Page 1 Users of this Service Note shall be deemed to agree with the following Terms of Use. 1. USERS This Service Note is only for authorized persons with user ID and password issued by Roland DG Corporation. 2. PURPOSE Authorized persons can use this Service Note only for the purposes of selling and providing to the customers maintenance service of VP-540/VP-300.
Page 2: Table Of Contents
Contents 1 Structure & Spare Parts COVERS ................................1-1 FRAME ................................1-4 DRIVE UNIT ............................... 1-8 HEAD CARRIAGE (VP-540) ..........................1-12 HEAD CARRIAGE (VP-300) ..........................1-14 BASE FRAME ..............................1-16 CHASSIS ................................1-18 PINCH ROLLER ............................... 1-19 STAND ................................1-20 1-10 TOOL CARRIAGE .............................
Page 3 Revision Record Revision Date Description of Changes Approval Issued 2007.3.9 First Edition Kato Uchiyama Sect1 : Parts have been revised. Sect3 : Procedures have been revised. 2007.4.25 Kato Mabuchi Sect4 : Procedures have been revised. Sect7 : Installation Check List has been revised. Sect1 : Parts have been revised.
Page 4 To Ensure Safe Work About Notices. Used for instructions intended to alert the operator to the risk of death or severe injury should the unit be used improperly. Used for instructions intended to alert the operator to the risk of injury or material damage should the unit be used improperly.
Page 5 About the Labels Afﬁ xed to the Unit These labels are af xed to the body of this product. The following gure describes the location. Caution : Moving Print Heads The print heads move at high speed and pose a hazard. Caution : Pinching Hazard Contact during operation may cause the hand or ngers to become pinched, rsult-...
Page 6 WARNING - FOR CONTINUED HIGH VOLTAGE, PROTECTION AGAINST RISK OF FIRE, REPLACE ONLY WITH FUSE OF THE HANDLING ATTENTION SPECIFIED TYPE AND CURRENT RATING. • Do not touch during power on Electric shock, Compornents damage • Do not repair. Replace power unit. F80L HS •...
Page 7: Covers
1 Structure & Spare Parts 1-1 COVER ( VP-540：Below ZW65382, VP-300：Below ZW61509 ) S1 S7 S2 S5 Revised 1 PARTS LIST -Main Parts- Parts Name Parts Name Parts No. Parts No. W700461210 ASSY,PANEL BOARD VP-540 1000002637 SHEET,PANEL VP-540 23505834 CABLE-ASSY MAINT-COVER SW FJ-540 1000002625 STAY,PANEL VP-540 1000002608 COVER,INK CARTRIDGE VP-540 1000003029 SHEET,LCD VP-540...
Page 8 1-1 COVER ( VP-540：Above ZW65383, VP-300：Above ZW61510) Revised 6 S1 S7 Revised 6 30 31 S2 S5 Revised 1...
Page 9 1-1 COVER ( VP-540：Above ZW65383, VP-300：Above ZW61510 ) PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name W700461210 ASSY,PANEL BOARD VP-540 31289111AS CUPSCREW SET, M4*6 NI 100 PCS. 23505834 CABLE-ASSY MAINT-COVER SW FJ-540 31289109AS CUPSCREW SET,M3*4 NI 100 PCS.
Page 10: Frame
1-2 FRAME ( VP-540：Below ZW65382, VP-300：Below ZW61509 ) S20 S10...
Page 11 1-2 FRAME ( VP-540：Below ZW65382, VP-300：Below ZW61509 ) PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name BUSH,NB-19 21905192 ADAPTER,CLAMP MEDIA SP-540V 31029101 BUSH,SQUARE SB-6025 7520501000 ASSY,CAP BOTTLE 2 FJ-52 31029106 W700461240 ASSY,FAN JUNCTION BOARD VP-540 31289111AS CUPSCREW SET, M4*6 NI 100 PCS.
Page 12 1-2 FRAME ( VP-540：Above ZW65383, VP-300：Above ZW61510 ) Revised 6 S20 S10...
Page 13 1-2 FRAME ( VP-540：Above ZW65383, VP-300：Above ZW61510 ) PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts Name Parts Name Parts No. Parts No. 1 21905192 ADAPTER,CLAMP MEDIA SP-540V S1 31029101 BUSH,NB-19 2 7520501000 ASSY,CAP BOTTLE 2 FJ-52 S2 31029106 BUSH,SQUARE SB-6025 3 W700461240 ASSY,FAN JUNCTION BOARD VP-540 S3 31289111AS...
Page 14: Drive Unit
1-3 DRIVE UNIT ( VP-540：Below ZW65382, VP-300：Below ZW61509 ) Revised 2 Revised 5 Revised 1 Revised 6...
Page 15 1-3 DRIVE UNIT ( VP-540：Below ZW65382, VP-300：Below ZW61509 ) PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 6700469030 ASSY,PULLEY VP-540 22175870 R-BEARING JIS 6800ZZ(B7) W700461290 ASSY,FLEX1 VP-540 15229506 SENSOR INTERRUPTER,GP1A05A5 W7004612A0 ASSY,FLEX2 VP-540 1000001480 SHAFT,DRIVE PULLEY XC-540 W7004612B0 ASSY,FLEX3 VP-540...
Page 16 Revised 2 1-3 DRIVE UNIT ( VP-540：Above ZW65383, VP-300：Above ZW61510 ) Revised 6 Revised 5 Revised 1 Revised 1-10...
Page 17 1-3 DRIVE UNIT ( VP-540：Above ZW65383, VP-300：Above ZW61510 ) PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 6700469030 ASSY,PULLEY VP-540 55 22175870 R-BEARING JIS 6800ZZ(B7) 2 W700461290 ASSY,FLEX1 VP-540 56 15229506 SENSOR INTERRUPTER,GP1A05A5 3 W7004612A0 ASSY,FLEX2 VP-540 57 1000001480...
Page 18: Head Carriage (Vp-540)
1-4 HEAD CARRIAGE (VP-540) Revised 2 Revised 5 Revised 2 1-12...
Page 19 1-4 HEAD CARRIAGE (VP-540) PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1 21905166 ADAPTER,HEAD FJ-540 S1 31329601AS CLAMP SET,INSULOK T-18S 100 PCS. 2 6085393800 ASSY,INK DAMPER L 3FAI 4 SJ-1000 S2 31289109AS CUPSCREW SET,M3*4 NI 100 PCS.
Page 20: Head Carriage (Vp-300)
1-5 HEAD CARRIAGE (VP-300) Revised 2 Revised 5 Revised 2 (Cut to 110mm when using.) (Cut to 130mm when using .) Revised 2 1-14...
Page 21 1-5 HEAD CARRIAGE (VP-300) PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1 21905166 ADAPTER,HEAD FJ-540 S1 31289109AS CUPSCREW SET,M3*4 NI 100 PCS. 2 1000002679 ADAPTER,JUNCTION VPY306 S2 31289102AS CUPSCREW SET,M3*6 NI 50 PCS. 3 11909167 ADAPTER,SCREW 3FAI FJ-540 S3 31299102AS...
Page 22: Base Frame
1-6 BASE FRAME 1-16...
Page 23 1-6 BASE FRAME PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1000002654 APRON,B VP-300 S1 31029101 BUSH,NB-19 1000002553 APRON,B VP-540 S2 31329501AS CLAMP SET,PUSH MOUNT RT30SSF5 20P 1000002152 APRON,F AL VP-300 S3 31289109AS CUPSCREW SET,M3*4 NI 100 PCS.
Page 24: Chassis
1-7 CHASSIS Revised 1 PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name Revised 1 1 6700469010 ASSY,MAIN BOARD VP-540 1000002755 CABLE-ASSY,HEATER VP-300 2 W700461220 ASSY,POWER BOARD VP-540 1000002183 CABLE-ASSY,HEATER VP-540 3 1000002144 ASSY,SERVO BOARD VP-540 26 1000002190 CABLE-ASSY,JUNBI B VP-540 4 15009101 BATTERY CR2032...
Page 25: Pinch Roller
1-8 PINCH ROLLER PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 6700460210 ASSY,PINCHROLL L VP-540 S1 31149702AS RING SET,E-RING ETW-3 100 PCS. 6700460220 ASSY,PINCHROLL R VP-540 S2 31019702AS SCREW SET,BIND P-TIGHT M3*6 3C 100P 2 6700460300 ASSY,PINCHROLL C VP-540 S3 31249211AS...
Page 26: Stand
1-9 STAND PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 1000002578 ARM,L VP-540 1000002149 STAND,LEG VP-540 2 1000002577 ARM,R VP-540 1000002678 STAY,STAND VP-300 3 7498805000 ASSY STOPPER SCREW PNS-501 1000002635 STAY,STAND VP-540 4 1000002636 ASSY,BASE STAND VP-540 11 1000001579 STOPPER,SHAFT POM XC-540 1000002153...
Page 27: Tool Carriage
1-10 TOOL CARRIAGE PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 22805292 ASSY, CLAMP BLADE CM-500 23 22175155 SPRING,SCREW CM-500 2 22805291 ASSY, HOLDER BLADE CM-500 24 22715168 STAY,AUTO CUTTER 2 CM-500 3 22805287 ASSY, PLATE CAM SLIDE CM-500 25 1000002531 STAY,CUT CARRIAGE BOARD VP-540 4 22805571...
Page 28: Wiper System
1-11 WIPER SYSTEM PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 1000002576 BASE,WIPER MOTOR VP-540 18 11379105 WIPER,HEAD ASP FJ-50 2 11929138 BELT,408P2M4-530 19 1000002573 COVER,SCRAPER VP-540 3 12159536 BUSH,B-S6-17 20 1000002571 HOLDER,SCRAPER VP-540 4 1000002572 COVER,WIPE VP-540 21 1000001658 WIPER,SCRAPER XC-540...
Page 29: Pump System
1-12 PUMP SYSTEM Revised 2 Revised 1 12 19 Revised 1 1-23...
Page 30 1-12 PUMP SYSTEM PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1 1000002537 ARM,LINK UP VP-540 S1 31029106 BUSH,SQUARE SB-6025 2 1000002794 ASSY,CAP-TOP XC-540 S2 31289109AS CUPSCREW SET,M3*4 NI 100 PCS. 3 1000002538 BASE,CAP VP-540 S3 31109601AS NUT SET,SQUARE M3*6*1.6 FE NI 100PCS...
Page 31: Ink System
1-13 INK SYSTEM (Cut to 110mm when using.) 21 18 (Cut to 110mm when using.) (Cut to 170mm when using.) PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 11909133 ADAPTER,SCREW 2FAI FJ-50 16 21435109 TUBE,SILICONE 3*5*8 2 1000001589 ADAPTER,TUBE 2-3FAI XC-540 17 1000002680...
