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AstroNova TrojanLabel T2-C Service Manual

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T2-C Service Guide
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Summary of Contents for AstroNova TrojanLabel T2-C

  • Page 1 T2-C Service Guide Confidential, Not for Redistribution...
  • Page 2 T2-C Service Guide Part Number 22834705-EN-E Revision 1.0 9/2021 ® ® TrojanLabel , An AstroNova Company World Headquarters 600 East Greenwich Ave., West Warwick, RI 02893 Tel: (877) 757-7978 E-mail: trojanlabel@astronovainc.com www.trojanlabel.com Confidential, Not for Redistribution...
  • Page 3 This manual is copyrighted with all rights reserved. No part of this manual may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language in any form by any means without written permission of AstroNova. Trademarks TrojanLabel®...

  • Page 4: Table Of Contents

    Contents Chapter 1: Introduction ........6 Intended Audience .
  • Page 5 Contents Chapter 6: Maintenance Module (MM) ....... 54 About the Maintenance Module ......54 Wiper Roller (MFR) Replacement .

  • Page 6: Introduction

    Introduction Intended Audience This service guide describes how to service and repair the T2-C. This guide is intended for use by qualified service and maintenance personnel. For operation and configuration information, refer to the T2-C User Guide. Note: This service guide is for use by authorized service and maintenance personnel. Do not distribute it to others.

  • Page 7: Safety When Working With Electricity

    Introduction • when soldering • when using solvents, cleaning agents or other chemicals Protective Equipment Danger: Risk of injury in case of missing or faulty protective equipment. • After performing maintenance work, attach all safety equipment (covers, safety precau- tions, ground cables, etc.). •...

  • Page 8: Safety

    Introduction If an Accident Occurs • Proceed in a very cautions and calm manner. • Avoid endangering yourself. • Switch the power off. • Request medical help (emergency physician). • Call for first aid if necessary. Safety This section identifies design considerations and practices for working safely with the T2-C press.
  • Page 9 Introduction As supplied, the T2-C press is well protected against electro-static discharge (ESD). However, precautions must be taken to minimize the potential for ESD when working around harness interconnects and exposed interface connectors. • Use static-free workstations for procedures when protective covers are removed. •...

  • Page 10: Hidden Service Menu

    Hidden Service Menu About the Hidden Service Menu The hidden service menu is a diagnostics tool integrated into the Trojan Control user interface (UI). This menu is not visible for end users and it is not recommended to show end users how to access to this menu.

  • Page 11: Changing The Service Menu Password

    Hidden Service Menu Changing the Service Menu Password The password is set up in the settings.ini file. This file is located in the following folder: C:\TrojanOne-data\settings\t2c If the default password of 321 does not work, or the password must be changed, the following entry should be updated in the settings.ini file.

  • Page 12: Functions Of The Service Menu

    Hidden Service Menu Functions of the Service Menu Service Functions tab The Service functions tab includes all operations and diagnostics that can be run on the print engine and web path system. Maintenance Module Buttons The maintenance module (MM) is responsible for cleaning and protecting the printhead. By pressing one of the above buttons, the MM moves to the desired position so physical movement and also position values can be checked.
  • Page 13 Hidden Service Menu Print Engine Options (Upper List) The upper scroll-down list is for the print engine diagnostic commands. The relevant item from the list should be selected, then launch the command by pressing the Run button. At PrintEngine tab the response to the command will be displayed. Check NVM Listing the current NVM (Non-Volatile Memory) variables.
  • Page 14 Hidden Service Menu fixed_print_height: 1 -> Tells the system that print head height is driven by encoder steps (must be 0 for Memjet Sirius PE, must be 1 for Trojan type Sirius PE). Note: Check NVM equals nvm_getset command in putty engine console. NVM variables cannot be changed in Service menu.
  • Page 15 Hidden Service Menu ISS Autofill Off Disabling autofill service which refills the reservoir ink (IR) tanks automatically when ink level drops in the IR tank. ISS Autofill On Enabling autofill service which refills the reservoir ink (IR) tanks automatically when ink level drops in the IR tank.
  • Page 16 Hidden Service Menu SS Lift Print Moves the printhead platen to print position vertically. SS Lift Wipe Moves the printhead platen to wipe position vertically. SS Sled Cap Moves maintenance module tray to cap position horizontally. Note: Lifter has to be up in home position. SS Sled Home Moves maintenance module tray to home position (outmost left) horizontally.
  • Page 17 Hidden Service Menu Webpath Related Options (Lower List) The lower scroll-down list is for the web path diagnostics commands. On web path, we mean the servo system that moves the label media and provides the tension for the label media. The relevant item from the list should be selected, then launch the command by pressing Run button.
  • Page 18 Hidden Service Menu displayed at the end of the calibration. If the calibration fails, then the machine stops and displays ‘ERROR 4’. Check Unwinder BLDC motor Equals ‘bchk 1’ command in putty Webpath console. Initial calibration check for the unwinder side BLDC motor that drives the unwinder shaft. This calibration is also done automatically whenever Calibrate Web button in Handling menu is pressed for the first time after a power cycle.
  • Page 19 Hidden Service Menu rewinder arm position. As there is no dancer arm in a T2-C, rap and uap commands are not relevant. Maintenance Settings Tab The maintenance settings tab part of the service menu will not be explained in details here. These settings will enable maintenance notifications appearing on the screen for users.

