Roland VersaCamm VS-640i Service Notes
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Roland VersaCamm VS-640i Service Notes

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SERVICE NOTES
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 VS-640i/540i/300i.
3. REUSE
Authorized persons shall not disclose, transfer, rent or distribute this Service Note to, or allow this Service Note
to be used in any manner by, any third party other than authorized persons.
4. REPRODUCTION
Authorized persons shall not copy, change or alter this Service Note without permission of Roland DG
Corporation.
5. EFFECT OF VIOLATION
Regardless of circumstances, we will vigorously respond to any violation hereof, through legal action.
TERMS OF USE
Confidential
Copyright © 2013 ROLAND DG CORPORATION
70240-02

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Summary of Contents for Roland VersaCamm VS-640i

  • 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 VS-640i/540i/300i.

  • Page 2: Table Of Contents

    Contents 1 Structure & Spare Parts 4 Adjustment OVERVIEW ..............1-1 4-1 SERVICE MODE ..............4-2 1-1 COVER ................1-2 4-2 HOW TO UPGRADE/INSTALL FIRMWARE ....4-13 1-2 PANEL ................1-3 4-3 HEAD ALIGNMENT ............4-20 1-3 FRAME ................1-4 4-4 LIMIT POSITION & CUT DOWN POSITION 1-4 LEVER ................1-5 INITIALIZE ..............4-24 1-5 BED .................1-6...
  • Page 3 Revision Record Revision Date Description of Changes Approval Issued 2013.9.20 First Edition Onoda Yamane 2013.12.9 5-3 MOTOR ERROR, 5-4 SERVICE CALL has been added. Onoda Eiko 2014.6.12 1-22 ACCESSORY 2 has been added. Onoda...
  • 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 affi xed to the body of this product. The following fi gure describes the location. Caution: Pinching Hazard Be careful not to allow the fi ngers to become pinched when loading media or closing covers.
  • Page 6 WARNING - FOR CONTINUED PROTECTION AGAINST RISK OF FIRE, REPLACE ONLY WITH FUSE OF THE SPECIFIED TYPE AND CURRENT RATING. F80L HS...

  • Page 7: Structure & Spare Parts

    1 Structure & Spare Parts Overview 1-1 COVER 1-15 INK CARTRIDGE 1-6 RAIL 1-16 CHOKE VALVE 1-18 INK TUBE WIRING 1-17 CIRCULATION PUMP 1-11 TOOL CARRIAGE 1-5 BED 1-3 FRAME 1-8 SCAN MOTOR 1-12 WIPER 1-10 HEAD CARRIAGE 1-7 CHASSIS 1-13 CAP 1-14 PUMP 1-19 PINCH ROLLER...

  • Page 8: Cover

    1-1 COVER PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1000010652 ASSY,COVER FRONT VS-300I 20 1000010705 LABEL,SET INK VS-640I#LA1487 1000010635 ASSY,COVER FRONT VS-540I 21 1000009754 LABEL,USE ECO-SOL MAX2#LA1407 1000010623 ASSY,COVER FRONT VS-640I 1000007288 PLATE,COVER F VS-300 (VS-300i) 1000010597...

  • Page 9: Panel

    1-2 PANEL PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name W701406010 ASSY,PANEL BOARD VS-640 S1 31289109AS CUPSCREW SET,M3*4 NI 100 PCS. W702406010 ASSY,PANEL BOARD VS-640I S2 31019149 SCREW SET,BINDING M2.3*8 3CBC 100PCS 1000010552 CABLE-ASSY,MAINT-COVER SW VS-640I 23475212...

  • Page 10: Frame

    1-3 FRAME S14 9 S16 27 PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 7520501000 ASSY,CAP BOTTLE 2 FJ-52 27 1000006788 STAY,FRAME SIDE R VS-640 W701406040 ASSY,FAN JUNCTION BOARD VS-640 28 1000002554 STAY,SUPPORT RAIL L VP-540 W702406040 ASSY,FAN JUNCTION BOARD VS-640I...

  • Page 11: Lever

    1-4 LEVER PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 21905192 ADAPTER,CLAMP MEDIA SP-540V S1 31289109AS CUPSCREW SET,M3*4 NI 100 PCS. 12159573 BUSH,80F-0603 S2 31129101 PIPE SET,POLYCA 3*6*8 20PCS (VS-540i/VS-640i) 12159563 BUSH,80F-1006 S3 31149705 RING SET,E-RING ETW-7 SUS 50PCS 1000006701...

  • Page 12: Bed

    1-5 BED...
  • Page 13 1-5 BED PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1000010649 APRON,B VS-300I S1 31029101 BUSH,NB-19 1000010632 APRON,B VS-540I S2 31329601AS CLAMP SET,INSULOK T-18S 100 PCS. 1000010598 APRON,B VS-640I 31329501AS CLAMP SET,PUSH MOUNT RT30SSF5 20P (VS-300i) 1000011688 APRON,F AL VS-300I 31329501AS...

  • Page 14: Rail

    1-6 RAIL 3 S10 S5 S16...

  • Page 15: Rail-Vs-640I

    1-6 RAIL - VS-640i - PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name W701406090 ASSY,FLEX 1 VS-640 47 1000003665 SHEET,LINEAR SCALE XJ-540 W702406090 ASSY,FLEX 1 VS-640I 48 1000010580 SHEET,TUBE GUIDE VS-640I W7014060A0 ASSY,FLEX 2 VS-640 49 22175122 SPRING,BACK UP PNC-960...

  • Page 16: Rail-Vs-540I

    1-6 RAIL - VS-540i - PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name W701406090 ASSY,FLEX 1 VS-640 47 1000002544 SHEET,LINEAR SCALE VP-540 W702406090 ASSY,FLEX 1 VS-640I 48 1000010637 SHEET,TUBE GUIDE VS-540I W7014060A0 ASSY,FLEX 2 VS-640 49 22175122 SPRING,BACK UP PNC-960...

  • Page 17: Rail-Vs-300I

    1-6 RAIL - VS-300i - PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name W701406090 ASSY,FLEX 1 VS-640 47 1000002665 SHEET,LINEAR SCALE VP-300 W702406090 ASSY,FLEX 1 VS-640I 48 1000010654 SHEET,TUBE GUIDE VS-300I W7014060A0 ASSY,FLEX 2 VS-640 49 22175122 SPRING,BACK UP PNC-960...

  • Page 18: Chassis

    1-7 CHASSIS PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 6702419000 ASSY,MAIN BOARD VS-640I 21 12559105 FUSE,5X20 021706.3MXP 6.3A/250V W701406020 ASSY,POWER BOARD VS-640 22 13429702 INLET AC P01CF01 15A250V W702406020 ASSY,POWER BOARD VS-640I 23 1000002682 LABEL,LAN VP-540#LA964 1000010546...

  • Page 19: Scan Motor

    1-8 SCAN MOTOR PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 6700469030 ASSY,PULLEY VP-540 S1 31329501AS CLAMP SET,PUSH MOUNT RT30SSF5 20P 6701979020 ASSY,SCAN MOTOR RE-640 S2 31289111AS CUPSCREW SET, M4*6 NI 100 PCS. 11869103 BALL,4MM S3 31289109AS...

  • Page 20: Feed Motor

    1-9 FEED MOTOR PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 6701409040 ASSY,FEED MOTOR VS-640 S1 31289111AS CUPSCREW SET, M4*6 NI 100 PCS. W701407040 ASSY,GRIT ENCODER BOARD VS-640 S2 31289109AS CUPSCREW SET,M3*4 NI 100 PCS. W702407040 ASSY,GRIT ENCODER VS-640I S3 31289102AS...

  • Page 21: Head Carriage

    1-10 HEAD CARRIAGE * Cut off necessary length when using the tape. PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 6701409010 ASSY,HEAD INKJET VS-640 27 22185127 SLIDER,CARRIAGE FJ-540 W701407030 ASSY,LINEAR ENCODER BOARD VS-640 28 1000002623 SPACER,U/D LEVER VP-540 6700989040...

  • Page 22: Tool Carriage

    1-11 TOOL CARRIAGE PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 22805292 ASSY,CLAMP BLADE CM-500 S1 31029801AS BUSH SET,ROLL 2*4 3C100PCS W701406050 ASSY,CROP SENS BOARD VS-640 S2 31029803AS BUSH SET,ROLL 3*5 3C 20PCS. W702406050 ASSY,CROP SENS BOARD VS-640I S3 31329601AS...

  • Page 23: Wiper

    1-12 WIPER PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1000009369 ARM,WIPER CAM VS-640_01 S1 31029803AS BUSH SET,ROLL 3*5 3C 20PCS. 1000006725 BELT,172P2M4-530 S2 31329501AS CLAMP SET,PUSH MOUNT RT30SSF5 20P 1000000796 BUSH,80F-0503 S3 31289109AS CUPSCREW SET,M3*4 NI 100 PCS.

  • Page 24: Cap

    1-13 CAP PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1000006747 ARM,LINK UP VS-640 S1 31029101 BUSH,NB-19 6701409200 ASSY,CAP TOP VS-640_01 S2 31049169AS SCREW SET,CAP M4*8 3CBC+PW 20PCS 1000006521 BASE,BACK-UP CAP VS-640 S3 31179106 SCREW,JACK UP SP-540V 1000006748...

  • Page 25: Pump

    1-14 PUMP (280mm) (50mm) PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1000008314 ADAPTER,JOINT 2L MCL-1 S1 31049142AS SCREW SET,CAP M3*6 NI MEC 20 PCS 6700319010 ASSY,PUMP SUB XC-540 S2 31199701AS SCREW SET,SET WP M3*3 NI 20 PCS 1000010561 CABLE-ASSY,PUMP MOTOR VS-640I S3 31289109AS...

  • Page 26: Ink Cartridge

    1-15 INK CARTRIDGE PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name W701406070 ASSY,CARTRIDGE IC BOARD VS-640 S1 31289112AS CUPSCREW SET,M3*10 NI 100 PCS. W702406070 ASSY,CARTRIDGE IC BOARD VS-640I S2 31289109AS CUPSCREW SET,M3*4 NI 100 PCS. 6702041180 ASSY,HOLDER I/C XF-640 S3 31409702...

  • Page 27: Choke Valve

    1-16 CHOKE VALVE PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 11909167 ADAPTER,SCREW 3FAI FJ-540 S1 31029820 BUSH SET,ROLL 3*2 3C 50PCS 1000010220 ARM,CHOKE 8 XF-640 S2 31289111AS CUPSCREW SET, M4*6 NI 100 PCS. 1000010611 BASE,CHOKE 8 VS-640I S3 31289109AS...

  • Page 28: Circulation Pump

    1-17 CIRCULATION PUMP PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 6701219010 ASSY,CIRCULATING PUMP LEC-330 S1 31199701AS SCREW SET,SET WP M3*3 NI 20 PCS W701406030 ASSY,INK TANK BOARD VS-640 S2 31289109AS CUPSCREW SET,M3*4 NI 100 PCS. W702406030 ASSY,INK TANK BOARD VS-640I S3 31409702...

