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Durst Rho P10 200 Service Manual

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Rho P10 200/250
Service Manual – Diagnostics
Edition 09.04.2014

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Summary of Contents for Durst Rho P10 200

  • Page 1 Rho P10 200/250 Service Manual – Diagnostics Edition 09.04.2014...
  • Page 2 Rho P10 200/250 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 3: Table Of Contents

    Testing the gear play ..................58 3.5.5 Testing the sine error ..................60 HMD motor (M-drive troubleshooting ) ................62 3.6.1 Checking communication .................. 62 3.6.2 Reading the error number ................. 62 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 4 Checking the temperature of the fusion board ..........70 3.8.5 Checking the quality of the signal in the light guide .......... 70 UV unit ..........................71 3.10 Print head ........................71 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 5: About This Document

    This document is part of the service documentation and contains information on the facilities for emergency operation and for diagnostics in the event of faults. This information applies to printers of the Rho P10 200/250 range of Durst Phototechnik AG and should be referred to by the following personnel: ...

  • Page 6: Structure Of Warnings

    Warnings are structured as follows (shown here as an example: the warning level “WARNING”): WARNING! Type and source of the hazard Consequences of the hazard.  Measures for avoiding the hazard.  Read the warning and comply with it. 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 7: Emergency Operation

    RhoUVLampEmergencyOperation with the respective value. Print mode Lamp required Value for RhoUVLampEmergencyOperation Not in emergency Both lamps operation Unidirectional glossy Lamp 1 Unidirectional matt Lamp 2 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 8: Emergency Operation With A Defective Media Feed Roll Unit

    1. Establish which component of the HMD unit is defective. 2. Remove the corresponding part from the MFR unit. 3. Activating emergency operation with a defective media feed roll unit ( Chapter 2.2, p. 8). 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 9: Using An Mfr Motor As A Hmd Motor

    10. Exchange the HMD motor for the MFR motor. 11. Switch the printer on at the main switch. 12. Adjust the reference switch for the HMD motor and the head media distance ( Service Manual Settings). 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 10: Resetting The Mfr Motor

    It may be necessary to select a higher print quality so as to minimise the banding effect. 1. Activate emergency operation in the DurstPrinter.setup file: Change the value for RhoMediaEncoderEmergencyOperation accordingly and insert the parameter with the respective value. 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 11: Deactivating Individual Print Heads

    Defines: Print head defective in row 2? Defines: Print head defective in row 3? Defines: Print head defective in row 4? Tab. 6: Variables for the serial command YSHPabcde for deactivation of print heads 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 12 Deactivation of cm2:  Send serial command YSHP61011 After the fault has been rectified (for instance by exchanging the print head module):  Restart the printer. Emergency operation is then switched off. 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 13: Deactivating Print Head Rows

    After the fault has been rectified (for instance by exchanging the print head module):  Delete the entries RhoNumOfPrintheadsPerColorToUse RhoNumOfPrintheadsPerColorOffet from the DurstPrinter.setup file, or comment them out by inserting # at the start of the line. The print head row is activated. 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 14: Diagnostics

    = Port O8 (LSB) – O15 Bit 0: HV ON Bit 1: HV ON Bit 2: END POS1 Bit 3: END POS2 Bit 4: UV Start f = Port O16 (LSB) – O23 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 15 Bit: 3 Reserved Bit: 2 TX_FAULT State Bit: 1 RX_LOS State Bit: 0 Data Ready (Bar) indicates transceiver is powered and real time sense data is ready (0 = ready) d = temperature 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 16 = number of passes with a positioning error > 5 µm Number of YCSP0 bbbb b = number of passes with a YCSP?VorschubErrC Advances positioning error > 5 µm nt_1 out of Range (minor errors) 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 17 0 = X-axis (carriage linear motor and encoder), A-axis (media Transport transport motor) Belt 2 = media transport encoder Controller Meaning of the bits ( Tab. 9, p. 18) Tab. 8: Useful commands 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 18 HSSI NOT CONNECTED 1 = the HSSI module is not connected Tab. 9: Meaning of the bits for the “Status of Spii Carriage and Transport Belt Controller” 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 19: Error Code List

