Anapurna L XL Service Manual

:Anapurna L/XL

Service ManualV1.0

Company Confidential

1 - 2 2007 V1.0 - Service ManualCompany Confidential :Anapurna L/XL

Trademarks and Copyright

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:

Copyright © 2007 Agfa Graphics, Belgium.

All software and hardware described in this document are subject to change without notice.

Agfa Graphics.Septestraat 27B-2640 Mortsel, BelgiumTel: (+)32 3 444 2111

http://www.agfa.com

Service Manual 2007 V1.0 - i:Anapurna L/XL Company Confidential

Contents

About this Service Manual ............................................................................................................................. 0 - 1

1. Service Manual Overview ............................................................................................................................................. 0 - 12. Scope .................................................................................................................................................................................... 0 - 13. Related Documentation ................................................................................................................................................ 0 - 1

Chapter 1 Functional Description ......................................................................................................................................... 1 - 1

1. General Description ........................................................................................................................................................ 1 - 31.1. System Description ............................................................................................................................................ 1 - 31.2. Block Diagram ...................................................................................................................................................1 - 13

2. Safety Circuits .................................................................................................................................................................1 - 142.1. Emergency Stop Circuit ..................................................................................................................................1 - 142.2. Door Open Detection ......................................................................................................................................1 - 15

3. Power Distribution ........................................................................................................................................................1 - 183.1. Functional Description ...................................................................................................................................1 - 18

4. Compressed Air Distribution ......................................................................................................................................1 - 204.1. Functional Description ...................................................................................................................................1 - 20

5. Data flow ...........................................................................................................................................................................1 - 285.1. Functional Description ...................................................................................................................................1 - 285.2. Printed Circuit Boards .....................................................................................................................................1 - 28

6. Media Transport .............................................................................................................................................................1 - 296.1. Functional Description ...................................................................................................................................1 - 296.2. Printed Circuit Boards .....................................................................................................................................1 - 44

7. Ink Supply System ........................................................................................................................................................1 - 457.1. Functional Description ...................................................................................................................................1 - 457.2. Printed Circuit Boards .....................................................................................................................................1 - 54

8. Head Carriage Movement ...........................................................................................................................................1 - 558.1. Functional Description ...................................................................................................................................1 - 558.2. Printed Circuit Boards .....................................................................................................................................1 - 60

9. Print Head .........................................................................................................................................................................1 - 619.1. Functional Description ...................................................................................................................................1 - 619.2. Printed Circuit Boards .....................................................................................................................................1 - 65

10. UV Curing .......................................................................................................................................................................1 - 6610.1. Functional Description .................................................................................................................................1 - 6610.2. Printed Circuit Boards ..................................................................................................................................1 - 74

11. Programmable Logic controller (PLC) .................................................................................................................1 - 7511.1. Functional Description .................................................................................................................................1 - 75

12. Anapurna Control Program ......................................................................................................................................1 - 8012.1. Control Program .............................................................................................................................................1 - 8012.2. Buttons used for Maintenance Purposes ..............................................................................................1 - 8112.3. Setup Parameters ...........................................................................................................................................1 - 8112.4. Test Menu .........................................................................................................................................................1 - 88

13. Working with White Ink - Guidelines ..................................................................................................................1 - 9013.1. Printing Jobs without White Ink ...............................................................................................................1 - 9013.2. Application requires no White Ink at All ...............................................................................................1 - 9013.3. Putting White Ink into the Circuit ...........................................................................................................1 - 91

14. Printed Circuit Boards ...............................................................................................................................................1 - 9514.1. MAIN PCB .........................................................................................................................................................1 - 9514.2. FPGA PCB ....................................................................................................................................................... 1 - 10214.3. HEAD PCB ...................................................................................................................................................... 1 - 10814.4. REFILL PCB ..................................................................................................................................................... 1 - 11714.5. CARTRIDGE PCB .......................................................................................................................................... 1 - 123

ii 2007 V1.0 - Service ManualCompany Confidential :Anapurna L/XL

14.6. HEAD LIFT PCB ............................................................................................................................................. 1 - 12714.7. ITV CONTROLLER PCB ............................................................................................................................... 1 - 13314.8. SUB PCB ......................................................................................................................................................... 1 - 13614.9. IF PCB .............................................................................................................................................................. 1 - 14014.10. I/O PCB ........................................................................................................................................................ 1 - 14414.11. TAKE UP PCB .............................................................................................................................................. 1 - 14814.12. REFILL CONTROL PCB ............................................................................................................................. 1 - 15014.13. INDICATOR PCB ........................................................................................................................................ 1 - 15314.14. DRIVER COMMUNICATION PCB ......................................................................................................... 1 - 156

Chapter 2 Technical Features and Specifications ............................................................................................2 - 1

1. Overview ..............................................................................................................................................................................2 - 21.1. Anapurna's Print Quality ...................................................................................................................................2 - 21.2. Outstanding Printing Potential ......................................................................................................................2 - 21.3. Inspired Design ....................................................................................................................................................2 - 31.4. User Profile ............................................................................................................................................................2 - 3

2. Features ...............................................................................................................................................................................2 - 42.1. Borderless Printing .............................................................................................................................................2 - 42.2. Roll to Roll and Rigid Printing .......................................................................................................................2 - 42.3. Dual Board Printing ............................................................................................................................................2 - 42.4. White Color Printing ..........................................................................................................................................2 - 42.5. Status Signal Lamp .............................................................................................................................................2 - 42.6. Automatic Ink Filling System .........................................................................................................................2 - 52.7. UV Curing ...............................................................................................................................................................2 - 52.8. Changeable UV Lamps ......................................................................................................................................2 - 52.9. Exhausting System ..............................................................................................................................................2 - 52.10. Automatic Print Head Height .......................................................................................................................2 - 52.11. Easy and Quick Installation ..........................................................................................................................2 - 52.12. Simple Maintenance .......................................................................................................................................2 - 5

3. Specifications ....................................................................................................................................................................2 - 63.1. Print Technology ..................................................................................................................................................2 - 63.2. Head Technology .................................................................................................................................................2 - 63.3. Media .......................................................................................................................................................................2 - 73.4. Inks ...........................................................................................................................................................................2 - 83.5. Working Conditions ............................................................................................................................................2 - 93.6. Electricity ...............................................................................................................................................................2 - 93.7. RIP PC ...................................................................................................................................................................2 - 103.8. Service PC ...........................................................................................................................................................2 - 103.9. Anapurna L ..........................................................................................................................................................2 - 113.10. Anapurna XL .................................................................................................................................................... 2 - 11

Chapter 3 Repair and Service ....................................................................................................................................................3 - 1

1. Safety Notes .......................................................................................................................................................................3 - 21.1. Warning/Caution/Note ....................................................................................................................................3 - 21.2. Emergency Stop ...................................................................................................................................................3 - 21.3. Handling UV Curable Ink ..................................................................................................................................3 - 31.4. UV Radiation .........................................................................................................................................................3 - 31.5. Electricity ...............................................................................................................................................................3 - 41.6. Maintenance Safety Instructions ..................................................................................................................3 - 41.7. MSDS Contents ....................................................................................................................................................3 - 5

2. Overview Safety Labels ..................................................................................................................................................3 - 63. Preparing for Service .......................................................................................................................................................3 - 8

3.1. Moving Head Carriage to Home or Purge Position .................................................................................3 - 83.2. Putting the print Engine in Service Mode .................................................................................................3 - 8

Service Manual 2007 V1.0 - iii :Anapurna L/XL Company Confidential

4. Disassembly/Assembly of Major Components .....................................................................................................3 - 94.1. Disassembly/Assembly of the Air Pressure Panel Components .......................................................3 - 94.2. Disassembly/Assembly of the Media Transport System Components ........................................ 3 - 134.3. Disassembly/Assembly of the Ink Supply System Components at Refill Unit ........................ 3 - 244.4. Disassembly/Assembly of the Ink Supply System Components at Head Carriage Unit ...... 3 - 464.5. Disassembly/assembly of the Head Carriage Movement Components ...................................... 3 - 534.6. Disassembly/Assembly of the Print Head Components ................................................................... 3 - 604.7. Disassembly/Assembly of the UV Curing System Components .................................................... 3 - 72

5. Installing the PCI I/O Card ....................................................................................................................................... 3 - 835.1. Location ............................................................................................................................................................... 3 - 835.2. Replacement of the PCI I/O Card .............................................................................................................. 3 - 84

6. Adjustment and Alignment Procedures ............................................................................................................... 3 - 896.1. Vacuum Blower Adjustments ...................................................................................................................... 3 - 896.2. Print Head Adjustments ................................................................................................................................. 3 - 916.3. Conveyer Belt Alignment .............................................................................................................................. 3 - 976.4. Head Base Alignment ..................................................................................................................................... 3 - 996.5. Lamp house Alignment ................................................................................................................................3 - 103

Chapter 4 Preventive Maintenance ...................................................................................................................................4 - 1

1. Maintenance Schedule ..................................................................................................................................................4 - 22. Print Media Unit Maintenance ...................................................................................................................................4 - 5

2.1. Guidelines and Specific Safety Instruction ...............................................................................................4 - 52.2. Conveyer Belt .......................................................................................................................................................4 - 62.3. Vacuum Holes ......................................................................................................................................................4 - 92.4. LM Guide ............................................................................................................................................................. 4 - 102.5. LM Blocks ........................................................................................................................................................... 4 - 112.6. Carriage Belt (S5M Belt) ................................................................................................................................ 4 - 132.7. S3M Belt .............................................................................................................................................................. 4 - 162.8. Linear Scale Encoder ...................................................................................................................................... 4 - 242.9. Bearings Print Media Unit ............................................................................................................................ 4 - 332.10. Waste Tank ...................................................................................................................................................... 4 - 35

3. Head Carriage Unit Maintenance ............................................................................................................................ 4 - 363.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 363.2. Print Head ........................................................................................................................................................... 4 - 383.3. UV Lamp Box / UV Lamp Box Housing .................................................................................................... 4 - 463.4. Head Carriage .................................................................................................................................................... 4 - 53

4. Refill Unit Maintenance ............................................................................................................................................. 4 - 544.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 544.2. Air filter 6 Color and White .......................................................................................................................... 4 - 554.3. Ink Filter .............................................................................................................................................................. 4 - 56

5. Purge Unit Maintenance ............................................................................................................................................ 4 - 635.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 635.2. Purge box ............................................................................................................................................................ 4 - 63

6. Home Unit Maintenance ............................................................................................................................................ 4 - 656.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 656.2. Home box ............................................................................................................................................................ 4 - 65

7. Safety Circuit .................................................................................................................................................................. 4 - 677.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 677.2. Emergency Stop Circuit ................................................................................................................................. 4 - 67

8. Air Tank Maintenance ................................................................................................................................................. 4 - 698.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 698.2. Air Tank ................................................................................................................................................................ 4 - 69

9. Air Pressure Panel Maintenance ............................................................................................................................. 4 - 709.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 709.2. Air Pressure Panel ............................................................................................................................................ 4 - 70

iv 2007 V1.0 - Service ManualCompany Confidential :Anapurna L/XL

10. Engine .............................................................................................................................................................................4 - 7510.1. Guidelines and Specific Safety Instruction ..........................................................................................4 - 7510.2. Engine Level .................................................................................................................................................... 4 - 75

Chapter 5 Troubleshooting ............................................................................................................................................................5 - 1

1. Troubleshooting Based on Visible Problems .........................................................................................................5 - 21.1. Troubleshooting Based on Tower Lamp Indications ..............................................................................5 - 21.2. Troubleshooting Based on Mechanical and/or Electrical Problems ................................................5 - 2

2. Troubleshooting Based on UI Error Messages ....................................................................................................5 - 133. Troubleshooting based on Image Quality Control ............................................................................................5 - 14

3.1. Encoder (MARK) Error ......................................................................................................................................5 - 143.2. Black Strips .........................................................................................................................................................5 - 153.3. Waves on the Media Surface .......................................................................................................................5 - 153.4. Only UNI MODE Output .................................................................................................................................5 - 163.5. Image Quality Failure .....................................................................................................................................5 - 163.6. Spray on your Image .......................................................................................................................................5 - 183.7. Print Length Exceeds Maximum Platen Length ....................................................................................5 - 18

4. UV Lamp Troubleshooting ..........................................................................................................................................5 - 205. Servo Motor Driver Troubleshooting ...................................................................................................................... 5 - 21

Chapter 6 Glossary ..................................................................................................................................................................................6 - 1

Chapter 7 Annex .........................................................................................................................................................................................7 - 1

1. Pneumatic Diagrams .......................................................................................................................................................7 - 31.1. Pneumatic Diagram ............................................................................................................................................7 - 5

2. Electrical Diagrams ..........................................................................................................................................................7 - 72.1. Main Power Distribution in the Electrical Circuit Panel .......................................................................7 - 92.2. Power Supply Distribution - 3 Phase with neutral with ground star 380V (EU) .......................7 - 112.3. Power Supply Distribution - 3 Phase no neutral with ground delta 208-240V (US) ...............7 - 132.4. UV Lamp Power Box Connections ..............................................................................................................7 - 152.5. UV Lamp Power Circuit ..................................................................................................................................7 - 172.6. UV Lamp Head Part ..........................................................................................................................................7 - 192.7. UV Lamp Power Cables ..................................................................................................................................7 - 21

3. Programmable Logic Controller (PLC) Block Diagram ....................................................................................7 - 233.1. Main PLC .............................................................................................................................................................7 - 253.2. UV Lamp PLC ......................................................................................................................................................7 - 27

4. Printed Circuit Boards ..................................................................................................................................................7 - 294.1. Total PCB Diagram Layout ............................................................................................................................7 - 314.2. MAIN PCB ............................................................................................................................................................7 - 334.3. FPGA PCB ............................................................................................................................................................7 - 354.4. HEAD PCB ............................................................................................................................................................7 - 374.5. REFILL PCB ..........................................................................................................................................................7 - 394.6. CARTRIDGE PCB ................................................................................................................................................7 - 414.7. HEAD LIFT PCB ..................................................................................................................................................7 - 434.8. ITV CONTROLLER PCB .....................................................................................................................................7 - 454.9. SUB PCB ...............................................................................................................................................................7 - 474.10. IF PCB .................................................................................................................................................................7 - 494.11. I/O PCB .............................................................................................................................................................7 - 514.12. TAKE UP PCB ...................................................................................................................................................7 - 534.13. REFILL CONTROL PCB ...................................................................................................................................7 - 554.14. INDICATOR PCB ..............................................................................................................................................7 - 574.15. DRIVER COMMUNICATION PCB ...............................................................................................................7 - 59

Service Manual 2007 V1.0 - 0 - 1:Anapurna L/XL Company Confidential

About this Service Manual

This section of the Service Manual explains how this document is structured.

1. Service Manual Overview

Functional DescriptionThis chapter describes how the Anapurna L/XL functions.

Technical Features and SpecificationsThis chapter briefly describes the features and technical specifications of the Anapurna L/XL.

Repair and ServiceThis chapter describes the preventive maintenance procedures for the Anapurna L/XL.

Preventive MaintenanceThis chapter describes repair and service procedures for the Anapurna L/XL.

TroubleshootingThis chapter describes how you can recognize and solve mechanical, electrical and image problems you could encounter when printing with the Anapurna L/XL.

GlossaryThis chapter describes definitions and abbreviations used throughout the Service Manual which you may not be familiar with.

AnnexThis 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

ABOUT THIS SERVICE MANUAL RELATED DOCUMENTATION


CHAPTER


1 Functional Description

This chapter describes how the Anapurna L/XL functions.

1. General Description ............................................................................................................................................... 1 - 31.1. System Description .................................................................................................................................. 1 - 31.2. Block Diagram ........................................................................................................................................ 1 - 13

2. Safety Circuits ....................................................................................................................................................... 1 - 142.1. Emergency Stop Circuit ....................................................................................................................... 1 - 142.2. Door Open Detection ........................................................................................................................... 1 - 15

3. Power Distribution .............................................................................................................................................. 1 - 183.1. Functional Description ........................................................................................................................ 1 - 18

4. Compressed Air Distribution ........................................................................................................................... 1 - 204.1. Functional Description ........................................................................................................................ 1 - 20

5. Data flow ................................................................................................................................................................ 1 - 285.1. Functional Description ........................................................................................................................ 1 - 285.2. Printed Circuit Boards .......................................................................................................................... 1 - 28

6. Media Transport ................................................................................................................................................... 1 - 296.1. Functional Description ........................................................................................................................ 1 - 296.2. Printed Circuit Boards .......................................................................................................................... 1 - 44

7. Ink Supply System .............................................................................................................................................. 1 - 457.1. Functional Description ........................................................................................................................ 1 - 457.2. Printed Circuit Boards .......................................................................................................................... 1 - 54

8. Head Carriage Movement ................................................................................................................................ 1 - 558.1. Functional Description ........................................................................................................................ 1 - 558.2. Printed Circuit Boards .......................................................................................................................... 1 - 60

9. Print Head .............................................................................................................................................................. 1 - 619.1. Functional Description ........................................................................................................................ 1 - 619.2. Printed Circuit Boards .......................................................................................................................... 1 - 65

10. UV Curing ............................................................................................................................................................. 1 - 6610.1. Functional Description ...................................................................................................................... 1 - 6610.2. Printed Circuit Boards ....................................................................................................................... 1 - 74

11. Programmable Logic controller (PLC) ....................................................................................................... 1 - 7511.1. Functional Description ...................................................................................................................... 1 - 75

12. Anapurna Control Program ............................................................................................................................ 1 - 8012.1. Control Program .................................................................................................................................. 1 - 8012.2. Buttons used for Maintenance Purposes ................................................................................... 1 - 8112.3. Setup Parameters ............................................................................................................................... 1 - 8112.4. Test Menu .............................................................................................................................................. 1 - 88

13. Working with White Ink - Guidelines ....................................................................................................... 1 - 9013.1. Printing Jobs without White Ink ................................................................................................... 1 - 9013.2. Application requires no White Ink at All ................................................................................... 1 - 9013.3. Putting White Ink into the Circuit ................................................................................................ 1 - 91

14. Printed Circuit Boards ..................................................................................................................................... 1 - 9514.1. MAIN PCB .............................................................................................................................................. 1 - 9514.2. FPGA PCB ............................................................................................................................................. 1 - 10214.3. HEAD PCB ............................................................................................................................................ 1 - 10814.4. REFILL PCB .......................................................................................................................................... 1 - 11714.5. CARTRIDGE PCB ................................................................................................................................ 1 - 12314.6. HEAD LIFT PCB ................................................................................................................................... 1 - 12714.7. ITV CONTROLLER PCB ..................................................................................................................... 1 - 13314.8. SUB PCB ............................................................................................................................................... 1 - 13614.9. IF PCB .................................................................................................................................................... 1 - 140

FUNCTIONAL DESCRIPTION FUNCTIONAL DESCRIPTION


14.10. I/O PCB ............................................................................................................................................. 1 - 14414.11. TAKE UP PCB ................................................................................................................................... 1 - 14814.12. REFILL CONTROL PCB ................................................................................................................... 1 - 15014.13. INDICATOR PCB .............................................................................................................................. 1 - 15314.14. DRIVER COMMUNICATION PCB ............................................................................................... 1 - 156

GENERAL DESCRIPTION FUNCTIONAL DESCRIPTION

Service Manual 2007 V1.0 - 1 - 3 :Anapurna L/XL Company Confidential

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

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.

1.1.2. Components And Locations

The Anapurna L/XL is separated in physical entities, called units. We distinguish 5 major units:

! Purge unit.

! Head carriage unit.

! Print media unit

! Home unit.

! Refill unit.

Left

Right

Front

Rear

PrintMediaTransportDirection

FUNCTIONAL DESCRIPTION GENERAL DESCRIPTION


1.1.2.1. Front view with printer parts and locations

Figure 1.2: Front view Anapurna XL

1.1.2.2. Rear view and composition

Figure 1.3: Rear view Anapurna XL

Vacuum controlFront cover

Emergency stop

Exhaust system

Towerlamp

Ink temperature and ink vacuum control

Refill unitPurge unit Print media unit Home unit

Emergency stop

Conveyer belt

Exhaust system

Head carriage unit

Emergency stop

Emergency stop

Vacuum control

Rear cover

Vacuum table Roll to roll systemCompressed air inlet



1.1.2.3. Purge unit

! 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).

purging part view (rear)purging part view (front)

1

2



! Main power panel.

Located behind the main box rear door.

1.1.2.4. Head carriage unit

Movable head carriage system (linear scale encoder) with 8 printing heads (printing the image), two UV sources (on the fly curing) positioned symmetrically left and right of the printing heads and a sub ink tank (ink buffer) mounted above the printing heads (ink supply to the heads).

1 4 5 6 72 3 8

3

1 UV lamp 5 Sub ink tank (6 colors)

2 Purge switch button 6 Sub ink tank (white)

3 Ink valve 7 Head base plate

4 Print head 8 Cleaning solution valve



1.1.2.5. Print media unit

! 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.

1.1.2.6. Home unit

! 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

1

2

3

4

5

6

8

7

12

4

10

9

11

1 Emergency button 7 UV lamp control (Left and right)

2 Vacuum control 8 Monitor

3 Media set (media register pins) 9 Take up control system

4 Media fixing bar (front and rear) 10 Ink temperature and ink vacuum control

5 Air inlet + air regulators 11 Tower lamp

6 Head base temperature control



! Main box right

Located behind the control system cover. Accessible via the ink supply door.

! Control box,

! SMPS panel,

! PLC.

! Components behind home rear door

! Ink supply chain / hose fixing guide(1),

! Shock absorber (3),

! Limit Switch (4),

! Carriage servo motor driver (2)

1 2 43 5

1 PLC 4 Sensor controller

2 Control box 5 SMPS panel

3 Stirrer timer (white)

21

3 4



! 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),

1.1.2.7. Refill unit

! Stainless steel ink tanks

! Ink tank indicator

! Refill system

3

2

1

3



1.1.2.8. Tower lamp

The tower lamp indicates if there are troubles. This is indicated by beeping and flashing of one or more lamps of the tower lamp. Along the color of the flashing lamp(s), the problem is defined. This is shown on the image below.

Each lamp of the tower lamp can also burn continuously. According to the color of the burning lamp, the Anapurna L/XL is in a certain state.

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).

Color Status Function

1 Red ON � Power ON

Flashing + Beeping � Air pressure below 0.3 MPa

2 Yellow Flashing + Beeping � Low ink level (at main tank)

3 Green ON � Ready state -> UV lamp curing available

Flashing + Beeping � Overheat� Lamp power off

4 Blue ON � Media register pins down

Flashing + Beeping � Full waste tank (> 3.5 litre)

5 White ON � Vacuum in use

All colors Flashing + Beeping � Overflow (of ink) in sub air tank

2

3

4

5

1

RED

YELLOW

GREEN

BLUE

WHITE



1.1.3. Covers and Doors

Figure 1.4: Front side doors/covers

Figure 1.5: Rear side doors/covers

1 2 3 4 5

1 Purge front door 4 Monitor cover2 Main box front cover 5 Control system cover3 Front cover

3

5

4

2

1

1 Purge rear door 4 Home rear door2 Main box rear door 5 Air pressure cover3 Rear cover



Figure 1.6: Left side doors/covers

Figure 1.7: Right side doors/covers

1

2 3

1 Purge top door 3 Main box left side door2 Purge left side door

1 2

3

4

1 Home right side door 3 Ink tank indicator cover2 Ink supply door 4 Ink Refill system cover



1.2. Block Diagram

The illustration below shows the total system diagram.

The printed circuit boards (PCB) are indicated in yellow.

P C

PC FOR RTL FILE(RIPPING)

HEAD LIFTPCB

UP/DOWNSENSOR

UP/LOCKSOLENOID

STEP MOTOR

MEMORY

FPGA CIRCUIT

RS 232

FPGA PCB

CONTROL CIRCUIT

INTERFACE CIRCUIT

MAIN PCB

SUB PCB

P L C (K7M-DR60S)

PUSH ROLLER(FRONT/REAR)

UV LAMP CONTROL

TOWER LAMP CONTROL

MEDIA STOP CONTROL

UV LAMP

REFILL PCB

PRESSURE SENSOR

NEGATIVEPRESSURECONTROL

FEED BACK ON/OFF

ZERO GAIN CONTROL

ITVCONTROLLERPCB

ITV

SUB INK TANK FLOAT SENSOR

HEAD PCB

CARTRIDGE PCB

PRINT HEAD

HEATING120VDC

WASTE TANK OVER FLOW SENSOR

SUB SOLUTION TANK FLOAT SENSOR

REFILL CONTROL PCB

MAIN INK TANK INDICATOR PCB

TAKE UPMOTOR

TAKE UP PCB

I/O PCB DRIVER COMM. PCB

IF PCB

PID CONTROLLER

CARRIAGE SERVO MOTOR DRIVE

FEED SERVOMOTOR DRIVE

FEED MOTORCARRIAGE

MOTOR

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.

! 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.

3P2P1P

zH06/05 ,V083CA ESAHP-3

ELBAC FTCV 21#GWA)KCALB(

A-CM

11P

CDV42+

V42 CD

DNG 2

W/S CP


TRATSER

1 OME OME OME OME3

8# SPMS

SPMS-CPW003

CP ROTAREPO

N

4

22P 32P 22PN

22PN

EP

N

N

1 21 21 21 2

)A05(1# CM )A05(1# CM1 2 3

4 5 6

1 2

1 2

3P2P1P

ESAHP-3(1# BCLE)A05,V083CA

zH06/05 ,V042~802CA ESAHP-3


A-CM

11P

CDV42+

V42 CD

DNG 2

W/S CP


TRATSER

1 OME OME 3

8# SPMS

SPMS-CPW003

CP ROTAREPO

4

22P 32P11P22P

11P

32P

EP N

)1(

)4(

)3(

)5(1 2 1 2

)A05(1# CM )A05(1# CM1 2 3

4 5 6

1 2 1 2

1 2

1 2

OME OME

SAFETY CIRCUITS FUNCTIONAL DESCRIPTION


2.2. Door Open Detection

2.2.1. Door Open Sensor

The engine is equipped with a safety sensor on the front and rear cover. Carriage movements and printing can only be done with covers closed. Check the working of the door sensors in the two following cases:

Figure 1.8: Door sensor

! 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.

1 2

1 Door sensor front cover 2 Door sensor rear cover

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.

FUNCTIONAL DESCRIPTION SAFETY CIRCUITS


2.2.2. Sensor Controller

The sensor controller, PA10-U, detects when doors or open or closed for safety reasons. The PA10-U module reads the information coming form the 2 sensors IN1 and IN2 (front and back door) and returns the information to the MAIN PCB.

The sensor controller is located behind the control system cover. To get access to the sensor controller, open the ink supply door.

Figure 1.9: Sensor controller

2.2.2.1. Connectors

Connectors Pin Connected to

Name and Function

Nr. Nr. Name PCB or Part Conn. Pin

PA10-U

SENSOR CON-TROLLER

- 1 ACI NPUT L51 SMPS#6 6

2 OUT NC

3 OUT COM MAIN PCB J10 4

4 OUT NO MAIN PCB J10 5

5 ACI NPUT L52 SMPS#6 7

6 N.C

7 N.C

8 N.C

9 SEN#1 DC12V FRONT SENSORPR12-4DN

brown DC12-24V

1

10 SEN#1 GND blueGND

2

11 IN 1 blackSIGNAL OUT

3

12 O.C OUT 1

13 SEN#2 DC12V REAR SENSORPR12-4DN

brown DC12-24V

1

14 SEN#2 GND blueGND

2

15 IN 2 blackSIGNAL OUT

3

16 O.C OUT 2

SENSOR CONTROLLER

SAFETY CIRCUITS FUNCTIONAL DESCRIPTION


2.2.2.2. Led�s

2.2.2.3. Switches

LED Type Color Indication

OUT 1 red Not in use

OUT 2 red Not in use

IN 1 orange Front door

IN 2 red Rear door

POWER green 220V AC

Switch Setting Description

AND/OR AND 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 Selection switch to invert the inputs.

NORM/FLANK NORM 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 SA = ONSB, SC and SD = OFF

TIME SET T1 = ONT2 = 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.

TIME ANALOG Fine adjustment for TIME SET switches

FUNCTIONAL DESCRIPTION POWER DISTRIBUTION


3. Power Distribution

3.1. Functional Description

3.1.1. Electrical Circuit Panel

Figure 1.10: Electrical circuit panel

1

2

1 3

4 5 6

7

8

9

1 Main power inlet terminal block 6 Ring blower #1 MC - Ring blower switch 1st step on, �Circuit Close�

2 1st circuit breaker (MCCB #1, main circuit braker 50A)

7 Ring blower #2 MC - Ring blower switch 2nd step on, �Circuit Close�

3 Noise filter 8 SMPS8 - supply power (+24VDC) to main MC and FAN in power distribution panel

4 Main MC (MC #1) - Closed by Start button - Open when activating one of the emer-gency stops.

9 Terminal blockRouting emergency switch, start button and Main MC

5 2nd circuit breaker (MCCB#2 to #6)MCCB #2, LampMCCB #3, Ring blower 1MCCB #4, Ring blower 2MCCB #5, Motor driverMCCB #6, Control Rack

POWER DISTRIBUTION FUNCTIONAL DESCRIPTION


3.1.2. System Needed Power

To check the permanent voltage, refer to �Checking the Permanent Voltage� on page 5-7 of the Troubleshooting chapter.

3.1.3. Circuit Diagrams

! 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 7-13 (chapter Annex).

S YS TE M N E E D P O W E R Model : :ANAPURNA

in le t p o w e r N o ite m F re q u e n c y d e ta ilso u tp u tvo lta g e(V )

c u rre n t(A )P o w e r(K w ) Q 'ty M A X (K w )w e ig h te

dva lu e

V oltage: P C 24 12.5 0.3 1 0.3

3P H A S E 120 2 0.24 2 0.48

380V 24 5 0.12 2 0.24

frequency 24 3 0.072 2 1.5

2.5

50/60H z :ANAPURNA L 220 2 0.44 2 0.88

220 2 0.44 1 0.44

220 3.6 0.8 1 0.8

3P hase 380V -50H z 380-50H z 3.8 1.5

3P hase 380V -60H z 220-60H z 3.7 1.75

3P hase 380V -50H z 220-50H z 3.8 1.5

3P hase 380V -60H z 220-60H z 3.7 1.75

3 LA M P V :230V / F :50H z 220 20 4.4 1 4.4

4 C O M P R E S S O R 220 2 0.44 1 0.44

5 E X H A U S T 220 2 0.44 1 0.44

11.66 11.66

12.02 13.42

100%

:ANAPURNA L

:ANAPURNA XL

2

2

3

3

S M P SC O N TR O L R A C K

:ANAPURNA XL

1 V :230V / F :50H z

S ub-Total

Total:ANAPURNA L

:ANAPURNA XL

S E R V O M O TO R

* M otor pem issible voltage: A C 200V ~ A C 240V (50H z/60H z) prevoltage test is required.

3 R IN G B LO W E R

2

FUNCTIONAL DESCRIPTION COMPRESSED AIR DISTRIBUTION


4. Compressed Air Distribution


4.1.1. Pneumatic Flow Chart & Circuit

The pneumatic air flow is represent in the diagram below. Each component, indicated by means of a colour, is discussed in this section.

! 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).

R

P

A

Air Tank

Waste TankOver-flow Sig.

Setting Press UV lamp0.10 - 0.15 MPa

Air Filter # 1

Air Filter # 2

EBEA

A

P

B

EBEA

A

P

B

� �

INOUT

Media set Cylinders

Media Hold Front/Rear Cylinders

0.3 MPa 0.15 MPa

Setting Press Carriage

Setting Press CarriageSetting Press Carriage

0.03 MPa

VACUUMEJECTOR

Purge S/WSig.

Purge S/W Sig.

EBEA

A

P

B

EBEA

A

P

B

Lamp Shutter Left/Right Cylinders

I/O PC B Sig. I/O PC B Sig.

4f Air Tube

A P

R

SU P OU T

P A R

P

A

P A

R

PCB

E/PRegulator

Float Sensor Sig.

Float SensorSig.

Pressure Sig.Float SensorSig.

PSE531-M5

Checkvalve

Checkvalve

SOLUTIONSUB-TANK

SOLUTIONBAR

MAIN WASTEINKTANK

SUBAIR

TANK

INKTANK

T

Carriage Part

Main Air Press.0.4 - 0.8 MPa

Max. Press. 2MPaCapacity 0.005M3

Setting Press0.6 MPa

0.3 - 0.7 MPaPurge Sig.

COMPRESSED AIR DISTRIBUTION FUNCTIONAL DESCRIPTION


4.1.2. Compressed Air Pressure

Figure 1.11: Air pressure panel

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

1

2 3 4 5 6 7

8

0.15 MPa0.10 - 0.15 MPa

0.40 - 0.80 MPa 0.30 MPa

1 Main air pressure inlet portMain air inlet pressure indicator

5 1st regulator at carriage div. (0.3 MPa)

2 Main regulator (0.4-0.8 MPa) 6 Air filter #2

3 Lamp shutter regulator (0.10 MPa-0.15 MPa)

7 2nd regulator at carriage div. (0.15 MPa)

4 Air filter #1 8 Water drain out



4.1.3. Carriage Part

4.1.3.1. Head carriage unit - pneumatic flow key parts

Figure 1.13: Rear side head carriage unit

! 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 2 5 6 7

8 11109

12

43

1 Sub air tank and ink overflow tank 7 Solution valve

2 Air relief valve sub air tank(speed V/V (AS1001F-06) + air filter)

8 Electro-pneumatic regulator ITV2010

3 Pressure sensor PSE531-M5-L 9 Vacuum ejector INO-4336-4

4 Drain cock (when overflow) 10 Purge air valve VT301V-025GB

5 Solution tank 11 Purge air valve VT301-025GB

6 Lamp shutter solenoid valves 12 ITV2010 display



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.

Figure 1.14: Front side head carriage unit

NOTE: The other items of Figure 1.13 are discussed in other paragraphs.

1 2

1 Purge switch 2 Purge regulator (0.03 MPa)



4.1.4. Air Tank

The system is provided with a main air tank and serves as a buffer to remove the pressure fluctuations.

Figure 1.15: Air tank

! 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).

4.1.5. Lamp Shutter Left/Right Cylinders

The two 5/2-way valves are mounted inside the UV lamp box housing and are driven by a signal coming from the I/O PCB. By pressing the lamp shutter solenoid valve, you can check the function-ality of the lamp shutter.

21

1 Main air tank 2 Drain cock

2 31

1 Lamp shutter solenoid valves 3 Lamp shutter closed

2 Lamp shutter open



4.1.6. Media Set Cylinders and Media Hold Front/Rear Cylinders

4.1.6.1. Location and Drivers

! 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.



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

PLC

Main Air Supply

Main Air Supply

8

6

1 2 3 4 5

7

MainAir Supply

MainAir Supply

Front

GND

Gnd24 Vdc

Back

NO

NO NC

3 Level SwitchMedia Set

Front

NO

P 040P 051P 052P 04E

P 04A

A1

A2

A1

A2

A1 A2

A1 A2

P 002P 000

P 018P 019

Back

NO

Front

NO

Rear

Front

Rear

1 2 3 6 5 4



4.1.7. Negative Pressure Setting

Without negative pressure, all ink in the sub ink tanks would be flowing away through the heads. By means of negative pressure, the ink is kept in the print heads. A too high setting will cause missing nozzles, or no ink firing at all. When the pressure is too low, the ink will leak out of the heads.

When the system is switched on (pushing the Start button), the uninterrupted compressed air should be supplied.

! The pressure distribution can be controlled as follows:

1 Check the positive pressure (Refer to Figure 1.12)

1.1 Go to the air pressure panel (home rear side).

1.2 Check the incoming compressed air pressure with a pressure gauge.

1.3 The main regulator should indicate 0.6 MPa.

1.4 Check the pressure of the other regulators with a pressure gauge.

The UV lamp regulator should indicate 0.1-0.15 MPa.

The first carriage regulator should indicate 0.3 MPa, the second 0.15 MPa.

2 Check the negative pressure

2.1 Go to the vacuum pressure PID panel (home front side).

2.2 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).

2.3 Drain water from the three air filters at the air pressure panel (home rear side).

For more informztion about draining water from the air filter, refer to �Draining the Air Filter� on page 4-70 (chapter Preventive Maintenance)

CAUTION: When controlling the regulator, in case of no pressure changes, check the connection of the hose and setting values of the regulators.

NOTE: Make sure the power part does not make contact with water.

FUNCTIONAL DESCRIPTION DATA FLOW


5. Data flow


The table below briefly describes the image data flow:

5.2. Printed Circuit Boards

The following printed circuits boards are part of the data flow:

! �FPGA PCB� on page 1-102

! �MAIN PCB� on page 1-95

! �HEAD PCB� on page 1-108

! �CARTRIDGE PCB� on page 1-123

Number Data Flow Connection

1 The image files (.rtl) generated on the RIP station are sent to the Anapurna PC via a network cable.

2 Direct connection between PC main board and the FPGA PCB via PCI I/O card.

3 The image data is transferred via a direct connection from the FPGA PCB to the MAIN PCB.

4 The ripped data is sent from the MAIN PCB (J16, pin 1-16) to the HEAD PCB (J9, pin 1-16)

5 Color data is sent from HEAD PCB (J1-J8, pin 6-7) to the eight (6C + 2 W) CARTRIDGE PCBs (J5, pin 6-7) via flat ribbon cable.