  • Page 20: Using Teamviewer

    Using TeamViewer About TeamViewer TeamViewer is software that enables remote desktop access to the embedded PC on the T2-C press. The TeamViewer client can be downloaded free of charge from www.teamviewer.com. The TeamViewer client is installed and running on all our machines for being able to log in and run diagnostics on the machine.
  • Page 21 Using TeamViewer From remote, open TeamViewer client and type the service ID as partner ID, then press on connect. When the connection is established, TeamViewer will ask for a password. See password in below note. Note: Password is 5GK3fj27. This password works with all T2-C units. Connected to a T2-C unit from remote via TeamViewer after password authentication: T2-C Service Guide Confidential, Not for Redistribution...

  • Page 22: Accessing The T2-C From The Local Network

    Using TeamViewer Accessing the T2-C from the Local Network This method is for when the service technician is on site where the T2-C unit is installed and connected to the same local network as the machine. In this case the Service ID does not work as the TeamViewer ID based log in would require to go through TeamViewer server and thus over the Internet.
  • Page 23 Using TeamViewer Type the current IP address of the T2-C press as a partner ID in TeamViewer client instead of the Service ID, then press connect button: When the connection is established, TeamViewer will ask for a password. See password in below note.

  • Page 24: Accessing The T2-C With Direct Ethernet

    Using TeamViewer Accessing the T2-C with Direct Ethernet This method is for when the service technician is on site where the T2-C unit is installed and there is no local network or no possibility for the technician to connect to the local network. This can be a likely scenario at a trade show as well.
  • Page 25 Using TeamViewer Double check if the current IP address of the T2-C press is the same as what has been set in step 3. Refresh the screen at Network menu (exit and re-enter to network menu). Type the current IP address of the T2-C press as a partner ID in Teamviewer client instead of the Service ID, then press connect button: When the connection is established, TeamViewer will ask for a password.

  • Page 26: Putty Console

    Putty Console About the Putty Console The Putty console is the most important real time diagnostics tool on the T2-C press. Putty is already by default set up on all T2-C machines. If Putty does not start on a particular machine that can be due to 2 reasons: In case the hidden service menu is open.

  • Page 27: Accessing The Putty Console

    Putty Console Button to manually start/reset the T1021 board: Accessing the Putty Console Log in via Teamviewer to the T2-C press. See “Using TeamViewer” on page 20. Make sure that ‘send key combinations’ check box is selected at the Teamviewer client at Actions menu: Press CTRL + SHIFT + ESC keys on the keyboard to open Task Manager on T2-C press.
  • Page 28 Putty Console Putty configuration window opens: For doing diagnostics on the print engine, select pre-saved Engine session for print engine console and press load, then press open button to open the session: Putty engine console opened: T2-C Service Guide Confidential, Not for Redistribution...
  • Page 29 Putty Console For doing diagnostics on the web path system, select pre-saved ‘webpath’ session for web path console and press load, then press open button to open the session: Putty webpath console opened: T2-C Service Guide Confidential, Not for Redistribution...

