BG) (3), the water drain out connector (4) and the drain pipe (5).
3 3
4 Drain the water from the 2 air filters. 4.1 Place a receiving bin underneath the drain pipe (7). 4.2 Open the black nut (6) underneath the filter to remove the water.
4 - 71
PREVENTIVE MAINTENANCE
4.3 Close the black nut (6) when the water is removed.
76
NOTE: Follow the same procedure to drain the water from the main regulator (AW20-02BCG) (8)
B. MANPOWER
Qualification Service technician 1 Number of people Man-hours 15 15 Execution time
C. SPECIAL TOOLS
Description Code
E. PROCEDURE 1 Set all print head valves (K, C, M, Y, Lc, Lm, W1 and W2) to the solution outlet position (S). 2 Set the solution valve to the ink outlet position (I).
4 - 72
PREVENTIVE MAINTENANCE
1 2 3
4 5
3 Switch off the engine. 4 Turn off the compressed air supply. 5 Locate the air filter (AF20-01BG) (6).
6 6
6.1 Unscrew the 2 cross-slotted screws. 6.2 Disconnect the air hoses.
4 - 73
PREVENTIVE MAINTENANCE
6.3 Mount a new air filter, tighten the 2 cross-slotted screws and reconnect the air hoses. 7 Restore the compressed air supply. 8 Restart the engine. 9 Set all print head valves and the solution valve to the proper outlet position. 10 Verify the printing conditions and if necessary clean the print heads. Refer to Cleaning a Print Head on page 4-38.
4 - 74
ENGINE
PREVENTIVE MAINTENANCE
10. Engine
10.1. Guidelines and Specific Safety Instruction
None
Levelling in the longitudinal direction (Front/Rear side): Use the levels mounted on the left and right side panels. Levelling in the cross direction (Left/Right side): Use the level mounted in the middle of the connection bar.
4 - 75
PREVENTIVE MAINTENANCE
ENGINE
B. MANPOWER
Qualification Service technician 1 Number of people Man-hours 10 10 Execution time
C. SPECIAL TOOLS
Description Nut wrench no.36 Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Manually turn the 8 support feet downwards until they touch the ground. 2 Lower each support foot further by turning them over one complete turn. 3 Use the left and right built-in level to check the level of the print engine in longitudinal direction. 4 Look at the position of the air bubble of the left built-in level. If necessary, adjust the lowest (on the opposite side of the air bubble) point of support foot number 1, slightly until the air bubble of the level is in the middle.
REAR 1 2
1 FRONT
5 Look at the position of the air bubble of the right built-in level. If necessary, adjust the lowest (on the opposite side of the air bubble) point of support foot number 2, slightly until the air bubble of the level is in the middle.
REAR 1 2
1 FRONT
6 Repeat steps 4 to 5 until the air bubble is exactly in the middle. 7 Look at the position of the air bubble of the middle built-in level. If necessary, adjust the lowest (on the opposite side of the air bubble) point of support foot number 3, slightly until the air bubble of the level is in the middle. Make sure not to disturb the longitudinal balance. This is done by adjusting both support feet (number 3A or 3B) equally over the same distance.
REAR
3A 3B
3A
3B
FRONT
4 - 76
ENGINE
PREVENTIVE MAINTENANCE
8 Lower the outer support feet until they touch the ground.
REAR
FRONT
NOTE: Check whether the air bubble of the three built-in levels is still in the middle. If not redo the levelling. 9 When the correct height is reached, is it necessary to secure the feet by tightening the locknut against the frame. 10 Check whether the ink supply door is leveled. If not do the ink supply door levelling. For more information, refer to Levelling the Ink Supply Door on page 4-77.
B. MANPOWER
Qualification Service technician 1 Number of people Man-hours Execution time
C. SPECIAL TOOLS
Description Nut wrench no.24 Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Level the ink supply door, using a nut wrench no. 24, in such a way: 1.1 the ink supply door does not drag when you open it, 1.2 the ink supply door closes easily, 1.3 the 3 door hinges are not extremely overloaded.
4 - 77
PREVENTIVE MAINTENANCE
ENGINE
4 - 78
CHAPTER
Troubleshooting
This chapter describes how you can recognize and solve mechanical, electrical and image problems you could encounter when printing with the Anapurna L/XL. 1. Troubleshooting Based on Visible Problems ............................................................................................... 5 - 2 1.1. Troubleshooting Based on Tower Lamp Indications .................................................................... 5 - 2 1.2. Troubleshooting Based on Mechanical and/or Electrical Problems ..................................... 5 - 2 2. Troubleshooting Based on UI Error Messages .......................................................................................... 5 - 13 3. Troubleshooting based on Image Quality Control .................................................................................. 5 - 14 3.1. Encoder (MARK) Error ........................................................................................................................... 5 - 14 3.2. Black Strips .............................................................................................................................................. 5 - 15 3.3. Waves on the Media Surface ............................................................................................................ 5 - 15 3.4. Only UNI MODE Output ...................................................................................................................... 5 - 16 3.5. Image Quality Failure .......................................................................................................................... 5 - 16 3.6. Spray on your Image ............................................................................................................................ 5 - 18 3.7. Print Length Exceeds Maximum Platen Length ......................................................................... 5 - 18 4. UV Lamp Troubleshooting ................................................................................................................................ 5 - 20 5. Servo Motor Driver Troubleshooting ............................................................................................................ 5 - 21
5-1
TROUBLESHOOTING
Check the industrial compresso- 1 4.1.2. compressor. Check the status of the tube connection. Refill ink into main ink tank. Check air at ink filter. Installation manual 4 4.3.1.
Overheat
BLUE lamp is flashing and Full waste ink tank (> 3.5 litre) beeping (Blue lamp lights up when the register pins are down) All lamps are flashing and Overflow (of ink) in sub air tank. beeping Ink run from sub ink tank to sub air tank
5 1.2.2.
Rear TAKE-UP motor does No media detected not stop Rear TAKE-UP motor does Obstacle (e.g. vacuum pumps) in not move the beam of the media detection signal sensor. Beeping (every 3 sec) [main PCB beeping] Take-up overload
Pressing CW/CCW button for a long time at the take-up control system panel
5-2
TROUBLESHOOTING
Action
See
Check whether the print medium 1 6.1.4.4. is loaded correctly on the rear media roll bar. Check whether the tension roll bar is inserted correctly. Check the position of the print medium on the print table. Check whether the 2 tension roll bars of the roll to roll system are mounted correctly 1 6.1.4.1.
Tension roll bar (rear/ Wrong positioning of the tension front) lifted out of its posi- roll bar tion. Media fixing roll bar (rear/ Wrong positioning of the media front) lifted out of its posi- fixing roll bar tion. Ink not cured Immediate stop during printing Check UV lamp life span
Check whether the 2 media fixing 1 6.1.2.1. roll bars above the print table are mounted correctly Replace lamp 4 3.3.3.
Communication error, output data Check communication cables error and data Check RTL file Adjust feed speed value 1 12.3.4. Check parameters at servo driver 1 6.1.6.1. Remove obstacle and supply grease to S3M belt Check obstacles in the range of the head carriage unit. Check power and cable between carriage and feed servo motor Turn off main power and start again Check servo motor driver error message Clean head nozzle and check minus pressure Remove air at ink filter Adjust servo motor driver according to gain value. Check negative gauge, adjust to normal value 4 2.7.1. 5 5. 4 3.2.1. 1 4.1.3.1. 4 4.3.1. 1 6.1.6.1. 1 9.1.1. 1 4.1.3.1. 4 3.2.1.
Strange noise and no Feed speed movement of print media Noise while head carriage Obstacles unit is moving Head carriage unit does not move Obstacles exist while head carriage unit is moving
Ink drips on the print media Motor noise (Feed and carriage) Lots of ink drops on print media
Contaminated print head or foreign materials ink remainders Check servo motor driver Negative pressure error
Not ejecting ink instantly Electrical noise by static current, it Static current hinders electrical influences head ejecting signals of head Check ground By purging 2~3, supply ink and clean head Can not supply ink to sub Refill device does not work propink tank erly Unexpected line appeared Head nozzle is clogged on image Dark lines in the print, as a Wrong Step Size value result of overlapping passes White lines in the print, as Wrong Step Size value a result of a gap between the passes. Check ink at main ink tank and then call service
Check nozzle conditions by doing 1 12.4.1. jet test 4 3.2.1. Adjust Step Size value 1 12.3.2.
1 12.3.2.
5-3
TROUBLESHOOTING
Trouble
Cause
Action Check connection PT sensor head base plate with Head Lift PCB (J17). Replace if necessary. Check connection head temperature sensor with Head PCB (J29) + check connection with Magenta print head. Replace thermistor if necessary Check connection with Head PCB and replace head heater if necessary. Check safety thermostat and replace if necessary. Ink filter should be filled with sufficient ink without air Replace level sensor
Head heater temperature Problem with PT sensor head is increasing or decreasing base plate Problem with head temperature sensor (safety thermostat 45C)
Problems with the heating elements of each print head (heater bar - red cables) Problem with the safety thermostat (80C) mounted on the head base plate Overflow Air in the ink filter Malfunction of the sub ink tank level sensors
Malfunction of the waste ink Replace level sensor tank level sensor Connection error/minus pressure Check compressor and tube con- 1 4.1.2. error nection status. Adjust the air pressure to the appropriate value. Ink in sub air tank Check sub air tank if air exists or 1 4.1.3.1. not. It should be always empty and clean. Loss of voltage Overheating base plate Head base plate temperature > 38C during printing Check the permanent voltage 5 1.2.4. Stop printing at the end of the current print job. Switch off the UV-lamps. 1 10.1.3. Run the Encoder Test for 5 min- 1 9.1.2. utes Change the secondary of the UV 5 1.2.1. coil to 60 Hz (Note: only possible for 50Hz countries) The metal connector inside the ceramic block is completely burned up Replace lamp house 5 1.2.3.
Overheating UV assembly
UV lamp burnout
The S3M belt wears out, it looses its teeth, parts as well as complete teeth. Noisy movement of the head carriage unit Vacuum not strong enough on printing table Discontinuity of the teeth of the S3M belt results in noisy movements of the head carriage unit Vacuum holes printing tabla are clogged up
4 2.7.2.
4 2.7.2.
4 2.3.1.
5-4
TROUBLESHOOTING
50 60 CHOKE(R)-LOW CHOKE(R)-HIGH
5-5
TROUBLESHOOTING
3 Open the drain cock (2) of the sub air tank and empty the waste ink from the sub air tank.
4 Close the drain cock (2) of the sub air tank. 5 Adjust the vacuum pressure by turning the pressure control adjustment knob until you reach the desired pressure (range -0.032 MPa to -0.038 MPa). 6 Restart printing.
4 1 3
1 2
5-6
3 4
TROUBLESHOOTING
4 Check whether the UV lamp power settings (left and right) are set correctly (voltage/frequency check). If necessary, switch the plug connectors. WARNING: Keep in mind always to plug the connector to the voltage connection equal to or larger than the effective input voltage. Possible connections are: 208/220/250V, 50/60Hz. e.g. if the input voltage is 235V (Spain), connect to the 250V connection.
5-7
TROUBLESHOOTING
The system is provided with 4 emergency stops, two at the front side and two at the back side. WARNING: When the emergency button is activated all systems are cut off from the mains, except for the PC. 6 Check the first circuit breaker.
