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6. EIE gr ge OS VS Y 2 3057 45 9 1 ximo C ic AA HAS VE TANT AS ini v ki Sid Hs Y y TIS Tv as M E TV VS LIV ds IV s 2 10 xx CVs mc pz aaas YE DIINOO LIV LV dS ct a rac UV VS ANOJ LTV 2 3v X 51795 4 FDA 11 Y TVS TESI ps tV VS T 134 T ev viva AM na mm 04 45 roo Aro Aroma aroa sre 1 I VEEN rop mor som YEODS _ oT VA PIOS 1
7. y 34 4 T SODA lt aroo LL G8INEec 001 10V 117 9001 renis SAASTA IDR T 7HINOQU SC THIE OXA cR 20 I8S88 100 sa E AASTA E IQASHH TASHA OCASHH xuvqut XIVAN T nOD 8504 STA rogo arogo Naaos 124 LL dOI0CR LIE VOO8S809IZININ ED anov Trosa TERETE Bsa 01 po oL l1SNOY aT MOI mck me 31 1 A Ed ee x NALSAL XV x 5DA raai MOL HJ ls ALVIOSI east REN 1810 SINL 513 sal ALASAY 1110 OdL NH SI sas amp
8. mer LIED AC avassayx SE auo T s d NGA ino 6 7 at GV INAS 106 Nos s 44 5 ul STL ITL HEL Cram aves 2 na i r BEBBE I vy ives BEBER GO VENT nr is 5 231 ai EE T gt toris E L EIJA 9 5 TO 5 A sar Laer dir bbe bbb H Lexi 4 c EEEE FEEFEE 2 1X4 EE Fu i 1 aud MA En ERIS SRE Nx i XL 4 41 14 t T Te SI L ori c vy 2 iT se Nds LO gdl pdl sdl TS 2 L 333
9. 3 9 ircuit Diagram MAIN BOARD C gt C EDA T NO OA Wow SUA e Ble 5 A BOSHA bhl 4 2 8 Blu 5 AND BB EB EE TDT 5 SNIS Sd SNAS 547 E L NG 4085 dOND t Ea SERRE
10. y 2 al 2 SERVICE MENU 247 gt SERIAL NO 45 This menu is for entering the Serial No of the machine 7 digits The cursor moves SUB MENU 4 SERIAL NO 417500000 between digits with 4 and gt keys parameter be changed with and v AY t v keys v SUB MENU 45 CHANGE 4 NOW PROCESSING To Setup Vi 4 gt gt gt Setup View CHANGE INKTYPE gt 4 PMAX 44 P Av BUSY LED flashes This is for changing the Ink Type Different from the process in the User Menu Ink Type Max 4 ECO SOL Max CMYK operations such as Head Wash and Fill Ink are not included PIG 4 PIG CMYK This menu is used as a correction purpose when a wrong type ink is selected UNKNOWN Ink Type not specified When the ink type is changed Ink System is initialized internally and then it exits the menu and Setup is canceled ay SUB MENU 4 4 lt gt FILL INK 4 DRAIN BOTTLE 4 4 3 Wheninkisnotfiled EEE 1 SELECT
11. 6955 TISSA TOSSA 09SSA 6SSSA SSSSA 155 9SSSA Mo 085 SSSSA PSSSA ESSSA ZSSSA ISSSA OSSSA 6755 9 SESSA 17884 PSSA GPSSA VESSA EEN A9IMOI A9IMOI A9UUOT TED 612 A arogo arogo TOAD arogo GESSA RITA 60 080 58504 1004 SESSA LESSA 9ESSA SESSA ESSA lt 227 ZEqNOVX 0 TESSA arogo OESSA TAAGA SSA eom 6TSSA SCSSA TEAGE LCSSA B E RIIA 1021 SCSSA a 169 052 812 55A PISSA ESSA 207 TESSA LU 2 occ 0 EETA EEN SUA 98910 arogo SISSA i gt 9 ddA A0T 0001 TIAMdX VOO8S809IZININ SISSA
12. RIVETs 9 zi o o 6 Q l 3 9 2 TOOL CARRIAGE BOARD COVER CROP MARK SENSOR SOLENOID PINCHROLLERSENSOR TOOL CARRIAGE BOARD Remove the 2 screws to remove the Tool Carriage Board Stay from the Tool Carriage Assy TOOL CARRIAGE BOARD STAY 4 2 SCREW 0 A 5 2 B Du D Rp b s L mier 7 LL LLL TOOL CARRIAGE ASSY Loosen the 2 fixingscrews as shown in the figure lt Top View Left Side of th
13. 2 20 1 2 ircuit Diagram CARRIAGE BOARD C AISMA waa 7 4 SOT 1022 T r dan QHVO8 39VIHHVO LNIHd Stal I 5 4 Ferdi zs A US d dos porn OL OL 0650 108 YOSNAS AYAH OL es s CHA DIOS
14. Bs o g 81967621 01N2 LINI P 3 lus 00000 00000 5 ME js r o0 lt INO ee neir 402 2 gt 588 2862 H E 8 i 4 3 4263 HH E H m o 02 Mw LL es 2 m 41 5 SES spes 7 o s MUT Orn en 121 1 JE 9 8 1 8 32 i to m a MIR 7 SSH 8 2 8 52 Lr 16 sevap T eevu 651 Li jo i ve 504 22 0624 sy O 3 reng 2 ds IN sy 58 L 8 s 2 amp 5 5 12194 8 K SEE 8 3 d 478 8 2 g gt Zr odd Billet 5 TIE E ol 3 eme 3 8 5552 g 00088 pa 552 god 2 1918 u 2 9918 qoo Li 3 2 igu E e 2 8 i EE 5 8 ag b eI 90 Susp aeu e H ED EL LTY 578 3 i em 77 LL LL oo e IF osos ozva 6cvH ive 4 envy 5279 LEVY BR zs Oor 3 E 22 t zou Ty 1 92 89 3 g
15. Disconnect the Crop Mark Sensor Pinch Roller Sensor nah CROP MARK SENSOR SOLENOID and Solenoid wirings PINCHROLLERSENSOR Remove the 2 screws fixing the Tool Carriage Board TOOL CARRIAGE BOARD z SCREW o R rr E RN 5 9 2 0 E 1t Remove the 2 screws to remove the Tool Carriage Board TOOL CARRIAGE BOARD STAY Stay from the Tool Carriage Assy SCREW i gm 7 5 9 LIT Z a _ TOOL CARRIAGE ASSY Remove the 2 screws as shown in the figure to remove the Tool Carriage Assy Ene OL SCREW 9 J d __ 2 O 8 x eO SSS SS SSS TOOL CARRIAGE ASSY 3 17 10 11 Remove the Auto Sheet Cutter together with the plate from Tool Carriage and fix the Auto Sheet Cutter to the new Tool Carriage Fix the new Tool Carriage with the 2 screws as shown in the figure while holding it upwards Fix the Tool Carriage Assy to the Tool Carriage Board Stay with the 2 screws as shown in the figure 12 Fix the Tool Carriage Board with the 2 screws as shown in the figure 3 18 TOOL CARRIAGE AUTOSHEET CUTTER 5
16. J OO SCREW o1 lo 19 259 CARRIAGE TOOL CARRIAGE BOARD STAY SCREW 2 8 5 Z bi 770 _ TOOL CARRIAGE ASSY TOOL CARRIAGE BOARD SCREW 09 e S 9 5 D 8 C r _ 7 7 9 E 9 ce SS Connect the Crop Mark Sensor Pinch Roller Sensor and 13 apnd CROP MARK SENSOR SOLENOID Solenoid wirings 7 r _ am 5 PINCHROLLERSENSOR 14 Perform the following adjustments and settings 1
17. NONDYOL 5 ALANINO CHL H 1 O O xx O HA SAH 0 NIVIN OL OL 2 21 CARRIAGE BOARD Circuit Diagram 2 2 CUT CARRIAGE BOARD CN500 15 14 Solt Sol Solt 10 9 i To SERVO BOARD 5 PinchPos PinchPos Crop ON 2 CropSens C507 2 CED 1u NON 3 4 1 5 m 2 4 308 54 47K 5 6 0500 TH 52808 1591 2 d DTBI23EK cso R500 10358 R507 R506 CE0 5 e 2 0 T R504 100 E Crop Sens 506 aE 503 1000 CE1000p R502 D501 ONON 188355 NON TRO R503 CEO 1u 4Tu 16V D500 ONON 188355 NON c502 3 7977 77 BA10358F 1 LEVCC T Em 1 5
18. MENU lt 4 V 8 gt MENU skeyrcg MENU ajb alb ajb Lp SERVICE MENU 4 PRINT MENU HEADRRANE HEAD RANE Ln NSF This menu is used for entering the Head Rank for each head PRINT MENU gt 4 HEAD RANK 4 1 41234567 1 5 4 with 35 digit number and alphabet The digits be changed AY AW w with 4 and keys and parameters can be changed with A keys The digit being changed is marked with an 21 under bar Press ENTER key to save the settings HEAD RANK 4 4 HEAD RANK 4 44 It beeps for alerting when the calculation for verification 4 HEAD 4 4 1234567 1 5 4 CHECK SUM is not correct in order to avoid input error A 2 HEAD ADJUST 1 BIAS 219 PERFORMING PRINT MENU 45 45 45 4 HEAD ADJUST 4 4 5 PRINT TEST PRINT A Feeds media for visual check of the test pattern by pressing x 3 keys while in TEST PRINT menu Also pressing A or keys again after feeding media returns BIAS ing A keys again after feeding medi to the original position HEAD ADJUST 4 VERTICAL 4519 PERFORMING 4 VERTICAL PRINT 4 TEST PRINT AY Feeds media for visual check of the test pattern
19. before pressing ENTER key Set cartridge to SLOT1 CHECK menu I S MENU s CARTRIDGE 4 4 It detects Ink Cartridge IC writes and loads information lt 4 checks the communication First it confirms if CARTRIDGE 4 IC CHECK 4 SLOTI INSERT there is the driver for IC detection The message below AY is shown when an error is found on the driver Error IC CHECK IC CHECK SYSTEM ERROR SLOTI ERROR Next IC communication is checked individually by slot Normal When a cartridge is inserted it automatically starts to communicate with the cartridge IC for checking Display IC CHECK shows OK when the communication is done properly SLOT1 OK As cartridge is removed the slot number of next 1 cartridge to be inserted is displayed Starting from 50071 it continues to SLOT4 in order When the check FromSLOT1to4inorder of SLOT4 is completed the following message is Set cartridge to SLOT12 displayed at the end of check IC CHECK 4 IC CHECK SLOT4 INSERT COMPLETED 4 It returns to IC CHECK menu by pressing ENTER key Error When communication is failed it displays as below CHECK IC CHECK SLOT4 ERROR 6 SLOT1 ERROR Norma It returns to IC CHECK menu by pressing ENTER key IC CHECK NOTE SLOTS OK Any cartridge can be used for this check as long as it has
20. NON T T wl pi A 88 P Peed DA DA z 8 1 Vion FI poo 1010 2 t 5 i 2 DA GA se 0 IS sr STA ZS 101 n i 5 PIOATRL nose vor MONA fCOTARASXI RPM pi Joo a u 12 qux gt qu iiA INNO 165 gt 2 17 sowie WD ost Wadacdis Wadvedis A Sido y lt NONIM 4100 5 SIOLOIN IHdIAA IATA 3 4 YOLOW t Diagram OL Ircul SISSVHO SERVO BOARD_C 2 91 a sorioes konor 06 SDA 8 TORNO ES 8 91 Wada dis Wav idis m V NONIS 1 NONSE VOETINOXE NONDIOI ores Wadvedis HI NOwAV HI aaa