  • Page 30: Print Engine (Pe)

    Print Engine (PE) About the Print Engine The print engine (PE) is the module that moves the printhead and the maintenance tray. The part number is T2ENGINE. Print Engine Replacement (Complete Module) Use the following instructions to replace the print engine. Required Parts •...
  • Page 31 Print Engine (PE) Procedure Go to TrojanTwo tab > Maintenance menu > Release Printhead button to remove the ink from the printhead and tubes around it. Open top cover to gain access to PE module. Open the blue printhead latch all the way and remove the printhead. Shut down the T2-C press at HOME >...
  • Page 32 Print Engine (PE) Remove the 2 screws for the metal rod on the outer side using a 3mm Allen key. Remove the screw at the print engine leveler using a 2.5mm Allen key. Watch for the lock washer. Carefully disconnect all 5 harnesses from the T1011 connector board. T2-C Service Guide Confidential, Not for Redistribution...
  • Page 33 Print Engine (PE) Disconnect all the ink tubes at the hose connectors and connect the tubes to each other by the matching colored tube on both the print engine’s side and on the machine’s side as well. This prevents ink dripping down from the tubes. Cannot really make a mistake here due to the male and female type hose connectors.
  • Page 34 Print Engine (PE) Connect all 11 ink tubes from the print engine module to the matching ink tubes on the T2-C. See step 10 for reference. Logically due to the female-male type hose connectors, the tubes cannot really be connected incorrectly. Make sure the colors of the tubes are matching.

  • Page 35: Printhead Latch Replacement

    Print Engine (PE) Enter the PH and WH values from the stickers into the appropriate fields of the settings.ini file, then save the modifications (File > Save). Note: The above sticker values are for illustration only. For the proper values always check the stickers on the particular print engine as these might be different for each print engine.
  • Page 36 Print Engine (PE) • Wide flat-head screwdriver • Rubber gloves Procedure Remove the printhead if it is still in the machine and shut down the system. Then power off the machine. If the latch is still closed, use the Release Printhead button at Handling menu or ph_latch_open command in putty engine console to open the printhead latch.
  • Page 37 Print Engine (PE) Gently insert a small, flat-head screwdriver between the blue printhead latch pin and the black plastic hinge and rotate to pop the latch out of the hinge without damaging either piece. The second side should easily slide out of the hinge. Discard the printhead latch according to local regulations.
  • Page 38 Print Engine (PE) Align the right tab of the new latch with the right hinge and gently press into place. Repeat for the left side. Caution: Be careful not to brake the hinges or the tabs. Sometimes it is really tight. Use needle-nose pliers to install the right spring into the plastic tab in the base of the housing.

  • Page 39: Cartridge Locator Replacement

    Print Engine (PE) Cartridge Locator Replacement The Assy Cartridge Locator is the black plastic cradle and plate that holds the printhead. It is very rare that this part needs to be replaced. The only occasion where the replacement would be necessary is when the black plastic part is broken or cracked and therefore it cannot hold the printhead in the proper position.

  • Page 40: Lifter Motor Replacement

    Print Engine (PE) Lifter Motor Replacement Use the following instructions to replace the lifter motor. Required Parts • T2/T3 Assy Lifter Motor with Cover (part number 10003079) Required Tools • Torx screwdriver size 8 • Allen key size 2 can be used if no Torx screw-driver is available •...

  • Page 41: Sled Motor Replacement

    Print Engine (PE) Disconnect the harness of the lifter motor carefully from the motor. Connect the lifter motor’s harness to the replacement lifter motor. Install the replacement lifter motor into the hole on the metal chassis. Make sure that the teeth of the brass gear on the lifter motor fits to the teeth of the black plastic gear underneath the motor’s brass gear.
  • Page 42 Print Engine (PE) Remove the print engine module from the T2-C press. See “Print Engine Replacement (Complete Module)” on page 30. Remove the 2 screws that fix the sled motor marked with red arrows on below picture using a Torx 8 bit or a size 2 Allen key. Watch for the washers under each screw. T2-C Service Guide Confidential, Not for Redistribution...