Page 32 1-14 ACCESSORY ( VP-540：Below ZW65382, VP-300：Below ZW61509 ) 117V 230V 230VC 240VA 240VE (Assemble all these parts.) 1-26...
Page 33 1-14 ACCESSORY ( VP-540：Below ZW65382, VP-300：Below ZW61509 ) PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 23495124 AC CORD 3ASL100 240VA 10A SAA 1000003111 PAD,BASE STAND VP-540 13499111 AC CORD H05VV-F 240VE 10A S 1000002690 PAD,L-LEFT VP-540 13499109 AC CORD SJT 117V 10A 3PVC...
Page 34 1-14 ACCESSORY ( VP-540：Above ZW65383, VP-300：Above ZW61510 ) 117V 230V 230VC 240VA 240VE Revised 6 (Assemble all these parts.) 1-28...
Page 35 1-14 ACCESSORY ( VP-540：Above ZW65383, VP-300：Above ZW61510 ) PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 23495124 AC CORD 3ASL100 240VA 10A SAA 37 1000003111 PAD,BASE STAND VP-540 2 13499111 AC CORD H05VV-F 240VE 10A S 38 1000002690 PAD,L-LEFT VP-540 3 13499109...
Page 36: Wiring Map
2 Electrical Section 2-1 WIRING MAP...
Page 37 VP-540/300 WIRING MAP Cable List VP-540 VP-300 Parts No. Parts Name 100V 200V 100V 200V 1 1000002189 CABLE-ASSY,JUNBI A VP-540 2 1000002190 CABLE-ASSY,JUNBI B VP-540 3 23415268 CABLE-ASSY AC GROUND GREEN SP-540 4 23415116 CABLE ASSY,JUNBI D SP-300 5 1000002173 CABLE-ASSY,JUNBI E VP-540 6 1000002177 CABLE-ASSY,POWER SERVO VP-540...
Page 38: Main Board
2-2 MAIN BOARD MAIN BOARD_Arrangement Diagram (Component Side) It indicates the version of the Main Board. DP SW Bit1 Bit2 Bit3 Bit4 Bit5 Bit6 Bit7 Bit8 VP-540 VP-300...
Page 39 MAIN BOARD_Arrangement Diagram (Soldering Side)
Page 40 MAIN BOARD_Circuit Diagram 1/9...
Page 41 MAIN BOARD_Circuit Diagram 2/9...
Page 42 MAIN BOARD_Circuit Diagram 3/9...
Page 43 MAIN BOARD_Circuit Diagram 4/9...
Page 44 MAIN BOARD_Circuit Diagram 5/9...
Page 45 MAIN BOARD_Circuit Diagram 6/9 2-10...
Page 46 MAIN BOARD_Circuit Diagram 7/9 2-11...
Page 47 MAIN BOARD_Circuit Diagram 8/9 NETWORK 2-12...
Page 48 MAIN BOARD_Circuit Diagram 9/9 2-13...
Page 49: Servo Board
2-3 SERVO BOARD SERVO BOARD_Arrangement Diagram (Component Side) It indicates the version of the Servo Board. 2-14...
Page 50 SERVO BOARD_Arrangement Diagram (Soldering Side) 2-15...
Page 51 SERVO BOARD_Circuit Diagram 1/4 /SERVO_RES /Serial_Start 2-16...
Page 52 SERVO BOARD_Circuit Diagram 2/4 2-17...
Page 53 SERVO BOARD_Circuit Diagram 3/4 2-18...
Page 54 SERVO BOARD_Circuit Diagram 4/4 2-19...
Page 55 2-4 CARRIAGE BOARD CARRIAGE BOARD_Arrangement Diagram (Component Side) It indicates the version of the Carriage Board. 2-20...
Page 56 CARRIAGE BOARD_Circuit Diagram 1/2 2-21...
Page 57 CARRIAGE BOARD_Circuit Diagram 2/2 CUT CARRIAGE BOARD CN500 CCVCC CN502 Sol+ To SOLENOID Sol- Sol+ IL-S-2P-S2T2-EF Sol- CCVCC CN504 To SERVO BOARD PinchPos PinchPos To PINCH ROLLER /Crop_ON C507 CropSens CCVCC CE0.1u(NON) SENSOR R501 0(NON) R505 53398-0490 IC500B 4.7K VR500 220KVR Q500 DTB123EK...
Page 58: Sub Board
2-5 SUB BOARD SUB BOARD_Arrangement Diagram (Component Side) It indicates the version of the Board. 2-23...
Page 59 SUB BOARD_Circuit Diagram 1/4 2-24...
Page 60 SUB BOARD_Circuit Diagram 2/4 2-25...
Page 61 SUB BOARD_Circuit Diagram 3/4 2-26...
Page 62 SUB BOARD_Circuit Diagram 4/4 CN1000 CN1001 to FAN 5267-02A to Servo Board CN1002 to FAN 53398-0890 5267-02A CN1003 to Bed Thermistor Board 53014-02 CN1004 to Apron Thermistor Board 53014-02 FAN JUNCTION BOARD CN1100 CN1101 CN1200 CN1201 5268-02A 5268-02A CN1102 CN1202 CN032-004 CN032-004 5268-03A(NON)
Page 63: Maintenance Parts List
2-6 MAINTENANCE PARTS LIST _ Electrical Parts MAIN BOARD IC No. Parts No. Description Function IC207 15199237 V.RGL L4960 5V Regulator IC22 1000001098 IC,E09A54RA D/A Converter for Head BK IC21 1000001098 IC,E09A54RA D/A Converter for Head CY IC26 1000001098 IC,E09A54RA D/A Converter for Head MG IC25 1000001098...
Page 64: Head Replacement
3 Replacement of Main Parts The necessary adjustments after the replacement of each part, and the referential time for each work are described as follows. HEAD REPLACEMENT : 20min. (1 Head) 1. THERMISTER CHECK 2. HEAD ALIGNMENT 3. HEAD INFORMATION CLEAR 4.
Page 65 MAIN BOARD REPLACEMENT (In case that the parameters can be transferred by Peck.) : 35 min. 1. DIP SW SETTING 2. BATTERY INSTALLATION 3. FIRMWARE INSTALLATION 4. SYSTEM PARAMETER INITIALIZE 5. IP ADDRESS SETTING Start the machine with the Service Mode and set in the User Menu. 6.
Page 66 Revised 4 Static electricity can harm some electronic devices. To prevent static damage, discharge static electricity from your body before you touch any of electronic devices. You can do so by touching an unpainted metal surface on the chassis. You can also take the following steps to prevent damage from electrostatic discharge (ESD): When unpacking a static-sensitive device from its shipping carton, do not remove the device from the antistatic packing material until you are ready to install the device to the machine.
Page 67 3-1 HEAD REPLACEMENT Revised 1 VP-540/300 support the new head only. The parts number of the new head is as follows. Parts No. : 1000002201 Parts name : ASSY,HEAD INKJET SOL XC-540 The number written on the back side of the Printhead Board is the way for identifying whether it is a new or current Head."R4CJ520"...
Page 68 Turn off the sub power, and then turn off the main power. MAIN POWER SW <Back Side> Be sure to turn off the main power when replacing the head. The head or Main Board could break, otherwise. It is recommended to disconnect the AC code.
Page 69 DAMPER SCREW DAMPER PLATE HEAD BOARD COVER <VP-300> Remove the 2 screws fixing the Head Board Cover, and move it upward. There is a tab on the left side of the Head Board Cover. HEAD BOARD COVER SCREW Disconnect the 2 flexible cables from the head. FLEXIBLE CABLE Remove the Spring, and remove the 3 screws fixing the head.
Page 70 Remove the head from the adapter and fix the new head HEAD to the adapter. 5CY2F2F Make sure to fix the head by pressing it to the bottom left corner of the adapter. Use the 2kgf·cm torque driver (ST-056) to tighten up the screws.
Page 71 Fix the 2 new Ink Dampers to the head. DAMPER Make sure to replace the Dampers when replacing the head. Do not hold both sides of the Ink Damper tight. It could break. Fix the Damper Plate. SCREW DAMPER Make sure not to press it to the Dampers. Dampers could break.
Page 72 Select [SERVICE MENU] > [SUB MENU] > [HEAD REPLACE], and perform Head Cleaning and filling ink by SERVICE MENU SUB MENU following the sequences. FILLING INK... >>> SUB MENU HEAD REPLACE CHECK DRAIN BOTTLE CHECK [ENTER] DRAIN BOTTLE [ENTER] SET SOL CRT. 1234 SET SOLCL-LIQUID 1234...
Page 73 < HOW TO CLEAR THE HEAD INFORMATION > SERVICE MENU HISTORY MENU After THERMISTER CHECK and HEAD ALIGNMENT, HEAD GROUP HISTORY MENU clear the head information from the [SERVICE MENU] > HEAD GROUP CLEAR ALL [HISTORY MENU] > [HEAD GROUP]. Select the head you replaced and press the [ENTER] key.
Page 74: Wiper Replacement
3-2 WIPER REPLACEMENT Select [SUB MENU] > [MAINTENANCE] > [REPLACE WIPER] in the User's Menu, and press the [ENTER] key. SUB ENU SUB ENU AINTENANCE AINTENANCE REPLACE WIPER The Head Carriage moves to a location permitting wiper OPEN FRONT replacement, and then the message shown in the figure COVER appears.
Page 75 Remove the wiper and install the new one. Make sure to fix the Wiper so that the rubber side faces the front. Use the tweezers to press the area shown in the figure and engage the wiper on the hook. Make sure to engage it on the hook.
Page 76: Cap Top Replacement
3-3 CAP TOP REPLACEMENT Remove the I/S Cover. SCREW I/S COVER HOOK Move the Head Carriage slowly leftwards to the position HEAD CARRIAGE where it is not above the Capping Unit. Remove the Pump Cover. PUMP COVER Disconnect the tube of the Cap Top from the tube of the Y TUBE JOINT Pump.
Page 77 Unhook the Cap Frame while holding it with the other CAP FRAME hand, and remove it. Make sure to hold the Cap Frame. There is a spring under the Cap Top. The Cap Top jumps out unless you hold the Cap Frame when removing it.
