Gerber Technology MP+ Series Technical Manual

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TECHNICAL GUIDE

FOR MP+ PLOTTERS

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Page 1 TECHNICAL GUIDE FOR MP+ PLOTTERS...
Page 3: Table Of Contents
INDEX Technic mode �� 4 INTRODUCTION TO PRINTING Introduction to printing �� 6 CALIBRATION Calibration �� 9 PRINT DATA FLOW Print data flow �� 14 SCHEMATICS Schematics �� 16 TROUBLESHOOTINGS Plotter firmware �� 21 Plotter movement alerts �� 31 Software errors on printing �� 37 Plotter sensors ��...
Page 4: Technic Mode
TECHNIC MODE REMEMBER To activate the TECHNIC MODE, turn on the plotter and hold the “Menu” key during the Startup process. · With this mode plotter is able to print with the front cover open in order to allow the technician to check plotter during working.
Page 5: Introduction To Printing
INTRODUCTION TO PRINTING...
Page 6: Introduction To Printing
INTRODUCTION TO PRINTING GENERAL According to the cartridge deck: Standard 2PH, option to 4PH. The printheads position is agreed as below: A 4PH plotter can have 1 to 4 active printheads. A 2PH plotter can have 1 or 2 active printheads. For Printing it is mandatory to have at least one active printhead, no matter the position where it is located.
Page 7 INTRODUCTION TO PRINTING Each HP45 cartridge has a maximum resolution of 600dpi in a ½ inch swath, so each cartridge has 300 dots distributed in 2 print lines as seen in picture below: DISPOSITION The 2PH plotter has a print swath of 1 inch (2,54 cm) and the 4PH has a print swath of 2 inches (5,08 cm). See the picture to view the final line result in the 4PH distribution: 2 inches The relative height position of the cartridge deck to the plotter beam can be adjusted using 4 screws.
Page 8: Calibration
CALIBRATION...
Page 9: Calibration
CALIBRATION GENERAL To achieve a good appearance printing with these cartridges’ placement, some steps must be done. In the plotter menu this procedure is called “Head align". The calibration can be done only if all available holders have cartridges installed and active. It’s important to follow the steps in the correct order to keep the proper dependencies between them.
Page 10 CALIBRATION OFFSET The offset adjusts the distance between two cartridges in the X axis. This calibration needs special attention. This is a critical adjustment because the other calibration steps are based on it. Offset By adjusting it is possible to achieve aligned vertical lines. To achieve it the plotter will print all different possibilities to let the user select the best one.
Page 11 CALIBRATION PAPER ADVANCE The Y axis (paper) encoder is used to measure real paper feed movement. There is a small mechanical tolerance that need to be adjusted. Paper advance With this calibration the deviation is corrected to not have gaps or overlaps between swaths. The purpose of this calibration is to find the raster parameters to ensure exact print out dimensions.
Page 12 CALIBRATION PARALLELISM The purpose of this step is to have the deck height on equal level in each measurement point. The goal is to have 9,7 - 9,8mm as shown below. 9,7 - 9,8mm Be careful to not push the deck with caliper while taking measurement. BIDIRECTIONAL In a bidirectional printing, the cartridge print height is causing a misalignment between the two directions.
Page 13: Print Data Flow
PRINT DATA FLOW...
Page 14: Print Data Flow
PRINT DATA FLOW VECTOR FILE *.plt, *.hpgl, *.iso, ... Drawing.hpgl USER MANAGER AppData\ ... \incoming\PLOTTER BACKUP AppData\ ... \BACKUP AppData\ ...\ incoming\PLOTTER\pattern FOLDER Drawing.hpgl + Settings SERVER MANAGER pltserver.exe Raster.dll RASTER AppData\ ... \sw\incoming\11111 INCOMING FILE *.tkt, *.kfc Status, file data, size calibration, SWITCH VECTOR...
Page 15: Schematics
SCHEMATICS...
Page 16: Schematics
SCHEMATICS General electrical schematics Options are remarked in yellow background. Spare part number is indicated. Multi-wire cables are also indicated.