  • Page 43: Revolver Replacement (Pump And Valve Side)

    Print Engine (PE) Loosen the tension adjusting screw marked with a red circle to loosen the tension on the transmission belt using a size 4 Allen key. Unhook the transmission belt from the gear of the Sled Motor. Pull the Sled motor out inwards and disconnect the motor’s harness carefully. Install the new sled motor by repeating from step 4 to step 7 in reverse order.
  • Page 44 Print Engine (PE) Procedure Go to Maintenance menu and press the ’Release Printhead’ button to de-prime the printhead and open the blue plastic printhead latch. Remove the printhead and place the removed printhead into a moistened cap for the duration of the replacement to avoid dehydration of the printhead. Leave the printhead latch open.
  • Page 45 Print Engine (PE) Use an E-clip puller or a flat headed screwdriver to remove the E-clip from the fluidic coupling latch, as shown in the next figure. Pull out and remove the latch pin. Slide the fluidic coupling forward, towards the PPCA board, along its track. Once it has cleared the track, lift it up to free it from the dock.
  • Page 46 Print Engine (PE) Disconnect (twist counter-clock wise) the tubes of the particular revolver at the hose connectors. The valve side revolver’s tubes are in the upper row of tubes and the pump side revolver’s tubes are in the lower row of tubes (there are 5 tubes to disconnect for each revolver, from left to right in CMYKK order).

  • Page 47: Ppca Board Replacement

    Print Engine (PE) PPCA Board Replacement The Pen Driver PCA or also called as PPCA board is the circuit board that is in direct contact with the printhead. Important: It is extremely important that the alignment of this board is done properly otherwise PH FAULTY errors can happen or communication issues between the PE MPCA board and the printhead.
  • Page 48 Print Engine (PE) Remove the top and side plate that covers the PPCA board. Use an Allen key size 2.5 to remove the 4 screws for each cover. From left to right disconnect the Power Supply Cable (1), Temperature Sensor board (2), blue RJ45 data cable (3) and the gray RJ45 data cable (4).
  • Page 49 Print Engine (PE) Remove the PPCA board along with the black plastic holder. The PPCA board is aligned with 2 black plastic datum on the Assy Cartridge Locator that goes through the 2 holes on the sides of the PPCA board. This is usually really tight, so carefully move the PPCA out of the 2 datum.
  • Page 50 Print Engine (PE) Mount the black plastic holder to the new PPCA board with the 3 screws. Make sure that the 3 datum on the plastic holder are aligned with the new PPCA board (red arrows). Then make sure that the 3 screws (marked with yellow circles) are also fully driven in and aligned.
  • Page 51 Print Engine (PE) Inspect the PPCA board installation alignment by viewing from the top, as in picture below. The PPCA should look straight, not curved or warped. Refer to the yellow dashed line. Hold the PPCA and bracket assembly in the proper position, insert the screws along with the washers through the black plastic bracket into the threaded holes, and tighten each screw only enough to hold the screw upright in the hole.

  • Page 52: Belt Tension Adjustment

    Print Engine (PE) Power on the T2-C press. Belt Tension Adjustment Use the following instructions to adjust the belt tension. Required Tools • Allen key size 4 • Rubber gloves Procedure To be able to adjust the belt tension for the maintenance module tray, the print engine must be removed from the T2-C press.
  • Page 53 Print Engine (PE) Belt tension is good if the maintenance module tray can move back and forth freely and the belt can be pushed down manually with a finger by approximately 5mm. Tighten the tension adjusting screw when tension is verified from step 4. Install the print engine back in the T2-C press.

  • Page 54: Maintenance Module (Mm)

    Maintenance Module (MM) About the Maintenance Module The maintenance module includes the capping station and the wiper module. Note: In Putty engine console the commands related to the maintenance module are referred to as ‘ss’ which means Service Station in older terminology. See “Putty Console”...
  • Page 55 Maintenance Module (MM) Apart from the metal base tray, the replaceable parts and main components of the maintenance module are the following: Part Number Description 10003346 T2/T3 Maintenance Cradle 10003357 T2/T3 Module Wiper Transfer Gen 2 Assembly, CAP MODULE W/ SPACERS Item Description Quantity...