AnapurnaP C

PC FOR RTL FILE(RIP PC)

MEMORY

FPGA CIRCUIT

RS 232

FPGA PCB

CONTROL CIRCUIT

INTERFACE CIRCUIT

MAIN PCB

HEAD PCB

CARTRIDGE PCB

PRINT HEAD

1

2 3 4

5

6

MEDIA TRANSPORT FUNCTIONAL DESCRIPTION


6. Media Transport


6.1.1. General Information

P C


HEAD LIFTPCB

UP/DOWNSENSOR

UP/LOCKSOLENOID

STEP MOTOR

MEMORY

FPGA CIRCUIT

RS 232

FPGA PCB

CONTROL CIRCUIT

INTERFACE CIRCUIT

MAIN PCB

SUB PCB

P L C (K7M-DR60S)


UV LAMP CONTROL

TOWER LAMP CONTROL

MEDIA STOP CONTROL

UV LAMP

REFILL PCB

PRESSURE SENSOR


FEED BACK ON/OFF

ZERO GAIN CONTROL

ITVCONTROLLERPCB

ITV


HEAD PCB

CARTRIDGE PCB

PRINT HEAD

HEATING120VDC



REFILL CONTROL PCB


TAKE UPMOTOR

TAKE UP PCB


IF PCB

PID CONTROLLER



FEED MOTORCARRIAGE

MOTOR

FUNCTIONAL DESCRIPTION MEDIA TRANSPORT


6.1.2. 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.

6.1.2.1. Media Fixing Roll Bars

The engine is equipped with two media fixing roll bars (1), one on the front and one on the rear. They are located underneath the front and rear covers. These bars will help to keep the media flat during transport on the conveyor belt. It can be used for roll media as well as for rigid media. To lower the bars, use the front/rear switched at the home unit (both front and rear).

1 132

2

4

1 Feed servo motor (400W) 3 Polyester woven conveyer belt

2 Vacuum blower 4 Reduction gear motor

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.



6.1.2.2. Vacuum Plate Usage

On the table are 2 vacuum-zones with a fixed strength. The table is evenly divided in a right and a left side, which can be switched on in that order by means of the vacuum switch located at the home unit (front and rear).

! 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.

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

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.

5

1 2 3 4

1 Vacuum blower 4 Compressed air connection

2 Air controller with air relief valve 5 Electrical connection

3 Silencer



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).



6.1.3.2. Functioning

The illustration below describes the functioning of the vacuum blowers.

Figure 1.18: Functioning vacuum blowers

HOME UNIT

PLC

Step 10

NC NO

NCNO

1 2

0

NC NO

1 2

0

NC NO

1 2

Step 2

Step 3

Front

Gnd

3 Level SwitchFront Panel

Push buttonBack Panel

Gnd

24Vdc

41

42

4B

04

05

0C

Rear

A131

34

Relay #2A2

A1A2

L1 L2 L3

Gnd

24 Vdc

11

12

A141

44

Relay #3A2

A1A2Gnd

24 Vdc

11

12

NOTE: For more information about the use of the vacuum blowers, refer to �Vacuum Plate Usage� on page 1-31.



6.1.4. Roll to Roll Media

6.1.4.1. Auto Feeding System

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.

4

1

3

2

1

Front side Rear side

1 Tension roll bar 3 Rear media roll bar

2 Front media roll bar 4 Rubber roll bar

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.



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.

6.1.4.2. Take Up Control System

! (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)

! (4) Select Mode (Manual or Auto)

1 2

Take-up Motor Box1 2 3 4



6.1.4.3. Roll Alignment

Always use the left or right dark blue border on the conveyer belt as a reference to align the paper edge of the print medium. When the roll media is loaded, measure the distance from the right side to the point where you want to start printing. Enter this value on the engine's Control Program, as a Left Margin.

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.

6.1.4.4. Loading Roll to Roll Media

When using roll to roll media, it is imperative to have a good roll to roll transportation, to ensure long print runs.

Use the rear media roll bar to mount the print medium roll. Mind the following print medium roll restrictions:

! 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 print-able 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

Anapurna L 1,30 m - 1,58 m (max width) Load along the dark blue border of the printing table

< 1,30 m (20% of max width)

Load in the middle of the printing table

Anapurna XL 2,00 m - 2,48 m (max width) Load along the dark blue border of the printing table

< 2,00 m (20% of max width)

Load in the middle of the printing table



! Load a print medium roll as follows:

1 Remove the rear media roll bar.

The rear media roll bar is equipped with two movable flanges between which the print medium roll is clamped.

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.

2

1

1 Rear media roll bar with movable clamping flange

2 Flange with black turning knobs

CAUTION: If you do not use the media core, the tension roll bar will be lifted out of its position .



6.2 Proceed with step 8.

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.

WWRONG OK

2

11

1 Dark blue border on the conveyer belt 2 Print medium positioned on the print table at the front side



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.

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.

1

2

3

1 Rubber roll bar 3 Rear media roll bar2 Rear tension roll bar

NOTE: For more information about the operating instructions, refer to the Operator Manual of the Anapurna L/XL.



6.1.5. Rigid Media

6.1.5.1. Rigid table

The Anapurna L and Anapurna XL can handle rigid materials. You can level the rigid table with the print table using the height control handle.

6.1.5.2. Media register pins

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.



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.

5 Start printing.

6.1.6. Servo Motor Driver Settings and Usage

! 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.

NOTE: Image placement for printing on two rigids must be done at RIP level.

Feed Servo Motor Driver Carriage Servo Motor Driver

1 3 42

1 SW1: MODE change 3 SW3: DOWN - change by descending order

2 SW2: UP - change by ascending order 4 SW4: SET - save values, it can be consid-ered as �ENTER key�



6.1.6.1. Servo motor parameters

Check the values of feed and carriage at the corresponding servo motor driver in the following cases:

! 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.

NO. Symbol Name and functionInitial Value

Unit

Customer setting

Feed Carriage

Basic Parameters

0 *STY Command system/regenerative brake option selection 0000 0010 0410

1 *FTY Feeding function selection 0000 0001 0001

2 *OP1 Function selection 1 0002 0001 0002

3 ATU Auto tuning 0105 040B 0405

4 *CMX Electronic gear numerator 1 2048 2048

5 *CDV Electronic gear denominator 1 125 125

6 FED Movement complete output range 100 µm 100 100

7 PGI Position loop gain 35 rad/s 200 20

8 *ZTY Home position return type 0010 0004 0004

9 ZRF Home position return speed 500 r/min 500 500

10 CRF Creep speed 10 r/min 10 10

11 ZST Home position shift distance 0 µm 0 0

12 CRP For manufacturer setting 0 x10STMµm 0 0

13 JOG JOG Jog speed 100 r/min 100 100

14 *STC S-pattern acceleration/deceleration time constant 0 ms 100 0

15 *SNO Station number setting 0 station 1 2

16 *BPS Communication baudrate selection, alarm history clear 0000 0102 0102

17 MOD Analog monitor output 0100 0100 0100

18 *DMD Status display selection 0000 0000 0000

19 *BLK Parameter block 0000 000E 000E

Expansion Parameters 1

20 *OP2 Function selection 0000 0000 0000

21 For manufacturer setting 0002 0002 0002

22 *OP4 Function selection 0000 0000 0000

23 SIC Serial communications time-out selection 0 0 0

24 FFC Feed forward gain 0 % 0 0

25 VCO Override offset 0 mV 0 0

26 TLO Torque limit offset 0 mV 0 0

27 *ENR Encoder output pulses 4000 pulse/rev 4000 4000

28 TL1 Internal torque limit 100 % 100 100

29 TL2 Internal torque limit 100 % 100 100

30 *BKC Backlash compensation 0 pulse 0 0

31 MO1 Analog monitor 1 offset 0 mV 0 0



32 MO2 Analog monitor 2 offset 0 mV 0 0

33 MBR Electromagnetic brake sequence output 100 ms 100 100

34 GD2 Ratio of load inertia moment to Servo motor inertia moment 70 0.1 times 1.0 8.0

35 PG2 Position loop gain 35 rad/s 250 25

36 VG1 Speed loop gain 177 rad/s 1300 1100

37 VG2 Speed loop gain 817 rad/s 1300 900

38 VIC Speed integral compensation 48 ms 5 40

39 VDC Speed differential compensation 980 980 980

40 JOG operation acceleration/deceleration time constant 0 0

41Home position return operation acceleration/deceleration time constant

0 0

42 *ZPS Home position return position data 0 x10STMµm 0 0

43 DCT Moving distance after proximity dog 1000 x10STMµm 1000 1000

44 ZTM Stopper type home position return stopper time 100 ms 100 100

45 ZTT Stopper type home position return torque limit value 15 % 15 15

46*LMP Software limit + 0 x10STMµm 0 0

47

48*LMN Software limit - 0 x10STMµm 0 0

49

50*LPP Position range output address + 0 x10STMµm 0 0

51

52*LNP Position range output address - 0 x10STMµm 0 0

53

Expansion Parameters 2






59 *OPA Function selection A 0000 0000 0000


61 NH1 Machine resonance suppression filter 1 0000 0000 0000

62 NH2 Machine resonance suppression filter 2 0000 0000 0000

63 LPF Low-pass filter, adaptive vibration suppression control 0000 0000 0000

64 GD2B Ratio of load inertia moment to Servo motor inertia moment 70 1/10 Ratio 70 80

65 PG2B Position control gain 2 changing ratio 100 % 100 100

66 VG2B Speed control gain 2 changing ratio 100 % 100 120

67 VICB Speed integral compensation changing ratio 100 % 100 100

68 *CDP Gain changing selection 0000 0000 0004

69 CDS Gain changing condition 10 (Note) 10 10

70 CDT Gain changing time constant 1 ms 1 1

71

For manufacturer setting

100 100 100

72 10000 10000 10000

73 10 10 10

74 OUT1 output time selection 10 10 10


Unit

Customer setting

Feed Carriage




The following printed circuits boards are part of the servo drivers:

! �TAKE UP PCB� on page 1-148

! �DRIVER COMMUNICATION PCB� on page 1-156



77 Selected to program input polarity selection 100 100 100

Special Parameters

78

For manufacturer setting

0000 0000 0000

79 0009 0009 0009

80 080A 080A 080A

81 0706 0706 0706

82 020B 020B 020B

83 0504 0504 0000

84 0032 0032 0032

85 0000 0000 0000

86 0005 0005 0005

87 0D04 0D04 0D04

88 0102 0102 0102

89 0 0 0

90 0 0 0


Unit

Customer setting

Feed Carriage

INK SUPPLY SYSTEM FUNCTIONAL DESCRIPTION


7. Ink Supply System



P C


HEAD LIFTPCB

UP/DOWNSENSOR

UP/LOCKSOLENOID

STEP MOTOR

MEMORY

FPGA CIRCUIT

RS 232

FPGA PCB

CONTROL CIRCUIT

INTERFACE CIRCUIT

MAIN PCB



FEED MOTORCARRIAGE

MOTOR

SUB PCB

P L C (K7M-DR60S)


UV LAMP CONTROL

TOWER LAMP CONTROL

MEDIA STOP CONTROL

UV LAMP

REFILL PCB

PRESSURE SENSOR


FEED BACK ON/OFF

ZERO GAIN CONTROL

ITVCONTROLLERPCB

ITV


HEAD PCB

CARTRIDGE PCB

PRINT HEAD

HEATING120VDC



REFILL CONTROL PCB


TAKE UPMOTOR

TAKE UP PCB


IF PCB

PID CONTROLLER

FUNCTIONAL DESCRIPTION INK SUPPLY SYSTEM


7.1.2. Ink Supply Flowchart

The Ink supply flowchart below shows:

! The ink flow in the machine.

! The different parts of the ink system.

Figure 1.19: Ink supply flowchart

7.1.3. Key Parts For Ink Supply

InkBottle

ColorInk Tank+Air Filter

Sub Ink Tank (6C)

SolutionTank

Ink/SolutionValve

Print Head

Ink

Ink Pump

IN OUT IN OUT

Ink Filter

1 2 3

4 5 6

7 8 97

1 Ink bottle 4 Ink filter 7 Sub ink tank (6C and W)

2 Main ink tank 5 Ink hose fixing (top) 8 Ink/Solution Valve

3 Ink pump 6 Ink hose fixing (bottom) 9 Print head



7.1.3.1. Main ink tank / Main solution tank

! 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).

! Ink tank indicator

! 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.

2

1



! Refill system

! The system is provided with an automatic/manual ink refill system.

! Ink can be refilled in while printing.

! Ink bottle/Solution Bottle

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.



7.1.3.2. Ink pump

The ink pump pumps the ink from the main ink tank into the sub ink tank. The ink is transported via an ink supply tube located in the chain.

7.1.3.3. Ink filter

Bleeding the ink filter is necessary in two circumstances:

! 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.

Checking the ink filter.

! 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.

7.1.3.4. Ink tubes

! 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.

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: Don�t bleed inks around the tanks.

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.

NOTE: For more information about bleeding the ink filters, refer to �Bleeding the Ink Filters� on page 4-56 (chapter Preventive Maintenance).



7.1.3.5. Sub ink tank (6C + White)

The sub ink tanks are located at the front side of the head carriage unit. We distinguish two sub ink tanks:

! 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.

21

1 6 Sub ink tank for each color 2 1 Sub ink tank for white

21



! Temperature setting sub ink tank (6C + W) should be:

! To adjust the sub ink tank temperature and the white sub ink tank temperature, use the keypad underneath the display.

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).

! A head temperature sensor (safety thermostat 45°C) 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.

Settings Printing with white ink Printing without white ink

Sub ink tank temperature (1) 38°C 38°C

White sub ink tank temperature (2) 40°C 25°C

3

2

1

1 PV: processing value indicator (RED) 3 Keypad

2 SV: setting value indicator (GREEN

21 3 4

1 Heater Plate of white sub ink tank 3 J14 Head Lift PCB

2 Heater Plate of 6C sub ink tank 4 J25 Head Lift PCB



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 key, until you reach the desired digit.

4 Press the and keys to adjust the set value of the selected 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.

7.1.3.6. Solution tank

The solution tank is located at the rear side of the head carriage unit besides the sub air tank.

! 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.

7.1.3.7. The 2-way valves

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.

CAUTION: Be aware that the solution tank is always full with solution liquids.

1 2 3

4 5

1 K, C, M, Y, Lc and Lm valve 4 Ink outlet direction2 W valves 5 Solution outlet direction3 Solution (S) valve

NOTE: For more information about cleaning the print heads, refer to �Cleaning a Print Head� on page 4-38 (chapter Preventive Maintenance).



7.1.3.8. Print head

7.1.3.9. Waste tank

The stainless steel waste tank is located underneath the conveyor belt, attached with 2 clamping brackets to the rear left side of the engine.

! Full detection sensor.

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).

NOTE: For more information, refer to the functional description of the �Print Head� on page 1-61.




The following printed circuits boards are part of the ink supply system:

! �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

HEAD CARRIAGE MOVEMENT FUNCTIONAL DESCRIPTION


8. Head Carriage Movement



P C


HEAD LIFTPCB

UP/DOWNSENSOR

UP/LOCKSOLENOID

STEP MOTOR

MEMORY

FPGA CIRCUIT

RS 232

FPGA PCB

CONTROL CIRCUIT

INTERFACE CIRCUIT

MAIN PCB



FEED MOTORCARRIAGE

MOTOR

SUB PCB

P L C (K7M-DR60S)


UV LAMP CONTROL

TOWER LAMP CONTROL

MEDIA STOP CONTROL

UV LAMP

REFILL PCB

PRESSURE SENSOR


FEED BACK ON/OFF

ZERO GAIN CONTROL

ITVCONTROLLERPCB

ITV


HEAD PCB

CARTRIDGE PCB

PRINT HEAD

HEATING120VDC



REFILL CONTROL PCB


TAKE UPMOTOR

TAKE UP PCB


IF PCB

PID CONTROLLER

FUNCTIONAL DESCRIPTION HEAD CARRIAGE MOVEMENT


8.1.2. Head Carriage Part View

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.

! Vertical movement

head lifting along the along 2 LM guides (head lifting type).

Figure 1.20: Head carriage unit - parts & movement

1 2 4 5 63

7

8

9

10

1

1 UV source 6 Sub ink tank (W)

2 Print Head 7 Upper LM guide

3 Head base plate 8 Linear scale (Encoder strip)

4 Manual head height setting knob 9 Lower LM guide

5 Sub ink tank (6C) 10 S3M belt, carriage belt



8.1.3. Head Base Height Control

Two manners to control the head base height;

! Automatic head base height control.

! Manual head base height control

8.1.3.1. Automatic head base height setup

The printer is equipped with an automatic head measuring device to be able to measure the media height easily and correctly. The automatic head base height must be done every time you change the print medium.

Fill out the parameters in the Head Gap Control group of the Setup parameters window.

8.1.3.2. Manual head base height setup

This is just a quick way to check the current Head Base Height. You can use this procedure to check the head base height at different positions along the entire media width.

To execute a manual head base height, proceed as follows:

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).

NOTE: For more information about how to set the head gap, refer to �Head Gap Control� on page 1-84.

1

2

3



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.

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.

8.1.3.3. Manual head height setting knob

The manual height adjustment knob (1) is located at the rear side of the head carriage. Use this knob to calibrate the Reference parameter (2) in the Head Gap Control group.

12

34

56

7

2

1

NOTE: For more information about the Reference value, refer to �Factory Set� on page 1-86.



8.1.4. Linear Scale Encoder

8.1.4.1. General Information

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 µm (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

5

76

432

1 Linear scale (encoder strip) 5 Main PCB

2 Encoder 6 ENC LED (Encoder)

3 Encoder bracket 7 MARK LED

4 Limit switch (home position)



8.1.4.2. Encoder Test

Execute an encoder test in the following circumstances:

! 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 (> 38°C), 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 <40°C should be possible with a 2-ventilator system.

8.1.4.3. Encoder Check

An encoder check is required in the following circumstances:

! the head carriage unit is not moving,

! the head carriage unit is not moving smoothly,

! the position of the head carriage unit is shifting.


The following printed circuits boards are part of the ink supply system:

! �HEAD LIFT PCB� on page 1-127

! �DRIVER COMMUNICATION PCB� on page 1-156

NOTE: For more information about the encoder check, refer to �Encoder Checking� on page 4-25 (chapter Preventive Maintenance)

PRINT HEAD FUNCTIONAL DESCRIPTION


9. Print Head


P C


HEAD LIFTPCB

UP/DOWNSENSOR

UP/LOCKSOLENOID

STEP MOTOR

MEMORY

FPGA CIRCUIT

RS 232

FPGA PCB

CONTROL CIRCUIT

INTERFACE CIRCUIT

MAIN PCB

SUB PCB

P L C (K7M-DR60S)


UV LAMP CONTROL

TOWER LAMP CONTROL

MEDIA STOP CONTROL

UV LAMP

REFILL PCB

PRESSURE SENSOR


FEED BACK ON/OFF

ZERO GAIN CONTROL

ITVCONTROLLERPCB

ITV


HEAD PCB

CARTRIDGE PCB

PRINT HEAD

HEATING120VDC



REFILL CONTROL PCB


TAKE UPMOTOR

TAKE UP PCB


IF PCB

PID CONTROLLER



FEED MOTORCARRIAGE

MOTOR

FUNCTIONAL DESCRIPTION PRINT HEAD


9.1.1. Ink Supply By Means of Negative Pressure


! 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.

9.1.1.2. How To Make Changes

To adjust the vacuum pressure (1):

1 unlock the pressure control adjustment knob (3) by pushing the switch (2) to the left.

2 turn the pressure control adjustment knob until you reach the desired pressure (range -0.032 MPa to -0.038 MPa).

3 push the switch back to secure the pressure control adjustment knob.


Vacuum pressure -0.034 to -0.038 MPa -0.032 to -0.035 MPa

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.

1

2

3



9.1.2. Head Base Temperature Control


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 32°C when engine is not in use (cold engine).

! When printing, the temperature increase. For good printing results, the temperature indication should not exceed 38°C.

! Make sure you print with closed engine doors all the time, especially when room temperatures are 25°C and above. This will give you the best cooling inside the engine.

9.1.2.2. Temperature detection components and setting components

! 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.


Head base temperature (cold) 32°C 32°C

NOTE: In case the head base temperature > 38°C 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.

FUNCTIONAL DESCRIPTION PRINT HEAD


! A safety thermostat (80°C) is mounted on head base plate.

! 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.

1 2

1 PT sensor bracket 2 Temperature sensor cable

M Y Lc

M Y Lc Lm W



9.1.2.3. How To Make Changes

The temperature of the head base plate can only be tuned by changing the head PCB voltage.

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 32°C on most engine configurations.

The higher the voltage value, the lower the temperature value.


The following printed circuits boards are part of the print head:

! �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

Head PCB

Cartridge PCBs

FUNCTIONAL DESCRIPTION UV CURING


10. UV Curing


P C


HEAD LIFTPCB

UP/DOWNSENSOR

UP/LOCKSOLENOID

STEP MOTOR

MEMORY

FPGA CIRCUIT

RS 232

FPGA PCB

CONTROL CIRCUIT

INTERFACE CIRCUIT

MAIN PCB

SUB PCB

P L C (K7M-DR60S)


UV LAMP CONTROL

TOWER LAMP CONTROL

MEDIA STOP CONTROL

UV LAMP

REFILL PCB

PRESSURE SENSOR


FEED BACK ON/OFF

ZERO GAIN CONTROL

ITVCONTROLLERPCB

ITV


HEAD PCB

CARTRIDGE PCB

PRINT HEAD

HEATING120VDC



REFILL CONTROL PCB


TAKE UPMOTOR

TAKE UP PCB


IF PCB

PID CONTROLLER



FEED MOTORCARRIAGE

MOTOR

UV CURING FUNCTIONAL DESCRIPTION



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.

10.1.2. Curing Setup (Software Settings)

For more information, refer to the �UV Options� on page 1-83.

1 2

1 UV source (left) 2 UV source (right)



10.1.3. UV Lamp Power Setting

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.



10.1.4. UV Lamp Assembly

1

4

2

3

3

6

8

5

7

9

10

1 Lamp power connector (4P) 6 Lamp shutter signal connector (2P)(LAMP SHUTTER L label)

2 UV lamp box 7 Lamp shutter ON pneumatic tube (yellow)

3 Lamp case outer air inlet AC FAN 8 Lamp shutter OFF pneumatic tube (red

4 UV lamp box housing 9 Lamp case inner air outlet DC FAN

5 Lamp signal connector (10P)(LAMP-L-SIG label)

10 UV Lamp



10.1.5. UV Lamp Power Box Description

Located behind the main box left side door.

10.1.5.1. Outer Description

Figure 1.21: UV lamp power box (outer description) - parts

1

12

2 3 4 5 6 7 8 9 10

11

1 AC fuse 7 (R) HIRight UV lamp status indicator - full power

2 DC fuse 8 Air inhalation hole

3 POWLamp status indicator - Power ON

9 RIGHT lamp connector (7P)

4 (L) LOWLeft UV lamp status indicator - half power

10 RIGHT lamp connector (4P)

5 (R) LOWRight UV lamp status indicator - half power

11 LEFT lamp connector (7P)

6 (L) HILeft UV lamp status indicator - full power

12 LEFT lamp connector (4P)



10.1.5.2. Inner Description

Figure 1.22: UV lamp power box (inner description) - parts

Figure 1.23: UV lamp power box (inner description) - detail low voltage and high voltage relays

7 6 5

4

3

2

1

9

8

1 Low voltage relays 6 Elcos (#6)

2 Right lamp power settings 7 High voltage relays

3 Left lamp power settings 8 UV lamp PLC, type K7M-DR40S

4 AC cooling fan 9 Relays

5 Power supply SMPS #6

1

2

3

4

5

6

1 Relay ACfan (L) 5 Relay MC(R) - HIGH

2 Relay ACfan (R) 6 Relay MC(R) - LOW

3 Relay SHUTTER (L) 7 Relay MC(L) - HIGH (not visible)

4 Relay SHUTTER (R) 8 Relay MC(L) - LOW (not visible)



Figure 1.24: UV lamp power box (inner description) - detail Relays and UV lamp PLC

10.1.6. UV Lamp Power Settings

The left (1) and right (2) UV lamp power settings are set according to the outer power supply (voltage/frequency).

1

2

3

4

5

1 RK2 relay 4 LK1 relay

2 RK1 relay 5 UV lamp PLC, type K7M-DR40S

3 LK2 relay

1 2

250V

220V

208V

60Hz

50Hz

250V

220V

208V

60Hz

50Hz

1 UV lamp power (left) 2 UV lamp power (right)

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.



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

UV Lamp Assy (Left)

4P connector (L)

4P connector (L & R)7P connector (L & R)

10P connector (L)




The following printed circuits boards are part of the UV curing:

! �SUB PCB� on page 1-136

PROGRAMMABLE LOGIC CONTROLLER (PLC) FUNCTIONAL DESCRIPTION


11. Programmable Logic controller (PLC)


11.1.0.1. Figure

Figure 1.25: Main PLC - type K7M-DR60S

Figure 1.26: UV lamp PLC - type K7M-DR40S

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.

FUNCTIONAL DESCRIPTION PROGRAMMABLE LOGIC CONTROLLER (PLC)


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).

11.1.0.4. Connectors Main PLC


Name and Function


5045-4P SUB J4 1 P014

2 P00A

3 P013

4 P012

5 P011


Name and Function


5027-2P REFILL J13

1 P0B

2 NOT USED


Name and Function


SELECT S/W 1 GND

2 P005

3 GND

4 P004

+ 24V+

- P005

1 N.C

2 N.C

3 P016

4 GND

+ P051

- GND

1 N.C

2 N.C

3 P017

4 GND

+ P052

- GND

1 GND



2 P003

3 GND

4 P007

+ 24V+

- P003

1 GND

2 P006

3 GND

4 P008

+ 24V+

- P003

1 GND

2 P000

3 GND

4 P002

+ 24V+

- P000

1 N.C

2 N.C

3 P018

4 GND

+ P052

- GND

1 N.C

2 N.C

3 P019

4 GND

+ P052

- GND

N.O P0C

COM GND

+ P04B

- GND


Name and Function


D-SUB 15P LAMP PLC

GND 1

44 2

46 3

43 4

45 5

4D 6


Name and Function


FUNCTIONAL DESCRIPTION PROGRAMMABLE LOGIC CONTROLLER (PLC)


4F 7

9 9

10 10


Name and Function


EPDB BLOWER START

E066 GND

E044 P041

E034 P042


Name and Function


5557-8P SOL V/V P04E 1

P052 2

P051 3

GND 4

P040 5

GND 6

GND 7

GND 8


Name and Function


SOL VT 301 P015 VT301


Name and Function


5557 - 4P *2 TOWER LAMP

P047 1

P048 2

P049 3

P04A 4

P04B 1

P04C 2

GND 3


Name and Function





Name and Function


5557-2P WASTE TANK SENSOR

P001 1

GND 2

FUNCTIONAL DESCRIPTION ANAPURNA CONTROL PROGRAM


12. Anapurna Control Program

12.1. Control Program

The Anapurna Control program on the engine's PC.

NOTE: The Anapurna Control Program is discussed in detail in the Operator Manual.

NOTE: Here only the buttons used for maintenance actions are discussed.

1 3 4 5

6

7

8

9

10

1112141516

22

13

1 IMAGE SIZE display window 9 To indicate the printing progress

2 To open an image file(.rtl) 10 STATUS Message display window

3 To access the Setup Parameters window 11 To move head carriage unit to Home position

4 Select pass mode 12 To move head carriage unit to Purge position

5 To access the Test Menu window 13 To jog the loaded media Forwards/Backwards

6 To set Top (forward) and Left Margin 14 To move the loaded media Forwards/Backwards

7 To select Uni-Directional printing 15 To lift the head to highest position (>50mm)

8 To start printing 16 IMAGE display window

ANAPURNA CONTROL PROGRAM FUNCTIONAL DESCRIPTION


12.2. Buttons used for Maintenance Purposes

The table below lists the buttons that are used for maintenance purposes.

12.3. Setup Parameters

In the Control Program, click Setup to get access to the Setup Parameters window.

Button Explanation

Head Lift - Up To lift the head carriage in emergency situations, e.g. head colli-sion with the print media.

Carriage Position - Purge To move the head carriage to the purge position.

Carriage Position - Home To move the head carriage to the home position.

Media Feed - Jog To jog the loaded media forwards (+ value) or backwards (- value)Value range: -300 mm to + 300 mm

Media Feed - Back To move the loaded media backwards.

Media Feed - Forward To move the loaded media forwards.

Setup To open the Setup Parameters window.See �Setup Parameters� on page 1-81.

Test To open the Test Menu window.See �Test Menu� on page 1-88.

Window Fields

� Bi-Dir Alignment,� Step Size (Media Feed)� Carriage Speed� Feed Speed� UV Options� Head Gap Control� Factory Set

(password protected)� Data File Name� Head Offset



12.3.1. Bi-Dir Alignment

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.

12.3.2. Step Size (Media Feed)

The Step Size is also known as Media Feed. You can visually see on a printed image if you need to adjust the Step Size.

! To adjust the Step size, proceed as follows:

1 Visually check the printed image (see example below).

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: This only applies to Bi-directional printing!

Dark lines in the print, as a result of overlapping passes.

White lines in the print, as a result of a gap between the passes.

Solution: Increase the Step Size value from: e.g.: 51660 to 51680

Solution: Decrease the Step Size value from: e.g.: 51660 to 51640.

NOTE: For more information about the Test Menu window, refer to �Test Menu� on page 1-88.



12.3.3. Carriage Speed

The carriage speed is the printing speed of the head carriage unit. The engine has 5 pre-defined carriage speeds: 640, 900, 1060, 1230 and 1380.

! 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.

12.3.4. Feed Speed

This is the forward speed of the conveyor belt between the print passes. A Feed Speed of "500" is considered the default.

No changes have to be made, unless you print at a high speed/low pass, and the conveyor belt is STILL feeding forward when the carriage already started to print the next pass.

12.3.5. UV Options

The table below lists the parameters of the UV Options group.

NOTE: Changes on the carriage speed, requires a �Parameter Download� in the Test menu.

Group Parameter Explanation

Cont. ON 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

WarmUp Time Time needed to warm-up the UV-lamps after switching on. (= the time before the green tower lamp lights up).

Cooling Time 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).

Lamp Type � Cure (Default),� Set� Both



12.3.6. Head Gap Control

12.3.6.1. Head gap control parameters

The table below lists the parameters of the Head Gap Control group.

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).

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.

Group Parameter Explanation

Gap Distance between media and head base.� recommended values: 1.5 mm for Rigid media, and 2 mm for Roll

media� range: min 1.5 mm to max. 6 mm.

Check Distance Check Distance = measured distance from the right side of the print-ing table to the first red bullet + 400 mm.

The head carriage unit will move from the home position to the check check distance to execute the "Set Gap".

Reference Distance where the sensing bracket recognize the position of the out-put material. This is also the point where the "Head Base" will wait for an on-screen confirmation, before going down to set the desired gap.

Note: � The reference value can only be changed in the Factory Data Set-

tings window. (See �Factory Set� on page 1-86).� To calibrate the reference value, use the manual head height setting

knob.

WARNING: Always make sure the head carriage is positioned in the HOME position, when you perform the "Set Gap" procedure.



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.

12.3.6.3. Example head gap control

1 Fill out a Gap value of 1.5 mm and a Check Distance value of 800 mm and 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.



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.

Verify the correct gap setting with a measuring device.

6 Click OK.

The head gap setup is completed.

12.3.7. Factory Set

This are the parameters behind the (password protected) button "Factory Set" in the Setup Parame-ters window. The Factory.set files (C:\anapurna\ )contain the settings from the engine.

12

34

56

7



1

2

3

4

5

6

7

8

9

10

11

12

13

14

16

17

18

15

1 No. of Colors: select color numbers to be output (default 6)

10 Uni-Speed: The return speed of the head carriage unit when printing in uni-directional mode.

2 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)

11 Top Margin Feed: The feed before a new print start

3 Left Margin Offset: The distance between the home position and the zero position (black nozzle row) from the image.

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.

4 Mark Center Offset: The distance extra travelled after the image

13 Feed Gear Ratio: Reduction ratio at feed motor

5 Home Pos Offset: Distance between detecting Home position and real home position.

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 on-screen confirmation, before going down to set the desired gap.

6 Max. Mark Count:The markers counted (read by the encoder) from the home position to the purge position.

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 +

7 Weep Time (Sec): The time between 2 weep actions.

16 White Color: White Selection mode for forward/backward optional white color

8 Weep Amount: While weeping once, set Weep amount.

17 Head Type: Spectra NOVA/GALAXY selection mode

9 Firing Pulse (mS): Weep Pulse time signal

18 Units: Metric (mm), English (Inch), decision �Unit�



12.3.8. Head Offset

These are the Head alignment settings for each head, in reference to the Black head. This alignment is done in advance by an engineer, do not change these values! If changes are required, go to the Factory Data Settings window to change the head offset values. (See �Factory Set� on page 1-86)

12.4. Test Menu

In the Control Program, click Test to get access to the Test Menu window.

12.4.1. Jet Test

This test is used to check the condition of the nozzle.

Window Fields

� Jet Test,� H-Orientation Test� Parameter Download� Carriage Release Test� Reset Test� Encoder Count Test

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.



12.4.2. H-Orientation Test

This test is used to align all the heads, in reference to the black head, both horizontal and perpendicular.

When the engine is installed, or a print head has been exchanged, this test must be carried out by a technician.

12.4.3. Parameter Download

When you change one of the parameters marked with an "*" in the Setup Parameters window (�Setup Parameters� on page 1-81), select the option button Parameters Download to validate the new values.

12.4.4. Carriage Release Test

This feature is mainly intended for a service engineer, it allows the release of the carriage motor, which is normally anchored on both side's.

After executing, it is possible to move the head carriage unit by hand from right to left. To end this test, select Reset Test again, the head carriage unit will move slowly back to the Home position.

12.4.5. Reset Test

To reset the printer.

12.4.6. Encoder Count Test

To measure the encoder pulse.

WARNING: Do not push or pull on the UV-lamps. Only push on the back of the head carriage unit.

FUNCTIONAL DESCRIPTION WORKING WITH WHITE INK - GUIDELINES


13. Working with White Ink - Guidelines

13.1. Printing Jobs without White Ink

If not printing white ink jobs, proceed as follows:

1 During the printing process:

1.1 Close the white ink valves (S).Set the W1, W2 ink valve to the solution outlet position (S).

1.2 Lower the white sub ink tank temperature.See �Sub ink tank (6C + White)� on page 1-50.

2 During idle time or overnight:

2.1 Open white ink valves (I).Set the W1, W2 ink valve to the ink outlet position (I) for the automatic weeping functionality.

2.2 Keep the white sub ink tank temperature still low.

3 At restart, set the white ink valves back to the solution outlet position (S).

13.2. Application requires no White Ink at All

If no white ink is required at all for your range of application, execute the following adjustments:

1 Disconnect the stirrer drive connector (1) of the main white ink tank.

2 Disconnect the level sensor (2) of the main white ink tank.

12

1 Stirrer drive connector of main white ink tank

2 Level sensor connector of main white ink tank

WORKING WITH WHITE INK - GUIDELINES 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.

4 Disconnect the white ink pump from the refill PCB.

13.3. Putting White Ink into the Circuit

If at a certain point in time, you decide to fill your engine with white ink, execute the following actions one after the other:

! Filling White Ink,

! Connecting the Spot White and Pre White Cartridge PCB,

! Setting the Temperature and Vacuum Control Settings,

! Aligning the White Heads.

Each action is discussed briefly in this section.

CARTRIDGE PCBs

M

Y

LcLm

C

K

Wspot Wpre

HEAD 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.



13.3.1. Filling White Ink

1 Get access to the Refill PCB and check whether the following connectors are disconnected.

1.1 Connector J17 (power supply to the sub ink tank),

1.2 White ink pump connector.

2 Fill the white ink main with white ink.

3 Connect the following connectors.

3.1 Connect the white ink pump connector to the Refill PCB.

3.2 Connect the stirrer drive connector of the main white ink tank.

3.3 Connect the level sensor of the main white ink tank.

4 Bleed the white ink filter.

Connector J17 should remain disconnected.

4.1 Open the two caps of the white ink filter (top and bottom).

4.2 Place a receiving bin underneath the ink filter hole.

4.3 Press and hold the white priming switch. Use a 5/3 seconds on/off sequence (leave 5 seconds on, then 3 seconds off), until the white ink comes steadily out of the bottom hole of the filter for some seconds.

4.4 Screw, without tightening, the cap at the bottom of the white ink filter. Make sure that you put the cap straight onto the screw thread of the filter.