Page 18 SCHEMATICS Detailed electrical schematics More detailed view of the Master Board and 4 Heads PCBs connection.
Page 19 MASTER BOARD PCB 4 HEADS...
Page 20: Troubleshootings
TROUBLESHOOTINGS...
Page 21: Plotter Firmware
TROUBLESHOOTING Plotter firmware 19�04�001 SUBJECT: Main issues that can be found during working and start up. LEVEL REQUIRED: High - Technician. COMMENTS: Firmware version 6.1.3 or higher is required.
Page 22 NO POWER UP Description: · Verify plotter is plugged. · Verify the voltage in the power supply is 29.5V (between V+ and V-). · Verify the Voltages in the masterboard: -Voltage 29.5V between TP1 and TP2. -Voltage 5V between TP1 and TP3. -Voltage 3.3V between TP1 and TP4.
Page 23 FIRMWARE STARTUP SEQUENCE MESSAGE ACTION Black screen Initialize all drivers "Starting clock" Start internal clock/calendar. Test I2C. "Verifying memory", Test RAM memory. "Checking SD", Check SD card presence and integirty "Searching for updates", Search firmware update file in the SD card. "Verifying TAG", Check TAG format and electrical connection.
Page 24 Here is a block diagram of the complete start process done by the firmware: Firmware startup sequence: Loads and checks the main firmware modules. Stops with error when one fails. Get velocity map values in normal print mode. Plotter moves the print head, to measure the forward and backwards speed ramps (acelaration and deceleration) and the cruise speed to use them during the printing cycles.
Page 25 ERROR LEVEL INDICATOR Critical error Machine will be not able to start when this errors appears. Not Critical error Warning...
Page 26 MEMORY FAULT Description: RAM memory is not accesible. . Restart plotter and check again. Execute a System test. If no succeed replace master board. SD IS NOT WORKING Description: SD card is not present or cannot be read. Plotter cannot work without it. Not all SD cards are compatible (recommended Class IV).
Page 27 MISSING DEVICE Description: Some plotter option is activated but the master board cannot reach the device by I2C bus. It is only displayed momentarily on start-up. (As example, the automatic cutter electronics not connected). Verify the connection is properly done Contact Service CALENDAR FAILURE Description:...
Page 28 I2C SYSTEM FAILED Description: Error on I2C bus. Restart plotter and check again Check all I2C connections (CON40, CON41, CON 42, CON 43, CON 44, CON 45, CON46 ) Disconnect all the I2C connectors and restart plotter. In case that this does not clear the message, replace masterboard. Contact Service RFID DRIVER FAILED Description:...
Page 29 TAG CORRUPTED Plotter TAG has corrupted information that doesn't allows to work. Contact service to get the code to format it. TAG FAILURE Description: Plotter cannot read/write internal TAG. Critical information is not accesible to start-up. Restart machine. Check cable connected CON29. Check RED LED 5 (bottom one), it must be blinking.
Page 31: Plotter Movement Alerts
TROUBLESHOOTING Plotter movement alerts 19�04�002 SUBJECT: Troubleshooting of the main issues that can be found in plotter movements to print. Some tests can be done during start-up. LEVEL REQUIRED: High - Technician. COMMENTS:Firmware version 6.1.3 or higher.
Page 32 MASTERBOARD connectors Battery connectors Motor X (carriage) driver Motor Y (paper) driver Motor Y (paper) driver ALTERA Motor Z (GCB) driver Motor X (carriage) 600dpi (CON29) driver RFID module RFID module Power ALTERA Motor Z (Roll to Roll) driver 600dpi Paper encoder Paper end connector...
Page 33 OVERSPEED Description: The print head traction system slips, over-passing the theoretical speed of the movement. Print at low speed, if the plotter is able to print correctly, the issue is related to a slipery issue (head drive cable or pulley) and it’s not due a deffective motor.
Page 34 ENCODER ERROR Description: This error only appears when an X encoder error is detected. Visually check the encoder strip, it must be completely straight, without damages, wrinkles o scratches along it. Ensure the encoder reader reader is properly centered to the strip. Inspect and reseat long flat cables (CON8).