21. ZEOHAPL SPOTOT TLEIOHAFL os ds oL 09 qs os 20 00121 2 24 OOIND CN E 6 o S a 5 gt 47 0 MS 190g 01 SUB BOARD C 000 2dd 0005 244 gs 10684 i 9 0005 2054 40054 005541 voocd HA c paca 2 man TOEND K ddng AS 01 HA dcH c I IBD 399198 002 001 93 uoiddy 90 NO HA dcH 1 t 7 19H oi S0 NO HA LdtH 9 q 5 19919 002 001 0 60 HA dcH wH pga i t TOENO HA dcH jeosouuaqup pog 00 NO tno 8 8 38 d I dA ds0c WED 106 pt p 55 44 B E PU I dA dS07 WED 0054 Wr0 L9TS NONDdQLFRO 1055 ant peog 0j 2 25 HOLOIN Q334 OI HOGILESVO OL KCCASAHXH TGTARAXi JOW pag 1190 OL oos PEP
22. Waavoris IFCIDHAEL DNO ejr 2 18 NONJRT 0S2 18662240 e 12 62 0924 JDA vro Lozs JS 5 3 NO 6IL LSTA peog OL 0 NOTH 1 Sec 10551 19518531 6120 ESTA osza A JDA Q 8 90 SOMLSOGLONSC 8 lt z 19cc Lp VSTE LOL 5 oO GINA DAIISOY SOPND JDA D davod OL SERVO BOARD_C NO MOIS so HA dtH avis Steersc 10 MrIIDLG MS O AT T sla 00 901 81 sou osu 5 dooora a VOIOS IdS 8 N E uc E 1 JIA 2 80 2 Z FJ Ss lt sa o ON moms c 2 CoN N si SDA 87115 40 7 968 621 Ho Ly SSA VOIOS IdS 62
23. a 5905 95 3 2 ora 12 91 8 8 8 duo S E 8 88402 3 54 925 ON MOMS L AA MS xm 68 g ON ON n arogo Ly gra ug Pod peH A 9 n0001 HA d98 A Iddf1S HA Od MS OL IND 2 19 2 4 CARRIAGE BOARD CARRIAGE BOARD Arrangement Diagram Component Side 4 NYdY NI 30 JdVOt viIHHVO INISd 0 6 M 52 20201 D o a 2 22 0 gooey 20880 50 gt eoe a a ajo o T eU amp 0020 3018 Xd d P SE 5
24. 8 2 ONIS 4 ui E ini SOLARASINH ESTA IDA 000000 OQI gag amp m ao LL NIVIN OL 8 555 ulis 6 d 8 JE mi 2 8 Lora 201 lt v 000 dir 999 wO BI eee 2 SRL 9071 0 5 ir aw 2 moam 5660 3 i va vad 2 9 188 5 SUO E 7 X sia 2 16 YOLOW OL VALEN OF 2 4 557 ca LD 01 o 5 o YOLOW NVOS OL DO IND 400180 HOIVH SONVNNIVIN pae 5 i aroa F1 4 soT ox LH rec 164 Dae 40192 I NrvivdWns gt ree RIOLS WAS nec 1 100 vava ans nec nac xiuns 5 Da reat coat esaf rear esar SERVO BOARD C
25. Remove the 4 screws as shown in the figure to remove FLANGE the motor from the Flange And fix the new motor to the Flange 12 SS Be careful with the fixing direction of the Flange 3 27 13 Fix the Flange with the 3 screws temporarily 14 Fix the spring 15 Turn the gear by hand and check there is no backlash all the way around 1 Tighten up the 3 screws to fix the Flange in the order shown in the figure S Apply a proper quantity of grease FLOIL 6902 between gears 3 28 17 Slide the Gear Cover to the back side and fix the Gear Cover with the 4 rivets 18 Rotate the Shaft to check that the Gear does not touch the Gear Cover GEAR COVER Top View 19 Fix the Grit Encoder IE The both sides of the Grit Encoder is the same When fixing the Grit Encoder make sure not to scratch or leave any fingerprints on the Grit Encoder 20 Fix the Grit Encoder Stopper with the 3 screws as shown in the figure while holding the Shaft 3 29
26. tg t 144444 a E E llle eb eC esr bbb sr E EERE BEBE EREE REE BEBE al PRES BEBE EREE ble ek keke a 9 C 2222 2222 2220 2222 _ 22222222 27 7 20022202 055 2 DT lt B EE EE RE BERE Eg EE re rego 2 3 all NOD 3 em t HONTEL on DKES Proa eA GXUA SJA 45954588 ee E UAS cu yoj da 1 59 va 45 1 555525552455 417 S EERRUSBEEUG 212 8 T lt sj EA x T TOX Ln ND sum dis LA d YY Ga _ TWOQTSYOWIA LU sL tou TWOG ISVO TIA OOG OSVOREAA UA E IS 4 SL iv TM SSA TIYA 9 CTkESSA g D 2 ON OSSA SNHCODID 1 TROETAD ON ISAL mmm 119899 1 1 8
27. 1 3 DRIVE UNIT VP 540 Below ZW65382 VP 300 Below ZW61509 PARTS LIST Main Parts Parts No Parts Name 6700469030 ASSY PULLEY VP 540 PARTS LIST Main Parts Parts No Parts Name 22175870 R BEARING 5 6800ZZ B7 W700461290 ASSY FLEX1 VP 540 15229506 SENSOR INTERRUPTER GP1A05A5 W7004612A0 ASSY FLEX2 VP 540 1000001480 SHAFT DRIVE PULLEY XC 540 W7004612B0 ASSY FLEX3 VP 540 1000003089 SHEET FRAME SUPPORT RAIL VP 540 W700461260 ASSY GRIT ENCODER BOARD VP 540 6700469020 ASSY SCAN MOTOR VP 540 1000003097 SHEET HOLDER CABLE VP 300 1000003096 SHEET HOLDER CABLE 540 11869103 BALL 4MM 1000001479 SHAFT IDLE PULLEY XC 540 1000002605 BASE G ENCODER SENSOR VP 540 22295117 SHAFT LOCK CJ 70 A OI N gt 1000002589 BASE RAIL VP 540 1000002533 BASE SCAN DRIVE VP 540 1000002665 SHEET LINEAR SCALE VP 300 100000254 SHEET LINEAR SCALE VP 540 1000002671 BELT 100S2M1539LW C 1000002547 BELT 150S2M2153LW C 1000002709 SHEET RAIL UNDER VP 540 23415124 CABLE ASSY G MOTOR SP 300 1000002162 SHEET ROTARY DISK SLIT 360LPI 1000002169 CABLE ASSY GRIT ENCODER VP 540 22185101 SLIDER LOCK CJ 70 23415114 CABLE ASSY MAINT COVER SW SP 300 7876709020 ASSY FEED MOTOR SP 540V 10
28. te TEVITA Obed Q 2 on 0408 o 09 on ES gt lt 05 ah E WO SU 0505 x on lt E Ed 4 1 OVTS o ON o ZT 227 4 war 4 on 5 e p Es 7 4 on 8 4 14VISIDHATL L 1 c 5555 5555555555555 lt Lc 5555 558 66655555555555555555 Lu 8 555 d Wuviovd st va sls estet E ia S GETH cn TON boe lolo le lo e o 5 XDHON DOLCV9 TTINOX sa COHONN ON aa 43551 lll L I 52 EIDA DO CV9 WOKS ta El E PEE EFFEEFFFF FPPEESEE 00 X E sl Aw THD EE LLL lli vs 629 I eon 2 _ aaa ere 40013 100190 90019 900190 m ccv a 18 ee chr LT Lams 55 90 9
29. OL 58 By x z 2 13 2 3 SERVO BOARD SERVO BOARD Arrangement Diagram Component Side 1 6268 8 e C219 16207 R260 T 15 1019 CY7C1399D 20 7 13990 1921 eszi 1 2 CN12 22 8 22 H 5 lt o 40 T42 T43 Ores T50 C18 C57 28104 R327 TEEN Lj R332 MTD2005F 20640 c41T402 ef 517 E 5 Os 8 24 C35 T28 1615 252 885 goo n SNL _ 2 FOSA 7191 2 50502 5 7251 No s Hg 9e 5 a a Ed 1 J 3 a 2 5 CJ m o 8 0 1 3 B 625 5 4 6218521 91 B 0163 u 2 5 60 Mn 5 276 00000 gogy E 2 Hn E gt 8 lt lt r x gt zQ Co x QS T 1 gi 4 lt 53 8 2 888662 se 9 5 gt 8 9 S m 21 8 OG M 2 5 Ea T S 8 ogc a 109 22 2 35 3 E 5 3 E 2 TB 800 858 O over ES 3 LU 9 10710 5 x WOL 2061 35 088 18 5 5029 x
30. Possible Causes Print amp Cut adjustment is not correctly done Actions 1 Perform ADJUST BI DIR in the User menu 2 Perform PRINT CUT ADJ in the User menu Symptom 2 Cut is OK at Right Side but is Getting Shifted as It Goes to the Left Side kkk kkk kk kkk 0 6 6 6 kk Possible Causes 1 Expansion Contraction of the Encoder Scale 2 There is some setting value other than 0 set in CUTTING MENU gt CALIBRATION gt SCAN SETTING 3 Expansion Contraction of the media Actions 1 Enable CUTTING MENU gt AUTO ENV MATCH in the User menu 2 Set 0 in CUTTING MENU gt CALIBRATION gt SCAN SETTING in the User menu 3 Perform ADJUST BI DIR in the User menu 4 Perform PRINT CUT ADJ in the User menu 5 Use the crop marks 6 4 Symptom 3 Cut is OK at Lead Edge but is Getting Shifted as It Goes to the End of Print Ye ee e OLOR toto te Possible Causes 1 There is some setting value other than 0 set in CUTTING MENU gt CALIBRATION gt FEED SETTING 2 Expansion Contraction of the media 3 Strong back tension of the heavy roll media causes the media to be fed less than it should be when printing Actions 1 Set CUTTING MENU gt CALIBRATION gt FEED SETTING in the User menu 2 Prefeed the media to make it unrolled before starting a printing to decrease the back tension 3 Use the crop marks 4
31. S stviavoisesaa 29593 LAN I aad j E ads P 1005 1897 wor Po Oo OSSA 8 eii SIA SSA ON oss T 222 D REI SA aw 4 p 4 45 TE ON 49 H3 3 Lads He ien a 1 oe soa B N SHE am ce BN 6 zaas TION ST Fal 3 m LE ADAS tads aNd i TQ TEC 1 WOGI 6E TROAS 1008 p 6r EVEI ia T ST 1985 D _ UNE ed 2908 TEE 93 eve on au NLIS 55 IND Haat sin ag S GUT pe Sr iod 9 id 8505 M L Hav a Nas ia mo idi a a a ta A id sel cv 0I SVdS a TE mom T Xi 1908 Ads OS Td Xi Rv 38 01 ae EDDA soa E BON EDA 2350 was mow 9 Sos t ae E S N toast ae aNd E Se iod ie Hae DX EB Sada tas oe Vaavi a07 Wi ux m Te ondas 5 62405 szaas 9 8 sads reads amp das 12805 5 61405 3144
32. 75 80 57 9 512 24 lt 55 PA 1 328 7 77 Su 522 518 27 66 27 d 54 1 10 1 3 DRIVE UNIT VP 540 Above ZW65383 VP 300 Above ZW61510 PARTS LIST Main Parts Paris No Pars Name F6 6700465020 ASSYSCANMOTORVP 540 78 00002605 BASE G ENCODER SENSOR VP S40 Fs 000002589 BASERALVP 40 34 1000003084 HILTER E SFT 3eSN Rovsen 56 1000003293 GUIDE TUBE TYPES vP 540 Revised 45 1000002685 1000002658 RAIL GUIDE VP 300 1000002525 VP 540 1000002659 RAIL LINEAR SCALE VP 300 000002543 RAIL LINEAR SCALE VP 540 PARTS LIST Main Parts Pars No PatsName i si 1000001479 PULLEY XC 4O ON 63 65 876709020 ASSY FEEDMOTORSP SKV 22175122 060 22175157 SPRING CP ROLLERCM 500_ 76 22135349 500 Revsedi 80 1000004142_ SUPPORT GUIDE CABLE VP 840 Revised 5 PARTS LIST Supplemental Parts pesNoe S1 31029101 BUSH NB 19 S2 31029106 BUSH SQUARE SB 6025 S3 31329501 5 CLAMP SET PUSH MOUNT RT30SSF5 20 S4 3000000033 CLAMP WIRE PLESS RFC 45VO S5 31289111AS CUPSCREW SET M4 6 NI 100 PCS 56 3