  • Page 29: Ink Tube Wiring

    1-18 INK TUBE WIRING 2 7 4 CARTRIDGE 80mm 110mm Length: f 2 7 4 CARTRIDGE 80mm 110mm Length: h 2 7 4 CARTRIDGE 80mm 110mm Length: a 2 7 4 CARTRIDGE 80mm 70mm Length: c 2 7 4 CARTRIDGE 80mm 70mm Length: b...

  • Page 30: Pinch Roller

    1-19 PINCH ROLLER PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 6700460300 ASSY,PINCHROLL C VP-540 (VS-300i) S1 31149702AS RING SET,E-RING ETW-3 100 PCS. 6700460300 ASSY,PINCHROLL C VP-540 (VS-540i) S2 31019702AS SCREW SET,BIND P-TIGHT M3*6 3C 100P 6700460300 ASSY,PINCHROLL C VP-540 (VS-640i) S3 31249211AS...

  • Page 31: Stand

    1-20 STAND PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1000006779 ARM,L VS-640 1000007243 STAY,STAND VS-300 (VS-300i) 1000006778 ARM,R VS-640 1000007198 STAY,STAND VS-540 (VS-540i) 1000006533 ASSY,BASE STAND VS-640 1000006787 STAY,STAND VS-640 (VS-640i) 1000004718 BASE,FEEDER RS-540 23 1000003635...

  • Page 32: Accessory 1

    1-21 ACCESSORY 1 PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1000011045 CARTON,COVER VS-300I 1000011043 PAD,SPACER VS-540I 1000011039 CARTON,COVER VS-540I 1000011036 PAD,SPACER VS-640I 1000011025 CARTON,COVER VS-640I 16 1000011032 PAD,STAND LEG VS-640I 1000011046 CARTON,SLEEVE VS-300I 17 1000011028 PAD,SUPPORT VS-640I 1000011040 CARTON,SLEEVE VS-540I...

  • Page 33: Accessory 2

    1-22 ACCESSORY 2 117V 230V 230V BR 230V AR 230VC 230VK 240VA 240VE Revised 2 PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 23495124 AC CORD 3ASL100 240VA 10A SAA 1000011614 MANUAL,USE2 EN VS-640I 13499111 AC CORD H05VV-F 240VE 10A S 1000011613 MANUAL,USE2 JP VS-640I 13499109...

  • Page 34: Electrical Section

    2 Electrical Section 2-1 WIRING MAP CN300 CN905 CN904 CN3 CN9 CN18...
  • Page 35 CABLE LIST Parts No. Parts Name Parts No. Parts Name 1000002189 CABLE-ASSY,JUNBI A VP-540 37 1000006702 CABLE-CARD,29P1 256L BB HIGH-V 1000002190 CABLE-ASSY,JUNBI B VP-540 38 1000006692 CABLE-ASSY,HEAD UD SENS VS-640 23415268 CABLE-ASSY,JUNBI C SP-500 39 1000010559 CABLE-ASSY,GRIT ENC VS-640I 23415116 CABLE-ASSY,JUNBI D SP-300 1000010556 CABLE-ASSY,HEATER VS-640I(VS-640I) 1000002173 CABLE-ASSY,JUNBI E VP-540...

  • Page 36: Main Board

    2-2 MAIN BOARD MAIN BOARD_Arrangement Diagram(Component Side) Bit 1 Bit 2 Bit 3 Bit 4 DIP SW It indicates the version of the Board.
  • Page 37 MAIN BOARD_Arrangement Diagram (Soldering Side)
  • Page 38 MD[0..31] RA[0..25] MA[0..25] DD[0..63] U_head U_HEAD_FPGA U_SDRAM U_CPU cg1022_head.SchDoc cg1022_HEAD_FPGA.SchDoc cg1022_SDRAM.SchDoc cg1022_CPU.SchDoc U_NW_SDRAM U_ROBI_fpga DD[0..63] DD[0..63] cg1022_NW_SDRAM.SchDoc cg1022_ROBI_fpga.SchDoc MD[0..31] RA[0..25] RA[0..25] ENC_PHA ENC_PHA ENC_PHA MA[0..25] ENC_PHB DQM0 NA[0..25] ENC_PHB ENC_PHB DQM0 DQM0 NA[0..25] NA[0..25] /DAC_RESET DQM1 ND[0..31] /DAC_RESET /DAC_RESET DQM1 DQM1 ND[0..31] ND[0..31]...
  • Page 39 MA[0..25] VCC3 VCC3 VCC3 VCC3 VCC3 VCC3 VCC3 VCC3 VCC3 MA[0..25] MD[0..31] PC21 PC29 PC37 PC38 PC216 PC218 PC229 PC223 MD[0..31] VCC3 TXD2 RA15 CE0.1u CE0.1u CE0.1u CE0.1u CE0.1u CE0.1u CE0.1u CE0.1u CE0.1u TXD2 RA16 VCC3 VCC3 RA17 RA14 RA24 RA32 RA40 VCC3...
  • Page 40 DD[0..63] DD[0..63] VCC3 VCC3 SDBK[0..2] MD[0..31] RA[0..25] LAB/BA /LOE MD[0..31] RA75 33ohm/1005 A[0..25] IC13 IC20 RA76 33ohm/1005 IC24 VCC3 DD48 DD32 DD16 R205 SDBK0 DD49 DD33 DD17 EXBV8V330JV DD50 DD34 DD18 R204 No Mount SDBK1 DD51 DD35 DD19 CE0.1u DD52 DD36 DD20 R208...
  • Page 41 VCC3 R171 /F0_INTREQ /ALT_STATUS /ALT_RESET /ALT_DCLK /ALT_DATA /ALT_CONF_DONE /ALT_CONFIG RA72 EXBV8V103JV VCC3 DB[0..15] DB[0..15] /SENSOR /PANEL VCC3 VCC3 VCC3 VCC3 VCC3 VCC3 VCC3 VCC3 VCC3 PC93 PC94 PC95 PC98 PC99 PC111 PC114 PC115 CE0.1u CE0.1u CE0.1u CE0.1u CE0.1u CE0.1u CE0.1u CE0.1u VCC3 /SW0...
  • Page 42 IC42 LLAT0 R149 R343 FL36 EXCML16A270U LAT0 LAT0 /ALT_RESET LLAT1 R148 R342 FL21 EXCML16A270U LAT1 /ALT_RESET LAT1 /RRD LLAT2 R147 R341 FL12 EXCML16A270U LAT2 /RRD LAT2 /FPGA_WE DAC[0..9] LLAT3 R146 R340 FL35 EXCML16A270U LAT3 /FPGA_WE DAC[0..9] LAT3 CCH0 R145 R339 FL37 EXCML16A270U /CCS5...
  • Page 43 TP335 RA80 R371 PC128 EXBV8V103JV NoMount CE0.1u C255 C254 C253 C252 CN23 IC11 RTC_WDATA RTC_DATA IC45 CE100p CE100p CE100p CE100p RTC_WDATA RTC_DATA RA82 RTC_CLK EXT_OUT0 TP351 RTC_CLK EXT_OUT0 RTC_CE EXT_OUT1 TP344 RTC_CE /INT EXT_OUT1 EXT_OUT2 FOUT EXT_OUT2 VCC3 D2 1SS355 EXT_OUT3 TP348 TP217...
  • Page 44 DAC[0..9] VHV0 VHV0 CN17 DAC[0..9] +41V IC22 CN19 VHV0 DAC0 VCC45 PC131 COM0 DAC1 TR13 CE0.1u DAC2 2SC2873 DAC3 PC257 COM0 NPNB 22u_50V 01543.15DR DAC4 CE0.1u VHV1 DAC5 COM0 PNPB R106 R110 B4P-VH PC130 PC129 DAC6 TR14 DAC7 2SC4131 COM0 VCC5 1ohm CE0.1u...
  • Page 45 VCC3 VCC3 VCC3 VCC3 DD[0..63] ND[0..31] NA[0..25] DD[0..63] ND[0..31] PC10 NA[0..25] PC19 PC26 CE0.1u CE0.1u CE0.1u CE0.1u IC30 RA[0..25] IC31 RA[0..25] LAB/BA /LOE LAB/BA /LOE RA60 EXBV8V330JV RA62 EXBV8V680JV VCC3 RA64 EXBV8V330JV RA66 EXBV8V680JV R213 R129 ND10 DD10 ND11 Cmd_StoM RRXD DD11 RA73...
  • Page 46 FPGA Power VCC3 IC44F Power Supply VCC3 all pin functions are com mon between VCCIO1 3C5, 3C10, 3C16, 3C25 unless otherwise noted VCCIO1 CB28 CB29 Place on bottom side under FPGA CE0.1u CE22u VCCIO2 VCCIO2 VCCIO3 VCCIO3 Place on bottom side under FPGA CB30 CB31 CB32...
  • Page 47 SDRAM IC44C NA[0..25] Bank 3+4 IC50 VREF B3N0 / I O xSDR_A0 xSDR_D0 VREF B4N0 / I O xSDR_A1 xSDR_D1 xSDR_D12 xSDR_A2 xSDR_D2 xSDR_D11 xSDR_A3 xSDR_D3 xSDR_WE xSDR_A4 xSDR_D4 LED_0 xSDR_A5 xSDR_D5 VREF (3C16 only ) LED_0 xSDR_A8 xSDR_A6 xSDR_D6 xSDR_DQM1 xSDR_A7 xSDR_D7...
  • Page 48 Power-up / reset setting for S trapping O ptions VCC3 PHYAD2 MII_RXD1P R181 1.0K PHYAD1 MII_RXD2P R182 1.0K PHYAD0 MII_RXD3P R183 1.0K CONFIG2 MII_RXDVP R184 1.0K CONFIG1 MII_CRS R185 1.0K CONFIG0 MII_COLP R186 1.0K MII_RXERP 1.0K SPEED NACT_LED R188 1.0K RA86 MII_RXDV MII_RXDVP...
  • Page 49 VCC3 SERIALIZATION & DEBUG CONNECTOR R200 SPI Serial Flash Brecis Nios2 Brecis VCC3 CY2_TDO 3.3V 3.3V JTAG_TDO SE_SW_CS SPI_NCS /SE_HOLD /SE_CS SE_BOOT_CS NMRES SPI_D IC51 SE_D SE_D TP22 R226 DIAG5V SPI_Q SPI_NCS SE_Q SE_Q UART_TX SPI_CLK SPI_D SPI_Q No Mount S_TX S_TX SE_CLK...
  • Page 50 ROBI interface at FPGA IC44E NA[0..25] NA[0..25] Bank 7+8 VREF B7N0 ND[0..31] VREF B8N0 ND[0..31] ND15 ND14 VREF (3C16 only ) ND13 ND12 Bank 7 ND11 ND10 RB_SENSE_A RB_NRDY TP25 RB_NBS RB_NBS RB_SENSE_B R244 TP26 ND23 ND24 ND22 ND25 ND21 ND26 ND20 Bank 8...

