Roland VersaArt RS-640 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 RS-640/540.

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.

Conﬁ dential

70098-03

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Summary of Contents for Roland VersaArt RS-640

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 RS-640/540.
Page 2: Table Of Contents
Contents 1 Structure & Spare Parts COVERS ................................1-1 FRAME ................................1-3 DRIVE UNIT ............................... 1-5 HEAD CARRIAGE ............................... 1-7 BASE FRAME ..............................1-9 CHASSIS ................................1-11 PINCH ROLLER ............................... 1-12 STAND ................................1-13 WIPER SYSTEM .............................. 1-14 1-10 PUMP SYSTEM ..............................1-15 1-11 INK SYSTEM ..............................
Page 3: Revision Record
Revision Record Revision No. Date Description of Changes Approval Issued 2008.12.2 First Edition Kato Mabuchi [1-1 COVER], [1-5 BASE FRAME] Parts have been revised. Mabuchi 2009.2.6 [5-2 SENSOR MAP] has been revised. Kato [1-1 COVER], [1-3 DRIVE UNIT], [1-10 PUMP SYSTEM], [1-12 ACCESSORY] Parts have been revised.
Page 4: About The Symbols
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
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 : Moving Print Heads The print heads move at high speed and pose a hazard. Caution : Pinching Hazard Contact during operation may cause the hand or ﬁ...
Page 6 WARNING - FOR CONTINUED HIGH VOLTAGE, PROTECTION AGAINST RISK OF FIRE, REPLACE ONLY WITH FUSE OF THE HANDLING ATTENTION SPECIFIED TYPE AND CURRENT RATING. • Do not touch during power on Electric shock, Compornents damage • Do not repair. Replace power unit. F80L HS •...
Page 7: Structure & Spare Parts
1 Structure & Spare Parts 1-1 COVER Revised 2 S1 S7 Revised 2 Revised 2 S2 S5 Revised 1...
Page 8 RING SET,PUSH-ON CS CSTW-3 100 PCS 23 1000004160 LABEL, REFLECTION XC-540#LA1041 S5 31019149 SCREW SET,BINDING M2.3*8 3CBC 100PCS 24 1000004741 LABEL,EMBLEM LOGO ROLAND 2 S6 31019703 SCREW,BINDING P-TIGHT M3*8 3C 100P 25 1000001099 LABEL,HARMFUL FIRE #LA915 S7 31139104 SCREW,PLAPOINT M4*6 BK FE...
Page 9: Frame
1-2 FRAME...
Page 10 1-2 FRAME PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 7520501000 ASSY,CAP BOTTLE 2 FJ-52 S1 31029101 BUSH,NB-19 W700981240 ASSY,FAN JUNCTION BOARD RS-540 S2 31029106 BUSH,SQUARE SB-6025 1000002527 BASE,BOTTOM VP-540 S3 31289111AS CUPSCREW SET, M4*6 NI 100 PCS.
Page 11: Drive Unit
1-3 DRIVE UNIT Revised 2...
Page 12 1-3 DRIVE UNIT PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 7876709020 ASSY,FEED MOTOR SP-540V 51 22175870 BEARING 10-19ZZ 2 W700981280 ASSY,FLEX2 RS-540 52 15229506 SENSOR INTERRUPTER,GP1A05A5 3 W700981290 ASSY,FLEX3 RS-540 53 1000001480 SHAFT,DRIVE PULLEY XC-540 4 W700981250 ASSY,GRIT ENCODER BOARD RS-540...
Page 13: Head Carriage
1-4 HEAD CARRIAGE...
Page 14 1-4 HEAD CARRIAGE PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 21905166 ADAPTER,HEAD FJ-540 46 1000002623 SPACER,U/D LEVER VP-540 1000002679 ADAPTER,JUNCTION VPY306 47 22175154 SPRING,BLADE UP CM-500 11909167 ADAPTER,SCREW 3FAI FJ-540 48 22175159 SPRING,CARRIAGE SIDE FJ-50 22805292 ASSY,CLAMP BLADE CM-500...
Page 15: Base Frame
1-5 BASE FRAME...
Page 16 1-5 BASE FRAME PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1000004795 APRON,B RS-540 S1 31029101 BUSH,NB-19 1000004772 APRON,B RS-640 S2 31329501AS CLAMP SET,PUSH MOUNT RT30SSF5 20P 1000002148 APRON,F AL VP-540 (For RS-540） S3 31289109AS CUPSCREW SET,M3*4 NI 100 PCS.
Page 17: Chassis
1-6 CHASSIS PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 23 1000004149 FILTER(E),FRC-40-12-1.7-013 6700989010 ASSY,MAIN BOARD RS-540 24 12559105 FUSE,5X20 021706.3MXP 6.3A/250V W700981220 ASSY,POWER BOARD RS-540 26 1000003015 FUSE,1543.15DR 1000004994 ASSY,SERVO BOARD RS-540 27 13429702 INLET AC P01CF01 15A250V 15009101 BATTERY CR2032 28 22535257...
Page 18: Pinch Roller
1-7 PINCH ROLLER PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1000005172 ADAPTER,GND PINCH RS-540 8 10 S1 31149702AS RING SET,E-RING ETW-3 100 PCS. 16 20 6700980190 ASSY,PINCHROLL RS-540 8 10 S2 31019702AS SCREW SET,BIND P-TIGHT M3*6 3C 100P 16 20 21745101...
Page 19: Stand
1-8 STAND PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1000004724 ARM,L RS-540 1000004725 PIPE,FEEDER SHAFT RS-540 1000004723 ARM,R RS-540 1000004764 PIPE,FEEDER SHAFT RS-640 1000002636 ASSY,BASE STAND VP-540 17 1000004721 SHAFT,FEEDER RS-540 1000004718 BASE,FEEDER RS-540 1000002635 STAY,STAND VP-540 1000001068 BUSH,80F-1610...
Page 20: Wiper System
1-9 WIPER SYSTEM PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1000002576 BASE,WIPER MOTOR VP-540 18 15229506 SENSOR INTERRUPTER,GP1A05A5 11929138 BELT,408P2M4-530 19 1000004034 SHAFT,WIPE PULLEY XC-540 12159536 BUSH,B-S6-17 20 22155961 SHAFT,WIPER FJ-540 1000002182 CABLE-ASSY,WIPER MOTOR VP-540 21 22175140 SPRING,TENSIONER STX-7 1000002186...
Page 21: Pump System
1-10 PUMP SYSTEM Revised 2 Revised 2 16 23 1-15...
Page 22 1-10 PUMP SYSTEM PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1000002537 ARM,LINK UP VP-540 S1 31029106 BUSH,SQUARE SB-6025 1000002794 ASSY,CAP-TOP XC-540 S2 31289109AS CUPSCREW SET,M3*4 NI 100 PCS. Revised 2 1000004546 ASSY,CAP-TOP 2 XC-540 S3 31109601 NUT SET,SQUARE M3*6*1.6 FE NI 100PCS...
