Anapurna L XL Service Manual

:Anapurna L/XL
Service Manual V1.0

Company Confidential
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:
Agfa Graphics. Septestraat 27 B-2640 Mortsel, Belgium Tel: (+)32 3 444 2111
Copyright 2007 Agfa Graphics, Belgium. All software and hardware described in this document are subject to change without notice.
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2007 V1.0 Company Confidential
Service Manual :Anapurna L/XL
Contents
About this Service Manual
............................................................................................................................. 0 - 1 1. Service Manual Overview ............................................................................................................................................. 0 - 1 2. Scope .................................................................................................................................................................................... 0 - 1 3. Related Documentation ................................................................................................................................................ 0 - 1
Chapter 1 Functional Description
......................................................................................................................................... 1 - 1
1. General Description ........................................................................................................................................................ 1 - 3 1.1. System Description ............................................................................................................................................ 1 - 3 1.2. Block Diagram ...................................................................................................................................................1 - 13 2. Safety Circuits .................................................................................................................................................................1 - 14 2.1. Emergency Stop Circuit ..................................................................................................................................1 - 14 2.2. Door Open Detection ......................................................................................................................................1 - 15 3. Power Distribution ........................................................................................................................................................1 - 18 3.1. Functional Description ...................................................................................................................................1 - 18 4. Compressed Air Distribution ......................................................................................................................................1 - 20 4.1. Functional Description ...................................................................................................................................1 - 20 5. Data flow ...........................................................................................................................................................................1 - 28 5.1. Functional Description ...................................................................................................................................1 - 28 5.2. Printed Circuit Boards .....................................................................................................................................1 - 28 6. Media Transport .............................................................................................................................................................1 - 29 6.1. Functional Description ...................................................................................................................................1 - 29 6.2. Printed Circuit Boards .....................................................................................................................................1 - 44 7. Ink Supply System ........................................................................................................................................................1 - 45 7.1. Functional Description ...................................................................................................................................1 - 45 7.2. Printed Circuit Boards .....................................................................................................................................1 - 54 8. Head Carriage Movement ...........................................................................................................................................1 - 55 8.1. Functional Description ...................................................................................................................................1 - 55 8.2. Printed Circuit Boards .....................................................................................................................................1 - 60 9. Print Head .........................................................................................................................................................................1 - 61 9.1. Functional Description ...................................................................................................................................1 - 61 9.2. Printed Circuit Boards .....................................................................................................................................1 - 65 10. UV Curing .......................................................................................................................................................................1 - 66 10.1. Functional Description .................................................................................................................................1 - 66 10.2. Printed Circuit Boards ..................................................................................................................................1 - 74 11. Programmable Logic controller (PLC) .................................................................................................................1 - 75 11.1. Functional Description .................................................................................................................................1 - 75 12. Anapurna Control Program ......................................................................................................................................1 - 80 12.1. Control Program .............................................................................................................................................1 - 80 12.2. Buttons used for Maintenance Purposes ..............................................................................................1 - 81 12.3. Setup Parameters ...........................................................................................................................................1 - 81 12.4. Test Menu .........................................................................................................................................................1 - 88 13. Working with White Ink - Guidelines ..................................................................................................................1 - 90 13.1. Printing Jobs without White Ink ...............................................................................................................1 - 90 13.2. Application requires no White Ink at All ...............................................................................................1 - 90 13.3. Putting White Ink into the Circuit ...........................................................................................................1 - 91 14. Printed Circuit Boards ...............................................................................................................................................1 - 95 14.1. MAIN PCB .........................................................................................................................................................1 - 95 14.2. FPGA PCB ....................................................................................................................................................... 1 - 102 14.3. HEAD PCB ...................................................................................................................................................... 1 - 108 14.4. REFILL PCB ..................................................................................................................................................... 1 - 117 14.5. CARTRIDGE PCB .......................................................................................................................................... 1 - 123
Service Manual :Anapurna L/XL 2007 V1.0 Company Confidential i
14.6. HEAD LIFT PCB ............................................................................................................................................. 1 - 127 14.7. ITV CONTROLLER PCB ............................................................................................................................... 1 - 133 14.8. SUB PCB ......................................................................................................................................................... 1 - 136 14.9. IF PCB .............................................................................................................................................................. 1 - 140 14.10. I/O PCB ........................................................................................................................................................ 1 - 144 14.11. TAKE UP PCB .............................................................................................................................................. 1 - 148 14.12. REFILL CONTROL PCB ............................................................................................................................. 1 - 150 14.13. INDICATOR PCB ........................................................................................................................................ 1 - 153 14.14. DRIVER COMMUNICATION PCB ......................................................................................................... 1 - 156
Chapter 2
Technical Features and Specifications
............................................................................................2 - 1
1. Overview ..............................................................................................................................................................................2 - 2 1.1. Anapurna's Print Quality ...................................................................................................................................2 - 2 1.2. Outstanding Printing Potential ......................................................................................................................2 - 2 1.3. Inspired Design ....................................................................................................................................................2 - 3 1.4. User Profile ............................................................................................................................................................2 - 3 2. Features ...............................................................................................................................................................................2 - 4 2.1. Borderless Printing .............................................................................................................................................2 - 4 2.2. Roll to Roll and Rigid Printing .......................................................................................................................2 - 4 2.3. Dual Board Printing ............................................................................................................................................2 - 4 2.4. White Color Printing ..........................................................................................................................................2 - 4 2.5. Status Signal Lamp .............................................................................................................................................2 - 4 2.6. Automatic Ink Filling System .........................................................................................................................2 - 5 2.7. UV Curing ...............................................................................................................................................................2 - 5 2.8. Changeable UV Lamps ......................................................................................................................................2 - 5 2.9. Exhausting System ..............................................................................................................................................2 - 5 2.10. Automatic Print Head Height .......................................................................................................................2 - 5 2.11. Easy and Quick Installation ..........................................................................................................................2 - 5 2.12. Simple Maintenance .......................................................................................................................................2 - 5 3. Specifications ....................................................................................................................................................................2 - 6 3.1. Print Technology ..................................................................................................................................................2 - 6 3.2. Head Technology .................................................................................................................................................2 - 6 3.3. Media .......................................................................................................................................................................2 - 7 3.4. Inks ...........................................................................................................................................................................2 - 8 3.5. Working Conditions ............................................................................................................................................2 - 9 3.6. Electricity ...............................................................................................................................................................2 - 9 3.7. RIP PC ................................................................................................................................................................... 2 - 10 3.8. Service PC ........................................................................................................................................................... 2 - 10 3.9. Anapurna L .......................................................................................................................................................... 2 - 11 3.10. Anapurna XL .................................................................................................................................................... 2 - 11
Chapter 3
Repair and Service
....................................................................................................................................................3 - 1
1. Safety Notes .......................................................................................................................................................................3 - 2 1.1. Warning/Caution/Note ....................................................................................................................................3 - 2 1.2. Emergency Stop ...................................................................................................................................................3 - 2 1.3. Handling UV Curable Ink ..................................................................................................................................3 - 3 1.4. UV Radiation .........................................................................................................................................................3 - 3 1.5. Electricity ...............................................................................................................................................................3 - 4 1.6. Maintenance Safety Instructions ..................................................................................................................3 - 4 1.7. MSDS Contents ....................................................................................................................................................3 - 5 2. Overview Safety Labels ..................................................................................................................................................3 - 6 3. Preparing for Service .......................................................................................................................................................3 - 8 3.1. Moving Head Carriage to Home or Purge Position .................................................................................3 - 8 3.2. Putting the print Engine in Service Mode .................................................................................................3 - 8
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4. Disassembly/Assembly of Major Components ..................................................................................................... 3 - 9 4.1. Disassembly/Assembly of the Air Pressure Panel Components ....................................................... 3 - 9 4.2. Disassembly/Assembly of the Media Transport System Components ........................................ 3 - 13 4.3. Disassembly/Assembly of the Ink Supply System Components at Refill Unit ........................ 3 - 24 4.4. Disassembly/Assembly of the Ink Supply System Components at Head Carriage Unit ...... 3 - 46 4.5. Disassembly/assembly of the Head Carriage Movement Components ...................................... 3 - 53 4.6. Disassembly/Assembly of the Print Head Components ................................................................... 3 - 60 4.7. Disassembly/Assembly of the UV Curing System Components .................................................... 3 - 72 5. Installing the PCI I/O Card ....................................................................................................................................... 3 - 83 5.1. Location ............................................................................................................................................................... 3 - 83 5.2. Replacement of the PCI I/O Card .............................................................................................................. 3 - 84 6. Adjustment and Alignment Procedures ............................................................................................................... 3 - 89 6.1. Vacuum Blower Adjustments ...................................................................................................................... 3 - 89 6.2. Print Head Adjustments ................................................................................................................................. 3 - 91 6.3. Conveyer Belt Alignment .............................................................................................................................. 3 - 97 6.4. Head Base Alignment ..................................................................................................................................... 3 - 99 6.5. Lamp house Alignment ................................................................................................................................3 - 103
Chapter 4
Preventive Maintenance
................................................................................................................................... 4 - 1
1. Maintenance Schedule .................................................................................................................................................. 4 - 2 2. Print Media Unit Maintenance ................................................................................................................................... 4 - 5 2.1. Guidelines and Specific Safety Instruction ............................................................................................... 4 - 5 2.2. Conveyer Belt ....................................................................................................................................................... 4 - 6 2.3. Vacuum Holes ...................................................................................................................................................... 4 - 9 2.4. LM Guide ............................................................................................................................................................. 4 - 10 2.5. LM Blocks ........................................................................................................................................................... 4 - 11 2.6. Carriage Belt (S5M Belt) ................................................................................................................................ 4 - 13 2.7. S3M Belt .............................................................................................................................................................. 4 - 16 2.8. Linear Scale Encoder ...................................................................................................................................... 4 - 24 2.9. Bearings Print Media Unit ............................................................................................................................ 4 - 33 2.10. Waste Tank ...................................................................................................................................................... 4 - 35 3. Head Carriage Unit Maintenance ............................................................................................................................ 4 - 36 3.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 36 3.2. Print Head ........................................................................................................................................................... 4 - 38 3.3. UV Lamp Box / UV Lamp Box Housing .................................................................................................... 4 - 46 3.4. Head Carriage .................................................................................................................................................... 4 - 53 4. Refill Unit Maintenance ............................................................................................................................................. 4 - 54 4.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 54 4.2. Air filter 6 Color and White .......................................................................................................................... 4 - 55 4.3. Ink Filter .............................................................................................................................................................. 4 - 56 5. Purge Unit Maintenance ............................................................................................................................................ 4 - 63 5.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 63 5.2. Purge box ............................................................................................................................................................ 4 - 63 6. Home Unit Maintenance ............................................................................................................................................ 4 - 65 6.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 65 6.2. Home box ............................................................................................................................................................ 4 - 65 7. Safety Circuit .................................................................................................................................................................. 4 - 67 7.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 67 7.2. Emergency Stop Circuit ................................................................................................................................. 4 - 67 8. Air Tank Maintenance ................................................................................................................................................. 4 - 69 8.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 69 8.2. Air Tank ................................................................................................................................................................ 4 - 69 9. Air Pressure Panel Maintenance ............................................................................................................................. 4 - 70 9.1. Guidelines and Specific Safety Instruction ............................................................................................ 4 - 70 9.2. Air Pressure Panel ............................................................................................................................................ 4 - 70
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10. Engine ............................................................................................................................................................................. 4 - 75 10.1. Guidelines and Specific Safety Instruction .......................................................................................... 4 - 75 10.2. Engine Level .................................................................................................................................................... 4 - 75
Chapter 5
Troubleshooting
............................................................................................................................................................5 - 1
1. Troubleshooting Based on Visible Problems .........................................................................................................5 - 2 1.1. Troubleshooting Based on Tower Lamp Indications ..............................................................................5 - 2 1.2. Troubleshooting Based on Mechanical and/or Electrical Problems ................................................5 - 2 2. Troubleshooting Based on UI Error Messages .................................................................................................... 5 - 13 3. Troubleshooting based on Image Quality Control ............................................................................................ 5 - 14 3.1. Encoder (MARK) Error ...................................................................................................................................... 5 - 14 3.2. Black Strips ......................................................................................................................................................... 5 - 15 3.3. Waves on the Media Surface ....................................................................................................................... 5 - 15 3.4. Only UNI MODE Output ................................................................................................................................. 5 - 16 3.5. Image Quality Failure ..................................................................................................................................... 5 - 16 3.6. Spray on your Image ....................................................................................................................................... 5 - 18 3.7. Print Length Exceeds Maximum Platen Length .................................................................................... 5 - 18 4. UV Lamp Troubleshooting .......................................................................................................................................... 5 - 20 5. Servo Motor Driver Troubleshooting ...................................................................................................................... 5 - 21
Chapter 6 Chapter 7
Glossary Annex
..................................................................................................................................................................................6 - 1
.........................................................................................................................................................................................7 - 1
1. Pneumatic Diagrams .......................................................................................................................................................7 - 3 1.1. Pneumatic Diagram ............................................................................................................................................7 - 5 2. Electrical Diagrams ..........................................................................................................................................................7 - 7 2.1. Main Power Distribution in the Electrical Circuit Panel .......................................................................7 - 9 2.2. Power Supply Distribution - 3 Phase with neutral with ground star 380V (EU) ....................... 7 - 11 2.3. Power Supply Distribution - 3 Phase no neutral with ground delta 208-240V (US) ............... 7 - 13 2.4. UV Lamp Power Box Connections .............................................................................................................. 7 - 15 2.5. UV Lamp Power Circuit .................................................................................................................................. 7 - 17 2.6. UV Lamp Head Part .......................................................................................................................................... 7 - 19 2.7. UV Lamp Power Cables .................................................................................................................................. 7 - 21 3. Programmable Logic Controller (PLC) Block Diagram .................................................................................... 7 - 23 3.1. Main PLC ............................................................................................................................................................. 7 - 25 3.2. UV Lamp PLC ...................................................................................................................................................... 7 - 27 4. Printed Circuit Boards .................................................................................................................................................. 7 - 29 4.1. Total PCB Diagram Layout ............................................................................................................................ 7 - 31 4.2. MAIN PCB ............................................................................................................................................................ 7 - 33 4.3. FPGA PCB ............................................................................................................................................................ 7 - 35 4.4. HEAD PCB ............................................................................................................................................................ 7 - 37 4.5. REFILL PCB .......................................................................................................................................................... 7 - 39 4.6. CARTRIDGE PCB ................................................................................................................................................ 7 - 41 4.7. HEAD LIFT PCB .................................................................................................................................................. 7 - 43 4.8. ITV CONTROLLER PCB ..................................................................................................................................... 7 - 45 4.9. SUB PCB ............................................................................................................................................................... 7 - 47 4.10. IF PCB ................................................................................................................................................................. 7 - 49 4.11. I/O PCB ............................................................................................................................................................. 7 - 51 4.12. TAKE UP PCB ................................................................................................................................................... 7 - 53 4.13. REFILL CONTROL PCB ................................................................................................................................... 7 - 55 4.14. INDICATOR PCB .............................................................................................................................................. 7 - 57 4.15. DRIVER COMMUNICATION PCB ............................................................................................................... 7 - 59
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About this Service Manual

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

Functional Description
This chapter describes how the Anapurna L/XL functions.

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

This chapter describes the preventive maintenance procedures for the Anapurna L/XL.
This chapter describes repair and service procedures for the Anapurna L/XL.
Troubleshooting
This chapter describes how you can recognize and solve mechanical, electrical and image problems you could encounter when printing with the Anapurna L/XL.
Glossary
This chapter describes definitions and abbreviations used throughout the Service Manual which you may not be familiar with.
Annex
This chapter gives an overview of the diagrams and printed circuit boards of the Anapurna L/XL. Finally, you can find a spare parts list.
2. Scope
The Service Manual is intended to provide all necessary information for the service technician to maintain the Anapurna L/XL so that the system runs smoothly, professionally and under optimum conditions.
3. Related Documentation
The following document can be referred to for more information:
! ! !
Anapurna L/XL Pre-Site Survey Anapurna L/XL Installation Guide Anapurna L/XL Operator Manual
0-1
ABOUT THIS SERVICE MANUAL
RELATED DOCUMENTATION
0-2
CHAPTER
Functional Description
This chapter describes how the Anapurna L/XL functions. 1. General Description ............................................................................................................................................... 1 - 3 1.1. System Description .................................................................................................................................. 1 - 3 1.2. Block Diagram ........................................................................................................................................ 1 - 13 2. Safety Circuits ....................................................................................................................................................... 1 - 14 2.1. Emergency Stop Circuit ....................................................................................................................... 1 - 14 2.2. Door Open Detection ........................................................................................................................... 1 - 15 3. Power Distribution .............................................................................................................................................. 1 - 18 3.1. Functional Description ........................................................................................................................ 1 - 18 4. Compressed Air Distribution ........................................................................................................................... 1 - 20 4.1. Functional Description ........................................................................................................................ 1 - 20 5. Data flow ................................................................................................................................................................ 1 - 28 5.1. Functional Description ........................................................................................................................ 1 - 28 5.2. Printed Circuit Boards .......................................................................................................................... 1 - 28 6. Media Transport ................................................................................................................................................... 1 - 29 6.1. Functional Description ........................................................................................................................ 1 - 29 6.2. Printed Circuit Boards .......................................................................................................................... 1 - 44 7. Ink Supply System .............................................................................................................................................. 1 - 45 7.1. Functional Description ........................................................................................................................ 1 - 45 7.2. Printed Circuit Boards .......................................................................................................................... 1 - 54 8. Head Carriage Movement ................................................................................................................................ 1 - 55 8.1. Functional Description ........................................................................................................................ 1 - 55 8.2. Printed Circuit Boards .......................................................................................................................... 1 - 60 9. Print Head .............................................................................................................................................................. 1 - 61 9.1. Functional Description ........................................................................................................................ 1 - 61 9.2. Printed Circuit Boards .......................................................................................................................... 1 - 65 10. UV Curing ............................................................................................................................................................. 1 - 66 10.1. Functional Description ...................................................................................................................... 1 - 66 10.2. Printed Circuit Boards ....................................................................................................................... 1 - 74 11. Programmable Logic controller (PLC) ....................................................................................................... 1 - 75 11.1. Functional Description ...................................................................................................................... 1 - 75 12. Anapurna Control Program ............................................................................................................................ 1 - 80 12.1. Control Program .................................................................................................................................. 1 - 80 12.2. Buttons used for Maintenance Purposes ................................................................................... 1 - 81 12.3. Setup Parameters ............................................................................................................................... 1 - 81 12.4. Test Menu .............................................................................................................................................. 1 - 88 13. Working with White Ink - Guidelines ....................................................................................................... 1 - 90 13.1. Printing Jobs without White Ink ................................................................................................... 1 - 90 13.2. Application requires no White Ink at All ................................................................................... 1 - 90 13.3. Putting White Ink into the Circuit ................................................................................................ 1 - 91 14. Printed Circuit Boards ..................................................................................................................................... 1 - 95 14.1. MAIN PCB .............................................................................................................................................. 1 - 95 14.2. FPGA PCB ............................................................................................................................................. 1 - 102 14.3. HEAD PCB ............................................................................................................................................ 1 - 108 14.4. REFILL PCB .......................................................................................................................................... 1 - 117 14.5. CARTRIDGE PCB ................................................................................................................................ 1 - 123 14.6. HEAD LIFT PCB ................................................................................................................................... 1 - 127 14.7. ITV CONTROLLER PCB ..................................................................................................................... 1 - 133 14.8. SUB PCB ............................................................................................................................................... 1 - 136 14.9. IF PCB .................................................................................................................................................... 1 - 140
1-1
FUNCTIONAL DESCRIPTION
14.10. 14.11. 14.12. 14.13. 14.14.
I/O PCB ............................................................................................................................................. TAKE UP PCB ................................................................................................................................... REFILL CONTROL PCB ................................................................................................................... INDICATOR PCB .............................................................................................................................. DRIVER COMMUNICATION PCB ...............................................................................................
1 - 144 1 - 148 1 - 150 1 - 153 1 - 156
1-2
GENERAL DESCRIPTION
1. General Description
1.1. System Description
1.1.1. General View Of the Anapurna L/XL
The illustration below indicates the front, rear, left and right side of the Anapurna L/XL.
Figure 1.1: Notation conventions
Rear
Pri Me nt Transpdia o Direction rt
Left
Right
Fron
The front, rear, left and right side are defined according to the opposite transport direction of the print media.
! !
The front side of the Anapurna L/XL corresponds with the print media output side. The rear side of the Anapurna L/XL corresponds with the print media input side.
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.
1-3
GENERAL DESCRIPTION
1.1.2.1. Front view with printer parts and locations

Figure 1.2: Front view Anapurna XL
Front cover Head carriage unit Tower lamp Vacuum control Emergency stop Exhaust system
Exhaust system Emergency stop
Ink temperature and ink vacuum control Purge unit Print media unit Conveyer belt Home unit Refill unit
1.1.2.2. Rear view and composition

Figure 1.3: Rear view Anapurna XL
Emergency stop Rear cover Vacuum control Emergency stop
Compressed air inlet
Vacuum table
Roll to roll system
1-4
GENERAL DESCRIPTION
1.1.2.3. Purge unit

!
Purging part. Accessible via the purge front door and the purge rear door.
purging part view (front)
purging part view (rear)
Main box left Located behind the main box left side door.
! !
Feed servo motor driver (1). UV lamp power box (=UV system power supply) (2).
1-5
GENERAL DESCRIPTION
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 2 3 4
UV lamp Purge switch button Ink valve Print head
5 6 7 8
Sub ink tank (6 colors) Sub ink tank (white) Head base plate Cleaning solution valve
1-6
GENERAL DESCRIPTION
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

11 2 1 1 2 3 8 4 7 4
10 6 9 5
1 2 3 4 5 6
!
Emergency button Vacuum control Media set (media register pins) Media fixing bar (front and rear) Air inlet + air regulators Head base temperature control
7 8 9 10 11
UV lamp control (Left and right) Monitor Take up control system Ink temperature and ink vacuum control Tower lamp
Console. Digital system that controls the Anapurna L/XL. It consists of a built-in monitor (UI) and a control PC.
Control system. Indicators and control buttons to control the head/ink quality parameters, the paper supply system, the vacuum system, the UV lamps and finally a tower light to indicate alarm conditions.
1-7
GENERAL DESCRIPTION
Main box right Located behind the control system cover. Accessible via the ink supply door.
! ! !
Control box, SMPS panel, PLC.
1 2 3
!
PLC Control box Stirrer timer (white)
4 5
Sensor controller SMPS panel
Components behind home rear door

! ! ! !
Ink supply chain / hose fixing guide(1), Shock absorber (3), Limit Switch (4), Carriage servo motor driver (2)
3 1 2
1-8
GENERAL DESCRIPTION
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
1-9
GENERAL DESCRIPTION
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.
RED 1
YELLOW 2
GREEN 3 BLUE 4
WHITE 5
Color 1 2 3 Red Yellow Green
Status ON Flashing + Beeping Flashing + Beeping ON Flashing + Beeping
Function Power ON Air pressure below 0.3 MPa Low ink level (at main tank) Ready state -> UV lamp curing available Overheat Lamp power off Media register pins down Full waste tank (> 3.5 litre) Vacuum in use Overflow (of ink) in sub air tank
4 5
Blue White All colors
ON Flashing + Beeping ON Flashing + Beeping
For more information about how to solve the alarm indications (flashing + beeping), refer to Troubleshooting Based on Tower Lamp Indications on page 5-2 (chapter Troubleshooting).
1 - 10
GENERAL DESCRIPTION
1.1.3. Covers and Doors

Figure 1.4: Front side doors/covers
1 2 3
Purge front door Main box front cover Front cover
4 5
Monitor cover Control system cover
Figure 1.5: Rear side doors/covers
3 4 1
2 5
1 2 3
Purge rear door Main box rear door Rear cover
4 5
Home rear door Air pressure cover
1 - 11
GENERAL DESCRIPTION
Figure 1.6: Left side doors/covers

1
1 2
Purge top door Purge left side door
Main box left side door
Figure 1.7: Right side doors/covers
1 2
Home right side door Ink supply door
3 4
Ink tank indicator cover Ink Refill system cover
1 - 12
GENERAL DESCRIPTION
1.2. Block Diagram

The illustration below shows the total system diagram. The printed circuit boards (PCB) are indicated in yellow.
TAKE UP MOTOR
WASTE TANK OVER FLOW SENSOR
SUB INK TANK FLOAT SENSOR
SUB SOLUTION TANK FLOAT SENSOR
PRESSURE SENSOR
TAKE UP PCB
REFILL PCB ITV CONTROLLER PCB ITV

REFILL CONTROL PCB
NEGATIVE PRESSURE CONTROL
ZERO GAIN CONTROL
MAIN INK TANK INDICATOR PCB
HEAD PCB
MAIN PCB
FEED BACK ON/OFF
FPGA PCB
MEMORY
INTERFACE CIRCUIT
HEATING 120VDC
FPGA CIRCUIT
CONTROL CIRCUIT
RS 232
PC
I/O PCB DRIVER COMM. PCB
CARTRIDGE PCB
PC FOR RTL FILE (RIPPING)
HEAD LIFT PCB

UP/DOWN SENSOR UP/LOCK SOLENOID
SUB PCB
FEED SERVO MOTOR DRIVE
CARRIAGE SERVO MOTOR DRIVE
PRINT HEAD
STEP MOTOR
FEED MOTOR
CARRIAGE MOTOR
IF PCB
P L C (K7M-DR60S)
PID CONTROLLER
PUSH ROLLER (FRONT/REAR) UV LAMP CONTROL TOWER LAMP CONTROL MEDIA STOP CONTROL
UV LAMP
1 - 13
SAFETY CIRCUITS
2. Safety Circuits
2.1. Emergency Stop Circuit
The system is provided with 4 emergency stops, two at the front side and two at the back side.The emergency stop circuit is activated when one of the emergency buttons is activated. When the emergency button is activated all systems are cut off from the mains, but certain parts remained powered.
3 - PHASE AC3 8 0 V, 5 0 / 6 0 Hz PE
P1 P2 P3
P1 1 P2 2 P2 3
P2 2 N
PC- SM S P 300W PC S/ W
OPERATOR PC
AWG # 1 2 VCTF CABL E ( BL ACK)
P2 2 N
P SM S # 8 +2 4 VDC GND
RESTART
2
E MO 1
MC #1(50A)
AWG # 1 2 VCTF CABL E ( BL ACK) DC 2 4 V
M -A C
E MO 2
E MO 3
E MO 4
2 5
3 - PHASE AC2 0 8 ~2 4 0 V, 5 0 / 6 0 Hz PE
P1 P2 P3
EL CB # 1 ( 3 - PHASE AC3 8 0 V, 5 0 A)
P1 1 P2 2 P2 3
( 1) ( 4)
P2 2 P1 1
PC- SM S P 300W PC S/ W
OPERATOR PC
AW # 1 2 VCTF CABL E G ( BL ACK)
( 5)
P1 1
( 3)
P2 3
P SM S # 8 +2 4 VDC GND AW # 1 2 VCTF CABL E G ( BL ACK) DC 2 4 V
RESTART
2
E MO 1
MC - A
E MO 2
E MO 3
E MO 4
MC #1(50A)
2 5
In case of emergency, push the emergency stop button immediately to stop the Anapurna L/XL. The emergency button cuts off the power, except for the PC and SMPS8.
By pulling the emergency button back, the emergency stop is cancelled. The Anapurna L/XL must be restarted.
1 - 14
SAFETY CIRCUITS
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
1
!
Door sensor front cover
Door sensor rear cover
Waiting mode When the carriage is at its home or purge position and you start a print job with open front or rear cover, a door open error appears.
Printing mode For engine < V1.1: When you open the front or rear cover during printing, the head carriage will move to the home position after finishing the swath. The print will be cancelled and the UV lamps will go off and the UV lamp shutter will be closed automatically. For engines V1.1 and V1.2: When you open the front or rear cover during printing, the head carriage stops, the UV lamps will go off, the UV lamp shutter will be closed and the UV cooling will start automatically.
WARNING: Opening the covers during printing will result in a cancelled print. Only open the covers in emergency situations. Head carriage movements and printing can only be done with closed covers.
1 - 15
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
SENSOR CONTROLLER
2.2.2.1. Connectors
Connectors Name and Function PA10-U SENSOR CONTROLLER Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Nr. Pin Name ACI NPUT L51 OUT NC OUT COM OUT NO ACI NPUT L52 N.C N.C N.C SEN#1 DC12V SEN#1 GND IN 1 O.C OUT 1 SEN#2 DC12V SEN#2 GND IN 2 O.C OUT 2 REAR SENSOR PR12-4DN brown DC12-24V blue GND black SIGNAL OUT 1 2 3 FRONT SENSOR PR12-4DN brown DC12-24V blue GND black SIGNAL OUT 1 2 3 MAIN PCB MAIN PCB SMPS#6 J10 J10 4 5 7 PCB or Part SMPS#6 Connected to Conn. 6 Pin
1 - 16
SAFETY CIRCUITS
2.2.2.2. Leds
LED OUT 1 OUT 2 IN 1 IN 2 POWER Type Color red red orange red green Indication Not in use Not in use Front door Rear door 220V AC
2.2.2.3. Switches
Switch AND/OR Setting AND Description Select AND or OR for IN1 and IN2 inputs Note: Switching this dipswitch from AND to OR means that the carriage movement is enabled when only ONE door is closed (for service purposes only). NORM/INV NORM/FLANK NORM NORM Selection switch to invert the inputs. Operating in a true/false mode Selection switch for a true\false (NORM) situation or a flank trigger (FLANK). With a flank trigger a time setting is needed (TIME SET and TIME ANALOG). MODE TIME SET SA = ON SB, SC and SD = OFF T1 = ON T2 = OFF With 2 switches you can set 4 time ranges, between 0.01 - 0.1 - 1 - 10 -100s. Here the range from 0.1 - 1s is used. Fine adjustment for TIME SET switches
TIME ANALOG
1 - 17
POWER DISTRIBUTION
3. Power Distribution
3.1. Functional Description
3.1.1. Electrical Circuit Panel
Figure 1.10: Electrical circuit panel
4 5 6
1 7 2
1 2 3 4
Main power inlet terminal block 1st circuit breaker (MCCB #1, main circuit braker 50A) Noise filter Main MC (MC #1) - Closed by Start button - Open when activating one of the emergency stops. 2nd circuit breaker (MCCB#2 to #6) MCCB #2, Lamp MCCB #3, Ring blower 1 MCCB #4, Ring blower 2 MCCB #5, Motor driver MCCB #6, Control Rack
6 7 8 9
Ring blower #1 MC - Ring blower switch 1st step on, Circuit Close Ring blower #2 MC - Ring blower switch 2nd step on, Circuit Close SMPS8 - supply power (+24VDC) to main MC and FAN in power distribution panel Terminal block Routing emergency switch, start button and Main MC
1 - 18
POWER DISTRIBUTION
3.1.2. System Needed Power
SYSTEM N EED P O W ER
Model : :ANAPURNA in le t p o w e r V olage: t 3P H A S E 380V f requency 50/60H z 2 S E R V O M O TO R 3P hase 380V -50H z 3 R I G B LO W E R N 3P hase 380V -60H z 3P hase 380V -50H z 3P hase 380V -60H z 3 4 5 LA M P C O M PRESSO R EXHAUST Tot al V :230V / F :50H z
:ANAPURNA L :ANAPURNA XL :ANAPURNA L :ANAPURNA XL
No
ite m
F re q u e n c y
d e ta ils PC
o u tp u t vo lta g e (V )
c u rre n t(A ) o w e r(K w ) Q 'ty P 24 120 24 24 S ub-Tot al 220 220 220 12.5 2 5 3 2 2 3.6 3.8 3.7 3.8 3.7 20 2 2 0.3 0.24 0.12 0.072 0.44 0.44 0.8 1.5 1.75 1.5 1.75 4.4 1 2 2 2 2 1 1 2 2 1
M A X (K w ) 0.3 0.48 0.24 1.5 2.5 0.88 0.44 0.8 3 3 4.4 0.44 0.44 11.66 12.02
w e ig h te d va lu e
C O N TR O L R A C K
V :230V / F :50H z
SM PS
100%
380-50H z 220-60H z 220-50H z 220-60H z 220 220 220
* M ot pem i bl volage: A C 200V ~ A C 240V (50H z/60H z) pre or ssi e t volage t i requi t est s red.
0.44 1 0.44 1 :ANAPURNA L :ANAPURNA XL
11.66 13.42
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 713 (chapter Annex).
1 - 19
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).
Main Air Press. 0.4 - 0.8 MPa Max. Press. 2MPa Capacity 0.005M 3
Air Tank
R P A
Setting Press UV lamp 0.10 - 0.15 MPa
Lamp Shutter Left/Right Cylinders
Media set Cylinders
Setting Press 0.6 MPa Waste Tank Over-flow Sig. 0.3 - 0.7 MPa Purge Sig.
Air Filter # 1
A B
4f Air Tube
EA P EB
I/O PC B Sig. I/O PC B Sig.
EA P EB
EA P EB
Media Hold Front/Rear Cylinders

OUT
IN
EA P EB
Carriage Part
Air Filter # 2
A R P
E/P Regulator
SU P OU T
P R
Setting Press Carriage 0.3 MPa

P CB
Check valve
Check valve
SOLUTION SUB-TANK
SOLUTION BAR
Purge S/W Sig.
MAIN WASTE INKTANK PSE531-M5 Pressure Sig. Float Sensor Float Sensor Sig. Sig.
P
Float Sensor Sig.
VACUUM EJECTOR
R P
SUB AIR TANK
INK TANK
Setting Press Carriage 0.03 MPa Purge S/W Sig.
1 - 20
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
2 3 4 5 6 7
0.40 - 0.80 MPa 0.10 - 0.15 MPa
0.30 MPa 0.15 MPa
1 2 3 4
Main air pressure inlet port Main air inlet pressure indicator Main regulator (0.4-0.8 MPa) Lamp shutter regulator (0.10 MPa0.15 MPa) Air filter #1
5 6 7 8
1st regulator at carriage div. (0.3 MPa) Air filter #2 2nd regulator at carriage div. (0.15 MPa) Water drain out
1 - 21
4.1.3. Carriage Part

4.1.3.1. Head carriage unit - pneumatic flow key parts
Figure 1.13: Rear side head carriage unit
1 2 34
12
10 11
1 2 3 4 5 6
!
Sub air tank and ink overflow tank Air relief valve sub air tank (speed V/V (AS1001F-06) + air filter) Pressure sensor PSE531-M5-L Drain cock (when overflow) Solution tank Lamp shutter solenoid valves
7 8 9 10 11 12
Solution valve Electro-pneumatic regulator ITV2010 Vacuum ejector INO-4336-4 Purge air valve VT301V-025GB Purge air valve VT301-025GB ITV2010 display
Purge air valve. Operational when purging (push purge switch at the front of the head carriage unit).
! !
VT301V-025GB (Figure 1.13, item 10), range -0.1 to 1 bar. VT301-025GB (Figure 1.13, item 11), range 0 to 10 bar.
Electro-pneumatic regulator ITV2010 (Figure 1.13, item 8 and 12). The IVT controller displays the overpressure (default + 0.30 mbar or lower, in case the vacuum pressure is set to -0.032MPa) which is sent through a venturi tube to create the desired negative pressure setting in the sub air tank. The pressure sensor PSE531-M5-L (Figure 1.13, item 3) constantly measures the negative pressure in the sub air tank and the read-out is sent back to the IVT controller. Base on this read-out, the ITV controller adjusts the flow pressured air through the venturi tube to compensate.
1 - 22
Fluctuations in the meniscus vacuum source (negative pressure) should be minimized. The air relief (Figure 1.13, item 2) on the top of the sub air tank regulates the strength of the negative pressure inside the sub air tank. NOTE: The other items of Figure 1.13 are discussed in other paragraphs.
Figure 1.14: Front side head carriage unit
Purge switch
Purge regulator (0.03 MPa)
1 - 23
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
1
!
Main air tank
Drain cock
When the air pressure at the main air tank is lower than 0.3 MPa, the following can occur:
! ! !
Red tower lamp start flashing and beeping. Refill system stops to prevent excessive ink outlet from print head. Head carriage is forced automatically to the purge position to prevent damages on the print head.
When the air pressure at the main air tank is higher than 0.7 MPa, the system automatically ejects the pressure. Drain water from the main air tank (1) by opening the drain cock (2).
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 functionality of the lamp shutter.
1 2
Lamp shutter solenoid valves Lamp shutter open
Lamp shutter closed
1 - 24
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.
1 - 25
4.1.6.2. Functioning
The illustration below describes the functioning of the media set cylinders and the media hold front/ rear cylinders.
Figure 1.16: Functioning media set cylinders and the media hold front/rear cylinders
HOME UNIT
5 Front
Front NO
GND
Back NO
6
A1 A2 P 040 P 051 P 052 P 04E
24 Vdc Gnd
PLC
Rear
3 Level Switch Media Set NO NC
A1 A2
Main Air Supply
P 002 P 000 Front Back NO
Main Air Supply

A1 A2
NO P 018 P 019
Rear
Main Air Supply 8

P 04A
A1
A2
Front
Main Air Supply 7
1 - 26
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. CAUTION: When controlling the regulator, in case of no pressure changes, check the connection of the hose and setting values of the regulators. 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) NOTE: Make sure the power part does not make contact with water.
1 - 27
DATA FLOW
5. Data flow
2
FPGA PCB
MEMORY
MAIN PCB
Anapurna PC
1
INTERFACE CIRCUIT
HEAD PCB
FPGA CIRCUIT
CONTROL CIRCUIT
RS 232
PC FOR RTL FILE (RIP PC)
CARTRIDGE PCB
6
PRINT HEAD
The table below briefly describes the image data flow:

Number Data Flow Connection 1 2 3 4 5 The image files (.rtl) generated on the RIP station are sent to the Anapurna PC via a network cable. Direct connection between PC main board and the FPGA PCB via PCI I/O card. The image data is transferred via a direct connection from the FPGA PCB to the MAIN PCB. The ripped data is sent from the MAIN PCB (J16, pin 1-16) to the HEAD PCB (J9, pin 1-16) 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.
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
1 - 28
MEDIA TRANSPORT
6. Media Transport
6.1.1. General Information
TAKE UP MOTOR
PRESSURE SENSOR
TAKE UP PCB

REFILL CONTROL PCB
ZERO GAIN CONTROL
HEAD PCB
MAIN PCB
FEED BACK ON/OFF
FPGA PCB
MEMORY
INTERFACE CIRCUIT
HEATING 120VDC
FPGA CIRCUIT
CONTROL CIRCUIT
RS 232
PC
CARTRIDGE PCB
HEAD LIFT PCB

SUB PCB
PRINT HEAD
STEP MOTOR
FEED MOTOR
CARRIAGE MOTOR
IF PCB
P L C (K7M-DR60S)
PID CONTROLLER
UV LAMP
1 - 29
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.
1 2
Feed servo motor (400W) Vacuum blower
3 4
Polyester woven conveyer belt Reduction gear motor
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 2
NOTE: When you insert the media fixing roll bar (1), make sure: the ball bearing is inside the guide (2), the media fixing roll bar is always horizontally levelled between the left and right frame when lowering the bar. NOTE: For more information about the media fixing roll bar, refer also to Media Set Cylinders and Media Hold Front/Rear Cylinders on page 1-25.
1 - 30
MEDIA TRANSPORT
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.
NOTE: Be aware that the vacuum (push) button at the home rear side is not connected (internal connection) with the vacuum (3 level) switch at the home front side (refer to Figure 1.18). the lamp in the push button (home rear side) is directly connected to the lamp tower, the lamp in the green switch (home front side) is connected to the switch. So if you switch the blowers on using the front switch, the lamp behind the switch is illuminated. If you switch on the blowers using the rear push button, the lamp behind the front switch is not illuminated.
NOTE: For more information about the vacuum blowers, refer to Vacuum on page 1-31.
6.1.3. Vacuum
6.1.3.1. Vacuum Blower - General Information
Two adjustable vacuum air pumps hold the media on the print table during printing and transport.
Figure 1.17: Vacuum air pump - parts
1 2 3
Vacuum blower Air controller with air relief valve Silencer
4 5
Compressed air connection Electrical connection
1 - 31
MEDIA TRANSPORT
The vacuum blower is set according to the engine configuration, star connection (Europe) or delta connection (USA).
The air relief valve is set according to the engine configuration (50 Hz or 60 Hz). Information can be found on the identification plate on top of the vacuum blower. The rated current 3.8A (50Hz engine) or 6.7A (60Hz engine).
1 - 32
MEDIA TRANSPORT
6.1.3.2. Functioning
The illustration below describes the functioning of the vacuum blowers.
Figure 1.18: Functioning vacuum blowers
L1 L2 L3
HOME UNIT
24Vdc Gnd
0 1 2
Front
3 Level Switch Front Panel
NO Gnd A2 A1 11 12 A1 Relay #2 24 Vdc A2 34 NC
Step 1
NC NO 0 1 2
Step 2
NC
NO 0 1 2
31
PLC
41 42 4B 04 05 Gnd
Step 3
NC NO
Rear
Push button Back Panel
Gnd
A2
A1
11 12
A1 Relay #3 A2
41
0C
24 Vdc
44
NOTE: For more information about the use of the vacuum blowers, refer to Vacuum Plate Usage on page 1-31.
1 - 33
MEDIA TRANSPORT
6.1.4. Roll to Roll Media