Page 35 MOVEMENT FAILED Description: Error checking the movement. Failure in motor, encoder, or other mechanical parts. For this issue the most important thing is to check the movements of the print head during the start-up of the plotter: Printhead is not moving during start-up: Verify that printhead movement motor is connected to CON22.
Page 36 CUTTER JAM Description: Only in case of having cutter option Cutter has a mechanical block and could not move to the desired position. Verify that there is nothing blocking the movement. Check that all the electrical connections are properly done. Ensure that the cutter motor is turning properly and the pulley is tight to the motor shaft.
Page 37: Software Errors On Printing
TROUBLESHOOTING Software errors on printing 19�04�003 SUBJECT: Troubleshooting of the main errors when printing a file. LEVEL REQUIRED: High - Technician. COMMENTS: Last compatible software version 5.1.0.8 or higher is required.
Page 38 ERROR STARTING DIRECTORIES Program needs access to its working folders and cannot work with them. Verify program execution rights in administrator installation and user execution. Check folder permissions on %localappdata%\Generic Wide Printer. Some folder or file permissions could have been restricted, files could be temporally blocked by external programs like antivirus, backup systems, etc.
Page 39 ERROR IN PREVIEW THE FILE IN USER MANAGER Once verified the format, check that all the CAD file format instructions are supported. If the preview shows lines that are not printed on paper, it can be that the file specifies a color not supported by HPGL (e.g.
Page 40 WRONG PRINTED FILE DIMENSIONS When printed and measured, the obtained dimensions aren't correct. Once verified the size in the queue, verify the printed file dimensions. • Calibrate file dimensions using the calibration square in the User Manager. This calibration settings are saved in the plotter and recovered by software every time it is connected. •...
Page 41 Error preparing queues There is not enough memory to support the data structure neede by the server. Usually, this would never happen. By some reason, the operating system is not providing the memory to load the printing queue. Check the system to determine who is consuming the resources . Error starting server Some error occurs with the folder structure needed by Server Manager to execute, or some internal resources are not being supplied by the operating...
Page 42: Plotter Sensors
TROUBLESHOOTING Plotter sensors 19�04�004 SUBJECT: Troubleshooting of the main plotter sensors. LEVEL REQUIRED: High - Technician. COMMENTS: Firmware version 6.1.3 or higher is required.
Page 43 SENSORS Description: · The plotter has several sensors to operate correctly and inform the user if any action must be done. · Some of the sensor only work in case the required option is activated. · Here is a troubleshooting of the main issues related to them. Output roll diameter sensor RFID Sensor Ink level Sensor...
Page 44 OUTPUT ROLL DIAMETER SENSOR Description: Infrared distance sensor located in the top cover. It’s sensitivity can be adjusted using a potentiometer. When the paper is too close an indicator is lighted on and it's showed on the plotter display and in the User Manager.
Page 45 RFID (RADIO FREQUENCY IDENTIFICATION) SENSOR Description: There is an antenna located under the right side cover to read RFID tags. The plotter is continuously reading, and when a card/part is approached it will decode the information and do the required actions.
Page 46 INK LEVEL(ANTENNAS) SENSOR Description: Ink level is controlled using RFID technology. The cartridge with optink enabled have an RFID tag with information about color, level and other features used by the machine. During normal operation, the plotter updates the ink level and other parameters in the RFID tag. In case of error reading the cartridge RFID it will be treated as a non-optink cartridge.
Page 47 NO PENS Description: Plotter doesn’t detect any cartridge available. Verify that the cartridges are properly installed on the holder. In case everything is properly placed, follow the “cartridge not detected” service note. REPLACE WORN POWER PADS Description: Power pads have reached lifecycle end. Replace the power pads.
Page 48 FRONT COVER SENSOR Description: There is a sensor to detect position of the cover. For safety reasons the plotter will pause movement when it detects opened cover. There are only two situations in which this sensor doesn't pause the movement: When working inside the calibration menu.