Page 78 Connect the tube of the Cap Top to the tube of the Pump Y TUBE JOINT using the Y tube joint. Fix the Pump Cover. PUMP COVER Move the Head Carriage by hand to the lock position. HEAD CARRIAGE Fix the I/S Cover. SCREW I/S COVER Perform the following adjustment.
Page 79: Tool Carriage Replacement
3-4 TOOL CARRIAGE REPLACEMENT Remove the following covers. LEFT SIDE COVER TOP COVER I/S Cover Maintenance Cover Left Side Cover Front Cover Top Cover MAINTENANCE COVER FRONT COVER I/S COVER Separate the Tool Carriage from the Head Carriage. TOOL CARRIAGE HEAD CARRIAGE Remove the Tool Carriage Cover.
Page 80 Disconnect the Crop Mark Sensor, Pinch Roller Sensor CROP MARK SENSOR SOLENOID and Solenoid wirings. PINCH ROLLER SENSOR Remove the 2 screws fixing the Tool Carriage Board. TOOL CARRIAGE BOARD SCREW Remove the 2 screws to remove the Tool Carriage Board TOOL CARRIAGE BOARD STAY Stay from the Tool Carriage Assy.
Page 81 Remove the Auto Sheet Cutter together with the plate TOOL CARRIAGE from Tool Carriage and fix the Auto Sheet Cutter to the new Tool Carriage. AUTO SHEET CUTTER PLATE Fix the new Tool Carriage with the 2 screws as shown in the figure while holding it upwards.
Page 82 Connect the Crop Mark Sensor, Pinch Roller Sensor and CROP MARK SENSOR SOLENOID Solenoid wirings. PINCH ROLLER SENSOR Perform the following adjustments and settings. 1. [4-5 LIMIT POSITION & CUT DOWN POSITION INITIALIZE] 2. [4-7 FLUSHING POSITION ADJUSTMENT] Revised 1 3.
Page 83: Carriage Motor Replacement
3-5 CARRIAGE MOTOR REPLACEMENT Turn off the sub power, and then turn off the main power. MAIN POWER SW Remove the following covers. SCREW I/S Cover I/S COVER Right Top Cover Panel Cover Chassis Cover HOOK RIGHT TOP COVER PANEL COVER When removing the Panel SENSOR CHASSIS COVER...
Page 84 Remove the spring on the Flange. FLANGE SPRING Remove the 3 screws fixing the Flange, and remove the FLANGE motor together with the Flange. SCREW Remove the 4 screws as shown in the figure to remove FLANGE the motor from the Flange. And fix the new motor to the Flange.
Page 85 Fix the spring. SPRING Revised 1 Check the gears mesh without backlash in the following HEAD CARRIAGE procedure. Unlock the Head Carriage. Turn the Drive Gear by hand and check there is no backlash all the way around. DRIVE GEAR MOTOR GEAR Move the Head Carriage by hand to the lock position.
Page 86 Tighten up the 3 screws to fix the Flange in the order shown in the figure. Apply a proper quantity of grease (FLOIL G902) between gears. Connect the connector of the Motor Cable. CONNECTOR < Top View > Fix the Chassis Cover, Right Top Cover and Panel Cover. RIGHT TOP COVER PANEL COVER CHASSIS COVER...
Page 87 In [MOTOR MENU] > [SERVO LOCK] menu, select [S]. Move the Head Carriage left and right by hand and make SERVICE MENU sure the value on the LCD changes depending on the MOTOR MENU head position. MOTOR MENU SERVO LOCK SERVO LOCK Press the [ENTER] key to excite the motor.
Page 88: Feed Motor Replacement
3-6 FEED MOTOR REPLACEMENT Turn off the sub power, and then turn off the main power. MAIN POWER SW < Rear View > Remove the following covers. INK CARTRIDGE COVER Maintenance Cover Left Side Cover Left Cover Ink Cartridge Cover LEFT COVER MAINTENANCE COVER LEFT SIDE COVER...
Page 89 Remove the connector of the Motor Cable. CONNECTOR Remove the screw as shown in the figure to remove the Grit Encoder Board together with the stay. SCREW STAY GRIT ENCODER BOARD Remove the 3 screws as shown in the figure to remove Grit Encoder Stopper.
Page 90 Remove the 4 rivets as shown in the figure, and slide the RIVET Gear Cover to the front side, and remove it. GEAR COVER RIVET Remove the spring. SPRING Remove the 3 screws fixing the Flange, and remove the motor together with the Flange. SCREW MOTOR FLANGE...
Page 91 Fix the Flange with the 3 screws temporarily. SCREW FLANGE Fix the spring. SPRING Revised 1 Turn the gear by hand and check there is no backlash all GEAR the way around. Tighten up the 3 screws to fix the Flange in the order shown in the figure.
Page 92 Slide the Gear Cover to the back side, and fix the Gear RIVET Cover with the 4 rivets. GEAR COVER RIVET Revised 1 Rotate the Shaft to check that the Gear does not touch the Gear Cover. SHAFT GEAR GEAR COVER <...
Page 93 Fix the Grit Encoder Board together with the stay so that the Grit Encoder is in between the gap of sensor. SCREW GRIT Adjust the position ENCODER of the sensor so that the clearance w i t h t h e G r i t STAY Encoder is around 1mm.
Page 94 Connect the connector of the sensor cable to the Feed FEED MOTOR BOARD Motor Board. CONNECTOR < Rear View / In the Ink Cartridge Cover> Perform the SERVO LOCK CHECK. After turning on the main power, turn on the sub power while pressing the left, right and down keys to enter the Service Mode.
Page 95 Check the Grit Encoder. Go back to the [MOTOR MENU], and select [G-ENC. SERVICE MENU MOTOR MENU CHECK] and press the [ENTER] key. Make sure the Grit Encoder functions correctly by confirming the display to MOTOR MENU show [G-ENC. CHECK COMPLETED]. G-ENC.
Page 96: Pump Replacement
3-7 PUMP REPLACEMENT Turn off the sub power, and then turn off the main power. MAIN POWER SW < Rear View > Remove the I/S Cover. SCREW I/S COVER HOOK Unlock the Head Carriage and move it leftward by hand. HEAD CARRIAGE Remove the Pump Cover and Panel Cover.
Page 97 Remove the connector of the motor. MOTOR CONNECTOR Disconnect the tubes of the Cap Top and the tubes of the TUBE (CAP TOP) Drain from the pumps. TUBE (DRAIN) PUMP Remove the 2 screws as shown in the figure to remove the Pump Unit.
Page 98 Separate the 2 pumps. Replace with the new pump. BEARING < Procedure for pump with the motor > Remove the setscrew as shown in the figure to remove SETSCREW the gear and bearing from the Shaft. SHAFT GEAR Remove the 3 screws as shown in the figure to remove MOTOR the pump from the motor.
Page 99 Fix the setscrew at the D-cut part by pushing the gear against the bearing. SETSCREW GEAR BEARING SETSCREW GEAR D-cut part < Procedure for pump without the motor > Remove the 3 screws as shown in the figure to remove the plate from the pump, and fix it to the new pump.
Page 100 fix the Pump Unit Stay with the 4 screws as shown in the figure. SCREW SCREW PUMP UNIT STAY Fix the Pump Unit with the 2 screws as shown in the figure. PUMP UNIT SCREW Connect the tubes of the Cap Top and the tubes of the TUBE (CAP TOP) Drain to the pumps.
Page 101 Fix the Pump Cover and Panel Cover. PANEL COVER When fixing the Panel SENSOR Cover, fix the sensor on the back side of the Panel Cover and connect the flexible cable on the Panel Board. FLEXIBLE CABLE < Back Side > PUMP COVER Turn on the main power, then turn on the sub power while pressing the left, right and down keys to enter the...
Page 102 Move the Head Carriage by hand to the lock position. HEAD CARRIAGE Fix the I/S Cover. SCREW I/S COVER HOOK 3-39...
Page 103: Ink Tube Replacement
3-8 INK TUBE REPLACEMENT Turn on the sub power while pressing the left, right and down keys to enter the Service Mode. MENU MENU SERVICE MENU Select [SERVICE MENU] > [SUB MENU] > [PUMP UP], SERVICE MENU and remove ink by following the sequence. SUB MENU SUB MENU PUMP UP...
Page 104 Revised 3 Remove the Cut Cable Guide. SCREW SCREW SCREW < VP-300 > Remove the 3 screws to remove the Cut Cable Guide. SCREW CUT CABLE GUIDE < VP-540 > Remove the 3 screws to remove the Cable Support. SCREW Pull the flexible cable to access the screw.
Page 105 Disconnect the ink tubes (Carriage Side) from the Y tube joints, and put the scotch tape at the tip of the ink tube to JOINTs prevent the ink from coming out. It is not necessary to replace the ink tubes of the other side (Carriage Side) of the joints.
Page 106 Revised 3 Make sure that the fixing direction of the Holder Cable Plate is correct. HOLDER CABLE PLATE < Rear View > CABLE HOLDER FLEXIBLE CABLE HOLDER CABLE PLATE HOLDER CABLE SHEET TUBE CABLE HOLDER HOLDER CABLE PLATE < Cross Section > Cross the tubes (Carriage Side) two by two as shown in CLAMPs the figure, and fix them to the Clamps.