4.5 Press and hold the white priming switch again. Use a 5/3 seconds on/off sequence (leave 5 seconds on, then 3 seconds off), until the white ink flows upwards and is spilled.

4.6 Wait 5 seconds and repeat pressing and holding the white priming switch using 1/2 seconds on/off sequence (leave 1 seconds on, then 2 seconds off), and verify if ink still comes out of the filter. Then screw the cap on top of the ink filter and clean the ink filter with a cleaning tissue.

5 It is possible that you need to repeat the bleeding of the white ink filter via the top cap the following day.

When the other main ink tanks have also been filled and the filters bled.

1 Set all print head valves (K, C, M, Y, Lc, Lm, W1 and W2) to the solution outlet position (S) and the solution valve is set to the ink outlet position (I).

2 Make sure that the vacuum is off (negative pressure is at zero).

3 Open the drain cock of the sub air tank.

The sub air tank is located behind the purge rear door.

4 Get access to the Refill PCB and verify whether all pump connectors are connected. If so, connect connector J17 to the Refill PCB.

As a result, ink is pumped from the main ink tanks to the sub ink tanks.

When the pumps have finished pumping ink:

1 Close the drain cock of the sub air tank.

WORKING WITH WHITE INK - GUIDELINES 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.

13.3.3. Setting the Temperature and Vacuum Control Settings

Set the vacuum pressure, sub ink tank temperature, white sub ink tank temperature and head base temperature to the following values:

Setting Printing with white ink

Printing without white ink

Vacuum pressure -0.034 to -0.038 Mpa -0.032 to -0.035 MPa

Sub ink tank temperature 38°C 38°C

White sub ink tank temperature 40°C 25°C

Head base temperature (cold) 32°C** 32°C**

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. One�s all nozzles are sufficient wetted, put the vacuum to a higher final value to get reliable printing (see table above).



13.3.4. Aligning the White Heads

1 Print the alignment targets for front/back and head slant alignment of the spot white head (head no 7), and correct the alignment.

2 Print the media feed target to adjust the step-size parameter of your media feed, and correct until step size is OK.

3 Print the alignment targets for front/back and head slant alignment of the pre-white head (head no 8), and correct the alignment.

PRINTED CIRCUIT BOARDS FUNCTIONAL DESCRIPTION


14. Printed Circuit Boards

14.1. MAIN PCB

14.1.1. Main PCB Layout

14.1.1.1. Figure

14.1.1.2. Location

The main PCB is located in the control box of the Home unit.

13

1

912 810 711

3

4

2

6

5

1 Connection to home limit switch 8 Connection to I/O PCB

2 Connection to Driver Comm. PCB 9 Connection to PC COM1 (D-SUB 9P)

3 Connection to door interlock module 10 Connection to I/O PCB

4 Connection to Driver Comm. PCB 11 Connection to Refill PCB

5 To ENCODER 12 Connection to Head PCB

6 To SMPS #3 13 Connection to FPGA board

7 Connection to Driver Comm. PCB

FUNCTIONAL DESCRIPTION PRINTED CIRCUIT BOARDS


14.1.1.3. Function

1 (J7) Connected to PC, execute User�s 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.

MAIN PCB



14.1.2. Main PCB Description

14.1.2.1. Connectors


Name and Function


PCN10-50P J16 1 DC3.3V+ PCI BOARD J10

2 DC3.3V+

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 DC3.3V+

50 DC3.3V+


Name and Function


D-SUB26P J15 1 DATA AB1 HEAD PCB J9 1

2 DATA CD1 2

3 DATA AB2 3

4 DATA CD2 4

5 DATE AB3 5

6 DATA CD3 6

7 DATA AB4 7

8 DATA CD4 8

9 DATA AB5 9

10 DATA CD5 10

11 DATA AB6 11

12 DATA CD6 12

13 DATA AB7 13

14 DATA CD7 14

15 DATA AB8 15

16 DATA CD8 16

17 MEDIA 17

18 SHIFT_CK 18

19 RX1_TTL 19

20 TX1_TTL 20

21 HV_CK 21

22 ERROR_OUT 22

23 HT_CNTRL 23

24 S.GND 24

25 S.GND 25

26 S.GND 26


Name and Function


5267-5P J10 1 GND INTERLOCK MOD-ULE2 DC5V+


Name and Function





Name and Function


5267-6P J11 1 GND REFILL PCB J17 3

2 N.C

3 N.C 2

4 TXD 1

5 N.C

6 N.C


Name and Function


5267-3P J7 1 GND PC - COM1 D-SUB 9P 5

2 TX 2

3 RX 3


Name and Function


5267-6P J5 1 GND DRIVER COMM. PCB

J5 (FEED) 1

2 TX 3

3 N.C.

4 RX 4

5 N.C.

6 N.C.


Name and Function


2P J4 1 GND

2 DC24V+


Name and Function



J6 (CARRIAGE) 1

2 MOTOR_RX_IN 2

3 3

4 GND 4

5 MOTOR_STOP 5

6 DC24V+ 7

7 N.C N.C

8 8




Name and Function



2 N.C

3 N.C

4 DC5V+


Name and Function


5267-3P J8 1 GND HOME LIMIT S/W

2 HOME SENSOR

3 DC5V+


Name and Function


5267-3P J17 1 DC5V+ I/O PCB J1 8

2 MEDIA SET 1 7

3 MEDIA SET 2 6

4 MEDIA SET 3 5

5 FEED LIMIT 4

6 LEFT SHTTER 3

7 RIGHT SHTTER 2

8 GND 1


Name and Function


5267-5P J18 1 GND I/O PCB J4 5

2 EXT8 4

3 EXT7 3

4 DC24V+ 2

5 DC5V+ 1


Name and Function


J14 1 CHASSIS GND

2 GND

3 ENCA+

4 ENCA-

5 ENCB+

6 GND



14.1.2.2. Led�s

14.1.2.3. Switches

14.1.2.4. Measurements

7 ENCRI+

8 ENCRI-

9 GND

10 DC5V+

11 ENCB-

12 DC5V+


Name and Function


RESET 1 24V+

2 GND

LED Color Indication

D1 Green 5V

D2 Green MOVE-L

D3 Green MOVE-R

D4 Green MEDIA

D5 Green WEEP

D6 Green SERV-R/S

D7 Green HV

D8 Green ERROR

D9 Green ENC

D10 Green MARK

D11 Green TEST

D12 Green TRAVEL


RUN

FEED

STOP

J10 - To interlock module

Pin 1 (white) +0Vdc Ground

Pin 2 (black) +5Vdc when door open, alarm on

0V when door closed, alarm off


Name and Function




14.2. FPGA PCB

14.2.1. FPGA PCB Layout

14.2.1.1. Figure

1

2

3

1 (J10) Connection to MAIN PCB 3 (J7) Connection to PCI I/O card CN2

2 (J8) Connection to PCI I/O card CN1



14.2.1.2. Location

The FPGA PCB is located in the control box of the Home unit.

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.

FGPA PCB



14.2.2. FPGA PCB Description



Name and Function


PCN10-50P J10 1 DC3.3V+ MAIN BOARD J16

2 DC3.3V+

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 DC3.3V+

50 DC3.3V+


Name and Function


PC1 J7 1 N.C PCI CARD CN2 IDC-40P

2 N.C

3 N.C

4 N.C

5 N.C

6 N.C

7 GND

8 N.C

9 PCD15

10 N.C

11 PCD14

12 N.C

13 PCD13

14 N.C

15 PCD12

16 N.C

17 PCD11

18 N.C

19 PCD10

20 N.C

21 PCD9

22 N.C

23 PCD8

24 N.C

25 PCD7

26 N.C

27 PCD6

28 N.C

29 PCD5

30 N.C

31 PCD4

32 N.C

33 PCD3


Name and Function




34 N.C

35 PCD2

36 N.C

37 PCD1

38 N.C

39 PCD0

40 N.C


Name and Function


PCN2 J8 1 N.C PCI CARD CN1 IDC-40P

2 PCSELA

3 N.C

4 PCSELB

5 N.C

6 N.C

7 N.C

8 N.C

9 N.C

10 N.C

11 N.C

12 N.C

13 N.C

14 N.C

15 N.C

16 N.C

17 N.C

18 N.C

19 N.C

20 N.C

21 N.C

22 N.C

23 N.C

24 N.C

25 N.C

26 N.C

27 N.C

28 N.C

29 N.C

30 N.C

31 N.C

32 N.C

33 N.C

34 GND


Name and Function




35 N.C

36 N.C

37 O_REQ

38 N.C

39 N.C

40 N.C


Name and Function




14.3. HEAD PCB

14.3.1. Head PCB Layout

14.3.1.1. Figure

24

1

5 3

6

6

7

1 Connection to MAIN PCB 5 Connection to head temperature sensor(2 black wires to the Magenta print head)

2 Level sensor connectors (K, C, M, Y, Lc, Lm, S, W)

6 Connection to each head heating device

3 Connection to cartridge PCBs (incoming data)

7 220V connector

4 Head temperature potentiometer



14.3.1.2. Location

The HEAD PCB is located at the back side of the head carriage unit, underneath the HEAD LIFT PCB.

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).

HEAD PCB

M

Y

LcLm

C

K

Wspot Wpre



14.3.2. Head PCB Description



Name and Function


5267-2P INK1 1 INK1 LEVEL SENSOR K K

2 GND


Name and Function


5267-2P INK2 1 INK2 LEVEL SENSOR C C

2 GND


Name and Function


5264-2P INK3 1 INK3 LEVEL SENSOR M M

2 GND


Name and Function


5267-2P INK4 1 INK4 LEVEL SENSOR Y Y

2 GND


Name and Function


5267-2P INK5 1 INK5 LEVEL SENSOR LC LC

2 GND


Name and Function


5267-2P INK6 1 INK6 LEVEL SENSOR LM LM

2 GND


Name and Function


5267-2P INK7 1 INK7 SOLUTION SEN-SOR

S

2 GND




Name and Function


5267-2P INK8 1 INK8 LEVEL SENSOR WHITE

W

2 GND


Name and Function


3951-2P 1 1 HV2 HEAD HEATER #1

2 HEATER #1

2 1 HV2 HEAD HEATER #2

2 HEATER #2


2 HEATER #3


2 HEATER #4


2 HEATER #5


2 HEATER #6


2 HEATER #7


2 HEATER #8


Name and Function


J1 1 GND_SIGNAL HEAD CARTRIDGE PCB J5 (black)

2 GND_SIGNAL

3 HV_ERR

4 HV_CK1

5 SHIFT_CK1

6 DATA_CDH1

7 DATA_ABH1

8 N.C

9 12V

10 12V

11 GND_POWER

12 GND_POWER

13 N.C

14 N.C

15 HV1

16 HV1




Name and Function


J2 1 GND_SIGNAL HEAD CARTRIDGE PCB J5 (Cyan)

2 GND_SIGNAL

3 HV_ERR

4 HV_CK2

5 SHIFT_CK2

6 DATA_CDH2

7 DATA_ABH2

8 N.C

9 12V

10 12V

11 GND_POWER

12 GND_POWER

13 N.C

14 N.C

15 HV1

16 HV1


Name and Function


J3 1 GND_SIGNAL HEAD CARTRIDGE PCB J5 (Magenta)

2 GND_SIGNAL

3 HV_ERR

4 HV_CK3

5 SHIFT_CK3

6 DATA_CDH3

7 DATA_ABH3

8 N.C

9 12V

10 12V

11 GND_POWER

12 GND_POWER

13 N.C

14 N.C

15 HV1

16 HV1




Name and Function


J4 1 GND_SIGNAL HEAD CARTRIDGE PCB J5 (Yellow)

2 GND_SIGNAL

3 HV_ERR

4 HV_CK4

5 SHIFT_CK4

6 DATA_CDH4

7 DATA_ABH4

8 N.C

9 12V

10 12V

11 GND_POWER

12 GND_POWER

13 N.C

14 N.C

15 HV1

16 HV1


Name and Function


J5 1 GND_SIGNAL HEAD CARTRIDGE PCB J5 (Light Cyan)

2 GND_SIGNAL

3 HV_ERR

4 HV_CK5

5 SHIFT_CK5

6 DATA_CDH5

7 DATA_ABH5

8 N.C

9 12V

10 12V

11 GND_POWER

12 GND_POWER

13 N.C

14 N.C

15 HV1

16 HV1




Name and Function


J6 1 GND_SIGNAL HEAD CARTRIDGE PCB J5 (Light Magenta)

2 GND_SIGNAL

3 HV_ERR

4 HV_CK6

5 SHIFT_CK6

6 DATA_CDH6

7 DATA_ABH6

8 N.C

9 12V

10 12V

11 GND_POWER

12 GND_POWER

13 N.C

14 N.C

15 HV1

16 HV1


Name and Function


J7 1 GND_SIGNAL HEAD CARTRIDGE PCB J5 (Spot White)

2 GND_SIGNAL

3 HV_ERR

4 HV_CK7

5 SHIFT_CK7

6 DATA_CDH7

7 DATA_ABH7

8 N.C

9 12V

10 12V

11 GND_POWER

12 GND_POWER

13 N.C

14 N.C

15 HV1

16 HV1




Name and Function


J8 1 GND_SIGNAL HEAD CARTRIDGE PCB J5 (Pre White)

2 GND_SIGNAL

3 HV_ERR

4 HV_CK8

5 SHIFT_CK8

6 DATA_CDH8

7 DATA_ABH8

8 N.C

9 12V

10 12V

11 GND_POWER

12 GND_POWER

13 N.C

14 N.C

15 HV1

16 HV1


Name and Function


J9 1 DATA AB1 MAIN PCB J15

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



14.3.2.2. Led�s

14.3.2.3. Adjustments

Refer to �Head Base Temperature Control� on page 1-63.

24 S.GND

25 S.GND

26 S.GND


Name and Function


5267-2P J29 1 SIGNAL

2 GND


Name and Function


STL950 J13 1 HV2

2 GND

3 HV1

4 GND

5 5V+

6 GND

7 24V+

8 GND


D1 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)

D2 HV_ERR (High Voltage)

D4 HT_ERR (Heather Error)

D6 INK_OVF (Ink Overflow)


Name and Function




14.4. REFILL PCB

14.4.1. Refill PCB Layout

14.4.1.1. Figure

14.4.1.2. Location

The REFILL PCB is located behind the swinging ink supply door.

1

1312

2

3

4

56910 78

11

1 Connection to Indicator PCB 8 Connection to Refill Control PCB

2 Connection to Main PCB 9 Connection to Rear media detection sensor

3 Connection to air tank 10 Connection to Rear gear motor

4 Connection to SMPS #3 11 Connection to Indicator PCB

5 Connection to Front media detection sensor 12 Connection to Take Up PCB

6 Connection to Front gear motor 13 Connection to Ink pumps (C, M, Y, K, Lm, Lc, W and S)

7 Connection to sub tank flow sensor



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.

14.4.2. Refill PCB Description



Name and Function


IDC-16 J18 1 GND TAKE UP PCB J11

2 DC5V+

3 GND

4 DC5V+

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


Name and Function


5267-2P J4 1 DCS5V+ INDICATOR PCB J10

2 INK-C




Name and Function


5267-2P J11 1 MOTOR REAR+ REAR TAKE UP MOTOR

2 MOTOR REAR-


Name and Function


3191-3P J16 1 DC24V+ TAKE UP REAR MEDIA DETEC-TION SENSOR

2 REAR-SENSE

3 GND


Name and Function


5557-2P J10 1 MOTOR FRONT+ FRONT TAKE UP MOTOR

2 MOTOR FRONT-


Name and Function


Apr-57 J15 1 F_SEN TAKE UP FRONT MEDIA DETEC-TION SENSOR

2 GND

3 N.C

4 DC24V+


Name and Function


Mar-45 J17-1 1 DC5V+ INDICATOR PCB J11 3

2 N.C 2

3 GND 1


Name and Function


5267-3P J17 1 RX MAIN PCB J11

2 N.C (TX)

3 GND




Name and Function


5267-4P BZ1 1 GND

2 N.C

3 N.C

4 BUZZER+


Name and Function


J20 1 PUMP_S KNF MOTOR SOLUTION

2 DC24V+

J27 1 PUMP_W KNF MOTOR WHITE

2 DC24V+

J24 1 PUMP_LM KNF MOTOR LM

2 DC24V+

J1 1 PUMP_LC KNF MOTOR LC

2 DC24V+

J25 1 PUMP_Y KNF MOTOR Y

2 DC24V+

J3 1 PUMP_M KNF MOTOR M

2 DC24V+

J26 1 PUMP_C KNF MOTOR C

2 DC24V+

J5 1 PUMP_K KNF MOTOR K

2 DC24V+


Name and Function


IDC-30P J 31 1 SW_Y REFILL CONTROL PCB

J 18 1

2 SW_M 2

3 SW_C 3

4 SW_K 4

5 SW_LM 5

6 SW_LC 6

7 SW_WHITE 7

8 SW_S 8

9 +5V 9

10 GND 10

11 S_LED_Y 11

12 S_LED_M 12

13 S_LED_C 13

14 S_LED_K 14



15 S_LED_LM 15

16 S_LED_LC 16

17 S_LED_WHITE 17

18 S_LED_S 18

19 +5V 19

20 GND 20

21 P_LED_Y 21

22 P_LED_M 22

23 P_LED_C 23

24 P_LED_K 24

25 P_LED_LM 25

26 P_LED_LC 26

27 P_LED_WHITE 27

28 P_LED_S 28

29 +24V 29

30 GND 30


Name and Function


5267-2P J13 1 LAMP ON Main PLC POB

2 24V+


Name and Function


5267-3P J34 1 LAMP ON

2 N.C

3 GND


Name and Function


5267-6P J32 1 5V Air tank

2 N.C

3 PRESSURE_LOW

4 N.C

5 N.C

6 N.C


Name and Function




14.4.2.2. Led�s

14.4.2.3. Switches



Name and Function


3951-2P J14 1 GND SMPS #3

2 24V


D12 Status ink pumps + 1 communication LED with Indicator PCB


SW1 RESET

J32 - Connection to air pressure sensor main air tank

Pin 6 (black) +5Vdc Permanent

Pin 4 (white) +5Vdc above 3 bar, alarm off

0V below 3 bar, alarm on



14.5. CARTRIDGE PCB

14.5.1. Cartridge PCB Layout

14.5.1.1. Figure

2

1

3

1 (J1 - J4) connection with the 4 data cables of one print head

3 DC Head voltage (factory set)To be adjusted when mounting a new head

2 (J5) connection to HEAD PCB



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.

14.5.1.3. Function

The CARTRIDGE PCB controls the head and the connected head ink jet function (ink drop).

CARTRIDGE PCBs

M

Y

LcLm

C

K

Wspot Wpre



14.5.2. Cartridge PCB Description



Name and Function


SIP-9P J1 to J4 1 HVPULSE HEAD #1 FLAT CABLE #1 to #4

1

2 N.C 2

3 N.C 3

4 GND 4

5 CLK 5

6 DATA OUT1 6

7 DATA IN 7

8 DC12V+ 8

9 GND 9


Name and Function


IDC-12P J5 1 GND_SIGNAL Head PCB 1

2 GND_SIGNAL 2

3 HV_ERROR 3

4 HV_CK 4

5 SHIFT_CK_HI 5

6 DATA_CD_HI 6

7 DATA_AD_HI 7

8 N.C 8

9 12V+ 9

10 12V+ 10

11 GND_POWER 11

12 GND_POWER 12


Name and Function


SIP-9P J7 1 HVPULSE HEAD #1 FLAT CABLE #7

1

2 N.C 2

3 N.C 3

4 GND 4

5 CLK 5

6 DATA OUT1 6

7 DATA IN 7

8 DC12V+ 8

9 GND 9



14.5.2.2. Led�s


Name and Function


SIP-9P J8 1 HVPULSE HEAD #1 FLAT CABLE #8

1

2 N.C 2

3 N.C 3

4 GND 4

5 CLK 5

6 DATA OUT1 6

7 DATA IN 7

8 DC12V+ 8

9 GND 9


D4 LEDG-SM 12V



14.6. HEAD LIFT PCB

14.6.1. Head Lift PCB Layout

14.6.1.1. Figure

1

2

3

4

5 6

1 Connection to IF PCB 4 Connection to IF PCB

2 Connection to Purge switch 5 Connection to heater plate of white sub ink tank

3 Connection to SMPS #6 6 Connection to heater plate of 6C sub ink tank



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 compo-nents 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).

HEAD LIFT PCB



14.6.2. Head Lift PCB Description



Name and Function


5045-5P J1 1 GND

2 DC5V+

3 UP_SEN

4 DN_SEN

5 N.C


Name and Function


GIL-G4P J4 1 GND PC-COM2 D-SUB 9P 5

2 RX 2

3 TX 3

4 N.C


Name and Function


3951-5P J6 1 GND

2 SOL (1)

3 N.C

4 GND

5 SOL (2)


Name and Function


5045-6P J7 4 SUB_A I/F PCB J2 8

5 SUB_B 7

6 SUB_B� 6

7 BASE_A 5

8 BASE_B 4

9 BASE_B� 3

1 N.C. 2

2 N.C. 1

3 N.C.




Name and Function


3951-6P J8 1 DC24V+ I/F PCB J1 6

2 DC24V+ 5

3 GND 4

4 GND 3

5 BASE_HEATER 2

6 SUB_HEATER 1


Name and Function


5267-3P J10 1 SUB_B� PT SENSOR SUB INK TANK

2 SUB_B�

3 SUB_A


Name and Function


5045-3P J11 1 IN+ SUB AIR TANK PRESSURE SEN-SOR

2 DC24V+

3 GND


Name and Function


3951-2P J12 1 DC24V+ PURGING S/W (PUSH BUTTON)

2 SOL(1), SOL(2)


Name and Function


5045-4P J13 1 OUT+ ITV2010

2 N.C

3 DC24V+

4 GND




Name and Function


3951-3P J14 1 GND WHITE SUB INK HEATER

2 GND

3 SUB_HEATER


Name and Function


J25 1 GND 6C SUB INK HEATER

2 SUB_HEATER


Name and Function


5045-7P J15 1 A HEAD BASE LIFT STEPPING MOTOR

2 GND

3 A~

4 B

5 GND

6 B~

7 N.C


Name and Function


5045-10P J16 1 OUT+ ITV CONTROLLER CN1 4

2 OUT+ 4

3 IN+ 3

4 IN+ 3

5 GND 2

6 GND 2

7 GND 2

8 DC24V+ 1

9 DC24V+ 1

10 DC24V+ 1



14.6.2.2. Led�s

14.6.2.3. Switches


Name and Function


5267-4P J17 1 BASE_B� PT SENSOR HEAD BASE2 BASE_B

3 N.C

4 BASE_A


Name and Function


3951-4P J18 1 GND SMPS #6 CH1 DC5V+

2 DC5V+ GND

3 GND CH2 DC24V+

4 DC24V+ GND


Name and Function


3951-7P J23 1 DC24V+ PLATEN SENSING B/K UP SOLENOID

2 N.C

3 SOLA

4 N.C

5 DC24V+ PLATEN SENSING B/K LOCK SOLE-NOID

6 N.C

7 SOLB


LED 1

LED 2


SW1 RESET



14.7. ITV CONTROLLER PCB

14.7.1. ITV Controller PCB Layout

14.7.1.1. Figure

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

1 (J4) collecting/controlling pressure signals

ITV Controller BCB



14.7.2. ITV Controller PCB Description



Name and Function


CN1 1 DC24V PSE200 J1 1

2 0V 2

3 IN+ 3

4 IN- 4

5 A(1) 5

6 B(2) 6

7 C(3) 7

8 OUT+ 8

9 OUT-


Name and Function


ITV GORE CABLE

1 DC24V+ HEAD LIFT PCB J16 1

2

3

2 GND 4

5

6

3 IN+ 7

8

4 OUT+ 9

10


Name and Function


J1 1 BROWN PSE200 REAR 1

2 BLUE 2

3 BLACK 3

4 WHITE 4

5 GRAY 5

6 RED 6

7 GREEN 7

8 YELLOW 8



14.7.2.2. Switches

14.7.2.3. Adjustments

It is not necessary to tune the variable resistors �GAIN� and �ZERO�. Both resistors are factory set.


Name and Function


CH-1 J2 1 BROWN IVT CONTROL 1

2 2

3 BLUE 4

9

4 BLACK 3


Name and Function


J3 1 BROWN IVT CONTROL 1

2 2

3 BLUE 4

9

4 BLACK 3


Name and Function



2 2

3 BLUE 4

9

4 BLACK 3


Name and Function



2 2

3 BLUE 4

9

4 BLACK 3


SW2 ON Factory setting



14.8. SUB PCB

14.8.1. Sub PCB Layout

14.8.1.1. Figure

1

3 2

1 (J4) Connection to PLC 3 (J43) Connection to SMPS (DC 5V/24V)

2 (J13) Connection to I/O PCB



14.8.1.2. Location

The SUB PCB is located in the control box of the Home unit.

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.

SUB PCB



14.8.2. Sub PCB Description



Name and Function


3951-2P J45 1 SSR OUT1 not used

2 SSR OUT2


Name and Function


3951-4P J43 1 DC24V+ SMPS (DC 5V/24V)2 DC24V-

3 DC5V+

4 GND


Name and Function


5045-14P 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 air tank pressure gauge signal

11 N.C

12 SHUTTER RIGHT I/O PCB

13 SHUTTER LEFT I/O PCB

14 UV LAMP ON I/O PCB


Name and Function


5267-4P J47 1 GND not used

2 LIFT-UP

3 LIFT-DN

4 DC5V+




Name and Function


3951-6P J4 1 AIR-LOW PLC

2 INK LOW

3 LAMP ON

4 MEDIA SET

5 BLOWER ON

6 N.C


Name and Function


5267-2P J48 1 SUC-LEVEL not used

2 DC5V+


Name and Function


5557-2P J44 1 MOTOR+

2 MOTOR-



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.

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.

IF BCB



14.9.2. IF PCB Description



Name and Function


power Jun-51 J1 1 Sub-Heater J8 1

2 Base-Heater 2

3 GND 3

4 GND 4

5 DC24V 5

6 DC24V 6


Name and Function


TEMP SENSOR Aug-51

J2 1 PSE HEAD LIFT PCB J7

2 ITV

3 BASE-B� 9

4 BASE-B 8

5 BASE-A 7

6 SUB-B� 6

7 SUB-B 5

8 SUB-A 4


Name and Function


5045-4P J3 1 ITV

2 N.C

3 GND

4 DC24V


Name and Function


Mar-51 J4 1 PSE

2 GND

3 DC24V


Name and Function


3951-2P J5 1 DC24V

2 GND




Name and Function


3951-2P J6 1 DC24V

2 GND


Name and Function


3951-2P J7 1 DC24V

2 GND


Name and Function


5267-3P J8 1 SUB-A

2 SUB-B

3 SUB-B�


Name and Function


3951-3P J9 1 SUB-HEATER

2 N.C

3 GND


Name and Function


5267-4P J10 1 BASE-B�

2 BASE-B

3 N.C

4 BASE-A


Name and Function


3951-2P J11 1 BASE HEATER

2 GND




Name and Function


5045-9P J12 1 GND

2 N.C

3 N.C

4 N.C

5 N.C

6 N.C

7 N.C

8 N.C

9 DC24V


Name and Function


5045-5P J13 1 PSE

2 N.C

3 N.C

4 GND

5 DC24V


Name and Function


PID 1 SV2 IN

2 SV2-COM

3 CA SENSOR

4

5 EV2-OUT2

6 EV2-OUT1

7 N.C

8 EV1-OUT2

9 EV1-OUT1

10 ACIN

11 ACIN

12 N.C

13 COM

14 N.O



14.10. I/O PCB

14.10.1. I/O PCB Layout

14.10.1.1. Figure

2

34

5

1

1 (J2) Connection to feed limit and media sensor

4 (J4) Connection to Main PCB

2 (J3) Connection to SUB PCB 5 (J1) Connection to Main PCB

3 (J6) Connection to SUB PCB



14.10.1.2. Location

The I/O PCB is located in the control box of the Home unit.

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.

I/O PCB



14.10.2. I/O PCB Description



Name and Function


5267-8P J1 1 DC5V+ MAIN PCB J17 1

2 MEDIA SET 1 2

3 MEDIA SET 2 3

4 MEDIA SET 3 4

5 FEED LIMIT 5

6 LEFT SHTTER 6

7 RIGHT SHTTER 7

8 GND 8


Name and Function


5267-5P J4 1 DC5V+ MAIN PCB J18 5

2 DC24V+ 4

3 UV LAMP ON 3

4 EXT I/O 8 2

5 GND 1


Name and Function


5045-5P J2 1 DC5V+

2 MEDIA SENSOR 1

3 MEDIA SENSOR 2

4 MEDIA SENSOR 3

5 FEED LIMIT


Name and Function


5045-3P J3 1 LEFT SHUTTER MAIN PCB J13

2 RIGHT SHUTTER

3 GND



14.10.2.2. Led�s


Name and Function


5045-4P J6 1 N.C MAIN PCB J14

2 UV LAMP ON

3 N.C

4 N.C


LED1 ON/OFF signals green Media sensor 1

LED2 green Media sensor 2

LED3 green Media sensor 3

LED4 green Feed Limit

LED5 green Left shutter

LED6 green Right shutter

LED7 green UV lamp on



14.11. TAKE UP PCB

14.11.1. Take Up PCB Layout

14.11.1.1. Figure

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.

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.

TAKE UP BCB



14.11.2. Take Up PCB Description


14.11.2.2. Led�s

14.11.2.3. Switches


Name and Function


IDC-16 J11 1 GND REFILL PCB J18

2 DC5V+

3 GND

4 DC5V+

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


D1 red auto/manual indicator

D2 green CW led

D3 green CCW led

D4 red Auto led

D5 green Error led


SW1CW switch

inout

rotate motor CW

SW2C switch

inout

rotate motor CCW

SW3 inout

FRONTREAR

SW4 inout

AUTO modeMANUAL mode



14.12. REFILL CONTROL PCB

14.12.1. Refill Control PCB Layout

14.12.1.1. Figure

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

2

3

4

1 (D1-D8) Empty Ink refill status LED indica-tions

3 Manual feeding switches

2 (D9-D16) Feeding Ink refill status LED indi-cations

4 (J18) Connection to the REFILL PCB



14.12.2. Refill Control PCB Description


14.12.2.2. Led�s


Name and Function


IDC-30P J 18 1 SW_Y J 31 1

2 SW_M 2

3 SW_C 3

4 SW_K 4

5 SW_LM 5

6 SW_LC 6

7 SW_WHITE 7

8 SW_S 8

9 +5V 9

10 GND 10

11 S_LED_Y 11

12 S_LED_M 12

13 S_LED_C 13

14 S_LED_K 14

15 S_LED_LM 15

16 S_LED_LC 16

17 S_LED_WHITE 17

18 S_LED_S 18

19 +5V 19

20 GND 20

21 P_LED_Y 21

22 P_LED_M 22

23 P_LED_C 23

24 P_LED_K 24

25 P_LED_LM 25

26 P_LED_LC 26

27 P_LED_WHITE 27

28 P_LED_S 28

29 +24V 29

30 GND 30


D1 red

D2 red

D3 red

D4 red

D5 red

D6 red

D7 red

D8 red

D9 green



14.12.2.3. Switches

D10 green

D11 green

D12 green

D13 green

D14 green

D15 green

D16 green


SW1 Manual feeding of white ink

SW2 Manual feeding of Lm ink

SW3 Manual feeding of Lc ink

SW4 Manual feeding of Y ink

SW5 Manual feeding of M ink

SW6 Manual feeding of C ink

SW7 Manual feeding of K ink

SW8 Manual feeding of solution




14.13. INDICATOR PCB

14.13.1. Indicator PCB Layout

14.13.1.1. Figure

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.

2

1

3

4

1 (J13) Transferring Ink empty signal to REFILL PCB

3 (J1-J8) Connection to ink tank flow sensor

2 (J11) +5VDC coming from REFILL PCB 4 (D1-D16) Ink Full/Empty LED indications



14.13.2. Indicator PCB Description



Name and Function


5267-3P J1 1 DC5V+

2 INK_EMPTY_WT

3 INK_FULL_WT

5267-3P J2 1 DC5V+

2 INK_EMPTY_LM

3 INK_FULL_LM

5267-3P J3 1 DC5V+

2 INK_EMPTY_Lc

3 INK_FULL_Lc

5267-3P J4 1 DC5V+

2 INK_EMPTY_Y

3 INK_FULL_Y

5267-3P J5 1 DC5V+

2 INK_EMPTY_M

3 INK_FULL_M

5267-3P J6 1 DC5V+

2 INK_EMPTY_C

3 INK_FULL_C

5267-3P J7 1 DC5V+

2 INK_EMPTY_K

3 INK_FULL_K

5267-3P J8 1 DC5V+

2 INK_EMPTY_S

3 INK_FULL_S


Name and Function


3951-3P J11 1 GND

2 N.C

3 DC5V+


Name and Function


5267-2P J12 1 DC5V+

2 INK_FULL_SIG



14.13.2.2. Led�s



Name and Function


5267-2P J13 1 INK_EMPTY_SIG

2 DC5V+


D1 green white ink tank full

D2 red white ink tank empty

D3 green Lm ink tank full

D4 red Lm ink tank empty

D5 green Lc ink tank full

D6 red Lc ink tank empty

D7 green Y ink tank full

D8 red Y ink tank empty

D9 green C ink tank full

D10 red White ink tank empty

D11 green M ink tank full

D12 red M ink tank empty

D13 green K ink tank full

D14 red K ink tank empty

D15 green Solution tank full

D16 red Solution tank empty

J13 - Connection to REFILL PCB J4

Pin 1 (green) +5Vdc empty alarm on

0V empty alarm off

Pin 2 (red) +5Vdc Permanent

J1 / J8 - Connection to level sensor ink tank

Pin 1 (black) +5Vdc Permanent

Pin 2 (red) +5Vdc empty detection on

0V empty detection off

Pin 3 (yellow) +5Vdc full detection on

0V full detection off



14.14. DRIVER COMMUNICATION PCB

14.14.1. Driver Communication PCB Layout

14.14.1.1. Figure

2

1

34

5

1 (J7) +5VDC coming from MAIN PCB 4 (J6-CARRIAGE) Connection to MAIN PCB

2 (J4) Connection to feed servo motor driver 5 (J5-FEED) Connection to MAIN PCB

3 (J3) Connection to carriage servo motor driver



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.

DRIVER COMMUNICATION PCB



14.14.2. Driver Communication PCB Description



Name and Function


5267-8P J5 1 GND MAIN PCB J5

FEED 2 CAR_POS_IN

3 TX2_SERVO

4 GND

5 FEED STOP

6 N.C

7 N.C

8 +24V


Name and Function


5267-8P J6 1 GND MAIN PCB J12 1

CARRIAGE 2 CAR_POS_IN 2

3 TX2_SERVO 3

4 GND 4

5 MOTOR STOP 5

6 N.C N.C.

7 6

8 +24V 8


Name and Function


5267-8P J4 1 TX+ CN3 5

FEED SERVO 2 TX- 15

3 RX+ 9

4 RX- 19

5 GND 1

6 FEED_PS_IN CN1B 6

7 GND 10

8

CHAPTER


2 Technical Features and Specifications

This chapter briefly describes the features and technical specifications of the Anapurna L/XL.

1. Overview .................................................................................................................................................................... 2 - 21.1. Anapurna's Print Quality ........................................................................................................................ 2 - 21.2. Outstanding Printing Potential ........................................................................................................... 2 - 21.3. Inspired Design ......................................................................................................................................... 2 - 31.4. User Profile ................................................................................................................................................. 2 - 3

2. Features ...................................................................................................................................................................... 2 - 42.1. Borderless Printing .................................................................................................................................. 2 - 42.2. Roll to Roll and Rigid Printing ............................................................................................................ 2 - 42.3. Dual Board Printing ................................................................................................................................. 2 - 42.4. White Color Printing ............................................................................................................................... 2 - 42.5. Status Signal Lamp .................................................................................................................................. 2 - 42.6. Automatic Ink Filling System .............................................................................................................. 2 - 52.7. UV Curing .................................................................................................................................................... 2 - 52.8. Changeable UV Lamps ........................................................................................................................... 2 - 52.9. Exhausting System ................................................................................................................................... 2 - 52.10. Automatic Print Head Height ............................................................................................................ 2 - 52.11. Easy and Quick Installation ............................................................................................................... 2 - 52.12. Simple Maintenance ............................................................................................................................ 2 - 5

3. Specifications ........................................................................................................................................................... 2 - 63.1. Print Technology ....................................................................................................................................... 2 - 63.2. Head Technology ...................................................................................................................................... 2 - 63.3. Media ............................................................................................................................................................ 2 - 73.4. Inks ................................................................................................................................................................ 2 - 83.5. Working Conditions ................................................................................................................................. 2 - 93.6. Electricity ..................................................................................................................................................... 2 - 93.7. RIP PC ........................................................................................................................................................ 2 - 103.8. Service PC ................................................................................................................................................ 2 - 103.9. Anapurna L ............................................................................................................................................... 2 - 113.10. Anapurna XL ......................................................................................................................................... 2 - 11

TECHNICAL FEATURES AND SPECIFICATIONS 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.