  • Page 51: Servo Board

    2-3 SERVO BOARD SERVO BOARD_Arrangement Diagram (Component Side) 2-18...
  • Page 52 SERVO BOARD_Arrangement Diagram (Soldering Side) 2-19...
  • Page 53 TP409 DDA_StoMExtin VCC3 DDA_StoMExtin IC15 VCC3 DTC114EK /Cmd_StoM_out DDA_CLK VCC3 R120 /Cmd_MtoS_ /Cmd_HS_StoM_out /Cmd_HS_MtoS IC20 IC19 SEL-6414E DDA_MtoS HC49/U-S 8MHZ CE0.1u RA11 I/O0 I/O0 INTDDA TP19 I/O1 I/O1 EXBA10E103J CE0.1u I/O2 I/O2 I/O3 I/O3 I/O4 I/O4 CE27p CE27p Slow_Power_On TP412 I/O5 I/O5 1.8K...
  • Page 54 VCC3 C107 CE0.22u/50V CE0.1u + C5 C105 100u/63V CE0.22u/50V IC6A DAN217U Y_En_Pha C104 Y_En_Pha CE0.22u/50V C106 C111 74LVC14 CE0.01u CE1u/25V IC6B TP69 TP77 TP76 Scan_Encoder_Phase_A Scan_Encoder_Phase_B Y_En_Phb Y_En_Phb TP72 Y_PWM+ Y_PWM+ Y_PWM- FL18 74LVC14 Y_PWM- EXBV8V102J Sol_PWM+ EXCML20A390U Sol_PWM+ R5 0.1ohm/1W Scan_Motor+ IC6C TP78...
  • Page 55 TP42 TP41 IC12 VMTD FANPWM1 FANPWM1 FANPWM2 IC17 FANPWM2 /CropOn /Crop_ON@ CE0.1u MTD2005-7101 CE0.22u/50V VMTD /CropOn /Crop_ON@ /MTD_En0 CE0.22u/50V /MTD_En0 TP14 TP16 TP24 VMMA /MTD_En1 /MTD_En1 VMMB /MTD_En2 /MTD_En2 DG1S6 FL16 /MTD_En3 /MTD_En3 Stp0APh OUT1 Stp0BPh OUT2 EXCML20A390U Stp0Decay DECAY OUT3 DG1S6 TP18...
  • Page 56 +41V +VHEAD 2SJ553S +41V R158 C109 +41V 1K/0.5W CE1000p R155 To MAIN BOARD To SW POWER SUPPLY R154 R153 B4P-VH 2.2K/0.5W B6P-VH + C2 1000u/63V Head_Power_On DTC114EK DTC114EK Head_Slow_Power_On +24V VCC3 CN405 VMTD To SW POWER SUPPLY 11CT 3.15A R152 DE3L20U-7061 +41V 5267-05A...
  • Page 57 2-4 CARRIAGE BOARD CARRIAGE BOARD_Arrangement Diagram (Component Side) 2-24...
  • Page 58 VHV0 +5 +3.3 VHV0 VHV0 VHV0 COM1A To LINEAR ENCODER CE0.1u LED1 PRINT CARRIAGE BOARD COM1A 47u_16V CE0.1u CE0.1u 47u_16V 10u_50V BOARD COM1A SEL6410E COM1A +3.3 CE0.1u COM2B enc_phA TP12 CN10 enc_phA enc_phB TP11 COM2A 53261-04 enc_phB CE0.1u NCHG Head_TH head_th from MAIN BOARD CN17 CE1000p...
  • Page 59 CARRIAGE BOARD_Circuit Diagram 2/2 CUT CARRIAGE BOARD C104 CE0.1u IC100A BA-10358F CN100 CN101 So1+ To SOLENOID So1- So1+ B2B-PH-K-S So1- CN103 To SERVO BOARD Pi nchPos PinchPos PINCH POS SENSOR / Cr op_O N Cr opSens C106 R101 NoMount R100 IC100B 53398-04 CE0.1u...

  • Page 60: Sub Board

    2-5 SUB BOARD SUB BOARD_Arrangement Diagram (Component Side) 2-27...
  • Page 61 IC502A IC503D TC74VHC32FT TC74VHC14FT PANEL BOARD IC500 RIVET1 RIVET2 RIVET3 RIVET4 TC74VHCT574AFT C500 NoMount IC503B TC74VHC32FT R514 P2655B P2655B P2655B P2655B LED505 BUSY R512 C507 R508 LCD1 CE100p C508 Q507 IC503A TC74VHC32FT SEL6410E 47u_16V R513 DTD113EK R505 WDH0087-YGH-JT#01 C506 CE100p TC74VHC32FT IC503C CN500...
  • Page 62 SUB BOARD_Circuit Diagram 2/4 POWER BOARD to SWPower Supply to Power SW CN1101 CN1102 B2P3-VH B2(4-2 3)P -VH CN1103 to Print Thermostat CLIP P FC-5000-0202 CLIP P FC-5000-0202 FS1100 B2P-VH CN1104 5X20 021706.3MXP 6.3A/250V FS1101 to Print Heater 1 5X20 021706.3MXP 6.3A/250V SSR1100 RELAY,SSR AQ1208 B2P3-VH...
  • Page 63 +3.3 INK TANK BOARD +3.3 to MIX PUMP +3.3 53014-05 53398-10 +3.3 CN17 EXBA10E103J INK_Exist_0 TP12 +3.3 1SS355 Ink_Emputy_0 To Ink 1 /RESET 47u_16V 47u_16V 292132-4 2.2u_50V CN16 INK_Exist_1 EXBV8V101JV CN18 To Ink 2 Ink_Emputy_1 to PINCH U/D SENSOR 292132-4 5267-03 CN15 +3.3...
  • Page 64 JUNCTION BOARD NoMount R901 NoMount CN902 CN900 MAINTENANCE COVER_R RESERVE R900 D900 NoMount (1SS355) (53014-03) (53014-04) Q900 CN908 NoMount DTC114EK to RELAY BOARD R902 RELAY900 NoMount NoMount NoMount CN909 D902 NoMount D903 RELAY901 (5267-02) (10K) NoMount (G5NB-1A) NoMount NoMount (D1FL20U) (D1FL20U) (G5NB-1A) (to PINCH U/D)

  • Page 65: Replacement Of Main Parts

    3 Replacement of Main Parts To Ensure safe Work Turn off the Sub Power SW, Main Power SW, and unplug the power cable of the Printer and deodorization equipment before performing parts replacement. Performing the parts replacement while the power is on may result in injury by unintended operation of the machine.
  • Page 66 The necessary adjustments after the replacement of each part, and the referential time for each work are described as follows. 3-1 HEAD REPLACEMENT : 20min. 1. THERMISTER CHECK It can be checked in the SERVICE MENU>[THERMISTOR CHK]. 2. HEAD ALIGNMENT 3.
  • Page 67 3-11 MAIN BOARD REPLACEMENT (In case that the parameters can be transferred by Peck.) : 35 min. 1. BATTERY INSTALLATION 2. FIRMWARE INSTALLATION 3. SYSTEM PARAMETER INITIALIZE 4. IP ADDRESS SETTING Start the machine with the Service Mode and set in the User Menu. 5.
  • Page 68 OTHER BOARDS CUTTING CARRIAGE BOARD REPLACEMENT : 7min. 1. TOOL UP/DOWN CHECK 2. PINCH ROLLER SENSOR CHECK 3. CROP MARK SENSOR ADJUSTMENT 4. CROP-CUT ADJUSTMENT Adj. Time : 23min Total Time : 30min. CARRIAGE BOARD REPLACEMENT : 10min. 1. HEAD UP/DOWN SENSOR CHECK It can be performed in the SERVICE MENU>[SENSOR CHECK].

  • Page 69: Head Replacement

    3-1 HEAD REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power Be sure to turn off the main power when replacing the head. The Head or Main Board could break, oth- erwise. It is recommended to disconnect the power cord.
  • Page 70 Disconnect all Head Ribbon Cables from the Head. Put the disconnected Head Ribbon Cables underneath the Carriage Board. Unhook the Head Cover from the Head. <Left> <Right> Hook Hook Open the Wire Saddles for bundling the ink tubes and pull the ink tubes toward you.
  • Page 71 Pull up the Damper, the ink tubes and the Head Covers slow- ly with opening the Hook of the Head Cover. Do not touch the valve of the Damper. When you touch the valve, Valve the ink leaks from the Damper.
  • Page 72 Fix the Damper, the ink tubes and the Head Cover set to the new Head. Tu r n t h e h e a d rank label to the Head rank left and fix the Label Head. D o n o t t o u c h t h e valve of the Damper.
  • Page 73 Fix the Head with the screws as shown in the fi gure. <Left> You do not have to care about the order for fi xing the screws. <Right> Use the 6kgf·cm torque driver (ST-056) and the Screw hexagonal bit (1000006902 TOOL,BIT HEXAGO- NAL ST-118) to tighten up the screws.
  • Page 74 Turn on the Main Power SW, and then turn on the Sub Power SW while pressing the left, right and down keys to enter the Service Mode. In [PRINT MENU]>[HEAD RANK] menu, input the Head SERVICE MENU Rank shown in the fi gure printed on the label on the carton PRINT MENU box of the Head.
  • Page 75 C l e a r t h e H e a d i n f o r m a t i o n . P e r f o r m [ S E RV I C E SERVICE MENU MODE]>[HISTORY MENU]>[HEAD GROUP]>[SHOT HISTORY MENU COUNT 1] to [SHOT COUNT 8]>[CLEAR].