6.1.4.1. Auto Feeding System
Front side Rear side
2 4
1 3
1 2
Tension roll bar Front media roll bar
3 4
Rear media roll bar Rubber roll bar
For information about mounting the roll bars of the auto feeding system, refer to the paragraph Installing the Roll Bars of the Roll to Roll System of the Installation Manual. The auto feeding system has 2 tension bars (in the form of gear type). Holding the media under a constant tension, those tension bars prevent distortion of and waves on the media, so stable and qualified print can be acquired. NOTE: When you insert the tension roll bar, make sure: the ball bearing is inside the guide, the tension roll bar is always horizontally levelled between the left and right roll bar bracket when lowering the bar.
1 - 34
MEDIA TRANSPORT
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
Take-up Motor Box
! ! ! !
(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 - 35
MEDIA TRANSPORT
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 printable width of the roll. Use the table below to check whether you use the correct loading procedure:
ti
Table 1.1
Loading a print medium roll Media width Load procedure Load along the dark blue border of the printing table Load in the middle of the printing table Load along the dark blue border of the printing table Load in the middle of the printing table
Anapurna L
1,30 m - 1,58 m (max width) < 1,30 m (20% of max width)
Anapurna XL
2,00 m - 2,48 m (max width) < 2,00 m (20% of max width)
1 - 36
MEDIA TRANSPORT
! 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.
Rear media roll bar with movable clamping flange
Flange with black turning knobs
2 Remove one of the movable flanges by unscrewing the black turning knob. 3 Slide the print medium roll over the rear media roll bar. 4 Mount the flange. 5 Put both flanges on the proper position according to the width of the print medium roll and mount the black turning knobs again (refer to Table 1.1).
!
If the print media roll is smaller than 20% of the maximum printable size, load the print media in the middle of the rear media roll bar and proceed with step 6. Otherwise, load the print medium roll to the far end of the rear media roll bar and proceed with step 7.
6 In case the print medium roll is positioned in the middle of the rear media roll bar, the print media is not positioned in the beam of the media detection signal sensor. 6.1 Hang a piece of media core over the tension roll bar and position the core in the beam of the media detection signal sensor. As a result the media will be detected and will provide the best tension onto the system. CAUTION: If you do not use the media core, the tension roll bar will be lifted out of its position .
1 - 37
MEDIA TRANSPORT
W RONG
6.2 Proceed with step 8.
OK
7 In case the print medium roll is positioned to the far end of the rear media roll bar, always use the left or right dark blue border on the conveyer belt (print table) as a reference to align the paper edge of the print medium and to define the position of one of the flanges. 8 Remove the rear tension roll bar. 9 Pull the print medium over the rubber roll bar towards the print table. 10 Pull the print medium far enough towards the front side.
1 2
Dark blue border on the conveyer belt
Print medium positioned on the print table at the front side
1 - 38
MEDIA TRANSPORT
11 Mount the rear tension roll bar on top of the print medium and slowly lower the rear tension roll bar to the bottom position.
1 2 3
1 2
Rubber roll bar Rear tension roll bar
Rear media roll bar
12 Go to the front side and remove the front tension roll bar. 13 Pull the print medium to the front media roll bar. 14 Mount some dummy cores around the front media roll bar. 15 Use the two flanges and the dummy core(s) to roll up the print medium. Tape the front edge of the print medium to the front media core(s). 16 Mount the front tension roll bar on top of the print medium and slowly lower the front tension roll bar to the bottom position. NOTE: For more information about the operating instructions, refer to the Operator Manual of the Anapurna L/XL.
1 - 39
MEDIA TRANSPORT
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.
1 - 40
MEDIA TRANSPORT
4 Set the margin values, top and left. The "A" and "B" positions, the "o-point" at the corner of your media, are known distances. The "A" point has a Top Margin of 300 mm and 50 mm as a Left Margin. These can be entered in the Control program.
NOTE: Image placement for printing on two rigids must be done at RIP level.
5 Start printing.
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.
Feed Servo Motor Driver
Carriage Servo Motor Driver
1 2 3 4
1 2
SW1: MODE change SW2: UP - change by ascending order
3 4
SW3: DOWN - change by descending order SW4: SET - save values, it can be considered as ENTER key
1 - 41
MEDIA TRANSPORT
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.
Customer setting Feed Carriage 0010 0001 0001 040B 2048 125 m rad/s r/min r/min m x10STMm r/min ms station 100 200 0004 500 10 0 0 100 100 1 0102 0100 0000 000E 0000 0002 0000 0 % mV mV pulse/rev % % pulse mV 0 0 0 4000 100 100 0 0 0410 0001 0002 0405 2048 125 100 20 0004 500 10 0 0 100 0 2 0102 0100 0000 000E 0000 0002 0000 0 0 0 0 4000 100 100 0 0
NO. Symbol Basic Parameters 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 *OP4 SIC FFC VCO TLO *ENR TL1 TL2 *BKC MO1 *STY *FTY *OP1 ATU *CMX *CDV FED PGI *ZTY ZRF CRF ZST CRP JOG *STC *SNO *BPS MOD *DMD *BLK *OP2
Name and function
Initial Value
Unit
Command system/regenerative brake option selection Feeding function selection Function selection 1 Auto tuning Electronic gear numerator Electronic gear denominator Movement complete output range Position loop gain Home position return type Home position return speed Creep speed Home position shift distance For manufacturer setting JOG Jog speed S-pattern acceleration/deceleration time constant Station number setting Communication baudrate selection, alarm history clear Analog monitor output Status display selection Parameter block Function selection For manufacturer setting Function selection Serial communications time-out selection Feed forward gain Override offset Torque limit offset Encoder output pulses Internal torque limit Internal torque limit Backlash compensation Analog monitor 1 offset
0000 0000 0002 0105 1 1 100 35 0010 500 10 0 0 100 0 0 0000 0100 0000 0000 0000 0002 0000 0 0 0 0 4000 100 100 0 0
Expansion Parameters 1
1 - 42
MEDIA TRANSPORT
NO. Symbol 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 NH1 NH2 LPF GD2B PG2B VG2B VICB *CDP CDS CDT *OP8 *OP9 *OPA *OP6 *ZPS DCT ZTM ZTT *LMP *LMN *LPP *LNP MO2 MBR GD2 PG2 VG1 VG2 VIC VDC
Name and function Analog monitor 2 offset Electromagnetic brake sequence output Position loop gain Speed loop gain Speed loop gain Speed integral compensation Speed differential compensation JOG operation acceleration/deceleration time constant Home position return operation acceleration/deceleration time constant Home position return position data Moving distance after proximity dog Stopper type home position return stopper time Stopper type home position return torque limit value Software limit + Software limit Position range output address + Position range output address -
Initial Value 0 100 35 177 817 48 980 mV ms
Unit 0
Customer setting Feed Carriage 0 100 8.0 25 1100 900 40 980 0 0 0 1000 100 15 0 0 0 0 100 1.0 250 1300 1300 5 980 0 0
Ratio of load inertia moment to Servo motor inertia moment 70
0.1 times rad/s rad/s rad/s ms
0 1000 100 15 0 0 0 0
x10STMm x10 ms % x10STMm x10STMm x10STMm x10STMm

STM
0 1000 100 15 0 0 0 0
Expansion Parameters 2 For manufacturer setting Function selection 6 For manufacturer setting Function selection 8 Function selection 9 Function selection A For manufacturer setting Machine resonance suppression filter 1 Machine resonance suppression filter 2 Low-pass filter, adaptive vibration suppression control Position control gain 2 changing ratio Speed control gain 2 changing ratio Speed integral compensation changing ratio Gain changing selection Gain changing condition Gain changing time constant For manufacturer setting OUT1 output time selection 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 1/10 Ratio % % % (Note) ms 100 100 100 0000 10 1 100 10000 10 10 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 70 100 100 100 0000 10 1 100 10 10 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 80 100 120 100 0004 10 1 100 10 10
Ratio of load inertia moment to Servo motor inertia moment 70
10000 10000
1 - 43
MEDIA TRANSPORT
NO. Symbol 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90
Name and function OUT2 output time selection OUT3 output time selection Selected to program input polarity selection
Initial Value 100 100 100 0000 0009 080A 0706 020B 0504
Unit
Customer setting Feed Carriage 100 100 100 0000 0009 080A 0706 020B 0504 0032 0000 0005 0D04 0102 0 0 100 100 100 0000 0009 080A 0706 020B 0000 0032 0000 0005 0D04 0102 0 0
Special Parameters
For manufacturer setting
0032 0000 0005 0D04 0102 0 0

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
1 - 44
INK SUPPLY SYSTEM
7. Ink Supply System

TAKE UP MOTOR
PRESSURE SENSOR
TAKE UP PCB

REFILL CONTROL PCB
ZERO GAIN CONTROL
HEAD PCB
MAIN PCB
FEED BACK ON/OFF
FPGA PCB
MEMORY
INTERFACE CIRCUIT
HEATING 120VDC
FPGA CIRCUIT
CONTROL CIRCUIT
RS 232
PC
CARTRIDGE PCB
HEAD LIFT PCB

SUB PCB
PRINT HEAD
STEP MOTOR
FEED MOTOR
CARRIAGE MOTOR
IF PCB
P L C (K7M-DR60S)
PID CONTROLLER
UV LAMP
1 - 45
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

IN OUT IN OUT
Ink Pump
Ink Filter
Solution Tank
Color Ink Tank + Air Filter
Sub Ink Tank (6C) Ink/Solution Valve
Ink Bottle
Print Head Ink
7.1.3. Key Parts For Ink Supply
1 2 3
Ink bottle Main ink tank Ink pump
4 5 6
Ink filter Ink hose fixing (top) Ink hose fixing (bottom)
7 8 9
Sub ink tank (6C and W) Ink/Solution Valve Print head
1 - 46
INK SUPPLY SYSTEM
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.
1 - 47
INK SUPPLY SYSTEM
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.
1 - 48
INK SUPPLY SYSTEM
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: Dont 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.
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.
NOTE: For more information about bleeding the ink filters, refer to Bleeding the Ink Filters on page 4-56 (chapter Preventive Maintenance).
7.1.3.4. 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.
1 - 49
INK SUPPLY SYSTEM
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:
1
!
6 Sub ink tank for each color
1 Sub ink tank for white
Sub ink tank (6C) A sub ink tank for the six colors, the successive colors from left to right are: K, C, M, Y, Lc, Lm. Each sub ink tank has a content of 35 ml per color.
Sub ink tank (White) A white sub ink tank for the spot-white and pre-white print head.
! !
The level of each sub ink tank is controlled by means of a float senor connected to the Head PCB. The temperature of the 6C sub ink tank and the white sub ink tank is controlled by means of a temperature sensor build underneath an orange heater plate. The upper value on the Sub Ink Tank Temp. PID panel (1) and the White Sub Ink Tank Temp. PID panel (2) indicates the actual temperature respectively measures by the temperature sensor of the 6C sub ink tank and the white sub ink tank.
1 - 50
INK SUPPLY SYSTEM
Temperature setting sub ink tank (6C + W) should be:

Settings Sub ink tank temperature (1) White sub ink tank temperature (2) Printing with white ink 38C 40C Printing without white ink 38C 25C
To adjust the sub ink tank temperature and the white sub ink tank temperature, use the keypad underneath the display.
1 2
PV: processing value indicator (RED) SV: setting value indicator (GREEN
Keypad
Adjusting the sub ink tank temperature (6C and/or white) will affect the orange heater plates (6c and/or white) build underneath the sub ink tank (6C and/or white).
3 4
1 2
!
Heater Plate of white sub ink tank Heater Plate of 6C sub ink tank
3 4
J14 Head Lift PCB J25 Head Lift PCB
A head temperature sensor (safety thermostat 45C) is connected on the Magenta print head (Head 3 - black cable). The sensor in the Magenta print head controls output to the heater bars to each head. This head temperature sensor is connected to J29 on the Head PCB.
1 - 51
INK SUPPLY SYSTEM
To change the set value during run, proceed as follows: 1 Press the key.
The right digit of the SV indicator is flashing red. 2 Use the key, to shift one digit to the left.
As a result the second digit of the SV indicator is flashing red now. 3 Repeat pressing the 4 Press the and key, until you reach the desired digit.
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.
CAUTION: Be aware that the solution tank is always full with solution liquids.
7.1.3.7. The 2-way valves
1 2 3
K, C, M, Y, Lc and Lm valve W valves Solution (S) valve
4 5
Ink outlet direction Solution outlet direction
When the print head valves (K, C, M, Y, Lc, Lm, W1 and W2) are set to the ink outlet position (I). The ink can flow to the head. In case of clogged nozzles, or misfiring nozzles, clean the print heads to unclog the missing nozzles. NOTE: For more information about cleaning the print heads, refer to Cleaning a Print Head on page 438 (chapter Preventive Maintenance).
1 - 52
INK SUPPLY SYSTEM
7.1.3.8. Print head

NOTE: For more information, refer to the functional description of the Print Head on page 1-61.
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).
1 - 53
INK SUPPLY SYSTEM

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
1 - 54
HEAD CARRIAGE MOVEMENT
8. Head Carriage Movement

TAKE UP MOTOR
PRESSURE SENSOR
TAKE UP PCB

REFILL CONTROL PCB
ZERO GAIN CONTROL
HEAD PCB
MAIN PCB
FEED BACK ON/OFF
FPGA PCB
MEMORY
INTERFACE CIRCUIT
HEATING 120VDC
FPGA CIRCUIT
CONTROL CIRCUIT
RS 232
PC
CARTRIDGE PCB
HEAD LIFT PCB

SUB PCB
PRINT HEAD
STEP MOTOR
FEED MOTOR
CARRIAGE MOTOR
IF PCB
P L C (K7M-DR60S)
PID CONTROLLER
UV LAMP
1 - 55
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
7 8
9 10
1 2 3 4 5
UV source Print Head Head base plate Manual head height setting knob Sub ink tank (6C)
6 7 8 9 10
Sub ink tank (W) Upper LM guide Linear scale (Encoder strip) Lower LM guide S3M belt, carriage belt
1 - 56
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.
NOTE: For more information about how to set the head gap, refer to Head Gap Control on page 184.
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 3
1 Select Carriage Release Test (1) in the Test Menu window. As a result, the head carriage unit is disconnected from the motor, which allows you to move the head carriage unit manually. 2 Click Test (2).
Service Manual :Anapurna L/XL 2007 V1.0 Company Confidential 1 - 57
The head carriage unit can now be moved manually from right to left. 3 Push the head carriage unit to the desired position and check the head height by using a thickness measuring device underneath the head base plate.
1 2 3 4 5
4 Repeat step 3. 5 When finished, push the head carriage close to the home position. 6 Select Reset Test (3) in the Test Menu window.
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.
NOTE: For more information about the Reference value, refer to Factory Set on page 1-86.
1 - 58
8.1.4. Linear Scale Encoder

8.1.4.1. General Information
2 3
5 6 7
1 2 3 4
Linear scale (encoder strip) Encoder Encoder bracket Limit switch (home position)
5 6 7
Main PCB ENC LED (Encoder) MARK LED
The head carriage unit moves from the home to the purge along a metal linear scale encoder (1). The linear scale is divided as follows:
! !
Thick stripes every 50 mm, named MARK. Small stripes every 20 m (50/2500 steps), named ENC.
The encoder (2) is used to determine the position of the head carriage unit. The encoder is mounted on the encoder bracket (3), which is attached to the carriage bottom plate. The encoder reads the linear scale (1) in order to encode the position of the head carriage unit. Every time the encoder (2) passes a MARK and ENC stripe on the linear scale (1) during the movement of the head carriage unit from the home limit switch (4) to the purge position, the MARK LED (7) and ENC LED 6) on the Main PCB (5) lights up respectively. The encoder parameters are Max. Platen Size, Home Pos.Offset, Max. Mark Count and Carriage Gear Ratio and are defined in the Factory Data Setting window. Refer to Factory Set on page 1-86.
1 - 59
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 (> 38C), run the encoder test for 5 minutes allowing the head carriage unit to move without printing. As a result temperature of the head base plate will go down. For more information about the head base plate temperature, refer to Head Base Temperature Control on page 1-63. Note that a temperature of <40C should be possible with a 2-ventilator system.
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.
NOTE: For more information about the encoder check, refer to Encoder Checking on page 4-25 (chapter Preventive Maintenance)

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
1 - 60
PRINT HEAD
9. Print Head
TAKE UP MOTOR
PRESSURE SENSOR
TAKE UP PCB

REFILL CONTROL PCB
ZERO GAIN CONTROL
HEAD PCB
MAIN PCB
FEED BACK ON/OFF
FPGA PCB
MEMORY
INTERFACE CIRCUIT
HEATING 120VDC
FPGA CIRCUIT
CONTROL CIRCUIT
RS 232
PC
CARTRIDGE PCB
HEAD LIFT PCB

SUB PCB
PRINT HEAD
STEP MOTOR
FEED MOTOR
CARRIAGE MOTOR
IF PCB
P L C (K7M-DR60S)
PID CONTROLLER
UV LAMP
1 - 61
PRINT HEAD
9.1.1. Ink Supply By Means of Negative Pressure

Settings Vacuum pressure

!
Printing with white ink -0.034 to -0.038 MPa
Printing without white ink -0.032 to -0.035 MPa
By means of negative pressure, the ink is kept in the print heads. A too high setting will cause missing ink nozzles, or no ink firing at all. When the pressure is too low, the ink will leak out of the heads. The negative pressure should be set to -.0.32 MPa. The system will adjust the setting, when the temperature on the head base plate is too high. This is an automatic function, the customer will never see a change on the display. When using White ink: It is possible that the negative pressure needs to be tuned towards approximately -0.036 MPa, to get a stable nozzle behavior for the white heads. With the white ink, a higher temperature will result in a lower viscosity (more liquid state), which can lead to ink pooling underneath the print head. Tip: Let the print heads leaking and adjust 4 units higher.
NOTE: Pooling: ink build up underneath the print head, causing nozzle failure. As the head needs to fire drops, the fired drops are not getting through the pool of ink underneath the head. An increase of negative pressure, (-0.036 MPa) will bring the ink more upwards into the meniscus of the print head, thus preventing the pooling.
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.
2 3
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PRINT HEAD
9.1.2. Head Base Temperature Control

Settings Head base temperature (cold)
Printing with white ink 32C
Printing without white ink 32C
Read-out on display:
!
The upper value on the display is the actual temperature, the lower value is only an indication without meaning. The actual temperature will not change if you change the lower value. The actual temperature needs to be 32C when engine is not in use (cold engine). When printing, the temperature increase. For good printing results, the temperature indication should not exceed 38C. Make sure you print with closed engine doors all the time, especially when room temperatures are 25C and above. This will give you the best cooling inside the engine.
! !
NOTE: In case the head base temperature > 38C during printing, do the following: stop printing at the end of the current print job switch off the UV-lamps and run the Encoder Test for 5 minutes (refer to Encoder Count Test on page 1-89). The carriage will now move continuously without printing, allowing the base plate to cool down.
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.
1 - 63
PRINT HEAD
1
!
PT sensor bracket
Temperature sensor cable
A safety thermostat (80C) 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.
Lc M Y Lc Lm
1 - 64
PRINT HEAD
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 32C on most engine configurations. The higher the voltage value, the lower the temperature value.
Head PCB
Cartridge PCBs

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
1 - 65
UV CURING
10. UV Curing
TAKE UP MOTOR
PRESSURE SENSOR
TAKE UP PCB

REFILL CONTROL PCB
ZERO GAIN CONTROL
HEAD PCB
MAIN PCB
FEED BACK ON/OFF
FPGA PCB
MEMORY
INTERFACE CIRCUIT
HEATING 120VDC
FPGA CIRCUIT
CONTROL CIRCUIT
RS 232
PC
CARTRIDGE PCB
HEAD LIFT PCB

SUB PCB
PRINT HEAD
STEP MOTOR
FEED MOTOR
CARRIAGE MOTOR
IF PCB
P L C (K7M-DR60S)
PID CONTROLLER
UV LAMP
1 - 66
UV CURING
UV source (left)
UV source (right)
Two UV sources take care of the on the fly curing. They are positioned symmetrically left and right of the printing heads.
! ! ! ! ! ! !
High speed on-the-fly curing. Curing power: 120 W/cm. 2 fixed settings: full and half strength. Air cooled lamp-house. Quick and easy replacement of the UV-bulbs (always change both the lamps). Expected lifetime 1000 hours (full strength). Use of an automated shutter system.
10.1.2. Curing Setup (Software Settings)

For more information, refer to the UV Options on page 1-83.
1 - 67
UV CURING
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.
1 - 68
UV CURING
10.1.4. UV Lamp Assembly
2 3 3
5 6 7 8
9 10
1 2 3 4 5
Lamp power connector (4P) UV lamp box Lamp case outer air inlet AC FAN UV lamp box housing Lamp signal connector (10P) (LAMP-L-SIG label)
Lamp shutter signal connector (2P) (LAMP SHUTTER L label) 7 Lamp shutter ON pneumatic tube (yellow) 8 Lamp shutter OFF pneumatic tube (red 9 Lamp case inner air outlet DC FAN 10 UV Lamp
1 - 69
UV CURING
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
12 11
3 4 5 6
10
1 2 3 4 5 6
AC fuse DC fuse POW Lamp status indicator - Power ON (L) LOW Left UV lamp status indicator - half power (R) LOW Right UV lamp status indicator - half power (L) HI Left UV lamp status indicator - full power
7 8 9
(R) HI Right UV lamp status indicator - full power Air inhalation hole RIGHT lamp connector (7P)
10 RIGHT lamp connector (4P) 11 LEFT lamp connector (7P) 12 LEFT lamp connector (4P)
1 - 70
UV CURING
10.1.5.2. Inner Description

Figure 1.22: UV lamp power box (inner description) - parts
1
2 3
1 2 3 4 5
Low voltage relays Right lamp power settings Left lamp power settings AC cooling fan Power supply SMPS #6
6 7 8 9
Elcos (#6) High voltage relays UV lamp PLC, type K7M-DR40S Relays
Figure 1.23: UV lamp power box (inner description) - detail low voltage and high voltage relays
1 2 3 4
1 2 3 4
Relay ACfan (L) Relay ACfan (R) Relay SHUTTER (L) Relay SHUTTER (R)
5 6 7 8
Relay MC(R) - HIGH Relay MC(R) - LOW Relay MC(L) - HIGH (not visible) Relay MC(L) - LOW (not visible)
1 - 71
UV CURING
Figure 1.24: UV lamp power box (inner description) - detail Relays and UV lamp PLC
1 2 3 4
1 2 3
RK2 relay RK1 relay LK2 relay
4 5
LK1 relay UV lamp PLC, type K7M-DR40S
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).
250V 220V 208V 60Hz 50Hz
250V 220V 208V 60Hz 50Hz
UV lamp power (left)
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.
1 - 72
UV CURING
10.1.7. Diagrams
!
Connections in the UV lamp power box For the electrical diagram, refer to UV Lamp Power Box Connections on page 7-15 (chapter Annex).
Power supply distribution For the electrical diagram, refer to UV Lamp Power Circuit on page 7-17 (chapter Annex).
UV lamp head Part For the diagram, refer to UV Lamp Head Part on page 7-19 (chapter Annex).
UV lamp power cables For the diagram, refer to UV Lamp Power Cables on page 7-21 (chapter Annex). Briefly:
!
The 4P lamp connector provides voltage feed for the UV lamp (pin A and pin C) and the AC fan (pin B). The 10P (7P) connector provides the control signals for the shutter and the thermistors. If the UV lamp box is not correctly joined in the UV lamp box housing, pin J and pin K of the 10P connector are not closed.
UV Lamp Power Box
7P connector (L & R)
4P connector (L & R)
UV Lamp Assy (Left)
10P connector (L) 4P connector (L)
1 - 73
UV CURING

The following printed circuits boards are part of the UV curing:
!
SUB PCB on page 1-136
1 - 74
PROGRAMMABLE LOGIC CONTROLLER (PLC)
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.
1 - 75
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

Connectors Name and Function 5045-4P Nr. SUB J4 1 2 3 4 5 Connectors Name and Function 5027-2P Nr. REFILL J13 1 2 Connectors Name and Function SELECT S/W Nr. 1 2 3 4 + 1 2 3 4 + 1 2 3 4 + 1 Nr. GND P005 GND P004 24V+ P005 N.C N.C P016 GND P051 GND N.C N.C P017 GND P052 GND GND Nr. P0B NOT USED Pin Name PCB or Part Connected to Conn. Pin Nr. P014 P00A P013 P012 P011 Pin Name PCB or Part Connected to Conn. Pin Pin Name PCB or Part Connected to Conn. Pin
1 - 76
Connectors Name and Function Nr. 2 3 4 + 1 2 3 4 + 1 2 3 4 + 1 2 3 4 + 1 2 3 4 + N.O COM + Connectors Name and Function D-SUB 15P Nr. LAMP PLC Nr. GND 44 46 43 45 4D 1 2 3 4 5 6 Nr.
Pin Name P003 GND P007 24V+ P003 GND P006 GND P008 24V+ P003 GND P000 GND P002 24V+ P000 N.C N.C P018 GND P052 GND N.C N.C P019 GND P052 GND P0C GND P04B GND Pin Name PCB or Part PCB or Part
Connected to Conn. Pin
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Connectors Name and Function Nr. 4F 9 10 Connectors Name and Function EPDB BLOWER START Nr. Nr. E066 E044 E034 Connectors Name and Function 5557-8P Nr. Nr. 1 2 3 4 5 6 7 8 Nr. 7 9
Pin Name PCB or Part
10 Pin Name GND P041 P042 Pin Name PCB or Part Connected to Conn. Pin PCB or Part Connected to Conn. Pin
SOL V/V P04E P052 P051 GND P040 GND GND GND
Connectors Name and Function SOL VT 301 Connectors Name and Function 5557 - 4P *2 Nr. TOWER LAMP Nr. P047 P048 P049 P04A P04B P04C GND 1 2 3 4 1 2 3 Nr. Nr. P015
Pin Name VT301 Pin Name PCB or Part PCB or Part
1 - 78
Connectors Name and Function 5557-2P Nr. Nr. 1
Pin Name PCB or Part
WASTE P001 TANK SENSOR GND
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ANAPURNA CONTROL PROGRAM
12. Anapurna Control Program

NOTE: The Anapurna Control Program is discussed in detail in the Operator Manual.
NOTE: Here only the buttons used for maintenance actions are discussed.
12.1. Control Program

The Anapurna Control program on the engine's PC.
1 2 3 4 5
6 7 8 9
10
16
15
14
13
12
11
1 2 3 4 5 6 7 8
IMAGE SIZE display window To open an image file(.rtl) To access the Setup Parameters window Select pass mode To access the Test Menu window To set Top (forward) and Left Margin To select Uni-Directional printing To start printing
9 10 11 12 13 14 15 16
To indicate the printing progress STATUS Message display window To move head carriage unit to Home position To move head carriage unit to Purge position To jog the loaded media Forwards/Backwards To move the loaded media Forwards/Backwards To lift the head to highest position (>50mm) IMAGE display window
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12.2. Buttons used for Maintenance Purposes

The table below lists the buttons that are used for maintenance purposes.
Button Head Lift - Up Carriage Position - Purge Carriage Position - Home Media Feed - Jog Media Feed - Back Media Feed - Forward Setup Test Explanation To lift the head carriage in emergency situations, e.g. head collision with the print media. To move the head carriage to the purge position. To move the head carriage to the home position. To jog the loaded media forwards (+ value) or backwards (- value) Value range: -300 mm to + 300 mm To move the loaded media backwards. To move the loaded media forwards. To open the Setup Parameters window. See Setup Parameters on page 1-81. To open the Test Menu window. See Test Menu on page 1-88.
12.3. Setup Parameters

In the Control Program, click Setup to get access to the Setup Parameters window.
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
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12.3.1. Bi-Dir Alignment

NOTE: This only applies to Bi-directional printing!
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).
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.
2 Change the Step Size value according to what you see. 3 Click Save As and overwrite the existing .dat-file in the Data File Name text box. 4 In the Control Program, click Test. The Test Menu window appears. 5 In the Test Menu window, select Parameter Download and click Test. Now, the new value is active. NOTE: For more information about the Test Menu window, refer to Test Menu on page 1-88.
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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.
NOTE: Changes on the carriage speed, requires a Parameter Download in the Test menu.
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.
Group Parameter Cont. ON Explanation lamps continuous ON Selected: the lamp stays on between 2 jobs, this is preferred (longest lifetime) Cleared: the lamp goes out between 2 jobs, you need to respect cooling down- and warm-up time Time needed to warm-up the UV-lamps after switching on. (= the time before the green tower lamp lights up). Time needed to cool-down the UV-Lamps after switching off (= the time the fans on the head carriage unit stays on after switching off the lamps). Cure (Default), Set Both
WarmUp Time Cooling Time
Lamp Type
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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.
Group Parameter Gap Explanation 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 = measured distance from the right side of the printing 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 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. Note: The reference value can only be changed in the Factory Data Settings window. (See Factory Set on page 1-86). To calibrate the reference value, use the manual head height setting knob.
Check Distance
12.3.6.2. Executing a head gap control ! To set the head base height, execute a head gap control as follows:
1 Move the head carriage to the home position (front right side). WARNING: Always make sure the head carriage is positioned in the HOME position, when you perform the "Set Gap" procedure. 2 Load the media. If no media is present, position the desired blank A4 paper on the print table between the 2 red marking bullets positioned on the axle underneath the white transport belt and within the reach of the 2 marking bullets positioned on the side of the head carriage.
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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.
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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.

1 2 3 4
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 Parameters window. The Factory.set files (C:\anapurna\ )contain the settings from the engine.
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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 18 17 16
1 2
No. of Colors: select color numbers to be output (default 6) Max. Platen Size: The maximum width from home position to purge position, expressed in motor encoder counts. Max plate size = max mark count x carriage gear ratio (e.g. 379000 = 49 X 7742) Left Margin Offset: The distance between the home position and the zero position (black nozzle row) from the image. Mark Center Offset: The distance extra travelled after the image Home Pos Offset: Distance between detecting Home position and real home position.
10 Uni-Speed: The return speed of the head carriage unit when printing in uni-directional mode. 11 Top Margin Feed: The feed before a new print start
4 5
Max. Mark Count: The markers counted (read by the encoder) from the home position to the purge position.
7 8 9
Weep Time (Sec): The time between 2 weep actions. Weep Amount: While weeping once, set Weep amount. Firing Pulse (mS): Weep Pulse time signal
12 Carriage Gear Ratio: The gear pulley ratio from the carriage motor (the factor between head carriage unit encoder counts and linear encoder markers) Always 7742. 13 Feed Gear Ratio: Reduction ratio at feed motor 14 Head Gap Reference: Distance where the sensing bracket recognize the position of the output material. This is also the point where the "Head Base" will wait for an onscreen confirmation, before going down to set the desired gap. 15 Head Offset: Head delay to map other colors onto black (= Software alignment of the inline heads). e.g. K CY: CY has to move to the right CY has to move to the left + 16 White Color: White Selection mode for forward/backward optional white color 17 Head Type: Spectra NOVA/GALAXY selection mode 18 Units: Metric (mm), English (Inch), decision Unit
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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.
Window Fields Jet Test, H-Orientation Test Parameter Download Carriage Release Test Reset Test Encoder Count Test
12.4.1. Jet Test

This test is used to check the condition of the nozzle.
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.
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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.
WARNING: Do not push or pull on the UV-lamps. Only push on the back of the head carriage unit.
12.4.5. Reset Test

To reset the printer.
12.4.6. Encoder Count Test

To measure the encoder pulse.
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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.
Stirrer drive connector of main white ink tank
Level sensor connector of main white ink tank
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3 Disconnect the flat ribbon cable between the Spot White Cartridge PCB (J5) and the Head PCB and between the Pre White Cartridge PCB (J5) and the Head PCB, to avoid weeping of the white print heads.
HEAD PCB
K C M Y Lc Lm
CARTRIDGE PCBs
Wspot
Wpre
4 Disconnect the white ink pump from the refill PCB. NOTE: If at a certain point in time, you decide to fill your engine with white ink, refer to Putting White Ink into the Circuit on page 1-91.
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.
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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.
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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 Vacuum pressure Sub ink tank temperature White sub ink tank temperature Head base temperature (cold) Printing with white ink -0.034 to -0.038 Mpa 38C 40C 32C** Printing without white ink -0.032 to -0.035 MPa 38C 25C 32C**
NOTE: Be aware that a new head requires the first hour a slightly lower vacuum pressure to wet the head nozzles and to get nozzles open. Ones all nozzles are sufficient wetted, put the vacuum to a higher final value to get reliable printing (see table above).
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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.
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PRINTED CIRCUIT BOARDS
14. Printed Circuit Boards

14.1. MAIN PCB
14.1.1. Main PCB Layout
14.1.1.1. Figure
1 2 3
13
4 5
12
11 10
1 2 3 4 5 6 7
Connection to home limit switch Connection to Driver Comm. PCB Connection to door interlock module Connection to Driver Comm. PCB To ENCODER To SMPS #3 Connection to Driver Comm. PCB
8 9 10 11 12 13
Connection to I/O PCB Connection to PC COM1 (D-SUB 9P) Connection to I/O PCB Connection to Refill PCB Connection to Head PCB Connection to FPGA board
14.1.1.2. Location
The main PCB is located in the control box of the Home unit.
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MAIN PCB
14.1.1.3. Function
1 (J7) Connected to PC, execute Users command. 2 (J16) Connected to FPGA Board, collect output data (= image data). 3 (J15) Connected to Head PCB, control output data and collect signals from sub ink tank. 4 (J5, J12) Control feed and carriage motor driver. 5 (J14) Collect information from linear scale encoder. 6 (J11) Connected to Refill PCB, control Refill. 7 (J17, J18) Connected to I/O PCB, collect and control lamp-on, lamp shutter, media set, feed limit signal. 8 (J8) Connected to limit, and control initial position.
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14.1.2. Main PCB Description

14.1.2.1. Connectors
Connectors Name and Function PCN10-50P Nr. J16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Nr. Pin Name DC3.3V+ DC3.3V+ GND GND MCSELA MCSELB MCCLK VIA3 VIA4 PCSELA PCSELB MCD0 MCD1 MCD2 MCD3 MCD4 MCD5 MCD6 MCD7 MCD8 MCD9 MCD10 MCD11 MCD12 MCD13 MCD14 MCD15 OEA OEB VIA5 VIA6 GND GND GND GND GND GND GND GND GND GND GND PCB or Part PCI BOARD J10 Connected to Conn. Pin
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Connectors Name and Function Nr. 43 44 45 46 47 48 49 50 Connectors Name and Function D-SUB26P Nr. J15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Connectors Name and Function 5267-5P Nr. J10 1 2 Nr. Nr. Nr.
Pin Name GND GND GND GND GND GND DC3.3V+ DC3.3V+ Pin Name DATA AB1 DATA CD1 DATA AB2 DATA CD2 DATE AB3 DATA CD3 DATA AB4 DATA CD4 DATA AB5 DATA CD5 DATA AB6 DATA CD6 DATA AB7 DATA CD7 DATA AB8 DATA CD8 MEDIA SHIFT_CK RX1_TTL TX1_TTL HV_CK ERROR_OUT HT_CNTRL S.GND S.GND S.GND Pin Name GND DC5V+ PCB or Part INTERLOCK MODULE PCB or Part HEAD PCB PCB or Part
Connected to Conn. J9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Connected to Conn. Pin Pin
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Connectors Name and Function 5267-6P Nr. J11 1 2 3 4 5 6 Connectors Name and Function 5267-3P J7 Nr. 1 2 3 Connectors Name and Function 5267-6P J5 Nr. 1 2 3 4 5 6 Connectors Name and Function 2P J4 Nr. 1 2 Connectors Name and Function 5267-8P Nr. J12 1 2 3 4 5 6 7 8 Nr. Nr. Nr. Nr. Nr.
Pin Name GND N.C N.C TXD N.C N.C Pin Name GND TX RX Pin Name GND TX N.C. RX N.C. N.C. Pin Name GND DC24V+ Pin Name GND MOTOR_RX_IN GND MOTOR_STOP DC24V+ N.C PCB or Part DRIVER COMM. PCB PCB or Part PCB or Part DRIVER COMM. PCB PCB or Part PC - COM1 PCB or Part REFILL PCB
Connected to Conn. J17 3 2 1 Pin
Connected to Conn. D-SUB 9P 5 2 3 Connected to Conn. J5 (FEED) 1 3 4 Pin Pin
Connected to Conn. J6 (CARRIAGE) 1 2 3 4 5 7 N.C 8 Pin
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Connectors Name and Function 5267-4P J9 Nr. 1 2 3 4 Connectors Name and Function 5267-3P J8 Nr. 1 2 3 Connectors Name and Function 5267-3P Nr. J17 1 2 3 4 5 6 7 8 Connectors Name and Function 5267-5P Nr. J18 1 2 3 4 5 Connectors Name and Function Nr. J14 1 2 3 4 5 6 Nr. Nr. Nr. Nr. Nr.
Pin Name GND N.C N.C DC5V+ Pin Name GND HOME SENSOR DC5V+ Pin Name DC5V+ MEDIA SET 1 MEDIA SET 2 MEDIA SET 3 FEED LIMIT LEFT SHTTER RIGHT SHTTER GND Pin Name GND EXT8 EXT7 DC24V+ DC5V+ Pin Name CHASSIS GND GND ENCA+ ENCAENCB+ GND PCB or Part PCB or Part I/O PCB PCB or Part I/O PCB PCB or Part HOME LIMIT S/W PCB or Part DRIVER COMM. PCB
Connected to Conn. J1 8 7 6 5 4 3 2 1 Connected to Conn. J4 5 4 3 2 1 Connected to Conn. Pin Pin Pin
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Connectors Name and Function Nr. 7 8 9 10 11 12 Connectors Name and Function RESET Nr. 1 2 Nr. Nr.
Pin Name ENCRI+ ENCRIGND DC5V+ ENCBDC5V+ Pin Name 24V+ GND PCB or Part PCB or Part
14.1.2.2. Leds
LED D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 Color Green Green Green Green Green Green Green Green Green Green Green Green Indication 5V MOVE-L MOVE-R MEDIA WEEP SERV-R/S HV ERROR ENC MARK TEST TRAVEL
14.1.2.3. Switches
Switch RUN FEED STOP Setting Description
14.1.2.4. Measurements
J10 - To interlock module Pin 1 (white) Pin 2 (black) +0Vdc +5Vdc 0V Ground when door open, alarm on when door closed, alarm off
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14.2. FPGA PCB

14.2.1. FPGA PCB Layout
14.2.1.1. Figure
3 1 2
1 2
(J10) Connection to MAIN PCB (J8) Connection to PCI I/O card CN1
(J7) Connection to PCI I/O card CN2
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14.2.1.2. Location
The FPGA PCB is located in the control box of the Home unit.
FGPA PCB
14.2.1.3. Function
The main functions of the FPGA PCB are: 1 Dividing the image data stream in different colors. 2 Collecting output data from the PCI I/O card. The PCI I/O card is fixed on the PC Main board. 3 Transferring output data to the Main PCB.
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14.2.2. FPGA PCB Description