1.1. Anapurna's Print Quality

However you measure it, the Anapurna L/XL delivers exceptional results.

! Print resolution: 363 x 725 dpi.

! Prints up to 250 cm wide.

! Choice of media.

1.2. Outstanding Printing Potential

The sky is the limit with both Anapurna engines. You can produce top quality inkjet prints for both outdoor and indoor applications.

Material Examples

Roll materials � film� a paper� front- and backlit film� self adhesive vinyl and paper� canvas� banner� vinyl� blue back� coated and uncoated media

Rigid media � alu boards� corrugated cardboards� screenprinting boards� exhibition panels� stage graphics� ad panels� and much more.

OVERVIEW TECHNICAL FEATURES AND SPECIFICATIONS


1.3. Inspired Design

Innovation has been incorporated at every stage and the Anapurna will demonstrate clear desire and investment to your customers.

1.4. User Profile

Anapurna L/XL is a robustly engineered wide format industrial inkjet printer, designed to cope with heavy workloads in applications such as:

! posters

! billboards

! fleet displays

! POS & POP displays

! exhibition panels

! stage graphics

! construction announcements

! ad panels etc.

TECHNICAL FEATURES AND SPECIFICATIONS 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.

2.2. Roll to Roll and Rigid Printing

Both Anapurna L/XL can handle roll and rigid materials. In fact, changing from roll to rigid printing happens in a matter of seconds enabling fast interchange of short run jobs.

The Anapurna L/XL is provided with an easy and stable automatic feeding system.

2.3. Dual Board Printing

With the Anapurna engines you are able to feed through multiple boards in one and the same print run, maximizing the productivity of this state-of-the-art piece of machinery. Two different images can be queued and printed simultaneously making this a highly flexible machine.

Working faster will also:

! Reduce your costs.

! Make your business more profitable.

! Make it easier for you to offer your customers more attractive price quotations.

2.4. White Color Printing

The Anapurna L/XL also produce pre- or post-white printing for transparent surfaces and cardboard, handling a broad range of applications your customers are demanding.

2.5. Status Signal Lamp

You can see the status of the Anapurna printer from a distance so you won't have to run back and forth anymore but simply have a look from your workspace.

Print readiness as well as security signals are clearly indicated. This system is simple and efficient.

FEATURES TECHNICAL FEATURES AND SPECIFICATIONS


2.6. Automatic Ink Filling System

Ink levels are automatically detected in the main ink tanks. Both visible and audible warnings notify the user of low levels. Both warnings notify the operator of low ink level ensuring the production is maintained.

The ink quantity is controlled by manipulating the head ejecting voltage

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.

2.8. Changeable UV Lamps

The UV lamps are also easy to change that no service intervention is needed at all and this helps to keep the total costs to a minimum.

2.9. Exhausting System

! Anapurna L and Anapurna XL: 2 extraction units, consisting of an exhaust tube and the blower.

2.10. Automatic Print Head Height

Print head height is automatically set to the thickness of the substrate up to 5 cm thick. User defin-able head gap is possible from 1.5 to 6 mm.

2.11. Easy and Quick Installation

The Anapurna is packed as 1 engine and can therefore be installed fast so that you can start working the next day.

2.12. Simple Maintenance

The users can perform many of the maintenance functions themselves thus preventing that service interventions are needed, saving time and costs.

TECHNICAL FEATURES AND SPECIFICATIONS SPECIFICATIONS


3. Specifications

3.1. Print Technology

! 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 unnec-essary ink flow or ink waste during printing or standstill.

! Roll to roll and rigid printing

3.2. Head Technology

! Spectra Nova 256/80 AAA JA (Jetting Assembly)

! Calibrated drop size: 75 pl.

! 256 addressable jetting nozzles with spacing of 279 microns (0.011�)

! intrinsic resolution of 91 dpi.

NOTE: For detailed information about the Anapurna L/XL Specifications, refer to the User Manual.

SPECIFICATIONS TECHNICAL FEATURES AND SPECIFICATIONS


! 8 JA mounted in head base plate

! 7 heads in line (1).

! 1 head mounted in front of the other heads, used for �Pre-White� (2).

3.3. Media

3.3.1. Thickness

3.3.2. Type

! Foamboard

! Acryl

! Steel

! Glass

! Wood

! Flex

! Sheet

Material Thickness Weight

Rigids 1 to 50 mm max 28 kg/m2

Roll material min. 0.1 mm (max. roll diameter 36 cm) up to 50 kg

1

2

2

1



3.4. Inks

3.4.1. General Information UV Curable Ink

! UV-curable inks, 8 ink tanks:

! 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:

! 2 Mercury lamps

! 2 settings (full- and half power).

! Use of light inks:

! Enhances apparent output resolution by using Light Cyan and Light Magenta.

! Results in smooth highlights.

! Ink usage: 10 ml/m², all colors together.



3.4.2. Color Gamut

! 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.



16 pass:

3.5. Working Conditions

3.6. Electricity

Temperature Humidity

permissible range: 18-26 °Coptimal: 22°C

permissible range: 35-75 % RHoptimal: 40%

Voltage (V) Frequency (Hz)Maximum

Current rating (A)Fuse protection

Europe 3 phase with neutralwith ground star380 V-10% - 415 V+6%

50 Hz 40 A 50 A

US 3 phaseno neutralwith ground208 V-10% - 240 V+6%

60 Hz 36 A 50 A



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.

! Minimum system requirements:

! 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.

3.8. Service PC

If you want to connect a service PC to the Anapurna L/XL provide the following:

! 2 power sockets within 2 m of the Anapurna L/XL

200-240 VAC, 50 Hz, 16 A

! 2 ethernet RJ45 network sockets within 4 m of the Anapurna L/XL.

NOTE: Do not install the Wasatch SoftRIP on the Anapurna PC.

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 multi-gigabyte 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.



3.9. Anapurna L

! Dimensions

* 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

* 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")

Unit Width Height Depth Weight

Anapurna L 3700 mm146 inch

1660 mm*65 inch

2360 mm***93 inch

1700 kg3748 lbs

Rigid table L 1750 mm68.9 inch

± 970 mm **38.2 inch

1000 mm****43 inch

-

Unit Width Height Depth Weight

Anapurna XL 4750 mm187 inch

1660 mm*65 inch

2360 mm***93 inch

2300 kg5071 lbs

Rigid table XL 2650 mm104 inch

± 970 mm **38.2 inch

1000 mm****43 inch

-

CHAPTER


3 Repair and Service

This chapter describes repair and service procedures for the Anapurna L/XL.

1. Safety Notes ............................................................................................................................................................. 3 - 21.1. Warning/Caution/Note ......................................................................................................................... 3 - 21.2. Emergency Stop ........................................................................................................................................ 3 - 21.3. Handling UV Curable Ink ....................................................................................................................... 3 - 31.4. UV Radiation .............................................................................................................................................. 3 - 31.5. Electricity ..................................................................................................................................................... 3 - 41.6. Maintenance Safety Instructions ........................................................................................................ 3 - 41.7. MSDS Contents ......................................................................................................................................... 3 - 5

2. Overview Safety Labels ........................................................................................................................................ 3 - 63. Preparing for Service ............................................................................................................................................. 3 - 8

3.1. Moving Head Carriage to Home or Purge Position ...................................................................... 3 - 83.2. Putting the print Engine in Service Mode ....................................................................................... 3 - 8

4. Disassembly/Assembly of Major Components ........................................................................................... 3 - 94.1. Disassembly/Assembly of the Air Pressure Panel Components ............................................ 3 - 94.2. Disassembly/Assembly of the Media Transport System Components ............................. 3 - 134.3. Disassembly/Assembly of the Ink Supply System Components at Refill Unit .............. 3 - 244.4. Disassembly/Assembly of the Ink Supply System Components at Head Carriage Unit ... 3 -

464.5. Disassembly/assembly of the Head Carriage Movement Components ........................... 3 - 534.6. Disassembly/Assembly of the Print Head Components ......................................................... 3 - 604.7. Disassembly/Assembly of the UV Curing System Components ......................................... 3 - 72

5. Installing the PCI I/O Card .............................................................................................................................. 3 - 835.1. Location .................................................................................................................................................... 3 - 835.2. Replacement of the PCI I/O Card ................................................................................................... 3 - 84

6. Adjustment and Alignment Procedures ...................................................................................................... 3 - 896.1. Vacuum Blower Adjustments ............................................................................................................ 3 - 896.2. Print Head Adjustments ...................................................................................................................... 3 - 916.3. Conveyer Belt Alignment ................................................................................................................... 3 - 976.4. Head Base Alignment .......................................................................................................................... 3 - 996.5. Lamp house Alignment ..................................................................................................................... 3 - 103

REPAIR AND SERVICE 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

! Caution

! Note

1.2. Emergency Stop

In case of emergency, push the emergency stop button immediately to stop the Anapurna L/XL. The emergency button cuts off the power, but certain parts remain powered.

The system is provided with 4 emergency stops, two at the front side and two at the back side.

WARNING: Warnings are directions which, if not followed, can cause fatal or serious injuries to the operator or engineer.

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: A note contains additional information which may be useful to you but which is not vitally important to work safely.

SAFETY NOTES REPAIR AND SERVICE


1.3. Handling UV Curable Ink

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: Consult the appropriate Material Safety Data Sheets (MSDS) before handling UV curable ink.


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.

WARNING: Never mix non UV and UV curable ink waste.

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.

CAUTION: Do not remove the air filter without permission.

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.

REPAIR AND SERVICE SAFETY NOTES


1.5. Electricity

1.6. Maintenance Safety Instructions

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.

CAUTION: Always make sure the power cable is properly connected.

WARNING: Avoid heater temperature above 50°C. Always turn off the heater power when the Anapurna L/XL is shut down for a long period. Overheat can cause engine damage or fire.

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: Do not move the Anapurna L/XL while printing.

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 replace a damaged print head.

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.

SAFETY NOTES REPAIR AND SERVICE


1.7. MSDS Contents

The Material Safety Data Sheets are available on request. What will you find in the MSDS:

! 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.

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.

REPAIR AND SERVICE OVERVIEW SAFETY LABELS


2. Overview Safety Labels

Always take into account the safety labels provided on the inside and outside of the printer. They may appear throughout the different chapters of this manual. A brief overview of these labels and their meaning is given below.

Label Meaning

Before attempting to work with the Anapurna L/XL, the operator must read and understand the Anapurna L/XL Operator manual.

This label is located on panels that enclose gears and rollers that could potentially harm fingers and hands.

Hot surface! Allow sufficient cooling before handling.

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.

WARNING

Read and understand operator's

manual before using this machine.

Failure to follow operating

instructions could result in personal

injury or damage to equipment

WARNING

Moving parts cancrush and cut.Do not operate withguard removed.Lockout/tagoutbefore servicing

WARNING

BURN HAZARD

Do Not Touch.

TURN OFF POWER and

allow to cool before

servicing.

WARNING

HAZARDOUS VOLTAGEContact may causeElectric shock or burnTurn off and lock outSystem before servicing

WARNING

Avoid injury.

Do NOT operate withdoors open.Close all doors beforeoperating machine.

OVERVIEW SAFETY LABELS REPAIR AND SERVICE


Wear ear protectors.

Never look into UV light without wearing protective glasses.

Anapurna L/XL complies with CE standards.

Label Meaning

CAUTION

Loud noise

hazard.

Ear protection

must be worn

WARNING

UV LIGHT.

Do not look

directly at light.

Made in Korea

DILLI PRECISION IND.CO.LTD.

50 Hz

380VAC/3Phase, 50A

1325604058601

:ANAPURNA XL V1.0

2006-05Manufacturer's Serial No.

Type

Rated Voltage / Current

Rated Frequency

Manufactured By

This device complies with FCC PART 15 SUB PART 15 CLASS A

5909/900

REPAIR AND SERVICE PREPARING FOR SERVICE


3. Preparing for Service

Before executing any service or maintenance action, the service engineer should go to service mode. In service Mode, the service engineer is allowed to open all doors and covers without any risk.

3.1. Moving Head Carriage to Home or Purge Position

! 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.

3.2. Putting the print Engine in Service Mode

To put the print engine in service mode, proceed as follows:

1 Move the head carriage to the purge or home position

2 Switch off the UV lamps.

3 Switch off the main power or press one of the emergency stop buttons.

4 Open the desired doors using the door key if necessary.

DISASSEMBLY/ASSEMBLY OF MAJOR COMPONENTS REPAIR AND SERVICE


4. Disassembly/Assembly of Major Components

4.1. Disassembly/Assembly of the Air Pressure Panel Components

This section describes the following replacement procedures:

! Replacement of the Regulators,

! Replacement of the Air Filter,

! Replacement of the Solenoid.

4.1.1. Safety Instructions





1

2

21

5544

4

33

3

3

1 Regulator (AW20-02BCG) 4 Air filter (AF20-01BG)

2 Regulator (IR-1020-01BG) 5 Solenoid V/V

3 Regulator (IR-1000-01BG)

REPAIR AND SERVICE DISASSEMBLY/ASSEMBLY OF MAJOR COMPONENTS


4.1.2. Replacement of the Regulators

A. PRELIMINARY ACTIVITIES

B. MANPOWER

C. SPECIAL TOOLS

D. CONSUMABLES, MATERIALS AND SPARE PARTS

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).

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).

Operation Reference

Move the head carriage to the purge position. Chapter 3 §3.1.

Remove air pressure panel and cable trunk covers. Chapter 4 §9.2.

Qualification Number of people Man-hours Execution time

Service engineer 1

Description Code

Description Code

REGULATOR (AW20-02BCG) D2+2509101

REGULATOR (IR-1020-01BG D2+2509016

REGULATOR (IR-1000-01BG)

1 2 3

4 5




6 Replace the regulator(s).

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.

6 8 7 8

Regulator AW20-02BCG Regulator IR-1020-01BG Regulator IR-1000-01BG

1

2 3 4 5

0.15 MPa0.10 - 0.15 MPa

0.40 - 0.80 MPa 0.30 MPa



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).


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.

4.1.3. Replacement of the Air Filter

Refer to �Replacing the Air Filter� on page 4-72 (chapter Preventive Maintenance).

4.1.4. Replacement of the Solenoid

-.- Not Available Yet -.-



4.2. Disassembly/Assembly of the Media Transport System Components


! 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.


4.2.2. Replacement of the Conveyer Belt


B. MANPOWER

C. SPECIAL TOOLS



CAUTION: The print table is not to be used as a worktable. Never lean on the printer and do not Avoid direct light on inner parts such as sensors. Direct light can cause malfunctions that lead to a reduced image quality.

Operation Reference


Put the print engine in service mode. Chapter 3 §3.2.


Service engineer 1

Operator 1

Description Code

Allen key no.12

Conveyer belt wire D2+2509266

Description Code

Conveyer belt L D2+250314

Conveyer belt XL D2+250315

Protective gloves



E. PROCEDURE

1 Move the conveyer belt until the belt�s 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 Loosen the tension on the belt:

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.

5 Snap both ends in each other.

1

NOTE: There is no difference between the bottom and top side of the conveyer belt



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.

2

2



4.2.3. Replacement of the Feed Servo Motor

The conveyor belt is driven by a servo motor (400W).


B. MANPOWER

C. SPECIAL TOOLS


E. PROCEDURE


Operation Reference




Description Code

Description Code

1 12 3

1 Feed servo motor (400W)) 3 Reduction gear motor

2 Polyester woven conveyer belt



4.2.4. Replacement of the Winder/Unwinder Drive Motor

The Anapurna L/XL is equipped with an automated winder/unwinder system to wind/unwind the print medium rollers. The two drive motors, one at the paper input side and one at the paper output side, are mounted on the right-hand roll bar bracket.


B. MANPOWER

C. SPECIAL TOOLS

None


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.

Operation Reference




Service technician 1

Description Code

1



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.

2 3



4.2.5. Replacement of a Media Register Pin


B. MANPOWER

C. SPECIAL TOOLS


E. PROCEDURE


Operation Reference




Description Code

Description Code



4.2.6. Replacement of the Limit Switch and Shock Absorber

4.2.6.1. General information


B. MANPOWER

C. SPECIAL TOOLS


E. PROCEDURE


Operation Reference




Description Code

Description Code

limit switch D2+2509143

Shock absorber D2+2509058

1 2



4.2.7. Replacement of a Vacuum Pump

Two adjustable vacuum air pumps hold the media on the print table during printing and transport.


B. MANPOWER

C. SPECIAL TOOLS


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).

NOTE: Each vacuum pump together with the silencer and air controller is marked with a color dot.

NOTE: If you need to replace both vacuum pumps, respect the yellow and blue color dots when mounting the silencer and the air controller to the vacuum pump.

Operation Reference





Description Code

Teflon tape

Description Code

1

2



2 Remove the air controller (3) and the silencer (4).

! Assemble

1 Take the following items:

! vacuum pump, marked with a color dot.

! silencers and air controller, marked with the same color dot.

2 Mount the silencer and the air controller as illustrated:

3 4

1 2 3

1 Vacuum blower 3 Silencer2 Air controller with air relief valve



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.

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.

NOTE: To avoid leakage, wind isolation tape around the cylinder input before attaching the hose.



4.3. Disassembly/Assembly of the Ink Supply System Components at Refill Unit


! 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.


InkBottle


Sub Ink Tank (6C)

SolutionTank

Ink/SolutionValve

Print Head

Ink

Ink Pump

IN OUT IN OUT

Ink Filter

Components Refill Unit

WARNING: Avoid heater temperature above 50°C. Always turn off the heater power when the Anapurna L/XL is shut down for a long period. Overheat can cause engine damage or fire.



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



4.3.2. Replacement of the Printed Circuit Boards (PCB)

There are three PCBs at the refill unit side:

! Indicator PCB

! Refill Control PCB

! Refill PCB


B. MANPOWER

C. SPECIAL TOOLS

None


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.

4 Reconnect all connectors.

Operation Reference





Description Code

Indicator PCB D2+2359109

Refill Control PCB D2+2359048

Refill PCB D2+2359049

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



4.3.3. 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.


B. MANPOWER

C. SPECIAL TOOLS

None


E. PROCEDURE

! Air filter (6C and W)

Refer to �Inspecting and Replacing the Air Filter� on page 4-55 (Chapter Preventive Maintenance).

Operation Reference





Description Code

Air filter (Color and White) D2+2509046

Refill float sensor (Color and white) D2+2357004

Circling motor (white) D2+2509165

Twin Timer D2+2509253



! Refill float sensor (6C and W)

1 Open the ink supply door and remove the cover (1) above the main ink tanks.

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).

4 Remove the old refill float sensor.

1

2

3

4



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).

6 Guide the 3-pin connector through the nearest hole (8) in the ink supply door and reconnect the level sensor (step 2).

! Circling motor (White)


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).

5 6

8

7

5

1

2



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).

3

4

5 56

7



! 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.

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).

! Main Ink tank


3

2

2

3

4



4.3.4. Replacement of the Ink Pump


B. MANPOWER

C. SPECIAL TOOLS

None


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.

Operation Reference





Description Code

Ink pump (KNF) D2+2509047

1

2



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.

6 Remove the ink pump.

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.

3

4

5

7

6

8

IN

OUT



! Assemble:

1 Take out the new ink pump.

2 Mount the new ink pump

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.

541

2IN

OUT 2

3

6



4 Reconnect the following ink pump tubes:

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.

7

8

IN

OUT

8



4.3.5. Replacement of the Ink Filter


B. MANPOWER

C. SPECIAL TOOLS

None


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.

Operation Reference





Description Code

Ink filter D2+2509004



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.

1

2



6 Remove the following tubes from the ink filter:

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).

3

4

5

IN

OUT



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.


B. MANPOWER

C. SPECIAL TOOLS


E. PROCEDURE

Operation Reference

Move the head carriage to the purge position. Chapter 3 §3.1..



Service engineer.

Description Code

open-end wrench

cross head screwdriver

wire-cutter

pincer

Description Code

Tie wrap

O-ring

Ink filter D2+2509004

Ink pump (KNF) D2+2609047

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.



! Disassemble:

Remove the ink tube between the main tank and the ink pump IN connection:


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.

1

32

4



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).

5

6

7

8

9

10



11 Disconnect the ink tube from the ink filter OUT connection (top of the ink filter) (11).

Close the filter cap to avoid leakage.


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).


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).

11

IN

OUT

1 2



1.3 Wrap a cable protection around the ink tubes (3).

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).

3 Replace the main ink tank cover (8).

21 3

4

67

5

8



4.3.7. Replacement of the Ink Tubes in the Chain


B. MANPOWER

C. SPECIAL TOOLS


E. PROCEDURE

1 Get access to the hose fixing guide (1).

Operation Reference



Open the home rear door to get access to the hose fixing guide.



Description Code

open-end wrench

wire-cutter

Description Code

Tie wrap

ink tube

sticky tape

NOTE: The replacement procedure is written for one ink tube. Repeat the procedure for the other ink tubes.

1



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.

2

34 4



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.



4.4. Disassembly/Assembly of the Ink Supply System Components at Head Carriage Unit


! 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.

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).


B. MANPOWER

C. SPECIAL TOOLS

None

Operation Reference





InkBottle


Sub Ink Tank (6C)

SolutionTank

Ink/SolutionValve

Print Head

Ink

Ink Pump

IN OUT IN OUT

Ink Filter

Components Head Carriage Unit




E. PROCEDURE

! Float sensor (6C and W)


! Temperature sensor (6C and W)


4.4.2. Replacement of the Solution Tank


4.4.3. Replacement of the Sub Air Tank Components

The following sub air tank components are discussed:

! Float sensor,

! Pressure sensor (PSE531-M5-L),

! Air filter,

! Speed V/V (AS1001F-06).

Description Code

Float sensor (Color and White) D2+2509129

Refill float sensor (Color and white) D2+2509184

1

2

3

1 Air filter 3 Pressure sensor (PSE531-M5-L)2 Speed V/V (AS1001F-06)




B. MANPOWER

C. SPECIAL TOOLS

None


E. PROCEDURE

! Float sensor


! Pressure sensor

The pressure sensor PSE531-M5 on the top of sub air tank measures the negative pressure. The read-out is feedback to ITV controller.


! Air filter

1 Inspect the air filter for any moisture.

2 If saturated, remove and replace the air filter.

! Speed V/V (AS1001F-06)

To replace the speed V/V:


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

Operation Reference





Description Code

Float sensor D2+2509129

Pressure sensor (PSE531-M5-L) D2+2357005

Air filter D2+2509046

Speed V/V (AS1001F-06)



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.

4.4.4. Replacement of a 2-Way Valve


1



4.4.5. Replacement of the Carriage Assembly Components

The following carriage assembly components are discussed:

! Electro-pneumatic regulator ITV2010,

! Air purge valve VT301V-025GB and VT301-025GB,

! Vacuum ejector (INO-4336-4) INO-4336-4,

! Encoder


B. MANPOWER

C. SPECIAL TOOLS


E. PROCEDURE

! Electro-pneumatic regulator ITV2010


Operation Reference





Description Code

Description Code

Electro-pneumatic regulator ITV2010 D2+2509028

Air purge valve VT301V-025GB D2+2509027

Air purge valve VT301-025GB

Vacuum ejector (INO-4336-4) D2+2509170

Encoder D2+2162037



! Air purge valve VT301V-025GB and VT301-025GB


! Vacuum ejector (INO-4336-4)


! Encoder




4.4.6. Replacement of the Waste Tank


B. MANPOWER

C. SPECIAL TOOLS

None


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.

Operation Reference





Description Code

Refill float sensor D2+2357004



4.5. Disassembly/assembly of the Head Carriage Movement Components


! 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).

4.5.1. Replacement of the Ball Screw Assy

1

2

3

1

1 Ball screw upper unit 1 Ball screw lower unit

2 Ball screw




B. MANPOWER

C. SPECIAL TOOLS

None


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.

Operation Reference





Description Code

Step motor D2+2501123

Ball screw upper unit

Ball screw

Ball screw lower unit

1



3 Remove the step motor (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).

4.1 Remove the 4 screws.

4.2 Lift the ball screw unit over the shaft.

2

34

23

4

5

5

5



5 Remove the aluminium motor fixing plate (support bracket) (6) by unscrewing the 4 screws.

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).

6

6

6

7

9

8



8 Remove the ball screw (10).

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.

8.3 To remove the moving plate fixing block (11), unlock and unscrew the lock nut () at the bottom.

! Assemble

To assemble, proceed in the opposite way.

4.5.2. Replacement of the Head Base Components

The replacement of the head base components is discussed in the section �Disassembly/Assembly of the Print Head Components� on page 3-60.

10

11

NOTE: Be aware of the ball screw spring, it is still loaded. To unload, move the ball screw completely up.

CAUTION: Do not remove the bearing from the shaft. The ball is not fixed.



4.5.3. Replacement of the Head Base Lifting Assembly


B. MANPOWER

C. SPECIAL TOOLS


E. PROCEDURE


Operation Reference





Description Code

Description Code

Solenoid (small) D2+2359104

solenoid (large) D2+2359103

shading sensor (Omron) D2+2509104



4.5.4. Replacement of the Printed Circuit Boards (PCB)

There are three PCBs at the refill unit side:

! Head Lift PCB

! Head PCB

! Cartridge PCB


B. MANPOWER

C. SPECIAL TOOLS

None


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.

4 Reconnect all connectors.

Operation Reference





Description Code

Head Lift PCB D2+2359275

Head PCB D2+2359045

Cartridge PCB D2+2359044

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



4.6. Disassembly/Assembly of the Print Head Components


! Replacement of a Print Head,

! Replacement of the Heater Bar and the Thermistor,

! Replacement of the Temperature Sensor.



CAUTION: Always replace a damaged print head.

CAUTION: Always clean the print head using cleaning fluid after printing and before turning off the system.




4.6.2. Replacement of a Print Head


NOTE: The replacement procedure is written for one print head (the Magenta print head). Repeat the procedure if more than one print head has to be replaced.

1

2

M

Y

Lc

Lm

C

K

W spotW pre

M

1 Detail Magenta Print Head 2 Head Base Plate

Operation Reference



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).



B. MANPOWER

C. SPECIAL TOOLS


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.



Description Code

Allen Key no.1.5 and no.2.5

Crosshead screwdriver

Long Philips screwdriver

Spanner no.10

Long nose plier

Description Code

Print Head (Spectra Nova 80pico) D2+2409007

Teflon washer D2+2509185

Head adjusting spring D2+2501133

Spring fixing pipe D2+2102156

Eccentric bushing shaft D2+2102154

Wave washer D2+2509186

Protective gloves

Operation Reference



E. PROCEDURE

! 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.

1.2 Detach the black thermostat cable (3) which is connected to J29 of the HEAD PCB.

1.3 Detach the red heater cable (4) which is connected to the HEAD PCB.

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.

B C M Y Lc

1

2

NOTE: Only applicable for the Magenta head.

M Y Lc

M Y Lc Lm W

33, 4



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).

5 66

7 8

9

101113 12



5 Remove head adjusting springs (14) in front and side using an Allen key no. 2.5.

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.

7 Loosen the ink tube (18) on of the print head valve.

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.

14

15

1614, 15, 16

NOTE: The head adjusting bolts are the bolts which allows you to do the front/back alignment of the print head.

17

18

NOTE: Place the head always on the black side on the table. Not on the Aluminum side.



9 Remove the print head (19) from the head fixing (Aluminum block) (20).

Unscrew the 2 screws underneath the head.

! 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.

12 Mount the print head on the head fixing.

19

20

21

21



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.

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.

NOTE: Mind the order: socket screw, spring fixing pipe (22), teflon washer (23), head adjusting spring (24) and teflon washer (23).

24

23

22

25 26

27 28 29 30 31 31



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.

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

NOTE: Only applicable for the Magenta head.



4.6.3. Replacement of the Heater Bar and the Thermistor

! 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).


B. MANPOWER

C. SPECIAL TOOLS


21

12 2

1 Thermistor (only for Magenta) 2 Heater bar

Operation Reference

Disassemble the print head. 3 §4.6.2., step 1 to 9.


Service technician

Description Code

Description Code

Heater bar (Spectra) D2+2401001

Thermistor (Spectra) (also called head temperature sensor) D2+2409006



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).

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.

1

2

3

NOTE: Thermistor, only applicable for the Magenta head.

2 11 2



4.6.4. Replacement of the Temperature Sensor

The temperature of the head base plate is measured by means of a temperature sensor, which is built into the PT sensor bracket. The temperature sensor is connected to J17 of the Head Lift PCB and leads through the Head Base Temp. PID display (home unit).

For more information about the temperature sensor, refer to �Temperature detection components and setting components� on page 1-63 (chapter Functional Description).


B. MANPOWER

C. SPECIAL TOOLS


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.

Operation Reference



Open the top purge door to get full access to the head base plate



Description Code

cross-slotted screwdriver

Description Code

Temperature sensor stick (rear) D2+2509184

1 2



4.7. Disassembly/Assembly of the UV Curing System Components


! 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

6

8

6

4

3

5

7

1 UV lamp box (left) 5 Lamp shutter

2 UV lamp box (right) 6 UV lamp box housing

3 Lamp case outer air inlet AC fan 7 Lamp case inner air outlet DC fan

4 UV Lamp fixing 8 Lamp (190 mm)




4.7.2. Replacement of the UV Lamp Box


B. MANPOWER

C. SPECIAL TOOLS


E. PROCEDURE

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).

Operation Reference

Left UV lamp box: Move the head carriage to the purge position.Right UV lamp Box: Move the head carriage to the home position.

Chapter 3 §3.1.


Left UV lamp box: Open the front and left purge door to get full access to the left UV lamp box.Right UV lamp Box:Open the home right side door to get full access to the right UV lamp box.



Description Code

Allen Key no.


Description Code

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 1

2

View: Purge side



3 Tilt the UV lamp box out of the UV lamp box housing.

4 Put the UV lamp box aside.

5 To replace, proceed in the opposite way.

4.7.3. Replacement of the UV Lamp Box Housing


B. MANPOWER

Operation Reference

Left UV lamp box: Move the head carriage to the purge position.Right UV lamp Box: Move the head carriage to the home position.

Chapter 3 §3.1.


Left UV lamp box: Open the front and left purge door to get full access to the left UV lamp box.Right UV lamp Box:Open the home right side door to get full access to the right UV lamp box.

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.

Remove the UV lamp box. Chapter3 §4.7.2.





C. SPECIAL TOOLS


E. PROCEDURE

1 Disconnect the following electrical connections:

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.

Description Code

Allen Key no.


Description Code

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.

4

3

1 2



3 Put the UV lamp box housing aside.

4 Establish the UV lamp Adjustment

Refer to �Lamp house Alignment� on page 3-103.

4.7.4. Replacement of the Air Inlet AC Fan

The UV lamp box is provided with two air inlet AC fans.


B. MANPOWER

C. SPECIAL TOOLS


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).

Operation Reference

Remove the UV lamp box Chapter3 §4.7.2.



Description Code

Allen Key no.


Description Code

1 2



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.

3 Replace the AC fan(s) by a new one.

Be careful with the electrical connections.

3 4

step 1 step 2

step 3 step 4

WARNING: Do not touch the reflector surface.



4 Mount the reflector bracket back into the cover as illustrated in the five steps below.

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.

step 1 step 2

step 3 step 4

step 5



5 Reassemble the AC fans and the grids as illustrated in the three steps below.

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.

4.7.5. Replacement of the Air Oulet DC Fan


4.7.6. Replacement of the Ignitor


B. MANPOWER

C. SPECIAL TOOLS


Operation Reference

Remove the UV lamp box. Chapter3 §4.7.2.



Description Code

Allen Key no.


Description Code

Ignitor D2+

step 1 step 2

step 3



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.

3 Mount the new ignitor to the reflector bracket.

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.

4.7.7. Replacement of the UV Lamp

Refer to the chapter Preventive Maintenance, �Replacing the UV Lamps� on page 4-49 (chapter Preventive Maintenance).

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



4.7.8. Replacement of the UV Lamp Shutter

Refer to the chapter Preventive Maintenance, �Replacing the Lamp Shutter� on page 4-52 (chapter Preventive Maintenance).

4.7.9. Replacement of the Thermistor


B. MANPOWER

C. SPECIAL TOOLS


E. PROCEDURE

! Replacement of the thermistor mounted in the UV lamp box housing

1 Unscrew the cover (1).

2 Disconnect the electrical connections (2).

3 Unscrew the thermistor from the bracket (3).

4 Mount the new thermistor on the bracket.

5 Reconnect the electrical connectors.

6 Close the cover.

Operation Reference



Open the front and left purge door to get full access to the UV lamp box.


Description Code

cross-slotted screwdriver

Description Code

110'C THERMISTOR D2+2509134

1 2 23



! Replacement of the thermistor mounted on the reflection cap of the UV lamp box


INSTALLING THE PCI I/O CARD REPAIR AND SERVICE


5. Installing the PCI I/O Card

5.1. Location

The PCI I/O card is located in the control box of the Home unit. The PCI I/O card is plugged into the PCI slot of the PC Main Board. The PCI I/O card is connected to the FPGA PCB

PCI I/O Card

PC Main Board

PC Main Board

PCI slot

FPGA PCB

REPAIR AND SERVICE INSTALLING THE PCI I/O CARD


5.2. Replacement of the PCI I/O Card


B. MANPOWER

C. SPECIAL TOOLS

None


E. PROCEDURE

! Mechanical


! Driver Installation

1 Put the PCI card driver into CD ROM drive.

2 Select �Driver Installation�.

Operation Reference



Open the ink supply door to get access to the main box right.



Description Code

PCI I/O card D2+2359062



3 Select NuDAQ PCI.

4 Select PCI-7200.

5 Select WIN98/NT/2000/XP DLL DRIVER(PCIS-DASK) to start the installation.



6 After a short while, the Welcome screen is displayed:

7 Click Next.

The User Information screen is displayed:

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.



9 Click Next.

The next window show the setup type, where you are asked to set the type of setup you prefer.

10 Click Next.

A Summary screen is displayed:

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.



12 Select

The following screen appears:

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.

ADJUSTMENT AND ALIGNMENT PROCEDURES REPAIR AND SERVICE


6. Adjustment and Alignment Procedures

6.1. Vacuum Blower Adjustments


When mounting a new vacuum blower or when problems with the vacuum blower, check the following:

! vacuum blower setting,

! air relief valve setting.

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.

REPAIR AND SERVICE ADJUSTMENT AND ALIGNMENT PROCEDURES


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 blower�s power cable.

2.7 Adjust the spring tension, by turning the head screw, until you measure the rated current indicated on the identification plate.

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.

NOTE: Turn the head screw clock wise to increase the current.

1 2

1 Vacuum blower 1 2 Vacuum blower 2

NOTE: Secure the fixing bolt into the nut.



6.2. Print Head Adjustments

6.2.1. Adjusting the Head Base Temperature


The temperature of the head base plate can only be tuned by changing the head PCB voltage.

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 32°C on most engine configurations.

The higher the voltage value, the lower the temperature value.

NOTE: Refer to �Head Base Temperature Control� on page 1-63 of the chapter Functional Description.

Head PCB

Cartridge PCBs



6.2.2. Adjusting the Head Voltage


Each new print head is delivered with a sheet containing the spectra recommended voltage value of the manufacturer. If you have replaced a print head by a new one, you need to adjust the head voltage of the new print head.

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 corre-sponding Agfa voltage using the correction table below.

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).

Drive voltage Anapurna headsBlack Cyan Magenta Yellow Li. Cyan Li Mag. white 1 white 2

Spectra recommended voltage for Nova head : 92 92 93 92 90 91 94 92

Correction factor for Anapurna G1 at 35°C: 1 0,911702 0,9537634 0,98495 0,98418 1,034483Corrected voltages for Anapurna G1Inks: 92,0 83,9 88,7 90,6 88,6 94,1 0,0 0,0

1 2 3



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.

! To decrease, turn clockwise.

! To increase, turn counterclockwise.

Cartridge PCB

5

6

6



6.2.3. Hardware Alignment of the Print Head


For the hardware alignments of the print heads use:

! 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

! Front/back correction

! 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.

NOTE: Except for pre-white

1



! 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.

6.2.4. Software Alignment of the Print Head


When you notice a timing delay in jetting the colors (=head delay to map other heads onto black) you need to adjust the head alignment settings for each head, in reference to the black head.

For the software alignments of the print heads it is recommended to use:

! 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:


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

4



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.

5 After changing the values, Click Save.


6 Click Save As and create a new .dat file, or overwrite the old one.

6.2.5. Media Feed Correction

For a brief description, refer to �Step Size (Media Feed)� on page 1-82 (chapter Functional Descrip-tion). For a detailed description, refer to the Operator Manual.

6.2.6. Bidir Adjustments

For a brief description, refer to �Bi-Dir Alignment� on page 1-82 (chapter Functional Description). For a detailed description, refer to the Operator Manual.