  • Page 76: Damper Replacement

    3-2 DAMPER REPLACEMENT Before replacing the damper, check which ink is fi lled in the damper that you will replace by referring the following image. (CMYKLcLmWHMT) (CMYKLcLmLkWH) (CMYKLcLmLkMT) (CMYK CMYK) (CMYKLcLmLkCL) 3-12...
  • Page 77 Turn on the Main Power SW, and then turn on the Sub Power SW while pressing the left, right and down keys to enter the Service Mode. Close choke valve. Perform [SERVICE MENU] > [I/S MENU] SERVICE MENU > [I/S CONTROL] > [CHOKE VALVE] > [CLOSE] I/S MENU I/S MENU I/S CONTROL...
  • Page 78 Open the Front Cover and move the Tool Carriage with the Head Carriage leftwards to the position where it is not above the Capping Unit. Then, disconnect the Tool Carriage from the Head Carriage. Remove the Carriage Cover. The positions of fi xing screws for the Carriage Cover are at Carriage Cover the left, right and top of the cover.
  • Page 79 Unhook the Head Cover from the Head. <Left> <Right> Hook Hook Open the Wire Saddles for bundling the ink tubes and pull the ink tubes toward you. Wire Saddle Pull up the Damper, the ink tubes and the Head Covers slow- ly with opening the Hook of the Head Cover.
  • Page 80 Pick the both ends of the Damper Joint and remove it from the Damper. Damper Joint Ink leaks from the Damper right after removing the Damper Joint. Pull out the Damper from the Head Cover. Head Cover Damper Insert the new Damper into the Head Cover. Head Cover The Damper has no particular right or left orienta- tion.
  • Page 81 Fix the Damper, the ink tubes and the Head Cover set to the Head with opening the hook of the Head Cover. When you straighten the Damper, the ink tubes and the Head Cover set, you can fi x them easily. Do not touch the valve of the Damper.
  • Page 82 Check whether the Head Ribbon Cables are connected to the correct connectors. Fix the Right Top Cover. Right Top Cover Connect the Tool Carriage to the Head Carriage. Then, move the Head Carriage by hand to the lock position. Turn on the Main Power SW, and then turn on the Sub Power SW while pressing the left, right and down keys to enter the Service Mode.
  • Page 83 Open choke valve. Perform [SERVICE MENU] > [I/S MENU] SERVICE MENU > [I/S CONTROL] > [CHOKE VALVE] > [OPEN] I/S MENU I/S MENU I/S CONTROL I/S CONTROL CHOKE VALVE CHOKE VALVE OPEN ENTER Perform [FUNCTION]>[CLEANING]>[POWERFUL CL.] once. FUNCTION CLEANING CLEANING POWERFUL CL.

  • Page 84: Wiper Replacement

    3-3 WIPER REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power Select [SUB MENU]>[MAINTENANCE]>[REPLACE WIPER] in the Users Menu and press the [ENTER] key. MENU SUB MENU SUB MENU MAINTENANCE MAINTENANCE REPLACE WIPER When the message shown in the fi gure appears, remove the Right Cover.
  • Page 85 Touch the location shown in the fi gure to discharge any static electricity. Detach the Hook to the hole on the Felt Wiper with the twee- zers. When you press the Wiper Frame, it will rotate and you can return it to the original position. Even if you rotate the Wiper Frame and change its position, there is no problem because the machine always detects the wiper origin position after replacing the...
  • Page 86 Attach the Hook and press the part shown in the fi gure with the tweezers. You have to attach the Hook. When you do not at- tach the Hook, the Wiper may be removed during the operation. Fix the Right Cover and press the [ENTER] key.  ...

  • Page 87: Felt Wiper Replacement

    3-4 FELT WIPER REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power Select [SUB MENU]>[MAINTENANCE]>[REPLACE FELT] in the Users Menu and press the [ENTER] key. MENU SUB MENU SUB MENU MAINTENANCE MAINTENANCE REPLACE FELT When the message shown in the fi gure appears, remove the Right Cover.
  • Page 88 Touch the location shown in the fi gure to discharge any static electricity. Detach the Hook to the hole on the Felt Wiper with the twee- zers. When you press the Wiper Frame, it will rotate and you can return it to the original position. Even if you rotate the Wiper Frame and change its position, there is no problem because the machine always detects the wiper origin position after replacing the...
  • Page 89 Attach the Hook and press the part shown in the fi gure with the tweezers. You have to attach the Hook. When you do not attach the Hook, the Felt Wiper may be removed during the operation. Fix the Right Cover and press the [ENTER] key.  ...

  • Page 90: Wiper Scraper Replacement

    3-5 WIPER SCRAPER REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power Remove Right Cover and Right Top Cover. Right Top Cover Right Cover Move the Head Carriage leftwards to the position where it is not above the Capping Unit.
  • Page 91 Remove these connectors. Connectors Remove these screws. Then, remove the Wiper Unit. Screws Remove the Scraper and install new one. Scraper Install the Wiper Unit. Connect the connectors. Fix the Right Under Cover. Right Under Cover 3-27...

  • Page 92: Cap Top Replacement

    3-6 CAP TOP REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power Remove the Right Cover. Right Cover Move the Head Carriage leftwards to the position where it is not above the Capping Unit. Remove the Right Under Cover. Right under Cover 3-28...
  • Page 93 Open the Wire Saddles for bundling the tubes of the Cap Top. Wire Saddle Remove the tubes of the Cap Top from the Pump. Remove the Spring. Do not lose the Spring becasue it is small. Spring Remove the Cap Top with pressing the [T] shape hook down- ward and pull up the Cap Top.
  • Page 94 Fix the new Cap Top by fi tting the [T] shape hook with the Cap Top Base. Groove When you fix the Cap Top, fit the Spring in the Groove on the bottom of the Cap Top. Fix the Spring. Spring Connect the tubes of the Cap Top to the Pump.
  • Page 95 Bundle the tubes of the Cap Top with the Wire Saddles. Bundle the tubes as shown in the fi gure. If you do not bundle the tubes, the ink is not drained correctly. Wire Saddle Move the Head Carriage by hand to the lock position. Turn on the Main Power SW, and then turn on the Sub Power SW while pressing the left, right and down keys to enter the Service Mode.
  • Page 96 Fix the Right Under Cover. Be careful not to pinch the tubes of the Cap Top with the Right Under Cover. Right Under Cover 3-32...

  • Page 97: Tool Carriage Replacement

    3-7 TOOL CARRIAGE REPLACEMENT Remove the following covers in order. 1. Right Cover 2. Front Cover Top Cover 3. Front Rail Cover Left Cover 4. Left Cover 5. Top Cover Front Rail Cover Front Cover Right Cover Separate the Tool Carriage from the Head Carriage. Remove the Tool Carriage Cover.
  • Page 98 Disconnect the Crop Mark Sensor, Pinch Roller Sensor and Solenoid Solenoid wirings. Crop Mark Sensor Cable Pinch Roller Sensor Cable Remove the two screws fi xing the Tool Carriage Board. Tool Carriage Board Remove the two screws to remove the Tool Carriage Board Tool Carriage Board Stay Stay from the Tool Carriage Assy.
  • Page 99 Remove the screws shown in the fi gure and remove the Auto Sheet Cutter from the Tool Carriage. Tool Carriage Be careful not to lose the spring. Screw < Rear side > Auto Sheet Cutter Spring Screw Fix the Auto Sheet Cutter to the new Tool Carriage. Tool Carriage Do not forget to fi...
  • Page 100 Fix the Tool Carriage Assy to the Tool Carriage Board Stay Tool Carriage Board Stay with the two screws as shown in the fi gure. Fix the Tool Carriage Board with the two screws as shown in the fi gure. Tool Carriage Board Connect the Crop Mark Sensor, Pinch Roller Sensor and Solenoid...
  • Page 101 Remove the Tool Carriage Cover. Tool Carriage Cover Perform the following adjustments and settings. 1. [4-4 LIMIT POSITION & CUT DOWN POSITION INITIALIZE] 2. [4-11 TOOL HEIGHT ADJUSTMENT] 3. [4-12 TOOL PRESSURE ADJUSTMENT] 4. [4-7 CROP MARK SENSOR ADJUSTMENT] 5. [4-8 CROP-CUT ADJUSTMENT] 6.

  • Page 102: Carriage Motor Replacement

    3-8 CARRIAGE MOTOR REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power Remove the following covers in order. 1. Right Cover 2. Right Top Cover 3. Chassis Cover 4. Panel Cover 5. Right Under Cover  ...
  • Page 103 Remove the spring on the Flange. Spring Remove the three screws fi xing the Flange, and remove the motor together with the Flange. The fixing direction of one screw near the spring is differ- ent from the others. Remove the three screws shown in the fi gure to remove the motor from the Flange.
  • Page 104 Fix the spring. Spring Unlock the Head Carriage. Turn the Drive Gear by hand to check if the gears mesh to- gether. Tighten up the three screws to fix the Flange in the order shown in the fi gure. 3-40...
  • Page 105 Turn the Drive Gear by hand for short steps back and forth to check if there is no backlash all the way around. Apply a proper quantity of grease (FLOIL G902) to gears of the motor and Drive Gear. Connect the connector of the Motor Cable. Move the Head Carriage by hand to the lock position.
  • Page 106 Fix the Right Frame and Panel Cover. When fixing the Panel Cover, fi x the sensor with the sensor cable and the ribbon cable to the Panel Board. Right Frame Panel Board Perform the SERVO LOCK CHECK. After turning on the Main Power SW, turn on the Sub Power SW while pressing the left, right and down keys to enter the Service Mode.
  • Page 107 Perform the AGING. Go back to the [MOTOR MENU], and select [AGING]>[SCAN] and press the [ENTER] key. Make sure the machine per- SERVICE MENU MOTOR MENU forms AGING and then, fi nish it by pressing [ENTER] key. MOTOR MENU AGING Do not load any media when performing [AGING].

  • Page 108: Feed Motor Replacement

    3-9 FEED MOTOR REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power Remove the following covers in order. 1. Right Cover 2. Right Top Cover 3. Chassis Cover 4. Panel Cover 5. Right Under Cover  ...
  • Page 109 Remove the Grit Encoder Board. Grit Encoder Board Remove the Grit Encoder Stopper. Grit Encoder Stopper Remove the Grit Encoder. Grit Encoder Make sure not to scratch or leave any fi ngerprints on the Grit Encoder. Move the Head Carriage leftwards by hand. 3-45...
  • Page 110 Remove the Inner Cover Inner Cover Remove the screw fixing the Cable Support and make it fl oated. Cable Support Remove the connector CN904 from the Junction Board. Junction Board Remove the spring. Spring 3-46...
  • Page 111 Remove the Motor Cover. Motor Cover Remove the three screws shown in the fi gure and remove the Feed Motor. Pull out the Feed Motor leftward and taking out it from the rear side of the Cap Top unit. Remove the Feed Motor Cable from the connector of the junction cable.
  • Page 112 Remove the three screws as shown in the fi gure to remove the motor from the Flange. And fi x a new motor to the Flange. Be careful with the fi xing direction of the Flange in relation to the motor cables. Connect the Feed Motor Cable to the junction cable.
  • Page 113 Fix the spring. Spring Turn the Drive Gear by hand to check if the gears mesh to- gether. Tighten up the three screws to fix the Flange in the order shown in the fi gure. Turn the Drive Gear by hand for short steps back and forth to check if there is no backlash all the way around.
  • Page 114 Fix the Motor Cover Motor Cover Connect the Feed Motor Cable to CN904 on the Junction Board. Junction Board Fix the Cable Support. Cable Support Fix the Inner Cover. Inner Cover 3-50...
  • Page 115 Move the Head Carriage by hand to the lock position. Fix the 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 fi ngerprints on it. Fix the Grit Encoder Stopper with the three screws while holding the Shaft Grit Encoder Stopper...
  • Page 116 Rotate the Shaft to check that the Grit Encoder does not touch the sensor Shaft Fix the Right Side Frame Stay. Right Side Frame Stay Fix the Right Frame and the Panel Cover. When fixing the Panel Cover, fi x the sensor with the sensor cable and the ribbon cable to the Panel Board.
  • Page 117 In [MOTOR MENU]>[SERVO LOCK] menu, select [F]. Move the Head Carriage left and right by hand and make sure the value on the LCD changes depending on the head SERVICE MENU MOTOR MENU position. MOTOR MENU SERVO LOCK SERVO LOCK F: 140 Press the [ENTER] key to excite the motor.
  • Page 118 Clear the motor working hours. SERVICE MENU G o b a c k t o t h e S e r v i c e M e n u , a n d s e l e c t [ H I S - HISTORY MENU TORY MENU]>[MOTOR GROUP]>[MOTOR HOURS F]>[CLEAR] and press the [ENTER] key.