Page 23: Ink System
1-11 INK SYSTEM PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 11909133 ADAPTER,SCREW 2FAI FJ-50 15 22625103 SPRING,PRESS CARTRIDGE SP-300 1000004796 ADAPTER,JOINT 2-3FAI RS-540 16 1000005645 PLATE,COVER CARTRIDGE IC RS-540 W700981270 ASSY,CARTRIDGE IC BOARD RS-540 17 21435109 TUBE,SILICONE 3*5*8 FJ-540 W700981230 ASSY,FEED MOTOR BOARD RS-540 PARTS LIST -Supplemental Parts-...
Page 24 1-12 ACCESSORY 117V 230V 240VA 240VE Revised 2 1-18...
Page 25 1-12 ACCESSORY PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 23495124 AC CORD 3ASL100 240VA 10A SAA 36 1000005198 PAD,ACCESSORY RS-540 2 13499111 AC CORD H05VV-F 240VE 10A S 37 1000004192 PAD,COVER FRONT VP-540 3 13499109 AC CORD SJT 117V 10A 3PVC...
Page 26: Electrical Section
2 Electrical Section 2-1 WIRING MAP...
Page 27: Cable List
CABLE LIST Parts No. Parts Name RS-540 RS-640 1000002189 CABLE-ASSY,JUNBI A VP-540 1000002190 CABLE-ASSY,JUNBI B VP-540 23415268 CABLE-ASSY AC GROUND GREEN SP-540 23415116 CABLE ASSY,JUNBI D SP-300 1000002173 CABLE-ASSY,JUNBI E VP-540 1000004961 CABLE-ASSY,POWER SERVO RS-540 23415117 CABLE ASSY,POWER MAIN SP-300 1000002188 CABLE-ASSY,SCAN MOTOR VP-540 1000002180...
Page 28: Main Board
2-2 MAIN BOARD MAIN BOARD_Arrangement Diagram(Component Side) DIP SW Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 Bit 8 It indicates the version of the Board. RS-640/540 OFF...
Page 29 MAIN BOARD_Arrangement Diagram (Soldering Side)
Page 30: Main Board_Circuit Diagram
MAIN BOARD_Circuit Diagram 1/9...
Page 31 MAIN BOARD_Circuit Diagram 2/9...
Page 32 MAIN BOARD_Circuit Diagram 3/9...
Page 33 MAIN BOARD_Circuit Diagram 4/9...
Page 34 MAIN BOARD_Circuit Diagram 5/9 Revised 2...
Page 35 MAIN BOARD_Circuit Diagram 6/9 2-10...
Page 36 MAIN BOARD_Circuit Diagram 7/9 2-11...
Page 37 MAIN BOARD_Circuit Diagram 8/9 2-12...
Page 38 MAIN BOARD_Circuit Diagram 9/9 Revised 2 2-13...
Page 39: Servo Board
2-3 SERVO BOARD SERVO BOARD_Arrangement Diagram (Component Side) It indicates the version of the Board. 2-14...
Page 40 SERVO BOARD_Circuit Diagram 1/4 Revised 3 /SERVO_RES /Serial_Start 2-15...
Page 41 SERVO BOARD_Circuit Diagram 2/4 Revised 3 2-16...
Page 42 SERVO BOARD_Circuit Diagram 3/4 2-17...
Page 43 SERVO BOARD_Circuit Diagram 4/4 2-18...
Page 44: Carriage Board
2-4 CARRIAGE BOARD CARRIAGE BOARD_Arrangement Diagram (Component Side) It indicates the version of the Board. 2-19...
Page 45 CARRIAGE BOARD_Circuit Diagram Revised 2 2-20...
Page 46: Sub Board
2-5 SUB BOARD SUB BOARD_Arrangement Diagram (Component Side) It indicates the version of the Board. 2-21...
Page 47 SUB BOARD_Circuit Diagram 1/4 2-22...
Page 48 SUB BOARD_Circuit Diagram 2/4 2-23...
Page 49 SUB BOARD_Circuit Diagram 3/4 Revised 3 Revised 3 Revised 3 2-24...
Page 50 SUB BOARD_Circuit Diagram 4/4 CN1000 CN1001 to FAN 5267-02A to Servo Board CN1002 to FAN 53398-08 5267-02A CN1003 to Bed Thermistor Board 53014-02 CN1004 to Apron Thermistor Board 53014-02 FAN JUNCTION BOARD CN1100 CN1101 CN1200 CN1201 5268-02A 5268-02A CN1102 CN1202 CN032-004 CN032-004 5268-03A(NON)
Page 51: Main Board
2-6 MAINTENANCE PARTS LIST_Electrical Parts MAIN BOARD Parts No Parts Name Description Function IC22 IC21 1000001098 IC,E09A54RA D/A Converter IC26 IC25 TR10 TR11 TR14 TR15 15129122 TR 2SC4131 GB POWER Transistor DC Fuse for Head MG&YE 1000000659 FUSE,01543.15DR DC Fuse for Head BK&CY SERVO BOARD Parts No Parts Name...
Page 52: Replacement Of Main Parts
3 Replacement of Main Parts To Ensure safe Work Turn off the Main Power SW and unplug the power cable of the Printer before performing parts replacement. It is not possible to cut power off completely only by turning off the Sub Power SWs. MAIN POWER SW <BACK>...
Page 53 The necessary adjustments after the replacement of each part and the referential time for each work are described as follows. HEAD REPLACEMENT : 20min. (1 Head) 1. THERMISTER CHECK 2. HEAD ALIGNMENT 3. HEAD INFORMATION CLEAR 4. FLUSHING POSITION ADJUSTMENT Adj.
Page 54 MAIN BOARD REPLACEMENT (In case that the parameters can be transferred by Peck) : 30 min. 1. DIP SW SETTING 2. BATTERY INSTALLATION 3. FIRMWARE INSTALLATION 4. SYSTEM PARAMETER INITIALIZE 5. IP ADDRESS SETTING Start the machine with the Service Mode and set it in the User Menu. 6.
Page 55: Head Replacement
3-1 HEAD REPLACEMENT Turn on the sub power while pressing the left, right and down keys to enter the Service Mode. Revised 2 MENU When replacing the HEAD of the machine using the pigment ink, it is NOT necessary to remove the ink from the machine.
Page 56 Remove the I/S Cover. SCREW I/S COVER HOOK Remove the Right Top Cover and Carriage Cover. CARRIAGE COVER RIGHT TOP COVER Remove the 2 screws to remove the Damper Plate. And remove the 2 Ink Dampers from the head which SCREW will be replaced.
Page 57: Ribbon Cable
Disconnect the 2 Ribbon Cables from the head. RIBBON CABLE Remove the spring, and remove the 3 screws ﬁ xing the head. Then, pull the head towards the front and pull it up to remove it. SPRING Remove the head from the adapter and fix the new HEAD head to the adapter.
Page 58 Connect the 2 Ribbon Cables to the Head Board. RIBBON CABLE Do not connect the cables to the wrong connecter. Fix the Head Board Cover. When ﬁ xing the Head Board Cover, hook the tab to the Carriage Base. HEAD BOARD COVER SCREW CARRIAGE BASE...
Page 59 Turn on the main power, and then turn on the sub power while pressing the left, right and down keys to enter the Service Mode. Revised 2 MENU When replacing the HEAD of the machine using the pigment ink, it is NOT necessary to clean the ink line.