33. 1 SUB MENU 44 FILL INK 4 gt 4 DRAIN BOTTLE 4 ENTER FILLING INK gt gt gt 4 DRAIN BOTTLE 4 3 45 3 9 BOARDS REPLACEMENT MAIN BOARD SW POWER SUPPLY BOARD LAYOUT IN CHASSIS SW POWER SUPPLY MAIN BOARD REPLACEMENT MAIN BOARD CONNECTOR LAYOUT 3 46 Turn on the main power 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 3 47 E c c c g o cl gt MAIN POWER SW Rear View Peck 4 0 1 Get Report Get Parameters Put Parameters Set Head Rank Firmware Upgrade Exit MAIN POWER SW Rear View Remove the 1 5 Cover Right Top Cover and Chassis Cover Remove the 4 screws as shown in the figure Disconnect the flexible cables and connector and remove the cables from the Clamps Pull out the Chassis to the front side 3 48 I S COVER RIGHT TOP COVER CHASSIS COVER FLEXIBLE CABLE CHASSIS
34. SINE 7912000001 NYdv NI 900 2222 4 2 2 2 0 7 2 5 12 181 6 UrdI tc cc EX314 B 8 7 9 000001 8 00 500 8 A o 88508000 i L 89 8 e 079 5 5 CUI E ror EN 4 2 PueloHr 2 2 Puelogr C E ume E 912000001 NI 3QvW 912000001 NI 08 H010N 1334 5109 eer 55 7912000001 2 91 6 3901818Y9 2 91 6 08408 21 39018149 S Bn umm MIL 8 0 6 ZE NI 62 20ZIND g 002806 600180 5 D v cory pueJour e 5 2 8 888 SU i 85 192 SC E al 5 me zz zz EOE BE 2 SES 3 S x 5 2 lo 3 5 NI 30vW 0 10921 1 5 T T I gm 0 n QT SR 2 2 ea 2 2 2 2 8 2 3 3 CROP SENSOR po T 900 gooey Cc x gt AL PLL URL JL JS Lem gH 0 8 oH s x ts st E 5 K 0 6 0 86 5 SO ier C NI 3QYW 0 vG 15 51 2 Roland 72 38 z in Pueloyur T ipit s 7912000001
35. e N Oo g E o 2 49 THERMISTOR It takes the temperature around the Head 5 Supplemental Information PINCH ROLLER SENSOR It detects the positions of Pinch Roller CROP MARK SENSOR It detects the Crop Mark It communicates with the IC chip of the Ink INK EMPTY SENSOR Cartridge It detects whether the Ink Cartridge is empty or not INK CARTRIDGE SENSOR It detects whether the Ink Cartridge is installed or not 6 Troubleshooting 6 1 DEFECT OF PRINT QUALITY BANDING SCRATCHY PRINTING BLURRED PRINTING Missing dot or deflected fired dot appears on the test Perform Normal Improved Cleaning Not Improved Several Normal Cleanings and a Powerful Cleaning do not improve the printing result To 11 16 To 1 10 NO CHECKING POINT ACTION REFERENCE OUTLINE 4 Machine is not installed in Install in a location that is Never install the machine in a location where it is tilted or an appropriate location level and stable where it may wobble or librate Media is not set up odd and set up the Feed is not smooth when media is tilted or tensioned unevenly 2 media correctly at the User s Manual correctly 72 on the left and right Reload and set up the media correctly correct position When the temperature of the print heater is too high and the Temperature of the print Set appropriate 3
36. 12 Start the Peck4 on Peck4 screen is displayed and click Put Parameters button 13 OPEN screen is displayed Select the System Parameter file that is saved before the Main Board replacement Click Open Peck4 starts to send the System Parameter to VP 540 300 file 1 Click Get Report button to import the System Report Confirm that the System Parameter is reloaded properly E The network settings set at the step 11 are replaced with the ones saved in the System Parameter as Put Parameters is executed Please do the network settings again if necessary 4 21 Peck 4 0 1 Select Port Bet Report Get Parameters Put Parameters Set Head Rank Firmware Upgrade Exit Look in CJ vp540 2 B vp540parameters Recent Documents 2 Desktop My Documents My Computer Network File name vp54 parameters Places Files of type Peck 4 0 1 Select Port Get Report Get Parameters Put Parameters Set Head Rank Firmware Upgrade 17 58 2 90000000 2 00 40 28 00 00 2 82108 07 0 0 0 1 Low Aw Temperature 11807 RAF ester tome PRINT 0 ester temp DRYER xe detection ply mode ation adis ull width sownint Sow interval unit Slow interes Wheel remain 4 3 HOW UPGRADE FIRMWARE OF THE N
37. 5 Supplemental Information 5 1 5 2 SPECIAL TOOLS SENSOR MAP 6 Troubleshooting 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 6 10 6 11 6 12 6 13 6 14 DEFECT OF PRINT QUALITY BANDING SCRATCHY PRINTING BLURRED 6 1 PARTICULAR COLOR IS NOT PRINTED AT ALL SHIFTING IN PRINTING COLOR SHIFTING INK DROPS ON THE MEDIA amp PER POOR CUTTING QUALITY STITCH CUT DISTORTED CUT MISMATCHED START AND END POINTS 6 7 oe a tee rs MOTOR ERROR HEATER DRYER TEMPERATURE DOES NOT GO UP PROBLEM IN NETWORK RIP DOES NOT RECOGNIZE THE PRINTER ERROR MESSAGE III E LL LE 7 Service Activities 7 1 7 2 7 3 INSTALLATION CHECK LIST MAINTENANCE CHECK LIST SPAGIFIGATION Windows MS DOS are registered trademark or trademark of Microsoft Corporation in the United States and or other countries Revision Record Description of Changes Approval Parts have been revised Procedures have been revised Procedures have been revised Installation Check List has been revised Parts have been revised 200r 9715 Procedures have been added 2007 8 24 Procedures have been revised 2007 4 25 Parts have been revised 200
38. MAIN POWER SW Rear View 2 Remove the 1 5 Cover Right Top Cover and Chassis Cover 5 COVER RIGHT COVER CHASSIS COVER 3 53 Remove the 4 screws as shown in the figure Disconnect the flexible cables and connector and remove the cables from the Clamps FLEXIBLE CABLE Pull out the Chassis to the front side CHASSIS Disconnect all the cable from the SW Power Supply 3 54 Remove the 4 screws as shown in the figure and replace with the new SW Power Supply Connect all the cables to the SW Power Supply Set the output voltage of SW Power Supply to 41V 1 Disconnect the connector on the Servo Board Make sure to disconnect the connector 2 Turn on the main power IE Use the Digital Multi Meter that can measure the direct voltage 3 Putthe black probe into CN51 1pin GND and the red probe into CN51 6pin Vout on the SW Power Supply 3 55 MAIN POWER SW Rear View 4 Rotate the volume clockwise using the screwdriver to adjust the output voltage value to 41 0 1 IE When the output voltage exceeds the 41 4V SW Power Supply does not output the voltage by the protection circuit on i
39. gt Wo SDA PISSA as EISSA 100 c 55A 10221 57 ISSA AAA 90741 GESSI OISSA E IHN gt 6554 8SSA 0 LSSA uaaa H Ius 18 NMd eo 8 5 955 1 BETA 2 0 SSSA 5 PSSA TASA 20 4 301 Sr 1 ESSA XOXddA 25 T 2 9 e Se Se gt SA Nd wd 50 SETA fa fa fa 9d NH mmm T ISSA DIDIXH OXIDIXH pomas 20018584 gt lt ady 0149 10018884 Som Jasa an ae a CCOIdO 5 9 orou 5 odM 158 Nad ICOIdO lt 02040 FIUNOYX ca TICNDVX LU HU NORD WAV 7 6 3 610145 gt 100 L 34 dk TINT AV BL 018 v TIAMdX mu oscod deao E 9A siono anx TA 910 E Dev NONDIL E LA eu 144 T 2 2 oido I 925 4002 ta 10140 8970 31000 100 10M I TaN OI 9d 049 ceGNOWX E fA IDO CdHW 92 TEAMdX i za j m NON soni SZISINOM Dior V 0 fA 50551 2 11
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41. oa s 20 15 T adis Lolaga gt E 20 Lent 2 ova 7 10506 SI Exo oN poe 000 32329 amp SEREH zui ava 30 CHL THL T E bu a 117 H ATSA z sa EN 1E oy IHL 3 qM fona E 2 eo 151 JAVIPSIDHAFLOLL 0610 46 DOR NON AE 1 VSSPOI XM IOSUOS 1207 TOW gun FA0CHOS n3 SSA NEL d n W 5571 5 5 9r sil 9 L st Svea 4 0 INT LIXA OLN CEUCHO Ft E 20 Mi Eom op I LIO 1X4 als E spt t OI IX 2 wondoscorseees H FPE C BET Dom Ppa 5 4 OD OLW XIVOA OLT SA 7 E uc Vive 0 VIVAN ADI yvan HL ANT INO 9 SCR 22 DA 6 9 it Diagram MAIN BOARD C Eola
42. 10 11 Disconnect all the cables from the Servo Board Remove the 4 screws as shown in the figure to remove the Servo Board Disconnect the cables as shown in the figure from the Main Board 12 Disconnect the connector and flexible cable as shown in the figure and fix them to the new Main Board Remove the 4 screws as shown in the figure and replace with the new Main Board 3 49 1 Connect the cables as shown in the figure to the Main Board 1 Fix the Servo Board with the 4 screws as shown in the figure 15 Put back the Chassis 16 Connect all the cables to the Servo Board 3 50 CHASSIS 17 Fix the Chassis with the 4 screws as shown in the figure 1 Connect the flexible cables and connector and fix the cables with the Clamps CONNECTOR FLEXIBLE CABLE 19 Perform the following operations after replacement 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 in the User Menu 6 PUT PARAMETER 7 TIME AND DATE SETTING Set the date and time in the SSERVICE MENU SUB MENU CLOCK Set the DATE in order of the Year Month Day 8 FIRMWARE VERSION CONFIRMATION OF NETWORK CONTROL