Page 107 Fix the Carriage Cover. CARRIAGE COVER Revised 3 Fix the Cut Cable Guide. SCREW SCREW SCREW < VP-300 > Fix the Cut Cable Guide with the 3 screws as shown in the figure. SCREW CUT CABLE GUIDE < VP-540 > Fix the Cut Cable Guide with the 3 screws as shown in SCREW SCREW...
Page 108 Adjust the position of the flexible cable so that it comes PROTECTION PLATE in the middle of the Protection Plates. FLEXIBLE CABLE After turning on the main power, turn on the sub power while pressing the left, right and down keys to enter the Service Mode.
Page 109: Board Replacement (Main Board Sw Power Supply)
3-9 BOARDS REPLACEMENT (MAIN BOARD / SW POWER SUPPLY) BOARD LAYOUT (IN CHASSIS) POWER BOARD MAIN BOARD SERVO BOARD SW POWER SUPPLY MAIN BOARD REPLACEMENT MAIN BOARD CONNECTOR LAYOUT CN14 CN15 CN17 CN19 3-46...
Page 110 Turn on the main power. MAIN POWER SW < Rear View > Start the Peck. Perform [Get Report] and [Get Parameters], and save the Service Report and the parameters. Turn off the main power and pull out the AC cord. MAIN POWER SW <...
Page 111 Remove the I/S Cover, Right Top Cover and Chassis Cover. RIGHT TOP COVER I/S COVER CHASSIS COVER Remove the 4 screws as shown in the figure. SCREW < Top View > SCREW Disconnect the flexible cables and connector and FLEXIBLE CABLE remove the cables from the Clamps.
Page 112 Disconnect all the cables from the Servo Board. Remove the 4 screws as shown in the figure to remove the Servo Board. Disconnect the cables as shown in the figure from the Main Board. Disconnect the connector and flexible cable as shown in the figure and fix them to the new Main Board.
Page 113 Connect the cables as shown in the figure to the Main Board. Fix the Servo Board with the 4 screws as shown in the figure. Put back the Chassis. CHASSIS Connect all the cables to the Servo Board. 3-50...
Page 114 Fix the Chassis with the 4 screws as shown in the figure. SCREW < Top View > SCREW Connect the flexible cables and connector and fix the FLEXIBLE CABLE cables with the Clamps. CLAMP CONNECTOR FLEXIBLE CABLE Perform the following operations after replacement. 1.
Page 115 Perform the following operations if it is not possible to transfer the parameters by Peck4.exe. 1. DIP SW SETTING 2. BATTERY INSTALLATION 3. FIRMWARE INSTALLATION 4. SYSTEM PARAMETER INITIALIZE 5. TIME AND DATE SETTING Set the date and time in the [SERVICE MENU] > [SUB MENU] > [CLOCK]. Revised 4 *Set the [DATE] in order of the [Year/Month/Day].
Page 116 SW POWER SUPPLY REPLACEMENT (41V) SW POWER SUPPLY CONNECTOR LAYOUT Connected to the [CN1] on the SERVO BOARD Connected to the [CN302] on the POWER BOARD Turn off the sub power, and then turn off the main power and pull out the AC cord. MAIN POWER SW <...
Page 117 Remove the 4 screws as shown in the figure. SCREW < Top View > SCREW Disconnect the flexible cables and connector and FLEXIBLE CABLE remove the cables from the Clamps. CLAMP CONNECTOR FLEXIBLE CABLE Pull out the Chassis to the front side. CHASSIS Disconnect all the cable from the SW Power Supply.
Page 118 Remove the 4 screws as shown in the figure and replace with the new SW Power Supply. Connect all the cables to the SW Power Supply. Set the output voltage of SW Power Supply to +41V. 1. Disconnect the connector on the Servo Board. CONNECTOR Make sure to disconnect the connector.
Page 119 4. Rotate the volume clockwise using the screwdriver to VOLUME adjust the output voltage value to +41+0.1. When the output voltage exceeds the +41.4V, SW Power Supply does not output the voltage by the protection circuit on it. In this case, SW Power Supply will output the v o l t a g e b y r o t a t i n g t h e v o l u m e counterclockwise.
Page 120: Battery Replacement
3-10 BATTERY REPLACEMENT Do not recharge, short-circuit, disassembly the lithium battery, nor put it into fire. It may cause heat, explosion and fire. Put tape around the lithium battery for insulation for disposal or preservation. It may cause heat, explosion and fire. Turn off the sub power, and then turn off the main power.
Page 121 Remove the battery on the Main Board by pushing it down and tilting towards right. SOCKET MAIN BOARD Replace the battery with new one. SOCKET Be careful with the direction of the battery. BATTERY MAIN BOARD Turn on the main power, then turn on the sub power while pressing the left, right and down keys to enter the Service Mode.
Page 122 Select [SUB MENU] > [CLOCK] > [DATE], and set the date and press [ENTER] key. SERVICE MENU SUB MENU SUB MENU CLOCK CLOCK DATE DATE 00/00/00 DATE 06/08/08 Turn off the sub power, and then turn off the main power. Fix the Chassis Cover.
Page 123: Carriage Belt Replacement
3-11 CARRIAGE BELT REPLACEMENT !! IMPORTANT !! When replacing the Carriage Belt, make sure to connect the new belt to the current belt, and pass the new belt at the same time as removing the current belt. There is a possibility that the new belt cannot be fixed without connecting the new belt to the current belt. Turn off the sub power, and then turn off the main power.
Page 124 Remove the Tool Carriage Cover. TOOL CARRIAGE COVER Remove the 4 rivets as shown in the figure to remove RIVETs the Tool Carriage Board Cover. TOOL CARRIAGE BOARD COVER Disconnect the Crop Mark Sensor, Pinch Roller Sensor CROP MARK SENSOR SOLENOID and Solenoid wirings.
Page 125 Remove the 2 screws to remove the Tool Carriage Board Stay from the Tool Carriage Assy. TOOL CARRIAGE BOARD STAY SCREW TOOL CARRIAGE ASSY Loosen the 2 fixingscrews as shown in the figure. < Top View / Left Side of the BELT > And loosen the Adjustment Screw.
Page 126 Slowly pull the belt end which is not connected the new belt until the new one reaches to the Belt Stay. BELT STAY Check that the belt is not twisted. Apply adequate quantity of grease (P/# : 39008297 FLOIL G 902 14KG) to pulleys. <...
Page 127 Fix the Tool Carriage Assy to the Tool Carriage Board Stay. TOOL CARRIAGE BOARD STAY SCREW TOOL CARRIAGE ASSY Fix the Tool Carriage Board with the 2 screws as shown TOOL CARRIAGE BOARD in the figure. SCREW Connect the Crop Mark Sensor, Pinch Roller Sensor, CROP MARK SENSOR SOLENOID and Solenoid wirings.
Page 128: Encoder Scale Replacement
3-12 ENCODER SCALE REPLACEMENT Remove the following covers. LEFT SIDE COVER TOP COVER I/S Cover Maintenance Cover Left Side Cover Front Cover Top Cover MAINTENANCE COVER FRONT COVER I/S COVER Move the Head Carriage slowly leftwards. HEAD CARRIAGE Remove the Encoder Scale by removing the plate fixing the Encoder Scale at its right end and the spring on its left end.
Page 129 Put the Encoder Scale in between the Encoder Plate and the Guide Rail. ENCODER SCALE SPRING Then, fix the right end with the plate and hook up the PLATE spring on the left end. Make sure that the Encoder Scale is in place. Do not loosen or tighten the screws fixing the Encoder Plate.
Page 130: Grit Encoder Replacement
3-13 GRIT ENCODER REPLACEMENT Turn off the sub power, and then turn off the main power. MAIN POWER SW < Rear View > Remove the following covers. Maintenance Cover Left Side Cover Left Cover LEFT COVER MAINTENANCE COVER LEFT SIDE COVER <...
Page 131 Replace with the new Grit Encoder. GRIT ENCODER The both sides of the Grit Encoder is the same. When fixing the Grit Encoder, make sure not to scratch or leave any fingerprints on the Grit Encoder. Fix the Grit Encoder Stopper with the 3 screws as shown in the figure by holding the Shaft.
Page 132 Perform the SERVO LOCK CHECK. After turning on the main power, turn on the sub power while pressing the left, right and down keys to enter the Service Mode. MENU MENU SERVICE MENU Check the GRIT ENCODER. Go back to the [MOTOR MENU], and select [G-ENC. SERVICE MENU MOTOR MENU CHECK] and press the [ENTER] key.
Page 133: Pinch Roller Replacement
3-14 PINCH ROLLER REPLACEMENT Conical type is used on both left & right Pinch Rollers Left Pinch Roller Right Pinch Roller and flat type is used for the Middle Pinch Rollers. Red marking is done on the outer side of left & right Pinch Rollers.
Page 134: Cutter Protection Replacement