Page 60 Enter the Service Mode and perform the following adjustments. 1. THERMISTER CHECK 2. [4-4 HEAD ALIGNMENT] 3. HEAD INFORMATION CLEAR 4. [4-7 FLUSHING POSITION ADJUSTMENT] < HOW TO CLEAR THE HEAD INFORMATION > SERVICE MENU HISTORY MENU After THERMISTER CHECK and HEAD ALIGNMENT, clear the head information from the [SERVICE MENU] >...
Page 61: Wiper Replacement
3-2 WIPER REPLACEMENT Select [SUB MENU] > [MAINTENANCE] > [REPLACE WIPER] in the User's Menu, and press the [ENTER] MENU SUB MENU key. SUB MENU MAINTENANCE MAINTENANCE REPLACE WIPER The Head Carriage moves to a location permitting OPEN FRONT wiper replacement, and then the message shown in COVER the ﬁ...
Page 62 Remove the wiper and install the new one. Make sure to ﬁ x the Wiper so that the rubber side faces the front. Use the tweezers to press the part shown in the ﬁ gure and engage the wiper on the hook. Make sure engage it on the hook.
Page 63: Cap Top Replacement
3-3 CAP TOP REPLACEMENT Remove the I/S Cover. SCREW I/S COVER HOOK Move the Head Carriage leftwards by hand. HEAD CARRIAGE Remove the Pump Cover. PUMP COVER Disconnect the tube of the Cap Top from the tube of Y TUBE JOINT the Pump.
Page 64: Cap Frame
Unhook the Cap Frame while holding it, and remove it. CAP FRAME HOOK Make sure to hold the Cap Frame. There is a spring under the Cap Top. The Cap Top jumps out unless you hold the Cap Frame when removing it. Remove the Cap Top upward together with the tube.
Page 65 Connect the tube of the Cap Top to the tube of the Y TUBE JOINT Pump using the Y tube joint. Fix the Pump Cover. PUMP COVER Move the Head Carriage by hand to the lock position. HEAD CARRIAGE Fix the I/S Cover. SCREW Perform the following adjustment.
Page 66: Carriage Motor Replacement
3-4 CARRIAGE MOTOR REPLACEMENT Turn off the sub power, and then turn off the main power. MAIN POWER SW Remove the following covers. SCREW I/S Cover I/S COVER Right Top Cover Panel Cover Chassis Cover HOOK RIGHT TOP COVER PANEL COVER W h e n r e m o v i n g t h e SENSOR CHASSIS COVER...
Page 67 Remove the spring on the Flange. FLANGE SPRING Remove the 3 screws ﬁ xing the Flange, and remove FLANGE the motor together with the Flange. SCREW Remove the 4 screws to remove the motor from the Flange. And ﬁ x a new motor to the Flange. BASE FLANGE Be careful with the fixing direction of the...
Page 68: Drive Gear
Fix the spring. SPRING Move the Head Carriage leftwards by hand. HEAD CARRIAGE Turn the Drive Gear by hand and check there is no backlash all the way around. DRIVE GEAR MOTOR GEAR Tighten up the 3 screws to ﬁ x the Flange in the order shown in the ﬁ...
Page 69 Turn the Drive Gear by hand little by little and check there is no backlash. DRIVE GEAR Grease the gear of the motor and Drive Gear properly (FLOIL G902). MOTOR GEAR Connect the connector of the Motor Cable. CONNECTOR < Top View > Move the Head Carriage by hand to the lock position.
Page 70 Perform the SERVO LOCK CHECK. After turning on the main power, turn on the sub power while pressing the left, right and down keys to enter the Service Mode. MENU MENU SERVICE MENU In [MOTOR MENU] > [SERVO LOCK] menu, select [S]. Move the Head Carriage left and right by hand and SERVICE MENU make sure the value on the LCD changes depending...
Page 71 Clear the motor working hours. Go back to the Service Menu, and select [HISTORY MENU] > [MOTOR GROUP] > [MOTOR HOURS S] > [CLEAR] and press the [ENTER] key. The motor HISTORY MENU MOTOR GROUP working hours will be reset to 0. MOTOR HOURS S 1653 hours MOTOR HOURS S...
Page 72: Feed Motor Replacement
3-5 FEED MOTOR REPLACEMENT Turn off the sub power, and then turn off the main power. MAIN POWER SW < Rear View > Remove the following covers. INK CARTRIDGE COVER Maintenance Cover Left Side Cover Left Cover Ink Cartridge Cover LEFT COVER MAINTENANCE COVER LEFT SIDE COVER...
Page 73 Remove the connector of the Motor Cable. CONNECTOR Remove the screw as shown in the ﬁ gure to remove the Grit Encoder Board together with the stay. SCREW STAY GRIT ENCODER BOARD Remove the 3 screws as shown in the ﬁ gure to remove Grit Encoder Stopper.
Page 74 Remove the 4 rivets as shown in the ﬁ gure, and slide RIVET the Gear Cover to the front side, and remove it. GEAR COVER RIVET Remove the spring. SPRING Remove the 3 screws ﬁ xing the Flange, and remove the motor together with the Flange.
Page 75 Fix the Flange with the 3 screws temporarily. SCREW FLANGE Fix the spring. SPRING Turn the Drive Gear by hand and check there is no backlash all the way around. DRIVE GEAR MOTOR GEAR Tighten up the 3 screws to ﬁ x the Flange in the order shown in the ﬁ...
Page 76 Turn the Drive Gear by hand little by little and check there is no backlash. DRIVE GEAR Grease the gear of the motor and Drive Gear properly (FLOIL G902). Slide the Gear Cover to the back side, and ﬁ x the Gear RIVET Cover with the 4 rivets.
Page 77 Fix the Grit Encoder Stopper with the 3 screws while holding the Shaft. GRIT ENCODER STOPPER SHAFT SCREW Fix the Grit Encoder Board together with the stay so that the Grit Encoder is in between the gap of sensor. SCREW GRIT Adjust the position ENCODER...
Page 78: Service Menu
Fix the Cutter Frame. When fixing the Cutter Frame, be careful not to squeeze the sensor cable on the back side. Fix the sensor cable to the Clamp. CLAMP CUTTER FRAME CUTTER FRAME CABLE Connect the connector of the sensor cable to the Feed FEED MOTOR BOARD Motor Board.
Page 79: Servo Lock
Press the [ENTER] key to excite the motor. Check the Grit Roller can not be rotated easily by hand and the value on the LCD doesn't change. SERVO LOCK [ ENTER ] SERVO LOCK F:* 80 Check the Grit Encoder. SERVICE MENU Go back to the [MOTOR MENU], and select [G-ENC.
Page 80 Clear the motor working hours. SERVICE MENU Go back to the Service Menu, and select [HISTORY HITORY MENU MENU] > [MOTOR GROUP] > [MOTOR HOURS F] > [CLEAR] and press the [ENTER] key. The motor HITORY MENU MOTOR GROUP working hours will be reset to 0. MOTOR HOURS F 1653 hours MOTOR HOURS F...
Page 81: Pump Replacement
3-6 PUMP REPLACEMENT Turn off the sub power, and then turn off the main power. MAIN POWER SW < Rear View > Remove the I/S Cover. SCREW I/S COVER HOOK Remove the Pump Cover and Panel Cover. PANEL COVER W h e n r e m o v i n g t h e SENSOR Panel Cover, remove the sensor on the back side...