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44. 6 4 48 Move the Head Carriage to the highest position of the bed Confirm that Head Carriage is connected to Tool Carriage and lock the connected carriages rs 2 The right end is the highest position of the 55 gt gt bed 2 E Turn the Adjustment Screw to adjust the space between the Pen end and Bed to be 2 5mm to 2 6mm Move on to the TOOL PRESSURE ADJUSTMENT 4 49 4 13 TOOL PRESSURE ADJUSTMENT Referential Time 15min This adjustment is to correct the tool pressure during cutting Before this adjustment it is necessary to perform 4 12 TOOL HEIGHT ADJUSTMENT 1 Install the White Dummy Pen ST 006 to the Tool Carriage see WHITE DUMMY PEN E 2 Move the Pinch Rollers at the positions as shown in PINCH ROLLER the figure and lower them GRIT ROLLER VP 300 3 Remove the Covers in order TOP COVER 1 1 6 Cover 5 Maint C LEFT Maintenance Cover COVER 3 Left Cover 4 Front Cover MAINTENANCE 5 Cover COVER FRONT COVER I S COVER 4 50 Move the Head Carriage to the highest position of the bed Confirm that Head Carriage is connected to Tool Carri
45. Make sure to fix the head by pressing it to the bottom left corner of the adapter Use the 2kgf cm torque driver ST 056 to tighten up the screws Install the head to the Head Carriage and fix the 3 screws temporarily Then fix the spring and tighten up the 3 screws in order as shown in the figure E Use the 2 torque driver ST 056 to tighten up the screws 13 Connect the 2 flexible cables to the Head Board HEAD 90 Do not connect the cables to the wrong connecter Fix the Head Board Cover When fixing the Head Board Cover hook the tab to the Carriage Base CARRIAGE BASE T y 0 0 2 JV lt 0 6 4 9 3 2 E Ie SCREW 2 tier en 3 7 RAIL HEAD BOARD COVER gt V GO SERVICE MENU MENU 15 Fix the 2 new Ink Dampers to the head Make sure to replace the Dampers when replacing the head a tight It c
46. BRR P aT 2 3 SAIS VETO 3 fie EINO IXa mfe 5 E EF B s am 20 Iz 312 d E id LU UU LU 53 22 m el 019119 XT FREReEEEERESEERE Eeke SOON e E ZEEEZZZZHUZZEZOZODZZZEEZZE zzozzzco B 55455485554482 5 AAQASS SSSA SARS ASS 59548845555555 _ ron 65855548 g EEEE 88 072888 8 02 88508208 884 888288 2562528 25 0233 BOTER 488 25 D E ese eee eee ee gee NONDR TORO 588 8 8 49 5 SECR 883555655 x LuxI Bg 5E 5 lt C EB 843 9 ZSEE 72204304 9 26 8 EE 2 8 8 55535855 a Fe 2 8 8 8 2 g 3 8 3 S 5 5 an avs ATOSA VIAT VOD OS ano OX SAAT dosa von IND xo 290 DANON s SN LSQA VOI pr ito FF 1 4 aso 7 NON um on SIW ANOD ROT anc 4 d 9 9650 T Vi ANOD LTV E das 22 NN ANOA ANOO ANOA ANOD LIV IN d saA YHOWH DANON 9 lt TINO IXA z on ON no DG Toa Seas Samo Xd TN isan von
47. 10 Replace with the new pump BEARING lt Procedure for pump with the motor gt 1 Remove the setscrew as shown in the figure to remove the gear and bearing from the Shaft 57 2 Remove the 3 screws as shown in the figure to remove MOTOR the pump from the motor ae Fix the new pump to the motor 5 E C SCREW PUMP 0 0 3 the bearing and gear to the Shaft TE Be careful with the fixing direction of the bearing and gear 3 35 4 Fix the setscrew at the D cut part by pushing the gear against the bearing lt Procedure for pump without the motor gt 1 Remove the 3 screws as shown in the figure to remove the plate from the pump and fix it to the new pump 11 Assemble the 2 pumps 3 36 BEARING GEAR 12 fix the Pump Unit Stay with the 4 screws as shown in the figure 13 Fix the Pump Unit with the 2 screws as shown in the figure 14 Connect the tubes of the Cap Top and the tubes of the Drain to the pumps Connect the tubes as shown in the figure TUBE DR
48. 117 1 es 19 9440 0650 3659 59 t ov Ld gt s Tolga t 1 INAS SH PHY ir gt SON SH PU doo tao tosa E T SOI SH PEN D L 3 t TOE vad s vaa gt swa 4 rap VON vad J4VLSLOHAFLOL Bn VAGINI DDA o DA a 5 OL E ESI 11 G3VO8 THNVd OL En s T ms ca ao ONS a EENE LNVIS TVIWis x 80 045 dav NO ud SY SOIIDNH SHONI ir Rr Ex mm ERN axi sa FE FINI gt a 5 t TANI 5 SA s af YOLINOW OL DA Macs Lada 8 1984 Sad sada 9 EA rossas EY ASNI AIF 108096 WUT 060 366 40 5 i T 2l TO sun z eola ee AdDSEROOTL SOS 9058 el Josuog 11014 4 2 5 t 1 DA 3 s2 T EIE d wa Josuag Jadeg ow sce EI XU TION 5 E 5 DAO AOV ANV DNILLID 8 zaa SOY MOM OHdVd INOW 1 saad 9 raga 17 FEES S THE E 1 INONA f zaga Suvs 24 10 61 23
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50. er a 328 RES SSA 3 um FEKIS 5 T CSH PEN Uso 089 2 lalis 8 E sah BEBE EE Vi Y L Y uy se amp 1 L Ky E ev E 9 i kv 15 UY a lelle 2 B 2 Lari l E 444448 ENS 44444885 ES L ta osoasa E ES S Iva 39 iv b En var ova ES x SOA 50 SIA SA oA Lu 4
51. s amp lt lt o 098 s kar 2 1 8854 8193330 Ei m 28 5 oso 5 5 DES OO 58 mr an 000 Sue 95 8 5 S vod 3888 1 A955 cx Bes alo ri o n 5 d LA LI 9 2 p 8 or 2 2 2 E 8 5 88 OOF amp 8 E e o lt 12 gt x o 7 Ob 5 NL 5 5 2 CCHH z 5 3 lt 2 5 4 E E 828 ien w o E a 2 8 1 998 089d M 1624 en 328 H B 56 z 5 80 80 23 8 2 5 2 8 55 PE g Er 20 892 z HH sH T gt 5 b SiVU 12 8 ozvy JEVY BEVY 2778 gyvu SVY 15 65 924 Gas 5 6221 0624 9604 H H ez p 22 3 Bon 7904 P Foz sei 2 oevy A z ozida ak S m 5 259 a OOD DE gt y 3 iH 8N9 co 8 5 gt sz SEDI 8 55 OO OO PEE 5 EE H 1 1 9 8 2 PEG 7 oo 9 a 1824 2804 8225400 OO 5 8 BERE LI 5 00 CL
52. 4 VP 540 Versa CAMMI Confidential TERMS OF USE 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 PURPOSE Authorized persons can use this Service Note only for the purposes of selling and providing to the customers maintenance service of VP 540 VP 300 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 REPRODUCTION Authorized persons shall not copy change or alter this Service Note without permission of Roland DG Corporation EFFECT OF VIOLATION Regardless of circumstances we will vigorously respond to any violation hereof through legal action Roland DG Corporation Copyright 2008 ROLAND DG CORPORATION Roland DG Corporation 70046 06 Contents 1 Structure amp Spare Parts 1 1 1 2 1 3 0 1 2 3 4 COVERS 1 1 FRAME DRIVE UNIT HEAD CARRIAGE VP 540 HEAD CARRIAGE VP 300 BASE FRAME CHASSIS PINCH ROLLER TOOL CARRIAGE WIPER SYSTEM PUMP SYSTEM INK SYSTEM ACCESSORIES 2
53. Jar Oo NOL ou DA 655 3E IT ssa a Gan CO e 0 tor 0 m cs m SS NES SK 2 m E ODIO dada WID E EDD aan sowan 5 OSSA LIVIS TINE n 2 5 T si ior ODD 11 15 SALVIS 4 5 g 3v DSSA Y o 8 i M w xu Dee daaa 19 6 1 9 oy w SIV p B OSSA Inova ew Li LIV 16 ev oxova OTN 8 zsvusan SNR D y Diva OSSA IR ava LOI 30 4 DAIA Ap raw r4 Eus OSSA 2 a TV E Es EY fui LL 9IL LIL SL 1807 gt OSSA WV SV SSA SVN SAWN Sva T SC aui HiVvuussvOH uv OVW TN uv SV EIN OSSA 23 gt E Ss N att TUM Y 3 SUN __ dada fv c uy Xv 118 oy 7 ND ob SSA m oa t a DA sod JusdHW CNOS gt LES SSA Ted SU SH WU gt 00 10450 L oom xor LA sou EE 258 8 nr L tu 59 233 SHAO IGEINGN 5 554 52 E38 8558
54. LINEAR ENCODER 4 SETUP COMPLETED LINEAR ENCODER 4 SETUP FAILED PRINT MENU 45 LINEAR CALIB 4 X 4 NOW PROCESSING 1 LINEAR CALIB 4 SETUP COMPLETED qi LINEAR CALIB 4 0 18 PRINT MENU 435 LINEAR CALIB 4 Y 4 NOW PROCESSING LINEAR CALIB 4 FAILED TO SETUP 4 7 FLUSHING POSITION ADJUSTMENT Referential Time 5min This is to adjust the flushing position This adjustment is required when a Cap Top and a head are removed or replaced Without this adjustment the Flushing may not be performed properly 1 For 540 the Head height should be set LOW 2 Remove the 1 5 Cover gt keys to enter the Service Mode Turn on the Sub Power SW while pressing lt q and 4 36 SCREWs I S COVER GO v MENU SERVICE MENU 4 Select PRINT MENU gt FLUSHING ADJ and press ENTER key The Head Carriage automatically moves to the current flushing 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 44 keys Then press ENTER key to update the flushing position When you press MENU key the flushing position is not updated and exiting the menu SERVICE MENU lt PRINT MENU gt v PRINT M
55. vec PRINT CARRIAGE gt LENC_PHA 2 4 150 3 3 4 Vout A BOARD 4 LENC PHB 3 4 Vous k 6 CN700 KE207 CABLE ASSY LINEAR ENCODER VP 540 502 1 2 SOLENOID IL S 2P S2T2 EF 504 1 2 To PINCH ROLLER 4 53398 0490 SENS OR 503 2 CROP MARK 53398 0390 SENSOR BOARD Component Side iagram gement D It indicates the version of the Board 2 23 U U EONI
56. 1 l 1 1 di A CEA Sh CEA sad WOT gt Od nossa zd Ed 55 1 j iod Xd 1 t x SRL zu sod 90 ran 2015 5 LH ELS uu LE se 5 imr nroso 7 Lia i raro CTD iB 5 iJ 2 pe omit apavas apavora swe 9 wi Tad o ET 30V vaavi siad SoA EDA EE A Sa EDA GND Da GA 3 20 EDA Sa 1 T REEN Eo 22 x cx Dunn 27 LU 5 if aE HODOVSHOIMON ENS wod1 zT SINCE F 6 L AN o Es od numa Ls BR 6L m ESD Lt LU i ix i ia 2 2 Ey Wu Es HE ux S Sv SW 3 Sidd TNR UL Dude 1962 1821 vias INHOS lc TR ee a me si z Ed s 5 saq IE Us Pu Fag z Sud zu 200 TOS RS x sag meeasaaxa L EN 1 CREE tame E 5 5 12 0 IdN 9 1 RS vaavi A lt FU T 2 6 7HINOGEL EL