    Waste ink tank full. Please empty ink tank Empty the ink waste bin. 2271 Failed to control sledge heating system 2272 Unable to query printhead temperature 2273 Ink heating system error: Heater control switched 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 20 Printing Error - Data transfer failed - Please check the optical data link interface - (link status, cable, correct driver installation). - If the error persists, shutdown and restart the workstation 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 21 Print carriage check failed. Firmware error 6637 Print carriage check failed. Capping unit error 6638 Print carriage check failed. Purge unit error 6640 Purge vacuum pump failed 6641 Purge up/down motor failed 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 22 Print table check failed. Firmware error 6673 Loading door open 6674 Print table check failed. Loading door open 6675 Maintenance door open 6676 Print table check failed. Maintenance door open 6677 Key lock active 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 23 8233 Failed to open Fusion datalink interface channel 3 8234 Invalid Fusion datalink interface channel 8235 Failed to write to Fusion datalink interface - Error copying data from user-space to kernel-space 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 24 10007 Failed to query media advance 10008 Error querying status of media feed 10009 Unknown answer when querying status of media feed 10011 Failed to switch UV lamps On or Off 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 25 Media feed roll reference not found 10039 Vacuum system reference not found 10040 Print carriage reference not found 10041 Media transport reference not found 10042 Security unit not ready 10043 Edge holder up/down reference not found 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 26 Feature data mismatch. - Please update configuration or printer 10155 Media family is in use 10156 Vacuum system not adjustable 10157 Eject and remove board medium first 10158 Medium not unloaded! - Continue loading medium? 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 27 Media transport is busy 10182 Failed to set feature data 20000 Unable to switch on the head voltage 20003 Cannot create fifo 20004 Cannot open fifo 20006 Failed to write shared image buffer 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 28 Exchange the ink filter on the main Communication error in ink level control. Please tank for the relevant color. call Customer Service 20040 Error in checking printhead ink tanks. - Timeouterror caused by ink level control 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 29 Failed to detect medium - please reload medium 20063 Board feeding failed (timeout) 20064 Failed to query stacker status - Please check if the stacker is switched on and properly connected 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 30 20090 Failed to set feeder board count - Please check if the feeding unit is switched on and properly connected 20091 Failed to set feeder board measurement calibration 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 31 20114 Failed to set feeder track count - Please check if the feeding unit is switched on and properly connected 20115 Failed to set flexible board feed mode 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 32 Failed to query status of capping unit ink pump task 20144 Failed to set signal tower 20145 Failed to query signal tower 20146 Failed to set queue operation status 20147 Failed to set sledge velocity 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 33 Failed to query media eject roll distance 20177 Failed to set media eject roll up/down mode 20178 Failed to set registration table advance support mode 20179 Failed to query fusion temperature status 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 34 Failed to set registration table adjust mode 20205 Failed to set ionizer boost mode 20250 Loading door is open 20251 Maintenance door is open 20252 Back door is open 20253 MC4U EtherCAT error 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 35 20415 Security control unit version 20416 Security control unit communication 20417 Proc firmware versions different 20418 Proc communication 20419 Init signal tower 20430 Failed to switch printhead testmode on or off 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 36 Please check expiration date of ink(s) as soon as possible, otherwise the printheads will be damaged! 20458 Unable to set table vacuum fan intensity 21001 Unable to switch off the head voltage Code Description Possible solution 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 37 Empty the ink waste bin. 2271 Failed to control sledge heating system 2272 Unable to query printhead temperature 2273 Ink heating system error: Heater control switched 2274 Ink heating system error: Heating voltage fault 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 38 Printing Error - Data transfer failed - Please check the optical data link interface - (link status, cable, correct driver installation). - If the error persists, shutdown and restart the workstation 6005 Printing Error - Sledge start failed 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 39 6633 Sledge print encoder failed 6634 Print carriage check failed. Security unit not ready 6635 Print carriage check failed. Cover or purge tub open Tab. 10: List of the error codes 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 40: Pilz Safety Controller