Page 82 Disconnect the tubes of the Cap Top and the tubes of TUBE (CAP TOP) the Drain from the pumps. TUBE (DRAIN) PUMP Remove the 2 screws as shown in the ﬁ gure to remove the Pump Unit. PUMP UNIT SCREW Remove the 4 screws as shown in the ﬁ...
Page 83 Replace with the new pump. BEARING < Procedure for pump with the motor > Remove the setscrew as shown in the ﬁ gure to remove SETSCREW the gear and bearing from the Shaft. SHAFT GEAR Remove the 3 screws as shown in the ﬁ gure to remove MOTOR the pump from the motor.
Page 84 Fix the setscrew at the D-cut part by pushing the gear against the bearing. SETSCREW GEAR BEARING SETSCREW GEAR D-cut part < Procedure for pump without the motor > Remove the 3 screws as shown in the ﬁ gure to remove the plate from the pump, and ﬁ...
Page 85 Fix the Pump Unit Stay with the 4 screws as shown in the ﬁ gure. SCREW SCREW PUMP UNIT STAY Fix the Pump Unit with the 2 screws as shown in the ﬁ gure. PUMP UNIT SCREW Connect the tubes of the Cap Top and the tubes of the TUBE (CAP TOP) Drain to the pumps.
Page 86: Panel Cover
Fix the Pump Cover and Panel Cover. PANEL COVER When fixing the Panel SENSOR Cover, fix the sensor on the back side of the Panel Cover and connect the Ribbon Cable on the Panel Board. RIBBON CABLE < Back Side > PUMP COVER Turn on the main power, then turn on the sub power while pressing the left, right and down keys to enter the...
Page 87 Fix the I/S Cover. SCREW I/S COVER HOOK 3-36...
Page 88: Ink Tube Replacement
3-7 INK TUBE REPLACEMENT Turn on the sub power while pressing the left, right and down keys to enter the Service Mode. MENU MENU SERVICE MENU Select [SERVICE MENU] > [SUB MENU] > [PUMP Revised 2 < ECO-SOL MAX ink > <...
Page 89 Remove the Carriage Cover. CARRIAGE COVER Disconnect the ink tubes (Carriage Side) from the Y tube joints, and put the scotch tape at the tip of the ink JOINTs tube to prevent the ink from coming out. It is not necessary to replace the ink tubes of the other side (Carriage Side) of the joints.
Page 90 Put the new ink tubes in the Tube Guides. Connect the JOINT ADAPTERs new ink tubes to the Joint Adapters(Cartridge Side), and ﬁ x them to the Clamps. TUBE GUIDE Connect the tubes to the tube joints in the fixed positions with K on top as shown in the ﬁ...
Page 91 Connect the tubes to the Y tube joints (Carriage Side). JOINTs Fix the Carriage Cover. CARRIAGE COVER After turning on the main power, turn on the sub power while pressing the left, right and down keys to enter the Service Mode. MENU MENU SERVICE MENU...
Page 92: Board Replacement (Main Board Sw Power Supply)
3-8 BOARDS REPLACEMENT (MAIN BOARD / SW POWER SUPPLY) BOARD LAYOUT (IN CHASSIS) POWER BOARD SERVO BOARD MAIN BOARD SW POWER SUPPLY MAIN BOARD REPLACEMENT MAIN BOARD CONNECTOR LAYOUT CN14 CN15 CN17 CN19 CN22 3-41...
Page 93 Turn on the main power. MAIN POWER SW < Rear View > Start the Peck. Perform [Get Report] and [Get Parameters], and save the Service Report and the parameters. Turn off the main power and pull out the AC cord. MAIN POWER SW <...
Page 94: Right Top Cover
Remove the I/S Cover, Right Top Cover and Chassis Cover. RIGHT TOP COVER I/S COVER CHASSIS COVER Remove the 4 screws as shown in the ﬁ gure. SCREW < Top View > Disconnect the cables and release the cables from the clamps.
Page 95 Disconnect all the cables from the Servo Board. Remove the 4 screws as shown in the ﬁ gure to remove the Servo Board. Disconnect the cables as shown in the ﬁ gure from the Main Board. Disconnect the connector and Ribbon Cable as shown in the ﬁ...
Page 96 Connect the cables as shown in the ﬁ gure to the Main Board. Fix the Servo Board with the 4 screws as shown in the ﬁ gure. Put back the Chassis. CHASSIS Connect all the cables to the Servo Board. 3-45...
Page 97 Fix the Chassis with the 4 screws as shown in the ﬁ gure. SCREW < Top View > CHASSIS Connect the cables and bundle them with the clamps. Make sure to insert the connector of the Power Board to the proper sockets. On the connector...
Page 98: Ip Address Setting
Perform the following operations if it is not possible to transfer the parameters by Peck4.exe. 1. DIP SW SETTING 2. BATTERY INSTALLATION 3. FIRMWARE INSTALLATION 4. SYSTEM PARAMETER INITIALIZE 5. TIME AND DATE SETTING Set the date and time in the [SERVICE MENU] > [SUB MENU] > [CLOCK]. *Set the [DATE] in order of the [Year/Month/Day].
Page 99 SW POWER SUPPLY REPLACEMENT (41V,5V) SW POWER SUPPLY CONNECTOR LAYOUT Connected to the [CN1] and [CN405] on the Servo Board, and [CN22] on the Main Board Connected to the [CN302] on the Power Board. Turn off the sub power, and then turn off the main power and pull out the AC cord.
Page 100 Remove the 4 screws as shown in the ﬁ gure. SCREW < Top View > Disconnect the cables and release the cables from the clamps. Pull out the Chassis to the front side. CHASSIS Disconnect all the cable from the SW Power Supply. 3-49...
Page 101 Remove the 5 screws as shown in the figure and replace with the new SW Power Supply. Connect all the cables to the SW Power Supply. In case that the volume is accidentaly turned around, adjust the output voltage value to +41 +/- 0.1.
Page 102: Battery Replacement
3-9 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. P u t t a p e a r o u n d t h e l i t h i u m battery for insulation for disposal or preservation.
Page 103 Remove the battery on the Main Board by pushing it SOCKET down and tilting towards left. MAIN BOARD Replace the battery with new one. SOCKET BATTERY Be careful with the direction of the battery. MAIN BOARD Turn on the main power, then turn on the sub power while pressing the left, right and down keys to enter the Service Mode.
Page 104 Select [SUB MENU] > [CLOCK] > [DATE], and set the date and press [ENTER] key. SERVICE MENU SUB MENU SUB MENU CLOCK CLOCK DATE DATE 00/00/00 DATE 06/08/08 Turn off the sub power, and then turn off the main power. Fix the Chassis Cover.
Page 105: Carriage Belt Replacement
3-10 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, and then turn off the main power.
Page 106 Remove the 2 screws ﬁ xing the Belt Holder Stay to the Head Carriage. Loosen the 2 Fixingscrews as shown in the ﬁ gure <Top View Left side of the Belt> located leftside of the Belt. And loosen the Adjustment Screw. Fixingscrew Adjustment Screw Remove the Belt Holder Stay from the Head Carriage...
Page 107 Replace with the new Carriage Belt. Check that the Belt is not twisted. Put adequate quantity of grease(P/# : 21675102 GREASE, FLOIL G-902Y 10ML) on the pulleys. <Left side> < > Right Side Tighten the screws as shown in the ﬁ gure to ﬁ x both <...