5-8
TROUBLESHOOTING
Lamp power Ring blower 1 Ring blower 2 Motor drive Control rack
NOTE: Make sure that the carriage servo motor connectors are plugged in and that the head carriage has a free path to its home position (head altitude high enough to pass over the conveyor belt without any obstruction). 9 Push and hold the Start button (white button) for 1 second until you hear the relays and the head carriage starts moving to its home position.
10 After starting up for the first time, the yellow tower lamp starts blinking (the head carriage moves slowly to the home position) and the print engine produces a beeping sound.
5-9
TROUBLESHOOTING
! When you fill an ink tank with the wrong ink proceed as follows:
!
1 Press one of the emergency stop buttons. 2 Drain the main ink tank. To get access to the drain cock (1) of the main ink tank, remove the panel underneath the ink tank indicator panel.
3 Rinse the main tank with cleaning solution using a squeeze bottle.
4 Fill the main ink tank. Refer to Filling the Ink Tanks of the Installation Manual. 5 Bleed the corresponding ink filter. Refer to Bleeding the Ink Filters on page 4-56 (chapter Preventive Maintenance)
5 - 10
TROUBLESHOOTING
1 Drain the main ink tank. To get access to the drain cock of the main ink tank, remove the panel underneath the ink tank indicator panel.
2 Replace the corresponding ink filter. Refer to Replacement of the Ink Filter on page 3-35 (chapter Repair and Service) 3 Fill the main ink tank with cleaning solution. 4 Clean the complete ink circuit and print with cleaning. 5 Refill the main ink tank with the correct color. Refer to Filling the Ink Tanks of the Installation Manual. 6 Load new ink and bleed the ink filter. Refer to Bleeding the Ink Filters on page 4-56 and Draining the First Ink from the Sub Ink Tanks on page 4-59(chapter Preventive Maintenance).
5 - 11
TROUBLESHOOTING
3 If the problem still persists, first press one of the emergency stop buttons and restart the system. 4 If problem still persists, proceed as follows: 4.1 Bleed the ink filter of the appropriate color(s). Refer to Bleeding the Ink Filters on page 4-56 (chapter Preventive Maintenance) 4.2 Check the ink pump of the appropriate color(s). 4.3 Check the float sensor connection of the sub ink tank of the appropriate color(s). The level of each sub ink tank is controlled by means of a float senor connected to the Head PCB (Refer to the diagram HEAD PCB on page 7-37).
5 - 12
TROUBLESHOOTING
Try to print, move, feed or test when media set sensors are triggered. Try to jog feed media. Try to save values in Setup Menu.
5 - 13
TROUBLESHOOTING
Encoder (MARK) Error, Black Strips, Waves on the Media Surface Only UNI MODE Output, Image Quality Failure, Spray on your Image, Print Length Exceeds Maximum Platen Length.
3.1.2. Action
1 Clean the linear scale (encoder strip) with acetone. Refer to Inspecting and Cleaning the Encoder Strip on page 4-24 (chapter Preventive Maintenance). 2 Adjust the distance between the encoder and the linear scale using the 0.5 mm gap gauge in order to maintain a regular gap. Refer to Adjusting the depth between encoder head an linear scale on page 4-32 (chapter Preventive Maintenance). 3 Check the flashing of the ENC LED and MARK LED at the MAIN PCB: Refer to Testing the number of pulses the encoder reader counts on page 4-30 (chapter Preventive Maintenance).
5 - 14
TROUBLESHOOTING
3.2.2. Action
1 Check whether there is an Encoder error See Encoder (MARK) Error on page 5-14. 2 Check whether there is a FPGA PCB error 2.1 Check the connection with the MAIN PCB (J10). 2.2 Check the Data LED flashing. For more information, refer to FPGA PCB on page 1-102 (chapter Functional Description). 3 Check whether there is a PCI CARD error 3.1 Check configuration (DI: 1, DO: 17.000). 3.2 Check the connection with the FPGA PCB (J8-Connection to PCI I/O card CN1 and J7Connection to PCI I/O card CN2). 3.3 Check whether the PCI I/O card is fixed correctly on the PC Main board slot. Direct connection between PC main board and the FPGA PCB via PCI I/O card. For more information, refer to FPGA PCB on page 1-102 (chapter Functional Description). 4 Execute a grounding check between MAIN, HEAD PCB + 24V, chassy G
5 - 15
TROUBLESHOOTING
3.3.2. Action
When printing with weak print media, increase the head base height (> 3mm). Refer to Automatic head base height setup on page 1-57 (chapter Functional Description).
3.5.2. Action
Execute one or more of the following checks: 1 Check the pressure distribution. Adjust all pressure values to the pressure values indicated on each sticker. For more information, refer to Negative Pressure Setting on page 1-27 (chapter Functional Description). 2 Check the head ejecting voltage. Check whether each print head voltage is set up to the regulated voltage values for that color. For more information, refer to Adjusting the Head Voltage on page 3-92 (chapter Repair and Service)
5 - 16
TROUBLESHOOTING
3 Check calibration (BI, STEP). 3.1 Bi-Dir Alignment control. Increase setting values, move to purge position. Decrease setting values, move to home position. 3.2 Step Size (Media Feed) control. If output overlap, increase value. If the opposite way, decrease value. For more information, refer to
! ! !
Bi-Dir Alignment on page 1-82 (chapter Functional Description). Step Size (Media Feed) on page 1-82 (chapter Functional Description). Software Alignment of the Print Head on page 3-95 (chapter Repair and Service).
4 Check carriage speed: Inferior output quality can be caused by overspeed. Adjust the carriage speed to an optimal quality speed. For more information, refer to Carriage Speed on page 1-83 (chapter Functional Description) 5 Check the head base height and the levelling of the engine. For more information, refer to:
! !
Head Gap Control on page 1-84 (chapter Functional Description). Engine Level on page 4-75 (chapter Preventive Maintenance).
UV lamp life span can be expired. Check UV lamp power and cooling time.
7 Check the sub ink tank temperature and the head base temperature. For more information, refer to:
! !
Sub ink tank (6C + White) on page 1-50 (chapter Functional Description). Head Base Temperature Control on page 1-63 (chapter Functional Description).
5 - 17
TROUBLESHOOTING
3.6.2. Action
When the head base plate temperature is too high (> 38C) during printing, do the following: 1 Stop printing at the end of the current print job. 2 Switch off the UV-lamps. 3 Run the Encoder Test for 5 minutes (refer to Encoder Count Test on page 1-89). As a result, the head carriage unit will now move continuously without printing, allowing the head base plate to cool down. For more information about the head base plate temperature, refer to Head Base Temperature Control on page 1-63 (chapter Functional Description).
3.7.2. Action
2 3 3
5 - 18
TROUBLESHOOTING
To solve this problem: 1 Increase the value for the Left Margin Offset (2) in order for the print to start at the leading edge of the media. Left Margin Offset shifts the origin (where the heads start to print) to the left when the value is increased. It is a permanently enabled Left Margin Offset. 2 Decrease the value for the Mark Center Offset (3) with a certain amount to reduce the extra travel (e.g. 5000 --> 0). 3 Increase the Bi-Dir Alignment value (1) with the exact same amount (-4960 -->+40). Mark Center Offset = the extra distance the head carriage unit travels in the fastscan direction after the last dots are printed. By increasing this value you can make sure that the head carriage unit and UV lamp completely surpass the substrate. E.g.: The Mark Center Offset value is default set to 5000. A value of 2500 pulses means that the head carriage unit travels 5 cm past the last cured area. A value of 5000 means that the head carriage unit surpasses the print 10 cm before returning for the next pass. You will notice that the Bi-Dir Alignment value is set to a value of -5000. This is no coincidence since the head carriage unit also needs a delay of 5000 units before it starts laying down dots on its return pass. When the Bi-Dir Alignment would be set to 0, it would indicate that the heads start firing immediately without delay on its return pass. This would result in the bidir being way off. If the head carriage unit moves 5000 marks after the last printed dot, the head carriage unit needs to be delayed 5000 marks when on its return pass. So if you decide to increase Mark Center Offset you will need to decrease the Bi-Dir Alignment value with the same amount. The exact value will not be -5000 but e.g.. -4960 because of difference in head carriage unit speed and head gap. So increasing the Mark Center Offset from 5000 to 15000 means decreasing the bidir from -4960 to -14960. The Bi-Dir Alignment can be found in the Setup Parameters window. The Left Margin Offset and the Mark Center Offset can be found in the Factory Data Setting window. For more information about accessing the Setup Parameters window and the Factory Data Setting window, refer to Anapurna Control Program on page 1-80 (chapter Functional Description).
5 - 19
TROUBLESHOOTING
UV LAMP TROUBLESHOOTING
4. UV Lamp Troubleshooting
Go through the troubleshooting flow diagram below to find out were the problem is situated and to solve the problem.
Main Power ON
no
no
Printing
Lamp ON?
no
yes
END
no
yes
Leakage Test
Servo / Control Circuit Breaker Check MCCB #5 Lamp Power Circuit Breaker Check MCCB #2
no yes
Repair Or Change
Lamp OK?
no
yes
Repair Or Change
no
no
no
Fuse Broken?
no
yes
Replace Fuse Check Power Cable Connection Lamp PLC Program Check OK?
Program Download
no
Printing Prepare
no
Printing Ready?
yes
5 - 20
TROUBLESHOOTING
Rotation ripples (speed Make gain adjustment in the Gain adjustment fault. fluctuations) are large following procedure: at low speed. 1. Increase the auto tuning response level. 2. Repeat acceleration and deceleration several times to complete auto tuning. Large load inertia moment causes the servo motor shaft to oscillate side to side. If the servo motor may be run Gain adjustment fault. with safety, repeat acceleration and deceleration several times to complete auto tuning. Confirm the cumulative com- Pulse counting error, etc. due to mand pulses and actual servo noise. motor position.
Cyclic operation
5 - 21
TROUBLESHOOTING
(Note 2) Alarm code Display CN1B-19 pin 0 0 0 0 1 0 0 1 1 1 1 0 1 1 0 1 0 0 0 0 0 0 1 1 1 0 0 0 CN1A-18 pin 1 0 0 0 1 0 0 1 1 0 1 0 0 0 0 01 0 0 1 1 1 1 0 0 0 0 0 0 CN1A-19 pin 0 0 0 0 0 0 0 0 0 0 0 1 1 0 1 1 0 0 1 1 1 1 1 1 1 0 0 0 Undervoltage Memory error 1 Clock error Memory error 2 Encoder error 1 Board error Memory error 3 Motor combination error Encoder error 2 Main circuit error Absolute position erase Regenerative error Overspeed Overcurrent Overvoltage Command pulse frequency error Parameter error Program error Main circuit device overheat Servo motor overheat Overload 1 Overload 2 Error excessive Home position return incomplete Home position setting error Serial communication time-out error Serial communication error Watchdog Open battery cable warning Program operation disable Software limit warning Battery warning Excessive regenerative warning Overload warning Absolute position counter warning Servo emergency stop warning Main circuit off warning Name
Alarm deactivation Power OFF"ON O O O O O O O O O O O O (NOTE 1) O O O O O O O O O (NOTE 1) O (NOTE 1) O O O O O O O O O (NOTE 1) O (NOTE 1) O O O O O O O O (NOTE 1) O (NOTE 1) O O O O O O O O (NOTE 1) O O O (NOTE 1) O O Press SET on current alarm reset (RES) signal alarm screen O O
AL. 10 AL. 12 AL. 13 AL. 15 AL. 16 AL. 17 AL. 19 AL. 1A AL. 20 AL. 24 AL. 25 AL. 30 AL. 31 Alarm Warning AL. 32 AL. 33 AL. 35 AL. 37 AL. 39 AL. 45 AL. 46 AL. 50 AL. 51 AL. 52 AL. 63 AL. 64 AL. 8A AL. 8E 88888 AL. 92 AL. 97 AL. 98 AL. 9F AL. E0 AL. E1 AL. E3 AL. E6 AL. E9
NOTE: 1. Deactivate the alarm about 30 minutes of cooling time after removing the cause of occurrence. NOTE: 2. 0: Pin-SG off (open) 1: Pin-SG on (short)
5 - 22
TROUBLESHOOTING
Display AL. 10
Name Undervoltage
Definition Power supply voltage dropped. MR-J2S-"CL: 160VAC or less MR-J2S-"CL1: 83 VAC or less
Cause 1. Power supply voltage is low. 2. There was an instantaneous control power failure of 60ms or longer. 3. Shortage of power supply capacity caused the power supply voltage to drop at start, etc. 4. Power was restored after the bus voltage had dropped o 200VDC. (Main circuit power switched on within 5s after it had switched off.)