6.2.7. Alignment of the Pre-White Head

The alignment of the pre-white head occurs almost identical as for the other print heads. The main differences are:

! 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.

f



6.3. Conveyer Belt Alignment

It is very important to have a perfect aligned conveyer belt. The belt should have a linear movement and there should be no side deviations.


None

B. MANPOWER

C. SPECIAL TOOLS


None

E. PROCEDURE

1 Loosen the tension on the belt:

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 belt�s joint is positioned in the middle at the underside of the printing table.



Description Code

NOTE: In case you have mounted a new conveyer belt, skip step 1.



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

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.

Measured distance < 0,5 cm Measured distance > 0,5 cm

increase the tension with the same amount on the side where the belt was moving to.

increase the tension with half of the measured differ-ence on the side where the belt was moving to.

reduce the tension with half of the measured differ-ence on the side where the belt was moving from.



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.

6.4. Head Base Alignment

6.4.1. Aligning the Head Base Plate

To achieve a good printing quality, you need to adjust the head base plate parallelism within the specifications. The maximum tolerances between left/right, front/back is < 0.5 mm.


None

B. MANPOWER

C. SPECIAL TOOLS


None

E. PROCEDURE

! 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.

NOTE: The position of the belt should not move more than 2 mm.

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.


Service technician

Description Code



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 devia-tion 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.

! Head base Front/Back alignment control.

The front back deviation can be adjusted by the reference screw as showed in the picture below.

Figure 3.1: Side view of the head carriage unit + top view head 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.

1

122

Base plate

Print table

Base plate

3

4



! Head base Left-right alignment control.

The evenness of the head carriage unit left right can adjusted by moving the position of the guiding blocks (LM block).

Figure 3.2: Head Base alignment Left-Right

1 Execute the head gap control partly.

Click OK and the head carriage unit will move above the print table


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.

Reference Blocks

Jig

Head base back panel

22

3

11

NOTE: Never loose the bolts of the reference blocks.



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.

1



6.5. Lamp house Alignment


B. MANPOWER

C. SPECIAL TOOLS


None

E. PROCEDURE

! Lamp house Left-Right alignment control.

For Left-Right alignment, adjust 2 screws.

Operation Reference




Service technician

Description Code

1 2Left alignment Right alignment



! Lamp house Top-Left tilt alignment control.

For Top-Down alignment, there is a fixed bolt and one screw that can be adjusted.

3

4

CHAPTER


4 Preventive Maintenance

This chapter describes the preventive maintenance procedures for the Anapurna L/XL.

1. Maintenance Schedule ........................................................................................................................................ 4 - 22. Print Media Unit Maintenance .......................................................................................................................... 4 - 5

2.1. Guidelines and Specific Safety Instruction ..................................................................................... 4 - 52.2. Conveyer Belt ............................................................................................................................................ 4 - 62.3. Vacuum Holes ............................................................................................................................................ 4 - 92.4. LM Guide .................................................................................................................................................. 4 - 102.5. LM Blocks ................................................................................................................................................. 4 - 112.6. Carriage Belt (S5M Belt) ..................................................................................................................... 4 - 132.7. S3M Belt ................................................................................................................................................... 4 - 162.8. Linear Scale Encoder ............................................................................................................................ 4 - 242.9. Bearings Print Media Unit .................................................................................................................. 4 - 332.10. Waste Tank ............................................................................................................................................ 4 - 35

3. Head Carriage Unit Maintenance .................................................................................................................. 4 - 363.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 363.2. Print Head ................................................................................................................................................. 4 - 383.3. UV Lamp Box / UV Lamp Box Housing ......................................................................................... 4 - 463.4. Head Carriage ......................................................................................................................................... 4 - 53

4. Refill Unit Maintenance .................................................................................................................................... 4 - 544.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 544.2. Air filter 6 Color and White ............................................................................................................... 4 - 554.3. Ink Filter .................................................................................................................................................... 4 - 56

5. Purge Unit Maintenance ................................................................................................................................... 4 - 635.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 635.2. Purge box .................................................................................................................................................. 4 - 63

6. Home Unit Maintenance .................................................................................................................................. 4 - 656.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 656.2. Home box ................................................................................................................................................. 4 - 65

7. Safety Circuit ......................................................................................................................................................... 4 - 677.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 677.2. Emergency Stop Circuit ....................................................................................................................... 4 - 67

8. Air Tank Maintenance ........................................................................................................................................ 4 - 698.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 698.2. Air Tank ..................................................................................................................................................... 4 - 69

9. Air Pressure Panel Maintenance .................................................................................................................... 4 - 709.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 709.2. Air Pressure Panel ................................................................................................................................. 4 - 70

10. Engine ................................................................................................................................................................... 4 - 7510.1. Guidelines and Specific Safety Instruction ............................................................................... 4 - 7510.2. Engine Level ......................................................................................................................................... 4 - 75

PREVENTIVE MAINTENANCE MAINTENANCE SCHEDULE


1. Maintenance Schedule

Unit Component Frequency Activity Required ToolsSpare Part Name

Spare Part Order Code

Operator/Service Engineer

See ...

Head Carriage unit

Print head Daily Clean lint-free cloth Operator 4 §3.2.1.

Print head Daily Nozzle Check and purge or clean the failed heads if necessary

Operator 4 §3.2.1.

Print head Weekly Clean Cleaning solution 4 §3.2.1.

Crystal Glass plate

(UV lamp box housing left and right)

1 Month Inspect and clean if necessary

lint-free cloth with isopropyl alcohol (IPA)

Crystal Plate (190)(8C)

D2+2509166 Operator 4 §3.3.1.

Print Head / UV lamp box

1 Month Check for printing and curing quality

print outs 4 §3.3.2.

Print Head / UV lamp box

3 Month Check for printing and curing quality and replace both UV lamp if neces-sary

lamp 190 mm D2+2509221 4 §3.3.2.4 §3.3.3.

UV lamp

(UV lamp box; left and right)

6 Month Replace Lamp 190 mm D2+2509221 Operator 4 §3.3.3.

Lamp Shutter 1 Year Inspect shutter functionality and replace if mal-functioning

SHUTTER (190 LAMP)(8C)

D2+2359234 4 §3.3.4.

4 §3.3.5.

LM guide

(Head Carriage)


Acetone Operator 4 §2.4.1.

LM blocks

(Head Carriage)

6 Month Grease AFB lubricating grease

4 §2.5.1.

Head PCB

(Head Carriage)

1 Year Inspect the head voltage

4 §3.4.2.(3 §6.2.2.)

Head base plate

(Head Carriage)

1 Year Inspect the head base plate paral-lelism

4 §3.4.3.(3 §6.4.1.)

MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE


Print Media unit

LM guide

(Frame Assembly - Box Beam)


Acetone Operator 4 §2.4.1.

LM blocks


6 Month Grease AFB lubricating grease

4 §2.5.1.

Linear scale encoder



Acetone or iso-propyl alcohol (IPA)

Operator 4 §2.8.1.

S5M belt(15 mm)

(= carriage belt)

Inspect the ten-sion and re ten-sion if necessary

4 §2.6.1.

6 Month Replace S5M BELT (15mm), grey

D2+2959029 4 §2.6.2.

S3M belt(564 mm)

6 Month Inspect the posi-tion and re posi-tion if necessary

4 §2.7.1.

1 Year Replace S3M BELT (564mm), black

D2+2959024 4 §2.7.2.

Bearing UFL004

(Double Pulley Assembly)

6 Month Inspect and grease

Bearing UFL004

D2+2509194 4 §2.9.1.

Idle pulley bearing

(Idle Pulley Assem-bly)


4 §2.9.1.

Tension Roll Bearings 6 Month Grease 4 §2.9.1.

Bearings Rigid Table 6 Month Grease 4 §2.9.1.

Bearing UFL diame-ter 40

(Frame Assembly)


4 §2.9.1.

Conveyer belt Weekly Clean, inspect and re tension if necessary

Operator 4 §2.2.1.

1 Month Inspect the posi-tion and adjust if necessary

Operator 4 §2.2.2.

6 Month Replace Conveyer belt XLConveyer belt L

D2+2503014

D2+2503015

4 §2.2.3. (3 §4.2.2.)

4 §2.2.4.(3 §6.3.)

Vacuum holes 6 Month Inspect vacuum holes and clean if necessary

4 §2.3.1.

Waste tank Weekly Inspect and empty if neces-sary

4 §2.10.1.




See ...

PREVENTIVE MAINTENANCE MAINTENANCE SCHEDULE


Print Media unit

Media thickness sen-sor

6 Month Inspect the func-tionality

6 Month Grease assy

Refill unit

Air filter (6C)Air filter (W)

Daily Inspect for any moisture and replace if neces-sary

4 §4.2.1.

Ink Filter 6 Month Bleed ink filters 4 §4.3.1.

1 Year Replace if neces-sary

Ink filter D2+2509004 4 §4.3.3.

Purge unit

Grid

(Ink fixing upholder #1 and #2)

Weekly Inspect and clean if necessary

Filling knife or screw driver.Solution.

Operator 4 §5.2.1.

Ink receiving bin

(Purge fixing upholder #3)

1 Year Inspect waste barrel and pierce hole. Clean if nec-essary

Filling knife or screw driver

Operator 4 §5.2.2.

Home unit

Grid

(Ink fixing upholder #1 and #2)

Weekly Inspect and clean if necessary

Filling knife or screw driver.Solution.

Operator 4 §6.2.1.

Air tank Air tank 6 Month Drain 4 §8.2.1.

Air pressure panel

Air filter 6 Month Drain Air filter AF20-01BG

4 §9.2.1.

1 Year Replace Air filter AF20-01BG

D2+2509015 4 §9.2.2.

Safety circuit

Emergency Stops 1 Year Inspect all four emergency stops

4 §7.2.1.

Door Open Sensor Inspect the func-tionality

Door sensor (Front/Rear)

D2+2509239

Door sensor controller (PA10-U)

D2+2509238

Engine Spirit level 1 Year Inspect and level again if necessary

Nut wrench no. 36

4 §10.2.1.

Covers and lockers




See ...

PRINT MEDIA UNIT MAINTENANCE PREVENTIVE MAINTENANCE


2. Print Media Unit Maintenance

2.1. Guidelines and Specific Safety Instruction

! Handling UV Curable ink

! UV radiation



! Maintenance safety instructions







PREVENTIVE MAINTENANCE PRINT MEDIA UNIT MAINTENANCE


2.2. Conveyer Belt

2.2.1. Cleaning the Conveyer Belt

When you have printed onto the Conveyor belt, remove the ink as soon as possible.


None

B. MANPOWER

C. SPECIAL TOOLS

None


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 (respec-tively 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).

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.


Operator 1

Description Code

Cleaning solution

Cleaning cloth

NOTE: When the belt is completely printed, vacuum can become insufficient.



2.2.2. Inspecting and Adjusting the Conveyer Belt Tension

The belt should have a linear movement and there should be no side deviations.

The position of the conveyer belt can move slightly during daily production. Those small shifts can be removed by controlling the conveyer belt tension.

For huge shifts it is recommended to execute a conveyer belt alignment. For more information, refer to �Conveyer Belt Alignment� on page 3-97 of the Repair and Service chapter.


B. MANPOWER

C. SPECIAL TOOLS


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.

Operation Reference




Operator 1

Description Code

Allen Key no. 12



2 If the belt tension is sufficiently and the belt is touching the left and right side narrowly, adjust-ments 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).

6 Proceed with step 1.

7 Replace the black metal cover.

2.2.3. Replacing the Conveyer Belt

Refer to �Replacement of the Conveyer Belt� on page 3-13 (chapter Repair and Service).

2.2.4. Aligning the Conveyer Belt

Refer to �Conveyer Belt Alignment� on page 3-97 (chapter Repair and Service).

NOTE: These small adjustments can be done while the conveyer belt is moving.



2.3. Vacuum Holes

2.3.1. Inspecting and Cleaning the Vacuum Holes


None

B. MANPOWER

C. SPECIAL TOOLS


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.

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).


Service technician 1 20� 20�

Description Code

Syringe needle

CAUTION: Do not use a drill to puncture the holes.

NOTE: Refitting the old belt is not always possible.



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.

! Vertical movement

head lifting along the along 2 LM guides (head lifting type).

2.4.1. Inspecting and Cleaning the LM Guide


B. MANPOWER

C. SPECIAL TOOLS

None


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.

1

2

3

4

1 Upper LM guide 3 Lower LM guide2 Linear scale (Encoder strip) 4 S3M belt, carriage belt

Operation Reference




Operator 1

Description Code

Acetone



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 Anapurna�s life expectancy.

2.5.1. Greasing the LM Blocks


B. MANPOWER

C. SPECIAL TOOLS


Operation Reference





Description Code

Spray gun MG70

Description Code

AFB lubricating grease



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.



2.6. Carriage Belt (S5M Belt)

2.6.1. Inspecting the Carriage Belt (S5M)


B. MANPOWER

C. SPECIAL TOOLS

None


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).

Operation Reference




1

2



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.

3

45 5



2.6.2. Replacing the Carriage Belt (S5M)


B. MANPOWER

C. SPECIAL TOOLS

None


E. PROCEDURE


Operation Reference




Description Code

S5M Belt (15 mm), grey D2+2959029

Bearing

Idle pulley



2.7. S3M Belt

2.7.1. Inspecting the Position of the S3M Belt


None

B. MANPOWER

C. SPECIAL TOOLS


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.

3 Inspect the position of the S3M belt on the double pulley.


Service technician

Description Code

Jig

1

2 3

2 S3M belt not centred 3 S3M belt centred



4 If the S3M belt is not centered, align the S3M belt as follows:

4.1 Take out the jig.

4.2 Insert the jig as illustrated in the figure below.

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 Replace and fix the double pulley protection cover.

44

5

6

NOTE: The tension of the S3M belt is determined by the distance between the double pulley and the motor pulley



2.7.2. Replacing the S3M Belt

When this belt wears out, it looses its teeth, parts as well as complete teeth. Discontinuity of the teeth results in noisy movements of the head carriage unit.


B. MANPOWER

C. SPECIAL TOOLS

None

Operation Reference




Service technician

S3M belt

Bearing ULF004

Double pulley

Carriage servo motor

S5M belt

Motor pulley

Bearing height adjusting block




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.

3 Disconnect the two connectors of the carriage servo motor (2)

4 Remove the carriage servo motor (3) by unscrewing the 4 socket-head screws (4).

Description Code

S3M Belt (564 mm), black D2+2959024

1

2

3

4



5 Remove the double pulley fixing support (5).

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.

5

6 6 8 7

9



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).

9 Remove the old S3M belt (13).

10 11 121011

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).

14 1515



10 Insert (wriggle) the new S3M belt along the right double pulley fixing bracket (16).

11 Remount the ULF004 bearing (17) and the ring (18) at carriage servo motor side.

12 Remount the ring (19) of the ULF Bearing at the opposite side.

16

17 18

19



13 Remount the double pulley fixing support (20).

14 Remount the carriage driver motor (21) using the 4 socket-head screws.

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.

20

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.



2.8. Linear Scale Encoder

2.8.1. Inspecting and Cleaning the Encoder Strip


None

B. MANPOWER

C. SPECIAL TOOLS

None


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.


Operator 1

Description Code

Isopropyl alcohol

Acetone

1



2.8.2. Encoder Checking

An encoder check is required in the following circumstances:

! the head carriage unit is not moving,

! the head carriage unit is not moving smoothly,

! the position of the head carriage unit is shifting.


None

B. MANPOWER

C. SPECIAL TOOLS

None


None

E. PROCEDURE



2 In the Test Menu window, select Enc. Count Test (1) and click Test (2).



2

1



The Encoder Test window appears.

! 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.


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).

3

4

NOTE: The default set value for the Carriage Gear Ratio (8) is always 7742.



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.

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.

5

7

8

6

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).



! Determining the number of marks on the linear scale

Definition Max. Mark Count: The markers counted (read by the encoder) from the home position (front right side) to the purge position (front left side).

To count the total number of marks the encoder passes between home and purge, proceed as follows:



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.

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.

2

1

3

NOTE: MARK = 1 thick stripe every 50 mm.



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).

! Defining the Home Position Offset

Definition Home Pos. Offset: Distance between detecting the home position and the real home position.

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.

NOTE: Make sure that the head carriage unit is in home position (front right side)

1



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.

! Testing the number of pulses the encoder reader counts


2 In the Setup Parameter window, set the carriage speed (1) to 100 and click Save.

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.

2

1 2

12



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.

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.

3

4 5

3 Main PCB 5 Mark LED

4 ENC LED (Encoder)

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 7



! Adjusting the depth between encoder head an linear scale

1 In the Control Program, click Head Lift Up.

2 Move the head carriage to home position.

3 Place the plastic 0.5 mm gap gauge between the encoder head (1) and the linear scale (2)

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).

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).

1 3 42

1 Encoder 3 Encoder bracket (view: home right side door side)

2 Linear scale (encoder strip) 4 Encoder bracket (view: purge top door)

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.



2.9. Bearings Print Media Unit

2.9.1. Greasing the Bearings of the Print Media Unit


None

B. MANPOWER

C. SPECIAL TOOLS

None


E. PROCEDURE

1 Lubricate the following bearings of the double pulley assembly:

1.1 Two UFL004 bearings (1).

1.2 Four bearing height adjusting blocks (2),

2 Lubricate the idle pulley bearing (3).



Description Code

AFB lubricating grease in a squeeze bottle

21 222 1

3



3 Lubricate the 2 bearings ULF diameter 40 (4), located behind the shaft cover (5).

4 Lubricate the tension roll-pipe bearings.

5 Lubricate the bearings of the rigid table.

4

5



2.10. Waste Tank

2.10.1. Inspecting and Emptying the Waste Tank


None

B. MANPOWER

C. SPECIAL TOOLS

None


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.


Operator 1

Description Code

Snap-on lid Black Polyethylene Containers.

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).

PREVENTIVE MAINTENANCE HEAD CARRIAGE UNIT MAINTENANCE


3. Head Carriage Unit Maintenance



! UV radiation



! Maintenance safety instructions










HEAD CARRIAGE UNIT MAINTENANCE 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.



3.2. Print Head

3.2.1. Cleaning a Print Head

The preserve optimal printing conditions, it is imperative to maintain the print heads.

The way to maintain the print heads, is mainly determined by the current conditions of the print heads, such as missing nozzles, no ink firing, leaking heads, ....

To avoid print head problems, attach great importance to the daily print head maintenance procedures.

In this section, we will discuss several cleaning procedures. The point of time and the sequence in which you should use the different cleaning possibilities is explained in the Operator Manual. One of the actions the operator should perform is the nozzle check, which is also explained in this section.

We distinguish the following cleaning possibilities:

! 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.




B. MANPOWER

C. SPECIAL TOOLS


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.

! 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.

Operation Reference



Operator 1

Description Code

Cleaning stick

Description Code

Lint-free cloth

NOTE: To order the cleaning stick, order D2+2161113 (cleaning stick rubber) and D2+2161115 (cleaning stick bracket).



! 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.


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.

Pressure control adjustment knob



4 Switch on the vacuum.



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.



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 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).

1 2 3

4 5


Multiple short pulses



4 Clean the print heads with a fiber-free cloth.

Refer to �Manual Clean Up� on page 4-39.

5 Check on weeping

Refer to �Automatic Weeping� on page 4-39.

! Large Purge

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 proce-dure by pushing the purge switch button again, but now frequent, at very short intervals.



4 Check on weeping


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)

1 2 3

4 5


Long pulse (2 seconds) + multiple short pulses




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.


5.5 Check on weeping


! Cleaning with solution

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).

NOTE: When purging with cleaning solution, always work in three steps. To clean all 8 print heads with solution, first purge the 4 right heads (Lc, Lm, W1, W2), close them, and in a second stage, flush the remaining 4 left heads (K, C, M, Y). Finally, open the 4 right heads again, and purge all 8 heads together now. This way, you attain the most optimal cleaning pressure.

1 2 3

4 5




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).



9 Check on weeping


3.2.2. Replacing a Print Head

Refer to �Replacement of a Print Head� on page 3-61 (chapter Repair and Service).

3.2.3. Adjustment of the Print Head

Refer to �Print Head Adjustments� on page 3-91 and �Head Base Alignment� on page 3-99 (chapter Repair and Service).




3.3. UV Lamp Box / UV Lamp Box Housing

3.3.1. Cleaning the Crystal Glass Plate


B. MANPOWER

C. SPECIAL TOOLS

None


E. PROCEDURE

1 Look into the UV lamp box housing. The lamp shutter (1) is closed.

2 To open the lamp shutter, do one of the following:

! 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.

Operation Reference

Remove the UV Lamp Box. Chapter 3 §4.7.2.



Description Code

Crystal Plate (190)(8C) D2+2509166

Isopropyl alcohol

1

2 3 4



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.

5 6



6 Remove at the bottom side the metallic blinking frame (4) that holds the glass plate, by unscrewing the four screws (5).

7 Replace the dirty glass plate by a new one.

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).

3.3.2. Checking the Printing and Curing Quality


5

4



3.3.3. Replacing the UV Lamps


B. MANPOWER

C. SPECIAL TOOLS

None.


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.

4 Take the new UV lamp out of the foil.

NOTE: Always change both UV lamps to avoid bi-banding.

Operation Reference



Open the front and left purge door to get full access to the left UV lamp box.

Remove the UV lamp box. Chapter 3 §4.7.2.

Move the head carriage to the home position. Chapter 3 §3.1.


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.


Operator 1

Description Code

Lamp 190mm D2+2509221

1

3

1 12

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.



5 Mount the new UV lamp into the lamp housing.

6 Reconnect the 2 wires to the connector blocs.

7 Remount the UV lamp box.


3.3.4. Inspecting the Lamp Shutter Functionality


B. MANPOWER

C. SPECIAL TOOLS

None


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.

NOTE: Make sure that the nipple of the UV lamp is positioned towards the reflection shield (metallic plate) of the lamp housing.

Operation Reference






3 Locate the 2 lamp shutter solenoid valves.

4 Check the lamp shutter functionality by pressing the blue points, of the lamp shutter solenoid valves, using a pointed object.

5 Listen if the lamp shutter toggles.

21

1 Lamp shutter solenoid valve(Right UV lamp box housing)

2 Lamp shutter solenoid valve (Left UV lamp box housing)

43

3 Lamp shutter open 4 Lamp shutter closed



3.3.5. Replacing the Lamp Shutter




3.4. Head Carriage

3.4.1. Inspecting and Adjusting the Position of the Head Carriage Unit.


None

B. MANPOWER

C. SPECIAL TOOLS


None

E. PROCEDURE

! To inspect the head base height, proceed as follows:

Refer to �Head Base Height Control� on page 1-57 (chapter Functional Description).

! To inspect the head gap, proceed as follows:

Refer to �Head Gap Control� on page 1-84 (chapter Functional Description).

! To replace a broken detection bracket


3.4.2. Checking the Head Voltage

Refer to �Adjusting the Head Voltage� on page 3-92 (chapter Repair and Service).

3.4.3. Inspecting the Head Base Plate Parallelism.

Refer to �Aligning the Head Base Plate� on page 3-99 (chapter Repair and Service).


Operator 1

Description Code

measuring device

PREVENTIVE MAINTENANCE REFILL UNIT MAINTENANCE


4. Refill Unit Maintenance



! UV radiation






REFILL UNIT MAINTENANCE PREVENTIVE MAINTENANCE


4.2. Air filter 6 Color and White

4.2.1. Inspecting and Replacing the Air Filter


None

B. MANPOWER

C. SPECIAL TOOLS

None


E. PROCEDURE

1 Inspect the air filter (1) for any moisture.

2 If saturated, remove and replace the air filter.



Description Code

Air filter (6C) D2+2509046

Air filter (W) D2+2509046

1



4.3. Ink Filter

4.3.1. 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 can occur (and as well leaking heads as missing nozzles) because the sub ink tank is filled with air. Bleeding occurs manually.

Bleeding the ink filter is necessary in two circumstances:

! 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.


None

B. MANPOWER

C. SPECIAL TOOLS

None


CAUTION: The ink filter should not be exposed to fluorescent light and sunlight.



Description Code

Absorbent lint free cleaning tissues



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).



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).

8 Screw the cap on top of the ink filter and clean the ink filter with a cleaning tissue.

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.



9 Repeat steps 4 to 8 for all other colors.

10 Mount the refill system panel using the four screws.

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).


None

B. MANPOWER

C. SPECIAL TOOLS

None


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)!

NOTE: Connector J17 on the Refill PCB is still disconnected.



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.

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.

1

2

1 Locknut 2 Tube

µ

1

1 Drain cock

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.



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

1 Locknut 2 Tube



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.

4.3.3. Replacing an Ink Filter

Refer to �Replacement of the Ink Filter� on page 3-35 (chapter Repair and Service).

PURGE UNIT MAINTENANCE PREVENTIVE MAINTENANCE


5. Purge Unit Maintenance



! UV radiation

5.2. Purge box

5.2.1. Inspecting and Cleaning the Purge Grid


B. MANPOWER

C. SPECIAL TOOLS


None






Operation Reference

Move the head carriage to the home position Chapter 3 §3.1.


Operator 1

Description Code

filling-knife or a wide screwdriver

PREVENTIVE MAINTENANCE PURGE UNIT 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.

5.2.2. Cleaning the Ink Receiving Bin


B. MANPOWER

C. SPECIAL TOOLS


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.

Operation Reference

Move the head carriage to the home position Chapter 3 §3.1.


Operator 1

Description Code


HOME UNIT MAINTENANCE PREVENTIVE MAINTENANCE


6. Home Unit Maintenance



! UV radiation

6.2. Home box

6.2.1. Inspecting and Cleaning the Home Grid


B. MANPOWER

C. SPECIAL TOOLS


None






Operation Reference

Move the head carriage to the purge position Chapter 3 §3.1.


Operator 1

Description Code


PREVENTIVE MAINTENANCE HOME UNIT 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.

6.2.2. Cleaning the Ink Receiving Bin


B. MANPOWER

C. SPECIAL TOOLS


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).

Operation Reference

Move the head carriage to the purge position Chapter 3 §3.1.

Take out the grid Chapter 4 §6.2.1.


Operator 1

Description Code


1

1

2

SAFETY CIRCUIT PREVENTIVE MAINTENANCE


7. Safety Circuit


None

7.2. Emergency Stop Circuit

7.2.1. Inspecting the Emergency Stops


None

B. MANPOWER

C. SPECIAL TOOLS

None


None

E. PROCEDURE

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.


1 20� 20�

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.

PREVENTIVE MAINTENANCE SAFETY CIRCUIT


4 Push the Start button (white button) to restart the engine.

NOTE: For more information about the emergency stop circuit, refer to �Emergency Stop Circuit� on page 1-14 (chapter Functional Description)

AIR TANK MAINTENANCE PREVENTIVE MAINTENANCE


8. Air Tank Maintenance


None

8.2. Air Tank

8.2.1. Draining the Air Tank


B. MANPOWER

C. SPECIAL TOOLS

None


None

E. PROCEDURE

1 Open the drain cock (2) to eliminate the water of the air tank (1).

Operation Reference



21

PREVENTIVE MAINTENANCE AIR PRESSURE PANEL MAINTENANCE


9. Air Pressure Panel Maintenance


9.2. Air Pressure Panel

9.2.1. Draining the Air Filter


B. MANPOWER

C. SPECIAL TOOLS


None

E. PROCEDURE

1 Remove the air pressure panel (1).





Operation Reference




Description Code

1

AIR PRESSURE PANEL MAINTENANCE PREVENTIVE MAINTENANCE


2 Remove the 2 cable trunk covers (2).

3 Locate the two air filters (AF20-01BG) (3), the water drain out connector (4) and the drain pipe (5).

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.

2

2

3 3

5

4



4.3 Close the black nut (6) when the water is removed.

9.2.2. Replacing the Air Filter


B. MANPOWER

C. SPECIAL TOOLS


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).

7 668

NOTE: Follow the same procedure to drain the water from the main regulator (AW20-02BCG) (8)

Operation Reference


Remove air pressure panel and cable trunk covers Chapter 4 §9.2.1.



Description Code

Description Code

Air filter (AF20-01BG) D2+2509015

AIR PRESSURE PANEL MAINTENANCE PREVENTIVE MAINTENANCE


3 Switch off the engine.

4 Turn off the compressed air supply.

5 Locate the air filter (AF20-01BG) (6).

6 Replace the air filter.

6.1 Unscrew the 2 cross-slotted screws.

6.2 Disconnect the air hoses.

1 2 3

4 5


6 6



6.3 Mount a new air filter, tighten the 2 cross-slotted screws and reconnect the air hoses.

7 Restore the compressed air supply.


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.

ENGINE PREVENTIVE MAINTENANCE


10. Engine


None

10.2. Engine Level

10.2.1. Checking the Engine Level

Balance influences the output quality, so it is essential that the Anapurna L/XL is levelled properly to ensure optimum printing conditions.

Regularly check the three built-in spirit levels.

10.2.2. Levelling the Print Engine

The print engine is provided with three built-in spirit levels at the front side, which can be used to level the print engine. The levels are positioned at print table height; one level is positioned at the middle of the connections bar, the 2 other levels are mounted on the left and right side panels.

Figure 4.1: Levelling

Levelling must be done in two directions:

! 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.


None

1 1

1 Spirit level (middle) 2 Spirit level (front right side panel)

PREVENTIVE MAINTENANCE ENGINE


B. MANPOWER

C. SPECIAL TOOLS


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.

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.

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.



Description Code

Nut wrench no.36

REAR

FRONT

1

1

2

2

REAR

FRONT

1

1 2

2

REAR

FRONT

3A

3A 3B

3B

ENGINE PREVENTIVE MAINTENANCE


8 Lower the outer support feet until they touch the ground.

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.

10.2.3. Levelling the Ink Supply Door


B. MANPOWER

C. SPECIAL TOOLS


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.

REAR

FRONT

NOTE: Check whether the air bubble of the three built-in levels is still in the middle. If not redo the levelling.

Operation Reference

Level the print engine Chapter 4 §10.2.2.



Description Code

Nut wrench no.24

PREVENTIVE MAINTENANCE ENGINE


2 When the correct height is reached, secure the support wheel.

CHAPTER


5 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 - 21.1. Troubleshooting Based on Tower Lamp Indications .................................................................... 5 - 21.2. Troubleshooting Based on Mechanical and/or Electrical Problems ..................................... 5 - 2

2. Troubleshooting Based on UI Error Messages .......................................................................................... 5 - 133. Troubleshooting based on Image Quality Control .................................................................................. 5 - 14

3.1. Encoder (MARK) Error ........................................................................................................................... 5 - 143.2. Black Strips .............................................................................................................................................. 5 - 153.3. Waves on the Media Surface ............................................................................................................ 5 - 153.4. Only UNI MODE Output ...................................................................................................................... 5 - 163.5. Image Quality Failure .......................................................................................................................... 5 - 163.6. Spray on your Image ............................................................................................................................ 5 - 183.7. Print Length Exceeds Maximum Platen Length ......................................................................... 5 - 18

4. UV Lamp Troubleshooting ................................................................................................................................ 5 - 205. Servo Motor Driver Troubleshooting ............................................................................................................ 5 - 21

TROUBLESHOOTING TROUBLESHOOTING BASED ON VISIBLE PROBLEMS


1. Troubleshooting Based on Visible Problems

1.1. Troubleshooting Based on Tower Lamp Indications

The tower lamp indicates if there are troubles. This is indicated by beeping and flashing of one or more lamps of the tower lamp. Along the color of the flashing lamp(s), the problem is defined.

1.2. Troubleshooting Based on Mechanical and/or Electrical Problems

Trouble Cause Action See

RED lamp is flashing and beeping.

(Red lamp lights up in nor-mal state)

Air pressure is under 0.3 MPa � Check the industrial compresso-compressor.

� Check the status of the tube connection.

1 §4.1.2.

YELLOW lamp is flashing and beeping.

(Yellow lamp lights up in normal state)

Low ink level at main ink tank � Refill ink into main ink tank.

� Check air at ink filter.

� Installation manual

� 4 §4.3.1.

GREEN lamp is flashing and beeping

(Green lamp lights up in when UV lamp is turned on).

� Lamp power off � Check the UV power switch if it is turned on or off.

� Check UV power cable connec-tion status.

� Check stability of electric supply.

� 1 §10.1.3.

� 1 §10.1.5.1 §10.1.6.1 §10.1.7.

� Overheat � Change the secondary of the UV coil to 60 (Note: only possible for 50Hz countries).

� 5 §1.2.1.

BLUE lamp is flashing and beeping

(Blue lamp lights up when the register pins are down)

Full waste ink tank (> 3.5 litre) Empty waste ink tank. 4 §2.10.1.

All lamps are flashing and beeping

Overflow (of ink) in sub air tank. Ink run from sub ink tank to sub air tank

� Lower the pressure to �0�� Empty sub air tank

5 §1.2.2.


Rear TAKE-UP motor does not stop

No media detected Media position check. The media should be between media detec-tion sensor and reflection plate.

� 1 §6.1.4.2.� 1 §6.1.4.4.� 1 §14.11.

Rear TAKE-UP motor does not move

Obstacle (e.g. vacuum pumps) in the beam of the media detection signal sensor.

Remove obstacle. � 1 §6.1.4.2.� 1 §6.1.4.4.

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

1 §6.1.4.2.

TROUBLESHOOTING BASED ON VISIBLE PROBLEMS TROUBLESHOOTING


Media distorting Wrong positioning of media � Check whether the print medium 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.

1 §6.1.4.4.

Tension roll bar (rear/front) lifted out of its posi-tion.

Wrong positioning of the tension roll bar

Check whether the 2 tension roll bars of the roll to roll system are mounted correctly

1 §6.1.4.1.

Media fixing roll bar (rear/front) lifted out of its posi-tion.

Wrong positioning of the media fixing roll bar

Check whether the 2 media fixing roll bars above the print table are mounted correctly

1 §6.1.2.1.

Ink not cured Check UV lamp life span Replace lamp 4 §3.3.3.

Immediate stop during printing

Communication error, output data error

� Check communication cables and data

� Check RTL file

Strange noise and no movement of print media

Feed speed � Adjust feed speed value� Check parameters at servo driver

� 1 §12.3.4.� 1 §6.1.6.1.

Noise while head carriage unit is moving

Obstacles Remove obstacle and supply grease to S3M belt

4 §2.7.1.

Head carriage unit does not move

Obstacles exist while head car-riage unit is moving

� 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

�

�

�

� 5 §5.

Ink drips on the print media

Contaminated print head or for-eign materials ink remainders

� Clean head nozzle and check minus pressure

� Remove air at ink filter

� 4 §3.2.1.� 1 §4.1.3.1.� 4 §4.3.1.

Motor noise(Feed and carriage)

Check servo motor driver Adjust servo motor driver accord-ing to gain value.

1 §6.1.6.1.

Lots of ink drops on print media

Negative pressure error Check negative gauge, adjust to normal value

� 1 §9.1.1.� 1 §4.1.3.1.

Not ejecting ink instantly Electrical noise by static current, it influences head ejecting

� Static current hinders electrical signals of head

� Check ground� By purging 2~3, supply ink and

clean head

�

�� 4 §3.2.1.

Can not supply ink to sub ink tank

Refill device does not work prop-erly

Check ink at main ink tank and then call service

Unexpected line appeared on image

Head nozzle is clogged Check nozzle conditions by doing jet test

� 1 §12.4.1.� 4 §3.2.1.

Dark lines in the print, as a result of overlapping passes

Wrong Step Size value Adjust Step Size value 1 §12.3.2.

White lines in the print, as a result of a gap between the passes.

Wrong Step Size value Adjust Step Size value 1 §12.3.2.




Head heater temperature is increasing or decreasing

� Problem with PT sensor head base plate

� Problem with head temperature sensor (safety thermostat 45°C)

� Problems with the heating ele-ments of each print head (heater bar - red cables)

� Problem with the safety thermo-stat (80°C) mounted on the head base plate

� Check connection PT sensor head base plate with Head Lift PCB (J17). Replace if necessary.

� Check connection head temper-ature 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.

� 1 §9.1.2.2. and 3 §4.6.4.

� 1 §9.1.2.2. and 3 §4.6.3.

� 1 §9.1.2.2. and 3 §4.6.3.

�

Overflow � Air in the ink filter

� Malfunction of the sub ink tank level sensors

� Malfunction of the waste ink tank level sensor

� Connection error/minus pressure error

� Ink in sub air tank

� Ink filter should be filled with sufficient ink without air

� Replace level sensor

� Replace level sensor

� Check compressor and tube con-nection status. Adjust the air pressure to the appropriate value.

� Check sub air tank if air exists or not. It should be always empty and clean.

� 4 §4.3.1.

� 1 §7.1.3.5. and 3 §4.4.1. and 3 §4.4.3.

� 4 §2.10.1.

� 1 §4.1.2.

� 1 §4.1.3.1.

Loss of voltage Check the permanent voltage 5 §1.2.4.

Overheating base plate Head base plate temperature > 38°C during printing

� Stop printing at the end of the current print job.

� Switch off the UV-lamps.� Run the Encoder Test for 5 min-

utes

�

� 1 §10.1.3.� 1 §9.1.2.