Page 108 Fix the Belt Holder Stay to the Head Carriage with the screws. Tighten the Adjustment Screw to have tension on the <Top View Left side of the Belt> Belt and then, tighten the 2 Fixingscrews shown in the ﬁ gure. Move the Head Carriage in a whole width of the machine.
Page 109: Encoder Scale Replacement
3-11 ENCODER SCALE REPLACEMENT Remove the following covers. LEFT SIDE COVER TOP COVER I/S Cover FRONT RAIL COVER Maintenance Cover Left Side Cover Front Rail Cover Front Cover MAINTENANCE COVER Top Cover FRONT COVER I/S COVER Move the Head Carriage slowly leftwards. HEAD CARRIAGE Remove the Encoder Scale by removing the plate ﬁ...
Page 110 Put the Encoder Scale in between the Encoder Plate and the Guide Rail. ENCODER SCALE Then, ﬁ x the right end with the plate and hook up the spring on the left end. GUIDE RAIL Make sure that the Encoder Scale is in place. ENCODER PLATE Do not loosen or tighten the screws ﬁ...
Page 111: Grit Encoder Replacement
3-12 GRIT ENCODER REPLACEMENT Turn off the sub power, and then turn off the main power. MAIN POWER SW < Rear View > Remove the following covers. Maintenance Cover Left Side Cover Left Cover LEFT COVER MAINTENANCE COVER LEFT SIDE COVER <...
Page 112 Replace with the new Grit Encoder. GRIT ENCODER The both sides of the Grit Encoder is the same. When ﬁ xing the Grit Encoder, make sure not to scratch or leave any fingerprints on the Grit Encoder. Fix the Grit Encoder Stopper with the 3 screws as shown in the ﬁ...
Page 113 After turning on the main power, turn on the sub power while pressing the left, right and down keys to enter the Service Mode. MENU MENU SERVICE MENU Check the GRIT ENCODER. SERVICE MENU Go back to the [MOTOR MENU], and select [G-ENC. MOTOR MENU CHECK] and press the [ENTER] key.
Page 114: Pinch Roller Replacement
3-13 PINCH ROLLER REPLACEMENT Remove the Pinch Roller from the Pinch Lever. Pinch Roller Pinch Lever Fix the new Pinch Roller to the Pinch Lever. < ZOOM > Pinch Lever Pinch Roller Make sure that the Pinch Roller is ﬁ xed ﬁ...
Page 115: Holder Cable Sheet Replacement
3-14 HOLDER CABLE SHEET REPLACEMENT Turn on the sub power while pressing the left, right and down keys to enter the Service Mode. MENU MENU SERVICE MENU Select [SERVICE MENU] > [SUB MENU] > [PUMP Revised 2 < ECO-SOL MAX ink > <...
Page 116 Remove the Carriage Cover. CARRIAGE COVER Disconnect the ink tubes from the Y tube joints, and CLAMPs put the scotch tape at the tip of the ink tube to prevent the ink from coming out. And remove them from the Clamps.
Page 117 Remove the Cable Holders and Holder Cable Sheets from the Tube Guides leaving the Ribbon Cables and HOLDER CABLE SHEET CABLE HOLDER Holder Cable Plates. HOLDER CABLE PLATE RIBBON CABLE TUBE GUIDEs Fix the new Cable Holders and Holder Cable Sheets to the Tube Guides with reference to the following ﬁ...
Page 118: Cable Holder
Be careful with < Fixing Position > the ﬁ xing order. CABLE HOLDER HOLDER CABLE SHEET x 2 RIBBON CABLE x 3 CABLE HOLDER HOLDER CABLE PLATE TUBE GUIDE Make sure that the ﬁ xing direction of CABLE HOLDER RIBBON CABLE HOLDER CABLE PLATE HOLDER CABLE SHEET the Holder Cable Plate is correct.
Page 119 Fix the 2 Tube Guides. Connect the Ribbon Cables to the Carriage Board, and ﬁ x them with the clamp. Make sure that the tubes do not touch the plate and Cable Guide Support. plate CABLE GUIDE TUBE GUIDEs SUPOORT In case of replacing the Tube Guides, cross <...
Page 120 Move the Head Carriage in a whole width of the machine manually to make sure that there is no noise. Conﬁ rm the cable assemblies when it makes abnormal noise. HEAD CARRIAGE After turning on the main power, turn on the sub power while pressing the left, right and down keys to enter the Service Mode.
Page 121: Adjustment
4 Adjustment 4-1 SERVICE MODE MENU ], [ ], [ ] + POWER ON [ MENU ] key SERVICE MENU HEAD RANK 1 SERVICE MENU PRINT MENU HEAD RANK This menu is used for entering the Head Rank for each head PRINT MENU HEAD RANK HEAD 1...
Page 122 Normal (beeps 1 time) PRINT MENU NOW PROCESSING.. LINEAR ENCODER LINEAR ENCODER POS: 1361.00mm SETUP COMPLETED Error (beeps 2 times) LINEAR ENCODER Error is found on Linear This is for checking the installation and Encoder and Scale. operation of Linear Encoder and Scale. SETUP FAILED Refer to [4-6 LINEAR ENCODER SETUP].
Page 123 Remove all cartridges All cartridges must be removed before entering IC Set cartridge to SLOT1 before pressing [ENTER] key CHECK menu. It detects Ink Cartridge IC, writes and loads information, CARTRIDGE IC CHECK I/S MENU and checks the communication. First, it confirms if IC CHECK SLOT1 INSERT...
Page 124 FRHDPULWwabC 1234 SERVICE MENU SENSOR CHECK This menu displays the real-time status of each sensor. It shows [ ] when the sensor is ON. The second page shows the status of each The first page shows the status of each sensor. Each alphabet stands for as follows. Cartridge Sensor and Ink Empty Sensor.
Page 125 SUB MENU PERIODIC CL. This is for selecting a cleaning type for [PERIODIC CL.] function. Options: WIPE / LIGHT / NORMAL / MEDIUM Default: NORMAL PERIODIC CL. LIGHT LIGHT WIPE: Wiping and Flushing only LIGHT: Wiping and light evacuation (lighter than regular cleaning) only NORMAL/MEDIUM: The regular NORMAL/MEDIUM cleaning SUB MENU FAN CHECK...
Page 126 AGING SCAN SERVICE MENU MOTOR MENU SCAN : Aging for Scan Motor. The Head Carriage runs max. printing width SCAN NOW AGING MOTOR MENU AGING in Scan direction. FEED : Aging for Feed Motor. Grit Roller runs 100mm back and forth. AGING FEED BOTH : The Head Carriage runs max.
Page 127 SERVICE MENU HISTORY MENU MOTOR HOURS F MOTOR HOURS F HISTORY MENU MOTOR GROUP 3 hours CLEAR CATEGORIES: MOTOR GROUP / HEAD GROUP / MAINTE GROUP / In History Menu, the parameters are separated in groups WIPE GROUP / PRINT GROUP / CUTTING GROUP / by categories.
Page 128: History Menu
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: 1500 hours PUMP TIMES Total time that the Pump Motor has been rotated. times Life: 200,000 times CLEAR　ALL...