Page 49 PAPER ENCODER READER Description: The plotter reads the paper movement from the encoder reader, to ensure the proper marker lenght. Mechanical tolerances are compensated using the software calibration file located in the User manager > Configuration > Plotter calibration. This correction values are saved in the plotter and the software uses them to rasterize the files.
Page 50 PAPER END SENSOR Description: The Paper End sensor hardware is present on all plotters but is used only when Paper End option is activated and switched ON in plotter options Menu. The sensor is located in bottom part of the right bench. It consists in an infrared working as a rotary encoder.
Page 51: Cartridge Not Detected 4Ph
TROUBLESHOOTING Cartridge not detected 19�04�005 SUBJECT: Cartridge detection involves master board, long flat cables, CON8,CON9,CON10. Print head board, small flat cables, cartridge control board and the cartridge. The communication from Master Board to PH 1&2 is done through CON8 (common) and CON9. The communication from Master Board to PH 3&4 is done through CON8 (common) and CON10.
Page 52 CARTRIDGE NOT DETECTED - 4PH 3� RESEAT ALL CABLES CON10 CON9 CON8 Turn off the plotter and Reconnect CON8, CON9, Reconnect small flat cable of Reconnect big flat cables of Turn on the plotter. wait until all led's are CON10 cables of master print head board.
Page 53 CARTRIDGE NOT DETECTED - 4PH 6� CROSS LONG FLAT CABLES CON9 - CON10 Turn off the Identify CON9 and Unplugg CON9 and Plugg CON10 cable in Plug CON9 in the first Turn on the plotter. CON10 long flat cables CON10. the middle of connector.
Page 54 FLOW CHART Visually check damaged Damaged Replace pad connector and pad connector clean contact pads. Error persist Replace Error moves Swap cartridge with cartridge with the cartridge a working one. Error on the same printhead Replace Error solved Reconnect all flat cables. cables Error persist Replace...
Page 55: Printing Quality
TROUBLESHOOTING Printing quality 19�07�001 SUBJECT: Main issus related with print quality. LEVEL REQUIRED: Medium COMMENTS: Firmware version 6.1.3 or higher is required. NOTE: Avoid the use of non original TKT cartridges or reused cartridges!
Page 56 LINES MISMATCHED ALL ALONG PRINTING SURFACE Probably due to a bad adjustment of the plotter.: Menu Head align Check that paper cones are well placed (with the arrows properly Perform a User adjust. aligned), and properly tight. If results get better but still little bit mismatched, perform adjust twice, as every time you realize again the adjustment, values on it are more accurate.
Page 57 MISMATCHED LINES IN SIDES ONLY If plotter have mismatched lines in the beginning of the printhead movement or in the end of it, means some issue with the head driver cable or motor X pulley. Note: This issue can also produce an "Overspeed" message. Check "Overspeed" in the movement alerts chapter for more information.
Page 58: Mechanical Issues
TROUBLESHOOTING Mechanical issues 19�07�002 SUBJECT: Typical mechanical plotter issues. LEVEL REQUIRED: Medium...
Page 59 CONTINUOUS NOISE ALONG MOVEMENT (LEFT AND RIGHT) When print head move, and produce a continuous noise moving from L to R and R to L, the causes can be: a) Dirty added on the printhead wheels b) Bearing damaged on printhead wheels Remove printhead cleaners to check the state of the wheels, if the wheels have some dirty added to it, clean it with a tissue.
Page 60: Preventive Mainteance
PREVENTIVE MAINTEANCE...
Page 61: Preventive Maintenance
PREVENTIVE MAINTENANCE Please perform this actions following the maintenance procedures. EVERY WEEK · Service Zone visual inspection. EVERY MONTH · Head drive steal wire visual inspection. · Flat cables visual inspection. · Wheel cleaners check. Oil and correct setup. · Top cover wheels verification.
Page 62: Smart Check List
SMART CHECK LIST TURN OFF THE PLOTTER Reseat head drive cable torsion: • Release the tensor screw completely and remove metal plate. • Check metal plate, if it is bent, straighten it and assemble again. • Make 30 times carriage movements using a marker printing. •...