  • Page 56: Wiper Roller (Mfr) Replacement

    Maintenance Module (MM) Item Description Quantity SCREW, M4 x 4mm, M3 - 0.5 x 4mm, SH, HX, SS SPACER, M4 x 2mm SCREW, M3 - 0.5 x 8mm, BHC, TORX, STEEL, ZINC Wiper Roller (MFR) Replacement Use the following instructions to replace the wiper roller. Required Parts •...
  • Page 57 Maintenance Module (MM) Press Home Maintenance Module button in the Maintenance menu to gain access to the wiper roller. The maintenance module slides out from under the printhead. The wiper roller (MFR) is indicated with arrow. T2-C Service Guide Confidential, Not for Redistribution...
  • Page 58 Maintenance Module (MM) Detach and remove the used wiper roller. Unclick and pull the wiper roller out from under the plastic latch: Wiper roller out: On the right side where there is a gear mounted to the wiper roller, just lift out the gear from the wiper motor gear house.
  • Page 59 Maintenance Module (MM) Install the new wiper roller. Fit the gear on the right end of the wiper roller into the proper place from above. The gear has to fit to the gear of the wiper motor. Push the axis of the wiper roller under the plastic latch until it clicks into the right place. Press Install Maintenance Module button in the Maintenance menu to move the maintenance module tray back into the proper position where it protects the printhead.

  • Page 60: Wiper Module Replacement

    Maintenance Module (MM) Wiper Module Replacement Use the following instructions to replace the wiper module. Required Parts • T2/T3 Module Wiper Transfer Gen 2 (part number 10003357) Required Tools • Flat head screwdriver • Rubber gloves Procedure Open top left side lid on machine. Press Home Maintenance Module button in the Maintenance menu to gain access to the wiper roller.
  • Page 61 Maintenance Module (MM) Remove current wiper module. The wiper module is sitting on 4 springs (2 on each side) and fixed by a plastic latch (1 on each side). Use a flat head screwdriver and pull the plastic latch away (step 1), so the wiper module can be removed freely (step 2).
  • Page 62 Maintenance Module (MM) Connect the harness of the new wiper module. Caution: When the harness is connected, make sure that the harness at the wiper motor is not being pushed under the metal lid as that would push the cable down thus tilting the whole wiper module which results in print quality issues.

  • Page 63: Capping Station Replacement

    Maintenance Module (MM) Capping Station Replacement There is no available part number for the capping station as this part usually lasts for a long time. Removal/Replacement is rather for cleaning the cap module than replacing it with a new one. Unless physically damaged, the capping station can be cleaned and used for years. Required Parts •...
  • Page 64 Maintenance Module (MM) Use a flat head screwdriver to strain the plastic latch outwards carefully (step 1), then pull the cap module upwards (step 2) and remove it. There is a latch on both sides of the cap module, it is enough to release the cap module on one side and then it can be pulled out. T2-C Service Guide Confidential, Not for Redistribution...
  • Page 65 Maintenance Module (MM) There are 2 black plastic spacers (one on each side) under the capping station which are sitting in their dedicated hole at the cradle. These spacers must be installed back along with the cap module, otherwise the cap module will not be aligned well. Install the capping station back in the proper direction and make sure that the black plastic spacers are on location.

  • Page 66: Wiper Module Spring Height Adjustment

    Maintenance Module (MM) Wiper Module Spring Height Adjustment The wiper module is sitting on 4 springs (2 springs on each side). It is extremely important that these springs are adjusted to be even in height and this height normally is about 3mm above the plastic tray (there is some tolerance so the height should be minimum 2.9mm and maximum 3.5mm).
  • Page 67 Maintenance Module (MM) The height of the springs can be adjusted easily with using a Torx 10 screwdriver. There is a hole melted and punched in the factory for every spring bed. This hole is above the bottom of the spring and enables the adjustment like a thread so that the spring can be driven in and out by putting a Torx 10 screwdriver into the spring and rotating the spring clockwise to drive it in (reduce height) or rotating the spring counter-clockwise to drive it out (increase height).

  • Page 68: Tray Cradle Replacement

    Maintenance Module (MM) Move the maintenance module back to position by pressing the Install Maintenance Module button in the Maintenance menu. If the maintenance module has been moved out of registration while replaced, then Main- tenance Jam message will be displayed at system status field on right side status bar. If this happens, then restart the print engine at HOME >...
  • Page 69 Maintenance Module (MM) Disconnect the waste ink tube by the hose connectors. Remove the 4 M3x8 screws from each corner (marked with red arrows on below drawing) of the maintenance module tray using an Allen key size 3. Look for the M3 washer and M3 lock washer under each screw.