Page 129 MAINTENANCE GROUP Item Contents Unit Reference Number of times the Head Maintenance([SUB MAINTE. COUNT MENU]>[MAINTENANCE]>[CLEANING]) has been times performed. This value is cleared automatically after carrying out the TOTAL　TIME Lapsed time from the last Head Maintenance hour Head Maintenance. This value is cleared automatically after carrying out the PRINTING TIME Printing time from the last Head Maintenance hour...
Page 130: Service Report
192.0 cc Calibration default -0.26 % Standard head Encoder position(L) 1516.6 mm Flushing pos adjust 0.00 mm Encoder position(R) 145.0 mm Roland Versa Art series Model RS-640 IP Address 192.168.000.100 Ink type E-SOL Max 4Color Version Subnet Mask 255.255.255.000 Ink remain (1-4) 76/ 62/ 59/ 73 Serial No.
Page 131: History Report
HISTORY REPORT History Report Model : RS-640 Serial No. : XXXXXXX Version : 2.0 Date : 2008/07/11 14:24 ==== Motor group ==== Motor feed (trip / total [clear]): hours Motor scan (trip / total [clear]): hours Pump Times (trip / total [clear]): 1,703/ 1,703 times...
Page 132: Event Log Report
INK CARTRIDGE REPORT Ink Cartridge Report Model : RS-640 Serial No. : XXXXXXX Version : 2.0 SERIAL/ INK TYPE/ CAP./ LOT No/ CONSUM./ TIME/ INS./ FLAG 14d178b002000071/ MAX K/ 400cc/ 60907A/ 47.879cc/ 0y015d04h14m08s/ 00000000 000000018ebb7700/ MAX C/ 400cc/ 61004A/ 75.914cc/ 0y015d04h14m03s/ 00000000 000000018ef67200/...
Page 133 [ ] key to start the machine in the Service Report Printing mode. The service report will be printed Roland DG Corp. RS-640 automatically when the media is set SERVICE REPORT up. It prints with Black ink. MENU LANGUAGE...
Page 134: Key Combinations
Key Combinations Function for Service Combination Key Selection Comments Press [MENU] and [ ] to enter Service Service Mode Menu. [UPDATE FIRMWARE?] will be F/W Upgrade Mode displayed. Press [ENTER] to upgrade F/W. Use this when the Main Board is replaced.
Page 135: System Info
4-2 HOW TO UPGRADE/INSTALL FIRMWARE It is necessary to prepare the followings to upgrade/install the rmware. 1.Firmware le 2.WindowsPC (Network port is required.) 3.Peck5.exe 4.Network cable (A cross cable is required when you connect RS-540/640 to PC directly.) HOW TO UPGRADE FIRMWARE (Referential Time : 5 min) Check the IP address of RS-540/640.
Page 136 Start the Peck5. [Peck5] screen is displayed, and click [Select Port] button. Select [Type3 ProIII, VP series etc.] from [Product]. Also, select [Via Network] and input IP address of RS-540/640. Click [OK] button. [Peck5] screen is displayed again. Click [Firmware Upgrade] button. [OPEN] screen is displayed.
Page 137: Update Firmware
T h e m a c h i n e g o e s i n t o t h e F i r m w a r e Upgrade mode automatically. FIRMWARE V1.0 DATA ERROR When upgrade is completed, the Sub Power turns off automatically.
Page 138 Press [MENU] key, and set [IP ADDRESS], [SUBNET MASK] and [GATEWAY ADDR.]. WAITING Press [ ] and [ ] keys for moving between digits, 000.000.000.000 and [ ] and [ ] keys for selecting value. After setting an address, press [ENTER] key to go next MENU address setting.
Page 139 [Peck5] screen is displayed again. Click [Firmware Upgrade] button. [OPEN] screen is displayed. Select the rmware le and click [Open]. It starts to send the rmware to RS-540/640. It starts loading the rmware. The rmware installation is completed when FIRMWARE V1.0 DATA ERROR [COMPLETED] message is displayed.
Page 140: Service Menu
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 141 Start the Peck5 on PC. [Peck5] 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]. Peck5 starts to send the System Parameter to RS-540/640. Click [Get Report] button to import the System Report Confirm that the System Parameter is reloaded properly.
Page 142: How To Upgrade Firmware Of The Network Controller
4-3 HOW TO UPGRADE FIRMWARE OF THE NETWORK CONTROLLER ( Referential Time : 5min.) Turn on the Main Power SW and Sub Power SW, then press [MENU] key. Select [SYSTEM INFO.]> [NETWORK]> [IP ADDRESS] MENU and set the IP address. Close the RIP when it is running.
Page 143 Specify the target le for upgrade and click [Update]. The progress is shown in percentage while upgrading. Do not turn off the power or press any keys while upgrading. When upgrade is completed, the version of upgraded Network Firmware appears. Turn off the Sub Power SW and Main Power SW once.
Page 144: Head Alignment
4-4 HEAD ALIGNMENT (Referential Time : 30 min._1 Head Alignment) This is necessary to obtain the good printing quality. Be sure to operate this alignment when the head is replaced. If the heads are not aligned, printing problems such as banding, ne lines and gap between bands could occur.
Page 145 Turn on the Sub Power SW while pressing [ ], [ and [ ] keys to enter the Service Mode. Set up the PET-G on the machine. MENU MENU SERVICE MENU [BIAS ADJUSTMENT] SERVICE MENU Select [PRINT MENU]> [HEAD ADJUST]> [BIAS]> [ PRINT MENU TEST PRINT], and press [ENTER] key.
Page 146: Adjustment Screw
Insert the 1.5 mm Hexagonal Wrench through the hole ADJUSTMENT of the Head Carriage, then turn the Adjustment Screw to SCREW make the lines of each color in the test pattern straight. Position of the printing moves 1 line by turning the screw 2/3 turn.
Page 147 [VERTICAL ADJUSTMENT] SERVICE MENU S e l e c t [ P R I N T M E N U ] > [ H E A D A D J U S T ] > PRINT MENU [VERTICAL]> [TEST PRINT], and press [ENTER] key. [ ] [ ] PRINT MENU HEAD ADJUST...
Page 148 When the lines other than K are above the K lines, turn the Adjustment Screw CW. When the lines other than K are below the K lines, turn the Adjustment Screw CCW. Adjust the head positions referring to the left-end K head as the base position. The position of K head on the left end does not need to be adjusted.
Page 149 Te s t P a t t e r n w i l l b e printed. Find the position where the line of each color Head Position: matches the K line and DT3.High +3 +4 +5 +6 High check the number. In case of having problem selecting one between 2 numbers, 1/2 is also...
Page 150 [BIDIRECTIONAL ADJUSTMENT] SERVICE MENU Select [PRINT MENU]> [HEAD ADJUST]> [BI-DIR. PRINT MENU DEFAULT]> [TEST PRINT], and press [ENTER] key. [ ] [ ] PRINT MENU HEAD ADJUST HEAD ADJUST BI-DIR.DEFAULT BI-DIR.DEFAULT TEST PRINT TEST PRINT 1234 Test pattern will be printed. Find the position where the two lines are overlapping and check the number of each color.