5. Faulty parts in the servo amplifier. Change the servo amplifier. Checking method Alarm (AL. 10) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables. AL. 12 AL. 13 Memory error 1 Clock error RAM, memory fault Printed board fault Faulty parts in the servo amplifier Change the servo amplifier. Checking method Alarm (any of AL. 11 and 13) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables. 1. Faulty parts in the servo amplifier Change the servo amplifier. Checking method Alarm (AL. 15) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables. 2. The number of write times to EEP-ROM exceeded 100.000. AL. 16 Encoder error 1 Communication error 1. Encode connector (CN2) disconnected. occurred between 2. Encoder fault encoder and servo 3. Encoder cable faulty (wire breakage or amplifier. short) CPU/parts fault ROM memory fault Connect correctly. Change the servo motor. Repair or change the cable.
AL. 15
Memory error 2
EEP-ROM fault
AL. 17 AL. 19
Faulty parts in the servo amplifier Change the servo amplifier. Checking method Alarm (AL. 17 or A. 18) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables. Use correct combination.
AL. 1A
Wrong combination of Wrong combination of servo amplifier and servo amplifier and servo motor connected. servo motor. Communication error 1. Encoder connector (CN2) disconnected. occurred between 2. Encoder fault encoder and servo 3. Encoder cable faulty (wire breakage or amplifier. shortage) Ground fault occurred at the servo motor outputs (U, V and W phases) of the servo amplifier. 1. Power input wires and servo motor output wires are in contact at main circuit terminal block (TE1).
AL. 20
Connect correctly. change the servo motor. Repair or change the cable. Connect correctly.
AL. 24
2. Sheathes of servo motor power cables dete- Change the cable. riorated, resulting in ground fault. 3. Main circuit of servo amplifier failed Change the servo amplifier. Checking method AL. 24 occurs if the servo is switched on after disconnecting the U, V, W power cables from the servo amplifier.
5 - 23
TROUBLESHOOTING
Display AL. 25
Name
Definition
Cause
Action After leaving the alarm occurring for a few minutes, switch power off, then on again. Always make home position setting again. Change battery. Always make home position setting again. After leaving the alarm occurring for a few minutes, switch power off, then on again. Always make home position setting again. Set correctly. Connect correctly. 1. Reduce the frequency of positioning. 2. Use the regenerative brake option of larger capacity 3. Reduce the load.
Absolute position erase Absolute position data 1. Reduced voltage of super capacitor in in error. encoder.
2. Battery voltage low. 3. Battery cable or battery is faulty. Power was switched 4. Super capacitor of the absolute position on for the first time in encoder is not charged. the absolute position detection system. AL. 30 Regenerative alarm Permissible regenerative power of built-in regenerative brake resistor or regenerative brake option is exceeded. 1. Wrong setting of parameter No. 0 2. Built-in regenerative brake resistor or regenerative brake option is not connected. 3. High-duty operation or continuous regenerative operation caused the permissible regenerative power of the regenerative brake option to be exceeded. Checking method Call the status display and check the regenerative load ratio. 4. Power supply voltage is abnormal. MR-J2S-"CL: 260VAC or more. MR-J2S-"CL1: 135VAC or more. 5. Built-in regenerative brake resistor or regenerative brake option faulty.
Regenerative transis- 6. Regenerative transistor faulty. Change the servo amplifier. tor fault Checking method 1) The regenerative brake option has overheated abnormally. 2) The alarm occurs even after removal of the built-in regenerative brake resistor or regenerative brake option. AL. 31 Overspeed Speed has exceeded 1. Input command pulse frequency exceeded Set command pulses correctly. the instantaneous per- the permissible instantaneous speed fremissible speed. quency. 2. Small acceleration/deceleration time con- Increase acceleration/deceleration stant caused overshoot to be large. time constant. 3. Servo system is instable to cause overshoot. 1. Re-set servo gain to proper value. 2. If servo gain cannot be set to proper value: 1) Reduce load inertia moment ratio, or 2) Reexamine acceleration/ deceleration constant. Set correctly. Change the servo motor.
5 - 24
TROUBLESHOOTING
Display AL. 32
Name Overcurrent
Definition Current that flew is higher than the permissible current of the servo amplifier.
2. Transistor (IPM) of the servo amplifier Change the servo amplifier. faulty. Checking method Alarm (AL. 32) occurs if power is switched on after U, V and W are disconnected. 3. Ground fault occurred in servo amplifier output phases U, V and W. 4. External noise caused the overcurrent detection circuit to misoperate. Correct the wiring. Take noise suppression measures.
AL. 33
Overvoltage
Converter bus voltage 1. Lead of built-in regenerative brake resistor 1. Change lead. exceeded 400VDC. or regenerative brake option is open or dis2. Connect correctly. connected. 2. Regenerative transistor faulty. 3. Wire breakage of built-in regenerative brake resistor or regenerative brake option. Change servo amplifier. 1. For wire breakage of built-in regenerative brake resistor, change servo amplifier. 2. For wire breakage of regenerative brake option, change regenerative brake option.
4. Capacity of built-in regenerative brake Add regenerative brake option or resistor or regenerative brake option is insuffi- increase capacity. cient. 5. Power supply voltage high. AL. 35 Command pulse frequency error Review the power supply. Input pulse frequency 1. Pulse frequency of the manual pulse gener- Change the pulse frequency to a of the command pulse ator is too high. proper value. is too high. 2. Noise entered the pulses of the manual Take action against noise. pulse generator. 3. Manual pulse generator failure. AL. 37 Parameter error Parameter setting is wrong. Change the manual pulse generator. 1. Servo amplifier fault caused the parameter Change the servo amplifier setting to be rewritten. 2. Regenerative brake option not used with Set parameter No. 0 correctly. servo amplifier was selected in parameter No. 0. 3. Value outside setting range has been set in Set the parameter correctly. some parameter. 4. Value outside setting range has been set in Set parameters No. 4, 5 correctly. electronic gear. 5. Opposite sign has been set in software Set parameters No. 46 to 49 corlimit increasing side (parameters No. 46, 47). rectly. Similarly, opposite sign has been set in software limit decreasing side (parameters No. 48, 49) 6. Opposite sign has been set in position Set parameters No. 50 to 53 corrange output address increasing side (parame- rectly. ters No. 50, 51). Similarly, opposite sign has been set in position range output address decreasing side (parameters No. 52, 53) 7. The number of write times to EEP-ROM exceeded 100,000 due to parameter write, program write, etc. Change the servo amplifier.
5 - 25
TROUBLESHOOTING
Display AL. 39
Definition
Cause
Action Change the servo amplifier. Programming correctly. Change the servo amplifier.
Program data is abnor- 1. Servo amplifier fault caused the program mal data to be rewritten. 2. Command argument is out of the setting range. 3. The number of write times to EEP-ROM exceeded 100,000 due to parameter write, program write, etc.
AL. 45
1. Servo amplifier faulty. 2. The power supply was turned on and off continuously by overloaded status. 3. Air cooling fan of servo amplifier stops.
Change the servo amplifier. The drive method is reviewed. 1. Exchange the cooling fan or the servo amplifier. 2. Reduce ambient temperature.
AL. 46
Servo motor tempera- 1. Ambient temperature of servo motor is over Review environment so that ambient temperature is 0 to 40C. ture rise actuated the 40C. thermal protector. 2. Servo motor is overloaded. 1. Reduce load. 2. Review operation pattern. 3. Use servo motor that provides larger output. 3. Thermal protector in encoder is faulty. Change servo motor. Load exceeded overload protection characteristic of servo amplifier. 1. Servo amplifier is used in excess of its con- 1. Reduce load. tinuous output current. 2. Review operation pattern. 3. Use servo motor that provides larger output. 2. Servo system is instable and hunting. 1. Repeat acceleration/deceleration to execute auto tuning. 2. Change auto tuning response settings 3. Set auto tuning to OFF and make gain adjustment manually. 1. Review operation pattern. 2. Install limit switch.
AL. 50
Overload 1
4. Wrong connection of servo motor. Servo Connect correctly. amplifiers output terminals U, V, W do not match servo motors input terminals U, V, W. 5. Encoder faulty. Change the servo motor. Checking method When the servo motor shaft is rotated with the servo off, the cumulative feedback pulses do not vary in proportion to the rotary angle of the shaft but the indication skips or returns midway.
5 - 26
TROUBLESHOOTING
Display AL. 51
Name Overload 2
Definition Machine collision or the like caused max. output current to flow successively for several seconds. Servo motor locked: 1s or more During rotation: 2.5s or more
2. Wrong connection of servo motor. Servo Connect correctly. amplifiers output terminals U, V, W do not match servo motors input terminals U, V, W. 3. Servo system is instable and hunting. 1. Repeat acceleration/deceleration to execute auto tuning. 2. Change auto tuning response setting. 3. Set auto tuning to OFF and make gain adjustment manually.
4. Encoder faulty. Change the servo motor. Checking method When the servo motor shaft is rotated with the servo off, the cumulative feedback pulses do not vary in proportion to the rotary angle of the shaft but the indication skips or returns midway. AL. 52 Error excessive The droop pulse value of the deviation counter exceeded 2.5 rotations. 1. Acceleration/deceleration time constant is Increase the acceleration/deceleratoo small. tion time constant. 2. Internal torque limit 1 (parameter No. 28) is Increase the torque limit value. too small. 3. Motor cannot be started due to torque shortage caused by power supply voltage drop. 1. Review the power supply capacity. 2. Use servo motor which provides larger output.
4. Position control gain 1 (parameter No. 7) is Increase set value and adjust to small. ensure proper operation. 5. Servo motor shaft was rotated by external force. 1. When torque is limited, increase the limit value. 2. Reduce load. 3. Use servo motor that provides larger output. 1. Review operation pattern. 2. Install limit switches. Change the servo motor.
8. Wrong connection of servo motor. Servo Connect correctly. amplifiers output terminals U, V, W do not match servo motors input terminals U, V, W. AL. 63 Home position return incomplete In incremental system: 1. Positioning operation was performed without home position return. 2. Home position return ended abnormally. In absolute position detection system: 1. Positioning operation was performed without home position setting. 2. Home position setting ended abnormally. 1. Positioning operation was performed without home position return. 2. Home position return speed could not be decreased to creep speed. 3. Limit switch was actuated during home position return starting at other than position beyond dog. 1. Perform home position return. 2. Review home position return speed/creep speed/moving distance after proximity dog.