  • Page 70: Adjusting And Verifying The Wipe Position

    Maintenance Module (MM) Move the maintenance module back to position by pressing the Install Maintenance Module button at Maintenance menu. If the maintenance module has been moved out of registration while replaced, then Main- tenance Jam message will be displayed at system status field on right side status bar. If this happens, then restart the print engine at HOME >...
  • Page 71 Maintenance Module (MM) Height requirements: • All four (4) springs should have the same height. • Height should be minimum 2.9mm and maximum 3.5mm. Measurement Alternative 1 (Best and More Precise Way) For this method, the best way is to remove the maintenance module tray cradle along with the wiper module.
  • Page 72 Maintenance Module (MM) Prepare a “tool” that is 3mm high and has a shape that it is possible to ‘move’ around in the print engine. For example a 3mm Allen key or a small metal piece as shown in below picture. The ‘front’...
  • Page 73 Maintenance Module (MM) • Measuring the left front spring: • Measuring the right front spring: • Measuring the back springs. Move the maintenance station manually to about 5-6 cm from the back ‘wall’: T2-C Service Guide Confidential, Not for Redistribution...
  • Page 74 Maintenance Module (MM) • Measuring the back right spring: • Measuring the left back spring: If spring needs to be adjusted, then remove the wiper module. See “Wiper Module Replacement” on page 60. Note: Never remove the springs out from the plastic holders because they cannot be re-inserted due to plastic indents that hold the springs in place will break when the spring is completely removed.
  • Page 75 Maintenance Module (MM) • Use another screwdriver or your fingers to lift the wiper module away (2). Use a Torx T10 screwdriver to adjust the height of the springs. Use the hole in the middle of the spring as a thread and put the head of the screwdriver into the hole. Adjust height by rotating the screwdriver and thus the spring clockwise to drive it in (reduce height) or rotating the spring counter-clockwise to drive it out (increase height).
  • Page 76 Maintenance Module (MM) • The pressure shall be even across the printhead. Too hard pressure can cause color contamination as the waste ink from the MFR is squeezed back to the printhead nozzles. Too low pressure will not clean the printhead properly. This procedure requires that a printhead is installed and the springs have been verified/adjusted.
  • Page 77 Maintenance Module (MM) Place a lamp at the back of the engine. The light will be used to determine the distance between the printhead and the wiper roller. If testing on the T2-C then it is easier to see if you remove the plate wall in front of the print engine.
  • Page 78 Maintenance Module (MM) Increasing the wipe position value drives the printhead up and decreasing the wiper position value brings the printhead closer to the wiper roller. Register the if the light (if any) is going through in between the wiper roller and prin- thead.
  • Page 79 Maintenance Module (MM) Press right click on the settings.ini file and open it for editing: In the settings.ini file overwrite the wipe_posn value with the correct wipe position value that you noted when went through from steps 5 to 6 above. Save the changes at the settings.ini file.

  • Page 80: Ink Delivery System (Ids)

    Ink Delivery System (IDS) Dual Pinch Valve Replacement The dual pinch valve comes mounted on a metal holder and comes without tubes The dual pinch valve is situated inside the T2-C cabinet on the lower left side under the reservoir ink tanks (viewed from the back): T2-C Service Guide Confidential, Not for Redistribution...
  • Page 81 Ink Delivery System (IDS) Required Parts • T2/T3 Dual Pinch Valve (part number 10003077) Required Tools • Allen key size 2.5mm • Clamps to close ink tubes • Small cable ties or zip ties, 10 pieces • Pinchers • Rubber gloves Procedure Go to Maintenance menu and press Release Printhead button to remove the ink from the printhead and tubes between reservoir ink tanks, dual pinch valve, printhead and ink...
  • Page 82 Ink Delivery System (IDS) Empty the reservoir ink tanks as well and pump most of the ink back to the 2L ink tanks. Go to TrojanTwo tab on the screen and then press the 3 points marked on below screenshot in sequential order to access to the hidden service menu: Enter to the hidden service menu.
  • Page 83 Ink Delivery System (IDS) The dual pinch valve will be visible from the back. T2-C Service Guide Confidential, Not for Redistribution...
  • Page 84 Ink Delivery System (IDS) Put a clamp to each tube coming in (CMYKK tubes are coming from the reservoir ink tanks) and going out (CMYKK tubes are going up towards the PH) from the dual pinch valve to close the tubes. See below pictures for reference. Put a clamp to each of the 5 tubes at the place where indicated with red arrows on below picture.
  • Page 85 Ink Delivery System (IDS) Use a pincher or a small pair of scissors to cut the 10 tubes below the clamps between the clamp and the cable tie at the connection point as close to the cable tie as possible so that the tube length will not be shortened significantly.
  • Page 86 Ink Delivery System (IDS) Connect the tubes back in their original order. This is from left to right Cyan, Magenta, Yellow, clear Black, smoky Black (CMYKK) for both front and back side tubes. Put a cable tie to each connection at the valve’s hose connector as shown in below pictures. Make sure that all white lever latches on the stopcock valves are perpendicular to the ink lines, meaning that the ink line is open and ink flow is free.
  • Page 87 Ink Delivery System (IDS) Once the reservoir ink tanks filled up, install the printhead back and close the blue printhead latch. The system status will change to PH UNPRIMED. Go to Maintenance menu and press the ‘Insert Printhead’ button to start filling up the printhead with ink through the dual pinch valve.