    The relay O4 is in series with the crash sensors and the media security switch(es) Open contact will start a controlled electrical brake sequence of all axis. Undervoltage circuit breaker of Q1 (Main switch) 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 41 UV-System Loopback –Q3 Emergency relais for main supply of ACS controller Emergency Stop Switches Clocked signal (channel 1) Emergency Stop Switches (channel 2) Safety switch light trap 1 (channel 1) 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 42 High input will generate a warning in the printer software. Always ON (bridged signal) Clocked signal Always ON (bridged signal) Tab. 11: Pin/LED assignment -A103 base module 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 43 Emergency Switch cover back middle left (CH1) Emergency Switch cover back middle left (CH2) Emergency Switch cover back left (CH1) Emergency Switch cover back left (CH2) Tab. 13: Pin/LED assignment -A105 PNOZ mi1p 8I 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 44 Clocked signal (from -X1:T3 on main unit) Keylock switch in Pos. 1 (CH2) Keylock switch in Pos. 2 Clocked signal (from -X1:T2 on main unit) Tab. 14: Pin/LED assignment -A106 PNOZ mi1p 8I 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 45: Meaning Of Leds On The Pnoz M1P

    External error on the base unit inputs which does not lead to a safe condition, e.g. partially operated. External error on the base unit outputs which does not lead to a safe condition, e.g. feedback input defective. 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 46 Error on cascading input; unit remains in a RUN condition. Error on cascading output; unit remains in a RUN condition. Tab. 16: LED displays on the PNOZ m1p (Pilz safety controller) 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 47: Acs Controller

    Fig. 4: Safety and Faults Monitor (after successful initialization procedure) System Faults (S_FAULT) – general faults Axis Faults and Safety Inputs of print carriage Axis Faults and Safety Inputs of media transport 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 48 Hardware Right Limit Not used Hardware Left Limit Motor Overheat Drive Fault Green – OK (Drive ready/enabled) Red – not OK (Drive not ready/enabled) Tab. 18: Description of media transport faults 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 49 Fig. 6: Print carriage limit switches (seen from printer’s output side) Hardware left limit switch Hardware right limit switch The resistance of the motor phases of the linear motor is approximately 7,5Ohm. 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 50: Print Carriage Motion Test

    Starting the motion test 9. Select Buffer 3 10. Start Buffer with button Run Buffer(s) The carriage will move left and right until the buffer will be stopped 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 51: Media Transport Belt Initialization

    Starting the initialization 1. Start the Program Manager in the SpiiPlus MMI Application Studio 2. Select Buffer 6 3. Start Buffer with button Run Buffer(s) The media transport belt will initialize. 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 52: Media Transport Analysis

    Version of the user program Axis number Encoder number (Durst application) LE3011P LE4011P LE4011P1 LE4211P LE5011P LE5011P1 LE5012P LE2511P LH2017P LH2017P1 Tab. 20: Software version of user program, axis number and encoder number 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 53 2 sec/div Tab. 21: Settings for the horizontal axis Option Setting Source Mode Auto Slope Rising Tab. 22: Trigger settings Option Setting Number Display Autofit Permanent Fullscreen Tab. 23: Signal settings 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 54: Testing The Encoder During Printing

    Tab. 25: Media settings for the encoder test 2. In the “Communication Terminal” software tool: Press the Show Messages button. 3. In the printer software: Select the Test pattern tab. 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 55 Transport belt slipping on the drive roll (belt tension not OK; increased friction between the transport belt and print boards)  Heavy dirt on the print boards (under the transport belt) 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 56: Testing The Belt Breakthrough