  • Page 119: Pump Replacement

    3-10 PUMP REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power Remove the Right Cover. Right Cover Move the Head Carriage leftwards to the position where it is not above the Capping Unit. Remove the Panel Cover and the Right Under Cover. Panel Cover When removing the Panel Cover, remove...
  • Page 120 Remove the motor cable from the connector. Remove the tubes of the Cap Top and the drain tube. Remove the two screws fi xing the Pump Unit Stay and take out the Pump Unit. Remove the two screws shown in the fi gure and remove the Pump Unit Stay.
  • Page 121 Remove the three screws shown in the fi gure and remove the motor from the Pump. Then, fi x the new Pump to the motor. Fox the Pump Unit Stay to the Pump with the two screws shown in the fi gure. Pump Unit Stay Fix the Pump Unit with the two screws shown in the fi...
  • Page 122 Connect the motor cable to the connector. Fix the Right Frame and the Panel Cover. Panel Board When fixing the Panel C o v e r, f i x t h e r i b b o n cable to the Panel Board. Right Frame Move the Head Carriage by hand to the lock position.
  • Page 123 Select [SERVICE MENU]>[I/S MENU]>[PUMP CHECK], and perform [PUMP SUCTION] and [PUMP RELEASE] to check the pumps work correctly. SERVICE MENU I/S MENU I/S MENU PUMP CHECK PUMP CHECK PUMP SUCTION PUMP CHECK PUMP RELEASE Clear the pump times. Select [SERVICE MENU]>[HISTORY MENU]>[MOTOR SERVICE MENU GROUP]>[PUMP TIMES]>[CLEAR], and press the [ENTER] HISTORY MENU...

  • Page 124: Board Replacement (Main Board)

    3-11 BOARDS REPLACEMENT (MAIN BOARD) BOARD LAYOUT (IN CHASSIS) POWER BOARD SERVO BOARD MAIN BOARD SW POWER SUPPLY MAIN BOARD REPLACEMENT MAIN BOARD CONNECTOR LAYOUT CN14 CN15 CN17 CN22 CN19 3-60...
  • Page 125 Turn on the 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 SW and pull out the Power Cord. < Rear View > 3-61...
  • Page 126 Remove the Right Cover, the Right Top Cover and the Chas- sis Cover. Chassis Cover Right Cover Right Top Cover Remove the fi ve screws shown in the fi gure. <Top View> Screw Screw Disconnect the cables and release the cables from the clamps.
  • Page 127 Pull out the Chassis to the front side. Chassis Remove the four screws shown in the fi gure to remove the Servo Board. Switch the DIP SW No.3 to ON on the new Main Board. Disconnect the connector and fl exible cable shown in the fi g- ure and fi...
  • Page 128 Fix the Servo Board with the four screws shown in the fi gure. Put back the Chassis. シャーシ Chassis Connect all the cables to the Servo Board. CN400 CN207 CN405 CN11 CN401 CN403 CN402 CN404 Connect the cables and bundle the cables with the clamps. Do not forget CN1108 CN1107...
  • Page 129 Fix the Chassis with the fi ve screws shown in the fi gure. <Top View> Screw Screw Perform the following operations after replacement. 1. BATTERY INSTALLATION Refer to [3-11 BATTERY REPLACEMENT]. 2. FIRMWARE INSTALLATION Refer to [4-2 HOW TO UPGRADE/INSTALL FIRMWARE]. 3.
  • Page 130 Perform the following operations if it is not possible to transfer the parameters by Peck4.exe. 1. BATTERY INSTALLATION Refer to [3-11 BATTERY REPLACEMENT]. 2. FIRMWARE INSTALLATION Refer to [4-2 HOW TO UPGRADE/INSTALL FIRMWARE]. 3. SYSTEM PARAMETER INITIALIZE Refer to [4-2 HOW TO UPGRADE/INSTALL FIRMWARE]. 4.

  • Page 131: Sw Power Supply Replacement

    3-12 SW POWER SUPPLY REPLACEMENT (41V) SW POWER SUPPLY CONNECTOR LAYOUT Connected to the [CN1] and [CN405] on the SER- VO BOARD, and [CN22] on the Main Board Connected to the [CN302] on the Power Board Turn off the Sub Power SW, and then turn off the Main Power SW and pull out the Power Cord.
  • Page 132 Remove the fi ve screws shown in the fi gure. <Top View> Screw Screw Disconnect the cables and release the cables from the clamps. Do not forget CN1108 to disconnect CN1107 t h e c a b l e s CN1106 shown in the CN1105...
  • Page 133 Remove the fi ve screws shown in the fi gure and replace with the new SW Power Supply. Connect all the cables to the SW Power Supply. In case that the volume is accidentally turned around, adjust the output voltage value to +41 +/- 0.1.

  • Page 134: Battery Replacement

    3-13 BATTERY REPLACEMENT Do not recharge, short-circuit, disassembly the lithium battery, nor put it into fi re. It may cause heat, explosion and fi re. Put tape around the lithium battery for insulation for disposal or preservation. It may cause heat, explosion and fi re. Turn off the Sub Power SW, and then turn off the Main Power Remove the Chassis Cover.
  • Page 135 Replace the battery with new one. Socket Battery Be careful with the direction of the battery. Main Board Turn on the Main Power SW, then turn on the Sub Power SW while pressing the left, right and down keys to enter the Service Mode.
  • Page 136 Turn off the Sub Power SW, and then turn off the Main Power Fix the Chassis Cover. Dispose of the battery. 3-72...

  • Page 137: Carriage Belt Replacement

    3-14 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 fi xed without connecting the new belt to the current belt. Turn off the Sub Power SW, and then turn off the Main Power Remove the Covers in order.
  • Page 138 Remove the Tool Carriage Cover. Tool Carriage Cover Remove the four rivets as shown in the fi gure to remove the Tool Carriage Board Cover. Tool Carriage Board Cover Disconnect the Crop Mark Sensor, Pinch Roller Sensor and Solenoid Cable Solenoid wirings.
  • Page 139 Remove the two screws to remove the Tool Carriage Board Tool Carriage Board Stay Stay from the Tool Carriage Assy. Loosen the two fi xing screws as shown in the fi gure. < Top View / Left Side of the BELT > And loosen the Adjustment Screw.
  • Page 140 Slowly pull the belt end which is not connected the new belt Belt Stay until the new one reaches to the Belt Stay. Check that the belt is not twisted. Apply adequate quantity of grease (P/# : 39008297 FLOIL G 902 14KG) to pulleys. <...
  • Page 141 Fix the Tool Carriage Assy to the Tool Carriage Board Stay. Tool Carriage Board Stay Fix the Tool Carriage Board with the two screws as shown in the fi gure. Tool Carriage Board Connect the Crop Mark Sensor, Pinch Roller Sensor and So- Solenoid Cable lenoid wirings.
  • Page 142 Fix the Tool Carriage Cover. Tool Carriage Cover Move the Head Carriage in a whole width of the Guide Rail several times to remove the slack in the Carriage Belt. Then, carry out the following adjustments. 1. [4-13 BELT TENSION ADJUSTMENT] 2.

  • Page 143: Encoder Scale Replacement

    3-15 ENCODER SCALE REPLACEMENT Remove the Covers in order. Ink Cartridge Cover 1. Right Cover 2. Left Cover Top Cover 3. Front Cover 4. Right Top cover Left Cover 5. Front Rail Cover Right Top Cover 6. Top Cover Front Rail Cover 7.
  • Page 144 Put the Encoder Scale in between the Encoder Plate and the Encoder Scale Guide Rail. Then, fi x the right end with the plate and hook up the spring on the left end. Make sure that the Encoder Scale is in place. Guide Rail Encoder Plate Do not loosen or tighten the screws fixing the...

  • Page 145: Grit Encoder Replacement

    3-16 GRIT ENCODER REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power Remove the following covers in order. 1. Right Cover 2. Right Top Cover 3. Chassis Cover 4. Panel Cover 5. Right Under Cover  ...
  • Page 146 Remove the Grit Encoder Board. Grit Encoder Board Remove the Grit Encoder Stopper. Grit Encoder Stopper Remove the Grit Encoder. Grit Encoder Make sure not to scratch or leave any fi ngerprints on the Grit Encoder. Fix a new Grit Encoder. Grit Encoder The both sides of the Grit Encoder is the same.
  • Page 147 Fix the Grit Encoder Stopper with the three screws while holding the Shaft Grit Encoder Stopper Fix the Grit Encoder Board together with the stay so that the Grit Encoder is in between the gap of sensor. Grit Encoder Board Adjust the position of the sensor so that the clearance with...
  • Page 148 Check the GRIT ENCODER. SERVICE MENU Go back to the [MOTOR MENU], and select [G-ENC. MOTOR MENU CHECK] and press the [ENTER] key. Make sure the Grit Encoder functions correctly by confi rming the display shows [G-ENC. CHECK COMPLETED]. MOTOR MENU G-ENC.

  • Page 149: Pinch Roller Replacement

    3-17 PINCH ROLLER REPLACEMENT Conical type is used on both left & right Pinch Rollers and fl at type is used for the Middle Pinch Rollers. Left Pinch Roller Right Pinch Roller The marking is done on the outer side of left and right Pinch Rollers.

  • Page 150: Cutter Protection Replacement

    3-18 CUTTER PROTECTION REPLACEMENT Open the Front Cover and remove the Cutter Protection. Cutter Protection Wipe and remove the adhesion on the Bed with alcohol. Install the Cutter Protection from 1mm from right edge Cutter Protection of the Bed. Make sure that the Cutter Protection is not bumpy. Cutter Protection 3-86...