Connectors Name and Function PCN10-50P Nr. J10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Nr. Pin Name DC3.3V+ DC3.3V+ GND GND MCSELA MCSELB MCCLK VIA3 VIA4 PCSELA PCSELB MCD0 MCD1 MCD2 MCD3 MCD4 MCD5 MCD6 MCD7 MCD8 MCD9 MCD10 MCD11 MCD12 MCD13 MCD14 MCD15 OEA OEB VIA5 VIA6 GND GND GND GND GND GND GND GND GND GND GND PCB or Part MAIN BOARD J16 Connected to Conn. Pin
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Connectors Name and Function Nr. 43 44 45 46 47 48 49 50 Connectors Name and Function PC1 J7 Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Nr. Nr.
Pin Name GND GND GND GND GND GND DC3.3V+ DC3.3V+ Pin Name N.C N.C N.C N.C N.C N.C GND N.C PCD15 N.C PCD14 N.C PCD13 N.C PCD12 N.C PCD11 N.C PCD10 N.C PCD9 N.C PCD8 N.C PCD7 N.C PCD6 N.C PCD5 N.C PCD4 N.C PCD3 PCB or Part PCI CARD PCB or Part
Connected to Conn. CN2 IDC-40P Pin
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Connectors Name and Function Nr. 34 35 36 37 38 39 40 Connectors Name and Function PCN2 J8 Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Nr. Nr.
Pin Name N.C PCD2 N.C PCD1 N.C PCD0 N.C Pin Name N.C PCSELA N.C PCSELB N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C N.C GND PCB or Part PCI CARD PCB or Part
Connected to Conn. CN1 IDC-40P Pin
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Connectors Name and Function Nr. 35 36 37 38 39 40 Nr.
Pin Name N.C N.C O_REQ N.C N.C N.C PCB or Part
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14.3. HEAD PCB

14.3.1. Head PCB Layout
14.3.1.1. Figure
6 7
1 2 3 4
Connection to MAIN PCB Level sensor connectors (K, C, M, Y, Lc, Lm, S, W) Connection to cartridge PCBs (incoming data) Head temperature potentiometer
5 6 7
Connection to head temperature sensor (2 black wires to the Magenta print head) Connection to each head heating device 220V connector
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14.3.1.2. Location
The HEAD PCB is located at the back side of the head carriage unit, underneath the HEAD LIFT PCB.
HEAD PCB
K C M Y Lc Lm Wspot Wpre
14.3.1.3. Function
The main functions of the HEAD PCB are: 1 Connected to MAIN PCB, collect output data and ink supplying signals from sub ink tank. 2 Connected to each CARTRIDGE PCBs, and transfer output data. 3 Collect floating signals from each ink tank. 4 Connect each head heating device. This is the connection to the heater bar of each print head (K, C, M, Y, Lc, lm, W, W) 5 Connect the head temperature sensor. Is this the black thermostat cable connected to the thermistor of the Magenta Print head (see Temperature detection components and setting components on page 1-63).
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14.3.2. Head PCB Description

Connectors Name and Function 5267-2P Nr. INK1 1 2 Connectors Name and Function 5267-2P Nr. INK2 1 2 Connectors Name and Function 5264-2P Nr. INK3 1 2 Connectors Name and Function 5267-2P Nr. INK4 1 2 Connectors Name and Function 5267-2P Nr. INK5 1 2 Connectors Name and Function 5267-2P Nr. INK6 1 2 Connectors Name and Function 5267-2P Nr. INK7 1 2 Nr. INK7 GND Nr. INK6 GND Pin Name PCB or Part SOLUTION SENSOR S Connected to Conn. Pin Nr. INK5 GND Pin Name PCB or Part LEVEL SENSOR LM LM Connected to Conn. Pin Nr. INK4 GND Pin Name PCB or Part LEVEL SENSOR LC LC Connected to Conn. Pin Nr. INK3 GND Pin Name PCB or Part LEVEL SENSOR Y Y Connected to Conn. Pin Nr. INK2 GND Pin Name PCB or Part LEVEL SENSOR M M Connected to Conn. Pin Nr. INK1 GND Pin Name PCB or Part LEVEL SENSOR C C Connected to Conn. Pin Pin Name PCB or Part LEVEL SENSOR K K Connected to Conn. Pin
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Connectors Name and Function 5267-2P Nr. INK8 1 2 Connectors Name and Function 3951-2P 1 2 3 4 5 6 7 8 Nr. 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 Connectors Name and Function J1 Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Nr. Nr. Nr.
Pin Name INK8 GND Pin Name HV2 HEATER #1 HV2 HEATER #2 HV2 HEATER #3 HV2 HEATER #4 HV2 HEATER #5 HV2 HEATER #6 HV2 HEATER #7 HV2 HEATER #8 Pin Name GND_SIGNAL GND_SIGNAL HV_ERR HV_CK1 SHIFT_CK1 DATA_CDH1 DATA_ABH1 N.C 12V 12V GND_POWER GND_POWER N.C N.C HV1 HV1 PCB or Part HEAD CARTRIDGE PCB J5 (black) HEAD HEATER #8 HEAD HEATER #7 HEAD HEATER #6 HEAD HEATER #5 HEAD HEATER #4 HEAD HEATER #3 HEAD HEATER #2 PCB or Part HEAD HEATER #1 PCB or Part LEVEL SENSOR WHITE
Connected to Conn. W Pin
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Connectors Name and Function J2 Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Connectors Name and Function J3 Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Nr. Nr.
Pin Name GND_SIGNAL GND_SIGNAL HV_ERR HV_CK2 SHIFT_CK2 DATA_CDH2 DATA_ABH2 N.C 12V 12V GND_POWER GND_POWER N.C N.C HV1 HV1 Pin Name GND_SIGNAL GND_SIGNAL HV_ERR HV_CK3 SHIFT_CK3 DATA_CDH3 DATA_ABH3 N.C 12V 12V GND_POWER GND_POWER N.C N.C HV1 HV1 PCB or Part HEAD CARTRIDGE PCB J5 (Magenta) PCB or Part HEAD CARTRIDGE PCB J5 (Cyan)
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Connectors Name and Function J4 Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Connectors Name and Function J5 Nr. 1 Nr. Nr.
Pin Name GND_SIGNAL GND_SIGNAL HV_ERR HV_CK4 SHIFT_CK4 DATA_CDH4 DATA_ABH4 N.C 12V 12V GND_POWER GND_POWER N.C N.C HV1 HV1 Pin Name GND_SIGNAL PCB or Part HEAD CARTRIDGE PCB J5 (Light Cyan) PCB or Part HEAD CARTRIDGE PCB J5 (Yellow)
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
GND_SIGNAL HV_ERR HV_CK5 SHIFT_CK5 DATA_CDH5 DATA_ABH5 N.C 12V 12V GND_POWER GND_POWER N.C N.C HV1 HV1
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Connectors Name and Function J6 Nr. 1 Nr.
Pin Name GND_SIGNAL PCB or Part HEAD CARTRIDGE PCB J5 (Light Magenta)
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Connectors Name and Function J7 Nr. 1 Nr.
GND_SIGNAL HV_ERR HV_CK6 SHIFT_CK6 DATA_CDH6 DATA_ABH6 N.C 12V 12V GND_POWER GND_POWER N.C N.C HV1 HV1 Pin Name GND_SIGNAL PCB or Part HEAD CARTRIDGE PCB J5 (Spot White) Connected to Conn. Pin
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
GND_SIGNAL HV_ERR HV_CK7 SHIFT_CK7 DATA_CDH7 DATA_ABH7 N.C 12V 12V GND_POWER GND_POWER N.C N.C HV1 HV1
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Connectors Name and Function J8 Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Connectors Name and Function J9 Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Nr. Nr.
Pin Name GND_SIGNAL GND_SIGNAL HV_ERR HV_CK8 SHIFT_CK8 DATA_CDH8 DATA_ABH8 N.C 12V 12V GND_POWER GND_POWER N.C N.C HV1 HV1 Pin Name DATA AB1 DATA CD1 DATA AB2 DATA CD2 DATA AB3 DATA CD3 DATA AB4 DATA CD4 DATA AB5 DATA CD5 DATA AB6 DATA CD6 DATA AB7 DATA CD7 DATA AB8 DATA CD8 MEDIA SHIFT_CK RX1_TTL TX1_TTL HV_CK ERROR_OUT HT_CNTRL PCB or Part MAIN PCB J15 PCB or Part
HEAD CARTRIDGE PCB J5 (Pre White)
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Connectors Name and Function Nr. 24 25 26 Connectors Name and Function 5267-2P Nr. J29 1 2 Connectors Name and Function STL950 Nr. J13 1 2 3 4 5 6 7 8 Nr. Nr. Nr.
Pin Name S.GND S.GND S.GND Pin Name SIGNAL GND Pin Name HV2 GND HV1 GND 5V+ GND 24V+ GND PCB or Part PCB or Part PCB or Part
14.3.2.2. Leds
LED D1 Color Indication the first 8 INK LEDs are related to the status of the sub ink tank (LED ON means sub ink tank empty and as a result a signal is sent to the pumps) HV_ERR (High Voltage) HT_ERR (Heather Error) INK_OVF (Ink Overflow)
D2 D4 D6
14.3.2.3. Adjustments
Refer to Head Base Temperature Control on page 1-63.
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14.4. REFILL PCB

14.4.1. Refill PCB Layout
14.4.1.1. Figure
12 13
2 11 3 4
10
1 2 3 4 5 6 7
Connection to Indicator PCB Connection to Main PCB Connection to air tank Connection to SMPS #3 Connection to Front media detection sensor Connection to Front gear motor Connection to sub tank flow sensor
8 9 10 11 12 13
Connection to Refill Control PCB Connection to Rear media detection sensor Connection to Rear gear motor Connection to Indicator PCB Connection to Take Up PCB Connection to Ink pumps (C, M, Y, K, Lm, Lc, W and S)
14.4.1.2. Location
The REFILL PCB is located behind the swinging ink supply door.
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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

Connectors Name and Function IDC-16 Nr. J18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Connectors Name and Function 5267-2P J4 Nr. 1 2 Nr. Nr. GND DC5V+ GND DC5V+ N.C N.C N.C N.C DIR_CW_SW CW_LED DIR_CCW_SW CCW_LED AUTO_SW AUTO_LED ERROR_SW ERROR_LED Pin Name DCS5V+ INK-C PCB or Part INDICATOR PCB J10 Connected to Conn. Pin Pin Name PCB or Part TAKE UP PCB J11 Connected to Conn. Pin
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Connectors Name and Function 5267-2P Nr. J11 1 2 Connectors Name and Function 3191-3P Nr. J16 1 Nr. Nr.
Pin Name MOTOR REAR+ MOTOR REARPin Name DC24V+ PCB or Part TAKE UP REAR MEDIA DETECTION SENSOR PCB or Part REAR TAKE UP MOTOR
2 3 Connectors Name and Function 5557-2P Nr. J10 1 2 Connectors Name and Function Apr-57 Nr. J15 1 Nr. Nr.
REAR-SENSE GND Pin Name MOTOR FRONT+ MOTOR FRONTPin Name F_SEN PCB or Part TAKE UP FRONT MEDIA DETECTION SENSOR Connected to Conn. Pin PCB or Part FRONT TAKE UP MOTOR Connected to Conn. Pin
2 3 4 Connectors Name and Function Mar-45 Nr. J17-1 1 2 3 Connectors Name and Function 5267-3P Nr. J17 1 2 3 Nr. Nr.
GND N.C DC24V+ Pin Name DC5V+ N.C GND Pin Name RX N.C (TX) GND PCB or Part MAIN PCB J11 Connected to Conn. Pin PCB or Part INDICATOR PCB J11 Connected to Conn. 3 2 1 Pin
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Connectors Name and Function 5267-4P Nr. BZ1 1 2 3 4 Connectors Name and Function Nr. J20 1 2 J27 1 2 J24 J1 J25 J3 J26 J5 1 2 1 2 1 2 1 2 1 2 1 2 Connectors Name and Function IDC-30P Nr. J 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Nr. Nr. Nr.
Pin Name GND N.C N.C BUZZER+ Pin Name PUMP_S DC24V+ PUMP_W DC24V+ PUMP_LM DC24V+ PUMP_LC DC24V+ PUMP_Y DC24V+ PUMP_M DC24V+ PUMP_C DC24V+ PUMP_K DC24V+ Pin Name SW_Y SW_M SW_C SW_K SW_LM SW_LC SW_WHITE SW_S +5V GND S_LED_Y S_LED_M S_LED_C S_LED_K PCB or Part REFILL CONTROL PCB KNF MOTOR K KNF MOTOR C KNF MOTOR M KNF MOTOR Y KNF MOTOR LC KNF MOTOR LM KNF MOTOR WHITE PCB or Part KNF MOTOR SOLUTION PCB or Part
Connected to Conn. J 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Pin
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Connectors Name and Function Nr. 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Connectors Name and Function 5267-2P Nr. J13 1 2 Connectors Name and Function 5267-3P Nr. J34 1 2 3 Connectors Name and Function 5267-6P Nr. J32 1 2 3 4 5 6 Nr. Nr. Nr. Nr.
Pin Name S_LED_LM S_LED_LC S_LED_WHITE S_LED_S +5V GND P_LED_Y P_LED_M P_LED_C P_LED_K P_LED_LM P_LED_LC P_LED_WHITE P_LED_S +24V GND Pin Name LAMP ON 24V+ Pin Name LAMP ON N.C GND Pin Name 5V N.C PRESSURE_LOW N.C N.C N.C PCB or Part Air tank PCB or Part PCB or Part Main PLC PCB or Part
Connected to Conn. 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Connected to Conn. POB Pin Pin
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Connectors Name and Function 3951-2P Nr. J14 1 2 Nr.
Pin Name GND 24V PCB or Part SMPS #3
14.4.2.2. Leds
LED D12 Color Indication Status ink pumps + 1 communication LED with Indicator PCB
14.4.2.3. Switches
Switch SW1 Setting Description RESET
J32 - Connection to air pressure sensor main air tank Pin 6 (black) Pin 4 (white) +5Vdc +5Vdc 0V Permanent above 3 bar, alarm off below 3 bar, alarm on
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14.5. CARTRIDGE PCB

14.5.1. Cartridge PCB Layout
14.5.1.1. Figure
1 2
(J1 - J4) connection with the 4 data cables of one print head (J5) connection to HEAD PCB
DC Head voltage (factory set) To be adjusted when mounting a new head
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14.5.1.2. Location
The eight CARTRIDGE PCBs are located at the back side of the head carriage unit, underneath the HEAD PCB. The CARTRIDGE PCB for white is positioned a little to the back.
K C M Y Lc Lm
CARTRIDGE PCBs
Wspot
Wpre
14.5.1.3. Function
The CARTRIDGE PCB controls the head and the connected head ink jet function (ink drop).
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14.5.2. Cartridge PCB Description

Connectors Name and Function SIP-9P Nr. J1 to J4 1 2 3 4 5 6 7 8 9 Connectors Name and Function IDC-12P J5 Nr. 1 2 3 4 5 6 7 8 9 10 11 12 Connectors Name and Function SIP-9P J7 Nr. 1 2 3 4 5 6 7 8 9 Nr. Nr. Nr. Pin Name HVPULSE N.C N.C GND CLK DATA OUT1 DATA IN DC12V+ GND Pin Name GND_SIGNAL GND_SIGNAL HV_ERROR HV_CK SHIFT_CK_HI DATA_CD_HI DATA_AD_HI N.C 12V+ 12V+ GND_POWER GND_POWER Pin Name HVPULSE N.C N.C GND CLK DATA OUT1 DATA IN DC12V+ GND PCB or Part HEAD #1 FLAT CABLE #7 Connected to Conn. 1 2 3 4 5 6 7 8 9 Pin PCB or Part Head PCB Connected to Conn. 1 2 3 4 5 6 7 8 9 10 11 12 Pin PCB or Part HEAD #1 FLAT CABLE #1 to #4 Connected to Conn. 1 2 3 4 5 6 7 8 9 Pin
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Connectors Name and Function SIP-9P J8 Nr. 1 2 3 4 5 6 7 8 9 Nr.
Pin Name HVPULSE N.C N.C GND CLK DATA OUT1 DATA IN DC12V+ GND PCB or Part HEAD #1 FLAT CABLE #8
Connected to Conn. 1 2 3 4 5 6 7 8 9 Pin
14.5.2.2. Leds
LED D4 Type Color Indication LEDG-SM 12V
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14.6. HEAD LIFT PCB

14.6.1. Head Lift PCB Layout
14.6.1.1. Figure
1 2 3
Connection to IF PCB Connection to Purge switch Connection to SMPS #6
4 5 6
Connection to IF PCB Connection to heater plate of white sub ink tank Connection to heater plate of 6C sub ink tank
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14.6.1.2. Location
The HEAD LIFT PCB is located at the back side of the head carriage unit.
HEAD LIFT PCB
14.6.1.3. Function
The main functions of the HEAD LIFT PCB are: 1 Controlling the head carriage lift step motor. 2 Connected to ITV PCB (J13), control ITV. 3 Connected to IF PCB, 4 Control head base (J17) and sub ink tank temp (J10). The temperature sensor which is connected to J17 of the Head Lift PCB leads through the Head Base Temp. PID panel. So this sensor only measures and indicates the actual temperature of the head base on the Head Base Temp PID display. If you disconnect J17 from the Head Lift PCB, the text "Open" appears on the Head Base Temp PID display (See Temperature detection components and setting components on page 1-63). 5 Connect heating device to white sub ink tank (J25) and 6C sub ink tank (J14). 6 Controlling the head gap sensor. 7 Controlling the purge solenoid of the purge switch (J12).
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14.6.2. Head Lift PCB Description

Connectors Name and Function 5045-5P J1 Nr. 1 2 3 4 5 Connectors Name and Function GIL-G4P J4 Nr. 1 2 3 4 Connectors Name and Function 3951-5P J6 Nr. 1 2 3 4 5 Connectors Name and Function 5045-6P J7 Nr. 4 5 6 7 8 9 1 2 3 Nr. Nr. GND SOL (1) N.C GND SOL (2) Pin Name SUB_A SUB_B SUB_B BASE_A BASE_B BASE_B N.C. N.C. N.C. PCB or Part I/F PCB J2 Connected to Conn. 8 7 6 5 4 3 2 1 Pin Nr. GND RX TX N.C Pin Name PCB or Part Connected to Conn. Pin Nr. GND DC5V+ UP_SEN DN_SEN N.C Pin Name PCB or Part PC-COM2 Connected to Conn. D-SUB 9P 5 2 3 Pin Pin Name PCB or Part Connected to Conn. Pin
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Connectors Name and Function 3951-6P J8 Nr. 1 2 3 4 5 6 Connectors Name and Function 5267-3P Nr. J10 1 2 3 Connectors Name and Function 5045-3P Nr. J11 1 Nr. Nr. Nr.
Pin Name DC24V+ DC24V+ GND GND BASE_HEATER SUB_HEATER Pin Name SUB_B SUB_B SUB_A Pin Name IN+ PCB or Part SUB AIR TANK PRESSURE SENSOR PCB or Part PT SENSOR SUB INK TANK PCB or Part I/F PCB
Connected to Conn. J1 6 5 4 3 2 1 Connected to Conn. Pin Pin
2 3 Connectors Name and Function 3951-2P Nr. J12 1 2 Connectors Name and Function 5045-4P Nr. J13 1 2 3 4 Nr. Nr.
DC24V+ GND Pin Name DC24V+ SOL(1), SOL(2) Pin Name OUT+ N.C DC24V+ GND PCB or Part ITV2010 Connected to Conn. Pin PCB or Part PURGING S/W (PUSH BUTTON) Connected to Conn. Pin
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Connectors Name and Function 3951-3P Nr. J14 1 2 3 Connectors Name and Function Nr. J25 1 2 Nr. Nr.
Pin Name GND GND SUB_HEATER Pin Name GND SUB_HEATER PCB or Part 6C SUB INK HEATER PCB or Part WHITE SUB INK HEATER
Connectors Name and Function 5045-7P Nr. J15 1 2 3 4 5 6 7 Connectors Name and Function 5045-10P Nr. J16 1 2 3 4 5 6 7 8 9 10 Nr. Nr. A
Pin Name PCB or Part HEAD BASE LIFT STEPPING MOTOR
GND A~ B GND B~ N.C Pin Name OUT+ OUT+ IN+ IN+ GND GND GND DC24V+ DC24V+ DC24V+ PCB or Part ITV CONTROLLER CN1 Connected to Conn. 4 4 3 3 2 2 2 1 1 1 Pin
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Connectors Name and Function 5267-4P Nr. J17 1 2 3 4 Connectors Name and Function 3951-4P Nr. J18 1 2 3 4 Connectors Name and Function 3951-7P Nr. J23 1 2 3 4 5 Nr. Nr. Nr.
Pin Name BASE_B BASE_B N.C BASE_A Pin Name GND DC5V+ GND DC24V+ Pin Name DC24V+ N.C SOLA N.C DC24V+ PLATEN SENSING B/K LOCK SOLENOID PCB or Part PCB or Part SMPS #6 PCB or Part PT SENSOR HEAD BASE
Connected to Conn. CH1 DC5V+ GND CH2 DC24V+ GND Connected to Conn. Pin Pin
PLATEN SENSING B/K UP SOLENOID
6 7
N.C SOLB
14.6.2.2. Leds
LED LED 1 LED 2 Color Indication
14.6.2.3. Switches
Switch SW1 RESET Setting Description
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14.7. ITV CONTROLLER PCB

14.7.1. ITV Controller PCB Layout
14.7.1.1. Figure
(J4) collecting/controlling pressure signals
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.
ITV Controller BCB
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.
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14.7.2. ITV Controller PCB Description

Connectors Name and Function Nr. CN1 1 2 3 4 5 6 7 8 9 Connectors Name and Function Nr. ITV GORE CABLE 1 Nr. Nr. Pin Name DC24V 0V IN+ INA(1) B(2) C(3) OUT+ OUTPin Name DC24V+ PCB or Part HEAD LIFT PCB J16 Connected to Conn. 1 2 3 2 GND 4 5 6 3 4 IN+ OUT+ 7 8 9 10 Connectors Name and Function J1 Nr. 1 2 3 4 5 6 7 8 Nr. Pin Name BROWN BLUE BLACK WHITE GRAY RED GREEN YELLOW PCB or Part PSE200 REAR Connected to Conn. 1 2 3 4 5 6 7 8 Pin Pin PCB or Part PSE200 J1 Connected to Conn. 1 2 3 4 5 6 7 8 Pin
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Connectors Name and Function CH-1 J2 Nr. 1 2 3 4 Connectors Name and Function J3 Nr. 1 2 3 4 Connectors Name and Function J4 Nr. 1 2 3 4 Connectors Name and Function J5 Nr. 1 2 3 4 Nr. Nr. Nr. Nr.
Pin Name BROWN BLUE BLACK Pin Name BROWN BLUE BLACK Pin Name BROWN BLUE BLACK Pin Name BROWN BLUE BLACK PCB or Part IVT CONTROL PCB or Part IVT CONTROL PCB or Part IVT CONTROL PCB or Part IVT CONTROL
Connected to Conn. 1 2 4 9 3 Connected to Conn. 1 2 4 9 3 Connected to Conn. 1 2 4 9 3 Connected to Conn. 1 2 4 9 3 Pin Pin Pin Pin
14.7.2.2. Switches
Switch SW2 ON Setting Description Factory setting
14.7.2.3. Adjustments
It is not necessary to tune the variable resistors GAIN and ZERO. Both resistors are factory set.
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14.8. SUB PCB

14.8.1. Sub PCB Layout
14.8.1.1. Figure
1 2
(J4) Connection to PLC (J13) Connection to I/O PCB
(J43) Connection to SMPS (DC 5V/24V)
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14.8.1.2. Location
The SUB PCB is located in the control box of the Home unit.
SUB PCB
14.8.1.3. Function
The main functions of the SUB PCB are: 1 Collecting the tower lamp signals air Low, ink low, lamp on, media set on, blower on coming from the PLC. 2 Transferring the signals air Low, lamp shutter L/R and UV lamp on to the I/O PCB. 3 Distributing the 5V and 24 V DC voltages coming from the SMPS (DC5V/24). SMPS is an acronym for Switch Mode Power Supply.
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14.8.2. Sub PCB Description

Connectors Name and Function 3951-2P Nr. J45 1 2 Connectors Name and Function 3951-4P Nr. J43 1 2 3 4 Connectors Name and Function 5045-14P Nr. J13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Connectors Name and Function 5267-4P Nr. J47 1 2 3 4 Nr. GND LIFT-UP LIFT-DN DC5V+ Nr. N.C N.C N.C N.C N.C N.C N.C N.C N.C AIR LOW N.C SHUTTER RIGHT SHUTTER LEFT UV LAMP ON Pin Name PCB or Part not used I/O PCB I/O PCB I/O PCB Connected to Conn. Pin air tank pressure gauge signal Nr. Nr. Pin Name SSR OUT1 SSR OUT2 Pin Name DC24V+ DC24VDC5V+ GND Pin Name PCB or Part Connected to Conn. Pin PCB or Part SMPS (DC 5V/24V) Connected to Conn. Pin PCB or Part not used Connected to Conn. Pin
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Connectors Name and Function 3951-6P J4 Nr. 1 2 3 4 5 6 Connectors Name and Function 5267-2P Nr. J48 1 2 Connectors Name and Function 5557-2P Nr. J44 1 2 Nr. Nr. Nr.
Pin Name AIR-LOW INK LOW LAMP ON MEDIA SET BLOWER ON N.C Pin Name SUC-LEVEL DC5V+ Pin Name MOTOR+ MOTORPCB or Part PCB or Part not used PCB or Part PLC
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14.9. IF PCB
14.9.1. IF PCB Layout
14.9.1.1. Figure
14.9.1.2. Location
The IF PCB is located behind the control system cover underneath the PID panel. To get access to the IF PCB, open the ink supply door.
IF BCB
14.9.1.3. Function
The main functions of the IF PCB are: 1 Distributing the 24 V DC voltages. 2 Connected to IF PCB, head base and sub ink tank temp. 3 Connected to the head base temperature, sub ink tank temperature and white sub ink tank temperature PID controller.
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14.9.2. IF PCB Description

Connectors Name and Function power Jun-51 J1 Nr. 1 2 3 4 5 6 Connectors Name and Function TEMP SENSOR Aug-51 J2 Nr. 1 2 3 4 5 6 7 8 Connectors Name and Function 5045-4P J3 Nr. 1 2 3 4 Connectors Name and Function Mar-51 J4 Nr. 1 2 3 Connectors Name and Function 3951-2P J5 Nr. 1 2 Nr. Nr. PSE GND DC24V Pin Name DC24V GND PCB or Part Connected to Conn. Pin Nr. ITV N.C GND DC24V Pin Name PCB or Part Connected to Conn. Pin Nr. PSE ITV BASE-B BASE-B BASE-A SUB-B SUB-B SUB-A Pin Name PCB or Part Connected to Conn. Pin 9 8 7 6 5 4 Nr. Pin Name Sub-Heater Base-Heater GND GND DC24V DC24V Pin Name PCB or Part HEAD LIFT PCB J7 Connected to Conn. Pin PCB or Part J8 Connected to Conn. 1 2 3 4 5 6 Pin
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Connectors Name and Function 3951-2P J6 Nr. 1 2 Connectors Name and Function 3951-2P J7 Nr. 1 2 Connectors Name and Function 5267-3P J8 Nr. 1 2 3 Connectors Name and Function 3951-3P J9 Nr. 1 2 3 Connectors Name and Function 5267-4P Nr. J10 1 2 3 4 Connectors Name and Function 3951-2P Nr. J11 1 2 Nr. Nr. Nr. Nr. Nr. Nr.
Pin Name DC24V GND Pin Name DC24V GND Pin Name SUB-A SUB-B SUB-B Pin Name SUB-HEATER N.C GND Pin Name BASE-B BASE-B N.C BASE-A Pin Name BASE HEATER GND PCB or Part PCB or Part PCB or Part PCB or Part PCB or Part PCB or Part
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Connectors Name and Function 5045-9P Nr. J12 1 2 3 4 5 6 7 8 9 Connectors Name and Function 5045-5P Nr. J13 1 2 3 4 5 Connectors Name and Function PID Nr. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Nr. Nr. Nr.
Pin Name GND N.C N.C N.C N.C N.C N.C N.C DC24V Pin Name PSE N.C N.C GND DC24V Pin Name SV2 IN SV2-COM CA SENSOR EV2-OUT2 EV2-OUT1 N.C EV1-OUT2 EV1-OUT1 ACIN ACIN N.C COM N.O PCB or Part PCB or Part PCB or Part
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14.10. I/O PCB

14.10.1. I/O PCB Layout
14.10.1.1. Figure
1 5
1 2 3
(J2) Connection to feed limit and media sensor (J3) Connection to SUB PCB (J6) Connection to SUB PCB
4 5
(J4) Connection to Main PCB (J1) Connection to Main PCB
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14.10.1.2. Location
The I/O PCB is located in the control box of the Home unit.
I/O PCB
14.10.1.3. Function
The main functions of the I/O PCB are: 1 (J3, J6) Indicating the signals of the lamp shutter L/R and the UV lamp on coming from the SUB PCB. 2 (J2) Collecting and transferring the signals of feed limit and media sensors. 3 (J1, J4) Indicating and transferring the signals UV lamp on, lamp shutter L/R, media sensors and feed limit to the MAIN PCB.
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14.10.2. I/O PCB Description

Connectors Name and Function 5267-8P J1 Nr. 1 2 3 4 5 6 7 8 Connectors Name and Function 5267-5P J4 Nr. 1 2 3 4 5 Connectors Name and Function 5045-5P J2 Nr. 1 2 3 4 5 Connectors Name and Function 5045-3P J3 Nr. 1 2 3 Nr. Nr. Nr. Nr. Pin Name DC5V+ MEDIA SET 1 MEDIA SET 2 MEDIA SET 3 FEED LIMIT LEFT SHTTER RIGHT SHTTER GND Pin Name DC5V+ DC24V+ UV LAMP ON EXT I/O 8 GND Pin Name DC5V+ MEDIA SENSOR 1 MEDIA SENSOR 2 MEDIA SENSOR 3 FEED LIMIT Pin Name LEFT SHUTTER RIGHT SHUTTER GND PCB or Part MAIN PCB J13 Connected to Conn. Pin PCB or Part Connected to Conn. Pin PCB or Part MAIN PCB J18 Connected to Conn. 5 4 3 2 1 Pin PCB or Part MAIN PCB J17 Connected to Conn. 1 2 3 4 5 6 7 8 Pin
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Connectors Name and Function 5045-4P J6 Nr. 1 2 3 4 Nr.
Pin Name N.C UV LAMP ON N.C N.C PCB or Part MAIN PCB
Connected to Conn. J14 Pin
14.10.2.2. Leds
LED LED1 LED2 LED3 LED4 LED5 LED6 LED7 Type ON/OFF signals Color green green green green green green green Indication Media sensor 1 Media sensor 2 Media sensor 3 Feed Limit Left shutter Right shutter UV lamp on
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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.
TAKE UP BCB
14.11.1.3. Function
The TAKE UP PCB is connected with the REFILL PCB and control the motor rotation of the take-up motor and displays the state signals.
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14.11.2. Take Up PCB Description

Connectors Name and Function IDC-16 Nr. J11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Nr. GND DC5V+ GND DC5V+ N.C N.C N.C N.C DIR_CW_SW CW_LED DIR_CCW_SW CCW_LED AUTO_SW AUTO_LED ERROR_SW ERROR_LED Pin Name PCB or Part REFILL PCB J18 Connected to Conn. Pin
14.11.2.2. Leds
LED D1 D2 D3 D4 D5 Type red green green red green Color Indication auto/manual indicator CW led CCW led Auto led Error led
14.11.2.3. Switches
Switch SW1 CW switch SW2 C switch SW3 SW4 in out in out in out in out Setting Description rotate motor CW rotate motor CCW FRONT REAR AUTO mode MANUAL mode
1 - 149
14.12. REFILL CONTROL PCB

14.12.1. Refill Control PCB Layout
14.12.1.1. Figure
1 2
(D1-D8) Empty Ink refill status LED indications (D9-D16) Feeding Ink refill status LED indications
3 4
Manual feeding switches (J18) Connection to the REFILL PCB
14.12.1.2. Location
The REFILL CONTROL PCB is located behind the refill system panel. To get access to the REFILL CONTROL PCB, unscrew the 4 screws of the refill system panel.
14.12.1.3. Function
The REFILL CONTROL PCB is connected to REFILL PCB. The REFILL CONTROL PCB indicates each ink refill status (empty, feeding) and the status of the manual feeding switches.
1 - 150
14.12.2. Refill Control PCB Description

Connectors Name and Function IDC-30P Nr. J 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Nr. SW_Y SW_M SW_C SW_K SW_LM SW_LC SW_WHITE SW_S +5V GND S_LED_Y S_LED_M S_LED_C S_LED_K S_LED_LM S_LED_LC S_LED_WHITE S_LED_S +5V GND P_LED_Y P_LED_M P_LED_C P_LED_K P_LED_LM P_LED_LC P_LED_WHITE P_LED_S +24V GND Pin Name PCB or Part J 31 Connected to Conn. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Pin
14.12.2.2. Leds
LED D1 D2 D3 D4 D5 D6 D7 D8 D9 red red red red red red red red green Color Indication
1 - 151
LED D10 D11 D12 D13 D14 D15 D16
Color green green green green green green green
Indication
14.12.2.3. Switches
Switch SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 Setting Description Manual feeding of white ink Manual feeding of Lm ink Manual feeding of Lc ink Manual feeding of Y ink Manual feeding of M ink Manual feeding of C ink Manual feeding of K ink Manual feeding of solution
1 - 152
14.13. INDICATOR PCB

14.13.1. Indicator PCB Layout
14.13.1.1. Figure
4
1 2
(J13) Transferring Ink empty signal to REFILL PCB (J11) +5VDC coming from REFILL PCB
3 4
(J1-J8) Connection to ink tank flow sensor (D1-D16) Ink Full/Empty LED indications
14.13.1.2. Location
The INDICATOR PCB is located behind the ink tank indicator panel. To get access to the INDICATOR PCB, unscrew the 4 screws of the ink tank indicator system panel.
14.13.1.3. Function
The main functions of the INDICATOR PCB are: 1 Connecting the flow sensor to each main ink tank. 2 Indicating the ink full or empty status. 3 Transferring the ink empty signal to the REFILL PCB.
1 - 153
14.13.2. Indicator PCB Description

Connectors Name and Function 5267-3P J1 Nr. 1 2 3 5267-3P J2 1 2 3 5267-3P J3 1 2 3 5267-3P J4 1 2 3 5267-3P J5 1 2 3 5267-3P J6 1 2 3 5267-3P J7 1 2 3 5267-3P J8 1 2 3 Connectors Name and Function 3951-3P Nr. J11 1 2 3 Connectors Name and Function 5267-2P Nr. J12 1 2 Nr. Nr. GND N.C DC5V+ Pin Name DC5V+ INK_FULL_SIG PCB or Part Connected to Conn. Pin Nr. Pin Name DC5V+ INK_EMPTY_WT INK_FULL_WT DC5V+ INK_EMPTY_LM INK_FULL_LM DC5V+ INK_EMPTY_Lc INK_FULL_Lc DC5V+ INK_EMPTY_Y INK_FULL_Y DC5V+ INK_EMPTY_M INK_FULL_M DC5V+ INK_EMPTY_C INK_FULL_C DC5V+ INK_EMPTY_K INK_FULL_K DC5V+ INK_EMPTY_S INK_FULL_S Pin Name PCB or Part Connected to Conn. Pin PCB or Part Connected to Conn. Pin
1 - 154
Connectors Name and Function 5267-2P Nr. J13 1 2 Nr.
Pin Name INK_EMPTY_SIG DC5V+ PCB or Part
14.13.2.2. Leds
LED D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 D16 red green red green red green red green red green red green red green red Color green Indication white ink tank full white ink tank empty Lm ink tank full Lm ink tank empty Lc ink tank full Lc ink tank empty Y ink tank full Y ink tank empty C ink tank full White ink tank empty M ink tank full M ink tank empty K ink tank full K ink tank empty Solution tank full Solution tank empty
J13 - Connection to REFILL PCB J4 Pin 1 (green) Pin 2 (red) +5Vdc 0V +5Vdc empty alarm on empty alarm off Permanent
J1 / J8 - Connection to level sensor ink tank Pin 1 (black) Pin 2 (red) Pin 3 (yellow) +5Vdc +5Vdc 0V +5Vdc 0V Permanent empty detection on empty detection off full detection on full detection off
1 - 155
14.14. DRIVER COMMUNICATION PCB

14.14.1. Driver Communication PCB Layout
14.14.1.1. Figure
1
2 5
1 2 3
(J7) +5VDC coming from MAIN PCB (J4) Connection to feed servo motor driver (J3) Connection to carriage servo motor driver
4 5
(J6-CARRIAGE) Connection to MAIN PCB (J5-FEED) Connection to MAIN PCB
1 - 156
14.14.1.2. Location
The DRIVER COMM PCB is located in the control box of the Home unit.
DRIVER COMMUNICATION PCB
14.14.1.3. Function
The main functions of the DRIVER COMMUNICATION PCB are: 1 Connected to the carriage and feed servo motor driver. 2 Receiving the carriage and feed motor driver signals from the MAIN PCB.
1 - 157
14.14.2. Driver Communication PCB Description

Connectors Name and Function 5267-8P FEED J5 Nr. 1 2 3 4 5 6 7 8 Connectors Name and Function 5267-8P CARRIAGE J6 Nr. 1 2 3 4 5 6 7 8 Connectors Name and Function 5267-8P FEED SERVO J4 Nr. 1 2 3 4 5 6 7 8 Nr. TX+ TXRX+ RXGND FEED_PS_IN GND CN1B +24V Pin Name PCB or Part CN3 Connected to Conn. 5 15 9 19 1 6 10 Pin Nr. GND CAR_POS_IN TX2_SERVO GND MOTOR STOP N.C Nr. GND CAR_POS_IN TX2_SERVO GND FEED STOP N.C N.C +24V Pin Name PCB or Part MAIN PCB J12 Connected to Conn. 1 2 3 4 5 N.C. 6 8 Pin Pin Name PCB or Part MAIN PCB J5 Connected to Conn. Pin
1 - 158
CHAPTER

This chapter briefly describes the features and technical specifications of the Anapurna L/XL. 1. Overview .................................................................................................................................................................... 2 - 2 1.1. Anapurna's Print Quality ........................................................................................................................ 2 - 2 1.2. Outstanding Printing Potential ........................................................................................................... 2 - 2 1.3. Inspired Design ......................................................................................................................................... 2 - 3 1.4. User Profile ................................................................................................................................................. 2 - 3 2. Features ...................................................................................................................................................................... 2 - 4 2.1. Borderless Printing .................................................................................................................................. 2 - 4 2.2. Roll to Roll and Rigid Printing ............................................................................................................ 2 - 4 2.3. Dual Board Printing ................................................................................................................................. 2 - 4 2.4. White Color Printing ............................................................................................................................... 2 - 4 2.5. Status Signal Lamp .................................................................................................................................. 2 - 4 2.6. Automatic Ink Filling System .............................................................................................................. 2 - 5 2.7. UV Curing .................................................................................................................................................... 2 - 5 2.8. Changeable UV Lamps ........................................................................................................................... 2 - 5 2.9. Exhausting System ................................................................................................................................... 2 - 5 2.10. Automatic Print Head Height ............................................................................................................ 2 - 5 2.11. Easy and Quick Installation ............................................................................................................... 2 - 5 2.12. Simple Maintenance ............................................................................................................................ 2 - 5 3. Specifications ........................................................................................................................................................... 2 - 6 3.1. Print Technology ....................................................................................................................................... 2 - 6 3.2. Head Technology ...................................................................................................................................... 2 - 6 3.3. Media ............................................................................................................................................................ 2 - 7 3.4. Inks ................................................................................................................................................................ 2 - 8 3.5. Working Conditions ................................................................................................................................. 2 - 9 3.6. Electricity ..................................................................................................................................................... 2 - 9 3.7. RIP PC ........................................................................................................................................................ 2 - 10 3.8. Service PC ................................................................................................................................................ 2 - 10 3.9. Anapurna L ............................................................................................................................................... 2 - 11 3.10. Anapurna XL ......................................................................................................................................... 2 - 11
2-1
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 Roll materials Examples film a paper front- and backlit film self adhesive vinyl and paper canvas banner vinyl blue back coated and uncoated media alu boards corrugated cardboards screenprinting boards exhibition panels stage graphics ad panels and much more.
Rigid media
2-2
OVERVIEW
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.
2-3
FEATURES
2. Features
2.1. Borderless Printing
Borderless printing means:
! ! ! !
No loss of time cutting. Less manpower. No wasted material. Print exactly what your customers order.
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.
2-4
FEATURES
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 definable 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.
2-5
SPECIFICATIONS
3. Specifications
NOTE: For detailed information about the Anapurna L/XL Specifications, refer to the User Manual.
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 unnecessary 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.
2-6
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).
1 1 2
3.3. Media
3.3.1. Thickness
Material Rigids Roll material 1 to 50 mm min. 0.1 mm (max. roll diameter 36 cm) Thickness max 28 kg/m up to 50 kg
2
Weight
3.3.2. Type
! ! ! ! ! ! !
Foamboard Acryl Steel Glass Wood Flex Sheet
2-7
SPECIFICATIONS
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/m, all colors together.
2-8
SPECIFICATIONS
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. 8 pass: 850000 colors. 12 pass: 1080000 colors. 16 pass:
3.5. Working Conditions