Page 63 Check the service station (Only with Service Station option activated) Verify that the wiping and parking caps are clean and correctly inserted. Ensure that both parts are on rails and to the left side before plotter starts. To ensure a correct working condition, verify that the deck height is between 9.7 mm - 9.8 mm Check carriage wheels and cleaners Verify that the wheels are clean (not noisy).
Page 64 Check paper load Paper is on origin position (or at the left of the origin position). The cone arrows are well aligned and tight. Paper tension is uniform in both sides. Move the print head by hand and place it about 10cm from the left pulley. TURN ON THE PLOTER To activate the TECHNIC MODE, hold the “Menu”...
Page 65 Check USB/ETH connectivity also PC and plotter link Check or install the last compatible printing suite. Setup a connection via USB or ethernet to the plotter and assure the communication is correct (cartridge de- tection, plotting operation). Cartridges and ink printing quality Visually check if there is any damage in the cartridge electrical pad.
Page 66: Parts Life Cycle
PARTS LIFE CYCLE Some plotter parts are recommended to be replaced to avoid a malfunction. These will prevent defective work, breakdowns and serious damage. Plotter will also inform you when RFID parts must be replaced if they have been previously activated (correctly passed on plotter RFID zone).
Page 67: Service Notes
SERVICE NOTES...
Page 68: Ffc Flat Flexible Cable - Replacement
SERVICE NOTE FFC Flat Flexible Cable - REPLACEMENT 16�08�001 SUBJECT: Replacement process for FFC (Flat flexible cable). BENEFITS: More resistant , more reliable, 2H to 4H ready. INSTALLATION LEVEL REQUIRED: High - Technician. Blue connectors 4H ready more resistant Best guidance More reliable...
Page 69 HOW TO REPLACE FLAT FLEXIBLE CABLE (FFC) Turn off the UWP. Remove the aluminum front cover. Remove the right and left side covers. Remove the aluminum rear cover. Disconnect CON 8, CON 9 and CON 10 Remove the FFC clip and disconnect the FFC from the printhead.
Page 70: Keyboard Membrane - Replacement
SERVICE NOTE KEYBOARD MEMBRANE - REPLACEMENT 19�03�001 SUBJECT: How to replace keyboard membrane BENEFITS: No electronics change involved. INSTALLATION LEVEL REQUIRED: Medium. Rear cover Tool Display cable Clips Keyboard Electronic membrane...
Page 71 HOW TO REPLACE KEYBOARD MEMBRANE Turn off the UWP. Open the top cover and Open the display´s rear cover Disconnect the display cable remove the two screws shown on using the tool. by pressing the latch and pulling picture. backward. Remove the two screws Turn the display over and Leave the board on vertical...
Page 72 HOW TO REPLACE KEYBOARD MEMBRANE 11 - 12 - 13 - Insert the wire as shown. Center the keyboard and Connect the keyboard attach it to the display assembly. cable (it should be flat, not twisted). Pay attention to the position: there is one free pin.
Page 73: Encoder Strip - Replacement
SERVICE NOTE Encoder strip - REPLACEMENT 19�06�001 SUBJECT: How to replace the encoder strip. BENEFITS: No electronics change involved. INSTALLATION LEVEL REQUIRED: Medium. Encoder strip Rubber gasket Slot Bridge...
Page 74 HOW TO REPLACE ENCODER STRIP Turn off the UWP. WARNING: Be aware of the gasket position. Place the encoder strip all The gap left between the Insert the rubber gasket in along the potter's bridge slot. ends of the strip and the benches the same slot than the encoder The aluminium joint plate must must be around 5mm in both...
Page 75: Carriage Electronic Board - Replacement
SERVICE NOTE Carriage electronic board - REPLACEMENT 19�06�002 SUBJECT: How to replace the PH board. INSTALLATION LEVEL REQUIRED: Medium. Flat cable Wires Clip Screw...
Page 76 HOW TO REPLACE PH BOARD BEFORE HANDLING ANY COMPONENT, Turn off the plotter. PLEASE PUT THE ANTI STATIC WRIST STRAP. Remove the front cover. Remove the rear cover. Move the printhead to the Remove the Clip on the PH Unplug all the all the wires left side.