  • Page 151: Cut Ribbon Cable Replacement

    3-19 CUT RIBBON CABLE REPLACEMENT Remove the following covers in order. Top Cover 1. Right Cover Chassis Cover 2. Right Top Cover Right Top Cover 3. Chassis Cover Left Cover 4. Front Cover 5. Front Rail Cover Front Rail Cover 6.
  • Page 152 Remove the Cable Holder and disconnect the Cut Ribbon Cable from the Carriage Board. Cut Ribbon Cable Cable Holder Remove the three screws shown in the fi gure and remove the Cable Support. Cable Support Remove the two Cable Holders at the rear side of the machine.
  • Page 153 Remove the 12 rivets fi xing the Cut Ribbon Cable and Cable Holder shown in the fi gure. Disconnect the Cut Ribbon Cable from the Servo Board and take out it from the Cable Guides. Cable Guide Cable Guide Cut Ribbon Cable 3-89...
  • Page 154 Connect the Cut Ribbon Cable to the Servo Board and put it between the Cable Guides. Make the Cut Ribbon Cable to have one curl for VS-540i/300i. VS-640i doesn't need the curl. Put the Cut Ribbon Cable rightward with holding the Inner Cable Guide so that the Cut Ribbon Cable fi...
  • Page 155 Fix the Cable Holders shown in the fi gure. Fix the Cable Holder and connect the Cut Ribbon Cable to the Carriage Board. Cut Ribbon Cable Cable Holder Connect the Tool Carriage to the Head Carriage by hand. Move the Head Carriage in a whole width of the machine and check whether the Cut Ribbon Cable does not jam.
  • Page 156 Fix the Cable Support with the three screws shown in the fi g- ure. Cable Support Fix the Tool Carriage Board Cover with the four rivets shown in the fi gure. Tool Carriage Board Cover Fix the Tool Carriage Cover. Tool Carriage Cover 3-92...

  • Page 157: Linear Encoder Board Replacement

    3-20 LINEAR ENCODER BOARD REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power Remove the following covers in order. Top Cover 1. Right Cover 2. Right Top Cover Chassis Cover 3. Chassis Cover Left Cover Right Top Cover 4.
  • Page 158 Remove the two rivets fi xing the Print Junction Cover. Print Junction Cover Disconnect all Head Ribbon Cables which are fi x to the Print Carriage Board. Remove four screws fi xing the Print Carriage Board. Disconnect the Linear Encoder Board Cable and the Head Up Down Sensor Cable from the Print Carriage Board.
  • Page 159 Remove the Linear Encoder Board with the Stay by erecting the Print Carriage Board as shown in the fi gure. Linear Encoder Board with the Stay Remove the Linear Encoder Board from the Stay. Then, fi x the new the Linear Encoder Board to the Stay Linear Encoder Board Stay Fix the Linear Encoder Board with the Stay by erecting the...
  • Page 160 Fix the Print Carriage Board with the four screws shown in the fi gure. Connect all Head Ribbon Cables to the Print Carriage Board. Fix the Print Junction Cover with the two rivets shown in the fi gure. Print Junction Cover Remove the Carriage Cover.
  • Page 161 Move the Head Carriage in a whole width of the machine. Make sure that the Encoder Scale doesn't make contact with the Encoder Module and also Encoder Scale is between the slit of the Encoder Module again. Carry out the [4-5 LINEAR ENCODER SETUP]. 3-97...

  • Page 162: How To Fold Ribbon Cable To The Head

    3-21 HOW TO FOLD RIBBON CABLE TO THE HEAD These procedures are for the ribbon cables to the Head. The ribbon cable and the procedure are different from each connector. Refer to the following list and procedures and fold the ribbon cables. Connector A : 1000006702 CABLE-CARD,29P1 256L BB HIGH-V Connector B : 1000006702 CABLE-CARD,29P1 256L BB HIGH-V Connector C : 1000006703 CABLE-CARD,29P1 276L BBR HIGH-V...
  • Page 163 <Connector B : 1000006702 CABLE-CARD,29P1 256L BB HIGH-V> <Connector B : 1000006702 CABLE-CARD,29P1 256L BB HIGH-V> Place the ribbon cable whose plain side faces up. Plain side There is no difference between left and right direc- tion. Fold the ribbon cable with 90 degree at the 18 +/-3 mm point 18 +/- 3mm from the left end.
  • Page 164 <Connector C : 1000006703 CABLE-CARD,29P1 276L BBR HIGH-V> <Connector C : 1000006703 CABLE-CARD,29P1 276L BBR HIGH-V> Place the ribbon cable whose plain side faces up. Plain side The black band should be placed at the left side. Black Band Fold the ribbon cable with 90 degree at the 18 +/-3 mm point 18 +/- 5mm from the left end.

  • Page 165: Ribbon Cable (Main Board To Carriage Board) Replacement

    3-22 RIBBON CABLE (MAIN BOARD TO CARRIAGE BOARD) REPLACEMENT Turn off the Sub power SW and the Main Power SW. You do not need to perform [PUMP UP]. Remove the following covers in order. 1. Right Cover Top Cover Chassis Cover 2.
  • Page 166 Remove the Front Cover Sensor Plate from the Frame by re- moving the two screws shown in the fi gure. Plate Remove the Right Support Frame shown in the fi gure. Right Support Frame Screws 3-102...
  • Page 167 Remove the Cut Cable Guide by removing the three screws Cut Cable Guide shown in the fi gure. Move the Tool Carriage and the Head Carriage leftwards to the position where it is not above the Capping Unit. Then, disconnect the Tool Carriage from the Head Carriage. 3-103...
  • Page 168 Remove the Carriage Cover. The positions of screws for fi xing the Carriage Cover are at Head Carriage Cover the left, right and top of the Carriage Cover. Open all Wire Saddles fi xing the Ink Tubes shown in the fi g- ure.
  • Page 169 Move the Ink Tubes with the Tube Guides rightward and re- Carriage Board move the Ribbon Cables from the Carriage Board. Remove the Ribbon Cables from the Main Board and remove Cable Clamp the Cable Clamp from the Ribbon Cables. Main Board Remove the Ferrite Core from the Ribbon Cables.
  • Page 170 Remove the Boards fi xed to the Ribbon Cables and remove the Ferrite Core from the Ribbon Cables. Board Ferrite Core Board Remove the Ferrite Core from the Ribbon Cables and take out the Ribbon Cables from the machine. Ribbon Cable Character Side Ferrite Core...
  • Page 171 Fold the new Ribbon Cable by referring the figure below. The position to fold the Ribbon Cable is different depending on the position to fi x the Ribbon Cable to the Carriage Board. There is no difference between left and right direc- tion.
  • Page 172 Locate the Ribbon Cables among the Cable Holders, the Holder Cable Sheets and the Holder Cable Plate. Ribbon Cable Character Side Connect the Ribbon Cables to the Carriage Board. Carriage Board Fix the Ink Tubes with the Tube Guides to the Holder and the Plate.
  • Page 173 Confi rm the Ribbon Cables, the Cable Holders, the Holder Cable Plate and the Holder Cable Sheets to the Tube Guides by referring the following fi gures. Cable Holder Ribbon Cable x 1 Holder Cable Sheet x 2 Ribbon Cable x 2 Cable Holder Holder Cable Plate Tube Guide...
  • Page 174 Pull out the Ribbon Cables from the Bush shown in the fi gure Ferrite Core and fi x them with the Board. Board And, move the Ferrite Core to the position shown in the fi g- ure. Bush Pull out the Ribbon Cables to the position near the Scan Mo- tor and fi...
  • Page 175 Close the four Clamps shown in the fi gure. Clamp Hook the Cable Tie to the Cable Clamp and close the Cable Clamp to cover the Ferrite Core. Cable Clamp Ferrite Core Cable Tie Move the Head Carriage to the position of the right fi gure. Then, check the clearance between the Ink Tube and the Guide Cable Support is more than 6mm.
  • Page 176 Move the Head Carridge to the capping position. Then, open the clamps that bundle the Ink Tube. Pull and move the Ink Tubes to the Print Head side. If the cable tie is extremely loosen, tighten it. Be careful not to make it too tight. 3-112...
  • Page 177 Fix the Ink Tubes with the clamps.    Perform 31 step [Checking the clearance] again. Fix the Cut Cable Guide with the three screws shown in the fi gure. Cut Cable Guide If the Head Carriage is not locked, lock it. Fix the Right Support Frame shown in the fi...
  • Page 178 Fix the Plate to the Right Cover Sensor shown in the fi gure. Plate Fix the Cut Cable Support shown in the fi gure. Cut Cable Support 3-114...
  • Page 179 Move the Head Carriage to the width of the machine manu- ally to check that the Tube Guides make physical contact with the Rail. When the Tube Guides make physical contact with the Rail, remove the Ink Tubes with the Tube Guides from the Cable Holder Plate and the Sup- port Frame.

  • Page 180: Adjustment

    4 Adjustment To Ensure safe Work Turn off the Sub Power SW, Main Power SW, and unplug the power cable of the Printer and deodorization equipment before performing parts replacement. Performing the parts replacement while the power is on may result in injury by unintended operation of the machine.

  • Page 181: Service Mode

    4-1 SERVICE MODE MENU + POWER ON [ MENU ] key SERVICE MENU SERVICE MENU PRINT MENU HEAD RANK This menu is used for entering the Head Rank for each head with 24 digit number and alphabet. PRINT MENU HEAD RANK 12345678 (1/3) The digits can be changed with [ ] and [...
  • Page 182 PUMP SUCTION NOW PROCESSING.. I/S MENU PUMP CHECK PUMP CHECK PUMP SUCTION PUMP SUCTION NOW PROCESSING.. CIR-PUMP PUMP RELEASE PUMP CHECK NOW PROCESSING.. PUMP RELEASE PUMP RELEASE NOW PROCESSING.. CIR-PUMP This is for checking the pump motor. The rotation for both ink suction and release can be checked. Pump motor rotates for 5 seconds and stop.
  • Page 183 CARTRIDGE SL1 : SERIAL Serial No. of the Ink Cartridge IC is displayed. SLOT 1 1402A30C010000A5 SL1 : INK TYPE Ink type of the Ink Cartridge IC is displayed. Max K SL1 : CAPACITY Ink capacity of the Ink Cartridge IC is displayed. 200cc SL1 : LOT NO.
  • Page 184 PRINT-CUT ADJ. CUTTING MENU PERFORMING This test pattern is for adjusting the print & cut TEST PRINT TEST PRINT PRINT-CUT ADJ. position. It prints three square Crop Marks along the scan direction and cuts the contours of the marks. PRINT-CUT ADJ. When it shows [ ], it means that it has never F:+0.30 +0.30mm...
  • Page 185 EMPTY SUB MENU SET SOLCL-LIQUID SET DUMMY CRT. REMOVE SOL CRT. DRAIN BOTTLE HEAD WASH 12345678 12345678 123456 Goes next, after pressing ENTER REMOVE CARTRIDGE SET CL-LIQUID 12345678 12345678 Goes next, when cartridge is removed Goes next, when cleaning cartridge is set EMPTY REMOVE DUMMY CRT SET SOLCL-LIQUID...
  • Page 186 CLOCK DATE DATE SUB MENU DATE 09/01/15 09/01/15 CLOCK 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 01:01:59 01:01:59 battery is dead. 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 187 The heater does not operate when the machine is started in Service Mode. SVC.MODE HEAT. SERVICE MENU HEATER MENU Set [START] here when the heater needs to be on. [START] is canceled once the HEATER MENU SVC. MODE HEAT. STOP >...
  • Page 188 HISTORY MENU MOTOR　GROUP Item Contents Unit Reference MOTOR HOURS F Total time that the Feed Motor has been rotated. hour MOTOR HOURS S Total time that the Scan Motor has been rotated. hour Life: 3000 hours PUMP TIMES Total time that the Pump Motor has been rotated. times Life: 200,000 times PUMP TIMES CIR...
  • Page 189 CUTTING GROUP Item Contents Unit Reference CUTTING TIME Total time of cutting performed. hour Test print time is excluded. Disconnection of Tool Carriage and Head DISCONNECT Number of times the carriage has been disconnected. times Carriage. CLEAR　ALL Clear all the value in the CUTTING GROUP. INK GROUP　...
  • Page 190 Turn on the Sub Power SW while MENU pressing [ ] key to start the machine in the service report printing mode. Roland DG Corp. The service report will be printed VS-640 automatically when the media is set up. It prints with Black ink. MENU LANGUAGE...
  • Page 191 Key Combinations Function for Service Combination Key Selection Comments Press [MENU] and [ ] to enter Service Service Mode Menu. "[UPDATE FIRMWARE?] will be displayed. F/W Upgrade Mode Press [ENTER] to upgrade F/W." Use this when the Main Board is replaced. F/W Installation Mode for a brand-new Main Board "[SUM-ERROR] will be displayed.