Overheating UV assembly Change the secondary of the UV coil to 60 Hz (Note: only possible for 50Hz countries)

5 §1.2.1.

UV lamp burnout The metal connector inside the ceramic block is completely burned up

Replace lamp house 5 §1.2.3.

The S3M belt wears out, it looses its teeth, parts as well as complete teeth.

Replace the S3M belt 4 §2.7.2.

Noisy movement of the head carriage unit

Discontinuity of the teeth of the S3M belt results in noisy move-ments of the head carriage unit

Replace the S3M belt 4 §2.7.2.

Vacuum not strong enough on printing table

Vacuum holes printing tabla are clogged up

Puncture all holes of the vacuum table using a syringe needle.

4 §2.3.1.




1.2.1. Overheat UV Assembly

The green tower lamp is flashing and beeping due to an overheat of the UV assembly.

! To solve the overheat, proceed as follows:

1 Get access to the UV lamp power box, which is located behind the main box left side door.

2 Change the secondary of the UV coil to 60 Hz for both the left and right UV lamp power.

If you have the UV lamp power box in front of you, the secondary is on the right hand side.

1.2.2. Overflow (of Ink) in Sub Air Tank

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.

! To solve an overflow in the sub air tank, proceed as follows:

1 Move the head carriage to the purge position (front right side).

2 Set the vacuum pressure to zero by turning the pressure control adjustment knob (1).

NOTE: This solution is only possible for 50 Hz countries.

1 2

250V

220V

208V

60Hz

50Hz

250V

220V

208V

60Hz

50Hz

5060

CHOKE(R)-LOW

CHOKE(R)-HIGH


1



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.

1.2.3. UV Lamp Burnout

! To solve an UV lamp burnout

1 Check the state of the components at the underside of the UV lamp box.

2 If only the bolt (4) of the ceramic block is burned through, replace the bolt of the ceramic connector.

3 If the ceramic connector bloc (1), the brackets (3), the UV lamp (2), ... are damaged due to the burn out, replace the complete UV lamp box.


µ

2

1

3

1 12

4

1 Ceramic connector block 3 Bracket2 UV lamp 4 Bolt ceramic connector



1.2.4. Checking the Permanent Voltage

! To check the permanent voltage, proceed as follows:

1 Make sure that all automatic fuses are in the off position.

2 Turn on the external main switch (at the switch box).

3 Check whether the input voltage is stable on the main power inlet terminal.

! 380V +/- 10% (50Hz)

! 208-240V (60Hz)

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.

1 2

250V

220V

208V

60Hz

50Hz

250V

220V

208V

60Hz

50Hz




5 Check the four emergency buttons.

The system is provided with 4 emergency stops, two at the front side and two at the back side.

6 Check the first circuit breaker.

7 Push the PC button (green button) to operate the PC.

WARNING: When the emergency button is activated all systems are cut off from the mains, except for the PC.

1

1 First circuit breaker (MCCB)



8 Activate the automatic fuses of the following systems one by one:

! Lamp power

! Ring blower 1

! Ring blower 2

! Motor drive

! Control rack

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.

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).



1.2.5. Wrong Ink in the Main Ink Tank

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, Solution.

! When you fill an ink tank with the wrong ink proceed as follows:

! If noted during ink filling:

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)

1



! If noted during printing

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).

1



1.2.6. Wrong Refill System LED Indications

If both the empty and feeding leds are burning on the Refill Control PCB, proceed as follows:

1 Visually check the ink level of the appropriate ink color(s).

2 Press the priming switch (manual feed) of the appropriate color(s).

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).

TROUBLESHOOTING BASED ON UI ERROR MESSAGES TROUBLESHOOTING


2. Troubleshooting Based on UI Error Messages

The purpose of this troubleshooting is to give an overview of all UI error messages, which are integrated in the system, and to deliver a cause and/or solution so you are able to solve the problem(s).

The table below lists all UI error messages of an V1.2 engine.

Error Message Cause/Solution

*** ERROR *** Factory Data File (Factory.Set) Open Failed ..*** Factory.Set File is missing or corrupted.

*** ERROR *** Setup Data File Open Failed ..*** Setup Data file is missing or corrupted.

*** ERROR *** Missing Resolution Header *** File header in RTL file missing. (ex: VERTICAL RESOLUTION=363)

*** ERROR *** Missing Color Number Header *** File header in RTL file missing. (ex: INKS=6).

*** ERROR *** Invalid Resolution Header *** File header in RTL file missing.

*** ERROR *** Carriage Not At Home Position.... *** Try to run TEST routine when carriage is not at home position.

*** ERROR ** Print Length Exceeds Max. Platen Length.*** Try to run/move carriage exceeding Max. Platen Length.

*** ERROR *** Command Download('O') Failed. *** Internal error message for Printing Download command.

*** ERROR *** Command Download('K') Failed. ***

*** ERROR *** Carriage Lift Error.. *** Time-out error during Carriage Lift Command.

*** ERROR *** Carriage Vacuume Error. ***Hardware Reset Required...

Carriage Vacuum loss sensor triggered.

*** ERROR *** Waste Can Overflow Error. ***Hardware Reset Required...

Waste Can Overflow sensor triggered.

*** ERROR *** Door Open Alarm Error. *** Close Door to Continue...

Try to print, move, feed or test when cover door is open.

*** ERROR *** Serial Com. Timeout Error. (No 'SI' Received..) ***Hardware Reset Required... Software Reboot Required...

When PC loses communication to Main board.

*** ERROR *** Inputs Not Ready for Print. *** Try to print, move, feed or test when media set sensors are triggered.

*** ERROR *** Value Should be between -300 to 300... *** Try to jog feed media.

*** ERROR *** Carriage Speed Should be between 100 .. 2700. Try to save values in Setup Menu.

*** ERROR *** Feed Speed Should be between 100 .. 2000.

** WARNING ** Gap Exceeds Max. Value (50 mm). Set to 50. ** During Set Gap routine.

** WARNING ** Check Distance Below Min. Distance (600 mm). Set to 600. **

*** ERROR *** Lower Limit SW Error....(DOWN). ***

*** ERROR *** Lower Limit Error.... (UP). ***

*** ERROR *** Carriage Down Error.. *** Time-out error during carriage moving down.

*** ERROR *** Lower Limit SW-ON Error.... ***

TROUBLESHOOTING TROUBLESHOOTING BASED ON IMAGE QUALITY CONTROL


3. Troubleshooting based on Image Quality Control

The purpose of this troubleshooting is to show and recognize the image defects (due to machine failures) one can encounter when printing.

This section discuss the following errors:

! 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. Encoder (MARK) Error

3.1.1. Description

This is when there are no images, even though the head is moving.

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 Preven-tive Maintenance).

NOTE: For detailed information, refer to the Image Artefacts Book where you can find for each artefact a sample, a description, a cause and a solution to be solved by either the operator or the service technician.

TROUBLESHOOTING BASED ON IMAGE QUALITY CONTROL TROUBLESHOOTING


3.2. Black Strips

3.2.1. Description

Black stripes appears on the image.

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 J7- Connection 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

3.3. Waves on the Media Surface

3.3.1. Description

When using weak print media, it is possible that due to the heat generated by the UV lamp waves appears on the media surface during the print process.



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).

3.4. Only UNI MODE Output

3.4.1. Action

1 Check encoder.

Refer to �Encoder Checking� on page 4-25 (chapter Preventive Maintenance).

2 Check the resolution at RIP program.

When �RTL FILE generated, check �RTL resolution� and �S/W printing pass�.

3.5. Image Quality Failure

3.5.1. Description

Reduced printing quality in general.

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)



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).

6 Check whether the ink is cured. If not:

! 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).



3.6. Spray on your Image

3.6.1. Description

Spray on your image when jetting ink, caused by a too high head base temperature e.g. > 38°C.

3.6.2. Action

When the head base plate temperature is too high (> 38°C) 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. Print Length Exceeds Maximum Platen Length

3.7.1. Description

When you are trying to print a file at the maximum specified width you might encounter the error message "Print Length Exceeds Max. Platen Length" when you start the print job.

This means that the Anapurna calculates the amount of Left Margin Offset + ripped image width + Mark Center Offset value (additional travel of head carriage unit) and decides that it cannot execute the print command since this length exceeds the maximum travel distance of the head carriage unit.

3.7.2. Action

3 3

3

2

1



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).

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.

UV lampOperation Process

Main Power ON

�Lamp WarmTime Check

Printing

Repair Or Change

Repair Or Change

Program Download

Push Start Button

�Servo / ControlCircuit Breaker

CheckMCCB #5

�Increase bulk or

connectseparately

�Reset Button Pushand Relay CableCheck or replace

MC1

�Ground Or Cable

Check

�Lamp Power

Circuit BreakerCheck

MCCB #2

�UV Lamp PowerUnit Switch ON

Main Software

Invoking

Replace Fuse

�Power unit to

Housing CableConnector

Printing Prepare

�Main

Circuit Breaker (50A)ON?

��

Lamp ON?

�Lamp House

Cable ConnectionOK?

Lamp OK?

�Main to

Lamp Power Control Cable Check

OK?

�Main PLC

Connection CheckOK?

�Main PLC

Program CheckOK?

�Lamp PLC

Program CheckOK?

�MC1�

Circuit Breaker (50A) ON?

�Lamp Power

Circuit BreakerON?

�UV Lamp

Power Unit Power LEDON?

PrintingReady?

��Leakage Test

�A

�B

�END

�B

�Reset Button Pushand Relay CableCheck or replace

MC1

�Check Power

Cable Connection

�Power unit to

Housing CableConnector Check

�Power bulk�Check OK?

Fuse Broken?

�Cable�

ConnectorOK?

Check Power bulk

Check

�A

��

yes

yes

yes

yes

yes

yes

yes

yes

yes

yes

no no

no

no

no

no

no

no

no

no

nono

no

no

yes

yes

yes

yes

SERVO MOTOR DRIVER TROUBLESHOOTING TROUBLESHOOTING


5. Servo Motor Driver Troubleshooting

The table below gives an overview of the servo motor driver error alarms.

No. Start-up sequence Fault Investigation Possible cause

1 Power on � LED is not lit.� LED flickers.

Not improved is connectors CN1A, CN1B, CN2 and CN3 are disconnected.

1. Power supply voltage fault.2. Servo amplifier is faulty.

Improved when connectors CN1A and CN1B are discon-nected.

Power supply of CNP1 cabling is shorted.

Improved when connector CN2 is disconnected.

1. Power supply of encoder cabling is shorted.2. Encoder is faulty.

Improved when connector CN3 is disconnected.

Power supply of CN3 cabling is shorted.

Alarm occurs.

2 Switch on servo-on sig-nal

Alarm occurs.

Servo motor shaft is not servo-locked (is free).

1. Check the display to see if the servo amplifier is ready to operate.2. Check the external I/O sig-nal indication to see if the servo-on (SON) signal is ON.

1. Servo-on signal is not input.(Wiring mistake)2. 24VDC power is not supplied to COM.

3 Gain adjustment Rotation ripples (speed fluctuations) are large at low speed.

Make gain adjustment in the following procedure:1. Increase the auto tuning response level.2. Repeat acceleration and deceleration several times to complete auto tuning.

Gain adjustment fault.

Large load inertia moment causes the servo motor shaft to oscillate side to side.

If the servo motor may be run with safety, repeat accelera-tion and deceleration several times to complete auto tun-ing.

Gain adjustment fault.

4 Cyclic operation Position shift occurs. Confirm the cumulative com-mand pulses and actual servo motor position.

Pulse counting error, etc. due to noise.

TROUBLESHOOTING SERVO MOTOR DRIVER TROUBLESHOOTING


Display

(Note 2) Alarm code

Name

Alarm deactivation

CN1B-19 pin

CN1A-18 pin

CN1A-19 pin

Power OFF"ON

Press �SET� on current

alarm screen

alarm reset (RES) signal

Ala

rm

AL. 10 0 1 0 Undervoltage O O O

AL. 12 0 0 0 Memory error 1 O

AL. 13 0 0 0 Clock error O


AL. 16 1 1 0 Encoder error 1 O

AL. 17 0 0 0 Board error O


AL. 1A 1 1 0 Motor combination error O

AL. 20 1 1 0 Encoder error 2 O

AL. 24 1 0 0 Main circuit error O

AL. 25 1 1 0 Absolute position erase O

AL. 30 0 0 1 Regenerative error O (NOTE 1) O (NOTE 1) O (NOTE 1)

AL. 31 1 0 1 Overspeed O O O

AL. 32 1 0 0 Overcurrent O O O

AL. 33 0 0 1 Overvoltage O

AL. 35 1 01 1 Command pulse frequency error O O O

AL. 37 0 0 0 Parameter error O

AL. 39 0 0 0 Program error O

AL. 45 0 1 1 Main circuit device overheat O O O

AL. 46 0 1 1 Servo motor overheat O O O

AL. 50 0 1 1 Overload 1 O (NOTE 1) O (NOTE 1) O (NOTE 1)

AL. 51 0 1 1 Overload 2 O (NOTE 1) O (NOTE 1) O (NOTE 1)

AL. 52 1 0 1 Error excessive O O O

AL. 63 1 0 1 Home position return incomplete O O O

AL. 64 1 0 1 Home position setting error O O O

AL. 8A 0 0 0 Serial communication time-out error O O O

AL. 8E 0 0 0 Serial communication error O O O

88888 0 0 0 Watchdog O

War

ning

AL. 92 Open battery cable warning

Removing the cause of occurrence deac-tivates the alarm automatically.

AL. 97 Program operation disable

AL. 98 Software limit warning

AL. 9F Battery warning

AL. E0 Excessive regenerative warning

AL. E1 Overload warning

AL. E3 Absolute position counter warning

AL. E6 Servo emergency stop warning

AL. E9 Main circuit off warning

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)



Display Name Definition Cause Action

AL. 10 Undervoltage Power supply voltage dropped.MR-J2S-"CL:

160VAC or lessMR-J2S-"CL1:

83 VAC or less

1. Power supply voltage is low. Review the power supply.

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.Checking method

Alarm (AL. 10) occurs if power is switched on after disconnection of all cables but the con-trol circuit power supply cables.

Change the servo amplifier.

AL. 12 Memory error 1 RAM, memory fault Faulty parts in the servo amplifierChecking 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.


AL. 13 Clock error Printed board fault

AL. 15 Memory error 2 EEP-ROM fault 1. Faulty parts in the servo amplifierChecking method

Alarm (AL. 15) occurs if power is switched on after disconnection of all cables but the con-trol circuit power supply cables.


2. The number of write times to EEP-ROM exceeded 100.000.

AL. 16 Encoder error 1 Communication error occurred between encoder and servo amplifier.

1. Encode connector (CN2) disconnected. Connect correctly.

2. Encoder fault Change the servo motor.

3. Encoder cable faulty (wire breakage or short)

Repair or change the cable.

AL. 17 Board error CPU/parts fault Faulty parts in the servo amplifierChecking 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.


AL. 19 Memory error 3 ROM memory fault

AL. 1A Motor combination error

Wrong combination of servo amplifier and servo motor.

Wrong combination of servo amplifier and servo motor connected.

Use correct combination.

AL. 20 Encoder error 2 Communication error occurred between encoder and servo amplifier.

1. Encoder connector (CN2) disconnected. Connect correctly.

2. Encoder fault change the servo motor.

3. Encoder cable faulty (wire breakage or shortage)

Repair or change the cable.

AL. 24 Main circuit error 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).

Connect correctly.

2. Sheathes of servo motor power cables dete-riorated, resulting in ground fault.

Change the cable.

3. Main circuit of servo amplifier failedChecking method

AL. 24 occurs if the servo is switched on after disconnecting the U, V, W power cables from the servo amplifier.




AL. 25 Absolute position erase Absolute position data in error.

1. Reduced voltage of super capacitor in encoder.

After leaving the alarm occurring for a few minutes, switch power off, then on again. Always make home position setting again.

2. Battery voltage low. Change battery.Always make home position setting again.

3. Battery cable or battery is faulty.

Power was switched on for the first time in the absolute position detection system.

4. Super capacitor of the absolute position encoder is not charged.

After leaving the alarm occurring for a few minutes, switch power off, then on again. Always make home position setting again.

AL. 30 Regenerative alarm Permissible regenera-tive power of built-in regenerative brake resistor or regenera-tive brake option is exceeded.

1. Wrong setting of parameter No. 0 Set correctly.

2. Built-in regenerative brake resistor or regenerative brake option is not connected.

Connect correctly.

3. High-duty operation or continuous regener-ative operation caused the permissible regen-erative power of the regenerative brake option to be exceeded.

Checking methodCall the status display and check the regener-ative load ratio.

1. Reduce the frequency of position-ing.2. Use the regenerative brake option of larger capacity3. Reduce the load.

4. Power supply voltage is abnormal.MR-J2S-"CL: 260VAC or more.MR-J2S-"CL1: 135VAC or more.

Review power supply

5. Built-in regenerative brake resistor or regenerative brake option faulty.

Change servo amplifier or regenera-tive brake option.

Regenerative transis-tor fault

6. Regenerative transistor faulty.Checking method

1) The regenerative brake option has over-heated abnormally.2) The alarm occurs even after removal of the built-in regenerative brake resistor or regen-erative brake option.


AL. 31 Overspeed Speed has exceeded the instantaneous per-missible speed.

1. Input command pulse frequency exceeded the permissible instantaneous speed fre-quency.

Set command pulses correctly.

2. Small acceleration/deceleration time con-stant caused overshoot to be large.

Increase acceleration/deceleration time constant.

3. Servo system is instable to cause over-shoot.

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.

4. Electronic gear ratio is large (parameters No. 4, 5).

Set correctly.

5. Encoder faulty. Change the servo motor.




AL. 32 Overcurrent Current that flew is higher than the per-missible current of the servo amplifier.

1. Short occurred in servo amplifier output phases U, V and W.

Correct the wiring.

2. Transistor (IPM) of the servo amplifier faulty.

Checking methodAlarm (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.

Correct the wiring.

4. External noise caused the overcurrent detection circuit to misoperate.

Take noise suppression measures.

AL. 33 Overvoltage Converter bus voltage exceeded 400VDC.

1. Lead of built-in regenerative brake resistor or regenerative brake option is open or dis-connected.

1. Change lead.2. Connect correctly.

2. Regenerative transistor faulty. Change servo amplifier.

3. Wire breakage of built-in regenerative brake resistor or regenerative brake option.

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 resistor or regenerative brake option is insuffi-cient.

Add regenerative brake option or increase capacity.

5. Power supply voltage high. Review the power supply.

AL. 35 Command pulse fre-quency error

Input pulse frequency of the command pulse is too high.

1. Pulse frequency of the manual pulse gener-ator is too high.

Change the pulse frequency to a proper value.

2. Noise entered the pulses of the manual pulse generator.

Take action against noise.

3. Manual pulse generator failure. Change the manual pulse generator.

AL. 37 Parameter error Parameter setting is wrong.

1. Servo amplifier fault caused the parameter setting to be rewritten.

Change the servo amplifier

2. Regenerative brake option not used with servo amplifier was selected in parameter No. 0.

Set parameter No. 0 correctly.

3. Value outside setting range has been set in some parameter.

Set the parameter correctly.

4. Value outside setting range has been set in electronic gear.

Set parameters No. 4, 5 correctly.

5. Opposite sign has been set in software limit increasing side (parameters No. 46, 47). Similarly, opposite sign has been set in soft-ware limit decreasing side (parameters No. 48, 49)

Set parameters No. 46 to 49 cor-rectly.

6. Opposite sign has been set in position range output address increasing side (parame-ters No. 50, 51). Similarly, opposite sign has been set in position range output address decreasing side (parameters No. 52, 53)

Set parameters No. 50 to 53 cor-rectly.

7. The number of write times to EEP-ROM exceeded 100,000 due to parameter write, program write, etc.





AL. 39 Program error Program data is abnor-mal

1. Servo amplifier fault caused the program data to be rewritten.


2. Command argument is out of the setting range.

Programming correctly.

3. The number of write times to EEP-ROM exceeded 100,000 due to parameter write, program write, etc.


AL. 45 Main circuit device overheat

Main circuit device overheat

1. Servo amplifier faulty. Change the servo amplifier.

2. The power supply was turned on and off continuously by overloaded status.

The drive method is reviewed.

3. Air cooling fan of servo amplifier stops. 1. Exchange the cooling fan or the servo amplifier.2. Reduce ambient temperature.

AL. 46 Servo motor overheat Servo motor tempera-ture rise actuated the thermal protector.

1. Ambient temperature of servo motor is over 40°C.

Review environment so that ambient temperature is 0 to 40°C.

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.

AL. 50 Overload 1 Load exceeded over-load protection char-acteristic of servo amplifier.

1. Servo amplifier is used in excess of its con-tinuous output current.

1. Reduce load.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 set-tings3. Set auto tuning to OFF and make gain adjustment manually.

3. Machine struck something. 1. Review operation pattern.2. Install limit switch.

4. Wrong connection of servo motor. Servo amplifier�s output terminals U, V, W do not match servo motor�s input terminals U, V, W.

Connect correctly.

5. Encoder faulty.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.

Change the servo motor.




AL. 51 Overload 2 Machine collision or the like caused max. output current to flow successively for sev-eral seconds.Servo motor locked:

1s or moreDuring rotation:

2.5s or more

1. Machine struck something. 1. Review operation pattern.2. Install limit switches.


Connect correctly.

3. Servo system is instable and hunting. 1. Repeat acceleration/deceleration to execute auto tuning.2. Change auto tuning response set-ting.3. Set auto tuning to OFF and make gain adjustment manually.

4. Encoder faulty.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.

Change the servo motor.

AL. 52 Error excessive The droop pulse value of the deviation counter exceeded 2.5 rotations.

1. Acceleration/deceleration time constant is too small.

Increase the acceleration/decelera-tion time constant.

2. Internal torque limit 1 (parameter No. 28) is too small.

Increase the torque limit value.

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 small.

Increase set value and adjust to 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.

6. Machine struck something. 1. Review operation pattern.2. Install limit switches.

7. Encoder faulty. Change the servo motor.


Connect correctly.

AL. 63 Home position return incomplete

In incremental sys-tem:1. Positioning opera-tion was performed without home position return.2. Home position return ended abnor-mally.

1. Positioning operation was performed with-out 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.

In absolute position detection system:1. Positioning opera-tion was performed without home position setting.2. Home position set-ting ended abnor-mally.

1. Positioning operation was performed with-out 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.




AL. 64 Home position setting error

Home position set-ting could not be made.

1. Droop pulses remaining are greater than the in-position range setting.

Remove the cause of droop pulse occurrence.

2. Command pulse entered after clearing of droop pulses.

Do not enter command pulse after clearing of droop pulses.

3. Creep speed high. Reduce creep speed.

AL. 8A Serial communication time-out error

RS-232C or RS-422 communication stopped for longer than the time set in parameter No. 23.

1. Communication cable breakage. Repair or change communication cable.

2. Communication cycle longer than parame-ter No. 23 setting.

Set correct value in parameter.

3. Wrong protocol. Correct protocol.

AL. 8E Serial communication error

Serial communication error occurred between servo ampli-fier and communica-tion device (e.g. personal computer)

1. Communication cable fault (open cable or short circuit)

Repair or change the cable

2. Communication device (e.g. personal com-puter) faulty.

Change the communication device (e.g. personal computer).

88888 Watchdog CPU, parts faulty Fault of parts in servo amplifierChecking method

Alarm (88888) occurs if power is switched on after disconnection of all cables but the con-trol circuit power supply cables.


AL. 92 Open battery cable warning

Absolute position detection system bat-tery voltage is low.

1. Battery cable is open. Repair cable or changed.

2. Battery voltage dropped to 2.8V or less. Change battery.

AL. 97 Program operation dis-able

Program was started in a program opera-tion disable status.

After a program change, the program was started without the servo amplifier being powered off/on.

Power off/on the servo amplifier.

AL. 98 Software limit warning Software limit set in parameter is reached.

1. Software limit was set within actual opera-tion range.

Set parameter No. 48 to 51 correctly.

2. Program of position data in excess of soft-ware limit was executed.

Set program correctly.

3. Software limit was reached during JOG operation or manual pulse generator opera-tion.

Perform operation within software limit range.

AL. 9F Battery warning Voltage of battery for absolute position detection system reduced.

Battery voltage fell to 3.2V or less. Change the battery.

AL. EO Excessive regenerative warning

There is a possibility that regenerative power may exceed permissible regenera-tive power of built-in regenerative brake resistor or regenera-tive brake option.

Regenerative power increased to 85% or more of permissible regenerative power of built-in regenerative brake resistor or regenerative brake option.

Checking methodCall the status display and check regenerative load ratio.

1. Reduce frequency of positioning.2. Change regenerative brake option for the one with larger capacity.3. Reduce load.

AL. E1 Overload warning There is a possibility that overload alarm 1 or 2 may occur.

Load increased to 85% or more of overload alarm 1 or 2 occurrence level.

Cause, checking methodRefer to AL. 50, 51.

Refer to AL. 50, AL. 51.




AL. E3 Absolute position counter warning

Absolute position encoder pulses faulty.

1. Noise entered the encoder. Take noise suppression measures.

2. Encoder faulty Change the servo motor.

AL. E6 Servo forced stop warn-ing

EMG-SG are open. External forced stop was made valid.(EMG-SG opened)

Ensure safety and deactivate forced stop.

AL. E9 Main circuit off warn-ing

Servo was switched on with main circuit power off.

Switch on main circuit power.


CHAPTER


6 Glossary

This chapter describes definitions and abbreviations used throughout the Service Manual which you may not be familiar with.

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 MSDS�s. 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.

CHAPTER


7 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 - 31.1. Pneumatic Diagram ................................................................................................................................. 7 - 5

2. Electrical Diagrams ................................................................................................................................................ 7 - 72.1. Main Power Distribution in the Electrical Circuit Panel ............................................................ 7 - 92.2. Power Supply Distribution - 3 Phase with neutral with ground star 380V (EU) ............ 7 - 112.3. Power Supply Distribution - 3 Phase no neutral with ground delta 208-240V (US) .... 7 - 132.4. UV Lamp Power Box Connections ................................................................................................... 7 - 152.5. UV Lamp Power Circuit ....................................................................................................................... 7 - 172.6. UV Lamp Head Part ............................................................................................................................... 7 - 192.7. UV Lamp Power Cables ....................................................................................................................... 7 - 21

3. Programmable Logic Controller (PLC) Block Diagram .......................................................................... 7 - 233.1. Main PLC ................................................................................................................................................... 7 - 253.2. UV Lamp PLC ........................................................................................................................................... 7 - 27

4. Printed Circuit Boards ........................................................................................................................................ 7 - 294.1. Total PCB Diagram Layout ................................................................................................................. 7 - 314.2. MAIN PCB ................................................................................................................................................. 7 - 334.3. FPGA PCB ................................................................................................................................................. 7 - 354.4. HEAD PCB ................................................................................................................................................. 7 - 374.5. REFILL PCB ............................................................................................................................................... 7 - 394.6. CARTRIDGE PCB ..................................................................................................................................... 7 - 414.7. HEAD LIFT PCB ........................................................................................................................................ 7 - 434.8. ITV CONTROLLER PCB .......................................................................................................................... 7 - 454.9. SUB PCB .................................................................................................................................................... 7 - 474.10. IF PCB ...................................................................................................................................................... 7 - 494.11. I/O PCB .................................................................................................................................................. 7 - 514.12. TAKE UP PCB ........................................................................................................................................ 7 - 534.13. REFILL CONTROL PCB ........................................................................................................................ 7 - 554.14. INDICATOR PCB ................................................................................................................................... 7 - 574.15. DRIVER COMMUNICATION PCB .................................................................................................... 7 - 59

5.

ANNEX ANNEX


PNEUMATIC DIAGRAMS


1. Pneumatic Diagrams

Overview pneumatic diagrams:

! Pneumatic Diagram

PNEUMATIC DIAGRAMS


1.1. Pneumatic Diagram

R

P

A

Air Tank

Waste TankOver-flow Sig.

Setting Press UV lamp0.10 - 0.15 MPa

Air Filter # 1

Air Filter # 2

EBEA

A

P

B

EBEA

A

P

B

� �

INOUT

Media set Cylinders

Media Hold Front/Rear Cylinders

0.3 MPa 0.15 MPa

Setting Press Carriage

Setting Press CarriageSetting Press Carriage

0.03 MPa

VACUUMEJECTOR

Purge S/WSig.

Purge S/W Sig.

EBEA

A

P

B

EBEA

A

P

B

Lamp Shutter Left/Right Cylinders

I/O PC B Sig. I/O PC B Sig.

4f Air Tube

A P

R

SU P OU T

P A R

P

A

P A

R

PCB

E/PRegulator

Float Sensor Sig.

Float SensorSig.

Pressure Sig.Float SensorSig.

PSE531-M5

Checkvalve

Checkvalve

SOLUTIONSUB-TANK

SOLUTIONBAR

MAIN WASTEINKTANK

SUBAIR

TANK

INKTANK

T

Carriage Part

Main Air Press.0.4 - 0.8 MPa

Max. Press. 2MPaCapacity 0.005M3

Setting Press0.6 MPa

0.3 - 0.7 MPaPurge Sig.

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

ELECTRICAL DIAGRAMS


2.1. Main Power Distribution in the Electrical Circuit Panel

PE

P1

N

N

L31L1

T-L3

L42

P1

L21

P1

6-3

T-NL3

N

L11

PEP3

L41

P11

PE

L3

Green

L23

1-4

T-L3

L2

L21

RELAY #2-4

L1

T-N

W1

GND

V2

N

PE

L1

L3

N

P2

P3

L2

L3

T-L3N

T-L3

L42

W2

L23

PE

5-3

P22

L51

T-N

PE

Green

PE

PE

L52

P22

P3U1

T-N L1

L52

L2

L2 T-L3L1

P11

N

Green

PE 24V

G

L41

2-1

T-N

L32

P22

RELAY #3-4

PE

PE

L11

L2

2-2

L1

P23

P2

L1

L51

L32

Green

L22

P2

L2

N

L33

U2

L1

4-3

T-L3

T-N

PE

N

L33

P22

L22

P23

3-2

L3L3

SMPS GND

V1P22

5-2

L31

L3

NN

N

N

NE

ER

G

24V

1L

1-1

GND

3PHASE AC380V , 50/60Hz POWER IN

NE

ER

GC3 )ERAUQS 5.3(21# GWA

24V

N

2-3

2-41-4

NE

ER

G

C3 )ERAUQS 5.3(21# GWA

GREEN - METAL BASE TERMINAL

3L-T

RESTART BUTTON

AWG #10 (5.5 SQ) Black

GND

MOTOR

DRIVE_F

AWG #8 (7.5 sqar) 5C


3.

1

3L

Teflon AWG #14 (2 sqar) Black

3

RING

BLOWER

5

96

: SHORT BAR


1L

2-1

3


24V

Ground- Green/Yellow 8AWG

EMERGENCYSWITCH

3L-T

4

N-T


TERMINAL600V-80A

4

GND

95

AWG #12(3.5 SQUARE) 3C

44

NE

ER

G

NE

ER

G

AWG #8 (7.5 Sq) Black

5

1L

3


1.

NE

ER

G

96

CONTROL

RACK

MOTOR

DRIVE_C

3L

RING

BLOWER

UV LAMP

POWER

51

2.

4.

43

2L

2-2

2L

NE

ER

G

AWG #8 (7.5 Sq) Black


1-2

TERMINAL600V-55A

2 STAGE TERMINAL 300V-30A

95

DC line -Teflon AWG #20(0.5 sqar) Blue Wire USED

NE

ER

G

N-T

4

5.

TERMINAL600V-55A

1-3

1

2 STAGE TERMINAL

AWG #86.