1. Positioning operation was performed without home position setting. 2. Home position setting speed could not be decreased to creep speed. 3. Limit switch was actuated during home position setting starting at other than position beyond dog.
1. Perform home position setting. 2. Review home position setting speed/creep speed/moving distance after proximity dog.
5 - 27
TROUBLESHOOTING
Display AL. 64
Name
Definition
Cause 1. Droop pulses remaining are greater than the in-position range setting. 2. Command pulse entered after clearing of droop pulses. 3. Creep speed high. 1. Communication cable breakage.
Action Remove the cause of droop pulse occurrence. Do not enter command pulse after clearing of droop pulses. Reduce creep speed. Repair or change communication cable.
Home position setting Home position seterror ting could not be made.
AL. 8A
RS-232C or RS-422 communication stopped for longer than the time set in parameter No. 23. Serial communication error occurred between servo amplifier and communication device (e.g. personal computer) CPU, parts faulty
2. Communication cycle longer than parame- Set correct value in parameter. ter No. 23 setting. 3. Wrong protocol. Correct protocol. 1. Communication cable fault (open cable or Repair or change the cable short circuit) 2. Communication device (e.g. personal com- Change the communication device puter) faulty. (e.g. personal computer).
AL. 8E
88888
Watchdog
Fault of parts in servo amplifier Change the servo amplifier. Checking method Alarm (88888) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables. Repair cable or changed. Change battery. Power off/on the servo amplifier.
AL. 92
Absolute position 1. Battery cable is open. detection system bat- 2. Battery voltage dropped to 2.8V or less. tery voltage is low. After a program change, the program was started without the servo amplifier being powered off/on.
AL. 97
Program operation dis- Program was started able in a program operation disable status.
AL. 98
Software limit warning Software limit set in 1. Software limit was set within actual opera- Set parameter No. 48 to 51 correctly. parameter is reached. tion range. 2. Program of position data in excess of soft- Set program correctly. ware limit was executed. 3. Software limit was reached during JOG operation or manual pulse generator operation. Perform operation within software limit range. Change the battery.
AL. 9F
Battery warning
Voltage of battery for Battery voltage fell to 3.2V or less. absolute position detection system reduced. Regenerative power increased to 85% or more of permissible regenerative power of built-in regenerative brake resistor or regenerative brake option. Checking method Call the status display and check regenerative load ratio.
AL. EO
Excessive regenerative There is a possibility warning that regenerative power may exceed permissible regenerative power of built-in regenerative brake resistor or regenerative brake option. Overload warning
1. Reduce frequency of positioning. 2. Change regenerative brake option for the one with larger capacity. 3. Reduce load.
AL. E1
There is a possibility Load increased to 85% or more of overload that overload alarm 1 alarm 1 or 2 occurrence level. or 2 may occur. Cause, checking method Refer to AL. 50, 51.
5 - 28
TROUBLESHOOTING
Definition
Cause
Action Take noise suppression measures. Change the servo motor. Ensure safety and deactivate forced stop. Switch on main circuit power.
Absolute position 1. Noise entered the encoder. encoder pulses faulty. 2. Encoder faulty External forced stop was made valid. (EMG-SG opened)
Servo forced stop warn- EMG-SG are open. ing Main circuit off warning Servo was switched on with main circuit power off.
5 - 29
TROUBLESHOOTING
5 - 30
CHAPTER
Glossary
This chapter describes definitions and abbreviations used throughout the Service Manual which you may not be familiar with.
6-1
GLOSSARY
GLOSSARY
Compressed Air An external air compressor delivers compressed air which is required for operating pneumatical parts and other specific functions of teh Anapurna.
Interlock Interlock switches are a safety feature for protecting the operator against hazards. It is forbidden to bypass these safety interlocks.
MSDS Material Safety Data Sheet. For the chemical products or consumables being used, the supplier should provide MSDSs. E.g. for ink, these data sheets will mention the hazards, handling and storage conditions.
Nozzle This is a microscopic opening from which an individual ink drop is jetted.in order to check if all nozzles are OK, you can print a special test job called Nozzle Test.
Ozone Triatomic oxygen or ozone (O3) is formed by oxygen being exposed to a high voltage and to wave lengths lower than 210 nm of UV energy. Ozone creates a barrier that absorbs the UV energy, resulting in a degradation of the UV curing.
Purging The maintenance and cleaning procedure includes purging of the ink. During this cleaning cycle, a small amount of ink is purged through one or more inkjet heads, if necessary e.g. to solve a problem of failing nozzles.
UV Curing Ultraviolet curing is a photochemical process in which UV energy is produced by a discharge lamp and focused at monomers in the ink, causing polymerization. Th ink contains phot-initiators to start the curing process.
6-2
CHAPTER
Annex
This chapter gives an overview of the diagrams and printed circuit boards of the Anapurna L/XL. Finally, you can find a spare parts list. 1. Pneumatic Diagrams ............................................................................................................................................. 7 - 3 1.1. Pneumatic Diagram ................................................................................................................................. 7 - 5 2. Electrical Diagrams ................................................................................................................................................ 7 - 7 2.1. Main Power Distribution in the Electrical Circuit Panel ............................................................ 7 - 9 2.2. Power Supply Distribution - 3 Phase with neutral with ground star 380V (EU) ............ 7 - 11 2.3. Power Supply Distribution - 3 Phase no neutral with ground delta 208-240V (US) .... 7 - 13 2.4. UV Lamp Power Box Connections ................................................................................................... 7 - 15 2.5. UV Lamp Power Circuit ....................................................................................................................... 7 - 17 2.6. UV Lamp Head Part ............................................................................................................................... 7 - 19 2.7. UV Lamp Power Cables ....................................................................................................................... 7 - 21 3. Programmable Logic Controller (PLC) Block Diagram .......................................................................... 7 - 23 3.1. Main PLC ................................................................................................................................................... 7 - 25 3.2. UV Lamp PLC ........................................................................................................................................... 7 - 27 4. Printed Circuit Boards ........................................................................................................................................ 7 - 29 4.1. Total PCB Diagram Layout ................................................................................................................. 7 - 31 4.2. MAIN PCB ................................................................................................................................................. 7 - 33 4.3. FPGA PCB ................................................................................................................................................. 7 - 35 4.4. HEAD PCB ................................................................................................................................................. 7 - 37 4.5. REFILL PCB ............................................................................................................................................... 7 - 39 4.6. CARTRIDGE PCB ..................................................................................................................................... 7 - 41 4.7. HEAD LIFT PCB ........................................................................................................................................ 7 - 43 4.8. ITV CONTROLLER PCB .......................................................................................................................... 7 - 45 4.9. SUB PCB .................................................................................................................................................... 7 - 47 4.10. IF PCB ...................................................................................................................................................... 7 - 49 4.11. I/O PCB .................................................................................................................................................. 7 - 51 4.12. TAKE UP PCB ........................................................................................................................................ 7 - 53 4.13. REFILL CONTROL PCB ........................................................................................................................ 7 - 55 4.14. INDICATOR PCB ................................................................................................................................... 7 - 57 4.15. DRIVER COMMUNICATION PCB .................................................................................................... 7 - 59
5.
7-1
ANNEX
ANNEX
7-2
PNEUMATIC DIAGRAMS
1. Pneumatic Diagrams
Overview pneumatic diagrams:
!
Pneumatic Diagram
7-3
PNEUMATIC DIAGRAMS
Air Tank
R P A
Setting Press 0.6 MPa Waste Tank Over-flow Sig. 0.3 - 0.7 MPa Purge Sig.
Air Filter # 1
A B
4f Air Tube
EA P EB
I/O PC B Sig. I/O PC B Sig.
EA P EB
EA P EB
IN
EA P EB
Carriage Part
Air Filter # 2
A R P
E/P Regulator
SU P OU T
P R
Check valve
Check valve
SOLUTION SUB-TANK
SOLUTION BAR
VACUUM EJECTOR
R P
7-5
ELECTRICAL DIAGRAMS
2. Electrical Diagrams
Overview electrical diagrams:
! ! ! ! ! ! !
Main Power Distribution in the Electrical Circuit Panel Power Supply Distribution - 3 Phase with neutral with ground star 380V (EU) Power Supply Distribution - 3 Phase no neutral with ground delta 208-240V (US) UV Lamp Power Box Connections UV Lamp Power Circuit UV Lamp Head Part UV Lamp Power Cables
7-7
ELECTRICAL DIAGRAMS
24V GND
24V GND
P1 P2 P3 N
24V GND
T-N T-N
L1 N
L1 L2 L3
L1 L2 L3
T-L3T-N
T-L3 T-N
L1
L2
L1
L2
L3
L3
T-L3
T-L3
L1
T-N
44
T-N
3-2
L1 L2 L3
L1
L2
L3
TERMINAL 600V-55A
L41 L42
L51 L52
95 96 95 96
T-N
T-L3 L11 N
AWG #8 (7.5 Sq) Black TERMINAL 600V-80A AWG #10 (5.5 SQ) Black
GND
24V
15 15 15
1.
: SHORT BAR
GREEN
GREEN
GREEN
GREEN
GREEN
GREEN
GREEN
GREEN
2. 2 STAGE TERMINAL
T-N
1-1
2-1
1-2 1-3
2-2 2-3
Green
Green
Green
P1 P2 P3 N
PE
TERMINAL 600V-55A
PE
P22
EMERGENCY SWITCH
1-4
2-4
6-3 1-4
4. Ground- Green/Yellow 8AWG 5. DC line Teflon AWG #20(0.5 sqar) Blue Wire USED AWG #8
6.
AWG #12(3.5 SQUARE) 3C
UV LAMP POWER
RING BLOWER
RING BLOWER
MOTOR DRIVE_C
MOTOR DRIVE_F
CONTROL RACK
7-9
ELECTRICAL DIAGRAMS
2.2. Power Supply Distribution - 3 Phase with neutral with ground star 380V (EU)
AWG#8 VCTF CABLE (BLACK)
= = = = =
5.5 SQUARE 3.5 SQUARE 2.0 SQUARE 1.25 SQUARE 1.0 SQUARE
P22 N
x xx xx x x - --- - | | | | |---- ( Cable No ) | | | | | | | |------- Level ( + / - ) | | | | | |--------- VOLTAGE(24V/5V) | | | |-------------- POWER SOURCE(AC/DC) | |----------------- SMPS No.