Page 77: Master Board Replacement & Firmware Installation
SERVICE NOTE Master board REPLACEMENT & FIRMWARE INSTALLATION 19�09�001 SUBJECT: Firmware installation. BENEFITS: Master board spare part compatible with all plotter types. INSTALLATION LEVEL REQUIRED: High - Technician. Just for MP+ NOTE: Masters that are already in your stock, will be used Make sure as usual (master for MP >...
Page 78 WHICH TYPE OF PLOTTER DO YOU HAVE? Depending on the type, you'll need to follow different steps. Please check before removing old materboard. 00:00 UPGRADE KIT 00:00 00:00...
Page 79 Before replacing a masterboard (just in case of MP): Download setting file to the computer: Turn on the plotter. Connect it through USB Open Server Manager. to the computer. Click on the Server Select the option Select the location where you Configuration button.
Page 80 MASTER BOARD REPLACEMENT Turn off the UWP. Connect the crocodile clip to the ground. Before handling any component, make sure you are using the antistatic wrist. CON 23 CON 3 CON 22 CON 28 CON10 CON 29 CON 9 CON 8 CON 5 CON 1 CON 44...
Page 81 ACTIVATE DFU MODE User Manager Server Manager Make sure User Manager and Turn OFF plotter. Move jumper from J1 to J3. Server Manager are turned off during this operation. 5 sec. /blank/ Turn on machine and after Plotter is in DFU mode now. 5 sec.
Page 82 MP+ FIRMWARE INSTALLATION SCENARIOS ( Fast review and tips ) MP Maintenance Tools is NOT suported on MP+ plotters. DO NOT install firmware versions previous to version 6.1.1.22. It can provoque an unrecoverable situation in case of a failed update. On these cases a pre-programmed PicKit will be neded to recover and reinstall fw on the corrupted modules of the plotter.
Page 83 In case of MP: FIRMWARE INSTALLATION Connect the plotter using Go to Install Firmware tab and click button Get current installation. USB cable to the computer and A message informing about DFU mode will appear. Click Yes, browse run Gerber Maintenance Tools. for fw package and install the firmware.
Page 84 In case of MP: SET UP SETTINGS Enter the setting file to the master board: Turn on the plotter. Connect it through USB Open Server Manager. to the computer. Click on the Printer Manager Select the option Click the "Open" button and button.
Page 85 In case of MP+ UPGRADE KIT or MP+: FIRMWARE INSTALLATION OPTION 1: SD card full installation. MP Maintenance Tools is NOT suported on MP+ plotters. DO NOT install firmware versions previous to version 6.1.1.22. It can provoque an unrecoverable situation in case of a failed update. On these cases a pre-programmed PicKit will be neded to recover and reinstall fw on the corrupted modules of the plotter.
Page 86 CON 29 PROGRAMMING Please wait . . . Do not turn off the plotter while Connect CON 29, and turn The display will show an firmware update is in process. on the plotter. installation message. Wait until Doing so may damage the main firmware is fully installed.
Page 87 In case of MP+ UPGRADE KIT or MP+: FIRMWARE INSTALLATION OPTION 2: Firmware install using Server Manager. Connect it to the PC using a Make a fast quick format Load the content of the micro SD card adapter. FAT32. firmware release folder to the SD card.
Page 88 x/xxxx/firmware.frm firmware.frm 10 - 11 - Choose "Printer Firmware" Open the "firmware.frm" file Click on the "Set firmware" folder. from the firmware release folder. button to install the program. PROGRAMMING Please wait . . . 12 - 13 - Do not turn off the plotter while The display will show an The plotter display will show firmware update is in process.
Page 89 MP+ START-UP LOCK ISSUES 00:00 Dealer finance protection. An unlock code must be introduced. 00:00 Manufacturer finance protection. An unlock code must be introduced. Serial number 2KC9 S Un loc k requ ire d The MP+ Upgrade Kit code must be installed.

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