ELECTRICAL DIAGRAMS


2.2. Power Supply Distribution - 3 Phase with neutral with ground star 380V (EU)

3P2P1P

BCP DAEHGNITAEH

ETIHW,)7-5(+42CD6

BCP VTI

KCALB,)4-5(-42CD4

ETIHW,)3-5(+42CD3

10-LVU

CLPS08 K -RETSAM

SPMS5#

DAEHBCP TFIL ESAB

CLPC2 ELBAC FTCV 61#GWA

DIP2# RELLORTNOC

C2 ELBAC FTCV 61#GWA

DER,)7-5(+5CD6

-V42CD

RETAEH



BCP LLIFER

ETIHW,)1-5(+42CD5

WOLLEY,)6-5(+021CD2

SPMS2#

+V42CD


,KCALB LLA ( ELBAC CA 01#GWA ,)NEERG : EP , + : ETIHW( ELBAC CD 61#GWA ,) - : KCALB

DAEH

SPMS6#

KCALB,)51-1(-42CD6

10-RVU

ETIHW,)6-5(+021CD1

BCP F/I

2HC

DER,)6-5(+42CD3

25L

DER,)51-1(+5CD6

ETIHW,)51-1(+42CD6

SPMS4#

DIP1# RELLORTNOC

EP

NEERG,)7-5(-5CD6

ETIHW,)5-5(+42CD3

+V5CD

BCP DAEH

KCALB,)1-5(-42CD5

KCALB,)5-5(-42CD3

10-HVU

S06RD-M7K

BCP DAEHGNIRIF KNI

CIGOL

EP

KCALB,)2-5(-42CD4

1HC

BCP AGPF/NIAM



15L

ETIHW,)4-5(+42CD4

10-FVU / 10-MVU

BCP BUS

NWORB,)6-5(-021CD1

NEERG,)51-1(-5CD6

KCALB,)3-5(-42CD3

NEERG,)6-5(-021CD2

15L

10-SVU


-V5CD

10-AVU

ETIHW,)2-5(+42CD4

SPMS3#

DIP3# RELLORTNOC25L

KCALB,)6-5(-42CD3

10-IVU

SPMS1#


KCALB,)7-5(-42CD6


N

2# EVIRD OVRES

2L

zH06/05 ,V083CA ESAHP-3

DEEFW004 ROTOM OVRES-CA


1# EVIRD OVRES

metsyS cinortcelE margaiD tiucriC

A-CM

1L

11P

CDV42+

V42 CD

EGAIRRACW057 ROTOM OVRES-CA

DNG 2 OME

W/S CP


TRATSER

1 OME 3 OME

8# SPMS

SPMS-CPW003

CP ROTAREPO

N

4 OME


ERAUQS 5.5 = 01GWAERAUQS 5.3 = 21GWAERAUQS 0.2 = 41GWAERAUQS 52.1 = 61GWAERAUQS 0.1 = 81GWA

x x xx xx x- - -- -- -

) oN elbaC ( ----| | | | || | | |

) - / + ( leveL -------| | | | | | |

)V5/V42(EGATLOV ---------| | || |

)CD/CA(ECRUOS REWOP --------------| ||

.oN SPMS -----------------|

22P 32P 22P

N

22P

N

3L

)KCALB( ELBAC FTCV 01#GWA

)A03,V022CA(6# BCCM





2U

)A03 ,V022CA(5# BCCM

GP)A02,V083CA(3# BCCM

2V

1V

25L

)A02,V083CA(4# BCCM

TFEL _WOLB GNIR

15L

1U

DNG emarF rotoM

)A05,V022CA(2# BCCM

THGIR _WOLB GNIR

DNG emarF rotoM

32L

13L

21L

22L

24L

daolrevO lamrehT1# yaleR

1W

14L


12L

11L

23L

33L

1L

2L3L

3L

2L

1L

2W

EP

1L

N

RETLIF ESION)A05(

3L

N

EP

EP

3L-T

N-T

EP

EP

EP

N-T

3L-T

EP

EP

N

N

212121

M

12

21

)A05(1# CM1 2 3

4 5 6

)L(PMAL VU

12

M

12

21

21

)A03(2# CM

1

2

3

4

5

6

M

12

)A03(2# CM

1

2

3

4

5

6

)R(PMAL VU

12

M

12

ELECTRICAL DIAGRAMS


2.3. Power Supply Distribution - 3 Phase no neutral with ground delta 208-240V (US)

3P2P1P

BCP DAEHGNITAEH

ETIHW,)7-5(+42CD6

BCP VTI

KCALB,)4-5(-42CD4

ETIHW,)3-5(+42CD3

10-LVU

CLPS08 K -RETSAM

SPMS5#

DAEHBCP TFIL ESAB

CLP


DIP2# RELLORTNOC


DER,)7-5(+5CD6

-V42CD

RETAEH



BCP LLIFER

ETIHW,)1-5(+42CD5

WOLLEY,)6-5(+021CD2

SPMS2#

+V42CD


,KCALB LLA ( ELBAC CA 01#GWA ,)NEERG : EP , + : ETIHW( ELBAC CD 61#GWA ,) - : KCALB

DAEH

SPMS6#

KCALB,)51-1(-42CD6

10-RVU

ETIHW,)6-5(+021CD1

BCP F/I

2HC

DER,)6-5(+42CD3

25L

DER,)51-1(+5CD6

ETIHW,)51-1(+42CD6

SPMS4#

DIP1# RELLORTNOC

EP

NEERG,)7-5(-5CD6

ETIHW,)5-5(+42CD3

+V5CD

BCP DAEH

KCALB,)1-5(-42CD5

KCALB,)5-5(-42CD3

10-HVU

S06RD-M7K

BCP DAEHGNIRIF KNI

CIGOL

EP

KCALB,)2-5(-42CD4

1HC

BCP AGPF/NIAM



15L

ETIHW,)4-5(+42CD4

10-FVU / 10-MVU

BCP BUS

NWORB,)6-5(-021CD1

NEERG,)51-1(-5CD6

KCALB,)3-5(-42CD3

NEERG,)6-5(-021CD2

15L

10-SVU


-V5CD

10-AVU

ETIHW,)2-5(+42CD4

SPMS3#

DIP3# RELLORTNOC25L

KCALB,)6-5(-42CD3

10-IVU

SPMS1#


KCALB,)7-5(-42CD6


2# EVIRD OVRES

2L

zH06/05 ,V042~802CA ESAHP-3

DEEFW004 ROTOM OVRES-CA


1# EVIRD OVRES

metsyS cinortcelE margaiD tiucriC

A-CM

1L

11P

CDV42+

V42 CD

EGAIRRACW057 ROTOM OVRES-CA

DNG 2 OME

W/S CP


TRATSER

1 OME 3 OME

8# SPMS

SPMS-CPW003

CP ROTAREPO

4 OME


ERAUQS 5.5 = 01GWAERAUQS 5.3 = 21GWAERAUQS 0.2 = 41GWAERAUQS 52.1 = 61GWAERAUQS 0.1 = 81GWA

x x xx xx x- - -- -- -

) oN elbaC ( ----| | | | || | | |

) - / + ( leveL -------| | | | | | |

)V5/V42(EGATLOV ---------| | || |

)CD/CA(ECRUOS REWOP --------------| ||

.oN SPMS -----------------|

22P 32P

11P22P

11P

32P

3L


)A03,V022CA(6# BCCM





2U

)A03 ,V022CA(5# BCCM

GP)A02,V083CA(3# BCCM

2V

1V

25L

)A02,V083CA(4# BCCM

TFEL _WOLB GNIR

15L

1U

DNG emarF rotoM

)A05,V022CA(2# BCCM

THGIR _WOLB GNIR

DNG emarF rotoM

32L

13L

21L

22L

24L


1W

14L


12L

11L

23L

33L

1L

2L

3L

3L

2L

1L

2W

EP

1L

2L

RETLIF ESION)A05(

3L

1L

EP

EP

3L-T

1L-T

EP

EP

EP

1L-T

3L-T

EP

EP

N

212121

M

12

21

)A05(1# CM1 2 3

4 5 6

)L(PMAL VU

12

M

12

21

21

)A03(2# CM

1

2

3

4

5

6

M

12

)A03(2# CM

1

2

3

4

5

6

)R(PMAL VU

12

M

12

ELECTRICAL DIAGRAMS


2.4. UV Lamp Power Box Connections

411

41

41

4147 7

5

1

1

1

47 7

45

46

46

6

6

20

21

22

23 24

25

30

31

27 26

50

51

52

53

54

55

56

57

60

61 55

71 53 70 61

60 51

50

86

87 84 85 80

81 82

83

80 80 81 81 82 82 83 83

86 87

84 85

30

31

56 57

52 54

70

71

28 28

28

28

28

28

29

29

29

29

29

K1 K1

K1 K2fan K1 K2L2 L3 L4 L5L1

U V L A M PP L C 24V DC

POWER(2A)

P00 P02 P04 P06 P08 P0A COM0 P0D P0F P11 P13 P15

P14P12P10P0EP0BP07P05P03P01 P09 P0C

FG P43 P45 P47 P49 P4B

AC100~240V P40 P41 P42 P44 P46 P48 P4A

P16

P17

24G 24V

COM1

COM0 COM1 COM2 COM3 COM4 COM5 P4D P4F

P4C P4E

1 2 3 4 6 7 85

9 10 11 13 14 1512

F1 AC 250V 3A

Main BoxRightD-SUB 15P

F2 DC 24V 3A

50Hz 60Hz 208V 220V 250V

S/W HI LOW S-2 S-1 60Hz 50Hz

50Hz 60Hz 208V 220V 250V

S/W HI LOW S-2 S-1 60Hz 50Hz

(POWER_4P)

(POWER_4P)

(SIGNAL_7P)

(SIGNAL_7P)

LOW

MC(L)HI

MC(L)LOW

T/R(L) T/R(R)

MC(R)LOW

MC(R)HI

L11

N

PE

L11 L12 PE-+

left ACfan

right AC fan

left shutter(open)

right shutter(open)

LEFT UV LAMP ASSY RIGHT UV LAMP ASSY

L MC1 LOW

L MC2 HI

R MC1 LOW

R MC2 HI

BA D

CBA D

C

AB C

D E F G

JKH

AB C

D E F G

JKH

3PHASE UVLAMP POWER BOX

LK2 RK1 RK2LK1

N

L11

ELECTRICAL DIAGRAMS


2.5. UV Lamp Power Circuit

L1

L2

L1

N

GND

MCCB #2(AC220V,50A)

GND

SMPS #9

+24VDC

PLC

INPUT COM

OUTPUT COM

NTC #2 CHOKE(R)-LOW

T/R(R)

F1 (250VAC-3A)F2(25VDC-3A)

MC(R)-LOW

MC(R)-HIGH

CAP.(R) #1

CAP.(R) #2

CAP.(R) #3

COOLRING (AC FAN)

ACFAN(R)

AC220V,50/60Hz

L12

L11

L12

PE

Ignitor(R)

L12L11PE

KDM-DR40S

L11

L12

L2L1PENL1PE

USEurope

AC 250V

AC 220V

AC 208V

60Hz

50Hz

S-1

HI

S-2

50Hz

LOW

60Hz

S/W

4P CON (R)

4P CON

S/W

L12 AC 250V

L11MC(L)-LOW

HI

CAP.(L) #1

60Hz

AC 220V

CAP.(L) #2

50Hz

NTC #1

T/R(L)

AC 208V S-2

LOW

4P CON

50Hz

60Hz

CHOKE(L)-LOWS-1

CAP.(L) #3

(41) (41)

(41) (41)

(47)

(47)

(45)

(46)

(46) (46)

(47)

(1) (1)

(1)(1)

(7)

(7)

(7)

(5)

(6)

(6) (6)

# UV LAMP HEAD ASS�Y(RIGHT)

MC(L)-HIGH

AWG #12 VCTF CABLE 3C

AC CABLE ( ALL BLACK, PE : GREEN), AWG #12CONTROL CABLE (WHITE : + , BLACK : - ), AWG #14

AWG10 = 5.5 SQUAREAWG12 = 3.5 SQUAREAWG14 = 2.0 SQUAREAWG16 = 1.25 SQUAREAWG18 = 1.0 SQUARE

ACFAN(L)

Ignitor(L)

# UV LAMP HEAD ASS�Y(LEFT)

4P CON (L)

B P L N

RT1

011

t

12

B PL N

41

52

63

UV LAMP(L)

1 2

1 4

2 3

1 4

2 3

RT1

011

t

12

A

BC

D

UV LAMP(R)

1 2

41

52

63

A

BC

D

A

BC

D

1 4

2 3

A

BC

D

1 4

2 3

ELECTRICAL DIAGRAMS


2.6. UV Lamp Head Part

A

B

D

C

2

3

4 5

6

7

1

temperatureS/W (110c)

Temperature S/W (110c)

1 2

A

B

D

C

2

3

4 5

6

7

1

1 2

Temperature S/W (110c)

temperatureS/W (110c)

AC FAN DC FAN

(POWER_4P)

(SIGNAL_7P)

UV Lamp box

UV Lamp box housing

(SOLVALVE SIGNAL_2P)

AC FAN DC FAN

LEFT RIGHT

IGNITER

UV LAMP

1

2

3

4 5

6

7

1 2

IGNITER

UV LAMP

B LP N B LP N

B

A D

C

ELECTRICAL DIAGRAMS


2.7. UV Lamp Power Cables

B

A D

C

AB C

D E F G

JKH

B

A D

C

1

2

3

4 5

6

7

4P CONNECTOR(FEMALE)4P CONNECTOR(MALE)

10P CONNECTOR(MALE)

UV Lamp Assy

UV Lamp Power Box

7P SCN6A16-7S CONNECTOR(FEMALE)

4P<-->4P CONNECTOR PIN ASSIGNMENT(1:1)

10P<-->7P CONNECTOR PIN ASSIGNMENT

10P �� 7P CONNECTOR PIN ASSIGNMENT

A �� 7P CONNECTOR 1B �� 7P CONNECTOR 2C �� 7P CONNECTOR 3D �� 7P CONNECTOR 4E �� 7P CONNECTOR 5F �� 7P CONNECTOR 6G �� 7P CONNECTOR 7H �� 7P CONNECTOR N.CJ � �� 10P CONNECTOR KK � �� 10P CONNECTOR J

left

L1(L)

AC FAN(L)

L2(L)

FG(L)

right

A

B

C

D

size

0.5M(AWG12)

0.5M(AWG12)

1M(AWG12)

1.3M(AWG12)

left right size

1.3M(AWG14)

0.5M(AWG14)

0.5M(AWG14)

1M(AWG14)

1M(AWG14)

1M(AWG14)

SHUTTER OPEN(L)A

B

C

D

E

F

G

H

J

K

DC 24V FAN(L)

DC GND(L)

INTERLOCK(K1)(L)

OVER HEAT(P0C)(L)

INTERLOCK(P44)(L)

N.C(L)

N.C(L)

N.C

N.C

SHUTTER OPEN(R)

DC 24V FAN(R)

DC GND(R)

INTERLOCK(K1)(R)

OVER HEAT(P0D)(R)

INTERLOCK(P44)(R)

N.C

N.C

N.C

N.C

L1(R)

AC FAN(R)

L2(R)

FG(R)

left

L1(L)

AC FAN(L)

L2(L)

FG(L)

right

A

B

C

D

size

0.3M(AWG12)

0.3M(AWG12)

0.3M(AWG12)

0.3M(AWG12)

L1(R)

AC FAN(R)

L2(R)

FG(R)

PROGRAMMABLE LOGIC CONTROLLER (PLC) BLOCK DIAGRAM


3. Programmable Logic Controller (PLC) Block Diagram

Overview PLC block diagrams:

! Main PLC

! UV Lamp PLC



3.1. Main PLC

MEDIA SET S / W

REFILL J13 SUB J4 3951-6P

VT 301 SOL V/V

36

LAMP P LC

TERMINAL

BLOCK (220V) EPDB

TOWER LAMP

SOL V/V

MS1 RF RR MS2 GND

1 2 3 4 – +

1

GND

1 AC220V P40 P41 P42 – P44 P46 – P48 P4A – P4C P4E – P50 P52 – P54 P56

CM1 CM2FG CM0 P43 CM3 P45 P47 CM4 P49 P4B CM5 P4D P4F CM6 P51 P53 CM7 P55 P57

P0 P04P02 P06 P08 P0A P0C P0E P10 CM0 P13 P15 P17 P19 P1B P1D P1F P21 P23 CM1

P05 P07P01

Wastetank

P03 P09 P0B P0D P0F P11 P12 P14 P16 P18 P1A P1C P1E P20 P22 24G 24+

E44 E34

2 3 4 1 2 3 4

1 2 3 4 – +

1 2 3 4

3 –

1 2 + 4

3 –

1

1

2 + 4

3 –

1 2 + 4

3 –

1 2 + 4

– + 1 2 3 4 – +

R/REAR S/W R/FRONT S/W

F/REAR S/WSMPS

LEFT LAMP RIGHT LAMP

24V

GND#4

F/FRONT S/W

RE

AR

BL

OW

ER

N.O

+

COM

–

5045-2P

BLOWER



3.2. UV Lamp PLC

The UV lamp PLC diagram is illustrated in the diagram �UV Lamp Power Box Connections� on page 7-15 .

PRINTED CIRCUIT BOARDS


4. Printed Circuit Boards

Overview Printed Circuit Boards:

! Total PCB Diagram Layout

! MAIN PCB

! FPGA PCB

! HEAD PCB

! REFILL PCB

! CARTRIDGE PCB

! HEAD LIFT PCB

! ITV CONTROLLER PCBµ

! SUB PCB

! IF PCB

! I/O PCB

! TAKE UP PCB

! REFILL CONTROL PCB

! INDICATOR PCB

! DRIVER COMMUNICATION PCB



4.1. Total PCB Diagram Layout

3.3V

TDO

TCX

TMS

TMS

TD

+24V

B

A~

IN+

SUB B

BASE A

+5VSUB B

GND

SUB_HEATER

DN_SEN

A

BASE BTX

SUB_HEATER

UP_SEN

SUB A

GND

+24V

BASE A

GND

SUB A

BASE B

GND

RX

GND

+24V

OUT+

GND

GND

SOL(2)

GND

GND

BASE B'

GND

GND

GND

+24V

GND

B~

SUB B'

BASE_HEATER

N.C

N.C

N.C

GND

N.C

+24V

+24V

SUB B'

SOL(1)

+5V

BASE B'

N.C

N.C

SOL(1),SOL(2)

HV2

HEAT#5

INK3

HV25V

GND

INK7

GND

HV2

HEAT#4 HEAT#8

INK2

HV2

GND

HEAT#2

INK_OVF(5V)

HV2

INK1

GND

HEAT#1

INK6

HV2

GND

HEAT#6

GND

TERMISTOR

GNDGND

INK5

HV2HV2

12V

HEAT#7

GND GNDGND

INK4

5V

INK8

GND

HEAT#3

SUB_B'

N.C

GND

N.C

+24V

N.C

SUB_B

BASE_A

N.C

N.C

GND

PSE

N.C

GND

N.C

WHITE_SUB_HEATER

GND

+24V

SUB_A

ITV

GND

N.C

BASE_B'

+24V

GND

+24V

N.C

+24V

N.C

SUB_HEATER

BASE_B

GND

PSE

GND

GND

+24V

N.C

3

2

1

IN-

OUT-

N.C

CW

+24VDC

INP

N.C

TX

PINCH SENSE

GND

OUT COM

GND

CCW LIMIT

+5VDC

+5VDC

N.C

N.C

HOME SENSE

GND

N.C

GND

N.C

GND

MEDIA ON

+5VDC

+24VDC

RX

BLOWER ON

GND(24V)

INK LOW

+5V

AIR_LOW

LIFT UP

SSR OUT1

GND(5V)

SUC_LEVEL

MEDIA SET

LIFT DN

SSR OUT2

GND

+5V

+5V

LAMP ON

MOTOR -

+24V

N.C

MOTOR +

+24V

24V

0V

IN+

OUT+

INK_FULL_LC

+5V

+5V

S_LED_S

INK_FULL_M

M_R_CW

E_TANK_LM

GND

E_TANK_Y

INK_PUMP_Y

LAMP

ERROR_SW

INK_FULL_K

P_LED_LC

INK_PUMP_C

E_TANK_WHITE

INK_EMPTY_C

5V

INK_PUMP_M

+24V

GND

INK_EMPTY_C INK_EMPTY_S

+5V

N.C

+5V

P_LED_C

GND

N.C

N.C+24V

INK_EMPTY_K

N.C

N.C

+24V

+5V

BUZZER

M_F_CCW

INK_EMPTY_Y

5V

OVERFLOW ERROR

S_LED_KS_LED_LM

INK_FULL_LC

P_LED_WT

INK_EMPTY_LM INK_EMPTY_K

GND

+5V

GND

E_TANK_M

+5V

INK_FULL_C

E_TANK_LC

+24V

INK_FULL_WT

INK_EMPTY_S

+24V

INK_FULL_Y

CCW_SW

+24V

+5V

INK_PUMP_K

5V

S_LED_Y

INK_EMPTY_Y

GND

+24V

E_TANK_C

INK_FULL_LM

INK_EMPTY_WT

MAIN ERROR

S_LED_WT

CCW_LED

INK_FULL_S

INK_FULL_S

5V

+24V

INK_PUMP_LM

P_LED_S

+24V

+5V

AUTO_SW

+24V

+24V

TAKE_F_SEN

CW_LED

S_LED_C

?

OVERFLOW_ERROR

INK_PUMP_WHITE

INK_FULL_SIGNAL

INK_PUMP_SOLUTION

N.C

INK_FULL_C

S_LED_LC

INK_FULL_Y

INK_EMPTY_WT

P_LED_Y

INK_EMPTY_SIGNAL

+24V

INK_EMPTY_M

E_TANK_SOL

N.C

+5V

M_F_CW

5VCW_SW

+5V

TAKE_R_SEN

P_LED_LM P_LED_M

INK_FULL_LM

N.C

INK_PUMP_LC

E_TANK_K TX

ERROR_LED

P_LED_K

AUTO_LED

INK_FULL_M

RX_INK

+24V

GND

+5V

M_R_CCW

PRESSURE_LOW

INK_EMPTY_M

S_LED_M

INK_EMPTY_LC

GND

INK_EMPTY_LM

INK_FULL_WT

+5V GND

INK_FULL_K

INK_EMPTY_LC

N.C

+5V

N.C

N.C

J1~J4

1. HVPULSE2. N.C3. N.C

4. GND

5. CLK

6. DATAOUT

7. DATAIN

8. +12V

9. GND

J51. GND_SIGNAL

2. GND_SIGNAL

3. HV_ERR

4. HV_CK

5. SHIFT_CK_HI6. DATA_CD_HI

7. DATA_AD_HI8. N.C

9. +12V

10. +12V

11. GND_POWER

12. GND_POWER

13. N.C

14. N.C

15. HVIN

16. HVIN

12V

JET

REV5

HV_ADJ

CARTRIDGE PCB

5V

5V

J8

7. GND

9. PCD1511.PCD14

13.PCD13

15.PCD1217.PCD11

19.PCD10

21.PCD9

23.PCD825.PCD7

27.PCD6

29.PCD5

31.PCD433.PCD3

35.PCD237.PCD1

39.PCD0

GN

D

J7

1. EXT1

2. PCSELA3. EXT2

4. PCSELB

34.GND37.O_REQ

J101. 3.3V

2. 3.3V3. GND

4. GND5.

MCSELA

6.

MCSELB7. MCCLK

8. VIA3

9. VIA4

10.PCSELA

11.PCSELB12.MCD0

13.MCD1

14.MCD2

15.MCD316.MCD4

17.MCD5

18.MCD6

19.MCD720.MCD8

21.MCD9

22.MCD1023.MCD11

24.MCD12

25.MCD13

26.MCD1427.MCD15

28.MCS1

29 MCS2

30. EXT1

31. EXT232. GND

33. GND34. GND

35. GND

36. GND

37. GND38. GND

39. GND

40. GND

41. GND

42. GND

43. GND44. GND

45. GND46. GND

47. GND

48. GND49. 3.3V

50. 3,3V

8 1

UV NEO FPGA PCB

GN

D

RE

V5

1. +24V

2. +24V

3. +24V4. GND

5. GND

6. GND

7. IN+

8. IN+

9. OUT+10.OUT+

101

24V

1. +24V2. N.C

3. SOL_A4. N.C

5. +24V

6. N.C

7. SOL_B

UV NEO HEAD BASE LIFT PCB

DILLI PRECISION

UVL_01

REV.1

2004.10.20

SOL(1)SOL(2)

7

RESET

1

24V

HEATER6

UV NEO HEAD PCB

HEATER5

JUMPERINSERT

J10

1. INK6

2. 5V

3. GND

4. GND

5. RESET

6. GND

7. INK8

8. GND9. INK7

10. GND

JET DRIVE

REV-3

HEATER7

J9

1. DATA AB1

2. DATA CD1

3. DATA AB2

4. DATA CD2

5. DATA AB36. DATA CD3


9. DATA AB5

10. DATA CD5

11. DATA AB6

12. DATA CD6


15. DATA AB8

16. DATA CD8

17. MEDIA

18. SHIFT-CK

19. RX1_TTL20. TX1_TTL

21. HV_CK

22. ERROR_OUT

23. HT_CNTRL

24. GND

25. GND26. GND

HEATER4

HE

AT

ER

1

HEATER2

EACH INK LEVEL SENSOR

HEATER3 HEATER8

J13

1. HV2

2. GND3. HV1

4. GND

5. 5V

6. GND

7. 24V

8. GND

UV NEO IF PCB

J11. SUB_HEATER

2. BASE_HEATER3. GND

4. GND

5. +24V

6. +24V

J2

1. PSE

2. ITV

3. BASE_B'4. BASE_B

5. BASE_A6. SUB_B'

7. SUB_B

8. SUB_A

UV LAMP ON

RIGHT SHUTTER

MEDIA SENSOR1

J6

1. N.C2. UV LAMP ON

3. N.C

4. N.C

J2

1. +5V

2. MEDIA SENSOR 1

3. MEDIA SENSOR 2

4. MEDIA SENSOR 3

5. FEED LIMITMEDIA SENSOR1

LEFT SHUTTER

J3

1. LEFT SHUTTER2. RIGHT SHUTTER

3. GND

UV NEO I/O PCB

FEED LIMITMEDIA SENSOR1

OFFON

+10V

UV NEO ITV PCB

-10V

+10V

-10V

J5

1. GND2. TX

3. RX4. GND

5. TX

6. RX

UV NEO MAIN BOARD PCB

J17

1. GND2. EXT6

3. EXT54. EXT4

5. EXT3

6. EXT2

7. EXT18.

+5VCD

MA

IN

PR

OC

ES

SO

R

RE

V-4

J18

1. GND2. EXT8

3. EXT74. +24VDC

5. +5VDC

J11

1. GND2. N.C

3. N.C4. TXD

5. N.C

6. N.C

J3

1. MOS3

2. +5V

3. GND4. GND

5. RES3

6. GND7. SCR3

8. GND9. MISO3

10. GND

J2

1. HV_LED

2. +5V

3. GND4. GND

5. RES2

6. GND7. SCR2

8. GND9. MISO2

10. GND

J4

J15



5. DATA AB3

6. DATA CD3



11. DATA AB6

12. DATA CD613. DATA AB7

14. DATA CD7

15. DATA AB8

16. DATA CD8

J1

1. OEB 2. +5V

3. GND

4. GND

5. RES6. GND

7. OEA

8. GND9. MCSELB

10. GND

J141. CHASSIS

2. GND

3. EN A+4. ENCA-

5. ENCB+

6. GND

7. ENCRI+

8. ENCRI-

9. GND10. +5VDC

11. ENCB-

12. +5VDC

1. PLATEN OVER LOAD

2. PLATEN LOCK

3. N.C

4. N.C

5. PLATEN LIFT MANUAL S/W DOWN6. PLATEN LIFT MANUAL S/W UP

7. PRESET

8. N.C

9. N.C

10. AIR LOW

11. PLATEN OVER LOAD

12. SHUTTER RIGHT13. SHUTTER LEFT

14. UV LAMP ON

AC-IN

UV NEO SUB PCB

+

--

F070494_SS

17. MEDIA18. SHIFT_CK

19. RX1_TTL

20. TX1_TTL

21. HV_CK22. ERROR_OUT

23. HT_CNTRL

24. S.GND25. S.GND

26. S.GND

<MAIN J17, J18 - I/O J1, J4>

<I/O J3, J6

- SUB J13>

AIR TANK PRESSURE

GAGE SIGNAL

P014P020P013P012P011

<SUB J43 -

SMPS #6>

DC24V

PID#2-13

PID#2-4

PID#2-3

PID#2-2

PID#2-1

PID#1-3

PID#1-4

PID#1-2

EACH

HEAD

J1~J81. 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.C14. N.C

15. HV1

16. HV1

<CARTRIDGE -

HEAD(J1~J8)>

HEAD TEMP.

SENSOR

HEAD BASE

THERMISTOR

SMPS #2 +120V

SMPS #2 GND

SMPS #1 120V

SMPS #1 GND

SMPS #3 24V

SMPS #3 GND

<GORE SIGNAL>

PLUS : #2~4 Cylinder Sensor

DELUXE : #2~4 Cylinder Sensor

#5 Limit Switch

J161. +3.3VDC

2. +3.3VDC

3. GND4. GND

5. MCSELA

6. MCSELB

7. MCCLK8. VIA3

9. VIA4

10.

PCSELA11.

PCSELB

12. MCD013. MCD1

14. MCD2

15. MCD3

16. MCD4

17. MCD518. MCD6

19. MCD7

20. MCD821. MCD9

22. MCD10

23. MCD11

24. MCD1225. MCD13

26. MCD14

27. MCD15

28. OEA29. OEB

30. VIA5

31. VIA632. GND

33. GND

34. GND

35. GND36. GND

37. GND38. GND

39. GND

40. GND

41. GND42. GND43. GND

44. GND

45. GND

46. GND47. GND

48. GND49.

+3.3VDC

50.

+3.3VDC

FPGA PCB J10 - MAIN PCBJ16 DIRECT CONNECTION

<MAIN 24V J4 -

SMPS#3>

<HOME MAIN

J8 - LIMIT S/W>

<CARRIAGE

CONTROL -

MAIN J12>

<ENCODER

HARNESS>

<MAIN J7 - PC COM1>

<MAIN J11 - REFILL J17>


SMPS #6

<GORE

POWER3>

PURGE

SWITCH

STEP

MOTOR

VT301V

VT301V

PSE531

ITV

#1,2,3

#4,5,6

#7,8

#9,10

PC

MOTHER PCB COM2

<GORE RS 232C>

SUB-INK TANK PT

SENSOR

HEAD BASE

PT SENSOR

UP-Limit Switch

<REFILL J17 -

MAIN J11>

<REFILL +24V

J14 - SMPS #3>

<REFILL J31 - CONTROL J18>

<TAKE UP J11

- REFILL J18>

<REFILL J18 -

TAKE UP J11>

PLC P0B

<IND J11, J13 -

RF J17-1, J4>


<AIR TANK -

REFILL J32>

<GORE HEAD REFILL>

+5V

-

+

+5V

-

-

UV NEO TAKE UP BOARD PCB

NOT USED

++

+5V

SW_M

C

-

LC

UV NEO CONTROL PCB

SW_C

-

U1

16. S_LED_LC

17. S_LED_WHITE18. S_LED_S

19. +5V

20. GND

21. P_LED_Y

22. P_LED_M

23. P_LED_C

24. P_LED_K25. P_LED_LM

26. P_LED_LC

27. P_LED_WHITE

28. P_LED_S

29. +24V

30. GND

+

-

16. S_LED_LC

17. S_LED_WHITE18. S_LED_S

19. +5V

20. GND

21. P_LED_Y22. P_LED_M

23. P_LED_C

24. P_LED_K

25. P_LED_LM26. P_LED_LC

27. P_LED_WHITE

28. P_LED_S29. +24V

30. GND

- -

-

+

S

1.

E_T

AN

K_W

HIT

E

2. E

_T

AN

K_LM

3. E

_T

AN

K_LC

4. E

_T

AN

K_Y

5. E

_T

AN

K_M

6. E

_T

AN

K_C

7. E

_T

AN

K_K

8. E

_T

AN

K_S

OL

-

UV NEO REFILL8COLOR PCB

+ -

K

+

+5V

+5V

SW_LM

+

+5V

-

1. GND

2. +5V

3. GND

4. +5V5. N.C

6. N.C

7. N.C

8. N.C

9. DIR_CW_SW

10. CW_LED

11. DIR_CCW_SW

12. CCW_LED13. AUTO_SW

14. AUTO_LED

15. ERROR_SW

16. ERROR_LED

+

SW_K

-

+

UV NEO INDICATOR PCB

1. SW_Y

2. SW_M3. SW_C

4. SW_K

5. SW_LM

6. SW_LC

7. SW_WHITE

8. SW_S

9. +5V10. GND

11. S_LED_Y

12. S_LED_M

13. S_LED_C

14. S_LED_K

15.

S_LED_LM

+

1.COMM LED

2.INK_PUMP_WHITE

3.INK_PUMP_LM

4.INK_PUMP_LC

5.INK_PUMP_Y

6.INK_PUMP_M7.INK_PUMP_C

8.INK_PUMP_K

9.SOLUTION PUMP

10.OVERFLOW_ERROR

-

-

+5V

+

+

+5V +5V

- -

<CONTROL J18 - REFILL J31>

+

+

+

LM

--

UV NEO CONTORL

REV.3

-

SW_WT

+

+

-

1. SW_Y

2. SW_M3. SW_C

4. SW_K

5. SW_LM

6. SW_LC7. SW_WHITE

8. SW_S

9. +5V

10. GND11. S_LED_Y

12. S_LED_M

13. S_LED_C14. S_LED_K

15.

S_LED_LM

-

WT

+5V

+

+5V

+-

+

+5V

-

+

SW_S

-

Y

-

+

+

SW_Y

+

1. GND

2. +5V

3. GND4. +5V

5. N.C

6. N.C

7. N.C

8. N.C

9. DIR_CW_SW

10. CW_LED11. DIR_CCW_SW

12. CCW_LED

13. AUTO_SW

14. AUTO_LED

15. ERROR_SW

16. ERROR_LED

U12

SW_LC

+ -

-+

+5V

+ +

+

+5V

+5V

-

+-

-

TAKE UP BOARD

REV 0

M

+5V

-

RE

FIL

L_

IND

ICA

TO

R

RE

V.2

+

SMPS #1(240W-DC 120V/2A)WK240S120A

PE L51 L52GND120V GND L1PE

SMPS #2(240W-DC 120V/2A)WK240S120A

120V L2 GND L1PE

SMPS #3(240W-DC 24V/5A)WK120S24A

24V L2 GND L1PE24V L2 G L1PE

SMPS #5(75W-DC 24V/1.5A, DC 5V/8A )WK75DS0524A

24V L2 L1PE L2

SMPS #4(240W-DC 24V/5A)WK120S24A

SMPS #6(75W-DC 24V/1.5A, DC 5V/8A )WK75DS0524A

5V G24V G

#1~3 : CARRIAGE DRIVER CN2

#4~6 : FEED DRIVER CN2

<MAIN J17, J18 - I/O J1, J4>

<MAIN J17, J18 - I/O J1, J4>

<MAIN J17, J18 - I/O J1, J4>

<I/O J3, J6

- SUB J13>

<GORE

I-TV/PSE>

<GORE I-TV/PSE>

<SUB J4 - PLC>

<PID SUB -IF J8>

<PID SUB -IF J7, J9>

<PID SUB - IF J7, J9>

<PID HEADBASE - IF J11>

<IF 24V J6 -SMPS #4>

I-TV CONTROL24V - SMPS #5

24V

0V

<GORE POWER1>

<GORE SENSOR>

<GORESENSOR>

<GOREPOWER1>

<CARTRIDGE -

HEAD(J1~J8)>

<GORE POWER2>

<GORE SIGNAL>

<IND J11, J13 -

RF J17-1, J4>

<TAKEUP MOTOR

- REFILL J10, J11>

<TAKEUP MOTOR

- REFILL J10,

J11>

<IND J11, J13 -

RF J17-1, J4>

<IND J11, J13 -

RF J17-1, J4>

<AIR TANK -

REFILL J32>

J4-1,3,5,7 & J1-1,4 : Height Adjustment Solenoide

J1-1,3 : Up Limit Switch

SUB PCB

HEAD LIFT PCBI-TV PCB

PLC

IF-PCB

FAN

REFILL PCB

HEAD PCB

MAIN PCB

FPGA PCB

HEAD

PCBHEAD

PCB

<HOME MAIN J8 -

SENSOR

CONTROLLER(2,3)>

B6

B6

A8

A8

D14 GREEND14 GREEN

J17

5267-3P

J17

5267-3P

RESETRESET

J18 5267-5PJ18 5267-5P

J4

GIL-G-4P

J4

GIL-G-4P

D6

SE

RV

-R/S

D6

SE

RV

-R/S

LED1LED1

J12

5267-8P

J12

5267-8P

P1

5K

P1

5K

A1

3A

13

PC

AP

CA

1

3

J3

5045-3P

1

3

J3

5045-3P

3

2

456

910

128

7

11

1J14

3

2

456

910

128

7

11

1J14

3 63 6

12

1112

J8

12

1112

J8

12

34

56

78

910

1112

J27

3951-2P

J27

3951-2P

INK7INK7GNDGND

1

5

3951-2P

5

3951-2P

J12

5267-2P

J12

5267-2P

J7

5267-3P

KJ7

5267-3P

K

J95

5267-3P

J95

5267-3P

J4

5267-3P

YJ4

5267-3P

Y

D10 REDD10 RED

REDRED

B8

B8

INK8INK8 12V12V

2

65

SW6

C

2

65

SW6

C

J13

5045-2P

J13

5045-2P

TEMPTEMP

1

D11 GREEND11 GREEN

D5 GREEND5 GREEN

J11J11

1

3951-2P

1

3951-2P

MC

AM

CA

J9

D-SUB26P(3row)

J9

D-SUB26P(3row)

INK6INK6

SW1SW1

J17-1

5045-3P

J17-1

5045-3P

J5

3951-2P

J5

3951-2P

2

65

SW2

LM

2

65

SW2

LM

D12

TR

AV

EL

D12

TR

AV

EL

BZ1

5267-4P

BZ1

5267-4P

RUNRUN

PC_CLKPC_CLK1

LED1LED1

LED4LED4

J29

5267-2P

J29

5267-2P

2

65

SW3

LC

2

65

SW3

LC

D3 REDD3 RED

CS

1C

S1

J2

5267-2P

J2

5267-2P

J1

5267-3P

WTJ1

5267-3P

WT

MEDIAMEDIA

1

1

5

J2

5045-5P

1

5

J2

5045-5P

J75045-6P

J75045-6P

J14

3951-3P

J14

3951-3P

CS

3C

S3

B2

0

D6

B2

0

D6

ENC ABNENC ABN

1

J4J4

123456789

J6

3951-5P

J6

3951-5P

12

1112

J3

12

1112

J3

12

34

56

78

910

1112

2

65

SW1

WT

2

65

SW1

WT

MCSELAMCSELA1

B5

B5

INK7

5267-2P

INK7

5267-2P

SW2

FEEDBACK

SW2

FEEDBACK

J3

5267-3P

LCJ3

5267-3P

LC

D1 GREEND1 GREEN

J6

5267-3P

CJ6

5267-3P

C

B1

6B

16

D8

ER

RO

R

D8

ER

RO

R

J1

5267-8P

J1

5267-8P

J11

3951-3P

J11

3951-3P

MCCLKMCCLK1

INK6-LM

5267-2P

INK6-LM

5267-2P

1

3

1

3

A2

A2

D13 GREEND13 GREEN

CS

6C

S6

INK2-C

5267-2P

INK2-C

5267-2P

12

1112

J7

12

1112

J7

12

34

56

78

910

1112

J30

5267-2P

J30

5267-2P

A2

0

D3

A2

0

D3

1929 91929 9

A1

5A

15

J7 5267-3PJ7 5267-3P

GNDGND

1

A4

A4

INK3-M

5267-2P

INK3-M

5267-2P

D2 GREEND2 GREEN

GNDGND

1

CS

5C

S5

J45

? -2P

J45

? -2P

2

65

SW4

Y

2

65

SW4

Y

CS

1C

S1

+ -

110

11

20

D12

+ -

110

11

20

D12

1929 9

J31

HRS-30P

1929 9

J31

HRS-30P

J11

5219-2P

J11

5219-2P

15J11

HRS-16P

15J11

HRS-16P

MCSELBMCSELB

1

J16

3951-10P

J16

3951-10P

A1

2A

12

INK4INK4

LED6LED6

A2

1A

21

D16 REDD16 RED

J25

3951-2P

J25

3951-2P

J26

3951-2P

J26

3951-2P

A1

9A

19

CS

2C

S2

B1

4B

14

B1

5B

15

J12

5045-9P

J12

5045-9P

B3

B3

J13

5045-4P

J13

5045-4P

HV-CLKHV-CLK

1

J30

5267-2P

J30

5267-2P

D1

INK1

D1

INK1

12

910

J3

CON10

12

910

J3

CON10

D10 GREEND10 GREEN

D4

LEDG-SM

D4

LEDG-SM

A3

A3

A5

A5

J29

5267-2P

J29

5267-2P

J1AJ1A

123

D7 REDD7 RED

J11

3951-2P

J11

3951-2P

1 2

11 12

J5

1 2

11 12

J5

1 2

3 4

5 6

7 8

9 10

11 12

J32

5267-6P

J32

5267-6P

J14

3951-2P

J14

3951-2P

LED2LED2

D6

INK

_O

VF

D6

INK

_O

VF

B4

B4

CS

4C

S4

12

1112

J1

12

1112

J1

12

34

56

78

910

1112

B1

9B

19

12

910

J2

CON10

12

910

J2

CON10

B2

1B

21

J475267-4P

J475267-4P

D7

HV

D7

HV

A1

A1

J8

5267-3P

SJ8

5267-3P

S

J9

5267-4P

J9

5267-4P

A1

8A

18

J43

3951-4P

J43

3951-4P

J49

5566-2P

J49

5566-2P

A1

4A

14

14 714 7

J28

5267-2P

J28

5267-2P

2

3951-2P

2

3951-2P

D9

EN

C

D9

EN

C

D16 GREEND16 GREEN

D5 GREEND5 GREEN

D2 REDD2 RED

B1

7B

17

J10

PCN10C 50S 2.54DS

J10

PCN10C 50S 2.54DS

1234567891011121314151617181920212223242526272829303132333435363738394041424344454647484950