  • Page 192: How To Upgrade/Install Firmware

    4-2 HOW TO UPGRADE/INSTALL FIRMWARE It is necessary to prepare the followings to upgrade/install the fi rmware. 1.Firmware fi le 2.WindowsPC (Network port is required.) 3.Peck.exe 4.Network cable (A cross cable is required when you connect the printer to PC directly.) HOW TO UPGRADE FIRMWARE (Referential Time : 5 min) Check the IP address of the printer.
  • Page 193 Start the Peck. [Peck] screen is displayed, and click [Select Port] button. Select [Type4 SPi,VS etc.] from [Product]. Also, select [Via Network] and input IP ad- dress of the printer. Click [OK] button. [Peck] screen is displayed again. Click [Firmware Upgrade] button. [OPEN] screen is displayed.
  • Page 194 The machine goes into the Firmware Upgrade mode automatically. FIRMWARE V3.0 DATA ERROR When upgrade is completed, the Sub Power SW 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 fi...
  • Page 195 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 ad- dress, press [ENTER] key to go next address setting. MENU When [GATEWAY ADDR.] is set, it returns to the waiting mode for receiving the fi...
  • Page 196 [Peck] screen is displayed again. Click [Firmware Upgrade] button. [OPEN] screen is displayed. Select the fi rmware le and click [Open]. The fi rmware will be sent to the printer. It starts loading the fi rmware. The firmware installation is completed when FIRMWARE V3.0 DATA ERROR...
  • Page 197 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 198 Start the Peck on PC. [Peck] screen is displayed, and click [Put Parameters] button. [OPEN] screen is displayed. Select the System Parameter le that is saved before the Main Board replacement. Click [Open]. Peck starts to send the System Parameter to the printer.

  • Page 199: Head Alignment

    4-3 HEAD ALIGNMENT (Referential Time : 15 min.) 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, fi ne lines and gap between bands could occur. The PET-G is required for this alignment.
  • Page 200 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 Select [PRINT MENU]>[HEAD ADJUST]>[BIAS]>[TEST SERVICE MENU PRINT] and press [ENTER] key. PRINT MENU [ ] [ ] PRINT MENU...
  • Page 201 Insert the 1.5 mm Hexagonal Wrench through the hole of the Head Carriage, then turn the Adjustment Screw to make the lines of each color in the test pattern straight. Position of the printing moves one line by turning the screw 1/4 turn.
  • Page 202 [BIDIRECTION ADJUSTMENT] SERVICE MENU Select [PRINT MENU]>[HEAD ADJUST]>[BI-DIR. DEFAULT] PRINT MENU >[TEST PRINT] and press [ENTER] key. [ ] [ ] PRINT MENU HEAD ADJUST HEAD ADJUST Loosen the screws fi xing the head for 1/2 turn. BI-DIR.DEFAULT If the screws are loosened too much, the adjustment cannot be done correctly.

  • Page 203: Limit Position & Cut Down Position Initialize

    4-4 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 204 Confi rm that the head is capped properly, and press [ENTER] SETTING UP key. The Tool Carriage will be separated from the Head Car- THE LIMIT riage and the limit position initialize will start. After initialize is completed, the message is displayed. DETECTING..

  • Page 205: Linear Encoder Setup

    4-5 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 op- eration environment. This operation is required when Limit Sensor, Encoder Scale or Encoder Module is replaced or the position is adjusted.
  • Page 206 One of the messages appears at the completion of the set up. In case of Setup error, check the followings. LINEAR ENCODER Dirt/Scratch on the Encoder Scale. 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 207: Flushing Position Adjustment

    4-6 FLUSHING POSITION ADJUSTMENT (Referential Time : 5min.) This is to adjust the fl ushing position. Without this adjustment, the Flushing may not be performed properly. Turn off the Sub Power SW, and then turn off the Main Power The Head height should be set LOW. High Remove the Right Cover.
  • Page 208 Remove the Right Under Cover and lock the Head Carriage. Right under Cover Turn on the Sub Power SW while pressing [ ], [ ] and ] keys to enter the Service Mode. MENU MENU SERVICE MENU Select [PRINT MENU]>[FLUSHING ADJ.], and press [EN- TER] key.

  • Page 209: 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 adjust- ment.
  • Page 210 Remove the four rivets as shown in the fi gure for removing the Tool Carriage Board Cover. ツールキャリッジボードカバー Turn on the Sub Power SW while pressing [ ], [ ] and ] keys to enter the Service Mode. Setup the SV-GG on the machine. MENU MENU SERVICE MENU...
  • Page 211 If the MAX voltage is not proper, refer to the voltage dis- played in [ ] on the lower screen. Adjust the VR on the Tool Carriage Board so that the voltage in [ ] to be 2.7 +/-0.2V. Because of the ink dry, the voltage displayed in [ ] decreases in time.

  • Page 212: Crop-Cut Adjustment

    4-8 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 cut- ting 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 213 From the test pattern, find the value where the print line <TEST PATTERN> matches the cut line. - .0 In this case, the correction value for the scan direction is Correction-value scale "- 0.3". - .0 If it is diffi cult to see the cut line visually, use a mag- -0.0 Scan nifi...
  • Page 214 Adjustment is completed if the position error of cut line is within +/-0.1mm. If not, select [SETTING] menu again for fur- CUTTING MENU ther 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 215: Print/Cut Position Adjustment

    4-9 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 216 From the test pattern, find the value where the print line <TEST PATTERN> matches the cut line. - .0 In this case, the correction value for the scan direction is "- 0.3". Correction-value scale - .0 If it is diffi cult to see the cut line visually, use a mag- -0.0 nifi...
  • Page 217 Adjustment is completed if the position error of cut line is within the range below. If not, select [SETTING] menu again CUTTING MENU for further adjustment. PRINT-CUT ADJ. Mark on the right: Within +/-0.1mm Mark on the left: Within +/-0.3mm (Make an adjustment based on the mark on the right) PRINT-CUT ADJ.
  • Page 218 4-10 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 calibrat- ing the variation in Grit Roller diameter. Calibration is made based on the value in feeding media [PET-G]. Without proper calibration, it may cause misalignment in the feed amount of media, and it results in the problems such as white banding, banding of overlap or the dimension error of print result compared to the original data.

  • Page 219: Calibration(Feeding Direction)

    Calculate the amount to be calibrated with the formula as shown in the fi gure. Measured 400 - Length Calibration x 100 Value Measured Length Select [PRINT MENU]>[CALIB.DEFAULT]>[SETTING], and SERVICE MENU enter the calibration value with [ ] and [ ] keys.

  • Page 220: Tool Height Adjustment

    4-11 TOOL HEIGHT ADJUSTMENT (Referential Time : 5min.) Install the White Dummy Pen (ST-006) to the Tool Carriage. White Dummy Pen Position the Pinch Rollers as shown in the fi gure, and lower the loading lever. Pinch Roller Grit Roller Remove the Right Cover.
  • Page 221 Remove the Tool Carriage Cover. Tool Carriage Cover Connect the Tool Carriage to the Head Carriage. Lock the Head Carriage. And move the Tool Carriage to the right side of the bed. Turn the Adjustment Screw to adjust the space between the pen end and bed to be 2.5 mm to 2.6 mm.

  • Page 222: Tool Pressure Adjustment

    4-12 TOOL PRESSURE ADJUSTMENT (Referential Time : 15min) This adjustment is to correct the tool pressure during cutting. Before this adjustment, it is necessary to perform [4-11 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 the fi...
  • Page 223 Disconnect the Tool Carriage from the Head Carriage. Remove the Tool Carriage Cover. Tool Carriage Cover Connect the Tool Carriage to the Head Carriage. Lock the Head Carriage. And move the Tool Carriage to the right side of the bed. Turn on the Sub Power SW while pressing [ ], [ ] and...
  • Page 224 Select [CUTTING MENU]>[FORCE ADJUST]. MENU SERVICE MENU SERVICE MENU CUTTING MENU Only the Tool Carriage can be moved in [FORCE ADJUST] menu. CUTTING MENU FORCE ADJUST Select [FORCE ADJUST]>[30gf], and press [PAUSE] key to move the Tool Carriage down. CUTTING MENU FORCE ADJUST FORCE ADJUST 30gf...
  • Page 225 Lift up the Tool Holder with the Tension Gauge (ST-002) and 200gf measure the pressure when the pen tip leaves the bed.   56     57 ST-002 Adjust the parameter in [200gf] menu with [ ] and [ [ ] [ ] keys for the pressure to be 195 to 205gf (1.9N to 2.0N).

  • Page 226: Belt Tension Adjustment

    4-13 BELT TENSION ADJUSTMENT (Referential Time : 20min.) Connect the Tool Carriage to the Head Carriage and move them to the right in the lock position. Remove the Covers in order. 1. Right Cover Top Cover 2. Left Cover 3. Front Cover Front Rail Cover 4.
  • Page 227 Loosen the two Fixing Screws which is located on the left <Top view> end of the belt halfway round. Fixing Screw Be careful with the sharp edges around the belt when loosening the screws. It may cause injury. Fixing Screw Insert a wrench through the holes on the Side Frame and loosen the two screws to make a gap of three millimeters between the tip of the screw and Idle Pulley Holder.
  • Page 228 Tighten the two screws shown in the fi gure to slightly contact with Idle Pulley Holder. Move on to [4-14 BELT POSITION ADJUSTMENT]. Screws Make sure not to tighten the screws too tight. It may move the fi xed Idle Pulley Holder acciden- tally.