    All passes have the same density and the advances by the transport belt are identical. Evaluating the data in the “Communication Terminal” software tool 1. Download the “Advance Check” Excel file from the Durst FTP server. 2. Open the Excel file.
  • Page 57 2. Select Cursors related to CH1. 3. Set the cursor markings so as to measure the differences in time and height between the steps. 4. If clear steps can be seen, inform Durst Service. 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 58: Testing The Gear Play

    11. As soon as the results are displayed (after approx. 20 seconds), press the Stop button. 12. In the “Motion Manager” software tool: Press the Stop Motion button. 13. In the printer software: Select the Other tab. 14. Switch off the vacuum. 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 59 The time should be less than 200 ms. 4. If an overshoot occurs and the time is more than 200 ms, inform Durst Service. 5. Create a screenshot in which the entire software can be seen. 6. Save the screenshot under the name “Gear_900xxxx.jpg”. When doing this, replace xxxx with the system number of the printer (type and number).

  • Page 60: Testing The Sine Error

    Otherwise the diagram will be displayed incorrectly. 5. Insert the values into cell A2 of the Excel file. The values must be within the range from A2 to A2000. 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 61 The sine error (distance between the lowest and highest value and the zero line) must be less than ± 25 µm. If deviations exceed the maximum permissible values:  Notify Durst Service. 7. To reboot the controller, right click on the controller and select Controller reboot. 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 62: Hmd Motor (M-Drive Troubleshooting )

     Cable defective 3.6.2 Reading the error number  To read the error number, send serial command YCMDxPR ER Refer to the explanations for error numbers ( Chapter 3.6.4, p. 64). 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 63: Interrogating The Reference Switch / Limit Switch

    Fig. 10: Position of the switch flag and the reference switch on the media feed roll unit Switch flag Reference switch Possible causes for incorrect feedback:  Sensor  Cable  LP M-drive PCB connection 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 64: M-Drive Error Code List

    The variable or flag cannot be increased (IC) or decreased (DC) incrementally. This applies for instance to version data or Baud rates. Activation request for a trip that has not yet been defined. 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 65 The program is blocked. User programs can be blocked with the command <LK>. The program can no longer be listed or processed in any way. Attempt at program space overflow. No in program mode. 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...
  • Page 66 Interrogate the limit switch ( Chapter 3.6.3, p. 63). The lower limit switch was reached. The limit switch was triggered in the minus direction.  Interrogate the limit switch ( Chapter 3.6.3, p. 63). 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 67: Testing The Media Detection Sensor

    If there are problems with edge detection or with the edge detection tripping when no medium is loaded:  Check on the status of the transport belt ( Service Manual - Maintenance). 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 68: Fusion Board

    With the printer switched on / workstation switched on, all power LEDs must light up continuously. If any LED does not light up, that power supply is defective:  Exchange the printed circuit board. 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 69: Checking That The Fusion Board Has Booted Up Correctly

    If the fusion board neither skips to the boot-loader nor starts up (no status LEDs light up): 1. Switch off the printer for approx. 10 minutes so that all components can be discharged. 2. Restart the printer. 3. If the problem still persists, contact Durst Service. 3.8.3 Checking the correct data connection...

  • Page 70: Checking The Temperature Of The Fusion Board

    1. In the printer software: Select the Communication tab. 2. Send serial command YQSFP 3. Evaluate the response of the printer ( Chapter 3.1.1, p. 14). Assessing the signal quality via the tab value 117 (response is parameter a): 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

  • Page 71: Uv Unit

    UV unit If there are faults on the UV unit:  Service Manual UV Unit. 3.10 Print head If there are faults on the print head:  Service Manual - Print Head. 2014 © Durst Phototechnik DIT GmbH, Diagnostics, Edition 09.04.2014...

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Rho p10 250

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