3-15 CUTTER PROTECTION REPLACEMENT Remove the Cutter Protection. CUTTER PROTECTION Wipe the adhesive on the Bed with alcohol. Install the Cutter Protection from 1mm from right edge of the Bed. CUTTER PROTECTION Make sure that the Cutter Protection is not bumpy. CUTTER PROTECTION 3-71...
Page 135 3-16 HOLDER CABLE SHEET REPLACEMENT Revised 2 Turn on the sub power while pressing the left, right and down keys to enter the Service Mode. MENU MENU SERVICE MENU Select [SERVICE MENU] > [SUB MENU] > [PUMP UP], SERVICE MENU and remove ink by following the sequence.
Page 136 Remove the Cut Cable Guide. SCREW SCREW SCREW < VP-300 > Remove the 3 screws to remove the Cut Cable Guide. CUT CABLE GUIDE < VP-540 > Remove the 3 screws to remove the Cable Support. SCREW Pull the flexible cable to access the screw. SCREW FLEXIBLE CABLE CABLE SUPPORT...
Page 137 Disconnect the ink tubes from the Y tube joints, and put the scotch tape at the tip of the ink tube to prevent the ink CLAMPs from coming out. And remove them from the Clamps. Y TUBE JOINTs Open the clamp and disconnect the 3 flexible cables PRINT CARRIAGE BOARD FLEXIBLE CABLE from the Carriage Board.
Page 138 Replace the tube guides if they are not following tube guide. TUBE GUIDEs Parts No. : 1000003293 Parts Name : GUIDE,TUBE TYPE3 VP-540 Revised 3 Fix the new Cable Holders and Holder Cable Sheets to the Tube Guides with reference to the following figures. TUBE GUIDEs Make sure that the cables fit in the grooves of the tube...
Page 139 Make sure that the fixing direction of CABLE HOLDER FLEXIBLE CABLE HOLDER CABLE PLATE HOLDER CABLE SHEET the Holder Cable Plate is correct. TUBE CABLE HOLDER HOLDER CABLE PLATE < Cross Section > Fix the 2 Tube Guides. Connect the flexible cables to the Carriage Board, and fix them to the clamps.
Page 140 Connect the tubes to the Y tube joints. Fix them to the Clamps. CLAMPs Y TUBE JOINTs Fix the Carriage Cover. CARRIAGE COVER Fix the Cut Cable Guide. SCREW SCREW SCREW < VP-300 > Fix the Cut Cable Guide with the 3 screws as shown in the figure.
Page 141 Fix the Cable Support with the 3 screws as shown in the SCREW figure. CABLE SUPPORT < Top View > Move the Head Carriage in a whole width of the machine manually to make sure that there is no noise. Confirm the cable assemblies when it makes abnormal noise.
Page 142: Service Mode
4 Adjustment 4-1 SERVICE MODE MENU ], [ ], [ ] + POWER ON [ MENU ] key SERVICE MENU SERVICE MENU PRINT MENU HEAD RANK HEAD RANK 1 This menu is used for entering the Head Rank for each head PRINT MENU HEAD RANK HEAD 1...
Page 143 Normal (beeps 1 time) PRINT MENU NOW PROCESSING.. LINEAR ENCODER LINEAR ENCODER POS: 1361.00mm SETUP COMPLETED Error (beeps 2 times) LINEAR ENCODER Error is found on Linear This is for checking the installation and Encoder and Scale. operation of Linear Encoder and Scale. SETUP FAILED Refer to [4-6 LINEAR ENCODER SETUP].
Page 144 Remove all cartridges All cartridges must be removed before entering IC before pressing [ENTER] key Set cartridge to SLOT1 CHECK menu. It detects Ink Cartridge IC, writes and loads information, CARTRIDGE IC CHECK I/S MENU and checks the communication. First, it confirms if CARTRIDGE IC CHECK SLOT1...
Page 145 CROPMARK SENSE MIN 0.7V MAX2.3 SERVICE MENU CUTTING MENU OUTLEVEL CHECK [2.0V ] CUTTING MENU CROPMARK SENSE This is for adjusting the level of Crop Mark Sensor. Refer to [4-8 CROP MARK SENSOR ADJUSTMENT]. CROPMARK SENSE ADJUST ADJUST This is for adjusting the Crop Mark Sensor sensitivity. There are 3 levels of sensitivity, 0, +1 and +2. This adjustment may help when Crop Mark detection is failed with the default level setting.
Page 146 SERVICE MENU SUB MENU SERIAL NO. This menu is for entering the Serial No. of the machine in 7 digits. The cursor moves SUB MENU SERIAL NO. ZS00000 between digits with [ ] and [ ] keys. The parameter can be changed with [ ] and ] keys.
Page 147 DATE SUB MENU CLOCK DATE Revised 4 CLOCK DATE 05/09/10 05/09/10 Display [Year/Month/Day] [Year/Month/Day] Edit TIME CLOCK TIME 01:01:59 TIME 01:01:59 Display Edit TIME TIME It shows [B], when battery is dead. 01:01:59 01:01:59 This is for displaying and editing the date and time. When it detects the battery exhaustion, [B] is indicated on the time display. In this case, battery needs to be replaced.
Page 148 SVC.MODE HEAT. SERVICE MENU HEATER MENU The heater does not operate when the machine is started in Service Mode. Set [START] here STOP > STOP HEATER MENU SVC. MODE HEAT. when the heater needs to be on. [START] is canceled once the Sub Power is turned off and the setting is back to [STOP] when entering the Service Mode next time.
Page 149 HISTORY MENU MOTOR GROUP Item Contents Unit Reference MOTOR FEED Total time that the Feed Motor has been rotated. hour MOTOR SCAN Total time that the Scan Motor has been rotated. hour Life: 1500 hours PUMP TIMES Total time that the Pump Motor has been rotated. times Life: 200,000 times CLEAR　ALL...
Page 150 MAINTENANCE GROUP Item Contents Unit Reference Number of times the Head Maintenance([SUB MAINTE. COUNT MENU]>[MAINTENANCE]>[CLEANING]) has been times performed. This value is cleared automatically after carrying out the TOTAL　TIME Lapsed time from the last Head Maintenance hour Head Maintenance. This value is cleared automatically after carrying out the PRINTING TIME Printing time from the last Head Maintenance hour...
Page 151 -0.40/ 0.00 mm Encorder calibration +0.028 % Print-cut adjust (F/S) -0.20/ +0.60 mm Force adjust 30gf Crop sensor adjust Force adjust 200gf Roland Versa CAMM series Model VP-540 IP Address 192.168.000.100 Ink type E-SOL Max 4Color Version 1.00 Subnet Mask 255.255.255.000...
Page 152 HISTORY REPORT History Report Model : VP-540 Serial No. : XXXXXXX Version : 1.00 Date : 2007/01/11 14:24 ==== Motor group ==== Motor feed (trip / total [clear]): hours Motor scan (trip / total [clear]): hours Pump Times (trip / total [clear]): 1,703/ 1,703 times...
Page 153 INK CARTRIDGE REPORT Ink Cartridge Report Model : VP-540 Serial No. : XXXXXXX Version : 0.50 SERIAL/ INK TYPE/ CAP./ LOT No/ CONSUM./ TIME/ INS./ FLAG 14d178b002000071/ eSOL K/ 200cc/ 60907A/ 47.879cc/ 0y015d04h14m08s/ 00000000 000000018ebb7700/ eSOL C/ 200cc/ 61004A/ 75.914cc/ 0y015d04h14m03s/ 00000000 000000018ef67200/...
Page 154 [ ] key to start the machine in the service report printing mode. The service report will be printed Roland DG Corp. automatically when the media is set VP-540 up. It prints with Black ink. (Printing Area : W270 L360mm)
Page 155 Key Combinations Function for Service Combination Key Selection Comments Press [MENU] and [ ] to enter Service Service Mode Menu. [UPDATE FIRMWARE?] will be F/W Upgrade Mode displayed. Press [ENTER] to upgrade F/W. Use this when the Main Board is replaced.
Page 156 4-2 HOW TO UPGRADE/INSTALL FIRMWARE It is necessary to prepare the followings to upgrade/install the firmware. 1.Firmware file 2.WindowsPC (Network port is required.) 3.Peck4.exe 4.Network cable (A cross cable is required when you connect VP-540/300 to PC directly.) HOW TO UPGRADE FIRMWARE (Referential Time : 5 min) Check the IP address of VP-540/300.
Page 157 Start the Peck4. [Peck4] screen is displayed, and click [Select Port] button. Select [Type3 ProIII etc.] from [Product]. Also, select [Via Network] and input IP address of VP-540/300. Click [OK] button. [Peck4] screen is displayed again. Click [Firmware Upgrade] button. [OPEN] screen is displayed.
Page 158 The machine goes into the Firmware Upgrade mode automatically. FIRMWARE V1.0 DATA ERROR When upgrade is completed, the Sub Power turns off automatically. ERASING DEVICE ERROR WRITING DEVICE ERROR DEVICE ERROR VERIFYING COMPLETED HOW TO INSTALL FIRMWARE (Referential Time : 10 min) This is required when a new Main Board without the firmware is installed.
Page 159 Press [MENU] key, and set [IP ADDRESS], [SUBNET MASK] and [GATEWAY ADDR.]. WAITING Press [ ] and [ ] keys for moving between digits, and 000.000.000.000 ] and [ ] keys for selecting value. After setting an address, press [ENTER] key to go next address setting. MENU When [GATEWAY ADDR.] is set, it returns to the waiting IP ADDRESS...