Temperature permissible range: 18-26 C optimal: 22C Humidity permissible range: 35-75 % RH optimal: 40%
3.6. Electricity
Voltage (V) Europe 3 phase with neutral with ground star 380 V-10% - 415 V+6% 3 phase no neutral with ground 208 V-10% - 240 V+6% Frequency (Hz) 50 Hz Maximum Fuse protection Current rating (A) 40 A 50 A
US
60 Hz
36 A
50 A
2-9
SPECIFICATIONS
3.7. RIP PC
The Wasatch SoftRIP is provided for ripping images. Install the Wasatch SoftRIP on a separate PC that fulfils the following platform specifications.
NOTE: Do not install the Wasatch SoftRIP on the Anapurna PC.
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.
NOTE: The faster the CPU, the faster the software will process your images. It is therefore advisable to buy the fastest available computer you can. While more RAM will also help speed up the processing, it is the speed of the CPU that directly affects how fast SoftRIP runs. If you are processing large files over 100 MB in size, it is also advisable to upgrade to at least 1 GB of memory. NOTE: Wasatch SoftRIP can process more than one image at a time and takes advantage of multiple CPUs for this purpose. For every additional processor in your computer, it is recommended you double the amount of RAM, up to a maximum of 512 MB per processor. It is important to use multigigabyte disk drives on computers that are intended for use in high resolution printing, especially if you plan to keep the RIPped images available in the Wasatch Print Queue.
3.8. Service PC
If you want to connect a service PC to the Anapurna L/XL provide the following:
!
2 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.
2 - 10
SPECIFICATIONS
3.9. Anapurna L
!
Dimensions
Unit Width 3700 mm 146 inch 1750 mm 68.9 inch Height 1660 mm* 65 inch 970 mm ** 38.2 inch Depth 2360 mm*** 93 inch 1000 mm**** 43 inch Weight 1700 kg 3748 lbs -
Anapurna L Rigid table L
* height without tower light (tower light = 670 mm) ** adjustable to the height of the printing table *** depth with mounted roll bar brackets (without brackets = 2075 mm) **** length without coupling
! ! !
Printing speed up to 22 boards/hr (70 x 100 cm) (= poster quality) Floor space 700 x 700 cm (276" x 276") Maximum media width 160 cm (62,9")
3.10. Anapurna XL
!
Dimensions
Unit Width 4750 mm 187 inch 2650 mm 104 inch Height 1660 mm* 65 inch 970 mm ** 38.2 inch Depth 2360 mm*** 93 inch 1000 mm**** 43 inch Weight 2300 kg 5071 lbs -
Anapurna XL Rigid table XL
* height without tower light (tower light = 670 mm) ** adjustable to the height of the printing table *** depth with mounted roll bar brackets (without brackets = 2075 mm) **** length without coupling
! ! !
Printing speed up to 30 boards/hr (70 x 100 cm) (= poster quality) Floor space 700 x 800 cm (276" x 316") Maximum media width 250 cm (98,4")
2 - 11
SPECIFICATIONS
2 - 12
CHAPTER
Repair and Service

This chapter describes repair and service procedures for the Anapurna L/XL. 1. Safety Notes ............................................................................................................................................................. 3 - 2 1.1. Warning/Caution/Note ......................................................................................................................... 3 - 2 1.2. Emergency Stop ........................................................................................................................................ 3 - 2 1.3. Handling UV Curable Ink ....................................................................................................................... 3 - 3 1.4. UV Radiation .............................................................................................................................................. 3 - 3 1.5. Electricity ..................................................................................................................................................... 3 - 4 1.6. Maintenance Safety Instructions ........................................................................................................ 3 - 4 1.7. MSDS Contents ......................................................................................................................................... 3 - 5 2. Overview Safety Labels ........................................................................................................................................ 3 - 6 3. Preparing for Service ............................................................................................................................................. 3 - 8 3.1. Moving Head Carriage to Home or Purge Position ...................................................................... 3 - 8 3.2. Putting the print Engine in Service Mode ....................................................................................... 3 - 8 4. Disassembly/Assembly of Major Components ........................................................................................... 3 - 9 4.1. Disassembly/Assembly of the Air Pressure Panel Components ............................................ 3 - 9 4.2. Disassembly/Assembly of the Media Transport System Components ............................. 3 - 13 4.3. Disassembly/Assembly of the Ink Supply System Components at Refill Unit .............. 3 - 24 4.4. Disassembly/Assembly of the Ink Supply System Components at Head Carriage Unit ... 3 46 4.5. Disassembly/assembly of the Head Carriage Movement Components ........................... 3 - 53 4.6. Disassembly/Assembly of the Print Head Components ......................................................... 3 - 60 4.7. Disassembly/Assembly of the UV Curing System Components ......................................... 3 - 72 5. Installing the PCI I/O Card .............................................................................................................................. 3 - 83 5.1. Location .................................................................................................................................................... 3 - 83 5.2. Replacement of the PCI I/O Card ................................................................................................... 3 - 84 6. Adjustment and Alignment Procedures ...................................................................................................... 3 - 89 6.1. Vacuum Blower Adjustments ............................................................................................................ 3 - 89 6.2. Print Head Adjustments ...................................................................................................................... 3 - 91 6.3. Conveyer Belt Alignment ................................................................................................................... 3 - 97 6.4. Head Base Alignment .......................................................................................................................... 3 - 99 6.5. Lamp house Alignment ..................................................................................................................... 3 - 103
3-1
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
WARNING: Warnings are directions which, if not followed, can cause fatal or serious injuries to the operator or engineer. Caution
CAUTION: A caution is used when there is a possible danger due to incorrect manipulation. As a result, you could damage the equipment, lose data or obtain an unexpected result. Note
NOTE: A note contains additional information which may be useful to you but which is not vitally important to work safely.
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.
3-2
SAFETY NOTES
REPAIR AND SERVICE
1.3. Handling UV Curable Ink

WARNING: Consult the appropriate Material Safety Data Sheets (MSDS) before handling UV curable ink. WARNING: UV ink contains some chemicals harmful to eyes and skin. Always wear safety gloves when handling UV ink. In case of accidental contact, rinse immediately with plenty of water and consult a doctor, if required. WARNING: UV ink contains chemicals harmful to eyes and skin. 1. Always wear splash-resistant nitril safety gloves when handling UV ink. (Only safety gloves for single use are allowed). 2. Always wear protective glasses when refilling or changing the ink. 3. Avoid inhalation of the ink. WARNING: Be aware of the waste disposal and regulations that bear on UV curable ink. Always follow the instructions on the label of the ink cartridge.
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.
1.4. UV Radiation
Ultraviolet radiation (UV) has a high photon energy range and is particularly hazardous because there are usually no immediate symptoms of excessive exposure. Always wear UV protective (tinted) glasses while working with an open front cover or while working on the head carriage.
WARNING: UV light can cause harmful damage to eyes and skin. Therefore never look into UV light without wearing protective glasses. Never exposure your skin to UV light.
3-3
REPAIR AND SERVICE
SAFETY NOTES
1.5. Electricity
WARNING: Do not touch the Anapurna L/XL or any electrical components when your hands are wet.
CAUTION: Avoid other electrical equipment near the printer. Electronic waves can cause wrong operation or can shorten the life span of the printer.
CAUTION: Always make sure the power cable is properly connected.
1.6. Maintenance Safety Instructions

WARNING: Avoid heater temperature above 50C. 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.
3-4
SAFETY NOTES
REPAIR AND SERVICE
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.
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.
3-5
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
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
Meaning Before attempting to work with the Anapurna L/XL, the operator must read and understand the Anapurna L/XL Operator manual.
WARNING
Moving parts can crush and cut. Do not operate with guard removed. Lockout/tagout before servicing
This label is located on panels that enclose gears and rollers that could potentially harm fingers and hands.
Hot surface! Allow sufficient cooling before handling.

WARNING
BURN HAZARD Do Not Touch.
TURN OFF POWER and allow to cool before servicing.
WARNING
HAZARDOUS VOLTAGE
Contact may cause Electric shock or burn Turn off and lock out System before servicing
Shock hazard. Make sure the power is switched off before opening areas marked with the flashing arrow.
WARNING Avoid injury.

Do NOT operate with doors open. Close all doors before operating machine.
Make sure the Anapurna L/XL is not in printing mode before opening doors provided with this label.
3-6
OVERVIEW SAFETY LABELS
REPAIR AND SERVICE
Label
CAUTION Loud noise hazard. Ear protection must be worn
Meaning Wear ear protectors.
Never look into UV light without wearing protective glasses.

WARNING
UV LIGHT.
Do not look directly at light.
Anapurna L/XL complies with CE standards.

:ANAPURNA XL V1.0
Manufacturer's Serial No. Type Rated Voltage / Current Rated Frequency Manufactured By 1325604058601 5909/900 380VAC/3Phase, 50A
50 Hz
DILLI PRECISION IND.CO.LTD.
2006-05
Made in Korea This device complies with FCC PART 15 SUB PART 15 CLASS A
3-7
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.
3-8
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

! ! !
2 3
1 2 3
Regulator (AW20-02BCG) Regulator (IR-1020-01BG) Regulator (IR-1000-01BG)
4 5
Air filter (AF20-01BG) Solenoid V/V
3-9
REPAIR AND SERVICE
4.1.2. Replacement of the Regulators

A. PRELIMINARY ACTIVITIES
Operation Move the head carriage to the purge position. Remove air pressure panel and cable trunk covers. Reference Chapter 3 3.1. Chapter 4 9.2.
B. MANPOWER
Qualification Service engineer Number of people 1 Man-hours Execution time
C. SPECIAL TOOLS
Description Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS

Description REGULATOR (AW20-02BCG) REGULATOR (IR-1020-01BG REGULATOR (IR-1000-01BG) Code D2+2509101 D2+2509016
E. PROCEDURE 1 Set all print head valves (K, C, M, Y, Lc, Lm, W1 and W2) to the solution outlet position (S). 2 Set the solution valve to the ink outlet position (I).
1 2 3
4 5
3 Switch off the engine. 4 Turn off the compressed air supply. 5 Locate the regulator (AW20-02BCG) (6), (IR-1020-01BG (7) and (IR-1000-01BG (8).
3 - 10
REPAIR AND SERVICE
6 Replace the regulator(s).
Regulator AW20-02BCG
Regulator IR-1020-01BG
Regulator IR-1000-01BG
6.1 Unscrew the 2 cross-slotted screws. 6.2 Disconnect the air hoses. 6.3 Mount a new regulator, tighten the 2 cross-slotted screws and reconnect the air hoses. 7 Restore the compressed air supply. 8 Check the positive pressure.
2 3 4 5
0.40 - 0.80 MPa 0.10 - 0.15 MPa
0.30 MPa 0.15 MPa
3 - 11
REPAIR AND SERVICE
8.1 Check the incoming compressed air pressure with a pressure gauge (1). 8.2 The main regulator (2) should indicate 0.6 MPa. 8.3 Check the pressure of the other regulators with a pressure gauge. The UV lamp regulator (3) should indicate 0.1-0.15 MPa. The first carriage regulator should indicate 0.3 MPa (4), the second 0.15 MPa (5). 9 Restart the engine. 10 Set all print head valves and the solution valve to the proper outlet position. 11 Verify the printing conditions and if necessary clean the print heads. Refer to Cleaning a Print Head on page 4-38.
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 -.-
3 - 12
REPAIR AND SERVICE
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.

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: 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.
4.2.2. Replacement of the Conveyer Belt

Operation Move the head carriage to the purge position. Put the print engine in service mode. Reference Chapter 3 3.1. Chapter 3 3.2.
B. MANPOWER
Qualification Service engineer Operator Number of people 1 1 Man-hours Execution time
C. SPECIAL TOOLS
Description Allen key no.12 Conveyer belt wire D2+2509266 Code

Description Conveyer belt L Conveyer belt XL Protective gloves Code D2+250314 D2+250315
3 - 13
REPAIR AND SERVICE
E. PROCEDURE 1 Move the conveyer belt until the belts joint is positioned in the middle (1) on top of the printing table. To move the conveyer belt, use Media Feed buttons in the Anapurna Control Program.
2 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. NOTE: There is no difference between the bottom and top side of the conveyer belt
5 Snap both ends in each other.
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REPAIR AND SERVICE
5.1 Start the concatenation link by link. 5.2 if you notice a bulb (2), adjust the concatenation (3)(e.g. relation 2 hook against 1 hook) so the bulb disappears.
6 Secure the concatenation by means of two paperclips (or two pieces from the old needle) and slightly tighten the conveyer belt to remove the bulb. 7 Drive the conveyer belt a complete turn, to verify if the belt remains flat during movement. 7.1 If the belt remains flat during movement, use the conveyer belt tool to re-insert the needle and proceed with step 8.
7.2 If the belt is not flat during movement, repeat steps 5 to 7. 8 Finally, establish the conveyer belt alignment. Refer to Adjustment and Alignment Procedures on page 3-89.
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REPAIR AND SERVICE
4.2.3. Replacement of the Feed Servo Motor

The conveyor belt is driven by a servo motor (400W). A. PRELIMINARY ACTIVITIES
B. MANPOWER
Qualification Number of people Man-hours Execution time
C. SPECIAL TOOLS
Description Code

Description Code
E. PROCEDURE
1 2
Feed servo motor (400W)) Polyester woven conveyer belt
Reduction gear motor
3 - 16
REPAIR AND SERVICE
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. A. PRELIMINARY ACTIVITIES
B. MANPOWER
Qualification Service technician Number of people 1 Man-hours Execution time
C. SPECIAL TOOLS None D. CONSUMABLES, MATERIALS AND SPARE PARTS

Description Code
E. PROCEDURE For both front right side and rear right side: 1 Remove the cover (1) of the motor by unscrewing the 2 cross-slotted screws.
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REPAIR AND SERVICE
2 Cut the tie wrap (2) around the motor and the 2 connectors and disconnect the 2-pin connector and the 4-pin connector (3).
3 Remove the drive motor and replace by a new one. 4 Connect the 2-pin connector and the 4-pin connector. 5 Strap the 2 connectors around the motor using a wide tie wrap. 6 Mount the cover of the motor using the 2 cross-slotted screws.
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REPAIR AND SERVICE
4.2.5. Replacement of a Media Register Pin

B. MANPOWER
C. SPECIAL TOOLS
Description Code

Description Code
E. PROCEDURE
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REPAIR AND SERVICE
4.2.6. Replacement of the Limit Switch and Shock Absorber

4.2.6.1. General information
B. MANPOWER
C. SPECIAL TOOLS
Description Code

Description limit switch Shock absorber Code D2+2509143 D2+2509058
E. PROCEDURE
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REPAIR AND SERVICE
4.2.7. Replacement of a Vacuum Pump

Two adjustable vacuum air pumps hold the media on the print table during printing and transport. 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. A. PRELIMINARY ACTIVITIES
B. MANPOWER
C. SPECIAL TOOLS
Description Teflon tape Code

Description Code
E. PROCEDURE
! Disassemble
1 Disconnect the electrical connections and the compressed air connections.
1.1 Disconnect the electrical connection (1) 1.2 Open the clamping bracket at the air cylinder input (2). 1.3 Remove the grey flexible hose of the air cylinder input (2).
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REPAIR AND SERVICE
2 Remove the air controller (3) and the silencer (4).
! Assemble
1 Take the following items:
1 2
! !
Vacuum blower Air controller with air relief valve
Silencer
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:
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REPAIR AND SERVICE
2.1 Mount the silencer to the OUT side. 2.2 Mount the air controller to the IN side. 3 Establish the electrical connection. 4 Establish the compressed air connection. 4.1 Connect the grey flexible hose to the air cylinder input. NOTE: To avoid leakage, wind isolation tape around the cylinder input before attaching the hose.
4.2 Take a clamping bracket and put it over the hose. 4.3 Tie up the clamping bracket and tighten the crosshead screw.
5 Establish or check the following adjustments for the new vacuum blower. 5.1 Adjust the vacuum blower settings according to the engine configuration, star connection (Europe) or delta connection (USA). 5.2 Adjust the air relief valve according to the engine configuration (50 Hz or 60 Hz). Refer to Vacuum Blower Adjustments on page 3-89. 6 Finally, position the vacuum pump underneath the print table with the silencers directed to the side (roll bar bracket) of the print engine. Be aware that the vacuum pump is not positioned in the beam of the media detection signal sensor.
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REPAIR AND SERVICE
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.
IN OUT IN OUT
Ink Pump
Ink Filter
Solution Tank
Ink Bottle
Print Head Ink
Components Refill Unit

WARNING: Avoid heater temperature above 50C. 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
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REPAIR AND SERVICE
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
Qualification Service technician 1 Number of people Man-hours Execution time

Description Indicator PCB Refill Control PCB Refill PCB Code D2+2359109 D2+2359048 D2+2359049
E. PROCEDURE Briefly: 1 Locate the PCB that needs to be replaced. 1.1 Indicator PCB, refer to INDICATOR PCB on page 1-153. 1.2 Refill control PCB, refer to REFILL CONTROL PCB on page 1-150. 1.3 Refill PCB, refer to REFILL PCB on page 1-117. 2 Disconnect all connectors. 3 Remove the PCB and replace by a new one. NOTE: When you replace a PCB board, replace all fixing screws to assure a correct working of the PCB/ engine. Some fixing screws fulfill the function of earth connection 4 Reconnect all connectors.
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REPAIR AND SERVICE
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

Description Air filter (Color and White) Refill float sensor (Color and white) Circling motor (white) Twin Timer Code D2+2509046 D2+2357004 D2+2509165 D2+2509253
E. PROCEDURE
! Air filter (6C and W)

Refer to Inspecting and Replacing the Air Filter on page 4-55 (Chapter Preventive Maintenance).
3 - 26
REPAIR AND SERVICE
! 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.
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REPAIR AND SERVICE
5 Insert the new refill float sensor and tighten the nut. Note that the new refill float sensor (5) contains a refill float sensor cover (6) and a nut (7).
67 8 5
6 Guide the 3-pin connector through the nearest hole (8) in the ink supply door and reconnect the level sensor (step 2).
! Circling motor (White)

1 Open the ink supply door and remove the cover (1) above the main ink tanks.
2 Disconnect the stirrer drive connector (2) of the main white ink tank. The 2-pin connector with the red/blue wire is connected with the circling motor of the white main ink tank. The 2-pin connector with the black/white wire leads through the stirrer timer, also know as Twin Timer (3).
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REPAIR AND SERVICE
3 Unscrew the circling motor (4) from the main ink tank.
.
4 Insert the new circling motor (5) and guide the 2-pin connector through the nearest hole (6) in the ink supply door and reconnect the stirrer drive connector (7).
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REPAIR AND SERVICE
! Twin Timer
1 Open the ink supply door to get access to the twin timer. 2 Remove the old twin timer (1). Press the two blue buttons (2) to unlock the twin timer from the bracket.
4 2 3
3 Clamp the new twin timer on the bracket. 4 Adjust the ON (4) and OFF (3) timer of the stirring rod to the desired value (hour scale division).
! Main Ink tank
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REPAIR AND SERVICE
4.3.4. Replacement of the Ink Pump

B. MANPOWER

Description Ink pump (KNF) Code D2+2509047
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.
3 - 31
REPAIR AND SERVICE
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.
OUT IN 6 7
6.1 Disconnect the tube from the ink pump IN connection (7) and close the tube to avoid leakage. The ink pump IN connection tube is connected with the corresponding main ink tank. 6.2 Disconnect the tube from ink pump OUT connection(6) and close the tube to avoid leakage. The ink pump OUT connection tube is connected with the bottom of the corresponding ink filter. 6.3 Unscrew the 2 cross-slotted screws (8) and remove the old ink pump.
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REPAIR AND SERVICE
! Assemble:
1 Take out the new ink pump.
2 Mount the new ink pump
OUT IN
2 2
2.1 Mount the new ink tube to the pump fixing bracket (1). 2.2 Slide a clamping ring (2) over the two ink pump connections (IN and OUT). 2.3 Position the cable behind the tubes (3). 2.4 Attach the cable to the other cables using a tie wrap (4). 2.5 Wrap cable protection around the ink pump cables (5). 3 Reconnect the appropriate pump connector (6) to the Refill PCB.
3 - 33
REPAIR AND SERVICE
4 Reconnect the following ink pump tubes:
OUT
IN
4.1 Connect the tube coming from the bottom of the appropriate ink filter (IN) to the ink pump OUT connection (6). 4.2 Slide the clamping ring over the tube and clamp using a pincer. 4.3 Connect the tube coming from the appropriate main ink tank to the ink pump IN connection (7) 4.4 Slide the clamping ring over the tube and clamp using a pincer. 5 Close the refill case cover (8) and close the ink supply door.
3 - 34
REPAIR AND SERVICE
4.3.5. Replacement of the Ink Filter

B. MANPOWER

Description Ink filter Code D2+2509004
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.
3 - 35
REPAIR AND SERVICE
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.
3 - 36
REPAIR AND SERVICE
6 Remove the following tubes from the ink filter:

OUT 3
IN 4
6.1 Unscrew the tube on top (OUT) of the ink filter (3) and close the tube. The tube on top of the ink filter (OUT) leads to the hose fixing guide. To close the tube, use a closing cap from the new ink filter (the black flexible cap that fits over the tube connector) and put it on the open tube connector of the installed filter. 6.2 Unscrew the tube on the bottom (IN) of the ink filter (4) and close the tube. The tube at the bottom of the ink filter (IN) is coming from the corresponding ink pump OUT connection. To close the tube, use the second closing cap of the new ink filter. 7 Loosen the filter fixing bracket (5) and remove the old ink filter.
! Assemble
1 Take out the new ink filter. 2 Connect the tube coming from the ink pump OUT connection to the bottom of the new ink filter (IN). 3 Attach the new ink filter using the filter fixing bracket. 4 Connect the tube coming from the hose fixing guide to the top of the new ink filter (OUT). 5 Bleed the new ink filter. Refer to Bleeding the Ink Filters on page 4-56 (chapter Preventive Maintenance).
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REPAIR AND SERVICE
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.
Operation Move the head carriage to the purge position. Put the print engine in service mode. Reference Chapter 3 3.1.. Chapter 3 3.2.
B. MANPOWER
Qualification Service engineer. Number of people Man-hours Execution time
C. SPECIAL TOOLS
Description open-end wrench cross head screwdriver wire-cutter pincer Code

Description Tie wrap O-ring Ink filter Ink pump (KNF) D2+2509004 D2+2609047 Code
E. PROCEDURE NOTE: When replacing the ink tubes of a certain color located in the ink supply door, it is recommended to install a new ink filter and a new ink pump for that color. NOTE: The replacement procedure only discuss the replacement of the ink tubes. For the replacement of the ink pump and the ink filter, refer to Replacement of the Ink Pump on page 3-31 and Replacement of the Ink Filter on page 3-35. NOTE: The replacement procedure is written for one ink tube (e.g. of the white main ink tank). Repeat the procedure for the other ink tubes.
3 - 38
REPAIR AND SERVICE
! Disassemble:
Remove the ink tube between the main tank and the ink pump IN connection: 1 Open the ink supply door and remove the cover (1) above the main ink tanks.
2 Disconnect the ink outlet tube (2). To disconnect the ink outlet tube from the ink outlet pipe of the main ink tank, unscrew the brass M6 pipe bolt. 3 Close the ink outlet tube (3), with a cap, to avoid any leakage.
4 Pull the ink outlet tube out at the rear side of the ink supply door.
5 Disconnect the ink tube from the ink pump IN connection. 6 Put away the ink tube. Remove the ink tube between the ink filter OUT connection and the hose fixing guide: 7 Disconnect the ink tube from the hose fixing guide: 7.1 Remove the hose fixing bracket (5). 7.2 Disconnect the ink tube (6) and close the tube to avoid ink leakage.
REPAIR AND SERVICE
7.3 Close the ink tube coming from the hose fixing guide (7).
8 Remove the tube protection (8). 9 Pull the tube out of the refill case cover (9). 10 Take the ink tube out of the pump hose fixing bracket (10).
10
3 - 40
REPAIR AND SERVICE
11 Disconnect the ink tube from the ink filter OUT connection (top of the ink filter) (11). Close the filter cap to avoid leakage.
11
OUT
IN
12 Put away the ink tube. Remove the ink tube between the ink pump OUT connection and the ink filter IN connection: 13 Disconnect the ink tube from the ink pump OUT connection. 14 Disconnect the ink tube from the ink filter IN connection (bottom ink filter) and close it (1). Close the filter connection cap to avoid leakage (2).
15 Put away the ink tube. 16 Remove the ink filter. Refer to the disassemble procedure of Replacement of the Ink Filter on page 3-35. 17 Remove the ink pump. Refer to the disassemble procedure of Replacement of the Ink Pump on page 3-31.
! Assemble:
1 Mount a new ink filter. But use new ink tubes. Refer to the assemble procedure of the Replacement of the Ink Filter on page 3-35. 1.1 Connect a new ink tube from the top of the ink filter (OUT) to the corresponding ink hose (1). 1.2 Mount the hose fixing bracket (2).
3 - 41
REPAIR AND SERVICE
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).
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REPAIR AND SERVICE
4.3.7. Replacement of the Ink Tubes in the Chain

Operation Move the head carriage to the purge position. Put the print engine in service mode. Open the home rear door to get access to the hose fixing guide. Reference Chapter 3 3.1.. Chapter 3 3.2.
B. MANPOWER
C. SPECIAL TOOLS
Description open-end wrench wire-cutter Code

Description Tie wrap ink tube sticky tape Code
E. PROCEDURE NOTE: The replacement procedure is written for one ink tube. Repeat the procedure for the other ink tubes. 1 Get access to the hose fixing guide (1).
3 - 43
REPAIR AND SERVICE
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.
3 - 44
REPAIR AND SERVICE
6 Go to the purge side and open all purge doors to get access to the sub ink tank.
6.1 Disconnect the corresponding ink tube from the sub ink tank. 6.2 Cut the tie wrap that keep all ink tubes together at sub ink tank side. 6.3 Pull the old tube gently out of the chain until the new tube become visible. 6.4 Remove the old ink tube from the new ink tube. 7 Connect both sides of the new ink tube. One side to the sub ink tank, the other side to the hose fixing guide.
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REPAIR AND SERVICE
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.
IN OUT IN OUT
Ink Pump
Ink Filter
Solution Tank
Ink Bottle
Print Head
Components Head Carriage Unit
Ink
4.4.1. Replacement of the Sub Ink Tank (Color and White) Components
The following sub ink tank components are discussed:
! !
Float sensor (6C and W), Temperature sensor (6C and W).
B. MANPOWER
C. SPECIAL TOOLS None
3 - 46
REPAIR AND SERVICE

Description Float sensor (Color and White) Refill float sensor (Color and white) Code D2+2509129 D2+2509184
E. PROCEDURE
! Float sensor (6C and W)
-.- Not Available Yet -.! 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).
1
1 2
Air filter Speed V/V (AS1001F-06)
Pressure sensor (PSE531-M5-L)
3 - 47
REPAIR AND SERVICE
B. MANPOWER

Description Float sensor Pressure sensor (PSE531-M5-L) Air filter Speed V/V (AS1001F-06) Code D2+2509129 D2+2357005 D2+2509046
E. PROCEDURE
! Float sensor
-.- Not Available Yet -.! Pressure sensor

The pressure sensor PSE531-M5 on the top of sub air tank measures the negative pressure. The readout is feedback to ITV controller.
-.- Not Available Yet -.! 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:
-.- Not Available Yet -.To adjust the speed V/V: The underpressure setting (-0.032MPa) are influenced by the air relief valve, called Speed V/V (AS1001F-06) mounted on the sub air tank. In case of problems with the vacuum, you can regulate the strength of the negative pressure inside the sub air tank by tuning the air relief valve, speed V/V (AS1001F-06). This is an extra regulating
3 - 48
REPAIR AND SERVICE
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

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REPAIR AND SERVICE
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
Description Code

Description Electro-pneumatic regulator ITV2010 Air purge valve VT301V-025GB Air purge valve VT301-025GB Vacuum ejector (INO-4336-4) Encoder D2+2509170 D2+2162037 Code D2+2509028 D2+2509027
E. PROCEDURE
! Electro-pneumatic regulator ITV2010
3 - 50
REPAIR AND SERVICE
! Air purge valve VT301V-025GB and VT301-025GB
! Vacuum ejector (INO-4336-4)
! Encoder
3 - 51
REPAIR AND SERVICE
4.4.6. Replacement of the Waste Tank

B. MANPOWER

Description Refill float sensor Code D2+2357004
E. PROCEDURE 1 Disconnect the full detection sensor connector (2-pin), located in the cable trunk.
2 Unscrew the nut on top of the waste tank to remove the refill float sensor. 3 Remove the old refill float sensor. 4 Insert the new refill float sensor and tighten the nut. Note that the new refill float sensor contains a refill float sensor cover and a nut. 5 Connect the full detection sensor connector (2-pin) and close the cable trunk.
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REPAIR AND SERVICE
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
Ball screw upper unit Ball screw
Ball screw lower unit
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REPAIR AND SERVICE
B. MANPOWER

Description Step motor Ball screw upper unit Ball screw Ball screw lower unit Code D2+2501123
E. PROCEDURE A head crash can lead to bending of the lifting bar and as a result the bearings of the ball screw will be damaged after some time. The procedure below explains how to remove the ball screw.
! Disassemble
1 Lower the head carriage unit using the manual head height setting knob until the bolts (1) are in front of the service hole. The service hole is situated in the back plate of the liftable part of the head carriage unit.
2 Support the head carriage unit so the ball screw does not carry the head carriage unit. Use the head transport protection plate to support the head carriage unit on top off the ink tray.
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REPAIR AND SERVICE
3 Remove the step motor (2).
3 4 3 2
3.1 Loosen the screws of the coupling (3). 3.2 Remove the four bolts that fix the support bracket (4). 4 Remove the ball screw upper unit (5).
5 5
4.1 Remove the 4 screws. 4.2 Lift the ball screw unit over the shaft.
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REPAIR AND SERVICE
5 Remove the aluminium motor fixing plate (support bracket) (6) by unscrewing the 4 screws.
6 6
6 Release the moving plate fixing block (7). This plate is attached with 4 screws to the moving plate.
7 Release the ball screw lower unit (8) by unscrewing the 2 bolts (9). Those 2 bolts are in front of the service hole (refer to step 1).
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REPAIR AND SERVICE
8 Remove the ball screw (10).
10
11
8.1 Tilt the complete ball screw pen, with all surrounding components, out off the engine. 8.2 Disassemble this part and replace the broken part by new ones. NOTE: Be aware of the ball screw spring, it is still loaded. To unload, move the ball screw completely up. 8.3 To remove the moving plate fixing block (11), unlock and unscrew the lock nut () at the bottom. CAUTION: Do not remove the bearing from the shaft. The ball is not fixed.
! Assemble
To assemble, proceed in the opposite way.
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.
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REPAIR AND SERVICE
4.5.3. Replacement of the Head Base Lifting Assembly

Operation Move the head carriage to the purge position. Put the print engine in service mode. Reference Chapter 3 3.1.. Chapter 3 3.2.
B. MANPOWER
C. SPECIAL TOOLS
Description Code

Description Solenoid (small) solenoid (large) shading sensor (Omron) Code D2+2359104 D2+2359103 D2+2509104
E. PROCEDURE
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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

Description Head Lift PCB Head PCB Cartridge PCB Code D2+2359275 D2+2359045 D2+2359044
E. PROCEDURE Briefly: 1 Locate the PCB that needs to be replaced. 1.1 Head Lift PCB, refer to HEAD LIFT PCB on page 1-127. 1.2 Head PCB, refer to HEAD PCB on page 1-108. 1.3 Cartridge PCB, refer to CARTRIDGE PCB on page 1-123. 2 Disconnect all connectors. 3 Remove the PCB and replace by a new one. NOTE: When you replace a PCB board, replace all fixing screws to assure a correct working of the PCB/ engine. Some fixing screws fulfill the function of earth connection 4 Reconnect all connectors.
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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.
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REPAIR AND SERVICE
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.
K C M Y Lc Lm W spot W pre
Detail Magenta Print Head
Head Base Plate
Operation Move the head carriage to the purge position. Put the print engine in service mode. Put the print head valve of the heads that need to be replaced, to the solution outlet position (S). Put the solution valve on the ink outlet position (I). Reference Chapter 3 3.1. Chapter 3 3.2.
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Operation Open all purge doors (front, rear, left and top), to get full access to the head carriage unit. Remove the head cover of the head carriage unit by unscrewing the two crosshead screws on each side and the three crosshead screws on the front side. Place some towels in front of the purge grid to keep the working area clean.
Reference
B. MANPOWER
C. SPECIAL TOOLS
Description Allen Key no.1.5 and no.2.5 Crosshead screwdriver Long Philips screwdriver Spanner no.10 Long nose plier Code

Description Print Head (Spectra Nova 80pico) Teflon washer Head adjusting spring Spring fixing pipe Eccentric bushing shaft Wave washer Protective gloves Code D2+2409007 D2+2509185 D2+2501133 D2+2102156 D2+2102154 D2+2509186
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REPAIR AND SERVICE
E. PROCEDURE NOTE: The replacement procedure is written for the replacement of one print head (complete disassembly/assembly of the Magenta print head). Repeat the procedure if more than one print head has to be replaced.
! Disassemble:
1 Detach the following cables: 1.1 Detach the 4 data cables of the print head (1) from the CARTRIDGE PCB (2) using a plier.
Lc
2
1.2 Detach the black thermostat cable (3) which is connected to J29 of the HEAD PCB. NOTE: Only applicable for the Magenta head.
1.3 Detach the red heater cable (4) which is connected to the HEAD PCB.
Lc M Y Lc Lm
3, 4
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REPAIR AND SERVICE
2 Detach the metal head PCB frame from the head base plate by unscrewing the 5 bolts on top of the head carriage unit. Use a long Philips screwdriver.
3 Raise the complete assembly (5) (head PCB frame) on 2 foam blocks (6).
4 Loosen the head fixing (13) from the head base plate (12). 4.1 Unlock the Eccentric nut (11) using an Allen key no. 1.5. 4.2 Remove the nut (11) using spanner no.10. 4.3 Remove the teflon washer (8), eccentric bushing (7), wave washer (9) and the 2 black washers (10).
7 8
13
12
11
10
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REPAIR AND SERVICE
5 Remove head adjusting springs (14) in front and side using an Allen key no. 2.5.
14
15
14, 15, 16
16
6 Loosen the head adjusting bolt at the rear side of the print head until you are able to pull out the print head easily. Use a screwdriver. NOTE: The head adjusting bolts are the bolts which allows you to do the front/back alignment of the print head. 7 Loosen the ink tube (18) on of the print head valve.
17 18
7.1 Unscrew the locknut (17) underneath the print head valve. 7.2 Shear the tube (18) of each valve. 8 Remove the print head.
NOTE: Place the head always on the black side on the table. Not on the Aluminum side.
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9 Remove the print head (19) from the head fixing (Aluminum block) (20). Unscrew the 2 screws underneath the head.
19 20
! Assemble:
10 Take the new print head.
11 Change (renew) O rings (21) if head is removed from aluminum block. New O-rings are delivered with the new print head.
21
21
12 Mount the print head on the head fixing.
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REPAIR AND SERVICE
13 Reconnect the tube of the print head valve and manually tighten the locknut.
14 Place the print head into the head base plate. 15 Mount the head adjusting springs in front and side as illustrated. Use an Allen key no. 2.5. NOTE: Mind the order: socket screw, spring fixing pipe (22), teflon washer (23), head adjusting spring (24) and teflon washer (23).
24
23
22
16 Attach the head fixing (25) to the head base plate (26). 16.1 Mind the order: eccentric nut (27), teflon washer (28), eccentric bushing (29), wave washer (30) and the 2 black washers (31) with the smooth sides to each other. 16.2 Tighten the nut (27) finger tight.
25
26
27
28
29
30
31
31
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17 Remove the 2 foam blocks and lower the complete metal head PCB frame.
18 Attach the metal head PCB frame from the head base plate by screwing the 5 bolts on top of the head carriage unit. 19 Reconnect the following cables: 19.1 Connect the red heater cable to the Head PCB. 19.2 Connect the black thermostat cable to J29 of the Head PCB. NOTE: Only applicable for the Magenta head.
19.3 Connect the 4 data cables of the print head to the corresponding Cartridge PCB. 20 Finally, establish the following adjustments and alignment procedures for the new print head: 20.1 Adjusting the Head Base Temperature on page 3-91, 20.2 Adjusting the Head Voltage on page 3-92, 20.3 Hardware Alignment of the Print Head on page 3-94, 20.4 Software Alignment of the Print Head on page 3-95
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REPAIR AND SERVICE
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).
1 2 2 1 2
Thermistor (only for Magenta)
Heater bar
Operation Disassemble the print head. Reference 3 4.6.2., step 1 to 9.
B. MANPOWER
Qualification Service technician Number of people Man-hours Execution time
C. SPECIAL TOOLS
Description Code

Description Heater bar (Spectra) Thermistor (Spectra) (also called head temperature sensor) Code D2+2401001 D2+2409006
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E. PROCEDURE 1 Put the head fixing on his side and remove the head heather fixing plate (1). 2 Remove the heater bar (2) and the thermistor (3).
1 2 3
NOTE: Thermistor, only applicable for the Magenta head.
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.
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REPAIR AND SERVICE
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). A. PRELIMINARY ACTIVITIES
Operation Move the head carriage to the purge position. Put the print engine in service mode. Open the top purge door to get full access to the head base plate Reference Chapter 3 3.1. Chapter 3 3.2.
B. MANPOWER
C. SPECIAL TOOLS
Description cross-slotted screwdriver Code

Description Temperature sensor stick (rear) Code D2+2509184
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.
REPAIR AND SERVICE
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 3
4 6
5 8 6
1 2 3 4
UV lamp box (left) UV lamp box (right) Lamp case outer air inlet AC fan UV Lamp fixing
5 6 7 8
Lamp shutter UV lamp box housing Lamp case inner air outlet DC fan Lamp (190 mm)

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REPAIR AND SERVICE
4.7.2. Replacement of the UV Lamp Box

Operation Left UV lamp box: Move the head carriage to the purge position. Right UV lamp Box: Move the head carriage to the home position. Put the print engine in service mode. 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. Reference Chapter 3 3.1.
Chapter 3 3.2.
B. MANPOWER
C. SPECIAL TOOLS
Description Allen Key no. Crosshead screwdriver Code

Description Code
E. PROCEDURE NOTE: The replacement procedure is written for the left UV lamp box. If you want to remove the right UV lamp box, move the head carriage to the home position (front right side) and execute the same procedure as for the left UV lamp box. 1 Detach the UV lamp box from the UV lamp box housing by unscrewing the two head screws (1). 2 Disconnect the lamp power connector (4-pin) (2).
View: Purge side
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REPAIR AND SERVICE
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

Operation Left UV lamp box: Move the head carriage to the purge position. Right UV lamp Box: Move the head carriage to the home position. Put the print engine in service mode. 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. Reference Chapter 3 3.1.
Chapter 3 3.2.
B. MANPOWER
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REPAIR AND SERVICE
C. SPECIAL TOOLS

Description Code
E. PROCEDURE NOTE: The replacement procedure is written for the left UV lamp box. If you want to remove the right UV lamp box, move the head carriage to the home position (front right side) and execute the same procedure as for the left UV lamp box. 1 Disconnect the following electrical connections:
3 1 2
1.1 Disconnect the yellow lamp shutter on pneumatic connector (1). 1.2 Disconnect the red lamp shutter off pneumatic connector (3). 1.3 Disconnect the lamp signal connector (label = LAMP-L-SIG) (2). 1.4 Disconnect the lamp shutter signal connector (label = LAMP SHUTTER L) (4). 2 Dismount the UV lamp box housing by unscrewing the four head screws.
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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. A. PRELIMINARY ACTIVITIES
Operation Remove the UV lamp box Reference Chapter3 4.7.2.
B. MANPOWER
C. SPECIAL TOOLS