1 2 1 2
L52 L51 PE
HEAD 1DC120+(5-6),WHITE
SMPS #1
1DC120-(5-6),BROWN
AWG#16 VCTF CABLE 6C
2DC120+(5-6),YELLOW
SMPS #2
2DC120-(5-6),GREEN
UVH-01
3DC24+(5-6),RED
LOGIC
CH1
1 2 1 2 1 2
P2 2 N
RESTART
1 2
SMPS #3 CH2
UVR-01
EMO 1
MC-A
EMO 2
EMO 3
EMO 4
MAIN/FPGA PCB
MC # 1( 50A )
UVM-01 / UVF-01
I/F PCB
L3 L2 L1
AWG#10 VCTF CABLE (BLACK)
V1
SMPS #4
RING BLOW_ RIGHT
UVI-01
PE N
L1 L2 L3
U1 W1 PG
Thermal Overload Relay #2
4 5 6
M
2
PLC
MCCB #3(AC380V,20A)
L3 L2 L1
AWG#10 VCTF CABLE (BLACK)
SMPS #5
5DC24+(5-1),WHITE 5DC24-(5-1),BLACK
AWG#16 VCTF CABLE 2C
ITV PCB
UVA-01
V2 U2 W2
M
2
DC24V+
DC24V-
MCCB #4(AC380V,20A)
SUB PCB
UVS-01
PE L1 N L12 L11
2 1 1
SMPS #6
DC5V+ DC5V-
UV LAMP(L)
MCCB
M
PE
SERVO DRIVE #1
2
#2(AC220V,50A)
UVL-01
PE T-L3 T-N
AWG#10 VCTF CABLE (BLACK)
K7M-DR60S
PLC MASTER- K 80S PID CONTROLLER #1
N PE PE
N O I S E F I LT E R (50A)
L41
L3
L42
M
MCCB #5(AC220V, 30A) SERVO DRIVE #2
2
PE L52 L51 PE
T-L3 T-N
AWG#10 VCTF CABLE (BLACK)
L52 L51
MCCB #6(AC220V,30A)
7 - 11
ELECTRICAL DIAGRAMS
2.3. Power Supply Distribution - 3 Phase no neutral with ground delta 208-240V (US)
Electronic System Circuit Diagram
AWG#8 VCTF CABLE (BLACK)
= = = = =
5.5 SQUARE 3.5 SQUARE 2.0 SQUARE 1.25 SQUARE 1.0 SQUARE
P22 P11
PC-SMPS 300W
xx x x x xx - --- - | | |---- ( Cable No ) | | | | | | | | | |------- Level ( + / - ) | | | |--------- VOLTAGE(24V/5V) | | | | | |-------------- POWER SOURCE(AC/DC) | |----------------- SMPS No.
1 2 1 2
L52 L51 PE
HEAD 1DC120+(5-6),WHITE
SMPS #1
1DC120-(5-6),BROWN
AWG#16 VCTF CABLE 6C
2DC120+(5-6),YELLOW
SMPS #2
2DC120-(5-6),GREEN
UVH-01
3DC24+(5-6),RED
LOGIC
CH1
AWG#12 VCTF CABLE (BLACK)
1 2 1 2 1 2
HEAD PCB
P11 P23
MC #1(50A)
1 2 3
RESTART
1 2
SMPS #3 CH2
REFILL PCB
UVR-01
EMO 1
EMO 2
EMO 3
EMO 4
MC-A
MAIN/FPGA PCB
UVM-01 / UVF-01
DC 24V
AWG#16 VCTF CABLE 2C
L3 L2 L1
AWG#10 VCTF CABLE (BLACK)
V1 U1 W1 PG
Thermal Overload Relay #2
PE
SMPS #4
RING BLOW_ RIGHT
I/F PCB
UVI-01
L1 L2 L3
M
2
PLC
MCCB #3(AC380V,20A)
L3 L2 L1
AWG#10 VCTF CABLE (BLACK)
SMPS #5
RING BLOW_ LEFT
5DC24+(5-1),WHITE 5DC24-(5-1),BLACK
AWG#16 VCTF CABLE 2C
ITV PCB
UVA-01
V2 U2 W2 PE
1 1
M
2
DC24V+
DC24V-
UVS-01
SUB PCB
MCCB #4(AC380V,20A)
L2
AWG#10 VCTF CABLE (BLACK)
L11
2
UV LAMP(L)
UV LAMP(R)
L1
L12
SMPS #6
DC5V+ DC5V-
6DC5-(1-15),GREEN
AWG#16 VCTF CABLE 4C
6DC24+(5-7),WHITE 6DC24-(5-7),BLACK
M
2
MCCB
PE PE K7M-DR60S
PLC MASTER- K 80S PID CONTROLLER #1 FEED AC-SERVO MOTOR 400W
1
6DC5+(5-7),RED 6DC5-(5-7),GREEN
AWG#16 VCTF CABLE 4C
UVL-01
L3 L1 PE PE
N O I S E F I LT E R (50A)
T-L3 T-L1
AWG#10 VCTF CABLE (BLACK)
L42 L41
M
SERVO DRIVE #2
2
PE L52 L51 PE
T-L3 T-L1
AWG#10 VCTF CABLE (BLACK)
L52 L51
MCCB #6(AC220V,30A)
7 - 13
ELECTRICAL DIAGRAMS
N
28
PE
31 30 25 24
41 47
23
1 7
21 20
F2 DC 24V 3A
29
COM0
22
MC(L)LOW
MC(R)LOW
28
L11 L12 PE
COM1
+ -
K1
41 41
K1
1 1
P01 P03 P05 P07 P09 P0B P0C P0E P10 P12 P14 P16 24G 24V
UV LAMP PLC
7 1
47
41
AC100~240V
P44 P46
COM3
P48 P4A
COM4
50Hz
60Hz
208V
220V
250V
50Hz
60Hz
208V
220V
FG
P43
P45 P47
P49 P4B
P4D P4F
57
1 2 3 4 5 6 7 8
29
29
T/R(L)
S/W HI LOW S-2
46
T/R(R)
9 10 11 12 13 14 15
28
52 53
55 56 54 60 60 51 50 61 61
55
27
26 50
S-1
45
60Hz
50Hz
S/W
HI
LOW
S-2
6
S-1
5
60Hz
50Hz
51
70
53
71 28
LOW
46 6
N
left AC fan right AC fan
left shutter (open) right shutter (open)
L MC2 HI LK2
R MC2 HI RK2
MC(L)HI
MC(R)HI
85
(SIGNAL_7P)
84
L11
A B D E H F K J C G
86
56
A B D C
B D H E
A C F K J G
57 A B D C
81
82
83
30
28 31
28
29
(POWER_4P)
52 70
87
84
85
80
71
86
54
87
(POWER_4P) (SIGNAL_7P)
80
80
81
81
82
82
83
83
fan
L1
K1
L2
K2
L3
K1
L4
K2
L5
7 - 15
ELECTRICAL DIAGRAMS
= = = = =
5.5 SQUARE 3.5 SQUARE 2.0 SQUARE 1.25 SQUARE 1.0 SQUARE
AC CABLE ( ALL BLACK, PE : GREEN), AWG #12 CONTROL CABLE (WHITE : + , BLACK : - ), AWG #14
L2 N L1 L1 MCCB
L12 L11
F1 (250VAC-3A) SMPS #9
4P CON (R) D
L12
(7)
1 2 3
4 5 6 (1) 4 3
AC 250V
50Hz
(7)
RT1 A D
1 B C 2
110 t
60Hz S-1
#2(AC220V,50A)
+24VDC GND
F2 (25VDC-3A)
NTC #2
(1)
1 2
AC 220V
(1)
(5)
B 4P CON
MC(R)-LOW
LP
(6)
S-2
1 (6) 2 4 3 (6)
L11 L12
PLC OUTPUT COM
LOW HI S/W
AC FAN(R)
Ignitor(R)
MC(R)-HIGH UV LAMP(R)
# UV LAMP HEAD ASSY(RIGHT)
PE
INPUT COM
KDM-DR40S
GND T/R(L)
4P CON (L) A A D RT1
L12 L11 PE
L12
COOLRING (AC FAN)
1 (47) 2 3 1 (41) 2
4 5 6 4 3
CAP.(L) #1 CAP.(L) #2
(41)
AC 250V
50Hz
(47)
CAP.(L) #3 CHOKE(L)-LOW
(41)
60Hz S-1
1 B C 2
110 t
AC 220V
(41)
(45)
NTC #1
B C 4P CON
L11
MC(L)-LOW
AC 208V 60Hz
(47)
(46)
S-2
LP B N 1 2 (46) 4 3 (46)
LOW HI S/W
AC FAN(L)
Ignitor(L)
50Hz
MC(L)-HIGH
UV LAMP(L)
# UV LAMP HEAD ASSY(LEFT)
7 - 17
ELECTRICAL DIAGRAMS
UV Lamp box
1 2 3 4 5 7 6
(SIGNAL_7P)
(SOLVALVE SIGNAL_2P)
(POWER_4P)
B C
B C
AC FAN
DC FAN
AC FAN
DC FAN
LP N
LP N
IGNITER
IGNITER
UV LAMP
UV LAMP
LEFT
RIGHT
7 - 19
ELECTRICAL DIAGRAMS
A B D H E F K J C G
2 3 4
1 7 6 5
7P SCN6A16-7S CONNECTOR(FEMALE)
size 1M(AWG14)
right
SHUTTER OPEN(R)
N.C(L) N.C(L)
OVER HEAT(P0C)(L) DC 24V FAN(L) DC GND(L)
N.C N.C
OVER HEAT(P0D)(R) DC 24V FAN(R) DC GND(R)
N.C N.C
INTERLOCK(K1)(L) INTERLOCK(P44)(L)
N.C N.C
INTERLOCK(K1)(R) INTERLOCK(P44)(R)
0.5M(AWG14) 0.5M(AWG14)
UV Lamp Assy
< <
<----> <----> <----> <----> <----> <----> <----> <----> <----> <---->
7P CONNECTOR 1 7P CONNECTOR 2 7P CONNECTOR 3 7P CONNECTOR 4 7P CONNECTOR 5 7P CONNECTOR 6 7P CONNECTOR 7 7P CONNECTOR N.C 10P CONNECTOR K 10P CONNECTOR J
7 - 21
7 - 23
SUB J4
3951-6P
5045-2P
P02 P01
P04
P06
P08
P0A
P0C
P0E
P10
CM0
P13
P15
P17
P19
P1B
P1D
P1F
P21
P23
CM1 24+
P03
P05
P07
P09
P0B
P0D
P0F
P11
P12
P14
P16
P18
P1A
P1C
P1E
P20
P22
24G
2 + 4
3 1
2 + 4 1 24V SMPS #4 2 3 4 +
LEFT LAMP
GND
AC220V FG
P40 CM0
P41
P42 P43
P44 CM3
P46 P47
P48 CM4
P4A
P4C
P4E
P50
P52 P53
P54 CM7
P56 P57
CM1 CM2
P45
P49
P4F CM6
P51
P55
GND
E44 EPDB
E34 1 2 3 4 + 1 2 3 4 +
R/REAR S/W
R/FRONT S/W
2 3 4 TOWER
2 3 4 LAMP
RF
RR
MS2
GND
7 - 25
7 - 27
Total PCB Diagram Layout MAIN PCB FPGA PCB HEAD PCB REFILL PCB CARTRIDGE PCB HEAD LIFT PCB ITV CONTROLLER PCB SUB PCB IF PCB I/O PCB TAKE UP PCB REFILL CONTROL PCB INDICATOR PCB DRIVER COMMUNICATION PCB
7 - 29
J1
1
J2
LED1 LED2
MEDIA SENSOR1
MEDIA SENSOR1
PLUS : #2~4 Cylinder Sensor DELUXE : #2~4 Cylinder Sensor #5 Limit Switch
5
J3
J1
J4
J2
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
J1~J4 1. HVPULSE 2. N.C 3. N.C 4. GND 5. CLK 6. DATAOUT 7. DATAIN 8. +12V 9. GND
5045-5P J3
1
LED3
LED4
MEDIA SENSOR1
FEED LIMIT
J5
11
3 11 12
J5
12 10 8 6 4 2 12 10 8 6 4 2
2 D4 1 12 11
11 9 7 5 3 1
5267-8P
3 LED5 LED6
<CARTRIDGE HEAD(J1~J8)>
9 7 5 3
J4
1
1 2
P1
TP2
5267-5P
UV LAMP ON 5045-4P
5K
JET REV5
J5 1. GND_SIGNAL 2. GND_SIGNAL 3. HV_ERR 4. HV_CK 5. SHIFT_CK_HI 6. DATA_CD_HI 7. DATA_AD_HI 8. N.C 9. +12V 10. +12V 11. GND_POWER 12. GND_POWER 13. N.C 14. N.C 15. HVIN 16. HVIN
?