Page 160 [Peck4] screen is displayed again. Click [Firmware Upgrade] button. [OPEN] screen is displayed. Select the firmware file and click [Open]. It starts to send the firmware to VP-540/300. It starts loading the firmware. The firmware installation is completed when FIRMWARE V1.0 DATA ERROR [COMPLETED] message is displayed.
Page 161 Turn on the Sub Power SW while pressing [ ], [ and [ENTER] keys to enter [INITIALIZE ALL SYS. PARAMETER] menu. ENTER Select the model by pressing [ ] and [ ] keys, and press [ENTER] key to start initialization. The Sub Power turns off automatically when it is completed.
Page 162 Start the Peck4 on PC. [Peck4] screen is displayed, and click [Put Parameters] button. [OPEN] screen is displayed. Select the System Parameter file that is saved before the Main Board replacement. Click [Open]. Peck4 starts to send the System Parameter to VP-540/300. Click [Get Report] button to import the System Report file.
Page 163: How To Upgrade Firmware Of The Network Controller
4-3 HOW TO UPGRADE FIRMWARE OF THE NETWORK CONTROLLER ( Referential Time : 5min.) Turn on the Main Power SW and Sub Power SW, then press [MENU] key. Select [SYSTEM INFO.]> [NETWORK]> [IP ADDRESS] MENU and set the IP address. Close the RIP when it is running.
Page 164 Specify the target file for upgrade and click [Update]. The progress is shown in percentage while upgrading. Do not turn off the power or press any keys while upgrading. When upgrade is completed, the version of upgraded firmware appears. Turn off the Sub Power SW and Main Power SW once. 4-23...
Page 165: Head Alignment
4-4 HEAD ALIGNMENT (Referential Time : 30 min._1 Head Alignment) This is necessary to obtain the good printing quality. Be sure to operate this alignment when the head is replaced. If the heads are not aligned, printing problems such as banding, fine lines and gap between bands could occur.
Page 166 <VP-300> DAMPER PLATE Turn on the Sub Power SW while pressing [ ], [ ] and ] keys to enter the Service Mode. Set up the PET-G on the machine. MENU MENU SERVICE MENU [BIAS ADJUSTMENT] SERVICE MENU Select [PRINT MENU]> [HEAD ADJUST]> [BIAS], and PRINT MENU press [ENTER] key.
Page 167 Loosen the 3 screws fixing the head. Loosen the screws fixing the head for 1/2 turn. If the screws are loosened too much, the alignment cannot be done correctly. Insert the 1.5 mm Hexagonal Wrench through the hole of ADJUSTMENT the Head Carriage, then turn the Adjustment Screw to SCREW make the lines of each color in the test pattern straight.
Page 168 Print the test pattern again. SERVICE MENU If the result is not satisfactory, repeat step 5 to 9. PRINT MENU [ ] [ ] PRINT MENU The shifting of lines should be smaller than 1/2 HEAD ADJUST dot. HEAD ADJUST BIAS BIAS TEST PRINT...
Page 169 Turn the Adjustment Screw to make the lines of each color in the test pattern straight. Position of the printing moves 1 line by turning the screw 1/6 turn. ADJUSTMENT SCREW When the lines other than K are above the K lines, turn the Adjustment Screw CW.
Page 170 [HORIZONTAL ADJUSTMENT] SERVICE MENU S e l e c t [ P R I N T M E N U ] > [ H E A D A D J U S T ] > PRINT MENU [HORIZONTAL]> [TEST PRINT], and press [ENTER] key. [ ] [ ] PRINT MENU HEAD ADJUST...
Page 171 [BIDIRECTIONAL ADJUSTMENT] SERVICE MENU Select [PRINT MENU]> [HEAD ADJUST]> [BI- PRINT MENU DIR.DEFAULT]> [TEST PRINT], and press [ENTER] key. [ ] [ ] PRINT MENU HEAD ADJUST HEAD ADJUST BI-DIR.DEFAULT BI-DIR.DEFAULT TEST PRINT Test pattern will be printed. Find the position where the two lines are overlapping and check the number of each color.
Page 172 Select [DT1, Low], [DT3, Low], BI-DIR.DEFAULT [DT1, HIGH] and [DT3, HIGH] in the TEST PRINT [HEAD ADJUST] menu and enter the parameters checked at step 21 BI-DIR.DEFAULT DT1, Low with [ ] and [ ] keys. Press [ENTER] key to save the BI-DIR.DEFAULT settings.
Page 173: Limit Position & Cut Down Position Initialize
4-5 LIMIT POSITION & CUT DOWN POSITION INITIALIZE (Referential Time : 3min.) This is for adjusting the relative distance between the Limit Sensor and the Capping Position, and also detecting the distance from the Cut Down Position to the Limit Sensor after completing the adjustment. When the Limit Position is not correctly set, it may cause some problems such as a head capping error and a head carriage lock error.
Page 174 Confirm that the head is certainly capped, and press [ENTER] key. The Tool Carriage gets separated from the SETTING UP THE LIMIT Head Carriage and it starts limit position initialize. After the completion of the initialize, the message is displayed as shown in the figure. DETECTING..
Page 175: Linear Encoder Setup
4-6 LINEAR ENCODER SETUP (Referential Time : 5min.) This is for checking the reading of the linear encoder and for calibrating its expansion/contraction caused by the operation environment. This operation is required when Limit Sensor, Encoder Scale or Encoder Module is replaced or the position is adjusted.
Page 176 One of the messages appears at the completion of the set up. In case of Setup error, check the followings. Dirt/Scratch on the Encoder Scale. LINEAR ENCODER Dirt/Scratch on the Encoder Module. SETUP COMPLETED Encoder Scale is not between the Encoder Module. Backlash of the Carriage Motor Gear and the Drive Gear.
Page 177: Flushing Position Adjustment
4-7 FLUSHING POSITION ADJUSTMENT (Referential Time : 5min.) This is to adjust the flushing position. This adjustment is required when a Cap Top and a head are removed or replaced. Without this adjustment, the Flushing may not be performed properly. For VP-540, the Head height should be set LOW.
Page 178 Select [PRINT MENU]> [FLUSHING ADJ.], and press [ENTER] key. SERVICE MENU PRINT MENU The Head Carriage automatically moves to the current [ ] [ ] flushing position. PRINT MENU FLUSHING ADJ. FLUSHING ADJ. SET POSITION Move the Cap Tops and heads to the position where the leftmost Cap Top makes contact with the surface of the leftmost head by pressing [ ] and [...
Page 179: Crop Mark Sensor Adjustment
The result of the crop mark recognition on Roland media is not assured, when any media other than SV-GG is used for this adjustment.
Page 180 Select [CUTTING MENU]> [CROPMARK SENS]> SERVICE MENU [OUTLEVEL CHECK], and press [ENTER] key. CUTTING MENU A Crop Mark will be printed. CUTTING MENU CROPMARK SENSE CROPMARK SENSE OUTLEVEL CHECK After printing a Crop Mark, the Tool Carriage moves to above the Crop Mark automatically. Adjustment is unnecessary when the displayed MAX voltage is 2.7 +/-0.2V.
Page 181: Crop-Cut Adjustment
4-9 CROP-CUT ADJUSTMENT (Referential Time : 10min.) This adjustment is for calibrating the relative positions of Tool and Crop Mark Sensor. If it is not adjusted, the cutting position based on the detected Crop Marks becomes wrong, and that results in the mis- alignment of the Print and Cut performed under the auto crop mark detection.
Page 182 From the test pattern, find the value where the print line <TEST PATTERN> matches the cut line. +2.0 -2.0 In this case, the correction value for the scan direction is Correction-value scale +1.5 -1.5 "-0.3". +1.0 -1.0 If it is difficult to see the cut line visually, use -0.5 +0.5 -0.5...
Page 183 Adjustment is completed if the position error of cut line is within +/-0.1mm. If not, select [SETTING] menu again for CUTTING MENU further adjustment. CROP-CUT ADJ. key : Moves cut position towards front CROP-CUT ADJ. key : Moves cut position towards rear SETTING key : Moves cut position towards right key : Moves cut position towards left...
Page 184: Print/Cut Position Adjustment
4-10 PRINT / CUT POSITION ADJUSTMENT (Referential Time : 10min.) This adjustment is for calibrating the relative positions of printing and cutting. If it is not adjusted, it may result in the misalignment of the printing and cutting. This adjustment is required when Tool Carriage is replaced, or a head is replaced or adjusted, and also when the relative distance between the Carriage and head is changed.