Description Code
E. PROCEDURE 1 Unscrew the following screws: 1.1 2 x 4 screws of the fan grid (1). 1.2 4 screws of the 4 pin lamp power connector (2).
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REPAIR AND SERVICE
1.3 Screws at the front (3) and rear (4) side of the UV lamp box cover.
2 Remove the reflector bracket from the cover as illustrated in the four steps below.
step 1
step 2
step 3
step 4
WARNING: Do not touch the reflector surface.
3 Replace the AC fan(s) by a new one. Be careful with the electrical connections.
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REPAIR AND SERVICE
4 Mount the reflector bracket back into the cover as illustrated in the five steps below.
step 1
step 2
step 3
step 4
step 5
4.1 First, slide the reflector bracket partly into the cover. 4.2 Mount the 4 pin power connector and tighten the screws. 4.3 Then pull the reflector bracket completely into the cover. This to be sure not to touch the reflector surface.
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5 Reassemble the AC fans and the grids as illustrated in the three steps below.
step 1
step 2
step 3
6 Mount the UV lamp box back into the UV lamp box housing. Refer to Replacement of the UV Lamp Box on page 3-73.
4.7.5. Replacement of the Air Oulet DC Fan

4.7.6. Replacement of the Ignitor

Operation Remove the UV lamp box. Reference Chapter3 4.7.2.
B. MANPOWER
C. SPECIAL TOOLS

Description Ignitor Code D2+
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REPAIR AND SERVICE
E. PROCEDURE 1 Remove the reflector bracket from the UV lamp box cover. Refer to Replacement of the Air Inlet AC Fan on page 3-76, step 1 to 2. 2 Remove the old ignitor and replace by a new one as illustrated in the three steps below. NOTE: There are two ignitor types available. The way how to connect the electrical wires depends on the ignitor type. (See step 3 in the illustration below).
step 1
step 2
step 3
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).
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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

Operation Move the head carriage to the purge position. Put the print engine in service mode. Open the front and left purge door to get full access to the UV lamp box. Reference Chapter 3 3.1. Chapter 3 3.2.
B. MANPOWER
C. SPECIAL TOOLS
Description cross-slotted screwdriver Code

Description 110'C THERMISTOR Code D2+2509134
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.
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! Replacement of the thermistor mounted on the reflection cap of the UV lamp box
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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 slot PC Main Board
FPGA PCB
PC Main Board
PCI I/O Card
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REPAIR AND SERVICE
5.2. Replacement of the PCI I/O Card

Operation Move the head carriage to the purge position. Put the print engine in service mode. Open the ink supply door to get access to the main box right. Reference Chapter 3 3.1. Chapter 3 3.2.
B. MANPOWER

Description PCI I/O card Code D2+2359062
E. PROCEDURE
! Mechanical
-.- Not Available Yet -.! Driver Installation

1 Put the PCI card driver into CD ROM drive. 2 Select Driver Installation.
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3 Select NuDAQ PCI.
4 Select PCI-7200.
5 Select WIN98/NT/2000/XP DLL DRIVER(PCIS-DASK) to start the installation.
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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.
REPAIR AND SERVICE
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.
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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.
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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.
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REPAIR AND SERVICE
2.3 Close the air inlet by holding a piece of foam in front of the inlet tube of a running blower. 2.4 Remove the cover of the air controller.
2.5 Check if the rotation direction of the vacuum pump corresponds with the arrow indication on the vacuum pump. If not, switch two phases (e.g. L1 and L2). 2.6 Measure the current around the vacuum blowers power cable. 2.7 Adjust the spring tension, by turning the head screw, until you measure the rated current indicated on the identification plate. NOTE: Turn the head screw clock wise to increase the current.
If the spring is at its end position and you can still measure a current lower then the nominal current, screw the spring back approximately 5 turns until the current lowers, in order to have a little bit of spurious air for cooling.
Vacuum blower 1
Vacuum blower 2
NOTE: Secure the fixing bolt into the nut.
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REPAIR AND SERVICE
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.
NOTE: Refer to Head Base Temperature Control on page 1-63 of the chapter Functional Description.
6.2.1.2. Procedure
To adjust the head base temperature: 1 Adjust the head PCB voltage of the head PCB by turning the blue VR temperature potentiometer clock wise (CW) or counter clock wise (CCW). The head PCB is positioned underneath the sub ink tank. 2 Turn CCW to lower the temperature. Note that a voltage of approximately 1.6 V can be seen as guidance and corresponds with a temperature of 32C on most engine configurations. The higher the voltage value, the lower the temperature value.
Head PCB
Cartridge PCBs
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REPAIR AND SERVICE
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 corresponding Agfa voltage using the correction table below.
Drive voltage Anapurna heads Spectra recommended voltage for Nova head : Correction factor for Anapurna G1 at 35C: Corrected voltages for Anapurna G1Inks: Black 92 Cyan 92 Magenta Yellow 93 92 Li. Cyan 90 Li Mag. white 1 white 2 91 94 92
1 0,911702 0,9537634 0,98495 92,0 83,9 88,7 90,6
0,98418 1,034483 88,6 94,1
0,0
0,0
1 2 3
2.1 Fill in the recommended value (1), which you can find on the paper of the manufacturer (e.g. Magenta 92) 2.2 Multiply the value with the correction factor (2) for that color (e.g. Cyan 0.911702) to become the correct voltage (3) for the Anapurna head (e.g. 83.9).
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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.
6 6 Cartridge PCB
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REPAIR AND SERVICE
6.2.3. Hardware Alignment of the Print Head

NOTE: Except for pre-white
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.
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REPAIR AND SERVICE
! 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: 1 In the Control Program, click Setup.
The Setup Parameters window appears. 2 In the Setup Parameters window, click Factory Set (3).
3 Enter the password (4) and click OK. The Factory Data Setting window appears.
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REPAIR AND SERVICE
4 Change the Head Offset values (e.g. K CY) 4.1 If CY has to move to the right: decrease the current value. 4.2 If CY has to move to the left: increase the current value.
f
5 After changing the values, Click Save. The Setup Parameters window appears. 6 Click Save As and create a new .dat file, or overwrite the old one.
6.2.5. Media Feed Correction

For a brief description, refer to Step Size (Media Feed) on page 1-82 (chapter Functional Description). 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.
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REPAIR AND SERVICE
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. A. PRELIMINARY ACTIVITIES None B. MANPOWER
C. SPECIAL TOOLS
Description Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Loosen the tension on the belt:
NOTE: In case you have mounted a new conveyer belt, skip step 1.
1.1 Remove the metal black cover on the left and right rear side.
1.2 Completely unscrew the left and right tension bolt (rotate CCW) to loosen the tension.
2 Position the conveyer belt 2.1 Move the conveyer belt until the belts joint is positioned in the middle at the underside of the printing table.
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REPAIR AND SERVICE
2.2 Go to the rear side of the print engine and measure the distance from the left/right side of the printing table to the conveyer belt. Do the same at the front side of the print engine. This measured distance should be equal, on front side as well as on rear side of the engine. 3 Tighten the conveyer belt. Alternately tighten the left and right tension bold. Only tighten maximal one complete turn a time. 4 Execute a transport test. 4.1 Mark the position of the belt regard to the printing table. 4.2 Move the conveyer belt for at least 10 minutes. 4.3 Mark the position of the belt regard to the printing table and measure the difference regard to the measurement before moving the conveyer belt.
5 Eliminate the measured difference by adjusting the belt tension. 5.1 Loosen the conveyer belt completely. 5.2 Reposition the conveyer belt and use the same marking technique as in step 2 and 4. 5.3 Tighten the conveyer belt taking the measured difference into consideration.
t
Measured distance < 0,5 cm increase the tension with the same amount on the side where the belt was moving to.
Measured distance > 0,5 cm increase the tension with half of the measured difference on the side where the belt was moving to. reduce the tension with half of the measured difference on the side where the belt was moving from.
6 Execute a transport test: 6.1 Move the conveyer belt for at least 10 minutes. 6.2 Check the markings on the conveyer belt and printing table.
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REPAIR AND SERVICE
NOTE: The position of the belt should not move more than 2 mm.
6.3 If necessary, adjust the position of the belt. Rotate the left and/or right tension bolt CW or CCW to control the tension while the conveyer belt is moving. NOTE: The position of the conveyer belt can still move slightly during daily production. Those small shifts can be removed by rotating the left and/or right tension bolt CW or CCW. For more information, refer to Inspecting and Adjusting the Conveyer Belt Tension on page 4-7of the Preventive Maintenance chapter.
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. A. PRELIMINARY ACTIVITIES None B. MANPOWER
C. SPECIAL TOOLS
Description Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS 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.
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REPAIR AND SERVICE
As a result, the head carriage unit can be moved easily by hand. 6 Lower the head carriage unit using the manual head height setting knob until the gap between dibond plate and base plate is around 2mm. Refer to Manual head height setting knob on page 1-58 (chapter Functional Description). 6.1 Measure the gap left right, front back. 6.2 Check if the max deviation of the four measurements is within tolerance. (maximum deviation is <0.5mm). 6.3 If the parallelism of the base plate is out of tolerance an adjustment of the base plate is advisable. 7 Reconnect the connector between the carriage servo motor and servo carriage driver.
! 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
Base plate Print table
1 2 2
Base plate
1 Locate the right-hand mounting hook (3). 2 Loosen the 2 fixing screws (2) of mounting hook (3). 3 Adjust the parallelism within tolerance by using the top screw (1). 4 Fasten the fixing screws again (2). 5 Repeat step 2 to 4 for the left-hand mounting hook (4). 6 Check if the tolerances are within the tolerances. Repeat if necessary.
3 - 100
REPAIR AND SERVICE
! 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
Reference Blocks
1 1
Jig
Head base back panel
1 Execute the head gap control partly. Click OK and the head carriage unit will move above the print table Refer to Executing a head gap control on page 1-84 (chapter Functional Description). 2 Push one of the emergency buttons to cut off the power. 3 On top of the fixed back panel of the head carriage unit you will find 2 reference blocks (1),this are the zero points.This is the reference to adjust the head carriage unit and is set in the factory. NOTE: Never loose the bolts of the reference blocks.
3 - 101
REPAIR AND SERVICE
4 To check the evenness of the head carriage unit use the 2 jigs (2) which are delivered with the engine as showed in the Figure 3.2. 5 Place the jigs on top of the back panel and the reference blocks using the manual head height setting knob. 6 If there is a difference release the adjustment screws (3) marked green as showed in the Figure 3.2. 7 Once an adjustment is done, put the jigs back in to see whether the position of the back plate is the same left to right. 8 Tighten the adjustment bolts if the back plate is leveled against the zero points. 9 Double check the level of the base plate by measuring the gap between base plate and print table.
3 - 102
REPAIR AND SERVICE
6.5. Lamp house Alignment

B. MANPOWER
C. SPECIAL TOOLS
Description Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE
! Lamp house Left-Right alignment control.

For Left-Right alignment, adjust 2 screws.
Left alignment
Right alignment
3 - 103
REPAIR AND SERVICE
! Lamp house Top-Left tilt alignment control.

For Top-Down alignment, there is a fixed bolt and one screw that can be adjusted.
3 - 104
CHAPTER
This chapter describes the preventive maintenance procedures for the Anapurna L/XL. 1. Maintenance Schedule ........................................................................................................................................ 4 - 2 2. Print Media Unit Maintenance .......................................................................................................................... 4 - 5 2.1. Guidelines and Specific Safety Instruction ..................................................................................... 4 - 5 2.2. Conveyer Belt ............................................................................................................................................ 4 - 6 2.3. Vacuum Holes ............................................................................................................................................ 4 - 9 2.4. LM Guide .................................................................................................................................................. 4 - 10 2.5. LM Blocks ................................................................................................................................................. 4 - 11 2.6. Carriage Belt (S5M Belt) ..................................................................................................................... 4 - 13 2.7. S3M Belt ................................................................................................................................................... 4 - 16 2.8. Linear Scale Encoder ............................................................................................................................ 4 - 24 2.9. Bearings Print Media Unit .................................................................................................................. 4 - 33 2.10. Waste Tank ............................................................................................................................................ 4 - 35 3. Head Carriage Unit Maintenance .................................................................................................................. 4 - 36 3.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 36 3.2. Print Head ................................................................................................................................................. 4 - 38 3.3. UV Lamp Box / UV Lamp Box Housing ......................................................................................... 4 - 46 3.4. Head Carriage ......................................................................................................................................... 4 - 53 4. Refill Unit Maintenance .................................................................................................................................... 4 - 54 4.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 54 4.2. Air filter 6 Color and White ............................................................................................................... 4 - 55 4.3. Ink Filter .................................................................................................................................................... 4 - 56 5. Purge Unit Maintenance ................................................................................................................................... 4 - 63 5.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 63 5.2. Purge box .................................................................................................................................................. 4 - 63 6. Home Unit Maintenance .................................................................................................................................. 4 - 65 6.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 65 6.2. Home box ................................................................................................................................................. 4 - 65 7. Safety Circuit ......................................................................................................................................................... 4 - 67 7.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 67 7.2. Emergency Stop Circuit ....................................................................................................................... 4 - 67 8. Air Tank Maintenance ........................................................................................................................................ 4 - 69 8.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 69 8.2. Air Tank ..................................................................................................................................................... 4 - 69 9. Air Pressure Panel Maintenance .................................................................................................................... 4 - 70 9.1. Guidelines and Specific Safety Instruction .................................................................................. 4 - 70 9.2. Air Pressure Panel ................................................................................................................................. 4 - 70 10. Engine ................................................................................................................................................................... 4 - 75 10.1. Guidelines and Specific Safety Instruction ............................................................................... 4 - 75 10.2. Engine Level ......................................................................................................................................... 4 - 75
4-1
PREVENTIVE MAINTENANCE
MAINTENANCE SCHEDULE
1. Maintenance Schedule
Unit Head Carriage unit Component Print head Print head Frequency Daily Daily Activity Clean Nozzle Check and purge or clean the failed heads if necessary Clean Cleaning solution Crystal Plate (190)(8C) D2+2509166 Operator Inspect and clean lint-free cloth if necessary with isopropyl alcohol (IPA) Check for printing print outs and curing quality Check for printing and curing quality and replace both UV lamp if necessary Replace lamp 190 mm D2+2509221 Required Tools lint-free cloth Spare Part Name Spare Part Order Code Operator/ Service See ... Engineer Operator Operator 4 3.2.1. 4 3.2.1.
Print head Crystal Glass plate (UV lamp box housing left and right)
Weekly 1 Month
4 3.2.1. 4 3.3.1.
Print Head / UV lamp 1 Month box Print Head / UV lamp 3 Month box
4 3.3.2. 4 3.3.2. 4 3.3.3.
UV lamp (UV lamp box; left and right) Lamp Shutter
6 Month
Lamp 190 mm D2+2509221 Operator
4 3.3.3.
1 Year
Inspect shutter functionality and replace if malfunctioning Inspect and clean Acetone if necessary Grease AFB lubricating grease
SHUTTER (190 D2+2359234 LAMP)(8C)
4 3.3.4. 4 3.3.5. Operator 4 2.4.1.
LM guide (Head Carriage) LM blocks (Head Carriage) Head PCB (Head Carriage) Head base plate (Head Carriage)
1 Month
6 Month
4 2.5.1.
1 Year
Inspect the head voltage Inspect the head base plate parallelism
4 3.4.2. (3 6.2.2.) 4 3.4.3. (3 6.4.1.)
1 Year
4-2
Unit
Component
Frequency 1 Month
Activity
Required Tools
Spare Part Name
Spare Part Order Code
Operator/ See ... Service Engineer Operator 4 2.4.1.
Print Media LM guide unit (Frame Assembly Box Beam) LM blocks (Frame Assembly Box Beam)
Inspect and clean Acetone if necessary
6 Month
Grease
AFB lubricating grease
4 2.5.1.
Linear scale encoder 1 Month (Frame Assembly Box Beam) S5M belt (15 mm) (= carriage belt) S3M belt (564 mm) 6 Month 6 Month
Inspect and clean Acetone or isoif necessary propyl alcohol (IPA) Inspect the tension and re tension if necessary Replace Inspect the position and re position if necessary Replace S3M BELT (564mm), black Bearing UFL004 D2+2959024 S5M BELT (15mm), grey D2+2959029
Operator
4 2.8.1.
4 2.6.1.
4 2.6.2. 4 2.7.1.
1 Year
4 2.7.2.
Bearing UFL004 (Double Pulley Assembly) Idle pulley bearing (Idle Pulley Assembly)
6 Month
Inspect and grease
D2+2509194
4 2.9.1.
6 Month
Inspect and grease
4 2.9.1.
Tension Roll Bearings 6 Month Bearings Rigid Table Bearing UFL diameter 40 (Frame Assembly) Conveyer belt Weekly 6 Month 6 Month
Grease Grease Inspect and grease
4 2.9.1. 4 2.9.1. 4 2.9.1.
Clean, inspect and re tension if necessary Inspect the position and adjust if necessary Replace Conveyer belt D2+2503014 XL Conveyer belt D2+2503015 L
Operator
4 2.2.1.
1 Month
Operator
4 2.2.2.
6 Month
4 2.2.3. (3 4.2.2.) 4 2.2.4. (3 6.3.) 4 2.3.1.
Vacuum holes
6 Month
Inspect vacuum holes and clean if necessary Inspect and empty if necessary
Waste tank
Weekly
4 2.10.1.
4-3
Unit
Component
Frequency
Activity Inspect the functionality Grease assy Inspect for any moisture and replace if necessary Bleed ink filters Replace if necessary
Required Tools
Spare Part Name
Spare Part Order Code
Operator/ See ... Service Engineer
Print Media Media thickness sen- 6 Month unit sor 6 Month Refill unit Air filter (6C) Air filter (W) Daily
4 4.2.1.
Ink Filter
6 Month 1 Year
4 4.3.1. Ink filter D2+2509004 Operator 4 4.3.3. 4 5.2.1.
Purge unit
Grid (Ink fixing upholder #1 and #2) Ink receiving bin (Purge fixing upholder #3)
Weekly
Inspect and clean Filling knife or if necessary screw driver. Solution. Inspect waste Filling knife or barrel and pierce screw driver hole. Clean if necessary Inspect and clean Filling knife or if necessary screw driver. Solution. Drain Drain Replace Inspect all four emergency stops Inspect the functionality Door sensor (Front/Rear) Door sensor controller (PA10-U) D2+2509239 D2+2509238 Air filter AF20-01BG Air filter AF20-01BG D2+2509015
1 Year
Operator
4 5.2.2.
Home unit
Grid (Ink fixing upholder #1 and #2)
Weekly
Operator
4 6.2.1.
Air tank
Air tank
6 Month 6 Month 1 Year
4 8.2.1. 4 9.2.1. 4 9.2.2. 4 7.2.1.
Air pressure Air filter panel
Safety circuit
Emergency Stops Door Open Sensor
1 Year
Engine
Spirit level Covers and lockers
1 Year
Inspect and level Nut wrench no. again if necessary 36
4 10.2.1.
4-4
PRINT MEDIA UNIT MAINTENANCE
2. Print Media Unit Maintenance

2.1. Guidelines and Specific Safety Instruction
!
Handling UV Curable ink
WARNING: Be aware of the waste disposal and regulations that bear on UV curable ink. Always follow the instructions on the label of the ink cartridge. UV radiation
WARNING: UV light can cause harmful damage to eyes and skin. Therefore never look into UV light without wearing protective glasses. Never exposure your skin to UV light. Maintenance safety instructions
4-5
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. A. PRELIMINARY ACTIVITIES None B. MANPOWER
Qualification Operator 1 Number of people Man-hours Execution time

Description Cleaning solution Cleaning cloth Code
E. PROCEDURE 1 Remove the ink using a cloth moistened with cleaning solution. 2 Check the proper functioning of the two vacuum zones. Test the two vacuum zones by using the vacuum switch/button located at the home unit (respectively front/rear) and in the meantime verify the correct functioning of the white tower lamp and measure the PLC outputs P041, P042 and P048. For more information refer to Vacuum Plate Usage on page 1-31 (chapter Functional Description). NOTE: When the belt is completely printed, vacuum can become insufficient.
3 If cleaning does not result in a proper vacuum functioning you need either to:
!
clean the vacuum holes. For more information about cleaning the vacuum holes, refer to Inspecting and Cleaning the Vacuum Holes on page 4-9.
or
!
replace the conveyer belt. For more information about replacing the conveyer belt, refer to Replacement of the Conveyer Belt on page 3-13 of the chapter Repair and Service.
4-6
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. A. PRELIMINARY ACTIVITIES
B. MANPOWER
C. SPECIAL TOOLS
Description Allen Key no. 12 Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Do the following two checks: 1 Manually check the tension of the belt.
2 Check if the belt is touching the left and right guide narrowly.
4-7
2 If the belt tension is sufficiently and the belt is touching the left and right side narrowly, adjustments are not necessary. 3 In case of a too low belt tension or a belt bending near the left and/or right guide, adjust the belt tensioning. Proceed with step 4.
4 Remove the metal black cover on the left and right rear side.
5 Rotate the left and/or right tension bolt CW or CCW to adjust the tension (that implies adjusting the position). NOTE: These small adjustments can be done while the conveyer belt is moving.
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).
4-8
2.3. Vacuum Holes

2.3.1. Inspecting and Cleaning the Vacuum Holes
A. PRELIMINARY ACTIVITIES None B. MANPOWER
Qualification Service technician 1 Number of people Man-hours 20 20 Execution time
C. SPECIAL TOOLS
Description Syringe needle Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Remove the conveyer belt. Refer to Replacement of the Conveyer Belt on page 3-13, step 1 to 3 (chapter Repair and Service). 2 Puncture all holes of the vacuum table using a syringe needle. This to open the points where the vacuum holes interfere with the honeycomb structure inside the table. CAUTION: Do not use a drill to puncture the holes.
3 Fit the old conveyer belt. Refer to Replacement of the Conveyer Belt on page 3-13, step 3 to 8 (chapter Repair and Service). NOTE: Refitting the old belt is not always possible.
4-9
2.4. LM Guide
The head carriage unit can move in two directions:
!
Horizontal movement from purge to home position and vice versa along 2 LM guides, also know as carriage rail.
1 2
3 4
1 2
!
Upper LM guide Linear scale (Encoder strip)
3 4
Lower LM guide S3M belt, carriage belt
Vertical movement head lifting along the along 2 LM guides (head lifting type).
2.4.1. Inspecting and Cleaning the LM Guide

B. MANPOWER

Description Acetone Code
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.
4 - 10
2.5. LM Blocks
There are 4 LM blocks at the back side of the head carriage unit, which guide the head carriage unit along the upper and lower LM guide. Greasing the LM blocks should be done regularly, in particular every 6 Months or depending on the operating conditions. Insufficient grease causes noise sounds of the head carriage unit, printing quality deterioration, and can reduce the Anapurnas life expectancy.
2.5.1. Greasing the LM Blocks

B. MANPOWER
C. SPECIAL TOOLS
Description Spray gun MG70 Code

Description AFB lubricating grease Code
4 - 11
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.
4 - 12
2.6. Carriage Belt (S5M Belt)

2.6.1. Inspecting the Carriage Belt (S5M)
Operation Move the head carriage to the purge position. Reference Chapter 3 3.1.
B. MANPOWER
C. SPECIAL TOOLS None D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Manually inspect the tension of the carriage belt (no belt sag?) (1) and re tension if necessary. 1.1 Open the purge left side door to get access to the idle pulley assembly. 1.2 Tighten the two socket screws (2) to re tension the carriage belt (1).
4 - 13
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.
4 - 14
2.6.2. Replacing the Carriage Belt (S5M)

B. MANPOWER

Description S5M Belt (15 mm), grey Code D2+2959029
E. PROCEDURE
Idle pulley
Bearing
4 - 15
2.7. S3M Belt

2.7.1. Inspecting the Position of the S3M Belt
C. SPECIAL TOOLS
Description Jig Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Open the home right side door to get access to the double pulley assembly. 2 Remove the double pulley protection cover (1) by unscrewing 5 screws.
3 Inspect the position of the S3M belt on the double pulley.
S3M belt not centred
S3M belt centred
4 - 16
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 6
NOTE: The tension of the S3M belt is determined by the distance between the double pulley and the motor pulley 5 Replace and fix the double pulley protection cover.
4 - 17
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.
Double pulley
S5M belt
Carriage servo motor Motor pulley S3M belt
Bearing ULF004
Bearing height adjusting block
B. MANPOWER
C. SPECIAL TOOLS None
4 - 18

Description S3M Belt (564 mm), black Code D2+2959024
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).
4 - 19
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.
4 - 20
8 Loosen 2 screw bolt (10) of the 2 bearing height adjusting blocks (11) at carriage servo motor side and remove the ULF004 bearing (12).
10
11 10 11
12
9 Remove the old S3M belt (13).
13
NOTE: For convenience's sake, you can loosen the tension of the carriage belt (S5M) (14) by unscrewing the 2 socket screws (15) of the idle pulley assembly (purge side).
15
14
15
4 - 21
10 Insert (wriggle) the new S3M belt along the right double pulley fixing bracket (16).
16
11 Remount the ULF004 bearing (17) and the ring (18) at carriage servo motor side.
17
18
12 Remount the ring (19) of the ULF Bearing at the opposite side.
19
4 - 22
13 Remount the double pulley fixing support (20).
20
14 Remount the carriage driver motor (21) using the 4 socket-head screws.
21
NOTE: If you have loosen the tension of the carriage belt (S5M) in step 9, re tension the carriage belt. Refer to Inspecting the Carriage Belt (S5M) on page 4-13, step 1. 15 Finally, establish the following two belt alignments:
!
Aligning the S3M belt. Refer to Inspecting the Position of the S3M Belt on page 4-16. Aligning the S5M belt. Refer to Inspecting the Carriage Belt (S5M) on page 4-13, step 2.
4 - 23
2.8. Linear Scale Encoder

2.8.1. Inspecting and Cleaning the Encoder Strip

Description Isopropyl alcohol Acetone Code
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.
4 - 24
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.

C. SPECIAL TOOLS None D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 In the Control Program, click Test.
The Test Menu window appears. 2 In the Test Menu window, select Enc. Count Test (1) and click Test (2).
4 - 25
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.
The Setup Parameters window appears. 3.2 In the Setup Parameters window, click Factory Set (3).
3.3 Enter the password (4) and click OK. The Factory Data Setting window appears. 3.4 Note down the following regulated values submitted by the manufacturer when the machine is shipped out. Max. Platen Size (5), Home Pos.Offset (6), Max. Mark Count (7) and Carriage Gear Ratio (8). NOTE: The default set value for the Carriage Gear Ratio (8) is always 7742.
4 - 26
6 7
4 Execute a field-test to determine the Max. Platen Size (5), Home Pos.Offset (6) and Max. Mark Count (7) values. This field-test involves three tests to be executed one after another: 4.1 Manually determine the number of marks (Max. Mark Count value) on the linear scale. Refer to Determining the number of marks on the linear scale on page 4-28. 4.2 Define the Home Pos.Offset value. Refer to Defining the Home Position Offset on page 4-29. 4.3 Test the number of pulses the encoder reader counts. Refer to Testing the number of pulses the encoder reader counts on page 4-30. 5 If necessary, adjust the values Max. Platen Size (5), Home Pos.Offset (6), Max. Mark Count (7) in the Factory Data Setting window. NOTE: When you change one of the three parameters, do not forget to download the parameters to validate the new values. See option Parameter Download in the Test Menu window. For more information about downloading parameters, refer to Parameter Download on page 1-89 (chapter Functional Description). 6 In the Control Program, click Test and select Jet Test to check the condition of the nozzle. Refer to Nozzle Check on page 4-40. 7 Print a sample and check the printing quality. 8 Clean the linear scale with acetone. Refer to Inspecting and Cleaning the Encoder Strip on page 4-24.
4 - 27
! 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: 1 In the Control Program, click Test.
The Test Menu window appears. 2 In the Test Menu window, select Carriage Release Test (1) and click Test (2).
As a result, the head carriage unit can be moved manually from home side to purge side. 3 First, push the head carriage unit to the limit switch (3), located in the home unit.
4 Secondly, slowly push the head carriage unit to the purge side (left) until you encounter the first MARK. Note this mark as the first mark. NOTE: MARK = 1 thick stripe every 50 mm.
5 Then, manually move the head carriage unit towards the purge side (left), while counting the number of MARKs the head carriage unit passes during the movement. Stop pushing the head carriage unit just before the head carriage unit touches the purge shock absorber.
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.
NOTE: Make sure that the head carriage unit is in home position (front right side)
To define the home position offset, proceed as follows: 1 Execute a Carriage Release Test. For more information on how to execute a Carriage Release Test, refer to Determining the number of marks on the linear scale on page 4-28, step 1 and 2. 2 First, push the head carriage unit to the limit switch (1), located in the home unit (= Detected home position).
3 Secondly, slowly push the head carriage unit towards the purge side and stop the head carriage unit just before you can see the first MARK (= real home position). 4 Measure the distance the head carriage unit has travelled between those 2 positions (step 2 and step 3). 5 Calculate the home position offset. Home Pos. Offset = measured distance in mm (step 4) x 154 and round down to the nearest 1000 (thousands). 6 Execute the following verification test to determine whether you need to fine-tune the calculated Home Pos. Offset of step 5. 6.1 Fill in the calculated Home Pos. Offset value in the Factory Data Setting window. 6.2 Execute a parameter download. In the Control Program, click Test to open the Test Menu window. In the Test Menu window, select Parameter Download and click Test.
4 - 29
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

1 In the Control Program, click Setup. 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.
4 - 30
4.1 In the Control Program, click Purge (1). 4.2 The message "Carriage Clear to Move..?" appears. 4.3 Hold your PC mouse on the Yes button. 5 Press the Enter key on your keyboard and count how many times the MARK LED (5) flashes at the Main PCB (3) while the head carriage unit is moving towards the purge side.
3 4 5
3 4
Main PCB ENC LED (Encoder)
Mark LED
NOTE: The number of pulses should be the same as the value filled in the Max. Mark Count field in the Factory Data Setting window. 6 Count how many times the MARK LED (5) flashes at the Main PCB (3) while the head carriage unit is moving from home to purge. The number of counted pulses should be the same as from purge to home (see step 5). If not the encoder head is slanting or the distance encoder head/encoder scale is incorrect. Adjust the depth between the encoder head and the encoder scale. See d. 7 Finally, execute the encoder test (Enc. Count Test in the Test Menu window) at low carriage speed (6) and afterwards at normal carriage speed (7). Normally there should be no error message and the ENC and Mark LED at the MAIN PCB are flashing.
4 - 31
! 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)
1 2
Encoder Linear scale (encoder strip)
3 4
Encoder bracket (view: home right side door side) Encoder bracket (view: purge top door)
4 Adjust the distance between the encoder head (1) and the linear scale (2) by unscrewing/ screwing the two bolts on top of the encoder bracket (3). NOTE: If you are not able to reach the two bolts when the head carriage is in the home position, execute the procedure at the purge position, where you can easily reach the two bolts of the encoder bracket (4) via the purge top door. 5 Make sure that you can remove the plastic 0.5 mm gap gauge. When the distance is OK, there will be no error message while executing the encoder test (Enc. Count Test in the Test Menu window).
4 - 32
2.9. Bearings Print Media Unit

2.9.1. Greasing the Bearings of the Print Media Unit

Description AFB lubricating grease in a squeeze bottle Code
E. PROCEDURE 1 Lubricate the following bearings of the double pulley assembly:
2 1
1.1 Two UFL004 bearings (1). 1.2 Four bearing height adjusting blocks (2), 2 Lubricate the idle pulley bearing (3).
4 - 33
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 - 34
2.10. Waste Tank

2.10.1. Inspecting and Emptying the Waste Tank

Description Snap-on lid Black Polyethylene Containers. Code
E. PROCEDURE 1 Inspect the following connections: Drain hose (thick), venturi hose (thin) and full detection sensor connector (2-pin) which is located in the cable trunk.
2 Place a black snap-on lid Polyethylene container underneath the waste tank. 3 Open the drain cock underneath the waste tank to empty the waste tank.
WARNING: Be aware of the waste disposal and regulations that bear on UV curable ink.
NOTE: The full detection sensor is activated when the contents of the waste tank reaches 3.5 litre. The signal P01 on the PLC, illuminates when the waste tank is full (3.5 litre).
4 - 35
HEAD CARRIAGE UNIT MAINTENANCE
3. Head Carriage Unit Maintenance

!
UV radiation
WARNING: UV light can cause harmful damage to eyes and skin. Therefore never look into UV light without wearing protective glasses. Never exposure your skin to UV light. Maintenance safety instructions
4 - 36
NOTE: At the end of the day, and when you stop printing, the head carriage unit needs to be placed in the purge position. For overnight or longer standstill times, the grid underneath the head carriage unit must be pushed to the back.
NOTE: A default "Weeping" time is set in the engine software to keep the heads open, this small amount of ink is collected in the underneath waste box, which leads to a waste tank underneath the engine. NOTE: Place some towels in front of the purge grid, this will help to keep the area clean, it is advisable to replace them weekly
NOTE: The purge grid must be placed forward again when you start to print.It prevents the ink in the underneath waste box from getting cured by the UV lamps during the printing stage. It also prevents the UV lamps from curing the ink onto the heads.
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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.
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B. MANPOWER
C. SPECIAL TOOLS
Description Cleaning stick Code

Description Lint-free cloth Code
E. PROCEDURE
! Manual Clean Up
Clean the heads with a fiber-free cloth or cleaning stick, by wiping from back to front on each head separately. Use backside of cloth, or a new cloth for every next head.
NOTE: To order the cleaning stick, order D2+2161113 (cleaning stick rubber) and D2+2161115 (cleaning stick bracket).
! Automatic Weeping
A default "Weeping" time is set in the engine software to keep the heads open. To capture an automatic weeping, proceed as follows: 1 Move the head carriage to the purge position (front left side). 2 Hold a white A4-paper underneath the base plate to check the nozzles. 3 Capture the ink when the heads are weeping during approximately 10 seconds. As a result, vertical lines appears on the sheet. 4 Check them on interruption.
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! 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.
Pressure control adjustment knob
3 Set the vacuum pressure by turning the pressure control adjustment knob to the desired pressure (range -0.032 MPa to -0.038 MPa).
! Nozzle Check
To execute a nozzle check, proceed as follows: 1 Move the head carriage to the home position (front right side).
2 Execute the head gap control. Refer to Executing a head gap control on page 1-84 (chapter Functional Description). 3 Position a blank A4 paper on the print table as follows: Between the 2 marking bullets positioned on the axle underneath the white transport belt and within the reach of the 2 marking bullets positioned on the side of the head carriage.
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4 Switch on the vacuum. 5 In the Control Program, click Test. The Test Menu window appears.
6 Select Jet Test and click Test to start the test print which checks the condition of the nozzles. The nozzle check will be printed between the 4 white marking bullets. NOTE: Use a black or colored paper to see the Spot- and Pre-white. The red area in the figure below shows the placement of the Spot- and Pre-white if it's turned on.
4 - 41
7 Evaluate the nozzle check for missing nozzles. For example, the nozzle condition is not good for black in the illustration below.
8 In case of nozzle failure: 8.1 Move the head carriage unit to purge position. 8.2 Push the grid backwards. 8.3 Execute a little and/or large purge. Refer to Little Purge on page 4-42 and Large Purge on page 4-43.
! Little Purge
1 2 3
4 5
1 Close the print heads valves of the print heads that are OK. Set them to the solution outlet positions (S). 2 Push the purge switch button at very short intervals.
Multiple short pulses
3 Open all print head valves again. Set them to the ink outlet positions (I).
4 - 42
4 Clean the print heads with a fiber-free cloth. Refer to Manual Clean Up on page 4-39. NOTE: Clean the heads with a fiber-free cloth, by wiping from back to front on each head separately. (Use backside of cloth, or a new cloth for every next head) 5 Check on weeping Refer to Automatic Weeping on page 4-39.
! Large Purge
1 2 3
4 5
1 Set all print head valves to the ink outlet position (I). 2 Push and hold the purge switch button during approximately 2 seconds and complete the procedure by pushing the purge switch button again, but now frequent, at very short intervals.
Long pulse (2 seconds) + multiple short pulses
3 Clean the print heads with a fiber-free cloth. Refer to Manual Clean Up on page 4-39. NOTE: Clean the heads with a fiber-free cloth, by wiping from back to front on each head separately. (Use backside of cloth, or a new cloth for every next head) 4 Check on weeping Refer to Automatic Weeping on page 4-39.
4 - 43
5 If nozzle failure still exists, proceed as follows: 5.1 Set the vacuum pressure to zero by turning the pressure control adjustment knob.
5.2 Leave the system for 1 to 2 minutes. Ink will starts dripping out the heads. 5.3 Restore the vacuum pressure to -0.034 MPa. 5.4 Clean the print heads with a fiber-free cloth. Refer to Manual Clean Up on page 4-39. 5.5 Check on weeping Refer to Automatic Weeping on page 4-39.
! Cleaning with solution

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
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).
4 - 44
3 Push the solution valve button until you see a full solution-curtain, then stop pushing. As a result, the solution runs from the refill system to the sub ink tank, mounted at the rear of the head carriage. Note that the solution valve button is located at the back side of the print heads.
4 Leave the print heads in this condition for at least 5 minutes. 5 Put all ink valves and the solution valve in the ink outlet (I) position and set the vacuum pressure to zero. 6 Wait till the ink drops out of the heads (a few minutes). 7 Set the vacuum pressure by turning the pressure control adjustment knob to the desired pressure (range -0.032 MPa to -0.038 MPa). 8 Clean the print heads with a fiber-free cloth. Refer to Manual Clean Up on page 4-39. NOTE: Clean the heads with a fiber-free cloth, by wiping from back to front on each head separately. (Use backside of cloth, or a new cloth for every next head) 9 Check on weeping Refer to Automatic Weeping on page 4-39.
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).
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3.3. UV Lamp Box / UV Lamp Box Housing

3.3.1. Cleaning the Crystal Glass Plate
Operation Remove the UV Lamp Box. Reference Chapter 3 4.7.2.
B. MANPOWER

Description Crystal Plate (190)(8C) Isopropyl alcohol Code D2+2509166
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.
4 - 46
or
!
Switch the connections on the corresponding lamp shutter solenoid valve (5,6). To get access the lamp shutter solenoid valves, open the purge top door and then open the head cover door of the head carriage unit.
3 Hold a white paper underneath the glass plate of the UV lamp box housing to inspect the state of the glass plate.
4 If the glass plate is dirty, do one of the following: 4.1 Clean using a lint-free cloth moistened with isopropyl alcohol (IPA). Proceed with step 9 4.2 Replace the crystal glass plate. Proceed with step 5. 5 Raise the head carriage unit to the maximum height for easy access.
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6 Remove at the bottom side the metallic blinking frame (4) that holds the glass plate, by unscrewing the four screws (5).
5 4
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

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3.3.3. Replacing the UV Lamps

NOTE: Always change both UV lamps to avoid bi-banding.
Operation Move the head carriage to the purge position. Put the print engine in service mode. Open the front and left purge door to get full access to the left UV lamp box. Remove the UV lamp box. Move the head carriage to the home position. Put the print engine in service mode. Open the home right side door to get full access to the right UV lamp box. Remove the UV lamp box. Chapter 3 4.7.2. Chapter 3 4.7.2. Chapter 3 3.1. Chapter 3 3.2. Reference Chapter 3 3.1. Chapter 3 3.2.
B. MANPOWER
C. SPECIAL TOOLS None. D. CONSUMABLES, MATERIALS AND SPARE PARTS

Description Lamp 190mm Code D2+2509221
E. PROCEDURE 1 Turn the UV lamp box upside down. 2 Unscrew the two wires out of the connector blocs (1). 3 Lift the UV lamp (2) out of the brackets (3) without touching.
1 3
4 Take the new UV lamp out of the foil. CAUTION: Do not touch the glass part of the UV lamp with your bare hands. Wear gloves when necessary. If grease of your hands gets on the glass, it can reduce the lifetime of the UV lamp significantly.
4 - 49
5 Mount the new UV lamp into the lamp housing.
NOTE: Make sure that the nipple of the UV lamp is positioned towards the reflection shield (metallic plate) of the lamp housing.
6 Reconnect the 2 wires to the connector blocs. 7 Remount the UV lamp box. Refer to Replacement of the UV Lamp Box on page 3-73 (chapter Repair and Service).
3.3.4. Inspecting the Lamp Shutter Functionality

B. MANPOWER
C. SPECIAL TOOLS None D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Open the purge top and rear door. 2 Open the head cover door of the head carriage unit to get access to the top side of the head carriage unit.
4 - 50
3 Locate the 2 lamp shutter solenoid valves.
12
Lamp shutter solenoid valve (Right UV lamp box housing)
Lamp shutter solenoid valve (Left UV lamp box housing)
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.
Lamp shutter open
Lamp shutter closed
4 - 51
3.3.5. Replacing the Lamp Shutter

4 - 52
3.4. Head Carriage

3.4.1. Inspecting and Adjusting the Position of the Head Carriage Unit.
C. SPECIAL TOOLS
Description Code
measuring device D. CONSUMABLES, MATERIALS AND SPARE PARTS 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).
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REFILL UNIT MAINTENANCE
4. Refill Unit Maintenance

!
UV radiation
4 - 54
4.2. Air filter 6 Color and White

4.2.1. Inspecting and Replacing the Air Filter

Description Air filter (6C) Air filter (W) Code D2+2509046 D2+2509046
E. PROCEDURE 1 Inspect the air filter (1) for any moisture. 2 If saturated, remove and replace the air filter.
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4.3. Ink Filter

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


Description Absorbent lint free cleaning tissues Code
4 - 56
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).
4 - 57
5 Hold an absorbent lint free cleaning tissue against the filter opening.
6 Press and hold the priming switch of the corresponding color until the ink flows upwards and is spilled. Use a 5 second on/off sequence (leave 5 seconds on, then 5 seconds off), in order to fill up both chambers of the filter.
7 Repeat the bleeding procedure a second and a third time to be sure that all air is extracted from the ink filter (reason: filter has a compartment that fills with a certain delay). NOTE: Wait some seconds in between the bleeds and reduce the sequence time when bleeding the second (e.g. 3 seconds on/off sequence) and third (e.g. 2 seconds on/off sequence) time. 8 Screw the cap on top of the ink filter and clean the ink filter with a cleaning tissue.
4 - 58
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). A. PRELIMINARY ACTIVITIES None B. MANPOWER
C. SPECIAL TOOLS None D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Unscrew the locknut underneath each print head valve (K, C, M, Y, Lc, Lm, W1 and W2).
NOTE: All print head valves are still set to the solution outlet position (S)!
NOTE: Connector J17 on the Refill PCB is still disconnected.
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1 2
Locknut
Tube
2 Shear the tube of each valve. 3 Open the drain cock of the sub air tank. The sub air tank is located behind the purge rear door.
Drain cock
4 Connect the connector J17 on the refill PCB to pump ink from the main ink tanks to the sub ink tanks and wait until all pumps are idle. All refill leds on the refill system indicator go out when all pumps are idle.
5 As soon as all pumps are idle, close the drain cock of the sub air tank. NOTE: The first time you drain the first ink, there is also air in the ink tubes between the main ink tanks and the sub ink tanks. The air can leave the tubes through the drain cock of the sub air tank.
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6 Drain the seven ink channels (K, C, M, Y, Lc, Lm, W1, W2) one after the other. To drain one ink channel, proceed as follows: 6.1 Place a receiving bin underneath the valve (e.g. K valve). 6.2 Put some absorbent lint free cleaning tissues near the receiving bin to catch possible spilled ink. 6.3 Set the valve to the ink outlet position (I).
6.4 Let the ink drop out completely (approx. 30 ml). 6.5 Wait a few seconds and let the ink drop out again (approx. 30 ml). 6.6 Set the valve to the solution outlet position (S).
7 Repeat steps 6. When draining the first ink from the sub ink tank a second time, the drained ink volume increases. 8 Repeat step 6 once again (third time) and then proceed with step 9. 9 Reconnect the tube of each print head valve and manually tighten the locknut.
1 2
Locknut
Tube
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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).
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PURGE UNIT MAINTENANCE
5. Purge Unit Maintenance

!
UV radiation
5.2. Purge box

5.2.1. Inspecting and Cleaning the Purge Grid
Operation Move the head carriage to the home position Reference Chapter 3 3.1.
B. MANPOWER
C. SPECIAL TOOLS
Description filling-knife or a wide screwdriver Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS None
4 - 63
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

Operation Move the head carriage to the home position Reference Chapter 3 3.1.
B. MANPOWER
C. SPECIAL TOOLS
D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Push the grid to the back. 2 Use a filling-knife or a wide screwdriver to cut off the cured ink in the receiving bin.
4 - 64
HOME UNIT MAINTENANCE
6. Home Unit Maintenance

!
UV radiation
6.2. Home box

6.2.1. Inspecting and Cleaning the Home Grid
Operation Move the head carriage to the purge position Reference Chapter 3 3.1.
B. MANPOWER
C. SPECIAL TOOLS
D. CONSUMABLES, MATERIALS AND SPARE PARTS None
4 - 65
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

Operation Move the head carriage to the purge position Take out the grid Reference Chapter 3 3.1. Chapter 4 6.2.1.
B. MANPOWER
C. SPECIAL TOOLS
D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Take out the grid (1).
2 Use a filling-knife or a wide screwdriver to cut off the cured ink in the receiving bin (2).
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SAFETY CIRCUIT
7. Safety Circuit
None
7.2. Emergency Stop Circuit

7.2.1. Inspecting the Emergency Stops
Qualification 1 Number of people Man-hours 20 20 Execution time
C. SPECIAL TOOLS None D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE NOTE: The system is provided with 4 emergency stops, two at the front side and two at the back side. The inspecting procedure is written for one emergency stop. Repeat the procedure for all four emergency stops. 1 Push the emergency stop button.
2 Verify whether the emergency button cuts off the power, except for the PC and SMPS8. 3 Pull the emergency button back. The emergency stop is cancelled.
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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)
4 - 68
AIR TANK MAINTENANCE
8. Air Tank Maintenance

None
8.2. Air Tank

8.2.1. Draining the Air Tank
Operation Reference
B. MANPOWER
Qualification Service technician 1 Number of people 5 Man-hours 5 Execution time
C. SPECIAL TOOLS None D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Open the drain cock (2) to eliminate the water of the air tank (1).
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AIR PRESSURE PANEL MAINTENANCE
9. Air Pressure Panel Maintenance

! ! !
9.2. Air Pressure Panel

9.2.1. Draining the Air Filter
B. MANPOWER
Qualification Service technician 1 Number of people 5 Man-hours 5 Execution time
C. SPECIAL TOOLS
Description Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Remove the air pressure panel (1).
4 - 70
2 Remove the 2 cable trunk covers (2).