  • Page 88: Pcbs

    PCBs USB Connections This section describes the USB connections on the PC to Touchscreen, MPCA, and T1021. The PC has two components: Motherboard USB extension board General start up power up information: • When power cycled the T1021 (webpath) will power on the PC •...
  • Page 89 PCBs • 1 USB FDTI cable (jack) is used for normal MPCA/PC communication (the port Putty uses when opening the engine) USB serial Port connection is usually COM8 in device manager and shows that we have FTDI cable access (jack cable) It is possible to send Usbsend -e through a command prompt, to validate if the MPCA is connected.
  • Page 90 PCBs T2-C Service Guide Confidential, Not for Redistribution...
  • Page 91 PCBs Extension Board USB Connections The T1021 and PC communicate through the PC USB extension board (1 USB). The touch-screen “mouse” is connected through the USB extension board (1 USB). T2-C Service Guide Confidential, Not for Redistribution...

  • Page 92: Pc Motherboard Replacement

    PCBs PC Motherboard Replacement Important: The Embedded PC motherboard should always be replaced along with a new mSATA SSD card which has the pre-installed Trojan Control software on it. The reason for this is that the embedded Windows 8 running on each T2-C press, has the activation license linked to the hardware ID of the certain motherboard.
  • Page 93 PCBs Required Tools • Allen key size 2.5mm • Rubber gloves Procedure Connect the new mSATA SSD card to the new PC motherboard (1). The card slot is on the back of the motherboard. Then use the RAM module from the old motherboard and install the RAM module to the new motherboard’s RAM slot (2).
  • Page 94 PCBs Put a plastic bag to the ink connectors and to the chip reader cables. Remove the 3 screws from the left side of the cover (pic. 1), then remove the 3 screws from the right side of the cover and then remove the 2 screws from the top (pic.
  • Page 95 PCBs Twist the ink tube cap until the pin on the cap reaches the gap at the top cover, then lift the cap out. Pin on back side of the ink tube cap: Lean the top cover over. Twist the Emergency Stop button housing counter clock wise until it unlocks, then take it off.
  • Page 96 PCBs The PC motherboard is situated on the inner wall as shown on below picture. T2-C Service Guide Confidential, Not for Redistribution...
  • Page 97 PCBs Disconnect all cables from the current motherboard. See below picture for reference: 1. Power Supply cable 2. Ground wire for LVDS cable 3. Screen backlight cable 4. LVDS cable 5. Small extension board USB ports 6. USB-A to MPCA 7.
  • Page 98 PCBs Remove the current PC motherboard using a size 2.5mm Allen key. Remove the 4 screws at the corners of the board that fixes the motherboard to the chassis. Pay attention to the washer under each screw. Try to prevent washers falling into the machine inside and try not to lose the washers.
  • Page 99 PCBs The LVDS settings must be changed at the first start in BIOS menu to match with the 7” screen size of the T2-C press: Connect an external display to the VGA port (1) of the new PC motherboard. Disconnect one of the USB A cables (2) from the motherboard and connect a USB keyboard (3).
  • Page 100 PCBs Select CH7511 EDID Panel Option and select 1280x800 18/1 resolution option. Save settings and exit from the BIOS menu. After exiting from BIOS menu, make sure that the T2-C press is connected to the Internet, when Windows OS is starting up for the first time after the PC motherboard replacement. This is mandatory for Windows OS to activate the license and also TeamViewer is activating, so the T2-C press will get a valid service ID from TeamViewer server.
  • Page 101 PCBs After the update, the T2-C logo appears on the top left corner indicating that product branding is now T2-C. If the particular T2-C unit has a VP (Volume Product) chipped MPCA, then the soft- ware needs to be further configured to VP brand. Go back to HOME > Settings > Updater menu and type the following update URL into the Alternate Update URL field: http://printerupdate.trojanlabel.com/trojanvp...
  • Page 102 PCBs When the system is up and running, the settings.ini file should be corrected with the correct print and wiper height values from the stickers of the print engine module. The stickers can be found on every PE module on the inside wall at the operator side (furthest side from the T2-C press’...