Page 151 Select [DT1, Low], [DT3, Low], BI-DIR.DEFAULT [DT1, HIGH] and [DT3, HIGH] in TEST PRINT the [HEAD ADJUST] menu and enter the parameters checked at BI-DIR.DEFAULT DT1, Low 21 with [ ] and [ ] keys. Press [ENTER] key to save the BI-DIR.DEFAULT settings.
Page 152: Limit Position & Cut Down Position Initialize
4-5 LIMIT POSITION & CUT DOWN POSITION INITIALIZE (Referential Time : 3min.) Followings must be done before this adjustment. 1) Operation check of wiper 2) Sensor check of wiper sensor and head rock sensor, and making sure if they work properly 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.
Page 153 Con rm that the head is certainly capped, and press [ENTER] key. Limit position initialize starts. SETTING UP After the completion of the initialize, the message is THE LIMIT displayed as shown in the gure. DETECTING.. SETTING UP CUTTER DOWN POS Move the Head Carriage with your hand until it makes full contact with the Left Frame with Cut Down status.
Page 154: Linear Encoder Setup
4-6 LINEAR ENCODER SETUP (Referential Time : 5min.) This is for checking the reading of the Encoder Scale and for calibrating its expansion/contraction caused by the operation environment. This operation is required when the Limit Sensor, Encoder Scale or Encoder Module is replaced or the position is adjusted. Turn on the Sub Power SW while pressing [ ], [ and [...
Page 155 One of the messages appears at the completion of the set up. In case of SETUP FAILED, check the followings. LINEAR ENCODER Dirt/Scratch on the Encoder Scale. SETUP COMPLETED Dirt/Scratch on the Encoder Module. Encoder Scale is not between the Encoder Module. Backlash of the Carriage Motor Gear and the Drive Gear.
Page 156: Flushing Position Adjustment
4-7 FLUSHING POSITION ADJUSTMENT (Referential Time : 5min.) This is to adjust the ushing position. This adjustment is required when a Cap Top and a head are removed or replaced, or LIMIT POSITION & CUT DOWN POSITION INITIALIZE is performed. Without this adjustment, the Flushing may not be performed properly.
Page 157 Select [PRINT MENU]> [FLUSHING ADJ.], and press [ENTER] key. SERVICE MENU The Head Carriage automatically moves to the current PRINT MENU ushing position. [ ] [ ] PRINT MENU FLUSHING ADJ. FLUSHING ADJ. SET POSITION Move the Cap Tops and heads to the position where the leftmost Cap Top makes contact with the surface of the leftmost head by pressing [ ] and [...
Page 158 4-8 CALIBRATION (FEEDING DIRECTION) (Referential Time : 20 min.) This adjustment is for calibrating the feed amount of the media. It allows the media to be fed proper amount by calibrating the variation in Grit Roller diameter. Calibration of the machine is made based on the value in feeding media [PET-G] (Roll media with a width of 1050mm.) Without proper calibration, it causes misalignment in the feed amount of media, and results in the problems such as white banding, banding of overlap or the dimension error of print result compared to...
Page 159: Calibration(Feeding Direction)
Calculate the amount to be calibrated with the formula as shown in the gure. Measured 400 - Length Calibration x 100 Value Measured Length S e l e c t [ P R I N T M E N U ] > [ C A L I B . D E FA U LT ] > SERVICE MENU [SETTING], and enter the calibration value with [ PRINT MENU...
Page 160: Belt Tension Adjustment
4-9 BELT TENSION ADJUSTMENT (Referential Time : 20min.) Lock the Head Carriage. Remove the Covers in order. TOP COVER 1. I/S Cover LEFT 2. Maintenance Cover COVER FRONT RAIL COVER 3. Left Cover 4. Front Rail Cover MAINTENANCE 5. Front Cover COVER 6.
Page 161 Loosen the 2 Fixing Screws which are located on the <TOP VIEW> left 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 2 screws to make a gap of 3mm between the tip of the screw and Idle Pulley Holder.
Page 162 Tighten the 2 screws shown in the figure to slightly contact with Idle Pulley Holder. Move on to [4-10 BELT POSITION ADJUSTMENT]. SCREWs Make sure not to tighten the screws too tight. It may move the fixed Idle Pulley Holder accidentally.
Page 163: Belt Position Adjustment
4-10 BELT POSITION ADJUSTMENT (Referential Time : 30min.) This adjustment is to prevent the belt wear which is caused by the belt contacting with the pulley anges excessively. The belt position needs to be con rmed after the Belt Tension Adjustment and adjusted if it is necessary.
Page 164: Chassis Cover
Con rm the belt position. <TOP VIEW(R)> The position is proper when the belt is not touching the flanges of the Drive Pulley excessively. When the position is proper, skip this adjustment and go to [ADJUSTMENT ON THE IDLE PULLEY SIDE] described in the later step of this adjustment leaving FLANGE the belt aging on.
Page 165 Press [ENTER] key to restart Aging. AGING SCAN Adjust the belt position turning the Adjustment Screw Touching the frange on the FRONT side of machine as follows. Belt leans to the front side of the machine -Turn the screw carefully in CCW (loosening). The work space is narrow.
Page 166 Con rm that the belt is not touching the pulley anges <TOP VIEW(R)> excessively. When the belt is in improper position, adjust it again. When it is proper, leave the belt aging on, and go to the following [ADJUSTMENT ON THE IDLE PULLEY SIDE].
Page 167 Insert a wrench through the holes on the Side Frame and loosen the 2 screws to make a gap of 3mm between the tip of the screw and Idle Pulley Holder. SCREWs The gap between the screws and Idle Pulley can be seen from both front side and rear side of the machine.
Page 168 Tighten one of the screws that has no contact with the Idle Pulley Holder to slightly touch the Idle Pulley Holder. SCREWs Make sure not to tighten the screws too tight. It may move the Idle Pulley Holder accidentally. IDLE PULLEY HOLDER Tighten the 2 Fixing Screws as shown in the gure.
Page 169: Take-Up Unit Operation Check
4-11 TAKE-UP UNIT OPERATION CHECK (Referential Time : 2min.) This is to check whether the Take-up Unit operates properly. Con rm that the cable of the Take-up Unit is connected <REAR VIEW> to the connector and turn on the Main Power SW. Turn on the Sub Power SW while pressing [ ], [ and [...
Page 170: Forward Or Backward
Con rm that [START] is selected, and press [ENTER] key to turn on the Take-up Unit. [START] or [STOP] can be selected with ] and [ ] keys. START START The current setting is displayed on the left and the new setting is diplayed on the right. Set the AUTO switch of the Take-up Unit to either FORWARD or BACKWARD.
Page 171 Move the Dancer Roller up and down by hand, and con 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 entering [TU] menu. DANCER ROLLER 4-51...
Page 172: Paper Side Sensor Adjustment
4-12 PAPER SIDE SENSOR ADJUSTMENT (Referential Time : 5min.) This is for adjusting the sensitivity of the PAPER SIDE SENSOR, which is for detecting the width of the media. If it is not adjusted, media width could not be detected correctly. Remove the I/S Cover.
Page 173 Turn on the Sub Power SW while pressing [ ], [ and [ ] keys to enter the Service Mode. MENU MENU SERVICE MENU S e l e c t [ S U B M E N U ] > [ PA P E R S I D E S E N S E ] > SERVICE MENU [OUTPUT LEVEL], and press [ ] key.