57. If there is a bad communication between the head and the Main Board the signal for driving head is not sent properly Bad contact Broken cable Refix Replace the cable and results in not printing properly If the Flexible cable is Error of Ink Empty Replace the ink cartridge detection sensor fixed slanted it may cause the bad electrical contact or short circuit And the cable which has been conneted and disconnected several times may have a damaged terminal 3 3 CAP TOP If the Head is not capped correctly the Head dries and it may Defect oL Top Cap Top Replacement REPLACEMENT cause the Head nozzle clogging NO When air bubbles come inside the Ink line the head may not Powerful Cleaning fire the Ink temporarily Air bubbles tend to go into the Ink line Remove air bubbles by if Ink Cartridge is installed and uninstalled so many times 5 Air bubbles in Ink line an syringe The air bubbles inside the lines can be removed by performing the powerful cleaning or using a syringe Eliminate the looseness If the tube has air due to the looseness of the tube joint fix of the tube joint the joint and remove the air 3 8 INK TUBE Broken Ink Tube Ink Tube Replacement REPLACEMENT The F1 Fuses are for M and Y and the F2 Fuses are for K Broken Fuse on the Main Replace the Fuse on the and C If the M and Y Heads do not fire any Ink at all the F1 Main Board Fuse may be defective If the K and C Heads do not the F2 Fuse may be d
58. NI 3QvW 7912000001 NI 3QwW ape a an gt 82 81 8 21 390181490 2 91 6 08408 21 39018192 8 m E DE 2 000 600702 RED 5 00002 9 5 520 P 6 Sr er NVdV NI 3QVWN O Av6 Les 1010 8 or alls 3 2 E C pig 822 5 CO CO E 508 gt lt gt gt 2 sr E 5 5 Oj 8 1 8110 alt soey 27 zal JE EI 7 5 018 51 2 S RES m 11090 gooey 110810 520 2 0 6 gt fo 5 a amp 5 EM ES 2 2 0 02 8 E E x a NI 30vH 5 56 cita Sess ies 0 16 0 16 5 5 E EL m 51228 2 58 in puey 22 57 puejour 3 5 2 t Er 7912000001 Nvdvn NI 3QvW 7912000001 Nvdvn NI 3QYW e 906 8 4 4 lo 2 91 6 08108 21 390181892 2 91 6 8 08 21 390181 2 2001 2 U C e 209 g 100902 ZOSINJ 000802 S n o ves Ble 5 a Cs CaS 2 nig 82 eH E 22500 p 5 IS 8 E 5 Se 2 gt a 8 5 c v 0 2 28 5 58 22 5 00599 Z rosa OLIONnP NY g2 g nS 5 A Co Ces 3 fa _ O001N2 5 m al e 55215 8 _ goly ron e5 CO owe 1808 Coe 9 m 5 ET
59. the Grit Encoder is in between the sensor IE Adjust the position of the sensor so that the clearance with the Grit Encoder is around 1mm SENSOR lt Top View gt 8 Rotate the Shaft by Flange to check that the Grit encoder does not touch the sensor IE In case that the Grit Encoder touches the sensor loosen the screw as shown in the figure to adjust the sensor by moving it right and left GRIT KE x ENCODER dn e e ENCODER BOARD SENSOR lt Top View gt 3 68 10 11 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 Checkthe GRIT ENCODER Go back to the MOTOR MENU and select G ENC CHECK and press the ENTER key Make sure the Grit Encoder functions correctly by confirming the display shows G ENC CHECK COMPLETED In case that G ENC CHECK FAILED appears check the followings 1 Grit Encoder is fixed correctly 2 Feed Motor is fixed correctly 3 There is no scratches or finger prints Fix the following covers MaintenanceCover Left Side Cover LeftCover 3 69 E 5 4 MENU SERVICE MENU SERVICE MENU 4 MOTOR MENU 4 MOTOR MENU G ENC CHECK 1 4 4 4 4 G ENC CHECK CO
60. the Service Menu Function for Users Combination Key Selection Language Unit Selection 4 14 4 2 HOW UPGRADE INSTALL FIRMWARE It is necessary to prepare the followings to upgrade install the firmware 1 Firmware file 2 WindowsPC Network port is required 3 Peck4 exe 4 Network cable A cross cable is required when you connect VP 540 300 to PC directly HOW TO UPGRADE FIRMWARE Referential Time 5 min Check the IP address of VP 540 300 1 Turn on the Main Power SW and Sub Power SW then press MENU key Select SYSTEM INFO NETWORK IP ADDRESS 17 lt gt SYSTEM INFO SYSTEM INFO 4 NETWORK 4 NETWORK lt gt IP ADDRESS V IH IP ADDRESS 45 192 168 000 100 4 2 Turn off the Sub Power SW 4 15 Start the Peck4 Peck4 screen is displayed and click Select Port button 184114 4 0 1 PLE Get Report Get Parameters Put Parameters Set Head Rank Firmware Upgrade Exit Select Type3 Prolll etc from Product Also select Via Network and input IP address of VP 540 300 Select Port Product C Select C via Parallel Oi Network C via USB Click OK button SP serise AJ 1000 etc ProlII etc 132 168 0 100
61. 8 5 8401 ue fiver iswas 5 A SL ISAL Ld IsWas TE E aroag 6 NN abe L l1Vq 1SIkds ose LL MST SEN 21 Dd 326 5 oan OIAWON 18 05 e LE 9 GIGINON JSAGS EA tr Dd 1 e asad 1 2 XDUISNOS als T ON 7 IOO0N lVq 0sWds wa art 880 SUDON 088108 5 wa gt o EM AXON ILYTOSNAS taxa Olvd 088408 2 0 x 4 17 1 i 088508 71 1 amp ACXMON 2 2 te 2 8 or 1 2 in T IL CIXION OWMd 121 2 st 1 5 028 2 NHX LON Xuan 1 8 E WIOXLON 1 Spr s zZz WiHasn 35 45 45 45 TIOATFL TIOATFL INoHgsan _ E doHasn td d31 SH 11 wa Dears De VOOSSSOSTZININ t XI Nd gt 1 rien Id d31 n FI
62. CHASSIS COVER 1 1 MAIN POWER SW Rear View 3 11 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 fixed without connecting the new belt to the current belt Turn off the sub power and then turn off the main power MAIN POWER SW Rear View 2 Remove the following covers LEFTSIDECOVER 15 Cover MaintenanceCover LeftSide Cover Front Cover Top Cover Right Top Cover RIGHTTOP COVER MAINTENANCECOVER FRONTCOVER I S COVER 3 Separate the Tool Carriage from the Head Carriage TOOLCARRIAGE HEADCARRIAGE 3 60 Remove the Tool Carriage Cover Remove the 4 rivets as shown in the figure to remove the Tool Carriage Board Cover Disconnect the Crop Mark Sensor Pinch Roller Sensor and Solenoid wirings Remove the 2 screws fixing the Tool Carriage Board 3 61 TOOL CARRIAGE COVER
63. MOTOR MENU Tn MOTOR MENU lt AGING 4 SCAN 4 4 Confirm the belt position The position is proper when the belt is not touching the flanges of the Drive Pulley excessively When the position is proper skip this adjustment and to ADJUSTMENT ON THE IDLE PULLEY SIDE described in the later step of this adjustment leaving the belt aging on When the position is improper make adjustment as follows IE Belt partly touching the flange is acceptable Press ENTER key to cancel Aging SCAN NOW AGING 4 Remove the Right Side Frame and Chassis Cover CHASSIS COVER RIGHT SIDE FRAME Loosen the 2 Fixing Screws located on the right end of the belt IE Loosen the screws about a few rounds for the bottom of the screw head not to contact with the Stay 4 57 17 FIXING Eb _ SCREWs 10 Press ENTER key to restart Aging Adjust the belt position turning the Adjustment Screw as follows Belt leans to the front side of the machine Turn the screw carefully in CW loosening 4 TE The work space is narrow Be careful and try not to touch the driving pulley and belt Belt leans to the rear side of the machine Turn the screw carefully in CCW tightening Tighten the 2 Fixin
64. The number with is the current setting Select DT1 Low DT3 Low DT1 HIGH and DT3 HIGH in the HEAD ADJUST menu and enter the parameters checked at step 18 with land keys Press ENTER key to save the settings E Parameters can be entered with an increment of 1 2 SERVICE MENU 4 PRINT MENU gt v PRINT MENU 4 HEAD ADJUST i gt v HEAD ADJUST 4 HORIZONTAL 19 HORIZONTAL 4 TEST PRINT 4 4 11 DEL TL 11 PUN TIA TU 2 H2 11111 Ll Position DT3 High 20 6 5 3 2 1 0 1 2 3 4
65. adjusted Tighten the screws fixing the head in order as shown in the figure using the Torque Driver ST 056 Torque for tightening is 2kgf 20cNm Make sure not to tighten the screws too strong Print the test pattern again If the result is not satisfactory repeat step 11 to 15 If the VERTICAL test print reult is satisfactory select HEAD ADJUST BIAS TEST PRINT and print the BIAS test pattern again If the BIAS test print result is not satisfactory repeat BIAS ADJUSTMENT IE The shifting of lines should be smaller than 1 2 dot 4 28 AS 2 As ADJUSTMENT SCREW SERVICE MENU 5 PRINT MENU gt gt PRINT MENU 4 HEAD ADJUST 4 gt HEAD ADJUST 4 BIAS 4 gt BIAS 4 TEST PRINT 4 17 18 19 HORIZONTAL ADJUSTMENT Select PRINT MENU gt HEAD ADJUST gt HORIZONTAL gt TEST PRINT and press ENTER key Test Pattern will be printed Find the position where the line of each color matches the K line and check the number In case of having problem selecting one between 2 numbers 1 2 is also available when setting up the value
66. gs 50 sot ld ad ie 0 4 ava 5 1 3 lt r LW TT 2 8 5 9 ircuit Diagram MAIN BOARD C eE 138 13 lass AMW LL TaNVA poas vi ERES L wo var lt 1 vaa EIL Bod 25 vy S sv sa e NONDICT mum M 558 SOIdG OL 1 5