  • Page 103: Mpca Board Replacement

    PCBs MPCA Board Replacement The MPCA board is the main board that controls the print engine and ink delivery system. Important: Check the sticker on the replacement MPCA board. The sticker has to match with the QA chip of the ink. The system can either be Trojan Standard Niagara (TSN) or Trojan Volume Product Niagara (TVPN).
  • Page 104 PCBs • Rubber gloves Procedure Shut down and power off the T2-C press. Remove the back cover screws (x16) using a size 2.5mm Allen key, then remove the back cover plate. Disconnect all cables from the MPCA board. Remove the screws (x7) circled with red on below picture that fix the MPCA board to the metal plate behind the board.
  • Page 105 PCBs Connect all the cables back to the newly installed MPCA board. See below drawing for reference: Note: On above drawing all ports marked with green are connected on the MPCA with a matching harness. The port numbers are labeled on the MPCA board and are labeled on each harness as well.
  • Page 106 PCBs When the system is up and running, the settings.ini file should be corrected with the correct print and wiper height values from the stickers of the print engine module. The stickers can be found on every PE module on the inside wall at the operator side (furthest side from the T2-C press’...

  • Page 107: Servo System

    Servo System NIP Rubber Roller Replacement Use the following instructions to replace the NIP rubber roller. Required Parts • Rubber NIP roller (part number 33340220) Required Tools • Allen key size 3mm • C-clip removal tool • 2x 10mm c-clips (as back-up) Procedure Shut down and power off the T2-C press.
  • Page 108 Servo System Remove the two springs (you can use a hook or a strip loop). Remove the C-clip that holds the assembly in place (use a c-clip tool) at the screen side. T2-C Service Guide Confidential, Not for Redistribution...
  • Page 109 Servo System Remove stud (pin) screen side, by pushing it out from the inside. Stud removed: Remove the C-clips that hold assembly in place (use the c-clip tool) at the wall side. T2-C Service Guide Confidential, Not for Redistribution...
  • Page 110 Servo System Remove the stud (pin) that holds the assembly in place at the wall side. Same principle as above, but only push the stud half way through to avoid the stud falling inside the machine. Push it as much to be able to remove the stud from the NIP clamp assembly. Remove rubber roller assembly frame.
  • Page 111 Servo System Loosen protective safety guard screw (left). Remove rubber roller shoulder screw (right). Remove protective safety guard screw (right). Tilt guard to access rubber roller. Replace rubber roller. Insert rubber roller shoulder screw (left). Do not over-tighten. Insert protective safety guard screw (left). Do not over-tighten. Insert rubber roller shoulder screw (right).
  • Page 112 Servo System Place on flat surface and ensure form is correct. Tighten screws. Ensure the rubber roller rotates freely. Note: The rubber roller should also be able to move about 0.5 mm sideways (this is to avoid burning the bearings). Install the rubber roller assembly back.
  • Page 113 Servo System Use a long screw or Allen key to push the assembly stud holder from the back of the T2-C. Reinsert the C-clips. Ensure that the C-clips clicks in place and can move freely. Mount the springs again using the strip circle tool. Note: Ensure that the springs are placed in the groove.
  • Page 114 Servo System Test. The clamp shall be able to open and close. Power on. Calibrate tension for the label material. Move the material back and forth. Do test printing. T2-C Service Guide Confidential, Not for Redistribution...

  • Page 115: Index

    Index Replacement ......107 Belt Tension Adjustment ..... 52 PC Motherboard Replacement .
  • Page 116 Index Wipe Position Wiper Module Spring Adjustment ......70 Height Adjustment ..... . 66 Wiper Module Wiper Roller (MFR) Replacement .

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