D2 GREEN D3 GREEN D4 RED D5 GREEN
CW_LED
CCW_LED
AUTO_LED
ERROR_LED
J4-1,3,5,7 & J1-1,4 : Height Adjustment Solenoide J1-1,3 : Up Limit Switch UP-Limit Switch
5V
5
SW1
2
SW2
2
SW3
2
SW4
2
WT
LM
LC
CW_SW
5V
CCW_SW
5V
AUTO_SW
5V
ERROR_SW
<GORE I-TV/PSE>
J11
15
SMPS #1 120V J13 1. HV2 2. GND 3. HV1 4. GND 5. 5V 6. GND 7. 24V 8. GND
<GORE POWER2>
1. +24V 2. N.C 3. SOL_A 4. N.C 5. +24V 6. N.C 7. SOL_B
J4
1 7
SMPS #1 GND SMPS #3 24V SMPS #3 GND BASE B' SUB B' BASE B SUB B N.C SUB A BASE A
J10 J17 5267-3P J30 5267-4P J23 3951-7P
24V 0V
ON
OFF
HV2 HEAT#2
ZERO
HV2 HEAT#3
HV2 HEAT#4
HV2 HEAT#5
HV2 HEAT#6
HV2 HEAT#7
HV2 HEAT#8
GND RX TX N.C
J1 GIL-G-4P
FEEDBACK
3951-2P HEATER2
20K STL950
3951-2P HEATER3
3951-2P HEATER4
3951-2P HEATER5
3951-2P HEATER6
3951-2P HEATER7
3951-2P HEATER8
GND
5267-2P
SUB A
5045-6P
J13
INK_OVF(5V)
J95
<GORE POWER1>
HEAT#1 HV2
3951-2P
J39
BZ1
12V
5267-3P
ITV
MAIN ERROR +24V N.C GND OVERFLOW ERROR +24V
1 2
GND 5V 5V
GND
SOL(1),SOL(2)
GND
PURGE SWITCH
J2 J3
11
+24V
PSE531
J28
E_TANK_SOL +5V
5267-2P 5267-3P
J34
<CARTRIDGE HEAD(J1~J8)>
12 10 8 6 4 2
20
12
11
11 9 7 5 3 1
12 10 8 6 4 2
12
11
12 11 10 9 7 8 5 6 3 4 1 2
12
12 11 10 9 7 8 5 6 3 4 1 2
12
11
12 11 10 9 7 8 5 6 3 4 1 2
12
11
12 11 10 9 7 8 5 6 3 4 1 2
12
11
12 11 10 9 7 8 5 6 3 4 1 2
12
11
12 11 10 9 7 8 5 6 3 4 1 2
12
11
12 11 10 9 7 8 5 6 3 4 1 2
12
11
11 9 7 5 3 1
HV-CK
J29
+5V GND
3951-5P
GND SOL(2)
E_TANK_WHITE
MEDIA
VT301V
+5V
5267-2P J23
J9
SHIFT-CK
E_TANK_LM
1
GND
J15
+5V N.C
5267-2P J6
1 D1
1
D2
J8
U12
3951-6P
B~ GND B A~ GND A
LED3 24V 5045-7P
E_TANK_LC
HT_ERR
INK_OVF
HV_ERR
CON10
10 9 GND
J21
E_TANK_Y +5V
5267-2P
F070494_SS
5267-2P
5267-2P
5267-2P
5267-2P
5267-2P
5267-2P
5267-2P
5267-2P
5267-2P
3951-3P J14
RED
5566-2P
MOTOR MOTOR +
J29
J10
INK1-K
INK2-C
INK3-M
INK4-Y
INK5-LC
INK6-LM
INK7
INK8-S
J2
E_TANK_M +5V
5267-2P
+
J49 5267-2P
GND TERMISTOR
+5V SUC_LEVEL
J48
AC-IN
J10 1. INK6 2. 5V 3. GND 4. GND 5. RESET 6. GND 7. INK8 8. GND 9. INK7 10. GND
GND INK1
GND INK2
GND INK3
GND INK4
GND INK5
GND INK6
GND INK7
GND INK8
GND GND
J22
E_TANK_C +5V
5267-2P J4
E_TANK_K +5V
5267-2P
SUB_HEATER
PLC P0B
LAMP +24V
J13
5045-2P
3951-6P
J4
J33
5267-4P
J11
J16
5219-3P
GND
J43 J13
M_R_CCW M_R_CW
TAKE_R_SEN +24V
J31
1. PLATEN OVER LOAD 2. PLATEN LOCK 3. N.C 4. N.C 5. PLATEN LIFT MANUAL S/W DOWN 6. PLATEN LIFT MANUAL S/W UP 7. PRESET 8. N.C 9. N.C 10. AIR LOW 11. PLATEN OVER LOAD 12. SHUTTER RIGHT 13. SHUTTER LEFT 14. UV LAMP ON
29
19
HRS-30P
GND
GND
ENC
MARK
TEST
RUN
FEED
RESET
STOP
10
PID#2-1
SUB_B SUB_B'
J8
10
SUB_A
J8 7. GND 9. PCD15 11.PCD14 13.PCD13 15.PCD12 17.PCD11 19.PCD10 21.PCD9 23.PCD8 25.PCD7 27.PCD6 29.PCD5 31.PCD4 33.PCD3 35.PCD2 37.PCD1 39.PCD0
J9 5267-4P
10
J10
J11
J4
5267-3P
3951-3P
3951-2P
5045-3P
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
O_REQ
1 J11
TMS TMS
1 1
3.3V TDO TD
1 1
WR PC_CLK
TCX
CLOCK
+24V N.C
J7
PC2
PC1
GND
GND
D6 D5 D4
PID#2-13
<PID SUB - IF J7, J9>
+24V
3951-2P J6
PWR
N.C
GND
UV NEO IF PCB
5045-9P
N.C GND
J13
3951-2P J5
J14 2 11 3 4 5 6
N.C PSE
1 10 9 8 12 7
3951-2P
3
5045-8P
3 8
3951-6P
6
J2
J1
29
19
<ENCODER HARNESS>
J15
19 10 1 26 18 9
J18
J11
J17
J7
J12
+ +5V INK_FULL_SIGNAL
5267-2P
INK_FULL_WT
INK_FULL_LM
INK_FULL_LC
INK_FULL_Y
INK_FULL_M
INK_FULL_C
<MAIN J11 - REFILL J17> <MAIN J18 - REFILL J34> <MAIN J17, J18 - I/O J1, J4>
NOT USED
D2
RED
D4
RED
D6
RED
D8
RED
D10
RED
D12
J1
WT
J2
LM
J3
LC
J4
J5
PLC
5267-3P 5267-3P 5267-3P 5267-3P 5267-3P 5267-3P 5267-3P 5267-3P
HEAD PCB
I-TV PCB
INK_FULL_WT INK_EMPTY_WT
INK_FULL_LM INK_EMPTY_LM
INK_FULL_LC INK_EMPTY_LC
INK_FULL_Y INK_EMPTY_Y
+5V
+5V
+5V
120V GND
PE L51 L52
120V GND
PE L1 L2
24V GND PE L1 L2
24V GND PE L1 L2
24V
PE L1 L2
24V G 5V
G PE L1 L2
19
29
DC 24V
+24V
J10 1. 3.3V 2. 3.3V 3. GND 4. GND 5. MCSELA 6. MCSELB 7. MCCLK 8. VIA3 MCSELB 9. VIA4 10.PCSELA PCSELA 11.PCSELB 12.MCD0 13.MCD1 PCSELB 14.MCD2 15.MCD3 16.MCD4 17.MCD5 18.MCD6 19.MCD7 20.MCD8 21.MCD9 22.MCD10 23.MCD11 24.MCD12 25.MCD13 26.MCD14 27.MCD15 28.MCS1 29 MCS2 30. EXT1 31. EXT2 32. GND 33. GND 34. GND 35. GND 36. GND 3.3V PCN10C 50S 2.54DS 37. GND 38. GND 39. GND 40. GND D9 41. GND 42. GND 43. GND GND 44. GND 45. GND 46. GND 47. GND 48. GND 49. 3.3V 50. 3,3V J10
MCCLK MCSELA
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
J16 1. +3.3VDC 2. +3.3VDC 3. GND 4. GND 5. MCSELA 6. MCSELB 7. MCCLK 8. VIA3 9. VIA4 10. PCSELA 11. PCSELB 12. MCD0 13. MCD1 14. MCD2 15. MCD3 16. MCD4 17. MCD5 18. MCD6 19. MCD7 20. MCD8 21. MCD9 22. MCD10 23. MCD11 24. MCD12 25. MCD13 26. MCD14 27. MCD15 28. OEA 29. OEB 30. VIA5 31. VIA6 32. GND 33. GND 34. GND 35. GND 36. GND 37. GND 38. GND 39. GND 40. GND 41. GND 42. GND 43. GND 44. GND 45. GND 46. GND 47. GND 48. GND 49. +3.3VDC 50. +3.3VDC
5045-2P J3
9 1 MEDIA SCAN 1
J16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 1
3.3V
J8
2
D1 MCSELA
D9
D10
D2
D3
D12
D6
D4
D5
D7
D11
D8
CON10
1
ENC ABN 1 MCSELB
TRAVEL 1
5267-3P
8 7 6 5 4 3 2 1
J17 ENC 1
J9
MCCLK
MARK 1
5267-4P J10
LM
RED D3
LC
RED D4
Y
RED D5
J2 9 1
5267-8P
5267-5P
1 10 9 8 12 7
J1
9 1
CON10
SHIFT CLK 1
HV-CLK 1
J18
5267-5P
J1 1. OEB 2. +5V 3. GND 4. GND 5. RES 6. GND 7. OEA 8. GND 9. MCSELB 10. GND
J2 1. HV_LED 2. +5V 3. GND 4. GND 5. RES2 6. GND 7. SCR2 8. GND 9. MISO2 10. GND
J3 1. MOS3 2. +5V 3. GND 4. GND 5. RES3 6. GND 7. SCR3 8. GND 9. MISO3 10. GND
+ S_LED_WT
+ S_LED_LM
+ S_LED_LC
S_LED_Y
CON10 J14 2 11 3 4 5 6
J12
ENCODER
+ P_LED_WT
+ P_LED_LM
+ P_LED_LC
P_LED_Y
GND 1
PCN10-50P J15
1 10 19
5267-8P D-SUB26P(3row)
9 18 26
SW1
SW2
2 2
SW3
2
SW4
2
J11
5267-6P
J7
5267-3P
J5
5267-6P
J4
J15 1. DATA AB1 2. DATA CD1 3. DATA AB2 4. DATA CD2 5. DATA AB3 6. DATA CD3 7. DATA AB4 8. DATA CD4 9. DATA AB5 10. DATA CD5 11. DATA AB6 12. DATA CD6 13. DATA AB7 14. DATA CD7 15. DATA AB8 16. DATA CD8
17. MEDIA 18. SHIFT_CK 19. RX1_TTL 20. TX1_TTL 21. HV_CK 22. ERROR_OUT 23. HT_CNTRL 24. S.GND 25. S.GND 26. S.GND