67. 1 4 14 BELT TENSION ADJUSTMENT 2 4 15 BELT POSITION ADJUSTMENT 3 4 5 LIMIT POSITION amp CUT DOWN POSITION INITIALIZE 4 4 7 FLUSHING POSITION ADJUSTMENT 5 CUTTING QUALITY CHECK 3 64 3 12 ENCODER SCALE REPLACEMENT 1 Remove the following covers 15 Cover MaintenanceCover Left Side Cover Front Cover TopCover LEFTSIDECOVER TopCOVER MAINTENANCE COVER FRONTCOVER I S COVER 2 Move the Head Carriage slowly leftwards Remove the Encoder Scale by removing the plate fixing the Encoder Scale at its right end and the spring on its left end Remove the Spring Plate from the Encoder Scale and fix it to the new Encoder Scale where there is no black dot written on it HEAD CARRIAGE IE Make sure not to scratch or put grease on the Encoder Scale when fixing it Do not touch the surface of the Encoder Scale 3 65 ENCODER SCALE SPRING PLATE H SPRING PLATE BLACK DOT 5 Encoder Scale in between the Encoder Plate and the Guide Rail ENCODER SCALE Then fix the right end with the plate and hook up the SPRING spring on the left end Make sure that the Encoder Scale is in place PLATE IE Do not loosen or tighten the screws fixi
68. 1000002583 SPACER BED UPPER VP 540 1000002669 STAY DRY HEATER VP 300 1000002606 STAY DRY HEATER VP 540 1000002585 STAY PAPER SENSOR VP 540 1000002668 STAY PRINT HEATER VP 300 1000002590 STAY PRINT HEATER VP 540 1000002656 PAD CUTTER VP 300 1000002598 PAD CUTTER VP 540 1000002181 CABLE ASSY THERMISTOR VP 540 1000002175 CABLE ASSY PAPER SENSOR VP 540 1000002184 CABLE ASSY THERMOSTAT VP 540 31179106 SCREW JACK UP SP 540V 1 7 CHASSIS PARTS LIST Main Parts Parts No 6700469010 Parts Name ASSY MAIN BOARD VP 540 W700461220 ASSY POWER BOARD VP 540 Parts No 1000002755 Parts Name CABLE ASSY HEATER VP 300 1000002183 CABLE ASSY HEATER VP 540 1000002144 ASSY SERVO BOARD VP 540 1000002190 CABLE ASSY JUNBI VP 540 15009101 BATTERY CR2032 1000002173 CABLE ASSY JUNBI E VP 540 1000002559 CHASSIS VP 540 1000002177 CABLE ASSY POWER SERVO VP 540 1000002633 COVER CHASSIS VP 540 1000002180 CABLE ASSY RELAY JUNCTION VP 540 1000000012 FAN 109R0624H459 23475216 CABLE CARD 40P1 1400L BB For VP 300 1000003085 FILTER E CHASSIS SHIELD VP 540 23475237 CABLE CARD 40P1 2070L BB HIGH V For VP 540 12559105 FUSE 1000002044 CABLE ASSY 117V SELECTOR XC 540 For 117V 1000003014 FUSE 1540
69. 1000003136 ASSY TUBING 3 150MM VP 540 1000003038 COVER CARTRIDGE IC VP 540 11659249 HOLDER RING 3FAI FJ 540 1 2 3 4 5 6 7 8 1 14 ACCESSORY VP 540 Below ZW65382 VP 300 Below ZW61509 230 230V P C Das 4 em TR 8 27 1 26 1 14 ACCESSORY VP 540 Below ZW65382 VP 300 Below ZW61509 PARTS LIST Main Parts 2 5 32 10 11 12 13 14 15 16 17 1 27 PARTS LIST Main Parts ___________ 43 44 45 46 47 48 50 5 52 53 54 55 56 57 58 59 EN 3 7 amm PARTS LIST Supplemental Parts O 49 31049157 SCREW CAP M6 20 3CBC PW SW 31139104 SCREW PLAPOINT M4 6 BK FE 31229103AS SCREW SET TRUSS M2 6 NI 100 PCS 1 14 ACCESSORY VP 540 Above ZW65383 VP 300 Above ZW61510 230 240VE 240VA QNS NON 25 oe 5 27 8 all these parts N A Ij Kat 1 28 1 14 ACCESSORY VP 540 Above ZW65383 VP 300 Above ZW61510 PARTS LIST Main Parts PARTS LIST Main Parts rans Name J ans name s 22805675 ASS SHORT MEDIA CLAMP
70. 21345105 LOCK CJ 500 22395108 MAGNET CJ 500 1000002586 PLATE DAMPER VP 540 22055547 PLATE GND FJ 540 22055548 PLATE SLIDER CARRIAGE FJ 540 15229506 SENSOR INTERRUPTER GP1A05A5 1000002521 SHAFT HEXAGON CARRIAGE VP 540 22185127 SLIDER CARRIAGE FJ 540 1000002623 SPACER U D LEVER VP 540 22175159 SPRING CARRIAGE SIDE FJ 50 22175520 SPRING HEAD ADJUST 500 FJ 540 22175519 SPRING HEAD PRESS 500 FJ 540 22625109 SPRING PULL CARRIAGE 3500 FJ 540 1000003863 STAY CARRIAGE TUBE TYPE2 VP 540 1000000417 STAY ENCORDER SENSOR SP 540V 1000002524 STAY HOLDER CARRIAGE BOARD VP 540 1000002522 SUPPORT CARRIAGE BOARD VP 540 1000002643 SUPPORT DAMPER VP 540 1000002679 ADAPTER JUNCTION VPY306 11909167 ADAPTER SCREW 3FAI FJ 540 1000003136 ASSY TUBING 3 150MM VP 540 1000003032 BASE CARRIAGE SIDE AL VP 540 23475206 CABLE CARD 21P1 330L BB 11659249 HOLDER RING 3FAI FJ 540 1000002681 TUBE SJ RDG3 4 4LINK VP 540 1000003031 SUPPORT ADJUST SCREW VP 540 1000003075 PAD PRINT CARRIAGE L VP 540 1000003074 PAD PRINT CARRIAGE R VP 540 1000002753 LABEL READ MANUAL VP 540 LA969 1000002171 CABLE ASSY HEAD U D SENSOR VP 540 1000002174 CABLE ASSY LINEAR ENCODER VP 540 31199905AS SCRW SET SET CONE M3 16 NI 20 PCS 1 5 HEAD CA
71. 3 16 HOLDER CABLE SHEET REPLACEMENT 15 Cover MaintenanceCover Left Side Cover Front Cover Top Cover Right Top Cover 1 Turn on the sub power while pressing the left right and down keys to enter the Service Mode 2 Select SERVICE MENU gt SUB MENU gt PUMP UP and remove ink by following the sequence 3 Turn off the sub power and then turn off the main power gt 72 v MENU 4 SERVICE MENU SERVICE MENU 4 SUB MENU SUB MENU 4 PUMP UP 4 gt DRAIN BOTTLE 4 1 ENTER REMOVE SOL CRT 1234 PUMPING UP gt gt gt c MAIN POWER SW 4 Remove the following covers LEFTSIDECOVER TopCOVER RIGHT TOP COVER MAINTENANCECOVER I S COVER 3 72 5 Remove the Cut Cable Guide lt VP 300 gt 1 Remove the 3 screws to remove the Cut Cable Guide a CUT CABLE GUIDE VP 540 1 Remove the 3 screws to remove the Cable Support 12 Pull the flexible cable to access the screw FLEXIBLE CABLE dd CABLE SUPPORT lt Back 5 gt lt gt 2 Remove the 3 scre
72. 3 Turn on the Sub Power SW while pressing lt q and TOOL CARRIAGE BOARD COVER M f TOOL CARRIAGE M COVER 296 4 YA gt 057 2 gt o 4 SERVICE MENU 4 38 4 Select CUTTING MENU gt CROPMARK SENS gt DUTLEVEL CHECK and press ENTER key A Crop Mark will be printed After printing a Crop Mark the Tool Carriage moves to above the Crop Mark automatically Adjustment is unnecessary when the displayed MAX voltage is 2 7 0 2V When the MAX voltage is not proper see the voltage displayed with on the lower LCD Adjust the VR on the Tool Carriage Board so that the voltage with changes to 2 7 0 2V S Due to the ink dry the voltage displayed with decreases in time This adjustment needs to be done quickly for smooth operation 7 Perform OUTLEVEL CHECK again and confirm that the MAX voltage is proper If itis out of range repeat the adjustment 4 39 SERVICE MENU 4 CUTTING MENU CUTTING MENU 4 CROPMARK SENSE CROPMARK SENSE 4 OUTLEVEL CHECK 4 4 9 CROP CUT ADJUSTMENT Referential Time 10min This adjustment is for calibrating the relative positions of Tool and Crop Mark Sensor
73. 4 5 LIMIT POSITION amp CUT DOWN POSITION INITIALIZE 2 4 7 FLUSHING POSITION ADJUSTMENT 3 4 12 TOOL HEIGHT ADJUSTMENT 4 4 13 TOOL PRESSURE ADJUSTMENT 5 4 8 CROP MARK SENSOR ADJUSTMENT 6 4 9 CROP CUT ADJUSTMENT 7 4 10 PRINT CUT POSITION ADJUSTMENT 3 19 3 5 CARRIAGE MOTOR REPLACEMENT 2 Remove the following covers Cover Right Top Cover Panel Cover Chassis Cover 1 Turn off the sub power and then turn off the main power MAIN POWER SW IE When removing the Panel Cover remove the sensor on the back side of the Panel Cover and flexible cable on the Panel Board SENSOR FLEXIBLE CABLE lt Back Side gt 3 Disconnect the connector of the Motor Cable 3 20 SCREW I S COVER CONNECTOR M S lt Top View gt Remove the spring on the Flange FLANGE SPRING Remove the 3 screws fixing the Flange and remove the motor together with the Flange Remove the 4 screws as shown in the figure to remove FLANGE the motor from the Flange And fix the new motor to the Flange IE Be careful with the fixing directio
74. ENTER key MENU key Saves new setting Moves cut position towards front Moves cut position towards rear Moves cut position towards right Moves cut position towards left Moves out SETTING menu Perform the test print again for confirmation Adjustment is completed if the position of cut line is satisfactory If not repeat the adjustment again 4 42 CUTTING MENU 4 CROP CUT ADJ v CROP CUT ADJ 49 SETTING F 0 30 gt 0 30mm 0 40 0 40mm y 4 Fine Adjustment Broken line is indicating the cut line Before adjustment a After adjustment gt 4 10 PRINT CUT POSITION ADJUSTMENT Referential Time 10min This adjustment is for calibrating the relative positions of printing and cutting If it is not adjusted it may result in the misalignment of the printing and cutting This adjustment is required when Tool Carriage is replaced or a head is replaced or adjusted and also when the relative distance between the Carriage and head is changed Before this adjustment it is necessary to confirm that ENABLE is selected for AUTO ENV MATCH Also Take up Unit must not be used during this adjustment 1 Turn on the Sub Power SW while pressing lt q V and gt keys to enter the Service Mode 4 coL Set up media on the machine IE