2
3 Locate the two air filters (AF20-01BG) (3), the water drain out connector (4) and the drain pipe (5).
3 3
4 Drain the water from the 2 air filters. 4.1 Place a receiving bin underneath the drain pipe (7). 4.2 Open the black nut (6) underneath the filter to remove the water.
4 - 71
4.3 Close the black nut (6) when the water is removed.
76
NOTE: Follow the same procedure to drain the water from the main regulator (AW20-02BCG) (8)
9.2.2. Replacing the Air Filter

Operation Move the head carriage to the purge position. Remove air pressure panel and cable trunk covers Reference Chapter 3 3.1. Chapter 4 9.2.1.
B. MANPOWER
C. SPECIAL TOOLS
Description Code

Description Air filter (AF20-01BG) Code D2+2509015
E. PROCEDURE 1 Set all print head valves (K, C, M, Y, Lc, Lm, W1 and W2) to the solution outlet position (S). 2 Set the solution valve to the ink outlet position (I).
4 - 72
1 2 3
4 5
3 Switch off the engine. 4 Turn off the compressed air supply. 5 Locate the air filter (AF20-01BG) (6).
6 6
6 Replace the air filter.
6.1 Unscrew the 2 cross-slotted screws. 6.2 Disconnect the air hoses.
4 - 73
6.3 Mount a new air filter, tighten the 2 cross-slotted screws and reconnect the air hoses. 7 Restore the compressed air supply. 8 Restart the engine. 9 Set all print head valves and the solution valve to the proper outlet position. 10 Verify the printing conditions and if necessary clean the print heads. Refer to Cleaning a Print Head on page 4-38.
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ENGINE
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
Spirit level (middle)
Spirit level (front right side panel)
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.
A. PRELIMINARY ACTIVITIES None
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ENGINE
B. MANPOWER
C. SPECIAL TOOLS
Description Nut wrench no.36 Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Manually turn the 8 support feet downwards until they touch the ground. 2 Lower each support foot further by turning them over one complete turn. 3 Use the left and right built-in level to check the level of the print engine in longitudinal direction. 4 Look at the position of the air bubble of the left built-in level. If necessary, adjust the lowest (on the opposite side of the air bubble) point of support foot number 1, slightly until the air bubble of the level is in the middle.
REAR 1 2
1 FRONT
5 Look at the position of the air bubble of the right built-in level. If necessary, adjust the lowest (on the opposite side of the air bubble) point of support foot number 2, slightly until the air bubble of the level is in the middle.
REAR 1 2
1 FRONT
6 Repeat steps 4 to 5 until the air bubble is exactly in the middle. 7 Look at the position of the air bubble of the middle built-in level. If necessary, adjust the lowest (on the opposite side of the air bubble) point of support foot number 3, slightly until the air bubble of the level is in the middle. Make sure not to disturb the longitudinal balance. This is done by adjusting both support feet (number 3A or 3B) equally over the same distance.
REAR
3A 3B
3A
3B
FRONT
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ENGINE
8 Lower the outer support feet until they touch the ground.
REAR
FRONT
NOTE: Check whether the air bubble of the three built-in levels is still in the middle. If not redo the levelling. 9 When the correct height is reached, is it necessary to secure the feet by tightening the locknut against the frame. 10 Check whether the ink supply door is leveled. If not do the ink supply door levelling. For more information, refer to Levelling the Ink Supply Door on page 4-77.
10.2.3. Levelling the Ink Supply Door

Operation Level the print engine Reference Chapter 4 10.2.2.
B. MANPOWER
C. SPECIAL TOOLS
Description Nut wrench no.24 Code
D. CONSUMABLES, MATERIALS AND SPARE PARTS None E. PROCEDURE 1 Level the ink supply door, using a nut wrench no. 24, in such a way: 1.1 the ink supply door does not drag when you open it, 1.2 the ink supply door closes easily, 1.3 the 3 door hinges are not extremely overloaded.
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ENGINE
2 When the correct height is reached, secure the support wheel.
4 - 78
CHAPTER
Troubleshooting
This chapter describes how you can recognize and solve mechanical, electrical and image problems you could encounter when printing with the Anapurna L/XL. 1. Troubleshooting Based on Visible Problems ............................................................................................... 5 - 2 1.1. Troubleshooting Based on Tower Lamp Indications .................................................................... 5 - 2 1.2. Troubleshooting Based on Mechanical and/or Electrical Problems ..................................... 5 - 2 2. Troubleshooting Based on UI Error Messages .......................................................................................... 5 - 13 3. Troubleshooting based on Image Quality Control .................................................................................. 5 - 14 3.1. Encoder (MARK) Error ........................................................................................................................... 5 - 14 3.2. Black Strips .............................................................................................................................................. 5 - 15 3.3. Waves on the Media Surface ............................................................................................................ 5 - 15 3.4. Only UNI MODE Output ...................................................................................................................... 5 - 16 3.5. Image Quality Failure .......................................................................................................................... 5 - 16 3.6. Spray on your Image ............................................................................................................................ 5 - 18 3.7. Print Length Exceeds Maximum Platen Length ......................................................................... 5 - 18 4. UV Lamp Troubleshooting ................................................................................................................................ 5 - 20 5. Servo Motor Driver Troubleshooting ............................................................................................................ 5 - 21
5-1
TROUBLESHOOTING
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.
Trouble RED lamp is flashing and beeping. (Red lamp lights up in normal state) YELLOW lamp is flashing and beeping. (Yellow lamp lights up in normal state) 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 1 10.1.3. is turned on or off. Check UV power cable connec- 1 10.1.5. tion status. 1 10.1.6. Check stability of electric supply. 1 10.1.7. Change the secondary of the UV 5 1.2.1. coil to 60 (Note: only possible for 50Hz countries). Empty waste ink tank. 4 2.10.1. Low ink level at main ink tank Cause Air pressure is under 0.3 MPa Action See
Check the industrial compresso- 1 4.1.2. compressor. Check the status of the tube connection. Refill ink into main ink tank. Check air at ink filter. Installation manual 4 4.3.1.
Overheat
BLUE lamp is flashing and Full waste ink tank (> 3.5 litre) beeping (Blue lamp lights up when the register pins are down) All lamps are flashing and Overflow (of ink) in sub air tank. beeping Ink run from sub ink tank to sub air tank
Lower the pressure to 0 Empty sub air tank
5 1.2.2.
1.2. Troubleshooting Based on Mechanical and/or Electrical Problems

Trouble Cause Action Media position check. The media should be between media detection sensor and reflection plate. Remove obstacle. See 1 6.1.4.2. 1 6.1.4.4. 1 14.11. 1 6.1.4.2. 1 6.1.4.4. 1 6.1.4.2.
Rear TAKE-UP motor does No media detected not stop Rear TAKE-UP motor does Obstacle (e.g. vacuum pumps) in not move the beam of the media detection signal sensor. Beeping (every 3 sec) [main PCB beeping] Take-up overload
Pressing CW/CCW button for a long time at the take-up control system panel
5-2
TROUBLESHOOTING
Trouble Media distorting
Cause Wrong positioning of media
Action
See
Check whether the print medium 1 6.1.4.4. is loaded correctly on the rear media roll bar. Check whether the tension roll bar is inserted correctly. Check the position of the print medium on the print table. Check whether the 2 tension roll bars of the roll to roll system are mounted correctly 1 6.1.4.1.
Tension roll bar (rear/ Wrong positioning of the tension front) lifted out of its posi- roll bar tion. Media fixing roll bar (rear/ Wrong positioning of the media front) lifted out of its posi- fixing roll bar tion. Ink not cured Immediate stop during printing Check UV lamp life span
Check whether the 2 media fixing 1 6.1.2.1. roll bars above the print table are mounted correctly Replace lamp 4 3.3.3.
Communication error, output data Check communication cables error and data Check RTL file Adjust feed speed value 1 12.3.4. Check parameters at servo driver 1 6.1.6.1. Remove obstacle and supply grease to S3M belt Check obstacles in the range of the head carriage unit. Check power and cable between carriage and feed servo motor Turn off main power and start again Check servo motor driver error message Clean head nozzle and check minus pressure Remove air at ink filter Adjust servo motor driver according to gain value. Check negative gauge, adjust to normal value 4 2.7.1. 5 5. 4 3.2.1. 1 4.1.3.1. 4 4.3.1. 1 6.1.6.1. 1 9.1.1. 1 4.1.3.1. 4 3.2.1.
Strange noise and no Feed speed movement of print media Noise while head carriage Obstacles unit is moving Head carriage unit does not move Obstacles exist while head carriage unit is moving
Ink drips on the print media Motor noise (Feed and carriage) Lots of ink drops on print media
Contaminated print head or foreign materials ink remainders Check servo motor driver Negative pressure error
Not ejecting ink instantly Electrical noise by static current, it Static current hinders electrical influences head ejecting signals of head Check ground By purging 2~3, supply ink and clean head Can not supply ink to sub Refill device does not work propink tank erly Unexpected line appeared Head nozzle is clogged on image Dark lines in the print, as a Wrong Step Size value result of overlapping passes White lines in the print, as Wrong Step Size value a result of a gap between the passes. Check ink at main ink tank and then call service
Check nozzle conditions by doing 1 12.4.1. jet test 4 3.2.1. Adjust Step Size value 1 12.3.2.
Adjust Step Size value
1 12.3.2.
5-3
TROUBLESHOOTING
Trouble
Cause
Action Check connection PT sensor head base plate with Head Lift PCB (J17). Replace if necessary. Check connection head temperature sensor with Head PCB (J29) + check connection with Magenta print head. Replace thermistor if necessary Check connection with Head PCB and replace head heater if necessary. Check safety thermostat and replace if necessary. Ink filter should be filled with sufficient ink without air Replace level sensor
See 1 9.1.2.2. and 3 4.6.4. 1 9.1.2.2. and 3 4.6.3.
Head heater temperature Problem with PT sensor head is increasing or decreasing base plate Problem with head temperature sensor (safety thermostat 45C)
Problems with the heating elements of each print head (heater bar - red cables) Problem with the safety thermostat (80C) mounted on the head base plate Overflow Air in the ink filter Malfunction of the sub ink tank level sensors
1 9.1.2.2. and 3 4.6.3.
4 4.3.1. 1 7.1.3.5. and 3 4.4.1. and 3 4.4.3. 4 2.10.1.
Malfunction of the waste ink Replace level sensor tank level sensor Connection error/minus pressure Check compressor and tube con- 1 4.1.2. error nection status. Adjust the air pressure to the appropriate value. Ink in sub air tank Check sub air tank if air exists or 1 4.1.3.1. not. It should be always empty and clean. Loss of voltage Overheating base plate Head base plate temperature > 38C during printing Check the permanent voltage 5 1.2.4. Stop printing at the end of the current print job. Switch off the UV-lamps. 1 10.1.3. Run the Encoder Test for 5 min- 1 9.1.2. utes Change the secondary of the UV 5 1.2.1. coil to 60 Hz (Note: only possible for 50Hz countries) The metal connector inside the ceramic block is completely burned up Replace lamp house 5 1.2.3.
Overheating UV assembly
UV lamp burnout
The S3M belt wears out, it looses its teeth, parts as well as complete teeth. Noisy movement of the head carriage unit Vacuum not strong enough on printing table Discontinuity of the teeth of the S3M belt results in noisy movements of the head carriage unit Vacuum holes printing tabla are clogged up
Replace the S3M belt
4 2.7.2.
Replace the S3M belt
4 2.7.2.
Puncture all holes of the vacuum table using a syringe needle.
4 2.3.1.
5-4
TROUBLESHOOTING
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. NOTE: This solution is only possible for 50 Hz countries.
250V 220V 208V 60Hz 50Hz
250V 220V 208V 60Hz 50Hz
50 60 CHOKE(R)-LOW CHOKE(R)-HIGH
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).
5-5
TROUBLESHOOTING
3 Open the drain cock (2) of the sub air tank and empty the waste ink from the sub air tank.
4 Close the drain cock (2) of the sub air tank. 5 Adjust the vacuum pressure by turning the pressure control adjustment knob until you reach the desired pressure (range -0.032 MPa to -0.038 MPa). 6 Restart printing.
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. Refer to Replacement of the UV Lamp Box on page 3-73 (chapter Repair and Service).
4 1 3
1 2
5-6
Ceramic connector block UV lamp
3 4
Bracket Bolt ceramic connector

TROUBLESHOOTING
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.
250V 220V 208V 60Hz 50Hz
250V 220V 208V 60Hz 50Hz
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TROUBLESHOOTING
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. WARNING: When the emergency button is activated all systems are cut off from the mains, except for the PC. 6 Check the first circuit breaker.
First circuit breaker (MCCB)
7 Push the PC button (green button) to operate the PC.
5-8
TROUBLESHOOTING
8 Activate the automatic fuses of the following systems one by one:

! ! ! ! !
Lamp power Ring blower 1 Ring blower 2 Motor drive Control rack
NOTE: Make sure that the carriage servo motor connectors are plugged in and that the head carriage has a free path to its home position (head altitude high enough to pass over the conveyor belt without any obstruction). 9 Push and hold the Start button (white button) for 1 second until you hear the relays and the head carriage starts moving to its home position.
10 After starting up for the first time, the yellow tower lamp starts blinking (the head carriage moves slowly to the home position) and the print engine produces a beeping sound.
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TROUBLESHOOTING
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)
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TROUBLESHOOTING
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).
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TROUBLESHOOTING
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).
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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 *** ERROR *** Factory Data File (Factory.Set) Open Failed ..*** *** ERROR *** Setup Data File Open Failed ..*** *** ERROR *** Missing Resolution Header *** *** ERROR *** Missing Color Number Header *** *** ERROR *** Invalid Resolution Header *** *** ERROR *** Carriage Not At Home Position.... *** *** ERROR ** Print Length Exceeds Max. Platen Length.*** *** ERROR *** Command Download('O') Failed. *** *** ERROR *** Command Download('K') Failed. *** *** ERROR *** Carriage Lift Error.. *** *** ERROR *** Carriage Vacuume Error. *** Hardware Reset Required... *** ERROR *** Waste Can Overflow Error. *** Hardware Reset Required... *** ERROR *** Door Open Alarm Error. *** Close Door to Continue... *** ERROR *** Serial Com. Timeout Error. (No 'SI' Received..) *** Hardware Reset Required... Software Reboot Required... *** ERROR *** Inputs Not Ready for Print. *** *** ERROR *** Value Should be between -300 to 300... *** *** ERROR *** Carriage Speed Should be between 100 .. 2700. *** ERROR *** Feed Speed Should be between 100 .. 2000. ** WARNING ** Gap Exceeds Max. Value (50 mm). Set to 50. ** ** 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.. *** *** ERROR *** Lower Limit SW-ON Error.... *** Time-out error during carriage moving down. During Set Gap routine. Time-out error during Carriage Lift Command. Carriage Vacuum loss sensor triggered. Waste Can Overflow sensor triggered. Try to print, move, feed or test when cover door is open. When PC loses communication to Main board. Cause/Solution Factory.Set File is missing or corrupted. Setup Data file is missing or corrupted. File header in RTL file missing. (ex: VERTICAL RESOLUTION=363) File header in RTL file missing. (ex: INKS=6). File header in RTL file missing. Try to run TEST routine when carriage is not at home position. Try to run/move carriage exceeding Max. Platen Length. Internal error message for Printing Download command.
Try to print, move, feed or test when media set sensors are triggered. Try to jog feed media. Try to save values in Setup Menu.
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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. 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. 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 Preventive Maintenance).
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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 J7Connection to PCI I/O card CN2). 3.3 Check whether the PCI I/O card is fixed correctly on the PC Main board slot. Direct connection between PC main board and the FPGA PCB via PCI I/O card. For more information, refer to FPGA PCB on page 1-102 (chapter Functional Description). 4 Execute a grounding check between MAIN, HEAD PCB + 24V, chassy G
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.
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TROUBLESHOOTING
3.3.2. Action
When printing with weak print media, increase the head base height (> 3mm). Refer to Automatic head base height setup on page 1-57 (chapter Functional Description).
3.4. 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)
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TROUBLESHOOTING
3 Check calibration (BI, STEP). 3.1 Bi-Dir Alignment control. Increase setting values, move to purge position. Decrease setting values, move to home position. 3.2 Step Size (Media Feed) control. If output overlap, increase value. If the opposite way, decrease value. For more information, refer to
! ! !
Bi-Dir Alignment on page 1-82 (chapter Functional Description). Step Size (Media Feed) on page 1-82 (chapter Functional Description). Software Alignment of the Print Head on page 3-95 (chapter Repair and Service).
4 Check carriage speed: Inferior output quality can be caused by overspeed. Adjust the carriage speed to an optimal quality speed. For more information, refer to Carriage Speed on page 1-83 (chapter Functional Description) 5 Check the head base height and the levelling of the engine. For more information, refer to:
! !
Head Gap Control on page 1-84 (chapter Functional Description). Engine Level on page 4-75 (chapter Preventive Maintenance).
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).
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TROUBLESHOOTING
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. > 38C.
3.6.2. Action
When the head base plate temperature is too high (> 38C) during printing, do the following: 1 Stop printing at the end of the current print job. 2 Switch off the UV-lamps. 3 Run the Encoder Test for 5 minutes (refer to Encoder Count Test on page 1-89). As a result, the head carriage unit will now move continuously without printing, allowing the head base plate to cool down. For more information about the head base plate temperature, refer to Head Base Temperature Control on page 1-63 (chapter Functional Description).
3.7. 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
2 3 3
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TROUBLESHOOTING
To solve this problem: 1 Increase the value for the Left Margin Offset (2) in order for the print to start at the leading edge of the media. Left Margin Offset shifts the origin (where the heads start to print) to the left when the value is increased. It is a permanently enabled Left Margin Offset. 2 Decrease the value for the Mark Center Offset (3) with a certain amount to reduce the extra travel (e.g. 5000 --> 0). 3 Increase the Bi-Dir Alignment value (1) with the exact same amount (-4960 -->+40). Mark Center Offset = the extra distance the head carriage unit travels in the fastscan direction after the last dots are printed. By increasing this value you can make sure that the head carriage unit and UV lamp completely surpass the substrate. E.g.: The Mark Center Offset value is default set to 5000. A value of 2500 pulses means that the head carriage unit travels 5 cm past the last cured area. A value of 5000 means that the head carriage unit surpasses the print 10 cm before returning for the next pass. You will notice that the Bi-Dir Alignment value is set to a value of -5000. This is no coincidence since the head carriage unit also needs a delay of 5000 units before it starts laying down dots on its return pass. When the Bi-Dir Alignment would be set to 0, it would indicate that the heads start firing immediately without delay on its return pass. This would result in the bidir being way off. If the head carriage unit moves 5000 marks after the last printed dot, the head carriage unit needs to be delayed 5000 marks when on its return pass. So if you decide to increase Mark Center Offset you will need to decrease the Bi-Dir Alignment value with the same amount. The exact value will not be -5000 but e.g.. -4960 because of difference in head carriage unit speed and head gap. So increasing the Mark Center Offset from 5000 to 15000 means decreasing the bidir from -4960 to -14960. The Bi-Dir Alignment can be found in the Setup Parameters window. The Left Margin Offset and the Mark Center Offset can be found in the Factory Data Setting window. For more information about accessing the Setup Parameters window and the Factory Data Setting window, refer to Anapurna Control Program on page 1-80 (chapter Functional Description).
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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 lamp Operation Process
Main Power ON
Lamp Warm Time Check
Main Circuit Breaker (50A) ON?

yes
no
Power bulk Check OK?

yes
no
Printing
Push Start Button
Reset Button Push and Relay Cable Check or replace MC1
Increase bulk or connect separately
Lamp ON?
no
yes
END
MC1 Circuit Breaker (50A) ON?

yes
no
Check Power bulk Check
yes
Leakage Test
Lamp House Cable Connection OK?

no
Servo / Control Circuit Breaker Check MCCB #5 Lamp Power Circuit Breaker Check MCCB #2
no yes
Reset Button Push and Relay Cable Check or replace MC1
Ground Or Cable Check
Repair Or Change
Lamp OK?
no
Power unit to Housing Cable Connector Check
yes
Main to Lamp Power Control Cable Check OK?

yes
Repair Or Change
Lamp Power Circuit Breaker ON?

yes
Cable Connector OK?
no
Power unit to Housing Cable Connector
UV Lamp Power Unit Switch ON
Main PLC Connection Check OK?

yes
no
no
UV Lamp Power Unit Power LED ON?

yes
Fuse Broken?
no
yes
Main PLC Program Check OK?

no yes
Main Software Invoking
Replace Fuse Check Power Cable Connection Lamp PLC Program Check OK?
Program Download
no
Printing Prepare
no
Printing Ready?
yes
5 - 20
SERVO MOTOR DRIVER TROUBLESHOOTING
TROUBLESHOOTING
5. Servo Motor Driver Troubleshooting

The table below gives an overview of the servo motor driver error alarms.
No. 1 Start-up sequence Power on Fault LED is not lit. LED flickers. Investigation Not improved is connectors CN1A, CN1B, CN2 and CN3 are disconnected. Improved when connectors CN1A and CN1B are disconnected. Improved when connector CN2 is disconnected. Improved when connector CN3 is disconnected. Alarm occurs. 2 Switch on servo-on sig- Alarm occurs. nal Servo motor shaft is not 1. Check the display to see if servo-locked (is free). the servo amplifier is ready to operate. 2. Check the external I/O signal indication to see if the servo-on (SON) signal is ON. Gain adjustment 1. Servo-on signal is not input. (Wiring mistake) 2. 24VDC power is not supplied to COM. Possible cause 1. Power supply voltage fault. 2. Servo amplifier is faulty. Power supply of CNP1 cabling is shorted. 1. Power supply of encoder cabling is shorted. 2. Encoder is faulty. Power supply of CN3 cabling is shorted.
Rotation ripples (speed Make gain adjustment in the Gain adjustment fault. fluctuations) are large following procedure: at low speed. 1. Increase the auto tuning response level. 2. Repeat acceleration and deceleration several times to complete auto tuning. Large load inertia moment causes the servo motor shaft to oscillate side to side. If the servo motor may be run Gain adjustment fault. with safety, repeat acceleration and deceleration several times to complete auto tuning. Confirm the cumulative com- Pulse counting error, etc. due to mand pulses and actual servo noise. motor position.
Cyclic operation
Position shift occurs.
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TROUBLESHOOTING
(Note 2) Alarm code Display CN1B-19 pin 0 0 0 0 1 0 0 1 1 1 1 0 1 1 0 1 0 0 0 0 0 0 1 1 1 0 0 0 CN1A-18 pin 1 0 0 0 1 0 0 1 1 0 1 0 0 0 0 01 0 0 1 1 1 1 0 0 0 0 0 0 CN1A-19 pin 0 0 0 0 0 0 0 0 0 0 0 1 1 0 1 1 0 0 1 1 1 1 1 1 1 0 0 0 Undervoltage Memory error 1 Clock error Memory error 2 Encoder error 1 Board error Memory error 3 Motor combination error Encoder error 2 Main circuit error Absolute position erase Regenerative error Overspeed Overcurrent Overvoltage Command pulse frequency error Parameter error Program error Main circuit device overheat Servo motor overheat Overload 1 Overload 2 Error excessive Home position return incomplete Home position setting error Serial communication time-out error Serial communication error Watchdog Open battery cable warning Program operation disable Software limit warning Battery warning Excessive regenerative warning Overload warning Absolute position counter warning Servo emergency stop warning Main circuit off warning Name
Alarm deactivation Power OFF"ON O O O O O O O O O O O O (NOTE 1) O O O O O O O O O (NOTE 1) O (NOTE 1) O O O O O O O O O (NOTE 1) O (NOTE 1) O O O O O O O O (NOTE 1) O (NOTE 1) O O O O O O O O (NOTE 1) O O O (NOTE 1) O O Press SET on current alarm reset (RES) signal alarm screen O O
AL. 10 AL. 12 AL. 13 AL. 15 AL. 16 AL. 17 AL. 19 AL. 1A AL. 20 AL. 24 AL. 25 AL. 30 AL. 31 Alarm Warning AL. 32 AL. 33 AL. 35 AL. 37 AL. 39 AL. 45 AL. 46 AL. 50 AL. 51 AL. 52 AL. 63 AL. 64 AL. 8A AL. 8E 88888 AL. 92 AL. 97 AL. 98 AL. 9F AL. E0 AL. E1 AL. E3 AL. E6 AL. E9
Removing the cause of occurrence deactivates the alarm automatically.
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)
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TROUBLESHOOTING
Display AL. 10
Name Undervoltage
Definition Power supply voltage dropped. MR-J2S-"CL: 160VAC or less MR-J2S-"CL1: 83 VAC or less
Cause 1. Power supply voltage is low. 2. There was an instantaneous control power failure of 60ms or longer. 3. Shortage of power supply capacity caused the power supply voltage to drop at start, etc. 4. Power was restored after the bus voltage had dropped o 200VDC. (Main circuit power switched on within 5s after it had switched off.)
Action Review the power supply.
5. Faulty parts in the servo amplifier. Change the servo amplifier. Checking method Alarm (AL. 10) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables. AL. 12 AL. 13 Memory error 1 Clock error RAM, memory fault Printed board fault Faulty parts in the servo amplifier Change the servo amplifier. Checking method Alarm (any of AL. 11 and 13) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables. 1. Faulty parts in the servo amplifier Change the servo amplifier. Checking method Alarm (AL. 15) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables. 2. The number of write times to EEP-ROM exceeded 100.000. AL. 16 Encoder error 1 Communication error 1. Encode connector (CN2) disconnected. occurred between 2. Encoder fault encoder and servo 3. Encoder cable faulty (wire breakage or amplifier. short) CPU/parts fault ROM memory fault Connect correctly. Change the servo motor. Repair or change the cable.
AL. 15
Memory error 2
EEP-ROM fault
AL. 17 AL. 19
Board error Memory error 3
Faulty parts in the servo amplifier Change the servo amplifier. Checking method Alarm (AL. 17 or A. 18) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables. Use correct combination.
AL. 1A
Motor combination error Encoder error 2
Wrong combination of Wrong combination of servo amplifier and servo amplifier and servo motor connected. servo motor. Communication error 1. Encoder connector (CN2) disconnected. occurred between 2. Encoder fault encoder and servo 3. Encoder cable faulty (wire breakage or amplifier. shortage) Ground fault occurred at the servo motor outputs (U, V and W phases) of the servo amplifier. 1. Power input wires and servo motor output wires are in contact at main circuit terminal block (TE1).
AL. 20
Connect correctly. change the servo motor. Repair or change the cable. Connect correctly.
AL. 24
Main circuit error
2. Sheathes of servo motor power cables dete- Change the cable. riorated, resulting in ground fault. 3. Main circuit of servo amplifier failed Change the servo amplifier. Checking method AL. 24 occurs if the servo is switched on after disconnecting the U, V, W power cables from the servo amplifier.
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TROUBLESHOOTING
Display AL. 25
Name
Definition
Cause
Action After leaving the alarm occurring for a few minutes, switch power off, then on again. Always make home position setting again. Change battery. Always make home position setting again. After leaving the alarm occurring for a few minutes, switch power off, then on again. Always make home position setting again. Set correctly. Connect correctly. 1. Reduce the frequency of positioning. 2. Use the regenerative brake option of larger capacity 3. Reduce the load.
Absolute position erase Absolute position data 1. Reduced voltage of super capacitor in in error. encoder.
2. Battery voltage low. 3. Battery cable or battery is faulty. Power was switched 4. Super capacitor of the absolute position on for the first time in encoder is not charged. the absolute position detection system. AL. 30 Regenerative alarm Permissible regenerative power of built-in regenerative brake resistor or regenerative brake option is exceeded. 1. Wrong setting of parameter No. 0 2. Built-in regenerative brake resistor or regenerative brake option is not connected. 3. High-duty operation or continuous regenerative operation caused the permissible regenerative power of the regenerative brake option to be exceeded. Checking method Call the status display and check the regenerative load ratio. 4. Power supply voltage is abnormal. MR-J2S-"CL: 260VAC or more. MR-J2S-"CL1: 135VAC or more. 5. Built-in regenerative brake resistor or regenerative brake option faulty.
Review power supply
Change servo amplifier or regenerative brake option.
Regenerative transis- 6. Regenerative transistor faulty. Change the servo amplifier. tor fault Checking method 1) The regenerative brake option has overheated abnormally. 2) The alarm occurs even after removal of the built-in regenerative brake resistor or regenerative brake option. AL. 31 Overspeed Speed has exceeded 1. Input command pulse frequency exceeded Set command pulses correctly. the instantaneous per- the permissible instantaneous speed fremissible speed. quency. 2. Small acceleration/deceleration time con- Increase acceleration/deceleration stant caused overshoot to be large. time constant. 3. Servo system is instable to cause overshoot. 1. Re-set servo gain to proper value. 2. If servo gain cannot be set to proper value: 1) Reduce load inertia moment ratio, or 2) Reexamine acceleration/ deceleration constant. Set correctly. Change the servo motor.
4. Electronic gear ratio is large (parameters No. 4, 5). 5. Encoder faulty.
5 - 24
TROUBLESHOOTING
Display AL. 32
Name Overcurrent
Definition Current that flew is higher than the permissible current of the servo amplifier.
Cause 1. Short occurred in servo amplifier output phases U, V and W.
Action Correct the wiring.
2. Transistor (IPM) of the servo amplifier Change the servo amplifier. faulty. Checking method Alarm (AL. 32) occurs if power is switched on after U, V and W are disconnected. 3. Ground fault occurred in servo amplifier output phases U, V and W. 4. External noise caused the overcurrent detection circuit to misoperate. Correct the wiring. Take noise suppression measures.
AL. 33
Overvoltage
Converter bus voltage 1. Lead of built-in regenerative brake resistor 1. Change lead. exceeded 400VDC. or regenerative brake option is open or dis2. Connect correctly. connected. 2. Regenerative transistor faulty. 3. Wire breakage of built-in regenerative brake resistor or regenerative brake option. Change servo amplifier. 1. For wire breakage of built-in regenerative brake resistor, change servo amplifier. 2. For wire breakage of regenerative brake option, change regenerative brake option.
4. Capacity of built-in regenerative brake Add regenerative brake option or resistor or regenerative brake option is insuffi- increase capacity. cient. 5. Power supply voltage high. AL. 35 Command pulse frequency error Review the power supply. Input pulse frequency 1. Pulse frequency of the manual pulse gener- Change the pulse frequency to a of the command pulse ator is too high. proper value. is too high. 2. Noise entered the pulses of the manual Take action against noise. pulse generator. 3. Manual pulse generator failure. AL. 37 Parameter error Parameter setting is wrong. Change the manual pulse generator. 1. Servo amplifier fault caused the parameter Change the servo amplifier setting to be rewritten. 2. Regenerative brake option not used with Set parameter No. 0 correctly. servo amplifier was selected in parameter No. 0. 3. Value outside setting range has been set in Set the parameter correctly. some parameter. 4. Value outside setting range has been set in Set parameters No. 4, 5 correctly. electronic gear. 5. Opposite sign has been set in software Set parameters No. 46 to 49 corlimit increasing side (parameters No. 46, 47). rectly. Similarly, opposite sign has been set in software limit decreasing side (parameters No. 48, 49) 6. Opposite sign has been set in position Set parameters No. 50 to 53 corrange output address increasing side (parame- rectly. ters No. 50, 51). Similarly, opposite sign has been set in position range output address decreasing side (parameters No. 52, 53) 7. The number of write times to EEP-ROM exceeded 100,000 due to parameter write, program write, etc. Change the servo amplifier.
5 - 25
TROUBLESHOOTING
Display AL. 39
Name Program error
Definition
Cause
Action Change the servo amplifier. Programming correctly. Change the servo amplifier.
Program data is abnor- 1. Servo amplifier fault caused the program mal data to be rewritten. 2. Command argument is out of the setting range. 3. The number of write times to EEP-ROM exceeded 100,000 due to parameter write, program write, etc.
AL. 45
Main circuit device overheat
Main circuit device overheat
1. Servo amplifier faulty. 2. The power supply was turned on and off continuously by overloaded status. 3. Air cooling fan of servo amplifier stops.
Change the servo amplifier. The drive method is reviewed. 1. Exchange the cooling fan or the servo amplifier. 2. Reduce ambient temperature.
AL. 46
Servo motor overheat
Servo motor tempera- 1. Ambient temperature of servo motor is over Review environment so that ambient temperature is 0 to 40C. ture rise actuated the 40C. thermal protector. 2. Servo motor is overloaded. 1. Reduce load. 2. Review operation pattern. 3. Use servo motor that provides larger output. 3. Thermal protector in encoder is faulty. Change servo motor. Load exceeded overload protection characteristic of servo amplifier. 1. Servo amplifier is used in excess of its con- 1. Reduce load. tinuous output current. 2. Review operation pattern. 3. Use servo motor that provides larger output. 2. Servo system is instable and hunting. 1. Repeat acceleration/deceleration to execute auto tuning. 2. Change auto tuning response settings 3. Set auto tuning to OFF and make gain adjustment manually. 1. Review operation pattern. 2. Install limit switch.
AL. 50
Overload 1
3. Machine struck something.
4. Wrong connection of servo motor. Servo Connect correctly. amplifiers output terminals U, V, W do not match servo motors input terminals U, V, W. 5. Encoder faulty. Change the servo motor. Checking method When the servo motor shaft is rotated with the servo off, the cumulative feedback pulses do not vary in proportion to the rotary angle of the shaft but the indication skips or returns midway.
5 - 26
TROUBLESHOOTING
Display AL. 51
Name Overload 2
Definition Machine collision or the like caused max. output current to flow successively for several seconds. Servo motor locked: 1s or more During rotation: 2.5s or more
Cause 1. Machine struck something.
Action 1. Review operation pattern. 2. Install limit switches.
2. Wrong connection of servo motor. Servo Connect correctly. amplifiers output terminals U, V, W do not match servo motors input terminals U, V, W. 3. Servo system is instable and hunting. 1. Repeat acceleration/deceleration to execute auto tuning. 2. Change auto tuning response setting. 3. Set auto tuning to OFF and make gain adjustment manually.
4. Encoder faulty. Change the servo motor. Checking method When the servo motor shaft is rotated with the servo off, the cumulative feedback pulses do not vary in proportion to the rotary angle of the shaft but the indication skips or returns midway. AL. 52 Error excessive The droop pulse value of the deviation counter exceeded 2.5 rotations. 1. Acceleration/deceleration time constant is Increase the acceleration/deceleratoo small. tion time constant. 2. Internal torque limit 1 (parameter No. 28) is Increase the torque limit value. too small. 3. Motor cannot be started due to torque shortage caused by power supply voltage drop. 1. Review the power supply capacity. 2. Use servo motor which provides larger output.
4. Position control gain 1 (parameter No. 7) is Increase set value and adjust to small. ensure proper operation. 5. Servo motor shaft was rotated by external force. 1. When torque is limited, increase the limit value. 2. Reduce load. 3. Use servo motor that provides larger output. 1. Review operation pattern. 2. Install limit switches. Change the servo motor.
6. Machine struck something. 7. Encoder faulty.
8. Wrong connection of servo motor. Servo Connect correctly. amplifiers output terminals U, V, W do not match servo motors input terminals U, V, W. AL. 63 Home position return incomplete In incremental system: 1. Positioning operation was performed without home position return. 2. Home position return ended abnormally. In absolute position detection system: 1. Positioning operation was performed without home position setting. 2. Home position setting ended abnormally. 1. Positioning operation was performed without home position return. 2. Home position return speed could not be decreased to creep speed. 3. Limit switch was actuated during home position return starting at other than position beyond dog. 1. Perform home position return. 2. Review home position return speed/creep speed/moving distance after proximity dog.
1. Positioning operation was performed without home position setting. 2. Home position setting speed could not be decreased to creep speed. 3. Limit switch was actuated during home position setting starting at other than position beyond dog.
1. Perform home position setting. 2. Review home position setting speed/creep speed/moving distance after proximity dog.
5 - 27
TROUBLESHOOTING
Display AL. 64
Name
Definition
Cause 1. Droop pulses remaining are greater than the in-position range setting. 2. Command pulse entered after clearing of droop pulses. 3. Creep speed high. 1. Communication cable breakage.
Action Remove the cause of droop pulse occurrence. Do not enter command pulse after clearing of droop pulses. Reduce creep speed. Repair or change communication cable.
Home position setting Home position seterror ting could not be made.
AL. 8A
Serial communication time-out error
RS-232C or RS-422 communication stopped for longer than the time set in parameter No. 23. Serial communication error occurred between servo amplifier and communication device (e.g. personal computer) CPU, parts faulty
2. Communication cycle longer than parame- Set correct value in parameter. ter No. 23 setting. 3. Wrong protocol. Correct protocol. 1. Communication cable fault (open cable or Repair or change the cable short circuit) 2. Communication device (e.g. personal com- Change the communication device puter) faulty. (e.g. personal computer).
AL. 8E
Serial communication error
88888
Watchdog
Fault of parts in servo amplifier Change the servo amplifier. Checking method Alarm (88888) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables. Repair cable or changed. Change battery. Power off/on the servo amplifier.
AL. 92
Open battery cable warning
Absolute position 1. Battery cable is open. detection system bat- 2. Battery voltage dropped to 2.8V or less. tery voltage is low. After a program change, the program was started without the servo amplifier being powered off/on.
AL. 97
Program operation dis- Program was started able in a program operation disable status.
AL. 98
Software limit warning Software limit set in 1. Software limit was set within actual opera- Set parameter No. 48 to 51 correctly. parameter is reached. tion range. 2. Program of position data in excess of soft- Set program correctly. ware limit was executed. 3. Software limit was reached during JOG operation or manual pulse generator operation. Perform operation within software limit range. Change the battery.
AL. 9F
Battery warning
Voltage of battery for Battery voltage fell to 3.2V or less. absolute position detection system reduced. Regenerative power increased to 85% or more of permissible regenerative power of built-in regenerative brake resistor or regenerative brake option. Checking method Call the status display and check regenerative load ratio.
AL. EO
Excessive regenerative There is a possibility warning that regenerative power may exceed permissible regenerative power of built-in regenerative brake resistor or regenerative brake option. Overload warning
1. Reduce frequency of positioning. 2. Change regenerative brake option for the one with larger capacity. 3. Reduce load.
AL. E1
There is a possibility Load increased to 85% or more of overload that overload alarm 1 alarm 1 or 2 occurrence level. or 2 may occur. Cause, checking method Refer to AL. 50, 51.
Refer to AL. 50, AL. 51.
5 - 28
TROUBLESHOOTING
Display AL. E3 AL. E6 AL. E9
Name Absolute position counter warning
Definition
Cause
Action Take noise suppression measures. Change the servo motor. Ensure safety and deactivate forced stop. Switch on main circuit power.
Absolute position 1. Noise entered the encoder. encoder pulses faulty. 2. Encoder faulty External forced stop was made valid. (EMG-SG opened)
Servo forced stop warn- EMG-SG are open. ing Main circuit off warning Servo was switched on with main circuit power off.
5 - 29
TROUBLESHOOTING
5 - 30
CHAPTER
Glossary
This chapter describes definitions and abbreviations used throughout the Service Manual which you may not be familiar with.
6-1
GLOSSARY
GLOSSARY
Compressed Air An external air compressor delivers compressed air which is required for operating pneumatical parts and other specific functions of teh Anapurna.
Interlock Interlock switches are a safety feature for protecting the operator against hazards. It is forbidden to bypass these safety interlocks.
MSDS Material Safety Data Sheet. For the chemical products or consumables being used, the supplier should provide MSDSs. E.g. for ink, these data sheets will mention the hazards, handling and storage conditions.
Nozzle This is a microscopic opening from which an individual ink drop is jetted.in order to check if all nozzles are OK, you can print a special test job called Nozzle Test.
Ozone Triatomic oxygen or ozone (O3) is formed by oxygen being exposed to a high voltage and to wave lengths lower than 210 nm of UV energy. Ozone creates a barrier that absorbs the UV energy, resulting in a degradation of the UV curing.
Purging The maintenance and cleaning procedure includes purging of the ink. During this cleaning cycle, a small amount of ink is purged through one or more inkjet heads, if necessary e.g. to solve a problem of failing nozzles.
UV Curing Ultraviolet curing is a photochemical process in which UV energy is produced by a discharge lamp and focused at monomers in the ink, causing polymerization. Th ink contains phot-initiators to start the curing process.
6-2
CHAPTER
Annex
This chapter gives an overview of the diagrams and printed circuit boards of the Anapurna L/XL. Finally, you can find a spare parts list. 1. Pneumatic Diagrams ............................................................................................................................................. 7 - 3 1.1. Pneumatic Diagram ................................................................................................................................. 7 - 5 2. Electrical Diagrams ................................................................................................................................................ 7 - 7 2.1. Main Power Distribution in the Electrical Circuit Panel ............................................................ 7 - 9 2.2. Power Supply Distribution - 3 Phase with neutral with ground star 380V (EU) ............ 7 - 11 2.3. Power Supply Distribution - 3 Phase no neutral with ground delta 208-240V (US) .... 7 - 13 2.4. UV Lamp Power Box Connections ................................................................................................... 7 - 15 2.5. UV Lamp Power Circuit ....................................................................................................................... 7 - 17 2.6. UV Lamp Head Part ............................................................................................................................... 7 - 19 2.7. UV Lamp Power Cables ....................................................................................................................... 7 - 21 3. Programmable Logic Controller (PLC) Block Diagram .......................................................................... 7 - 23 3.1. Main PLC ................................................................................................................................................... 7 - 25 3.2. UV Lamp PLC ........................................................................................................................................... 7 - 27 4. Printed Circuit Boards ........................................................................................................................................ 7 - 29 4.1. Total PCB Diagram Layout ................................................................................................................. 7 - 31 4.2. MAIN PCB ................................................................................................................................................. 7 - 33 4.3. FPGA PCB ................................................................................................................................................. 7 - 35 4.4. HEAD PCB ................................................................................................................................................. 7 - 37 4.5. REFILL PCB ............................................................................................................................................... 7 - 39 4.6. CARTRIDGE PCB ..................................................................................................................................... 7 - 41 4.7. HEAD LIFT PCB ........................................................................................................................................ 7 - 43 4.8. ITV CONTROLLER PCB .......................................................................................................................... 7 - 45 4.9. SUB PCB .................................................................................................................................................... 7 - 47 4.10. IF PCB ...................................................................................................................................................... 7 - 49 4.11. I/O PCB .................................................................................................................................................. 7 - 51 4.12. TAKE UP PCB ........................................................................................................................................ 7 - 53 4.13. REFILL CONTROL PCB ........................................................................................................................ 7 - 55 4.14. INDICATOR PCB ................................................................................................................................... 7 - 57 4.15. DRIVER COMMUNICATION PCB .................................................................................................... 7 - 59
5.
7-1
ANNEX
ANNEX
7-2
PNEUMATIC DIAGRAMS
1. Pneumatic Diagrams
Overview pneumatic diagrams:
!
Pneumatic Diagram
7-3
PNEUMATIC DIAGRAMS
1.1. Pneumatic Diagram