GND TX RX
J5 1. GND 2. TX 3. RX 4. GND 5. TX 6. RX
+24VDC GND
J14 1. CHASSIS 2. GND 3. EN A+ 4. ENCA5. ENCB+ 6. GND 7. ENCRI+ 8. ENCRI9. GND 10. +5VDC 11. ENCB12. +5VDC
WT
LM
LC
SW_WT +5V
SW_LM +5V
SW_LC +5V
J18
SW_Y +5V
HRS-30P
19
29
D-SUB26P(3row)
STEP MOTOR
10
11
5267-2P
J1~J8 1. GND_SIGNAL 2. GND_SIGNAL 3. HV_ERR 4. HV_CLK* 5. SHIFT_CK* 6. DATA_CDK* 7. DATA_ADH* 8. N.C 9. +12V 10. +12V 11. GND_POWER 12. GND_POWER 13. N.C 14. N.C 15. HV1 16. HV1
D4
D6
+5V
D108
J5
J1
J4
J5
J6
J7
J8
J9 1. DATA AB1 2. DATA CD1 3. DATA AB2 4. DATA CD2 5. DATA AB3 6. DATA CD3 7. DATA AB4 8. DATA CD4 9. DATA AB5 10. DATA CD5 11. DATA AB6 12. DATA CD6 13. DATA AB7 14. DATA CD7 15. DATA AB8 16. DATA CD8 17. MEDIA 18. SHIFT-CK 19. RX1_TTL 20. TX1_TTL 21. HV_CK 22. ERROR_OUT 23. HT_CNTRL 24. GND 25. GND 26. GND
+24V
J18
GND
3951-4P
VT301V
1. GND 2. +5V 3. GND 4. +5V 5. N.C 6. N.C 7. N.C 8. N.C 9. DIR_CW_SW 10. CW_LED 11. DIR_CCW_SW 12. CCW_LED 13. AUTO_SW 14. AUTO_LED 15. ERROR_SW 16. ERROR_LED
1. SW_Y 2. SW_M 3. SW_C 4. SW_K 5. SW_LM 6. SW_LC 7. SW_WHITE 8. SW_S 9. +5V 10. GND 11. S_LED_Y 12. S_LED_M 13. S_LED_C 14. S_LED_K 15. S_LED_LM
J31
15
<GORE I-TV/PSE>
1 2 3
GAIN 20K
J13 STL950 1 58
3951-5P
3951-10P
J7
15
J11
HRS-16P
1. GND 2. +5V 3. GND 4. +5V 5. N.C 6. N.C 7. N.C 8. N.C 9. DIR_CW_SW 10. CW_LED 11. DIR_CCW_SW 12. CCW_LED 13. AUTO_SW 14. AUTO_LED 15. ERROR_SW 16. ERROR_LED
INK_PUMP_SOLUTION INK_PUMP_Y INK_PUMP_K INK_PUMP_WHITE INK_PUMP_M INK_PUMP_LM INK_PUMP_LC INK_PUMP_C +24V +24V +24V +24V +24V +24V +24V
J18
J20 3951-2P
J27 3951-2P
J24 3951-2P
J1 3951-2P
J25 3951-2P
J3 3951-2P
J26 3951-2P
J5 3951-2P D12
1.COMM LED 2.INK_PUMP_WHITE 3.INK_PUMP_LM 4.INK_PUMP_LC 5.INK_PUMP_Y 6.INK_PUMP_M 7.INK_PUMP_C 8.INK_PUMP_K 9.SOLUTION PUMP 10.OVERFLOW_ERROR
J17-1 J17-1
5045-3P 5045-3P
J17
GND TX RX_INK
16. S_LED_LC 17. S_LED_WHITE 18. S_LED_S 19. +5V 20. GND 21. P_LED_Y 22. P_LED_M 23. P_LED_C 24. P_LED_K 25. P_LED_LM 26. P_LED_LC 27. P_LED_WHITE 28. P_LED_S 29. +24V 30. GND
5267-3P J32
SW1
5V
RESET
GND
5267-6P J14
5267-2P
5566-2P
14
PCA
MCA
CS6 CS6
CS5
CS4
CS3
CS2
CS1
A21
A20
A19
A18
A17
A16
A15
A14
A13
A12
A11
A10
A9 A9
A8
A7
A6
A5
A4 A4
A3
A2
A1
A0
M
RED D6
C
RED D7
K
RED D8
S
RED
+ S_LED_M
S_LED_C
S_LED_K
S_LED_S
+ P_LED_M
P_LED_C
+ P_LED_K
P_LED_S
SW5
2
SW6
2
SW7
2
SW8
2
REV5
SW_M +5V
SW_K +5V
SW_S
PCB
MCB
CS6 CS6
CS5
CS4
CS3
CS2
CS1
B21
B20
B19
B18
B17
B16
B15
B14
B13
B12
B11
B10
B9 B9
B8
B7
B6
B5
B4 B4
B3
B2
B1
B0
5V
GND
1. SW_Y 2. SW_M 3. SW_C 4. SW_K 5. SW_LM 6. SW_LC 7. SW_WHITE 8. SW_S 9. +5V 10. GND 11. S_LED_Y 12. S_LED_M 13. S_LED_C 14. S_LED_K 15. S_LED_LM
16. S_LED_LC 17. S_LED_WHITE 18. S_LED_S 19. +5V 20. GND 21. P_LED_Y 22. P_LED_M 23. P_LED_C 24. P_LED_K 25. P_LED_LM 26. P_LED_LC 27. P_LED_WHITE 28. P_LED_S 29. +24V 30. GND
INK_FULL_K
INK_FULL_S
REFILL_INDICATOR REV.2
INK_EMPTY_SIGNAL +5V
5267-2P
RED
D14
RED
D16
RED
J11
J6
J7
J8
7 - 31
SERV-R/S
MOVE-R
MOVE-L
TRAVEL
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
J16
ERROR
MEDIA
WEEP
RUN
FEED
STOP
RESET
MARK
TEST
ENC
HV
5V
SERVO/RS 1
5045-2P
J8
D1
D9
D10
D2
D3
D12
D6
D4
D5
D7
D11
D8
J17
HOME SENSOR
5267-3P J9
J15 1. DATA AB1 2. DATA CD1 3. DATA AB2 4. DATA CD2 5. DATA AB3 6. DATA CD3 7. DATA AB4 8. DATA CD4 9. DATA AB5 10. DATA CD5 11. DATA AB6 12. DATA CD6 13. DATA AB7 14. DATA CD7 15. DATA AB8 PCN10-50P 16. DATA CD8
J30
17. MEDIA 18. SHIFT_CK 19. RX1_TTL 20. TX1_TTL 21. HV_CK 22. ERROR_OUT 23. HT_CNTRL 24. S.GND 25. S.GND 26. S.GND
J17 1. DC5V+ 2. MEDIA SET1 3. MEDIA SET2 4. MEDIA SET3 5. FEED LIMIT 6. LEFT SHUTTER 7. RIGHT SHUTTER 8. +5VCD
5267-8P
5267-4P J10
DILLI MAIN 20
J5 1. GND 2. TX 3. RX 4. GND 5. TX 6. RX
J7 5267-3P J5 5267-6P
2 11 3 4 5 6
1 10 9 8 12 7
24V+
ENCODER
NOT USED
5267-2P J15
1 10 19
D-SUB26P(3row)
9 18 26
J11
5267-6P
J4
5267-8P
5267-8P
ENCODER
+24VDC
J1
GND
GND
GND
FPGA J10
J9
9 18 26
J4
GND
TX
RX
TX
TX RX
5267-8P
5267-5P
D-SUB26P(3row)
J7
J12
1 10 19
5267-8P
SMPS#3
5267-3P
<MAIN J7 PC COM1>
7 - 33
GND
PCA
MCA
CS6
CS5
CS4
CS3
CS2
CS1
A21
D3
A20
A19
A18
A17
A16
A15
A14
A13
A12
A11
A10
D2
A9
A8
A7
A6
A5
A4
A3
A2
A1
A0
D1
5V
GND
J10
1
MCCLK
J8 7. GND 9. PCD15 11.PCD14 13.PCD13 15.PCD12 17.PCD11 19.PCD10 21.PCD9 23.PCD7 27.PCD6 29.PCD5 31.PCD4 33.PCD3 35.PCD2 37.PCD1 39.PCD0
J8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
J7
1
O_REQ
1 J11
MCSELA
MCSELB
TMS TMS
1 1
3.3V TDO TD
1 1
WR PC_CLK
PCSELA
TCX
PCSELB
CLOCK
PC2
PC1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
8 7 6 5 4 3 2 1
1 1
3.3V
D9
GND
D6 D5 D4
PWR
REV5
5V PCB MCB CS6 CS5 CS4 CS3 CS2 CS1 B21 B20 B19 B18 B17 B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 B0 GND
GND
7 - 35
1,2 : SMPS#2(HEAD HEATER HV) 3,4 : SMPS#1(HEAD JET HV) 5,6 : N.C 7,8 : SMPS#3
HV2
2
HV2
HV2
HV2
HV2
HV2
HV2
3951-2P
HEAT#2
3
HEAT#8
3951-2P
HEAT#3
4
3951-2P
HEAT#4
5
3951-2P
HEAT#5
6
HEAT#7
3951-2P
HEAT#6
7
J13 1 5 8
3951-2P
3951-2P
STL950
J30 5267-2P
HEATER1
HEAT#1 HV2
1
1 2
J39
BZ1
12V
3951-2P
GND
J1~J8 1. GND_SIGNAL 2. GND_SIGNAL 3. HV_ERR 4. HV_CLK* 5. SHIFT_CK* 6. DATA_CDK* 7. DATA_ADH* 8. N.C 9. +12V 10. +12V 11. GND_POWER 12. GND_POWER 13. N.C 14. N.C 15. HV1 16. HV1
GND INK_OVF(5V)
J95
NOT USED
5267-3P
GND 1
J1
12
J1
11 12 11
J2
12 11
J3
12 11
J4
12 11
J5
12 11
J6
12 11
J7
12 11
J8
12 11
J9
J15
<GORE SIGNAL>
J9 1. DATA AB1 2. DATA CD1 3. DATA AB2 4. DATA CD2 5. DATA AB3 6. DATA CD3 7. DATA AB4 8. DATA CD4 9. DATA AB5 10. DATA CD5 11. DATA AB6 12. DATA CD6 13. DATA AB7 14. DATA CD7 15. DATA AB8 16. DATA CD8 17. MEDIA 18. SHIFT-CK 19. RX1_TTL 20. TX1_TTL 21. HV_CK 22. ERROR_OUT 23. HT_CNTRL 24. GND 25. GND 26. GND
HT_ERR
- VR TEMPERATURE
GND 1
INK_OVF
HV_ERR
<CARTRIDGE HEAD(J1~J8)>
5267-2P
TP
TP
2 1
D-SUB26P(3row)
D-SUB26P(3row)
1 D1
D4
D6
D2
VR
12V
CON10
10 9 GND
5267-2P
5267-2P
5267-2P
5267-2P
5267-2P
5267-2P
5267-2P
5267-2P
J21
J29 J10 INK1-K INK2-C INK3-M INK4-Y INK5-LC INK6-LM INK7_S INK8-W