B9

B9

J5

5267-3P

MJ5

5267-3P

M

D4 REDD4 RED

CS

6C

S6

B1

B1

J10

5267-5P

J10

5267-5P

GNDGND1

J24

3951-2P

J24

3951-2P

A0

D1

A0

D1

MEDIA SCANMEDIA SCAN

1

WRWR1

TRAVELTRAVEL

1

MCCLKMCCLK

1

12

1112

J2

12

1112

J2

12

34

56

78

910

1112

15

J11

15

J11

1

5

1

5

J34

5267-3P

J34

5267-3P

CS

3C

S3

20K

ZERO

20K

ZERO

J11

5045-3P

J11

5045-3P

3 83 8

J48

5267-2P

J48

5267-2P

J4

5267-2P

J4

5267-2P

J7

3951-2P

J7

3951-2P

2

65

SW7

K

2

65

SW7

K

LED3LED3

J4

STL950

J4

STL950

J17

5267-8P

J17

5267-8P

A1

1A

11

INK2INK2

J8

PC2

J8

PC2

123456789

10111213141516171819202122232425262728293031323334353637383940

1

4

J6

5045-4P

1

4

J6

5045-4P

2

65

SW5

M

2

65

SW5

M

J352

3951-2P

J352

3951-2P

B1

8B

18

J1

3951-5P

J1

3951-5P

1929 9

J18 HRS-30P

1929 9

J18 HRS-30P

PWR

D9

PWR

D9

B1

2B

12

5V5V

1

PC

BP

CB

J2

5267-3P

LMJ2

5267-3P

LM

D12 REDD12 RED

12

1112

J6

12

1112

J6

12

34

56

78

910

1112

2

65

SW8

S

2

65

SW8

S

2

65

SW3

LC

2

65

SW3

LC

J15 5566-2PJ15 5566-2P

D15 GREEND15 GREEN

A7

A7

A1

6A

16

LED8LED8

INK3INK3

GNDGND

1

GNDGND

1

D2

HV

_E

RR

D2

HV

_E

RR

STOP

5045-2P

STOP

5045-2P

D8 REDD8 RED

J43951-6P

J43951-6P

J39J39

12

MCSELAMCSELA

1

J83951-6P

J83951-6P

J55267-6P

J55267-6P

D11

TE

ST

D11

TE

ST

D9 GREEND9 GREEN

J13

5267-2P

J13

5267-2P

J10

5267-3P

J10

5267-3P

J11J11

12345678

J2J2

123456789

D4

HT

_E

RR

D4

HT

_E

RR

12

910

J10

CON10

12

910

J10

CON10

SHIFT-CKSHIFT-CK

1

MCSELBMCSELB1

J17-1

5045-3P

J17-1

5045-3P

J17

5267-4P

J17

5267-4P

1

4

1

4

D7 GREEND7 GREEN

D11 GREEND11 GREEN

D4 REDD4 RED

SERVO R/SSERVO R/S

1

3.3V3.3V1

TP1TP1

1

D3 GREEND3 GREEN

D3

MO

VE

-R

D3

MO

VE

-R

3

3951-2P

3

3951-2P

J6

5267-2P

J6

5267-2P

2

65

SW4

Y

2

65

SW4

Y

+

-

1 8

916

D108

+

-

1 8

916

D108

CS

4C

S4

B2

B2

FEEDFEED

GNDGND

1

A1

7A

17

8

3951-2P

8

3951-2P

D1 REDD1 RED

12

1112

J5

12

1112

J5

12

34

56

78

910

1112

D6 REDD6 RED

B1

1B

11

4

3951-2P

4

3951-2P

A1

0

D2

A1

0

D2

J22

5267-2P

J22

5267-2P

B7

B7

A6

A6

J16

5219-3P

J16

5219-3P

J7

PC1

J7

PC1

123456789

10111213141516171819202122232425262728293031323334353637383940

D10

MA

RK

D10

MA

RK

D2

MO

VE

-L

D2

MO

VE

-L

J5

3951-2P

J5

3951-2P

D8 REDD8 RED

PCSELBPCSELB1

ENCENC

1

20K

GAIN

20K

GAIN

12

1112

J5

12

1112

J5

12

34

56

78

910

1112

LED2LED2

TP2TP2

1

D4 REDD4 RED

CLOCKCLOCK1

J7J7

J8

5267-3P

J8

5267-3P

INK1-K

5267-2P

INK1-K

5267-2P

INK5-LC

5267-2P

INK5-LC

5267-2P

LED7LED7

MC

BM

CB

J20

3951-2P

J20

3951-2P

D2 REDD2 RED

MARKMARK

1

J1J1

123456789

A9

A9

J17J17

J1

3951-2P

J1

3951-2P

D9 GREEND9 GREEN

D5

WE

EP

D5

WE

EP

6

3951-2P

6

3951-2P

2

65

SW2

LM

2

65

SW2

LM

GNDGND1

LED5LED5

INK4-Y

5267-2P

INK4-Y

5267-2P

J21

5267-2P

J21

5267-2P

GNDGND1

J16

PCN10-50P

J16

PCN10-50P

123456789

1011121314151617181920212223242526272829303132333435363738394041424344454647484950

5V5V

J9

3951-3P

J9

3951-3P

INK5INK5

3 6

J1

3951-6P

3 6

J1

3951-6P

D13 GREEND13 GREEN

1

10

19

9

18

26

J15 D-SUB26P(3row)

1

10

19

9

18

26

J15 D-SUB26P(3row)

SW4SW4

B1

0

D5

B1

0

D5

J11 5267-6PJ11 5267-6P

J6

3951-2P

J6

3951-2P

3 8

J2

5045-8P

3 8

J2

5045-8P

CS

5C

S5

12

1112

J5

12

1112

J5

12

34

56

78

910

1112

15

J18

HRS-16P15

J18

HRS-16P

D14 REDD14 RED

CS

2C

S2

SHIFT CLKSHIFT CLK

1

12V12V

1

12

1112

J4

12

1112

J4

12

34

56

78

910

1112

J33

5267-4P

J33

5267-4P

J3J3

123456789

D4

ME

DIA

D4

ME

DIA

D5 REDD5 RED

LED3LED3

J123951-2P

J123951-2P

7

3951-2P

7

3951-2P

3

2

456

910

128

7

11

1J14

ENCODER

3

2

456

910

128

7

11

1J14

ENCODER

J13

5045-5P

J13

5045-5P

SW1

RESET

SW1

RESET

D12 GREEND12 GREEN

14 7

J13

5045-14P

14 7

J13

5045-14P

3.3V3.3V

1

J3

3951-2P

J3

3951-2P

5V5V

1

D3 GREEND3 GREEN

J15

5045-7P

J15

5045-7P

J183951-4P

J183951-4P

J3

5045-4P

J3

5045-4P

1515

J10

5566-2P

J10

5566-2P

J23

3951-7P

J23

3951-7P

PCSELAPCSELA1

B1

3B

13

12

910

J1

CON10

12

910

J1

CON10

J4

5267-5P

J4

5267-5P

HV-CKHV-CK

1

D1

5V

D1

5V

1929 9

J31 HRS-30P

1929 9

J31 HRS-30P

J10

5267-4P

J10

5267-4P

O_REQO_REQ1

INK8-S

5267-2P

INK8-S

5267-2P

D1 REDD1 RED

2

65

SW1

WT

2

65

SW1

WT

J23

5267-2P

J23

5267-2P

1 85

J13

STL950 1 85

J13

STL950

B0

D4

B0

D4

1

10

19

9

18

26

J15

1

10

19

9

18

26

J15

D17 LEDD17 LED

J4

5045-3P

J4

5045-3P

J8

5267-3P

J8

5267-3P

D6 REDD6 RED

J18J18



4.2. MAIN PCB

GN

D

+24VD

C

GNDHOME SENSE

+5VDC

GNDN.CN.C

+5VDC

GNDDOOR SENSE

GN

D

RX

J161. +3.3VDC2. +3.3VDC3. GND4. GND5. MCSELA6. MCSELB7. MCCLK8. VIA39. VIA410. PCSELA11. PCSELB12. MCD013. MCD114. MCD215. MCD316. MCD417. MCD518. MCD619. MCD720. MCD821. MCD922. MCD1023. MCD1124. MCD1225. MCD1326. MCD1427. MCD1528. OEA29. OEB30. VIA531. VIA632. GND33. GND34. GND35. GND36. GND37. GND38. GND39. GND40. GND41. GND42. GND43. GND44. GND45. GND46. GND47. GND48. GND49. +3.3VDC50. +3.3VDC

J51. GND2. TX3. RX4. GND5. TX6. RX

J141. CHASSIS2. GND3. EN A+4. ENCA-5. ENCB+6. GND7. ENCRI+8. ENCRI-9. GND10. +5VDC11. ENCB-12. +5VDCJ18

1. GND2. EXT83. UV LAMP ON4. +24VDC5. +5VDC

J171. DC5V+2. MEDIA SET13. MEDIA SET24. MEDIA SET35. FEED LIMIT6. LEFT SHUTTER7. RIGHT SHUTTER8. +5VCD

J151. DATA AB12. DATA CD13. DATA AB24. DATA CD25. DATA AB36. DATA CD37. DATA AB48. DATA CD49. DATA AB510. DATA CD511. DATA AB612. DATA CD613. DATA AB714. DATA CD715. DATA AB816. DATA CD8

17. MEDIA18. SHIFT_CK19. RX1_TTL20. TX1_TTL21. HV_CK22. ERROR_OUT23. HT_CNTRL24. S.GND25. S.GND26. S.GND

TO INTERLOCKMODULE

ENCODER

3#SPMS

PC-COM1

HEAD PCB J9

4J BCP O/I

REFILLPCB J17

HOMESENSOR

FPGA J10

<GORE SIGNAL>

<MAIN J7 - PC COM1>

<MAIN 24V J4 - SMPS#3>

<MAIN J8 - LIMIT S/W>

RESETPUSH S/W

<PUSH S/W #3 - MAIN RESET>

<I/O J3, J6 - MAIN J17, J18><I/O J3, J6 - MAIN J17, J18>

<REFILL J17 - MAIN J11>

I/O PCB J1

1

TX

REVIRD.MMOC7J BCP

DRIVER COMM. PCB J5

DRIVERCOMM.PCB J6

DILLIMAIN20

DILLIMAIN10-5 UV

DILLIMARK7-2M

AIN

PRO

CES

SOR

REV

-4

NOT USED

TX

GN

D

GN

D

TXR

X

GND

C-INP

GND

24V+

4J

J12 J12

D9

EN

C

D1

5V

D11

TES

T

RESET

5045-2P

D6

SE

RV-

R/S

3

2

456

910

128

7

11

1J14

ENCODER

D10

MA

RK

5267-6PJ11

J8

5267-3P

5267-4P

5267-5P

5267-8P 5267-8P

J12

5267-8P

J1

5267-8P

J10

D8

ER

RO

R

J30

5267-2P

D4

ME

DIA

RUN

J4

5267-5P

D2

MO

VE

-L

5J P6-7625

5267-5PJ18

61J

PCN10-50P

1234567890111213141516171819102122232425262728292031323334353637383930414243444546474849405

J7

5267-2P

D5

WE

EP

FEED

D3

MO

VE

-R

10191

981

62

D-SUB26P(3row)J15

J17

P8-7625 P8-7625

SERVO/RS

1

J9

11019

918

26J9

D-SUB26P(3row)

STOP

D7

HV

J7

5267-3P

P3-76257J

D12

TRAV

EL



4.3. FPGA PCB

TMS TDO

TD

TMS

TCX

3.3V

REV5

GND5V5V G

ND

18

J101. 3.3V2. 3.3V3. GND4. GND5. MCSELA6. MCSELB7. MCCLK8. VIA39. VIA410.PCSELA11.PCSELB12.MCD013.MCD114.MCD215.MCD316.MCD417.MCD518.MCD619.MCD720.MCD821.MCD922.MCD1023.MCD1124.MCD1225.MCD1326.MCD1427.MCD1528.MCS129.MCS230. EXT131. EXT232. GND33. GND34. GND35. GND36. GND37. GND38. GND39. GND40. GND41. GND42. GND43. GND44. GND45. GND46. GND47. GND48. GND49. 3.3V50. 3.3V

J71. EXT12. PCSELA3. EXT24. PCSELB34. GND37. O_REQ

J87. GND9. PCD1511.PCD1413.PCD1315.PCD1217.PCD1119.PCD1021.PCD923.PCD727.PCD629.PCD531.PCD433.PCD335.PCD237.PCD139.PCD0

PCI CARDCN2

PCI CARDCN1

MAINBOARD PCBJ16

<PCI-FPGA J7>

<PCI-FPGA J8>

CS

1

A14

CS

1

MCSELA1

GND1

A9

B13

PC

B

B2

CS

5

A10

D2

J8

PC2

12345678901112131415161718191021222324252627282920313233343536373839304

A4

CS

4

O_REQ1

MCSELB1

A21

A16

B9

B11

MC

B

3.3V1

J10

PPCN10C 50S 2.54DS

1234567890111213141516171819102122232425262728292031323334353637383930414243444546474849405

B3

A0

D1

B4

PC

A

CS

4

A18

B12

WR1PCSELA1

A6

B10

D5

A20

D3

A11

B21

B16

B15

A17

A8

B20

D6 PWRD9

PC_CLK1

B0

D4

PCSELB1

CS

3

A12

B6

A1

B18

A7

B17

B14

B1

MC

A

A15

A2

B8

J11

12345678

CS

5

CS

2

A13

B5

MCCLK1

A5

CS

3

J7

PC1

12345678901112131415161718191021222324252627282920313233343536373839304

B7

CS

2

GND1

CS

6

A19

KCOLC KCOLC1

A3

CS

6

GND1

B19



4.4. HEAD PCB

HV

2

2VH

HE

AT#2

1#TAEH

HE

AT#3

HV

2

HE

AT#4

HV

2

HE

AT#5

HV

2

HE

AT#6

HV

2

HV

2

HE

AT#8

HV

2

HE

AT#7

DNGV5V5

V21

DNG

DNG)V5(FVO_KNI

EVIRD TEJ3-VER

1RETAEH

HEATER

2

HEATER

3

HEATER

4

HEATER

5

HEATER

6

HEATER

7

HEATER

8

LEV

EL

SE

NS

OR

8J~1JLANGIS_DNG .1LANGIS_DNG .2

RRE_VH .3*KLC_VH .4

*KC_TFIHS .5*KDC_ATAD .6*HDA_ATAD .7

C.N .8V21+ .9V21+ .01

REWOP_DNG .11REWOP_DNG .21

C.N .31C.N .411VH .511VH .61

9J1BA ATAD .11DC ATAD .22BA ATAD .32DC ATAD .43BA ATAD .53DC ATAD .64BA ATAD .74DC ATAD .85BA ATAD .9

5DC ATAD .016BA ATAD .116DC ATAD .217BA ATAD .317DC ATAD .418BA ATAD .518DC ATAD .61

AIDEM .71KC-TFIHS .81LTT_1XR .91LTT_1XT .02

KC_VH .12TUO_RORRE .22LRTNC_TH .32

DNG .42DNG .52DNG .62

REPMUJTRESNI

31J2VH .1DNG .21VH .3DNG .4

V5 .5DNG .6

V42 .7DNG .8

DESU TON

DESU TON

NIAM51J BCP

K C CLYM SML

HE

AD

TEM

P.

SE

NS

OR

EA

CH

CA

RTR

IDG

EP

CB

J5

)VH RETAEH DAEH(2#SPMS : 2,1)VH TEJ DAEH(1#SPMS : 4,3

C.N : 6,53#SPMS : 8,7

>LANGIS EROG<

>2REWOP EROG<

- EGDIRTRAC<>)8J~1J(DAEH

SMPS#2

SMPS#1

SMPS#3

GGGGGGGG

LEV

EL

SE

NS

OR

LEV

EL

SE

NS

OR

LEV

EL

SE

NS

OR

LEV

EL

SE

NS

OR

LEV

EL

SE

NS

OR

LEV

EL

SE

NS

OR

G

LEV

EL

SE

NS

OR

12J

W

-

RV

ERUTAREPMET RV

PT PT

W-8KNI

P2-7625

W-8KNI

P2-7625

3

P2-1593

3

P2-1593

CL-5KNI

P2-7625

CL-5KNI

P2-7625

2

P2-1593

2

P2-1593

12

1121

6J

12

1121

6J

2KNI 2KNIV5V5

1

V5V56KNI 6KNI

4

P2-1593

4

P2-1593

Y-4KNI

P2-7625

Y-4KNI

P2-7625

4D

HT_

ER

R

4D

HT_

ER

R

12

1121

7J

12

1121

7J 9J

)wor3(P62BUS-D

9J

)wor3(P62BUS-D

M-3KNI

P2-7625

M-3KNI

P2-7625

59J

P3-7625

59J

P3-7625

1D

1KNI

1D

1KNI

51J

)wor3(P62BUS-D

51J

)wor3(P62BUS-D

5

P2-1593

5

P2-1593

DNG DNG

1

8

P2-1593

8

P2-1593

5KNI 5KNI

12

1121

8J

12

1121

8J

12

1121

2J

12

1121

2J

C-2KNI

P2-7625

C-2KNI

P2-7625

93J 93J

12

6

P2-1593

6

P2-1593

V21 V21

12

1121

3J

12

1121

3J

4KNI 4KNI

K-1KNI

P2-7625

K-1KNI

P2-7625

DNG DNG

1

7

P2-1593

7

P2-1593

8KNI 8KNI

S_7KNI

P2-7625

S_7KNI

P2-7625

2D

HV

_ER

R

2D

HV

_ER

R

12

1121

1J

12

1121

1J

1

P2-1593

1

P2-1593

V21 V21

1

12

1121

4J

12

1121

4J

DNG DNG1

92J

P2-7625

92J

P2-7625

ML-6KNI

P2-7625

ML-6KNI

P2-7625

1ZB

P4-7625

1ZB

P4-7625

3KNI 3KNI

12

901

01J

01NOC

12

901

01J

01NOC7KNI 7KNI

81 5

31J

059LTS

81 5

31J

059LTS

12

1121

1J

12

1121

1J

6D

INK

_OV

F

6D

INK

_OV

F

12

1121

5J

12

1121

5J

03J

P2-7625

03J

P2-7625



4.5. REFILL PCB

5V GND+5V

PRESSURE LOW

N.CN.CN.C

N.C

+24VA

IR E

RR

OR

N.C

E_TANK_SOL+5V

E_TANK_WHITE+5V

E_TANK_LM+5V

E_TANK_LC+5V

E_TANK_Y+5V

E_TANK_M+5V

E_TANK_K+5V

E_TANK_C+5V

+24V

GNDN.CN.C

BUZZER

LAMP

INK_PUMP_SOLUTION

INK_PUMP_WHITE

INK_PUMP_LM

INK_PUMP_LC

INK_PUMP_Y

INK_PUMP_M

INK_PUMP_C

INK_PUMP_K+24V

+24V

+24V

+24V

+24V

+24V

+24V

+24V

TX

+5VN.CGND

RX_INK

U12

U1

1. E_TA

NK

_WH

ITE2. E

_TAN

K_LM

3. E_TA

NK

_LC4. E

_TAN

K_Y

5. E_TA

NK

_M6. E

_TAN

K_C

7. E_TA

NK

_K8. E

_TAN

K_S

OL

MAIN PCB J18

<VT301 - REFILL J35><MAIN J18 - REFILL J34>

TAKE UP PCB

11J BCP ROTACIDNI

MAIN PCB J11

AIR TANK

3# SPMS

FRONTPHOTO SENSOR

FRONTGEAR MOTOR

REARPHOTO SENSOR

REARGEAR MOTOR

SUB-TANKFLOW SENSOR

CONTROL PCB J18

PLC P0B

INDICATOR PCB J10

<TAK

E UP J11 - R

EFILL J18>

>4J ,1-71J FR - 31J ,11J DNI<

<AIR TANK - REFILL J32>

<REFILL +24V J14 - SMPS#3>

<TAKEUP MOTOR - REFILL J10, J11>

<TAKEUP MOTOR - REFILL J10, J11> <CONTROL J18 - REFILL J31>

<GORE HEAD - REFILL>

<IND J11, J13 - RF J17-1, J4>

GND

GND+24V

<REFILL J17 - MAIN J11><REFILL J13 - PLC P0B>

MAIN

ERR

OR

GN

D

24VG

ND

TAKE_FRO

NT_SEN

N.C

M_F_C

CW

M_F_C

W

OVERFLO

W ERRO

R+5V

24V

GN

D

TAKE_REAR

_SEN

M_R

_CW

M_R

_CC

W

VT301

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED J25J21

J11

5219-2P

J17-1

5045-3P

J11

5045-3P

15

J18

HRS-16P

SW1

RESET

J3

J3

5045-4P

22J

+

-

1 8

61 9

D108

J28

31J

5045-2P33J

5267-4P

5267-2P

5267-2P

5267-2P

5267-2P

5267-2P

5267-2P

5267-2P

5267-2P5267-3P 3951-2P 3951-2P 3951-2P 3951-2P 3951-2P 3951-2P 3951-2P 3951-2P 3951-2P 3951-2P

J26

J14

3951-2P

92J

J20

+ -

110

11

20

D12

J10

5566-2P

4JJ13

5267-2P

J32

5267-6P

J5J27

5566-2PJ15

6J

J17

5267-3P

J18

5267-5P

51

J18

HRS-16P

9192 9

J31

HRS-30PJ30

5267-2P

J24

12J

32J

J32

5267-6P

J16

5219-3P

J34 J1

2J

91 929

81J

P03-SRH

J35

1. SW_Y2. SW_M3. SW_C4. SW_K5. SW_LM6. SW_LC7. SW_WHITE8. SW_S9. +5V10. GND11. S_LED_Y12. S_LED_M13. S_LED_C14. S_LED_K15. S_LED_LM

16. S_LED_LC17. S_LED_WHITE18. S_LED_S19. +5V20. GND21. P_LED_Y22. P_LED_M23. P_LED_C24. P_LED_K25. P_LED_LM26. P_LED_LC27. P_LED_WHITE28. P_LED_S29. +24V30. GND

1. GND2. +5V3. GND4. +5V5. N.C6. N.C7. N.C8. N.C9. DIR_CW_SW10. CW_LED11. DIR_CCW_SW12. CCW_LED13. AUTO_SW14. AUTO_LED15. ERROR_SW16. ERROR_LED

1. COMM LED2. INK_PUMP_WHITE3. INK_PUMP_LM4. INK_PUMP_LC5. INK_PUMP_Y6. INK_PUMP_M7. INK_PUMP_C8. INK_PUMP_K9. SOLUTION PUMP10. OVERFLOW_ERROR



4.6. CARTRIDGE PCB

JETREV5

J51. GND_SIGNAL2. GND_SIGNAL3. HV_ERR4. HV_CK5. SHIFT_CK_HI6. DATA_CD_HI7. DATA_AD_HI8. N.C.9. +12V10. +12V11. GND_POWER12. GND_POWER13. N.C.14. N.C.15. HVIN16. HVIN

J1~J41. HVPULSE2. N.C.3. N.C.4. GND5. CLK6. DATAOUT17. DATAIN8. +12V9. GND

HV_ADJ GND

<CARRIAGE - HEAD (J1~J8)>

EACHHEAD

HEAD PCB(J1~J8)

120V

FLAT RIBBON HARNESS

* FACTORY SET

J4

123456789

TP1

1

TP21

1 2

11 12

J1~J8

1 212

1112

J5

J1

123456789

J3

123456789

J2

123456789

D4

LEDG-SM 12V

K5

P1

K5



4.7. HEAD LIFT PCB

SOL(1)

OUT+N.C

N.C

+24VGND

SOL+24V

+24VGND+5VGND

SU

B B

�S

UB

BS

UB

A

BA

SE

B�

BA

SE

B

N.C

BA

SE

A GN

D

DN_SEN

UP

_SE

N

C.N

N.C

V5+

DNG

SUB_

HEAT

ER

1 7

1. +24V2. N.C3. SOL_A (THE VERTICAL)4. N.C5. +24V6. N.C7. SOL_B (HORIZONTALITY)

1. OUT+2. OUT+3. IN+4. IN+5. GND6. GND

7. GND8. +24V9. +24V10.+24V

RESET 24V

SOL(1)SOL(2)

J14-1,3SUB_INK TANK RUBBERHEATER

STEPMOTOR

1,2 : VT301V4,5 : VT301V

Pressure SensorPSE531

ITV2010

1,2 : ITV PCB OUT+3,4 : ITV PCB IN+5,6,7 : ITV PCB OV8,9,10 : ITV PCB 24VPT SENSOR

HEAD BASEPT SENSORSUB_INKTANK

PURGES/W

SMPS#6

IF PCB J1

IF PCB J2

PC MOTHERPCB COM2

HEIGHTADJUSTMENTSOL

<GORE SENSOR>

<GORE POWER3>

<GORE POWER1>

<GORE RS 232C>

<GORE I-TV/PSE>

SUB ASUB BSUB B�BASE ABASE BBASE B�

T/H BUST/H ESAB

DNGDNG

V42V42

B

AA�

B�

24V+

GND

GND

SOL(2)GND

IN+

IN-IN+24V V1G V3V2 0-0+1

UP LIMITS/W

RX

TX

GN

D

N.CN.CN.C

J17

5267-4P101

J16

5045

-10P

J6

3951-5P

SW1

J7

5045-6P

J7

5045-6P

J135045-4P

J23

3951-7P

J8

3951-6P

J4

GIL-G-4P

J115045-3P

8J

P6-1593

8J

P6-1593

J14

J25

3951-3P

J18

3951-4P

J155045-7P

LED2

LED1

J1

5045-5P

J12

3951-2P

J2

5045-9P

J10

5267-3P



4.8. ITV CONTROLLER PCB

2

+NI

1

V0

+TUO

+V42

-TUO

-NI

361J BCP TFIL DAEH

DNG 5# SPMS

4-1HC 002ESP

2-1HC 002ESP

1-RWP 002ESP

2-RWP 002ESP

1-1HC 002ESP

DNG 5# SPMS

DNG 5# SPMS3-R .RAV2-R .RAV1-R .RAV

+V42 5# SPMS

61J BCP TFIL DAEH

61J BCP TFIL DAEH

61J BCP TFIL DAEH

V01-

V01+V01+

V01-

NO

5# SPMS

002 ESP

>ESP/VTI EROG<

.RVELBAIRAVROTISIGER

EMULOV

12

34

FFO

)1(NOITISOP GNITTES *




GNITTES YROTCAF *K02

NIAG

K02

NIAG

4WS 4WS

K02

OREZ

K02

OREZ

P4-7555 P4-7555

A1J A1J123

4J

059LTS

4J

059LTS



4.9. SUB PCB

MOTOR -MOTOR +

+5V

+5VLIFT DNLIFT UPGND

SUC_LEVEL

N.C

GN

D(5

V)

+5V

+24V

GN

D(2

4V)

SSR OUT1SSR OUT2

AIR LOWINK LOWLAMP ONMEDIA SET ONBLOWER ON

F070494_SS

J131. N.C2. N.C3. N.C4. N.C5. N.C6. N.C7. N.C8. N.C9. N.C10. AIR LOW11. N.C12. SHUTTER RIGHT13. SHUTTER LEFT14. UV LAMP ON

SMPS#6 I/O PCB J3 I/O PCB J6<SUB J43 - SMPS#6> </O J3,J6 - SUB J13>

<SUB J4 - PLC>

PLC

AIRTANK

<AIR TANK - REFILL 32>

+

-

NOT USED

NOT USED

VR1

VR2

NOT USED

NOT USED

NOT USED

NOT USED

4 1

J6

J45

J45-2P

J475267-4P

J49

5566-2P

J43

3951-4P

1 7 14

J13

5045-14P

J48

5267-2P

J43951-6P

RED LED

13

J3

5045-3P 5045-4P

1: PO142: PO203: PO134: PO125: PO11



4.10. IF PCB

V42+C.NC.NC.NC.NC.NC.NC.N

DNG

V42+DNG

C.NC.N

ESP

DNG

DNGV42+

DNGV42+

SU

B_A N

.C

N.C

WH

ITE_S

UB

_HE

ATE

RG

ND

V42+

DNG

ESP

V42+

DNGC.N

VTI

SU

B_B

SU

B_H

EA

TER

BA

SE

_A

BA

SE

_B

BA

SE

_B�

SU

B_B

�

V42+

2JESP .1

VTI .2�B_ESAB .3

B_ESAB .4A_ESAB .5�B_BUS .6

B_BUS .7A_BUS .8

1JRETAEH_BUS .1RETAEH_ESAB .2

DNG .3DNG .4V42+ .5V42+ .6

DESU TON

>4#SPMS - 6J V42 FI<

2#DIP

8J BCP TFIL ESAB DAEH

7J BCP TFIL ESAB DAEH

>8J FI - BUS DIP<

BUS DIP<>9J ,7J FI -

>9J ,7J FI - BUS DIP<

DAEH DIP<>11J FI - ESAB

4# SPMS

>1REWOP EROG<

>ROSNES EROG<

1234

415432

1#DIP

41

1

5432

3#DIP

41

1

5

GN

D

313131

>ETIHW-DIP EROG<

RETAEHRERLRTNOC

DESU TON

DESU TON

DESU TON

DESU TON

31J

P5-5405

31J

P5-5405

6J

P2-1593

6J

P2-1593

3J

P4-5405

3J

P4-5405

36

8J

P6-159336

8J

P6-1593

11J

P2-1593

11J

P2-1593

5J

P2-1593

5J

P2-1593

01J

P4-7625

01J

P4-7625

3 6

1J

P6-1593

3 6

1J

P6-1593

3 8

2J

P8-5405

3 8

2J

P8-5405

9J

P3-1593

9J

P3-1593 21J

P9-5405

21J

P9-5405

8J

P3-7625

8J

P3-7625

36

8J

P6-159336

8J

P6-1593

4J

P3-5405

4J

P3-5405

7J

P2-1593

7J

P2-1593



4.11. I/O PCB

+5V

+5V+24VUV LAMP ONLED 8GND

MEDIA SENSOR1MEDIA SENSOR1MEDIA SENSOR1FEED LIMITLEFT SHUTTERRIGHT SHUTTERGND

J21. +5V2. MEDIA SENSOR33. MEDIA SENSOR24. MEDIA SENSOR15. FEED LIMIT

J61. N.C2. UV LAMP ON3. N.C4. N.C

J31. LEFT SHUTTER2. RIGHT SHUTTER3. GND

MEDIA SENSOR1

MEDIA SENSOR1

MEDIA SENSOR1

FEED LIMIT

LEFT SHUTTER

UV LAMP ON

RIGHT SHUTTER

MAIN BOARD J17

MAIN BOARD J18

CYLINDERSEN.

J3-2~3, J6-3 : SUB PCB J13

<I/O J1, J4 - MAIN J17, J18>

<I/O J1, J4 - MAIN J17, J18>

<I/O J3, J6 - SUB J13>

1

5

J2

1714J13 P41-5405 P41-5405

1

3

J3

J1

4

1J6

5045-4P

5045-3P

5045-5P

J4

LED1 LED2

LED3 LED4

LED5 LED6

LED7 LED8

J17

J18

5267-8P

5267-5P 5267-5P

5267-8P



4.12. TAKE UP PCB

CW_LED CCW_LED AUTO_LED ERROR_LED

5V CW_SW CCW_SW5V AUTO_SW5V ERROR_SW5V

1. GND2. +5V3. GND4. +5V5. N.C6. N.C7. N.C8. N.C9. DIR_CW_SW10. CW_LED11. DIR_CCW_SW12. CCW_LED13. AUTO_SW14. AUTO_LED15. ERROR_SW16. ERROR_LED

TAKE UP BOARDREV 0

REFILL PCB J18

<TAKEUP - REFILL J18>

AUTO/MANUALINDICATOR PCB

2

65

3WS

LC

REDD4

5111J

HRS-16P

2

65

4WS

Y

15

J18

HRS-16P

GREEND2 GREEND5GREEND3

2

65

1WS

WT

REDD1

2

65

2WS

LM



4.13. REFILL CONTROL PCB

S_LED_WT S_LED_LM S_LED_LC S_LED_Y S_LED_M S_LED_C S_LED_K S_LED_S

P_LED_WT P_LED_LM P_LED_LC P_LED_Y P_LED_M P_LED_C P_LED_K P_LED_S

S

1. SW_Y2. SW_M3. SW_C4. SW_K5. SW_LM6. SW_LC7. SW_WHITE8. SW_S9. +5V10. GND11. S_LED_Y12. S_LED_M13. S_LED_C14. S_LED_K15. S_LED_LM

16. S_LED_LC17. S_LED_WHITE18. S_LED_S19. +5V20. GND21. P_LED_Y22. P_LED_M23. P_LED_C24. P_LED_K25. P_LED_LM26. P_LED_LC27. P_LED_WHITE28. P_LED_S29. +24V30. GND

++

+++

++

+

++++

++++

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

V5+V5+V5+V5+V5+V5+V5++5V

S_WSK_WSC_WSM_WSY_WSCL_WSML_WSSW_WT

13J BCP LLIFER

UV NEO CONTROLREV.3

<REFILL J31 - CONTROL J18>

D15

2

65

SW3

CL

D13D11

2

65

SW4

Y

D7D5

2

65

SW5

M

D3

GREEN GREEN GREEN GREEN GREEN GREEN GREEN GREEND9

2

65

SW6

C

D16D14D12

2

65

SW7

K

HRS-30PJ189192 9

91 929

J31

HRS-30P

D10

D8

2

65

SW1

WT

D6

2

65

SW8

S

D4D2RED RED RED RED RED RED RED REDD1

2

65

SW2

ML



4.14. INDICATOR PCB

TW_YTPME_KNITW_LLUF_KNI

ML_YTPME_KNIML_LLUF_KNI

CL_YTPME_KNICL_LLUF_KNI Y_LLUF_KNI

M_YTPME_KNIM_LLUF_KNI

C_YTPME_KNIC_LLUF_KNI

K_YTPME_KNIK_LLUF_KNI

S_YTPME_KNIS_LLUF_KNI

Y_YTPME_KNI

TW_YTPME_KNI

TW_LLUF_KNI ML_LLUF_KNI CL_LLUF_KNI Y_LLUF_KNI M_LLUF_KNI K_LLUF_KNI S_LLUF_KNIC_LLUF_KNI

ML_YTPME_KNI CL_YTPME_KNI Y_YTPME_KNI M_YTPME_KNI C_YTPME_KNI K_YTPME_KNI S_YTPME_KNI

LANGIS_LLUF_KNIV5+

V5+

C.NV5+

DNG

V5+V5+V5+V5+V5+V5+V5+ V5+

ROSNES WOLF KNAT KNI HCAE

+

+

+

+

++++

+++ +++

+ -+

--

--

--

--

--

-

-

--

-

4J BCP LLIFER

ESU TON

REFILL_IN

DIC

ATO

RR

EV

.2

>4J ,1-71J FR - 31J ,11J DNI<

.GIS_YTPME_KNI

1-71J BCP LLIFER

>4J ,1-71J FR - 31J ,11J DNI<

DER8D DER8D

7J

P3-7625

K7J

P3-7625

K

NEERG5D NEERG5D

11J

P3-5405

11J

P3-5405

21J

P2-7625

21J

P2-7625

DEL71D DEL71DNEERG31D NEERG31D

8J

P3-7625

S8J

P3-7625

S

DER01D DER01D

31J

P2-7625

31J

P2-7625

2J

P3-7625

ML2J

P3-7625

ML

DER2D DER2D

3J

P3-7625

CL3J

P3-7625

CL

DER21D DER21D

4J

P2-7625

4J

P2-7625

11J

P3-1593

11J

P3-1593

4J

P3-7625

Y4J

P3-7625

Y

DER4D DER4D

NEERG1D NEERG1D

DER41D DER41D

NEERG9D NEERG9D

1J

P3-7625

TW1J

P3-7625

TW 5J

P3-7625

M5J

P3-7625

M

DER6D DER6D

NEERG3D NEERG3D

DER61D DER61D

6J

P3-7625

C6J

P3-7625

C

NEERG7D NEERG7D NEERG11D NEERG11D



4.15. DRIVER COMMUNICATION PCB

FEED

CARRIAGE

MAIN J9

MAIN J5

MAIN J12

CN

1B

1

CN

3

11

11

1

1

11

CN

1B

1

CN

3

11

CARRIAGE_SERVO

FEED_SERVO

GND

GND

GND

GND

INP

MOTOR DRIVER

24V+

J5

5267-8P

5267-6P

J6

5267-8P

J5

J12

5267-8P

J7

5267-2P

J4

5267-8P

J9

5267-4P

J3

5267-8P

Anapurna L XL Service Manual

Documents

Transcript of Anapurna L XL Service Manual