75. Head rank H1 75Y383DSXTZWWST iz 006 D H2 06A03737VVVYWVRT 002 D H3 T7AV4040TURXYXRS OOL D 76 39375 5 5 00W D H1 H2 Head hori DT1 Low 1 0 0 DT3 Low 1 0 0 5 DT1 High 1 1 0 1 DT3 High 41 5 0 0 Head bi DT1 Low 10 9 5 10 9 DT3 Low 8 7 8 7 1 High 20 18 5 21 19 DT3 High 416 415 5 17 16 Dip SW 00000000 System SW page 1 4 00000000 00000000 00000000 00000000 System SW page 5 8 00000000 00000000 00000000 00000000 System SW page 9 12 00000000 00000000 00000000 00000000 System SW page 13 16 00000000 00000000 00000000 00000000 Network I F version Print Server 1 1 Tue May 30 14 46 26 JST 2006 Maintenance request NONE Booter version 1 00 Heater adjust PRINT Battery Charged Heater adjust DRYER 0c Periodic CL degree NORMAL Preheat temperature s 30 Limit position 25 6 mm Heating timeout 20 min Cutter down position 1725 8 mm Drain liquid volume 192 0 cc Calibration default 0 26 Standard head 1 Encoder position 1 1516 6 mm Flushing pos adjust 0 00 mm Encoder position 145 0 Environment match 40 028 8 Crop tool adjust F S 0 40 0 00 mm Encorder calibration 40 028 9 Print cut adjust F S 0 20 0 60 mm Force adjust 30gf 14 Crop sensor adjust 0 Force adjust 200gf 2 53 Roland Versa CAMM series Model VP 540 IP Address 192 168 000 100 Ink type E SOL Max 4Color Versio
76. When the print carriage does not return to the standby position capping needs to be done manually by user 7 10 Consumable Parts and Replacement Cycle Replacement Cycle 6 billion shots nozzle 6 000 000 kshots Printing Head Damper needs to be replaced together with the Head replacement Wiper 6 months Wiping 3000 times or Rubbing 100 times Carriage Motor 1500 hours Cap Top 6 months Ink Tube 3000 hours Sponge for Wiper 12 months Lithium Battery 24 months Cutter Protection Replace it depending on the degree of scratches on it Pinch Roller Replace it depending on the degree of wear of its rubber part 7 11 7 2 Maintenance Check List VP 540 300 Maintenance Check List Date User Serial Number Check Items Operation Points interview ihe eustomer Ask the customer if there is something that he she is concerned Done about Output Get report before maintenance Get report with Get Report of the Peck or print ALL Report in the Service menu If large amount of ink is discharged in the drain bottle dispose of it and LI Good Check drain bottle give an explanation to the customer Make sure to reset the discharged Disposed Reset ink count Upgrade the firmware to the latest version peli the firmware if the installed firmware is not the latest Determine if they should be replaced based on the SHOT COUNT in the Good History Report the test print result and the custom
77. a 2 2 o z LiL 2 51 lt lt af He 5 8 hil SE 3 gt pP 2 H He Fe amp 8 CN402 R23 R22 Lnd 0 4 H H H H 1 8 1 71 5 1 CN404 C9 R156 840 ICA C101 C100 SP1 8010A His acm Lom C 8 c99 R157 SERVO BOARD 5 JE 5 a 12 40 8152 a 019 CN3 L6234 It indicates the version of the Servo Board 2 14 SERVO BOARD Arrangement Diagram Soldering Side f 92741 62741 72741 70741 R253 TP300 3 3b R113 1111 5 88800566 8 Ooo 3 Ossau 0528 10641 20641 2200 ria 95 d 219 sop H 58 58 as 814 oza 88 9 cma 2 5 udis 1177 E 5 E S 0 7060 1 820 720 oe e 440 2 g 8 4 3 799 5 1741 eus R119 R62 O 4 3 S 1 8 00741 Cg 798 413 R79 R339 R126 73030 a 2240 SE 5 o 8 8 8 3 3 9060 1 2 S
78. 1 High 2 1 3 4 4 2 Parameters can be v i Ay entered with an BI DIR DEFAULT 48 Hi H2 m 1 lt gt 6 9 increment of 1 2 5282 42 1 3 4 2 1 VP 540 only 23 Fix the Damper Plate IE Make sure to press the Damper Plate downward lightly when fixing it If you press the Damper Plate strongly the Damper may be damaged Fix the screws at the lower end of the long screw hole lt VP 540 gt OL lt VP 300 gt m a oN 4 31 4 5 LIMIT POSITION amp CUT DOWN POSITION INITIALIZE Referential Time This is for adjusting the relative distance between the Limit Sensor and the Capping Position and also detecting the distance from the Cut Down Position to the Limit Sensor after completing the adjustment When the Limit Position is not correctly set it may cause some problems such as a head capping error and a head carriage lock error Also when the cutter down position is not correct there will be some problems such as a cutter down error when separating the sheet Flushing Position Adjustment is required after this adjustment 1 Remove the 1 5 Cover 2 Turn on the Sub Power SW while pressing lt and gt keys to enter the Limit Initialize mode 3 Confirm that the Head Carriage is
79. 25min 1 LLNEAR ENCODER SETUP Adj Time 5 Total Time 30min BATTERY REPLACEMENT 7min 1 TIME AND DATE SETTING Adj Time 2min Total Time Static electricity can harm some electronic devices To prevent static damage discharge static electricity from your body before you touch any of electronic devices You can do so by touching an unpainted metal surface on the chassis You can also take the following steps to prevent damage from electrostatic discharge ESD When unpacking a static sensitive device from its shipping carton do not remove the device from the antistatic packing material until you are ready to install the device to the machine Just before unwrapping the antistatic packaging be sure to discharge static electricity from your body When transporting a sensitive device first place it in an antistatic container or packaging Handle all sensitive devices in a static safe area If possible use antistatic floor pads and workbench pads 3 3 3 1 HEAD REPLACEMENT VP 540 300 support the new head only The parts number of the new head is as follows Parts No 1000002201 Parts name ASSY HEAD INKJET SOL XC 540 The number written on the back side of the Printhead Board is the way for identifying whether it is a new or current Head R4CJ520 is written on the new head R4CJ520 1 Turn on the sub power while pressing the left
80. 4 05 09 10 AY Year Month Day Display Year Month Day Edit CLOCK 4 lt 4 4 01 01 59 4 01 01 59 Display Edit min 4 TIME 4 gt it shows B when 01 01 59 4 01 01 59 battery is dead This is for displaying and editing the date and time When it detects the battery exhaustion B is indicated on the time display In this case battery needs to be replaced However B does not disappear automatically when the battery is replaced B is deleted when the time is newly set up with ENTER key on the time edit menu When the real time clock is not active due to battery exhaustion the maintenance operation may be performed improperly For instance it performs cleaning every time the main power is turned on The time set here is used for the timings of maintenance operations and for the time record of Event Log function It must be aware that it affects the maintenance operations when the setting is changed here When this setting is changed it is recorded on the Event Log The time before change is used for the log time and the new time is recorded as a referential information SUB MENU gt DIP SW CHECK 4 This is for checking Dip Switch It displays the real time status of the No 1 to 8 in 4 DIP SW CHECK 4 0110 0000 order from the left 0 is OFF and 1 is ON AY bit 1234 5678 ay SUB
81. Delete Host Restart jc D Peck4 screen is displayed again Click Firmware Upgrade button Peck 4 0 1 Select Port Bet Report Get Parameters Put Parameters Set Head Rank C Firmre 2 Exit 6 OPEN screen is displayed Select the firmware file and click Open It starts to send the firmware to VP 540 300 03 475 4 16 The machine goes into the Firmware Upgrade When upgrade is completed the Sub Power turns off automatically ERASING DEVICE ERROR pee d preesse NG NG NG WRITING DEVICE ERROR VERIFYING DEVICE ERROR gt COMPLETED HOW TO INSTALL FIRMWARE Referential Time 10 min This is required when a new Main Board without the firmware is installed Turn on the Main Power SW while pressing 4 A and V keys a v UPDATE FIRMWARE J 2 Press ENTER key to set the machine ready to receive the firmware UPDATE FIRMWARE l 4 WAITING 000 000 000 000 4 17 Press MENU key and set ADDRESS MASK GATEWAY ADDR Press lt Q and gt keys for moving between digits and and W keys for selecting value After setting an address press ENTER key to go next address setting When GATEWAY ADDR is set it returns to the