K G LEVEL SENSOR
C G LEVEL SENSOR
M G LEVEL SENSOR
Y G LEVEL SENSOR
LC G LEVEL SENSOR
LM G LEVEL SENSOR
S G LEVEL SENSOR
W G LEVEL SENSOR
7 - 37
<VT301 REFILL J35> <MAIN J18 REFILL J34> MAIN PCB J18
J18
TAKE UP PCB
VT301
INK_PUMP_SOLUTION +24V INK_PUMP_WHITE +24V INK_PUMP_LM +24V INK_PUMP_LC +24V INK_PUMP_Y +24V INK_PUMP_M +24V INK_PUMP_C +24V INK_PUMP_K +24V
J18 J21 3951-2P J20 3951-2P J27 3951-2P J24 3951-2P J1 3951-2P J25 3951-2P J3 3951-2P J26 3951-2P J5 3951-2P D12
+ -
HRS-16P
5267-5P
MAIN ERROR
N.C
GND
NOT USED
E_TANK_SOL +5V
5267-2P
HRS-16P
NOT USED
J2 9
5267-2P J2 3
NOT USED
5267-2P J6
9 16
NOT USED
10
11
5267-2P
D108
1. GND 2. +5V 3. GND 4. +5V 5. N.C 6. N.C 7. N.C 8. N.C 9. DIR_CW_SW 10. CW_LED 11. DIR_CCW_SW 12. CCW_LED 13. AUTO_SW 14. AUTO_LED 15. ERROR_SW 16. ERROR_LED
U12
1. COMM LED 2. INK_PUMP_WHITE 3. INK_PUMP_LM 4. INK_PUMP_LC 5. INK_PUMP_Y 6. INK_PUMP_M 7. INK_PUMP_C 8. INK_PUMP_K 9. SOLUTION PUMP 10. OVERFLOW_ERROR
20
NOT USED
J21
5267-2P J2
NOT USED
5267-2P
E_TANK_K +5V
J13
E_TANK_C +5V
J4
5267-2P J1 3
PLC P0B
LAMP
5045-2P J3 3
NOT USED
N.C BUZZER
J3
5267-4P
J11
NOT USED
5045-4P 5219-2P 5219-3P
J18
REAR PHOTO SENSOR REAR GEAR MOTOR <TAKEUP MOTOR - REFILL J10, J11>
19
H R S -3 0 P
19
29
J17-1
J11
8. E_TANK_SOL
7. E_TANK_K
6. E_TANK_C
5. E_TANK_M
4. E_TANK_Y
3. E_TANK_LC
2. E_TANK_LM
1. E_TANK_WHITE
U1
5045-3P
GND TX RX_INK
1. SW_Y 2. SW_M 3. SW_C 4. SW_K 5. SW_LM 6. SW_LC 7. SW_WHITE 8. SW_S 9. +5V 10. GND 11. S_LED_Y 12. S_LED_M 13. S_LED_C 14. S_LED_K 15. S_LED_LM
J16
16. S_LED_LC 17. S_LED_WHITE 18. S_LED_S 19. +5V 20. GND 21. P_LED_Y 22. P_LED_M 23. P_LED_C 24. P_LED_K 25. P_LED_LM 26. P_LED_LC 27. P_LED_WHITE 28. P_LED_S 29. +24V 30. GND
HRS-30P J30
5267-3P J32
5267-6P
AIR TANK
SW1
5V
RESET
GND
5267-6P J14
SMPS #3
M_R_CW
M_R_CCW
24V
TAKE_REAR_SEN
GND
29
M_F_CCW
M_F_CW
7 - 39
J3 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
J1 1 2 3 4 5 6 7 8 9
J4 1 2 3 4 5 6 7 8 9
J2
EACH HEAD
J5 1. GND_SIGNAL 2. GND_SIGNAL 3. HV_ERR 4. HV_CK 5. SHIFT_CK_HI 6. DATA_CD_HI 7. DATA_AD_HI 8. N.C. 9. +12V 10. +12V 11. GND_POWER 12. GND_POWER 13. N.C. 14. N.C. 15. HVIN 16. HVIN
J5
12 11
J1~J8
11 12
D4 TP1 1
JET REV5
120V
LEDG-SM 12V
HV_ADJ GND
* FACTORY SET
7 - 41
UP_SEN
BASE A
J17 5267-4P
J23
1 7
J4
J16 10 1
3951-7P
5045-5P
IF PCB J2
J7
1. +24V 2. N.C 3. SOL_A (THE VERTICAL) 4. N.C 5. +24V 6. N.C 7. SOL_B (HORIZONTALITY)
5045-10P
SUB B
SUB A
BASE B
BASE B
GND
N.C
GND
J13 5045-4P
ITV2010
J11 5045-3P
5045-6P
<GORE SENSOR>
PURGE S/W SOL +24V
3951-2P
SOL(1) SOL(2)
J6
J18
SMPS#6
3951-4P
SOL(2)
3951-5P
J15 5045-7P
A A B B
<GORE POWER3>
J8
STEP MOTOR
IF PCB J1
J8 395 1-6P
3951-6P
3951-3P
<GORE POWER1>
J25
J14
SUB_HEATER
GND
7 - 43
PSE 200
PSE200 CH1-1 HEAD LIFT PCB J16 SMPS #5 GND VARIABLE REGISITOR VOLUME VAR. R-3 VR. VAR. R-2 VAR. R-1 HEAD LIFT PCB J16 SMPS #5 GND
* SETTING POSITION(2)
J1A 1 2 3
ON
OFF
ZERO
* SETTING POSITION(3)
GAIN
20K
20K
* FACTORY SETTING
* SETTING POSITION(4)
SW4 +10V +10V -10V
3 5557-4P
-10V
<GORE ITV/PSE>
7 - 45
RED LED
5566-2P
MOTOR MOTOR +
J49
NOT USED
5267-2P
+5V SUC_LEVEL
J48
NOT USED
1: PO14 2: PO20 3: PO13 4: PO12 5: PO11
PLC
NOT USED
VR2
+
VR1
NOT USED
NOT USED
J13 1. N.C 2. N.C 3. N.C 4. N.C 5. N.C 6. N.C 7. N.C 8. N.C 9. N.C 10. AIR LOW 11. N.C 12. SHUTTER RIGHT 13. SHUTTER LEFT 14. UV LAMP ON
3951-4P
7 14
N.C
J4
<SUB J4 - PLC>
NOT USED
GND
5045-14P
J43
J13
GND(24V) +24V
GND(5V)
+5V
J3
J6
5045-3P
5045-4P
I/O PCB J3
I/O PCB J6
7 - 47
4.10. IF PCB
PID#2
1 3
PID#1 1 2 3 13 14 4 5
PID#3
<GORE PID-WHITE>
HEATER CONTRLRER
2 3 4 5
4 5
13 14
NOT USED
NOT USED
N.C SUB_HEATER
SUB_B
J8
5267-3P 3951-3P
SUB_B
SUB_A
N.C
GND
J9 J10
J11 5267-4P
J4
J3 5045-4P J12
3951-2P
5045-3P
+24V N.C
J7
GND +24V
3951-2P J6 5045-9P
N.C N. C GND
J13
SMPS #4
GND +24V
NOT USED
N.C PSE
J2
J1
J8
J8
3951-6P
3951-6P
<GORE SENSOR>
<GORE POWER1>
7 - 49
+5V MEDIA SENSOR1 MEDIA SENSOR1 MEDIA SENSOR1 FEED LIMIT LEFT SHUTTER RIGHT SHUTTER GND
J1
J2
1 LED1 LED2
5045-5P J3
1
LED3
LED4
5267-8P J18
5267-8P
3 LED5 LED6
J4
5045-3P J6
1
LEFT SHUTTER
RIGHT SHUTTER
LED7
LED8
5267-5P
5267-5P
UV LAMP ON
5045-4P
J13
5045-14P
14
7 - 51
D1
RED
CW_LED
CCW_LED
AUTO_LED
ERROR_LED
SW1
2
SW2
2
SW3
2
SW4
2
WT
LM
LC
5V
CW_SW
5V
CCW_SW
J11 15
5V
AUTO_SW
5V
ERROR_SW
HRS-16P
1. GND 2. +5V 3. GND 4. +5V 5. N.C 6. N.C 7. N.C 8. N.C 9. DIR_CW_SW 10. CW_LED 11. DIR_CCW_SW 12. CCW_LED 13. AUTO_SW 14. AUTO_LED 15. ERROR_SW 16. ERROR_LED
J18
15
HRS-16P
7 - 53
+ S_LED_WT
D9 GREEN
+ S_LED_LM
+ S_LED_LC
S_LED_Y
D12
+ S_LED_M
D13 GREEN
+ S_LED_C
S_LED_K
D15
S_LED_S
D16
D10
GREEN
D11
GREEN
GREEN
D14
GREEN
GREEN
GREEN
+ P_LED_WT
+ P_LED_LM
+ P_LED_LC
P_LED_Y
+ P_LED_M
+ P_LED_C
P_LED_K
P_LED_S
SW1
2
SW2
2
SW3
2
SW4
2
SW5
2
SW6
2
SW7
2
SW8
2
WT
LM
LC
SW_WT +5V
SW_LM + 5V
SW_LC +5V
SW_Y +5V
SW_M +5V
SW_C +5 V +5V
S W_ K +5V
SW_S
J18
29
HRS-30P
19 9
J31
19
29
HRS-30P
1. SW_Y 2. SW_M 3. SW_C 4. SW_K 5. SW_LM 6. SW_LC 7. SW_WHITE 8. SW_S 9. +5V 10. GND 11. S_LED_Y 12. S_LED_M 13. S_LED_C 14. S_LED_K 15. S_LED_LM
16. S_LED_LC 17. S_LED_WHITE 18. S_LED_S 19. +5V 20. GND 21. P_LED_Y 22. P_LED_M 23. P_LED_C 24. P_LED_K 25. P_LED_LM 26. P_LED_LC 27. P_LED_WHITE 28. P_LED_S 29. +24V 30. GND
7 - 55
D1 J 12
GREEN D3
GREEN D5
GREEN
D7
GREEN
D9
GREEN
D11
GREEN
D13
GREEN
D17
LED
+5V INK_FULL_SIGNAL
J4 5267-2P
INK_FULL_WT INK_FULL_LM
D2 RED D4 RED
INK_FULL_LC
D6 RED
INK_FULL_Y
D8 RED
INK_FULL_M
D10 RED
INK_FULL_C
D12 RED
INK_FULL_K
D14 RED
INK_FULL_S
D16 RED
J13
INK_EMPTY_SIG. +5V
REFILL PCB J4
5267-2P
REFILL_INDICATOR REV.2
5267-2P
NOT USE
+5V N.C
3951-3P
GND
J1
WT
J2
LM
J3
LC
J4
J5
J6
J7
J8
5267-3P
5267-3P
5267-3P
5267-3P
5267-3P
5267-3P
5267-3P
5267-3P
INK_FULL_S INK_EMPTY_S
7 - 57
5267-4P
J7
MAIN J5
J5
GND
J5 5267-2P
J4
GND
11
5267-6P 5267-8P
5267-8P J3
11
MAIN J12
J12
J6
CARRIAGE_SERVO
5267-8P
11
5267-8P
5267-8P
CN3
CARRIAGE
CN3
FEED
FEED_SERVO
11
CN1B
CN1B
7 - 59