Page 174 If the voltage is less than 0.5V, increase the voltage for 0.1V in the [OUTPUT LEVEL] menu and carry out the [SENSOR AUTOTEST] for checking. If the voltage is more than 1.0V, decrease the voltage for 0.1V in the [OUTPUT LEVEL] menu and carry out the [SENSOR AUTOTEST] for checking.
Page 175: 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 NS Purpose HEAD ALIGNMENT Parts No. ST-001 Parts Name TENSION GAUGE 2000GF/2000CN Purpose BELT TENSION ADJUSTMENT Parts No.
Page 176: Sensor Map
5-2 SENSOR MAP LIMIT SENSOR REAR PAPER SENSOR It detects the limit positon of the head carriage It detects the rear edge of the media and also in the scan direction. whether the media is loaded or not. IS COVER SENSOR THERMOSTAT(HEATER) It detects whether the IS Cover is If the Heater exceeds the limit temperature,...
Page 177 WIPER SENSOR It detects the limit position of the Wiper movement. ENCODER MODULE It detects the coordinates in the carriage moving direction, and also generates the print signal. HEAD UP/DOWN SENSOR It detects the position of the Head Height Lever. PAPER SIDE SENSOR It detects the left and right edges of the media.
Page 178: Troubleshooting
6 Troubleshooting 6-1 DEFECT OF PRINT QUALITY (BANDING/SCRATCHY PRINTING/BLURRED PRINTING) Missing dot or Improved Perform Normal deflected-fired dot Solved Cleaning appears on the test Not Improved *Several Normal Cleanings and a Powerful Cleaning do not improve the printing result. To 1-10 To 11-16 CHECKING POINT ACTION...
Page 179: Particular Color Is Not Printed At All
6-2 PARTICULAR COLOR IS NOT PRINTED AT ALL CHECKING POINT ACTION REFERENCE OUTLINE When the machine keeps printing with ink cartridge almost Ink Cartridge is almost Check remaining Ink / empty, the negative pressure delivered in the ink tube causes User's Manual empty Replace the Ink Cartridge...
Page 180: Ink Drops On The Media
6-4 INK DROPS ON THE MEDIA CHECKING POINT ACTION REFERENCE OUTLINE When foreign substances such as fiber dust are stuck on the Foreign substances Manual Cleaning User's Manual surface of the Head, Ink sometimes leaks from it. Wipe the surface of Head with a cleaning stick. Use the media clamps/ If media tends to curl or become bumpy due to the Ink Media strikes Head...
Page 181: Motor Error
6-8 MOTOR ERROR CHECKING POINT ACTION REFERENCE OUTLINE Remove cause of Media Jamming Media Jam Back tension of media is When using hard-to-unroll or too heavy media, Motor Error Use appropriate media too high occurs due to the too much load for feeding the media. There is a dirt in teeth of When the Drive Gear has some dirt on its teeth and cannot Clean Drive Gear...
Page 182: Heater/Dryer Temperature Does Not Go Up
6-9 HEATER / DRYER TEMPERATURE DOES NOT GO UP CHECKING POINT ACTION REFERENCE OUTLINE The media is not loaded Set up the media. User's Manual Inappropriate Check the temperature When the setting of print heater/dryer is off, the Heater does temperature is set on the User's Manual setting...
Page 183: Service Call
6-12 SERVICE CALL CONTENTS CODE CAUSE ACTION Disorder of communication with Sub CPU Servo Board does not work correctly. Check cable connection between Main Board and Servo Sub CPU does not work correctly. Board. This occurs when the Sub CPU is not There is a bad connection between Main Check the other cable connections of Servo Board.
Page 184: Service Activities
7 Service Activities 7-1 INSTALLATION CHECK LIST RS-640/540 INSTALLATION CHECK LIST Date : User Name : Serial Number : Checking the place of installation There is a space necessary for installing the machine as follows. 2400 mm 650 mm 3560 （RS-640）...
Page 185 Unpacking Manual etc. Software disc etc. Accessories Accessories RS-640 only...
Page 186: Checking The Accessories
Checking the Accessories Power cord: 1 Casters: 2 Arm (right): 1 Arm (left): 1 Bolts : 32 Media clamps : 2 Stand leg: 1 Shafts: 2 Media Hexagonal wrench: 1 Media holder : 2 Pipe: 1 ﬂ anges: 2 Retaining screws : 2 Replacement Ink-cartridge blade for separa-...
Page 187: Installation And Preparation
Installation and Preparation Set up following items in reference to the Setup Guide [3.Assembling and Installing] to [7. Network Settings]. Assemble the Stand Install the Media Holder Install the Drain Bottle Attach the Ink-cartridge Tray Remove the Packing Materials Connect the Cables AQUEOUS PIGMENT ink (FPG2) / ECO-SOL MAX ink: Install the Ink Cartridges Revised 2 !! IMPORTANT !!
Page 188 Installing Roland Versaworks Install Roland VersaWorks in reference to the Quick Start Guide. System requirements for installing the software Windows Vista Ultimate Service Pack 1 (32-bit edition) or Windows Vista Business Service Pack 1 (32-bit edition) or Windows Vista Ultimate (32-bit edition)
Page 189: Basic Operation
Basic Operation Explain following items in reference to the User's Manual. Switching the power on and off Main power switch Keep the Loading Lever turned up while not using the machine. Sub power switch Revised 2 !! IMPORTANT !! Leave the main power on at all times. Maintenance operation is automatically carried out every 8 hours while the machine is not in use.
Page 190 - Never store ink at any locations where high temperature may occur or exposed to open ﬂ ame. Job outputting from Roland VersaWorks Explain each procedure as follows on a job outputting from Roland VersaWorks. Printing Adding Media Proﬁ les Explain the procedure of adding Media Proﬁ...
Page 191: Maintenance
Preset function All menu items listed below can be saved in Presets. It is useful to have saved settings that are different by media. Temperature setting of Heater/Dryer - [SIDE MARGIN] - [ADJUST BI-DIR SIMPLE SETTING] - [ADJUST BI-DIR DETAIL SETTING] - [CALIBRATION] - [SHEET TYPE], [SHEET WIDTH], [SHEET POS] - [SCAN INTERVAL]...
Page 192 Explain the following items in reference to the Setup Guide. Temperature and humidity Speciﬁ ed temperature and humidity must be maintained even while not in use. When the temperature is too high, the alteration of ink may damage the machine. And, when it is too low, frozen ink may damage the print heads.
Page 193: Maintenance Check List
Good Sponge for Wiper period from the last replacement. Replacement Done Replacement Cycle : 12 months Cleaning Done Clean it manually using the Roland cleaning stick and cleaning liquid. Wiper Scraper Replace it as necessary. Replacement Done Good Lithium Battery...
Page 194: Specifications
7-3 Speciﬁ cations Main unit speciﬁ cation RS-540 RS-640 Printing technology Piezoelectric inkjet Media Width 259 to 1,371 mm (10.2 to 54 in.) 259 to 1625 mm (10.2 to 64 in.) Thickness Maximum 1.0 mm (39 mil) with liner Roll outer diameter Maximum 210 mm (8.3 in.) Roll weight (*1) Maximum 30 kg (66 lb.)

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