Page 185 From the test pattern, find the value where the print line <TEST PATTERN> matches the cut line. +2.0 -2.0 In this case, the correction value for the scan direction is Correction-value scale "-0.3". +1.5 -1.5 +1.0 -1.0 -0.5 +0.5 -0.5 If it is difficult to see the cut line visually, use a magnifier.
Page 186 Adjustment is completed if the position error of cut line is within the range below. If not, select [SETTING] menu CUTTING MENU again for further adjustment. PRINT-CUT ADJ. Mark on the right: Within +/-0.1mm Mark on the left: Within +/-0.3mm PRINT-CUT ADJ.
Page 187: Calibration(Feeding Direction)
4-11 CALIBRATION (FEEDING DIRECTION) (Referential Time : 20 min.) This adjustment is for calibrating the feed amount of media. It allows the media to be fed proper amount by calibrating the variation in Grit Roller diameter. Calibration is made based on the value in feeding media [PET-G].
Page 188 Calculate the amount to be calibrated with the formula as shown in the figure. Measured 400 - Length Calibration x 100 Value Measured Length Select [PRINT MENU]> [CALIB.DEFAULT]> [SETTING], SERVICE MENU and enter the calibration value with [ ] and [ ] keys.
Page 189: Tool Height Adjustment
4-12 TOOL HEIGHT ADJUSTMENT (Referential Time : 5min.) Install the White Dummy Pen (ST-006) to the Tool Carriage. WHITE DUMMY PEN Move the Pinch Rollers at the positions as shown in PINCH ROLLER VP-540 the figure, and lower them. GRIT ROLLER VP-300 Remove the I/S Cover.
Page 190 Move the Head Carriage to the highest position of the bed. Click! Confirm that Head Carriage is connected to Tool Carriage and lock the connected carriages. The right end is the highest position of the bed. Turn the Adjustment Screw to adjust the space between the Pen end and Bed to be 2.5mm to 2.6mm.
Page 191: Tool Pressure Adjustment
4-13 TOOL PRESSURE ADJUSTMENT (Referential Time : 15min) This adjustment is to correct the tool pressure during cutting. Before this adjustment, it is necessary to perform [4-12 TOOL HEIGHT ADJUSTMENT]. Install the White Dummy Pen (ST-006) to the Tool Carriage. WHITE DUMMY PEN Move the Pinch Rollers at the positions as shown in...
Page 192 Move the Head Carriage to the highest position of the bed. Click! Confirm that Head Carriage is connected to Tool Carriage and lock the connected carriages. The right end is the highest position of the bed. Turn on the Sub Power SW while pressing [ ], [ ] and ] keys to enter the Service Mode.
Page 193 Lift up the Tool Holder with the Dial Gauge (ST-013) and 30gf measure the pressure when the pen tip leaves the bed. Adjust the parameter in [30gf] menu with [ ] and [ [ ] [ ] keys for the pressure to be 25 to 35gf (0.25N to 0.35N). [ENTER] Press [ENTER] key to save the settings.
Page 194: Belt Tension Adjustment
4-14 BELT TENSION ADJUSTMENT (Referential Time : 20min.) Connect the Tool Carriage to the Head Carriage and move them to the right in the lock position. Click! Remove the Covers in order. TOP COVER 1. I/S Cover LEFT 2. Maintenance Cover COVER 3.
Page 195 [VP-300] <*1> Measure the tension of the belt at the empty screw hole of the LM Guide between the 2nd and 3rd Grit Rollers from the left using Tension Gauge (ST-001)(*1). Pull up the belt until its inside comes to the top surface of the Cable Guide when you see it from the machine front(*2).
Page 196 Turn the Adjustment Screw as shown in the figure to adjust the value of the tension gauge within acceptable range refferring to step 3. ADJUSTMENT SCREW Turn the screw CW: Tension is increased Turn the screw CCW: Tension is decreased Tighten the 2 Fixing Screws shown in the figure, and again confirm that the tension is within the proper value.
Page 197: Belt Position Adjustment
4-15 BELT POSITION ADJUSTMENT (Referential Time : 30min.) This adjustment is to prevent the belt wear which is caused by the belt contacting with the pulley flanges excessively. The belt position needs to be confirmed after the Belt Tension Adjustment and adjusted if it is necessary.
Page 198 Confirm the belt position. <TOP VIEW(R)> The position is proper when the belt is not touching the flanges of the Drive Pulley excessively. When the position is proper, skip this adjustment and go to [ADJUSTMENT ON THE IDLE PULLEY SIDE] described in the later step of this adjustment leaving the belt aging on.
Page 199 Press [ENTER] key to restart Aging. AGING SCAN Adjust the belt position turning the Adjustment Screw as Touching the frange on the FRONT side of machine follows. Belt leans to the front side of the machine -Turn the screw carefully in CW (loosening). The work space is narrow.
Page 200 Confirm that the belt is not touching the pulley flanges <TOP VIEW(R)> excessively. When the belt is in improper position, adjust it again. When it is proper, leave the belt aging on, and go to the following [ADJUSTMENT ON THE IDLE PULLEY SIDE]. FLANGE [ADJUSTMENT ON THE IDLE PULLEY SIDE] <TOP VIEW(L)>...
Page 201 Insert a wrench through the holes on the Side Frame and loosen the 2 screws to make a gap of 3mm between the tip of the screw and Idle Pulley Holder. SCREWs The gap between the screws and Idle Pulley can be seen from both front side and rear side of the machine.
Page 202 Tighten one of the screws that has no contact with the Idle Pulley Holder to slightly touch the Idle Pulley Holder. SCREWs Make sure not to tighten the screws too tight. It may move the Idle Pulley Holder accidentally. IDLE PULLEY HOLDER Tighten the 2 fixing screws as shown in the figure.
Page 203: Take-Up Unit Operation Check
4-16 TAKE-UP UNIT OPERATION CHECK (Referential Time : 2min.) This is to check whether Take-up Unit operates properly. Confirm that the cable of Take-up unit is connected to the <REAR VIEW> connector and turn on the Main Power SW. Turn on the Sub Power SW while pressing [ ], [ ] and ] keys to enter the Service Mode.
Page 204 Confirm that [START] is selected, and press [ENTER] key to turn on the Take-up Unit. [START] or [STOP] can be selected with ] and [ ] keys. START START The current setting is displayed on the left and the new setting is diplayed on the right. Set the AUTO switch of the Take-up Unit to either FORWARD or BACKWARD.
Page 205 Move the Dancer Roller up and down by hand, and confirm that the drive part does not rotate. Drive Part The setting of [STOP] is canceled when exiting the menu. The initial setting is [START] every time entering [TU] menu. DANCER ROLLER 4-64...
Page 206: Special Tools
5 Supplemental Information 5 Supplemental Information 5-1 Special Tools Table shows a list of special tools recommended by Roland DG Corp. Tool No. ST-056 Tool Name TORQUE DRIVER N6 Purpose HEAD ALIGNMENT Tool No. ST-002 Tool Name TENSION GAUGE 300g (3N)
Page 207: Sensor Map
5 Supplemental Information 5-2 SENSOR MAP REAR PAPER SENSOR LIMIT SENSOR It detects the rear edge of the media and also It detects the limit positon of the head carriage in the scan whether the media is loaded or not. direction.
Page 208 5 Supplemental Information WIPER SENSOR It detects the limit position of the Wiper movement. ENCODER MODULE It detects the coordinates in the carriage moving direction, and also generates the print signal. HEAD UP/DOWN SENSOR (for VP-540 ONLY) It detects the position of the Head Height Lever.
Page 209 5 Supplemental Information PINCH ROLLER SENSOR It detects the positions of Pinch Roller. CROP MARK SENSOR It detects the Crop Mark. INK CARTRIDGE IC SENSOR It communicates with the IC chip of the Ink INK EMPTY SENSOR Cartridge. It detects whether the Ink Cartridge is empty or not. INK CARTRIDGE SENSOR It detects whether the Ink Cartridge is installed or not.
Page 210: Defect Of Print Quality (Banding/Scratchy Printing/Blurred Printing)
6 Troubleshooting 6-1 DEFECT OF PRINT QUALITY (BANDING/SCRATCHY PRINTING/BLURRED PRINTING) Missing dot or Improved Perform Normal deflected-fired dot Solved Cleaning appears on the test Not Improved *Several Normal Cleanings and a Powerful Cleaning do not improve the printing result. To 1-10 To 11-16 CHECKING POINT ACTION...
Page 211: Particular Color Is Not Printed At All