  • Page 229: Belt Position Adjustment

    4-14 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 exces- sively. The belt position needs to be confi rmed after the Belt Tension Adjustment and adjusted if it is necessary. Remove the Covers in order.
  • Page 230 Confi rm the belt position. 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 231 Loosen the two Fixing Screws located on the right end of the belt. Loosen the screws about a few rounds for the bottom of the screw head not to contact with the Fixing Screw Stay. Press [ENTER] key to restart Aging. AGING SCAN Adjust the belt position turning the Adjustment Screw as fol-...
  • Page 232 Tighten the two Fixing Screws for the bottom of the screw head to slightly contact with the Stay. Fixing Screw Confi rm that the belt is not touching the pulley anges exces- sively. When the belt is in improper position, adjust it again. When it is proper, leave the belt aging on, and go to the fol- lowing [ADJUSTMENT ON THE IDLE PULLEY SIDE].
  • Page 233 Loosen the two Fixing Screws located at the left end of the belt eighth to quarter round. Fixing Screw When the screw is loosen more than necessary, it gives diffi culty in adjusting the belt. Also, you need to be careful with the sharp edges around it when turning the screws.
  • Page 234 Belt leans to the rear side of the machine -Turn the screw 2 carefully in CW to press it to the Idle Pulley Holder. * Make sure to have a gap of three millimeters between the screw 1 and Idle Pulley Holder when turning the screw 2. Screw 1 Screw 2 Tighten one of the screws that has no contact with the Idle...
  • Page 235 Press [ENTER] key to restart Aging. The position is proper when the belt is not touching the Flanges excessively. When the position is proper, close this BELT POSITION ADJUSTMENT. When it is improper, go back to 18 and make adjustment again. AGING SCAN 4-56...

  • Page 236: Take-Up Unit Operation Check

    4-15 TAKE-UP UNIT OPERATION CHECK (Referential Time : 2min.) This is to check whether Take-up Unit operates properly. Confi rm 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...
  • Page 237 Confi rm that [START] is selected, and press [ENTER] key to turn on the Take-up Unit. START START [START] or [STOP] can be selected with [ ] and ] keys. The current setting is displayed on the left and the new setting is displayed on the right.
  • Page 238 Move the Dancer Roller up and down by hand, and confi rm 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 en- tering [TU] menu. Dancer Roller 4-59...

  • Page 239: Supplemental Information

    5 Supplemental Information 5-1 Special Tools Table shows a list of special tools recommended by Roland DG Corp. Parts No. ST-056 Parts Name TORQUE DRIVER N6 Purpose HEAD ALIGNMENT Parts No. 1000005463 Parts Name TOOL,BIT PHILLIPS NO.1 L150MM ST-107 Purpose HEAD ALIGNMENT Parts No.

  • Page 240: Sensor Map

    5-2 SENSOR MAP FRONT COVER SENSOR It detects whether the Front Cover is opened or closed. REAR PAPER SENSOR LIMIT SENSOR HEAD LOCK SENSOR It detects the rear edge of the It detects the limit positon of It detects whether the HEAD media and also whether the the head carriage in the scan CARRIAGE is at the lock position...
  • Page 241 (Left side of the machine) CHOKE VALVE SENSOR SHEET LOAD SENSOR It detects if the choke valve is It detects whether the Sheet Loading closed or not. Lever is UP or DOWN. LEFT COVER SENSOR It detects whether the Left Cover is opened or closed.
  • Page 242 WIPER SENSOR It detects the limit position of the Wiper movement. ENCODER MODULE It detects the coordinates in the carriage moving HEAD UP/DOWN SENSOR direction, and also generates the print signal. It detects the position of the Head Height Lever. THERMISTOR It takes the temperature around the Head.
  • Page 243 PINCH ROLLER SENSOR It detects the positions of Pinch Roller. CROP MARK SENSOR It detects the Crop Mark. INK CARTRIDGE SENSOR It detects whether the Ink Cartridge is installed or not. INK CARTRIDGE IC SENSOR INK EMPTY SENSOR It communicates with the IC chip of the Ink Cartridge.

  • Page 244: Motor Error

    5-3 MOTOR ERROR Revised 1 ERROR DESCRIPTION SCAN MOTOR ERROR CODE : 0000 0000                  Error detected as a result    Error Detected at fi rst MEANING CAUSE 0001 Feed Motor Deviation Error < External factors > (The order from the CPU does not match the 1.

  • Page 245: Service Call

    5-4 SERVICE CALL Revised 1 CODE CONTENTS CAUSE ACTION 0002 Disorder of communication Servo Board does not work correctly. Check cable connection between Main with Sub CPU Sub CPU does not work correctly. Board and Servo Board. There is a bad connection between Main Check the other cable connections of This occurs when the Sub Board and Servo Board.
  • Page 246 CODE CONTENTS CAUSE ACTION 0105 Tool Carriage Connection Fault of Tool Carriage Connection Check the mechanical Backlash or loose Error Loose of Connection Part with the Tool Carriage part. Fault of the Limit Position Initialize value Connection Part Replacement Limit Sensor does not work correctly or Limit Position Initialize is broken.

  • Page 247: Service Activities

    6 Service Activities 6-1 INSTALLATION CHECK LIST VS-640i/540i/300i INSTALLATION CHECK LIST Date : User Name : Serial Number : Checking the place of installation There is a space necessary for installing the machine as below. Work Space Unit Space Install the machine in a location that is level, stable, and able to bear the weight of the machine. The total weight of the machine including the media can reach approximately 200 kg (441 lb), having that the product weight of the 64- inch model is 140kg (308 lb), 54-inch model is 130kg (286 lb), and the 30-inch model is 100kg (220 lb).
  • Page 248 Unpacking...
  • Page 249 Checking the Accessories Stand legs (one for Arms (one for right and Power cord : 1 Casters : 2 right and left each left each) Stand stay : 1 Shafts : 2 Shaft clamps : 2 Bolts : 38 Media clamps* (one for Media holder and Pipe : 1 Cable clamp : 1...
  • Page 250 Assembling and Installing Set up the followings in reference to the Setup Guide [3.Assembling and Installing] to [7. Network Settings]. Assembling the Stand – Mounting the Machine Installing the Drain Bottle Removing the Packing Materials Connecting the Cables Apply the cleaning liquid to the rubber gasket of the Cap Top with the cleaning stick. It is necessary to apply the cleaning liquid to the Cap Top before performing the initial FILL INK because the Cap Top can not keep the air tight in case of the Cap Top is dry.
  • Page 251 To use Roland@NET and VersaWorks Online: Internet connection and web browser For the latest information, see the Roland DG Corp. website (http://www.rolanddg.com/) Make the setting for Roland@NET Select the check box [Download Updates Automatically and Notify] if the customer accepts it.
  • Page 252 - Registering the Roland DG Account if the customer accepts it When you register the Roland DG Account (Roland DG ID), you will become able to use OnSupport more effectively. You are to communicate with our OnSupport server in registering your account.
  • Page 253 Basic Operation Explain following items in reference to the User's Manual. Switch On! !! IMPORTANT !! Always leave the main power on. Maintenance operation is automatically carried out while the machine is not in use. Use the sub power switch for the daily powering on and off. Loading 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.
  • Page 254 Disposing of Discharged Ink The message "EMPTY DRAIN BOTTLE" appears when a certain amount of discharged fluid has collected in the bottle. Dispose of discharged fluid promptly. !! IMPORTANT !! - "EMPTY DRAIN BOTTLE" message disappears when "NO" is selected without disposing of discharged fluid. If "NO"...
  • Page 255 When Problems Such As Dot Drop-out are Not Cleared Up - About [INK RENEWAL] Even after performing cleaning using the cleaning function (normal, medium, or powerful) or manual cleaning, perform this operation. Replacing the Wiper (Be careful about the fitting direction.) Replacing the Felt Wiper Replacing the Blade Replacing the Separating Knife...
  • Page 256 Fully Utilize the Media Heating System !! IMPORTANT !! To obtain stable temperature, use the machine at an ambient temperature of 20 to 32°C (68 to 90°F). The optimal temperature for the media varies according to the type of media and differences in the print mode. If the ink forms lumps or smudges, raise the temperature.
  • Page 257 - Use Conditions of Take-up System When “TU2” is Selected (This is mainly for Print & Cut operation.) - How to Output by Limiting Length (Roland VersaWorks) (Select ”CustomCUT” from [Size] under “Media Settings.” and Set “H”at 300mm.) - If the length of output at one time is too long, the media may get soiled by touching the work floor. To avoid the media from getting soiled by touching the floor, output the media by about 300 mm.
  • Page 258 Output Operation Management Determining What Happens When Ink Runs Out - [EMPTY MODE] Returning All Settings to Their Initial Values When you use metallic silver ink and white ink * Only applicable when the WH or MT ink are in use. Explain following items in reference to the SPECIAL COLOR INK GUIDE.
  • Page 259 In the print mode for Mt ink, the ink may not dry fully depending on the type of the media. Confirm the proper printing result in a trial printing beforehand. 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.
  • Page 260 Others Explain to refer to the User's Manual when an error message is displayed. And also explain to switch off and on the machine and check what happens before calling for inquiry when [SERVICE CALL] is displayed, since it occasionally solves the problem just by restarting.

  • Page 261: Maintenance Check List

    6-2 Maintenance Check List VS-640i/540i/300i Maintenance Check List Date : User Name : Serial Number : Check items Check Operation points Interview the customer Ask the customer if there is something that he/she is concerned about. Done Done Output / Get Report before maintenance [Get Report] by Peck, or print both Service Report and History Report.

  • Page 262: Specification

    Eight colors (cyan, magenta, yellow, black, light cyan, light magenta, metallic silver, and white) Maximum 1,440 dpi Printing resolution (dots per inch) 10 to 300 mm/s Cutting speed 30 to 300 gf Blade force Roland CAMM-1 series compatible Cutting Type 0.000 to 1.500 mm (0.000 to 0.059 in) blade Blade offset 0.025 mm/step Software resolution (when cutting) Error of less than ±0.3% of distance traveled, or ±0.3 mm, whichever is greater...
  • Page 263 Note: The media holder of this machine is exclusive use for the media of paper tube (core) inner diameter The length of printing or cutting is subject to the limitations of the program. Temperature: 25°C (77°F), humidity: 50% Roll media must be loaded correctly. Applicable when all pinch rollers available to the media width are used.

This manual is also suitable for:

Versacamm vs-540iVs-300i

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