Main Air Press. 0.4 - 0.8 MPa
Air Tank
R P A
Max. Press. 2MPa Capacity 0.005M 3
Setting Press UV lamp 0.10 - 0.15 MPa
Lamp Shutter Left/Right Cylinders
Media set Cylinders
Setting Press 0.6 MPa Waste Tank Over-flow Sig. 0.3 - 0.7 MPa Purge Sig.
Air Filter # 1
A B
4f Air Tube
EA P EB
I/O PC B Sig. I/O PC B Sig.
EA P EB
EA P EB
Media Hold Front/Rear Cylinders

OUT
IN
EA P EB
Carriage Part
Air Filter # 2
A R P
E/P Regulator
SU P OU T
P R

P CB
Check valve
Check valve
SOLUTION SUB-TANK
SOLUTION BAR
Float Sensor Sig.
Purge S/W Sig.
PSE531-M5 Pressure Sig. Float Sensor Sig.
MAIN WASTE INKTANK Float Sensor Sig.

INK TANK
VACUUM EJECTOR
R P
SUB AIR TANK
Setting Press Carriage 0.03 MPa Purge S/W Sig.
7-5
ELECTRICAL DIAGRAMS
2. Electrical Diagrams
Overview electrical diagrams:
! ! ! ! ! ! !
Main Power Distribution in the Electrical Circuit Panel Power Supply Distribution - 3 Phase with neutral with ground star 380V (EU) Power Supply Distribution - 3 Phase no neutral with ground delta 208-240V (US) UV Lamp Power Box Connections UV Lamp Power Circuit UV Lamp Head Part UV Lamp Power Cables
7-7
ELECTRICAL DIAGRAMS
2.1. Main Power Distribution in the Electrical Circuit Panel

RELAY #2-4 SMPS GND RELAY #3-4
AWG #8 (7.5 SQ) Black
24V GND
24V GND
5-2 2-2 2-1
P1 P2 P3 N
24V GND
AWG #10 (5.5 SQ) Black

T-L3 T-L3
L31 L32 L33 L21 L22 L23
P11 P22 P23 L1 L1 L1 L2 L2 L3 L3

43
T-N T-N
L1 N
L1 L2 L3
L1 L2 L3
T-L3T-N
T-L3 T-N
L1
L2
L1
L2
L3
L3
T-L3
T-L3
L1
T-N
44
T-N
P11 P22 P23 N
3-2
L1 L2 L3
L1
L2
L3
TERMINAL 600V-55A
L21 L22 L23
L31 L32 L33
L41 L42
L51 L52
95 96 95 96
T-N
AWG #8 (7.5 Sq) Black
T-L3 L11 N
AWG #8 (7.5 Sq) Black TERMINAL 600V-80A AWG #10 (5.5 SQ) Black
Teflon AWG #14 (2 sqar) Black
GND
PE P22 N P1 P2 P3 N PE L3 PE T-L3 PE P22 N PE L11 N PE U1 V1 W1 PE U2 V2 W2 PE PE L41 L42 PE L51 L52

G
24V
15 15 15
1.
: SHORT BAR
GREEN
GREEN
GREEN
GREEN
GREEN
GREEN
GREEN
GREEN
2. 2 STAGE TERMINAL
T-N
2 STAGE TERMINAL 300V-30A

34 34 34
1-1
2-1
1-2 1-3
2-2 2-3
Green
Green
Green
P1 P2 P3 N
PE
TERMINAL 600V-55A
PE
P22
Green 5-3 4-3

AWG #12(3.5 SQUARE) 3C AWG #12(3.5 SQUARE) 3C AWG #12(3.5 SQUARE) 4C AWG #12(3.5 SQUARE) 4C AWG #12(3.5 SQUARE) 3C AWG #12(5.5 SQUARE) 3C
AWG #8 (7.5 sqar) 5C
EMERGENCY SWITCH
1-4
2-4
6-3 1-4
3.GREEN - METAL BASE TERMINAL

RESTART BUTTON
3PHASE AC380V , 50/60Hz POWER IN
4. Ground- Green/Yellow 8AWG 5. DC line Teflon AWG #20(0.5 sqar) Blue Wire USED AWG #8
6.
AWG #12(3.5 SQUARE) 3C
UV LAMP POWER
RING BLOWER
RING BLOWER
MOTOR DRIVE_C
MOTOR DRIVE_F
CONTROL RACK
7-9
ELECTRICAL DIAGRAMS
2.2. Power Supply Distribution - 3 Phase with neutral with ground star 380V (EU)
AWG#8 VCTF CABLE (BLACK)
Electronic System Circuit Diagram

N
ELCB #1(3-PHASE AC380V,50A)
AC CABLE ( ALL BLACK, PE : GREEN), AWG#10 DC CABLE (WHITE : + , BLACK : - ), AWG#16

AWG#16 VCTF CABLE 6C
3-PHASE AC380V, 50/60Hz PE

P1 P2 P3
AWG10 AWG12 AWG14 AWG16 AWG18

OPERATOR PC
= = = = =
5.5 SQUARE 3.5 SQUARE 2.0 SQUARE 1.25 SQUARE 1.0 SQUARE
P11 P22 P23
P22 N
PC-SMPS 300W PC S/W
x xx xx x x - --- - | | | | |---- ( Cable No ) | | | | | | | |------- Level ( + / - ) | | | | | |--------- VOLTAGE(24V/5V) | | | |-------------- POWER SOURCE(AC/DC) | |----------------- SMPS No.
1 2 1 2
L52 L51 PE
HEAD 1DC120+(5-6),WHITE
SMPS #1
1DC120-(5-6),BROWN
HEAD PCB INK FIRING

HEATER
2DC120+(5-6),YELLOW
SMPS #2
2DC120-(5-6),GREEN
HEAD PCB HEATING
UVH-01
3DC24+(5-6),RED
LOGIC
CH1
1 2 1 2 1 2
3DC24-(5-6),BLACK 3DC24+(5-5),WHITE 3DC24-(5-5),BLACK 3DC24+(5-3),WHITE 3DC24-(5-3),BLACK

AWG#16 VCTF CABLE 2C AWG#16 VCTF CABLE 2C
HEAD PCB REFILL PCB
P2 2 N
SMPS #8 +24VDC GND AWG#12 VCTF CABLE (BLACK) DC 24V
RESTART
1 2
SMPS #3 CH2
UVR-01
EMO 1
MC-A
EMO 2
EMO 3
EMO 4
MAIN/FPGA PCB
MC # 1( 50A )
UVM-01 / UVF-01
I/F PCB
L3 L2 L1
L23 L22 L21

1 2 3 MC #2(30A) 4 5 6
Thermal Overload Relay #1
V1
SMPS #4
RING BLOW_ RIGHT
4DC24+(5-2),WHITE 4DC24-(5-2),BLACK 4DC24+(5-4),WHITE 4DC24-(5-4),BLACK

UVI-01
PE N
L1 L2 L3
U1 W1 PG
4 5 6
M
2
PLC
MCCB #3(AC380V,20A)
Motor Frame GND

1
L3 L2 L1
L33 L32 L31

1 2 3 MC #2(30A)
SMPS #5
5DC24+(5-1),WHITE 5DC24-(5-1),BLACK
ITV PCB
UVA-01
V2 U2 W2
M
2
RING BLOW_ LEFT Motor Frame GND
DC24V+
DC24V-
6DC24+(1-15),WHITE 6DC24-(1-15),BLACK 6DC5+(1-15),RED 6DC5-(1-15),GREEN

MCCB #4(AC380V,20A)
SUB PCB
UVS-01
PE L1 N L12 L11
2 1 1
CARRIAGE AC-SERVO MOTOR 750W

UV LAMP(R)
1
SMPS #6
DC5V+ DC5V-
UV LAMP(L)
6DC24+(5-7),WHITE 6DC24-(5-7),BLACK 6DC5+(5-7),RED 6DC5-(5-7),GREEN

MCCB
M
PE
SERVO DRIVE #1
2
#2(AC220V,50A)
HEAD BASE LIFT PCB
UVL-01
PE T-L3 T-N
K7M-DR60S
PLC MASTER- K 80S PID CONTROLLER #1
N PE PE
N O I S E F I LT E R (50A)
L41
L3
L42
FEED AC-SERVO MOTOR 400W
M
MCCB #5(AC220V, 30A) SERVO DRIVE #2
2
PE L52 L51 PE
PID CONTROLLER #2 PID CONTROLLER #3
T-L3 T-N
L52 L51
MCCB #6(AC220V,30A)
7 - 11
ELECTRICAL DIAGRAMS
2.3. Power Supply Distribution - 3 Phase no neutral with ground delta 208-240V (US)
Electronic System Circuit Diagram
A C C A B L E ( A L L B L A C K , PE : G RE EN ), A W G # 10 DC CABLE (WHITE : + , BLACK : - ), AWG#16

3-PHASE AC208~240V, 50/60Hz PE

P1 P2 P3
ELCB #1(3-PHASE AC380V,50A)

OPERATOR PC PC S/W
= = = = =
P11 P22 P23
P22 P11
PC-SMPS 300W
xx x x x xx - --- - | | |---- ( Cable No ) | | | | | | | | | |------- Level ( + / - ) | | | |--------- VOLTAGE(24V/5V) | | | | | |-------------- POWER SOURCE(AC/DC) | |----------------- SMPS No.
1 2 1 2
L52 L51 PE
HEAD 1DC120+(5-6),WHITE
SMPS #1
1DC120-(5-6),BROWN
HEAD PCB INK FIRING

HEATER
2DC120+(5-6),YELLOW
SMPS #2
2DC120-(5-6),GREEN
HEAD PCB HEATING
UVH-01
3DC24+(5-6),RED
LOGIC
CH1
1 2 1 2 1 2
3DC24-(5-6),BLACK 3DC24+(5-5),WHITE 3DC24-(5-5),BLACK 3DC24+(5-3),WHITE 3DC24-(5-3),BLACK

HEAD PCB
P11 P23
MC #1(50A)
1 2 3
SMPS #8 +24VDC GND AWG#12 VCTF CABLE (BLACK)
RESTART
1 2
SMPS #3 CH2
REFILL PCB
UVR-01
EMO 1
EMO 2
EMO 3
EMO 4
MC-A
MAIN/FPGA PCB
UVM-01 / UVF-01
DC 24V
L3 L2 L1
L23 L22 L21

1 2 3 MC #2(30A) 4 5 6
V1 U1 W1 PG
PE
SMPS #4
RING BLOW_ RIGHT
4DC24+(5-2),WHITE 4DC24-(5-2),BLACK 4DC24+(5-4),WHITE 4DC24-(5-4),BLACK

I/F PCB
UVI-01
L1 L2 L3
M
2
PLC
MCCB #3(AC380V,20A)
Motor Frame GND

1
L3 L2 L1
L33 L32 L31

1 2 3 MC #2(30A) 4 5 6
SMPS #5
RING BLOW_ LEFT
ITV PCB
UVA-01
V2 U2 W2 PE
1 1
M
2
Motor Frame GND
DC24V+
DC24V-
6DC24+(1-15),WHITE 6DC24-(1-15),BLACK 6DC5+(1-15),RED
UVS-01
SUB PCB
MCCB #4(AC380V,20A)
L2
L11
2
UV LAMP(L)
UV LAMP(R)
L1
L12
CARRIAGE AC-SERVO MOTOR 750W
SMPS #6
DC5V+ DC5V-
6DC5-(1-15),GREEN
M
2
MCCB
#2(AC220V,50A) SERVO DRIVE #1

2
PE PE K7M-DR60S
PLC MASTER- K 80S PID CONTROLLER #1 FEED AC-SERVO MOTOR 400W
1
6DC5+(5-7),RED 6DC5-(5-7),GREEN
HEAD BASE LIFT PCB
UVL-01
L3 L1 PE PE
N O I S E F I LT E R (50A)
T-L3 T-L1
L42 L41
M
SERVO DRIVE #2
2
PE L52 L51 PE
MCCB #5(AC220V, 30A)
PID CONTROLLER #2 PID CONTROLLER #3
T-L3 T-L1
L52 L51
MCCB #6(AC220V,30A)
7 - 13
ELECTRICAL DIAGRAMS
2.4. UV Lamp Power Box Connections

F1 AC 250V 3A L11
29
N
28
PE
31 30 25 24
41 47
23
1 7
21 20
F2 DC 24V 3A
29
COM0
22
MC(L)LOW
MC(R)LOW
28
L11 L12 PE
P00 P02 P04 P06 P08 P0A
P0D P0F P11 P13 P15 P17
COM1
+ -
K1
41 41
K1
1 1
P01 P03 P05 P07 P09 P0B P0C P0E P10 P12 P14 P16 24G 24V
UV LAMP PLC
7 1
47
41
Main Box Right D-SUB 15P

250V
AC100~240V
24V DC POWER (2A)

P4C P4E
COM5
P40 P41 P42

COM0 COM1 COM2
P44 P46
COM3
P48 P4A
COM4
50Hz
60Hz
208V
220V
250V
50Hz
60Hz
208V
220V
FG
P43
P45 P47
P49 P4B
P4D P4F
57
1 2 3 4 5 6 7 8
29
29
T/R(L)
S/W HI LOW S-2
46
T/R(R)
9 10 11 12 13 14 15
28
52 53
55 56 54 60 60 51 50 61 61
55
27
26 50
S-1
45
60Hz
50Hz
S/W
HI
LOW
S-2
6
S-1
5
60Hz
50Hz
51
70
53
71 28
LOW
46 6
N
left AC fan right AC fan
left shutter (open) right shutter (open)
L MC1 LOW LK1
L MC2 HI LK2
R MC1 LOW RK1
R MC2 HI RK2
MC(L)HI
MC(R)HI
85
(SIGNAL_7P)
84
L11
A B D E H F K J C G
86
56
A B D C
B D H E
A C F K J G
57 A B D C
81
82
83
30
28 31
28
29
(POWER_4P)
52 70
87
84
85
80
71
86
54
87
(POWER_4P) (SIGNAL_7P)
80
80
81
81
82
82
83
83
3PHASE UVLAMP POWER BOX
fan
L1
K1
L2
K2
L3
K1
L4
K2
L5
LEFT UV LAMP ASSY
RIGHT UV LAMP ASSY
7 - 15
ELECTRICAL DIAGRAMS
2.5. UV Lamp Power Circuit

Europe US AC220V,50/60Hz PE L1 N PE L1 L2
AWG #12 VCTF CABLE 3C
T/R(R)
= = = = =
AC CABLE ( ALL BLACK, PE : GREEN), AWG #12 CONTROL CABLE (WHITE : + , BLACK : - ), AWG #14
L2 N L1 L1 MCCB
L12 L11
F1 (250VAC-3A) SMPS #9
4P CON (R) D
L12
(7)
1 2 3
4 5 6 (1) 4 3
CAP.(R) #1 CAP.(R) #2 CAP.(R) #3 CHOKE(R)-LOW

(1)
AC 250V
50Hz
(7)
RT1 A D
1 B C 2
110 t
60Hz S-1
#2(AC220V,50A)
+24VDC GND
F2 (25VDC-3A)
NTC #2
(1)
1 2
AC 220V
(1)
(5)
B 4P CON
MC(R)-LOW
LP
AC 208V 60Hz 50Hz

(7)
(6)
S-2
1 (6) 2 4 3 (6)
L11 L12
PLC OUTPUT COM
LOW HI S/W
AC FAN(R)
Ignitor(R)
MC(R)-HIGH UV LAMP(R)
# UV LAMP HEAD ASSY(RIGHT)
PE
INPUT COM
KDM-DR40S
GND T/R(L)
4P CON (L) A A D RT1
L12 L11 PE
L12
COOLRING (AC FAN)
1 (47) 2 3 1 (41) 2
4 5 6 4 3
CAP.(L) #1 CAP.(L) #2
(41)
AC 250V
50Hz
(47)
CAP.(L) #3 CHOKE(L)-LOW
(41)
60Hz S-1
1 B C 2
110 t
AC 220V
(41)
(45)
NTC #1
B C 4P CON
L11
MC(L)-LOW
AC 208V 60Hz
(47)
(46)
S-2
LP B N 1 2 (46) 4 3 (46)
LOW HI S/W
AC FAN(L)
Ignitor(L)
50Hz
MC(L)-HIGH
UV LAMP(L)
# UV LAMP HEAD ASSY(LEFT)
7 - 17
ELECTRICAL DIAGRAMS
2.6. UV Lamp Head Part

UV Lamp box housing
UV Lamp box
1 2 3 4 5 7 6
(SIGNAL_7P)
(SOLVALVE SIGNAL_2P)
(POWER_4P)
Temperature S/W (110c)

A D
1 2 3 7 6 4 5 1 2
Temperature S/W (110c)

A D
1 2 3 7 6 4 5 1 2
B C
B C
temperature S/W (110c)
temperature S/W (110c)
AC FAN
DC FAN
AC FAN
DC FAN
LP N
LP N
IGNITER
IGNITER
UV LAMP
UV LAMP
LEFT
RIGHT
7 - 19
ELECTRICAL DIAGRAMS
2.7. UV Lamp Power Cables

left A B C D L1(L) AC FAN(L) L2(L) FG(L) right L1(R) AC FAN(R) L2(R) FG(R) size 0.3M(AWG12) 0.3M(AWG12) 0.3M(AWG12) 0.3M(AWG12) A B C D left L1(L) AC FAN(L) L2(L) FG(L) right L1(R) AC FAN(R) L2(R) FG(R) size 0.5M(AWG12) 1M(AWG12) 1.3M(AWG12) 0.5M(AWG12)
4P<-->4P CONNECTOR PIN ASSIGNMENT(1:1)

4P CONNECTOR(MALE) 4P CONNECTOR(FEMALE)
A B D H E F K J C G
2 3 4
1 7 6 5
10P<-->7P CONNECTOR PIN ASSIGNMENT

10P CONNECTOR(MALE)
left A B C D E F G H J K
SHUTTER OPEN(L)
7P SCN6A16-7S CONNECTOR(FEMALE)
size 1M(AWG14)
right
SHUTTER OPEN(R)
UV Lamp Power Box

10P
N.C(L) N.C(L)
OVER HEAT(P0C)(L) DC 24V FAN(L) DC GND(L)
N.C N.C
OVER HEAT(P0D)(R) DC 24V FAN(R) DC GND(R)
1.3M(AWG14) 1M(AWG14) 1M(AWG14)
<--> 7P CONNECTOR PIN ASSIGNMENT

A B C D E F G H J K
N.C N.C
INTERLOCK(K1)(L) INTERLOCK(P44)(L)
N.C N.C
INTERLOCK(K1)(R) INTERLOCK(P44)(R)
0.5M(AWG14) 0.5M(AWG14)
UV Lamp Assy
< <
<----> <----> <----> <----> <----> <----> <----> <----> <----> <---->
7P CONNECTOR 1 7P CONNECTOR 2 7P CONNECTOR 3 7P CONNECTOR 4 7P CONNECTOR 5 7P CONNECTOR 6 7P CONNECTOR 7 7P CONNECTOR N.C 10P CONNECTOR K 10P CONNECTOR J
7 - 21
PROGRAMMABLE LOGIC CONTROLLER (PLC) BLOCK DIAGRAM
3. Programmable Logic Controller (PLC) Block Diagram

Overview PLC block diagrams:
! !
Main PLC UV Lamp PLC
7 - 23
3.1. Main PLC

REFILL J13
MEDIA 3 1 2 + 4 SET BLOWER 3 1 2 + 4 6 3 S/W VT 301 SOL V/V
SUB J4
3951-6P
5045-2P
P0 LAMP P LC Waste tank 3 1
P02 P01
P04
P06
P08
P0A
P0C
P0E
P10
CM0
P13
P15
P17
P19
P1B
P1D
P1F
P21
P23
CM1 24+
P03
P05
P07
P09
P0B
P0D
P0F
P11
P12
P14
P16
P18
P1A
P1C
P1E
P20
P22
24G
2 + 4
3 1
2 + 4 1 24V SMPS #4 2 3 4 +
LEFT LAMP
RIGHT LAMP 1 2 3 4 + F/REAR S/W F/FRONT S/W N.O + COM

REAR BLOWER
GND
AC220V FG
P40 CM0
P41
P42 P43
P44 CM3
P46 P47
P48 CM4
P4A
P4C
P4E
P50
P52 P53
P54 CM7
P56 P57
CM1 CM2
P45
P49
P4B CM5 P4D
P4F CM6
P51
P55
TERMINAL BLOCK (220V)
GND
E44 EPDB
E34 1 2 3 4 + 1 2 3 4 +
R/REAR S/W
R/FRONT S/W
2 3 4 TOWER
2 3 4 LAMP
MS1 SOL V/V
RF
RR
MS2
GND
7 - 25
3.2. UV Lamp PLC

The UV lamp PLC diagram is illustrated in the diagram UV Lamp Power Box Connections on page 7-15 .
7 - 27
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 PCB SUB PCB IF PCB I/O PCB TAKE UP PCB REFILL CONTROL PCB INDICATOR PCB DRIVER COMMUNICATION PCB
7 - 29
4.1. Total PCB Diagram Layout

CARTRIDGE PCB
UV NEO I/O PCB

1
J1
1
J2
LED1 LED2
<MAIN J17, J18 - I/O J1, J4>

5
MEDIA SENSOR1
MEDIA SENSOR1
J2 1. +5V 2. MEDIA SENSOR 1 3. MEDIA SENSOR 2 4. MEDIA SENSOR 3 5. FEED LIMIT
PLUS : #2~4 Cylinder Sensor DELUXE : #2~4 Cylinder Sensor #5 Limit Switch
5
J3
J1
J4
J2
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
J1~J4 1. HVPULSE 2. N.C 3. N.C 4. GND 5. CLK 6. DATAOUT 7. DATAIN 8. +12V 9. GND
UV NEO TAKE UP BOARD PCB

EACH HEAD
TAKE UP BOARD REV 0
D1 RED
5045-5P J3
1
LED3
LED4
MEDIA SENSOR1
FEED LIMIT
J3 1. LEFT SHUTTER 2. RIGHT SHUTTER 3. GND
J5
11
3 11 12
J5
12 10 8 6 4 2 12 10 8 6 4 2
2 D4 1 12 11
11 9 7 5 3 1
5267-8P
3 LED5 LED6
<I/O J3, J6 - SUB J13>
<CARTRIDGE HEAD(J1~J8)>
9 7 5 3
J4
5045-3P J6 LEFT SHUTTER RIGHT SHUTTER
<MAIN J17, J18 - I/O J1, J4>
J6 1. N.C 2. UV LAMP ON 3. N.C 4. N.C
1
1 2
1 LED7 LED8 4 TP1
P1
TP2
5267-5P
UV LAMP ON 5045-4P
5K
JET REV5
LEDG-SM HV_ADJ 12V
J5 1. GND_SIGNAL 2. GND_SIGNAL 3. HV_ERR 4. HV_CK 5. SHIFT_CK_HI 6. DATA_CD_HI 7. DATA_AD_HI 8. N.C 9. +12V 10. +12V 11. GND_POWER 12. GND_POWER 13. N.C 14. N.C 15. HVIN 16. HVIN
?
D2 GREEN D3 GREEN D4 RED D5 GREEN
CW_LED
CCW_LED
AUTO_LED
ERROR_LED
J4-1,3,5,7 & J1-1,4 : Height Adjustment Solenoide J1-1,3 : Up Limit Switch UP-Limit Switch
5V
5
SW1
2
SW2
2
SW3
2
SW4
2
WT
LM
LC
CW_SW
5V
CCW_SW
5V
AUTO_SW
5V
ERROR_SW
<GORE I-TV/PSE>
J11
15
SUB-INK TANK PT SENSOR

SMPS #2 +120V SMPS #2 GND
HEAD BASE PT SENSOR
PC MOTHER PCB COM2 <GORE RS 232C>

1. +24V 2. +24V 3. +24V 4. GND 5. GND 6. GND 7. IN+ 8. IN+ 9. OUT+ 10.OUT+
<TAKE UP J11 - REFILL J18>
UV NEO ITV PCB

SW2
J4
SMPS #1 120V J13 1. HV2 2. GND 3. HV1 4. GND 5. 5V 6. GND 7. 24V 8. GND
<GORE POWER2>
1. +24V 2. N.C 3. SOL_A 4. N.C 5. +24V 6. N.C 7. SOL_B
J4
1 7
SMPS #1 GND SMPS #3 24V SMPS #3 GND BASE B' SUB B' BASE B SUB B N.C SUB A BASE A
J10 J17 5267-3P J30 5267-4P J23 3951-7P
#1,2,3 #4,5,6 #7,8
24V 0V IN+ IN1 2
24V 0V
I-TV CONTROL 24V - SMPS #5

J1A
ON
OFF
HV2 HEAT#2
ZERO
HV2 HEAT#3
HV2 HEAT#4
HV2 HEAT#5
HV2 HEAT#6
HV2 HEAT#7
HV2 HEAT#8
GND RX TX N.C
J1 GIL-G-4P
FEEDBACK
N.C DN_SEN UP_SEN +5V GND

J16
1 10
3951-2P HEATER2
20K STL950
3951-2P HEATER3
3951-2P HEATER4
3951-2P HEATER5
3951-2P HEATER6
3951-2P HEATER7
3951-2P HEATER8
JET DRIVE REV-3

1 HEATER1
HEAD BASE THERMISTOR
GND
5267-2P
SUB A
5045-6P
J13
INK_OVF(5V)
J95
<GORE POWER1>
SUB B SUB B' BASE A

LED2
GND +24V N.C OUT+

5045-4P SW1 RESET 24V LED1 J11
SW4 +10V -10V +10V -10V
HEAT#1 HV2
3951-2P
J39
BZ1
12V
5267-3P
ITV
MAIN ERROR +24V N.C GND OVERFLOW ERROR +24V
1 2
GND 5V 5V
BASE B BASE B'

J12
UV NEO HEAD BASE LIFT PCB

3951-2P
JUMPER INSERT 5267-4P
GND
UV NEO HEAD PCB
GND +24V IN+

SOL(1) SOL(2) 5045-3P J6
SOL(1),SOL(2)
GND
PURGE SWITCH
J2 J3
11
+24V
PSE531
J28
E_TANK_SOL +5V
5267-2P 5267-3P
J34
J352 3951-2P HRS-16P

15
12 10 8 6 4 2
20
12
11
11 9 7 5 3 1
12 10 8 6 4 2
12
11
12 11 10 9 7 8 5 6 3 4 1 2
12
12 11 10 9 7 8 5 6 3 4 1 2
12
11
12 11 10 9 7 8 5 6 3 4 1 2
12
11
12 11 10 9 7 8 5 6 3 4 1 2
12
11
12 11 10 9 7 8 5 6 3 4 1 2
12
11
12 11 10 9 7 8 5 6 3 4 1 2
12
11
12 11 10 9 7 8 5 6 3 4 1 2
12
11
11 9 7 5 3 1
HV-CK
J29
+5V GND
3951-5P
GND SOL(2)
E_TANK_WHITE
MEDIA
VT301V
+5V
5267-2P J23
J9
SHIFT-CK
E_TANK_LM
1
GND
<GORE SIGNAL> <GORE SENSOR>
J15
+5V N.C
5267-2P J6
1 D1
1
D2
SUB_HEATER BASE_HEATER GND GND +24V +24V
J8
U12
3951-6P
B~ GND B A~ GND A
LED3 24V 5045-7P
E_TANK_LC
HT_ERR
INK_OVF
HV_ERR
GND TEMP 12V
CON10
10 9 GND
INK1 INK2 INK3 INK4 INK5 INK6 INK7 INK8 12V 5V

5V
J21
E_TANK_Y +5V
5267-2P
F070494_SS
5267-2P
5267-2P
5267-2P
5267-2P
5267-2P
5267-2P
5267-2P
5267-2P
5267-2P
3951-3P J14
RED
5566-2P
MOTOR MOTOR +
J29
J10
INK1-K
INK2-C
INK3-M
INK4-Y
INK5-LC
INK6-LM
INK7
INK8-S
DILLI PRECISION UVL_01 REV.1 2004.10.20
J2
E_TANK_M +5V
5267-2P
+
J49 5267-2P
GND TERMISTOR
+5V SUC_LEVEL
J48
AC-IN
AIR_LOW INK LOW

J45
LAMP ON MEDIA SET BLOWER ON N.C
SSR OUT1 SSR OUT2

? -2P
P014 P020 P013 P012 P011

<SUB J4 - PLC>
J10 1. INK6 2. 5V 3. GND 4. GND 5. RESET 6. GND 7. INK8 8. GND 9. INK7 10. GND
GND INK1
GND INK2
GND INK3
GND INK4
GND INK5
GND INK6
GND INK7
GND INK8
GND GND
J22
E_TANK_C +5V
<IND J11, J13 RF J17-1, J4>
5267-2P J4
E_TANK_K +5V
5267-2P
SUB_HEATER
EACH INK LEVEL SENSOR
PLC P0B
LAMP +24V
J13
5045-2P
3951-6P
J4
HEAD TEMP. SENSOR
GND N.C N.C BUZZER
J33
+5V LIFT DN LIFT UP GND

5267-4P J47
5267-4P
J11
J16
5219-2P 3951-4P 5045-14P

14 14 7
5219-3P
GND
J43 J13
M_R_CCW M_R_CW
TAKE_R_SEN +24V
J31
+24V GND(24V) +5V GND(5V)
1. PLATEN OVER LOAD 2. PLATEN LOCK 3. N.C 4. N.C 5. PLATEN LIFT MANUAL S/W DOWN 6. PLATEN LIFT MANUAL S/W UP 7. PRESET 8. N.C 9. N.C 10. AIR LOW 11. PLATEN OVER LOAD 12. SHUTTER RIGHT 13. SHUTTER LEFT 14. UV LAMP ON
AIR TANK PRESSURE GAGE SIGNAL

GND 5V SERV-R/S MOVE-R MOVE-L
5V
UV NEO MAIN BOARD PCB

TRAVEL ERROR MEDIA WEEP HV 5V
1
<TAKEUP MOTOR - REFILL J10, J11>
29
19
HRS-30P
<I/O J3, J6 - SUB J13>

D3 D2 D1
GND
GND
ENC
MARK
TEST
RUN
FEED
RESET
STOP
<REFILL J31 - CONTROL J18>

SERVO R/S
10
<SUB J43 SMPS #6>

J8 J7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 1
<PID SUB IF J8>
<PID SUB IF J7, J9>
<PID HEAD BASE - IF J11>
PID#2-4 PID#2-3 PID#2-2
PID#2-1
PID#1-4 PID#1-3 PID#1-2
MAIN PROCESSOR REV-4
SUB_B SUB_B'
J8
SUB_HEATER N.C GND
+24V GND N.C ITV

J3 5045-4P J12
10
SUB_A
BASE_A N.C BASE_B
WHITE_SUB_HEATER +24V GND GND PSE BASE_B'
J8 7. GND 9. PCD15 11.PCD14 13.PCD13 15.PCD12 17.PCD11 19.PCD10 21.PCD9 23.PCD8 25.PCD7 27.PCD6 29.PCD5 31.PCD4 33.PCD3 35.PCD2 37.PCD1 39.PCD0
J7 1. EXT1 2. PCSELA 3. EXT2 4. PCSELB 34.GND 37.O_REQ
J9 5267-4P
10
J10
J11
J4
5267-3P
3951-3P
3951-2P
5045-3P
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
O_REQ
1 J11
TMS TMS
1 1
3.3V TDO TD
1 1
WR PC_CLK
TCX
UV NEO FPGA PCB
CLOCK
+24V N.C
J7
PC2
PC1
N.C N.C N.C N.C

1
GND
GND
D6 D5 D4
PID#2-13
<PID SUB - IF J7, J9>
+24V
3951-2P J6
PWR
N.C
GND
UV NEO IF PCB
5045-9P
N.C GND
J13
<IF 24V J6 SMPS #4>

GND +24V
3951-2P J5
+24V GND N.C

5045-5P
J14 2 11 3 4 5 6
N.C PSE
1 10 9 8 12 7
3951-2P
3
5045-8P
3 8
3951-6P
6
J2
J1
J2 1. PSE 2. ITV 3. BASE_B' 4. BASE_B 5. BASE_A 6. SUB_B' 7. SUB_B 8. SUB_A
J1 1. SUB_HEATER 2. BASE_HEATER 3. GND 4. GND 5. +24V 6. +24V
29
19
#1~3 : CARRIAGE DRIVER CN2 #4~6 : FEED DRIVER CN2
<MAIN 24V J4 SMPS#3>
<ENCODER HARNESS>
<CONTROL J18 - REFILL J31>
J15
19 10 1 26 18 9
J18
J11
J17
J7
UV NEO INDICATOR PCB
<GORE SENSOR> <GORE POWER1> <GORE SIGNAL>