6-2 PARTICULAR COLOR IS NOT PRINTED AT ALL CHECKING POINT ACTION REFERENCE OUTLINE When the machine keeps printing with ink cartridge almost Ink Cartridge is almost Check remaining Ink / empty, the negative pressure delivered in the ink tube causes User's Manual empty Replace the Ink Cartridge...
Page 212: Ink Drops On The Media
6-4 INK DROPS ON THE MEDIA CHECKING POINT ACTION REFERENCE OUTLINE When foreign substances such as fiber dust are stuck on the Foreign substances Manual Cleaning User's Manual surface of the Head, Ink sometimes leaks from it. Wipe the surface of Head with a cleaning stick. Use the media clamps/ If media tends to curl or become bumpy due to the Ink Media strikes Head...
Page 213 6-7 Print & Cut Misalignment Ideal Conditions The above illustration shows the ideal print and cut conditions where the red stars signify the printed image and the black lines signify the cut path. Since the actions to be taken are different depending on the conditions of shifting, check how cutting is shifted first and take appropriate actions.
Page 214 Symptom 3 : Cut is OK at Lead Edge but is Getting Shifted as It Goes to the End of Print Possible Causes 1. There is some setting value other than 0 set in [CUTTING MENU]>[CALIBRATION]>[FEED SETTING]. 2. Expansion/Contraction of the media 3.
Page 215 Symptom 5 : Cut is Shifted When Using Crop Marks Possible Causes 1. Crop-cut adjustment is not correctly done. 2. Crop mark sensor adjustment is not correctly done. Actions 1. Perform [ADJUST BI-DIR] in the User menu. 2. Perform [CROP-CUT ADJ.] in the User menu. 3.
Page 216: Poor Cutting Quality(Stitch Cut, Distorted Cut, Mismatched Start And End Points)
6-8 POOR CUTTING QUALITY (STITCH CUT, DISTORTED CUT, MISMATCHED START AND END POINTS) CHECKING POINT ACTION REFERENCE OUTLINE Blade Holder is fixed Fix the Blade Holder loose tightly. Blade-offset setting is Set the blade-offset not correct correctly. Cutting force is not Tool pressure [4-13 TOOL PRESSURE correct...
Page 217: Motor Error
6-10 MOTOR ERROR CHECKING POINT ACTION REFERENCE OUTLINE Remove cause of Media Jamming Media Jam Back tension of media is When using hard-to-unroll or too heavy media, Motor Error Use appropriate media too high occurs due to the too much load for feeding the media. There is a dirt in teeth of When the Drive Gear has some dirt on its teeth and cannot Clean Drive Gear...
Page 218: Heater/Dryer Temperature Does Not Go Up
6-11 HEATER / DRYER TEMPERATURE DOES NOT GO UP CHECKING POINT ACTION REFERENCE OUTLINE The media is not loaded Set up the media. User's Manual Inappropriate Check the temperature When the setting of print heater/dryer is off, the Heater does temperature is set on the User's Manual setting...
Page 219: Error Message
6-13 ERROR MESSAGE CHECKING ACTION REFERENCE OUTLINE Restart the machine Restart the machine and see if the same error occurs again. service call Refer to [6-14 SERVICE [6-14 SERVICE CALL] CALL] Restart the machine Restart the machine and see if the same error occurs again. Internal Error Upgrade the firmware to Check the revision record of the firmware version and...
Page 220 CONTENTS CODE CAUSE ACTION Even though the machine carries out the Wiper Motor error Wiper Motor Replacement regular movement, the output of the Wiper Defect of Wiper Unit Wiper Unit Replacement 0109 Sensor does not reach the expected value. Defect of Wiper Sensor Wiper Sensor Replacement Cut-line or short-circuit of cable and Flexible Cable and Flexible cable Replacement...
Page 221: Installation Check List
7 Service Activities 7-1 INSTALLATION CHECK LIST VP-540/300 INSTALLATION CHECK LIST Date : User Name : Serial Number : Checking for Installing Place There is a space necessary for installing the machine as follows. 2400 mm (8 ft.) 650mm (2.17 ft.) VP-540: 3300mm (11ft.) VP-300: 2700mm (9 ft.) Install the machine in a location that is level, stable, and able to bear the weight of the machine.
Page 222 Unpacking Manual etc. CD-ROM etc.
Page 223 Checking the Accessories Power cord: 1 Arm (right): 1 Arm (left): 1 Casters: 2 Stand leg: 1 Shafts: 2 Stoppers: 2 Bolts : 26 Hexagonal Pipe: 1 Short media clamps : 2 Long media clamps : 2 Media (left and right) (left and right) flanges: 2 wrench: 1...
Page 224 Installation and Preparation Set up following items in reference to the Setup Guide [3.Assembling and Installing] to [7. Network Settings]. Assemble the Stand Attach the Shafts Install the Drain Bottle Revised 1 !! IMPORTANT !! Be careful not to pinch the drain tube. Drain Tube Drain Tube Cable tie...
Page 225 Installing Roland Versaworks Install Roland VersaWorks in reference to the Quick Start Guide. System requirements for installing the software Operating system : Windows XP Professional Service Pack 1 or later, or Windows 2000 Service Pack 4 or later CPU : Pentium 4 2.0 GHz or faster...
Page 226 Loading and cutting off media For the stable media feeding, place the middle pinch rollers above all the grit rollers that lie between the left and right pinch rollers. !! IMPORTANT !! Performing a sheet cut when the long media clamps are installed causes interference with the separating knife, which may result in malfunction or damage to the machine.
Page 227 Job outputting from Roland VersaWorks Explain each procedure as follows on a job outputting from Roland VersaWorks. Printing Cutting !! IMPORTANT !! Never use the Media Clamps during cutting. Printing and cutting During a print & cut, the cap of the cutter holder may scratch and damage the printed surface. Turn the cap of the blade holder to adjust the amount of blade extension or use the Dry Time setting on RIP as necessary.
Page 228 - These adjustments are required for each Media individually. - If you are setting Feed Calibration on your machine, check in advance that [Use Printer Settings] is set on Roland VersaWorks. Optimizing printing and cutting to match Media thickness - Bi-direction adjustment...
Page 229 Calibration for cutting !! IMPORTANT !! During Print & Cut, [CALIBRATION] in the [CUTTING MENU] is to be set to [0]. It may cause a misalignment of printing and cutting. This calibration is to be used only when performing cutting only. Preset function All menu items listed below can be saved in Presets.
Page 230 Cleaning the parts other than the print heads - Pinch Rollers - Grit Rollers - Platen !! IMPORTANT !! Never use gasoline, alcohol, thinner, or any other flammable materials. Cleaning using the cleaning kit !! IMPORTANT !! This is very important work for maintaining the heads in good condition and must be done periodically. Replacing the wipers Replacing the blade Replacing the separating knife...
Page 231 Consumable Parts and Replacement Cycle Parts Name Replacement Cycle 6 billion shots / nozzle (6,000,000 kshots) Printing Head * Damper needs to be replaced together with the Head replacement. Wiper 6 months, Wiping 3000 times or Rubbing 100 times Carriage Motor 1500 hours Cap Top 6 months...
Page 232: Maintenance Check List
Sponge for Wiper or the time period from the last replacement. Replacement Done Replacement Cycle : 12 months Cleaning Done Clean it manually using the Roland cleaning stick and cleaning liquid. Wiper Scraper Replacement Done Replace it as necessary. Good...
Page 233: Specifications
RIP, User's Manual, etc. The length of printing or cutting is subject to the limitations of the program. With Roland PET film, print travel: 1 m Temperature: 25 C (77 F), humidity: 50% 7-13...
Page 234 Not assured when the print heater or dryer is used. The following conditions must be met: Media type: Media specified by Roland DG Corp. Roll media must be loaded on the shaft. [PREFEED] menu item must be set to "ENABLE."...

This manual is also suitable for:

Versacamm vp-300

Roland VersaCAMM VP-540 Service Notes

1 Structure & Spare Parts

2 Electrical Section

3 Replacement of Main Parts

4 Adjustment

5 Supplemental Information

6 Troubleshooting

7 Service Activities

Quick Links

Related Manuals for Roland VersaCAMM VP-540

Summary of Contents for Roland VersaCAMM VP-540

This manual is also suitable for:

Table of Contents