D1 GREEN D3 GREEN D5 GREEN D7 GREEN D9 GREEN D11 GREEN D13 GREEN D17 LED
<MAIN J7 - PC COM1> <MAIN J17, J18 - I/O J1, J4>
J12
+ +5V INK_FULL_SIGNAL
5267-2P
INK_FULL_WT
INK_FULL_LM
INK_FULL_LC
INK_FULL_Y
INK_FULL_M
INK_FULL_C
<MAIN J11 - REFILL J17> <MAIN J18 - REFILL J34> <MAIN J17, J18 - I/O J1, J4>
NOT USED
D2
RED
D4
RED
D6
RED
D8
RED
D10
RED
D12
INK_EMPTY_WT INK_EMPTY_LM INK_EMPTY_LC INK_EMPTY_Y INK_EMPTY_M INK_EMPTY_C INK_EMPTY_K INK_EMPTY_S
J1
WT
J2
LM
J3
LC
J4
J5
REFILL PCB HEAD PCB
PLC
5267-3P 5267-3P 5267-3P 5267-3P 5267-3P 5267-3P 5267-3P 5267-3P
HEAD PCB
HEAD PCB MAIN PCB FPGA PCB IF-PCB FAN
I-TV PCB
SUB PCB HEAD LIFT PCB

+5V
INK_FULL_WT INK_EMPTY_WT
INK_FULL_LM INK_EMPTY_LM
INK_FULL_LC INK_EMPTY_LC
INK_FULL_Y INK_EMPTY_Y
INK_FULL_M INK_EMPTY_M +5V
+5V
+5V
+5V
120V GND
PE L51 L52
120V GND
PE L1 L2
24V GND PE L1 L2
24V GND PE L1 L2
24V
PE L1 L2
24V G 5V
G PE L1 L2
SMPS #1 (240W-DC 120V/2A) WK240S120A
SMPS #2 (240W-DC 120V/2A) WK240S120A
SMPS #3 (240W-DC 24V/5A) WK120S24A
SMPS #4 (240W-DC 24V/5A) WK120S24A
SMPS #5 (75W-DC 24V/1.5A, DC 5V/8A ) WK75DS0524A
SMPS #6 (75W-DC 24V/1.5A, DC 5V/8A ) WK75DS0524A
19
29
DC 24V
+24V
J10 1. 3.3V 2. 3.3V 3. GND 4. GND 5. MCSELA 6. MCSELB 7. MCCLK 8. VIA3 MCSELB 9. VIA4 10.PCSELA PCSELA 11.PCSELB 12.MCD0 13.MCD1 PCSELB 14.MCD2 15.MCD3 16.MCD4 17.MCD5 18.MCD6 19.MCD7 20.MCD8 21.MCD9 22.MCD10 23.MCD11 24.MCD12 25.MCD13 26.MCD14 27.MCD15 28.MCS1 29 MCS2 30. EXT1 31. EXT2 32. GND 33. GND 34. GND 35. GND 36. GND 3.3V PCN10C 50S 2.54DS 37. GND 38. GND 39. GND 40. GND D9 41. GND 42. GND 43. GND GND 44. GND 45. GND 46. GND 47. GND 48. GND 49. 3.3V 50. 3,3V J10
MCCLK MCSELA
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
FPGA PCB J10 - MAIN PCB J16 DIRECT CONNECTION
J16 1. +3.3VDC 2. +3.3VDC 3. GND 4. GND 5. MCSELA 6. MCSELB 7. MCCLK 8. VIA3 9. VIA4 10. PCSELA 11. PCSELB 12. MCD0 13. MCD1 14. MCD2 15. MCD3 16. MCD4 17. MCD5 18. MCD6 19. MCD7 20. MCD8 21. MCD9 22. MCD10 23. MCD11 24. MCD12 25. MCD13 26. MCD14 27. MCD15 28. OEA 29. OEB 30. VIA5 31. VIA6 32. GND 33. GND 34. GND 35. GND 36. GND 37. GND 38. GND 39. GND 40. GND 41. GND 42. GND 43. GND 44. GND 45. GND 46. GND 47. GND 48. GND 49. +3.3VDC 50. +3.3VDC
5045-2P J3
9 1 MEDIA SCAN 1
J16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 1
3.3V
J8
2
GND HOME SENSE +5VDC
D1 MCSELA
D9
D10
D2
D3
D12
D6
D4
D5
D7
D11
D8
CON10
<HOME MAIN J8 - LIMIT S/W>
1
ENC ABN 1 MCSELB
TRAVEL 1
5267-3P
8 7 6 5 4 3 2 1
J17 ENC 1
J9
GND N.C PINCH SENSE +5VDC
UV NEO CONTROL PCB

UV NEO CONTORL REV.3
WT
D1 RED D2
MCCLK
MARK 1
5267-4P J10
GND MEDIA ON N.C +5VDC N.C
LM
RED D3
LC
RED D4
Y
RED D5
J2 9 1
5267-8P
5267-5P
1 10 9 8 12 7
J1
9 1
CON10
SHIFT CLK 1
HV-CLK 1
J18
5267-5P
J1 1. OEB 2. +5V 3. GND 4. GND 5. RES 6. GND 7. OEA 8. GND 9. MCSELB 10. GND
J2 1. HV_LED 2. +5V 3. GND 4. GND 5. RES2 6. GND 7. SCR2 8. GND 9. MISO2 10. GND
J3 1. MOS3 2. +5V 3. GND 4. GND 5. RES3 6. GND 7. SCR3 8. GND 9. MISO3 10. GND
<HOME MAIN J8 SENSOR CONTROLLER(2,3)>
+ S_LED_WT
+ S_LED_LM
+ S_LED_LC
S_LED_Y
CON10 J14 2 11 3 4 5 6
J12
CCW LIMIT INP N.C OUT COM CW +24VDC N.C N.C

D9 GREEN D10 GREEN D11 GREEN D12 GREEN D13 GREEN D14 GREEN D15 GREEN D16 GREEN
ENCODER
<CARRIAGE CONTROL MAIN J12>
+ P_LED_WT
+ P_LED_LM
+ P_LED_LC
P_LED_Y
GND 1
PCN10-50P J15
1 10 19
5267-8P D-SUB26P(3row)
9 18 26
SW1
SW2
2 2
SW3
2
SW4
2
J11
5267-6P
J7
5267-3P
J5
5267-6P
J4
J15 1. DATA AB1 2. DATA CD1 3. DATA AB2 4. DATA CD2 5. DATA AB3 6. DATA CD3 7. DATA AB4 8. DATA CD4 9. DATA AB5 10. DATA CD5 11. DATA AB6 12. DATA CD6 13. DATA AB7 14. DATA CD7 15. DATA AB8 16. DATA CD8
17. MEDIA 18. SHIFT_CK 19. RX1_TTL 20. TX1_TTL 21. HV_CK 22. ERROR_OUT 23. HT_CNTRL 24. S.GND 25. S.GND 26. S.GND
J18 1. GND 2. EXT8 3. EXT7 4. +24VDC 5. +5VDC
J11 1. GND 2. N.C 3. N.C 4. TXD 5. N.C 6. N.C
GND TX RX
J17 1. GND 2. EXT6 3. EXT5 4. EXT4 5. EXT3 6. EXT2 7. EXT1 8. +5VCD
J5 1. GND 2. TX 3. RX 4. GND 5. TX 6. RX
+24VDC GND
J14 1. CHASSIS 2. GND 3. EN A+ 4. ENCA5. ENCB+ 6. GND 7. ENCRI+ 8. ENCRI9. GND 10. +5VDC 11. ENCB12. +5VDC
WT
LM
LC
SW_WT +5V
SW_LM +5V
SW_LC +5V
J18
SW_Y +5V
HRS-30P
19
29
UV NEO SUB PCB
D-SUB26P(3row)
STEP MOTOR
10
11
5267-2P
J1~J8 1. GND_SIGNAL 2. GND_SIGNAL 3. HV_ERR 4. HV_CLK* 5. SHIFT_CK* 6. DATA_CDK* 7. DATA_ADH* 8. N.C 9. +12V 10. +12V 11. GND_POWER 12. GND_POWER 13. N.C 14. N.C 15. HV1 16. HV1
D4
D6
+5V
D108
J5
J1
J4
J5
J6
J7
J8
J9 1. DATA AB1 2. DATA CD1 3. DATA AB2 4. DATA CD2 5. DATA AB3 6. DATA CD3 7. DATA AB4 8. DATA CD4 9. DATA AB5 10. DATA CD5 11. DATA AB6 12. DATA CD6 13. DATA AB7 14. DATA CD7 15. DATA AB8 16. DATA CD8 17. MEDIA 18. SHIFT-CK 19. RX1_TTL 20. TX1_TTL 21. HV_CK 22. ERROR_OUT 23. HT_CNTRL 24. GND 25. GND 26. GND
GND SOL(1) N.C
+24V
J18
SMPS #6 <GORE POWER3>
GND
3951-4P
VT301V
1. GND 2. +5V 3. GND 4. +5V 5. N.C 6. N.C 7. N.C 8. N.C 9. DIR_CW_SW 10. CW_LED 11. DIR_CCW_SW 12. CCW_LED 13. AUTO_SW 14. AUTO_LED 15. ERROR_SW 16. ERROR_LED
1. SW_Y 2. SW_M 3. SW_C 4. SW_K 5. SW_LM 6. SW_LC 7. SW_WHITE 8. SW_S 9. +5V 10. GND 11. S_LED_Y 12. S_LED_M 13. S_LED_C 14. S_LED_K 15. S_LED_LM
J31
15
<GORE I-TV/PSE>
1 2 3
GAIN 20K
J13 STL950 1 58
3 #9,10 OUT+ OUT-
3951-5P
3951-10P
<MAIN J18 - REFILL J34>
<AIR TANK REFILL J32>
<REFILL J18 TAKE UP J11>
J7
15
J11
HRS-16P
INK_PUMP_SOLUTION INK_PUMP_Y INK_PUMP_K INK_PUMP_WHITE INK_PUMP_M INK_PUMP_LM INK_PUMP_LC INK_PUMP_C +24V +24V +24V +24V +24V +24V +24V
J18
J20 3951-2P
J27 3951-2P
J24 3951-2P
J1 3951-2P
J25 3951-2P
J3 3951-2P
J26 3951-2P
J5 3951-2P D12
UV NEO REFILL8COLOR PCB
1.COMM LED 2.INK_PUMP_WHITE 3.INK_PUMP_LM 4.INK_PUMP_LC 5.INK_PUMP_Y 6.INK_PUMP_M 7.INK_PUMP_C 8.INK_PUMP_K 9.SOLUTION PUMP 10.OVERFLOW_ERROR
J17-1 J17-1
1. E_TANK_WHITE 2. E_TANK_LM 3. E_TANK_LC 4. E_TANK_Y 5. E_TANK_M 6. E_TANK_C 7. E_TANK_K 8. E_TANK_SOL

U1
+5V N.C GND
<IND J11, J13 RF J17-1, J4>
5045-3P 5045-3P
J17
GND TX RX_INK
16. S_LED_LC 17. S_LED_WHITE 18. S_LED_S 19. +5V 20. GND 21. P_LED_Y 22. P_LED_M 23. P_LED_C 24. P_LED_K 25. P_LED_LM 26. P_LED_LC 27. P_LED_WHITE 28. P_LED_S 29. +24V 30. GND
<REFILL J17 MAIN J11>
5267-3P J32
N.C N.C N.C PRESSURE_LOW N.C
SW1
5V
RESET
GND
5267-6P J14
+5V GND +24V
<AIR TANK REFILL J32> <REFILL +24V J14 - SMPS #3>
3951-2P HRS-30P J30 J10 J15 5566-2P
5267-2P
5566-2P
N.C M_F_CW +5V M_F_CCW OVERFLOW_ERROR +24V TAKE_F_SEN GND
<TAKEUP MOTOR - REFILL J10, J11>
14
PCA
MCA
CS6 CS6
CS5
CS4
CS3
CS2
CS1
A21
A20
A19
A18
A17
A16
A15
A14
A13
A12
A11
A10
A9 A9
A8
A7
A6
A5
A4 A4
A3
A2
A1
A0
<GORE HEAD REFILL>
M
RED D6
C
RED D7
K
RED D8
S
RED
+ S_LED_M
S_LED_C
S_LED_K
S_LED_S
+ P_LED_M
P_LED_C
+ P_LED_K
P_LED_S
SW5
2
SW6
2
SW7
2
SW8
2
REV5
SW_M +5V
SW_C +5V +5V
SW_K +5V
SW_S
PCB
MCB
CS6 CS6
CS5
CS4
CS3
CS2
CS1
B21
B20
B19
B18
B17
B16
B15
B14
B13
B12
B11
B10
B9 B9
B8
B7
B6
B5
B4 B4
B3
B2
B1
B0
5V
GND
INK_FULL_K
INK_FULL_S
<IND J11, J13 RF J17-1, J4>

J13
REFILL_INDICATOR REV.2
INK_EMPTY_SIGNAL +5V
5267-2P
RED
D14
RED
D16
RED
J11
+5V N.C GND

3951-3P
<IND J11, J13 RF J17-1, J4>
J6
J7
J8
INK_FULL_C INK_EMPTY_C +5V
INK_FULL_K INK_EMPTY_K +5V
INK_FULL_S INK_EMPTY_S +5V
7 - 31
4.2. MAIN PCB

RESET <PUSH S/W #3 PUSH S/W MAIN RESET>
J16 1. +3.3VDC 2. +3.3VDC 3. GND 4. GND 5. MCSELA 6. MCSELB 7. MCCLK 8. VIA3 9. VIA4 10. PCSELA 11. PCSELB 12. MCD0 13. MCD1 14. MCD2 15. MCD3 16. MCD4 17. MCD5 18. MCD6 19. MCD7 20. MCD8 21. MCD9 22. MCD10 23. MCD11 24. MCD12 25. MCD13 26. MCD14 27. MCD15 28. OEA 29. OEB 30. VIA5 31. VIA6 32. GND 33. GND 34. GND 35. GND 36. GND 37. GND 38. GND 39. GND 40. GND 41. GND 42. GND 43. GND 44. GND 45. GND 46. GND 47. GND 48. GND 49. +3.3VDC 50. +3.3VDC
SERV-R/S
MOVE-R
MOVE-L
TRAVEL
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
MAIN PROCESSOR REV-4
J16
ERROR
MEDIA
WEEP
RUN
FEED
STOP
RESET
MARK
TEST
ENC
HV
5V
SERVO/RS 1
5045-2P
J8
GND HOME SENSE +5VDC
D1
D9
D10
D2
D3
D12
D6
D4
D5
D7
D11
D8
J17
DILLI MARK 7-2

J14 1. CHASSIS 2. GND 3. EN A+ 4. ENCA5. ENCB+ 6. GND 7. ENCRI+ 8. ENCRI9. GND 10. +5VDC 11. ENCB12. +5VDC
J14
HOME SENSOR
5267-3P J9
J15 1. DATA AB1 2. DATA CD1 3. DATA AB2 4. DATA CD2 5. DATA AB3 6. DATA CD3 7. DATA AB4 8. DATA CD4 9. DATA AB5 10. DATA CD5 11. DATA AB6 12. DATA CD6 13. DATA AB7 14. DATA CD7 15. DATA AB8 PCN10-50P 16. DATA CD8
J30
17. MEDIA 18. SHIFT_CK 19. RX1_TTL 20. TX1_TTL 21. HV_CK 22. ERROR_OUT 23. HT_CNTRL 24. S.GND 25. S.GND 26. S.GND
J17 1. DC5V+ 2. MEDIA SET1 3. MEDIA SET2 4. MEDIA SET3 5. FEED LIMIT 6. LEFT SHUTTER 7. RIGHT SHUTTER 8. +5VCD
5267-8P
GND N.C N.C +5VDC

J7
<MAIN J8 LIMIT S/W>

DRIVER COMM. PCB J7 5267-2P
5267-4P J10
DILLI MAIN 10-5 UV
GND DOOR SENSE TO INTERLOCK MODULE
J18 1. GND 2. EXT8 3. UV LAMP ON 4. +24VDC 5. +5VDC

J18 5267-5P
DILLI MAIN 20
J5 1. GND 2. TX 3. RX 4. GND 5. TX 6. RX
J7 5267-3P J5 5267-6P
5267-5P J12 J12
2 11 3 4 5 6
1 10 9 8 12 7
24V+
DRIVER COMM. PCB J6
ENCODER
GND C-INP GND
NOT USED
5267-2P J15
1 10 19
D-SUB26P(3row)
9 18 26
J11
5267-6P
J4
5267-8P
5267-8P
ENCODER
+24VDC
J1
GND
GND
GND
FPGA J10
J9
9 18 26
J4
GND
TX
RX
TX
TX RX
5267-8P
5267-5P
D-SUB26P(3row)
HEAD PCB J9 <GORE SIGNAL>
J7
I/O PCB J4 <I/O J3, J6 MAIN J17, J18>

1
I/O PCB J1 <I/O J3, J6 - MAIN J17, J18>
J12
1 10 19
5267-8P
SMPS#3
DRIVER COMM. PCB J5

PC-COM1
<MAIN 24V J4 - SMPS#3>
5267-3P
REFILL PCB J17
<MAIN J7 PC COM1>
<REFILL J17 - MAIN J11>
7 - 33
4.3. FPGA PCB

J10 1. 3.3V 2. 3.3V 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.MCS1 29.MCS2 30. EXT1 31. EXT2 32. GND 33. GND 34. GND 35. GND 36. GND 37. GND 38. GND 39. GND 40. GND 41. GND 42. GND 43. GND 44. GND 45. GND 46. GND 47. GND 48. GND 49. 3.3V 50. 3.3V
GND
PCA
MCA
CS6
CS5
CS4
CS3
CS2
CS1
A21
D3
A20
A19
A18
A17
A16
A15
A14
A13
A12
A11
A10
D2
A9
A8
A7
A6
A5
A4
A3
A2
A1
A0
D1
5V
GND
J10
1
MCCLK
J8 7. GND 9. PCD15 11.PCD14 13.PCD13 15.PCD12 17.PCD11 19.PCD10 21.PCD9 23.PCD7 27.PCD6 29.PCD5 31.PCD4 33.PCD3 35.PCD2 37.PCD1 39.PCD0
J7 1. EXT1 2. PCSELA 3. EXT2 4. PCSELB 34. GND 37. O_REQ
J8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
J7
1
O_REQ
1 J11
MCSELA
MCSELB
TMS TMS
1 1
3.3V TDO TD
1 1
WR PC_CLK
PCSELA
TCX
PCI CARD CN2 <PCI-FPGA J7>
PCSELB
CLOCK
PCI CARD CN1 <PCI-FPGA J8>
PC2
PC1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
8 7 6 5 4 3 2 1
1 1
3.3V
D9
GND
D6 D5 D4
PCN10C 50S 2.54DS
PWR
REV5
5V PCB MCB CS6 CS5 CS4 CS3 CS2 CS1 B21 B20 B19 B18 B17 B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 B0 GND
GND
MAIN BOARD PCB J16
7 - 35
4.4. HEAD PCB

<GORE POWER2>
HEATER7 HEATER4 HEATER8 SMPS#2 SMPS#1 HEATER3 HEATER5 HEATER6 HEATER2 SMPS#3
1,2 : SMPS#2(HEAD HEATER HV) 3,4 : SMPS#1(HEAD JET HV) 5,6 : N.C 7,8 : SMPS#3
HV2
2
HV2
HV2
HV2
HV2
HV2
HV2
3951-2P
HEAT#2
3
HEAT#8
3951-2P
HEAT#3
4
3951-2P
HEAT#4
5
3951-2P
HEAT#5
6
HEAT#7
3951-2P
HEAT#6
7
J13 1 5 8
3951-2P
3951-2P
STL950
J30 5267-2P
HEATER1
HEAT#1 HV2
1
1 2
J39
BZ1
12V
JET DRIVE REV-3
3951-2P
JUMPER INSERT 5267-4P
GND
J1~J8 1. GND_SIGNAL 2. GND_SIGNAL 3. HV_ERR 4. HV_CLK* 5. SHIFT_CK* 6. DATA_CDK* 7. DATA_ADH* 8. N.C 9. +12V 10. +12V 11. GND_POWER 12. GND_POWER 13. N.C 14. N.C 15. HV1 16. HV1
J13 1. HV2 2. GND 3. HV1 4. GND 5. 5V 6. GND 7. 24V 8. GND
GND INK_OVF(5V)
J95
NOT USED
5267-3P
GND 5V 5V NOT USED
GND 1
J1
12
J1
11 12 11
J2
12 11
J3
12 11
J4
12 11
J5
12 11
J6
12 11
J7
12 11
J8
12 11
J9
J15
<GORE SIGNAL>
J9 1. DATA AB1 2. DATA CD1 3. DATA AB2 4. DATA CD2 5. DATA AB3 6. DATA CD3 7. DATA AB4 8. DATA CD4 9. DATA AB5 10. DATA CD5 11. DATA AB6 12. DATA CD6 13. DATA AB7 14. DATA CD7 15. DATA AB8 16. DATA CD8 17. MEDIA 18. SHIFT-CK 19. RX1_TTL 20. TX1_TTL 21. HV_CK 22. ERROR_OUT 23. HT_CNTRL 24. GND 25. GND 26. GND
MAIN PCB J15
HT_ERR
- VR TEMPERATURE
GND 1
INK_OVF
HV_ERR
5267-2P
TP
TP
2 1
EACH CARTRIDGE PCB J5
D-SUB26P(3row)
D-SUB26P(3row)
1 D1
D4
D6
D2
VR
12V
CON10
10 9 GND
INK1 INK2 INK3 INK4 INK5 INK6 INK7 INK8 12V 5V 5V

5V 5V
5267-2P
5267-2P
5267-2P
5267-2P
5267-2P
5267-2P
5267-2P
5267-2P
J21
J29 J10 INK1-K INK2-C INK3-M INK4-Y INK5-LC INK6-LM INK7_S INK8-W
G HEAD TEMP. SENSOR
K G LEVEL SENSOR
C G LEVEL SENSOR
M G LEVEL SENSOR
Y G LEVEL SENSOR
LC G LEVEL SENSOR
LM G LEVEL SENSOR
S G LEVEL SENSOR
W G LEVEL SENSOR
7 - 37
4.5. REFILL PCB

J18
15
<VT301 REFILL J35> <MAIN J18 REFILL J34> MAIN PCB J18
J18
TAKE UP PCB
VT301
INK_PUMP_SOLUTION +24V INK_PUMP_WHITE +24V INK_PUMP_LM +24V INK_PUMP_LC +24V INK_PUMP_Y +24V INK_PUMP_M +24V INK_PUMP_C +24V INK_PUMP_K +24V
J18 J21 3951-2P J20 3951-2P J27 3951-2P J24 3951-2P J1 3951-2P J25 3951-2P J3 3951-2P J26 3951-2P J5 3951-2P D12
+ -
HRS-16P
<TAKE UP J11 - REFILL J18>
AIR ERROR +24V
5267-5P
MAIN ERROR
N.C
GND
NOT USED
E_TANK_SOL +5V
J28 J34 5267-3P J35 3951-2P

15
5267-2P
HRS-16P
NOT USED
E_TANK_WHITE +5V E_TANK_LM +5V E_TANK_LC +5V
J2 9
5267-2P J2 3
NOT USED
5267-2P J6
9 16
NOT USED
10
11
5267-2P
D108
U12
1. COMM LED 2. INK_PUMP_WHITE 3. INK_PUMP_LM 4. INK_PUMP_LC 5. INK_PUMP_Y 6. INK_PUMP_M 7. INK_PUMP_C 8. INK_PUMP_K 9. SOLUTION PUMP 10. OVERFLOW_ERROR
20
NOT USED
E_TANK_Y +5V E_TANK_M +5V
J21
5267-2P J2
NOT USED
5267-2P
E_TANK_K +5V
J13
J2 2 J32 5267-2P J17
INDICATOR PCB J10

5267-2P
E_TANK_C +5V
J4
5267-2P J1 3
PLC P0B
LAMP
<IND J11, J13 - RF J17-1, J4>

+24V GND N.C
<REFILL J13 - PLC P0B>
5045-2P J3 3
NOT USED
N.C BUZZER
J3
5267-4P
J11
NOT USED
5045-4P 5219-2P 5219-3P
J31 5267-2P 5566-2P
J18
REAR PHOTO SENSOR REAR GEAR MOTOR <TAKEUP MOTOR - REFILL J10, J11>
19
H R S -3 0 P
CONTROL PCB J18 <CONTROL J18 - REFILL J31>
19
29
J17-1
+5V N.C GND
J11
8. E_TANK_SOL
7. E_TANK_K
6. E_TANK_C
5. E_TANK_M
4. E_TANK_Y
3. E_TANK_LC
2. E_TANK_LM
1. E_TANK_WHITE
U1
INDICATOR PCB J11

5045-3P
5045-3P
<IND J11, J13 - RF J17-1, J4>
MAIN PCB J11
GND TX RX_INK
J16
HRS-30P J30
5267-3P J32
N.C N.C N.C N.C
5267-6P
<REFILL J17 - MAIN J11>

PRESSURE LOW
AIR TANK
SW1
5V
RESET
GND
5267-6P J14
+5V GND +24V
SMPS #3
<AIR TANK - REFILL J32>
3951-2P J10 J15 5566-2P
<REFILL +24V J14 - SMPS#3>
M_R_CW
M_R_CCW
24V
TAKE_REAR_SEN
GND
29
SUB-TANK FLOW SENSOR <GORE HEAD REFILL>
+5V OVERFLOW ERROR
FRONT GEAR MOTOR <TAKEUP MOTOR REFILL J10, J11>
M_F_CCW
M_F_CW
FRONT PHOTO SENSOR
N.C TAKE_FRONT_SEN GND 24V
7 - 39
4.6. CARTRIDGE PCB

J1~J4 1. HVPULSE 2. N.C. 3. N.C. 4. GND 5. CLK 6. DATAOUT1 7. DATAIN 8. +12V 9. GND
J3 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
J1 1 2 3 4 5 6 7 8 9
J4 1 2 3 4 5 6 7 8 9
J2
EACH HEAD
J5 1. GND_SIGNAL 2. GND_SIGNAL 3. HV_ERR 4. HV_CK 5. SHIFT_CK_HI 6. DATA_CD_HI 7. DATA_AD_HI 8. N.C. 9. +12V 10. +12V 11. GND_POWER 12. GND_POWER 13. N.C. 14. N.C. 15. HVIN 16. HVIN
J5
12 11
J1~J8
11 12
HEAD PCB (J1~J8)
FLAT RIBBON HARNESS
D4 TP1 1
<CARRIAGE - HEAD (J1~J8)>

P1
5K TP2
JET REV5
120V
LEDG-SM 12V
HV_ADJ GND
* FACTORY SET
7 - 41
4.7. HEAD LIFT PCB

HEIGHT ADJUSTMENT SOL UP LIMIT S/W <GORE I-TV/PSE> 1,2 : ITV PCB OUT+ 3,4 : ITV PCB IN+ 5,6,7 : ITV PCB OV 8,9,10 : ITV PCB 24V 24V G IN+ IN- V1 V2 V3 0+ 0DN_SEN +5V TX N.C RX N.C
J1 GIL-G-4P
J2
UP_SEN
PT SENSOR SUB_INK TANK SUB B

J10 5267-3P J7
PT SENSOR HEAD BASE
<GORE RS 232C> PC MOTHER PCB COM2

1
BASE A
J17 5267-4P
J23
1 7
J4
J16 10 1
3951-7P
5045-5P
IF PCB J2
J7
SUB A SUB B SUB B BASE A BASE B BASE B

J12 5045-6P
1. +24V 2. N.C 3. SOL_A (THE VERTICAL) 4. N.C 5. +24V 6. N.C 7. SOL_B (HORIZONTALITY)
1. OUT+ 2. OUT+ 3. IN+ 4. IN+ 5. GND 6. GND
7. GND 8. +24V 9. +24V 10.+24V
5045-10P
SUB B
SUB A
BASE B
BASE B
GND
N.C
GND
J13 5045-4P
GND +24V N.C OUT+
ITV2010
LED2 SW1 RESET 24V LED1

5045-9P
J11 5045-3P
GND 24V+ IN+
Pressure Sensor PSE531
5045-6P
<GORE SENSOR>
PURGE S/W SOL +24V
3951-2P
SOL(1) SOL(2)
J6
GND SOL(1) N.C GND
1,2 : VT301V 4,5 : VT301V
J18
SMPS#6
+24V GND +5V GND
3951-4P
SOL(2)
3951-5P
J15 5045-7P
A A B B
<GORE POWER3>
J8
STEP MOTOR
IF PCB J1
SUB H/T BASE H/T GN D GND 24V 24V
J8 395 1-6P
N.C N.C N.C
3951-6P
3951-3P
<GORE POWER1>
J25
J14
SUB_HEATER
J14-1,3 SUB_INK TANK RUBBER HEATER
GND
7 - 43
4.8. ITV CONTROLLER PCB

SMPS #5
SMPS #5 24V+ PSE200 PWR-1 PSE200 CH1-4 HEAD LIFT PCB J16 SMPS #5 GND PSE200 PWR-2 PSE200 CH1-2 HEAD LIFT PCB J16
J4
PSE 200
* SETTING POSITION(1) 24V+ 0V IN+ IN1 2 3 OUT+ OUTSTL950
PSE200 CH1-1 HEAD LIFT PCB J16 SMPS #5 GND VARIABLE REGISITOR VOLUME VAR. R-3 VR. VAR. R-2 VAR. R-1 HEAD LIFT PCB J16 SMPS #5 GND
* SETTING POSITION(2)
J1A 1 2 3
ON
OFF
ZERO
GAIN
20K
20K
* FACTORY SETTING
SW4 +10V +10V -10V
3 5557-4P
-10V
<GORE ITV/PSE>
7 - 45
4.9. SUB PCB

F070494_SS
RED LED
5566-2P
MOTOR MOTOR +
J49
NOT USED
5267-2P
+5V SUC_LEVEL
J48
NOT USED
1: PO14 2: PO20 3: PO13 4: PO12 5: PO11
AIR LOW INK LOW

J45
PLC
NOT USED
SSR OUT1 SSR OUT2

J45-2P
VR2
+
VR1
NOT USED
NOT USED
J13 1. N.C 2. N.C 3. N.C 4. N.C 5. N.C 6. N.C 7. N.C 8. N.C 9. N.C 10. AIR LOW 11. N.C 12. SHUTTER RIGHT 13. SHUTTER LEFT 14. UV LAMP ON
3951-4P
7 14
LAMP ON MEDIA SET ON BLOWER ON

3951-6P
N.C
J4
<SUB J4 - PLC>
+5V LIFT DN LIFT UP

5267-4P J47
NOT USED
GND
5045-14P
J43
J13
GND(24V) +24V
GND(5V)
+5V
J3
J6
5045-3P
5045-4P
SMPS#6 <SUB J43 - SMPS#6> AIR TANK
I/O PCB J3
I/O PCB J6
</O J3,J6 - SUB J13>
<AIR TANK - REFILL 32>
7 - 47
4.10. IF PCB
PID#2
<PID SUB - IF J8> 2
1 3
<PID HEAD 1 BASE - IF J11>

13 14
PID#1 1 2 3 13 14 4 5
PID#3
<GORE PID-WHITE>
HEATER CONTRLRER
2 3 4 5
4 5
13 14
NOT USED
NOT USED
<PID SUB - IF J7, J9> <PID SUB - IF J7, J9>

BASE_B BASE_B BASE_A WHITE_SUB_HEATER
N.C SUB_HEATER
+24V GND PSE GND
+24V GND N.C ITV
SUB_B
J8
5267-3P 3951-3P
SUB_B
SUB_A
N.C
GND
J9 J10
J11 5267-4P
J4
J3 5045-4P J12
3951-2P
5045-3P
+24V N.C
J7
N.C N.C N.C N.C NOT USED
GND +24V
3951-2P J6 5045-9P
N.C N. C GND
J13
SMPS #4
GND +24V
<IF 24V J6 - SMPS#4>

3951-2P J5
GND NOT USED +24V

3951-2P
J2 1. PSE 2. ITV 3. BASE_B 4. BASE_B 5. BASE_A 6. SUB_B 7. SUB_B 8. SUB_A

5045-8P
3 8
J1 1. SUB_HEATER 2. BASE_HEATER 3. GND 4. GND 5. +24V 6. +24V

3951-6P
6 3
+24V GND N.C

5045-5P
NOT USED
N.C PSE
J2
J1
J8
J8
3951-6P
HEAD BASE LIFT PCB J8

6 3
3951-6P
<GORE SENSOR>
HEAD BASE LIFT PCB J7
<GORE POWER1>
7 - 49
4.11. I/O PCB

CYLINDER SEN.
<I/O J1, J4 - MAIN J17, J18> MAIN BOARD J17

J17
+5V MEDIA SENSOR1 MEDIA SENSOR1 MEDIA SENSOR1 FEED LIMIT LEFT SHUTTER RIGHT SHUTTER GND
J1
J2
1 LED1 LED2
MEDIA SENSOR1 MEDIA SENSOR1

5
J2 1. +5V 2. MEDIA SENSOR3 3. MEDIA SENSOR2 4. MEDIA SENSOR1 5. FEED LIMIT
5045-5P J3
1
LED3
LED4
MEDIA SENSOR1 FEED LIMIT
5267-8P J18
5267-8P
3 LED5 LED6
J3 1. LEFT SHUTTER 2. RIGHT SHUTTER 3. GND
MAIN BOARD J18
+5V +24V UV LAMP ON LED 8 GND
J4
5045-3P J6
1
LEFT SHUTTER
RIGHT SHUTTER
LED7
LED8
5267-5P
5267-5P
UV LAMP ON
J6 1. N.C 2. UV LAMP ON 3. N.C 4. N.C
<I/O J1, J4 - MAIN J17, J18>
5045-4P
J13
5045-14P
14
J3-2~3, J6-3 : SUB PCB J13 <I/O J3, J6 - SUB J13>
7 - 51
4.12. TAKE UP PCB

TAKE UP BOARD REV 0
D1
RED
AUTO/MANUAL INDICATOR PCB

D2 GREEN D3 GREEN D4 RED D5 GREEN
CW_LED
CCW_LED
AUTO_LED
ERROR_LED
SW1
2
SW2
2
SW3
2
SW4
2
WT
LM
LC
5V
CW_SW
5V
CCW_SW
J11 15
5V
AUTO_SW
5V
ERROR_SW
HRS-16P
J18
15
HRS-16P
REFILL PCB J18 <TAKEUP - REFILL J18>
7 - 53
4.13. REFILL CONTROL PCB

UV NEO CONTROL REV.3
S
D1 RED D2 RED D3 RED D4 RED D5 RED D6 RED D7 RED D8 RED
+ S_LED_WT
D9 GREEN
+ S_LED_LM
+ S_LED_LC
S_LED_Y
D12
+ S_LED_M
D13 GREEN
+ S_LED_C
S_LED_K
D15
S_LED_S
D16
D10
GREEN
D11
GREEN
GREEN
D14
GREEN
GREEN
GREEN
+ P_LED_WT
+ P_LED_LM
+ P_LED_LC
P_LED_Y
+ P_LED_M
+ P_LED_C
P_LED_K
P_LED_S
SW1
2
SW2
2
SW3
2
SW4
2
SW5
2
SW6
2
SW7
2
SW8
2
WT
LM
LC
SW_WT +5V
SW_LM + 5V
SW_LC +5V
SW_Y +5V
SW_M +5V
SW_C +5 V +5V
S W_ K +5V
SW_S
J18
29
HRS-30P
19 9
J31
19
29
HRS-30P
REFILL PCB J31 <REFILL J31 - CONTROL J18>
7 - 55
4.14. INDICATOR PCB
D1 J 12
GREEN D3
GREEN D5
GREEN
D7
GREEN
D9
GREEN
D11
GREEN
D13
GREEN
D17
LED
+5V INK_FULL_SIGNAL
J4 5267-2P
INK_FULL_WT INK_FULL_LM
D2 RED D4 RED
INK_FULL_LC
D6 RED
INK_FULL_Y
D8 RED
INK_FULL_M
D10 RED
INK_FULL_C
D12 RED
INK_FULL_K
D14 RED
INK_FULL_S
D16 RED
J13
INK_EMPTY_SIG. +5V
REFILL PCB J4
5267-2P
REFILL_INDICATOR REV.2
5267-2P
NOT USE
<IND J11, J13 - RF J17-1, J4>

J11 J11
+5V N.C
3951-3P
REFILL PCB J17-1

5045-3P
INK_EMPTY_WTINK_EMPTY_LM INK_EMPTY_LC INK_EMPTY_Y INK_EMPTY_M INK_EMPTY_C INK_EMPTY_K INK_EMPTY_S
GND
<IND J11, J13 - RF J17-1, J4>
J1
WT
J2
LM
J3
LC
J4
J5
J6
J7
J8
5267-3P
5267-3P
5267-3P
5267-3P
5267-3P
5267-3P
5267-3P
5267-3P
INK_FULL_WT INK_EMPTY_WT +5V +5 V
INK_FULL_LM INK_EMPTY_LM +5V
INK_FULL_LC INK_EMPTY_LC +5V
INK_FULL_Y INK_EMPTY_Y +5V
INK_FULL_M INK_EMPTY_M +5V
INK_FULL_C INK_EMPTY_C +5V
INK_FULL_K INK_EMPTY_K +5V
INK_FULL_S INK_EMPTY_S
EACH INK TANK FLOW SENSOR
7 - 57
4.15. DRIVER COMMUNICATION PCB

MAIN J9
J9
5267-4P
J7
MAIN J5
J5
GND
J5 5267-2P
J4
GND
11
5267-6P 5267-8P
5267-8P J3
11
MAIN J12
J12
GND INP GND MOTOR DRIVER 24V+
J6
CARRIAGE_SERVO
5267-8P
11
5267-8P
5267-8P
CN3
CARRIAGE
CN3
FEED
FEED_SERVO
11
CN1B
CN1B
7 - 59

Anapurna L XL Service Manual

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:Anapurna L/XL

Service Manual V1.0

Trademarks and Copyright

2007 V1.0 Company Confidential

Service Manual :Anapurna L/XL

Chapter 1 Functional Description

Technical Features and Specifications

Repair and Service

2007 V1.0 Company Confidential

Service Manual :Anapurna L/XL

Service Manual :Anapurna L/XL

2007 V1.0 Company Confidential

2007 V1.0 Company Confidential

Service Manual :Anapurna L/XL

About this Service Manual

1. Service Manual Overview

Technical Features and Specifications

Repair and Service

Service Manual :Anapurna L/XL

2007 V1.0 Company Confidential

ABOUT THIS SERVICE MANUAL

2007 V1.0 Company Confidential

Service Manual :Anapurna L/XL

Service Manual :Anapurna L/XL

2007 V1.0 Company Confidential

14.10. 14.11. 14.12. 14.13. 14.14.

1 - 144 1 - 148 1 - 150 1 - 153 1 - 156

2007 V1.0 Company Confidential

Service Manual :Anapurna L/XL

Pri Me nt Transpdia o Direction rt

1.1.2. Components And Locations

Service Manual :Anapurna L/XL

2007 V1.0 Company Confidential

1.1.2.1. Front view with printer parts and locations

Exhaust system Emergency stop

1.1.2.2. Rear view and composition

Compressed air inlet

Roll to roll system

2007 V1.0 Company Confidential

Service Manual :Anapurna L/XL

1.1.2.3. Purge unit

purging part view (front)

purging part view (rear)

Service Manual :Anapurna L/XL

2007 V1.0 Company Confidential

1.1.2.4. Head carriage unit

UV lamp Purge switch button Ink valve Print head

2007 V1.0 Company Confidential

Service Manual :Anapurna L/XL

1.1.2.5. Print media unit

1.1.2.6. Home unit

Service Manual :Anapurna L/XL

2007 V1.0 Company Confidential

Control box, SMPS panel, PLC.

PLC Control box Stirrer timer (white)

Sensor controller SMPS panel

Components behind home rear door

2007 V1.0 Company Confidential

Service Manual :Anapurna L/XL

1.1.2.7. Refill unit

Stainless steel ink tanks Ink tank indicator Refill system

Service Manual :Anapurna L/XL

2007 V1.0 Company Confidential