82. Divide the file into 2 or more and output them as separate jobs in order to make the feeding distance of each job shorter 2222222 4 444444 ndi REAR ERIE 14444444 Symptom 4 1 2 3 are Mixed or Details are Not Clear Jede he e he Ae e Actions 1 Enable CUTTING MENU gt AUTO ENV MATCH in the User menu 2 Set 0 in CUTTING MENU gt CALIBRATION gt SCAN SETTING and FEED SETTING in the User menu 3 Perform ADJUST BI DIR in the User menu 4 Perform PRINT CUT ADJ in the User menu 5 Prefeed the media to make it unrolled before starting a printing to decrease the back tension 6 Decrease SPEED and UP SPEED in CUT CONFIG T Divide the file into 2 or more and output them as separate jobs in order to make the feeding distance of each job shorter 8 Use the crop marks 9 Adjust the belt tension 6 5 Symptom 5 Cut is Shifted When Using Crop Marks IO I I Possible Causes 1 Crop cut adjustment is not correctly done 2 Crop mark sensor adjustment is not correctly done Actions 1 Perform ADJUST BI DIR in the User menu 2 Perform CROP CUT ADJ in the User menu 3 Perform the crop mark sensor adjustment by executing CROPMARK SENS gt OUTLEVEL CHECK in the Service menu 6 8
83. If it is not adjusted the cutting position based on the detected Crop Marks becomes wrong and that results in the mis alignment of the Print and Cut performed under the auto crop mark detection This adjustment is required when Crop Mark Sensor or Tool Carriage is replaced Before this adjustment it is necessary to confirm that ENABLE is selected for AUTO ENV MATCH Also Take up Unit must not be used during this adjustment 1 Turn on the Sub Power SW while pressing lt d V and gt keys to enter the Service Mode 4 GO Set up media on the machine IE Vinyl media is recommended for this adjustment 40 4 SERVICE MENU 2 Perform Bidirectional Adjustment referring to 4 4 HEAD SERVICE MENU 4 ALIGNMENT PRINT MENU gt v PRINT MENU 4 HEAD ADJUST 2n v HEAD ADJUST 45 BI DIR DEFAULT p gt Select CUTTING MENU gt CROP CUT ADJ gt TEST 3 SERVICE MENU 4 PRINT 2 and press ENTER key CUTTING MENU The test print and cut will be performed v CUTTING MENU 4 IE Bidirectional adjustment and this step must 4 be done by using the same media v CROP CUT ADJ 45 TEST PRINT 2 4 4 4 40 From the test pattern find the value where the print line matches the cut line In this case the
84. SCREW CARRIAGE BELT CARRIAGE BELT PLATI PLASTIC PLATE BELT HOLDER SCREW CARRIAGE BELT CARRIAGE BELT ETAL PLAT PLASTIC PLATE BELT HOLDER lt Top view Leftside of the Belt gt 15 Fix the Tool Carriage Assy to the Tool Carriage Board Stay TOOL CARRIAGE BOARD STAY 4 SCREW e 2 f 2 z _ S eee mom Re LL LT 9 IEEE TOOL CARRIAGE ASSY 16 Fix the Tool Carriage Board with the 2 screws as shown in the figure TOOL CARRIAGE BOARD 17 Connect the Crop Mark Sensor Pinch Roller Sensor CROPMARKSENSOR and Solenoid wirings SOLENOID PINCHROLLERSENSOR 18 Move the Head Carriage in a whole width of the Guide Rail several times to remove the slack in the Carriage Belt Then carry out the following adjustments
85. explosion and fire 1 Turn off the sub power and then turn off the main power Remove the Chassis cover cop CHASSIS COVER MAIN POWER SW Rear View 3 57 Remove the battery on the Main Board by pushing it down and tilting towards right SOCKET MAIN BOARD Replace the battery with new one SOCKET Be careful with the direction of the battery 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 oco v 2 v MENU 4 SERVICE MENU Select SUB MENU CLOCK TIME and set the time and press ENTER key oe gt CLOCK TIME The display of which shows a battery gt exhaustion disappears by this step TIME 13 01 59 ENTER 3 58 Select SUB MENU gt CLOCK gt DATE and set the date and press ENTER key Turn off the sub power and then turn off the main power Fix the Chassis Cover Dispose of the battery 3 59 ERVICE NU 8 gt DATE UB MENU LOCK Y LOCK 4 4
86. gt gt gt DRAIN BOTTLE ENTER MENU SUB MENU yy SUB MENU 45 gt v MAINTENANCE 4 DRA P MPTY RESET A DRAIN T m t m 20 ENTER lt HOW TO CLEAR THE HEAD INFORMATION gt SERVICE MENU 4 HISTORY MENU gt After THERMISTER CHECK and HEAD ALIGNMENT LP HISTORY MENU 4 clear the head information from the SERVICE MENU gt HEAD GROUP HISTORY MENU gt HEAD GROUP Select the head you gt replaced and press the ENTER key The head at the left end is HEAD1 and HEAD2 to HEAD4 in order to the right HEAD GROUP 4 lt NOTE FOR FIXING THE CARRIAGE COVER gt When fixing the Carriage Cover fix the screws on top after fixing the screws on the both sides temporarily 3 10 3 2 WIPER REPLACEMENT 1 Select SUB MENU MAINTENANCE REPLACE WIPER in the User s Menu and press the ENTER key MENU 45 SUB MENU 4 gt SUB MENU 44 MAINTENANCE gt 1 gt 43 REPLACE WIPER 2 The Head Carriage moves to a location OPEN FRONT replacement and then the message shown in the figure COVER appears g 4 SCREW the 1 5 Cover I S COVER gt 3 The message shown in t
87. or Sorvail 8 10 LN 1 0 9 WI OL g UND NONE S YUL oL VOS DRO cooker ES XT anso t E TND OARS OL t Diagram 3 4 Orv DNO LINDT 105095 WID OT WN 91 peojumoq dst 408196 19A0 92utu9jureJA OL losuog 12945 OL SUB BOARD Circu 2 26 SUB BOARD Circuit Diagram 4 4 CN1000 CNIO01 1 2 to FAN 4 5267 02 to Servo Board 5 CN1002 7 11 8 to FAN 53398 0890 5267 02 CN1003 11 CN1004 FAN JUNCTION BOARD 2 to Bed Thermistor Board 53014 02 da nss ae 12 to Apron Thermistor Board 53014 02 1 5 CN1100 1 5268 02 CN1102 7 CNI1200 CNI201 5 3 4 CN032 004 T 5268 03A NON 5268 02A E CNI202 3 3 CN032 004 CARTRIDGE IC BOARD CN1300 5268 03A NON CARTRIDGE IC BOARD 5268 02A NON 3 CN1502 i 2 032 004 7
88. 1 5268 03A NON CARTRIDGE IC BOARD CNI1301 CN1400 CNI401 2 1 2 1 1 1 14 2 1 2 5268 02A 3 5 5268 02 3 5 CN1302 1 CN1402 CN032 004 7 E CNO32 004 1 1 5268 03A NON 5268 03A NON CNI500 CNI501 CN1600 2 1 if 2 1 5268 02A NON 222 CN1602 CNOSZ WHNON 1 5268 03A NON CARTRIDGE IC BOARD CN1700 CN1701 1 5268 02A NON 3 CN1702 4 CNO32 004 NON 1 5268 03A NON CARTRIDGE IC BOARD CNI800 CNI8OL ti 5268 02A NON oe CNI802 3 3 5 1 5268 03A NON CARTRIDGE IC BOARD CNI 1 2 103KT 53398 0290 THERMISTOR BOARD TH2 1 103KT 53398 0290 THERMISTOR BOARD GRIT ENCODER BOARD GE3VCC CN2800 02800 3 R2800 A 3ENC3 Pi 3 4 Vou A An 4 GENCE PHB 4 4 156 4 vec 2 5268 03 VowB 77 _ _ 36 CEO lu CN900 CABLE ASSY P SIDE SENS NON 1 3 ZK 0900 GP2S40 NON PAPERSIDE SENSOR BOARD CABLE ASSY CROP SENSOR 540 10800 2840 CROP SENSOR BOARD 2 27 2 6 MAINTENANCE PARTS LIST _ Electrical Parts MAIN BOARD C2
89. 1 0 mm 39 mil with liner for printing M aximum 0 4 mm 16 mil with liner and 0 22 mm 9 mil without liner for cutting M aximum 180 mm 7 in M aximum 30 kg 66 Ib Maximum 20 kg 44 Ib 50 8 mm 2 in or 76 2 mm 3 in M aximum 1 346 mm 53 in M aximum 736 mm 29 in Roll outer diameter Roll weight Core diameter Printing cutting width 1 Ink cartridges Types 220 cc cartridge 440 cc cartridge Colors Four colors cyan magenta yellow and black Printing resolution dots per inch Maximum 1 440 dpi C utting speed 10 to 300 mm s Blade force 30 to 200 of C utting blade Type Roland CAM 1 series compatible Blade offset 0 to 1 5 mm 0 to 0 059 in Software resolution when cutting 0 025 mm step Distance accuracy when printing 52 Erroroflessthan 0 3 of distance traveled or 0 3 mm whichever is greater 3 Erroroflessthan 0 4 of distance traveled or 0 3 mm whichever is greater W hen distance correction has been performed when the setting for CALIBRA TION CUTTING ADJ has been made Error of lessthan 0 2 of distance traveled 0 1 mm whichever is greater Distance accuracy when cutting 3 Repeatability when cutting 3 4 0 1 mm or less Alignment accuracy for printing and cut ting 3 55 0 5 mm or less Alignment accuracy for printing and cut Error of less than 0 5 of distance traveled 3 mm wh
90. 1120 Procedures have been revised Procedures have been revised 00 1012 Service Mode has been revised Sect1 Parts have been revised 2008 1 29 2 1 Wiring Map Cable has been added Sect4 Service Mode has been revised Kato Mabuchi Ensure Safe Work About A WARNING and Notices Used for instructions intended to alert the operator to the risk of death NWARNINGQG 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 NCAUTION material damage refers to damage or other adverse effects caused with respect to the home and all its furnishings as well to domestic animals or pets About the Symbols The A symbol alerts the user to important instructions or warnings The speci meaning of the symbol is determined by the design contained within the triangle The symbol at left means danger of electrocution The amp symbol alerts the user to items that must never be carried out are forbidden The speci c thing that must not be done is indicated by the design contained within the circle The symbol at left means not to touch The symbol alerts the user to things that must be carried out The speci c thing that must be done is indicated by the design contained within the circle The symbol at left means the power cord plug must be unplugg
91. 22 5 5 8306 5 7458 23 56 E 5 3 m ba sd e 3 8 254 16203 3001 12329 R31 2 8298 5 33416324 26 ee 1 37338 TP325 m m 8326 8310 zm 200 R360 E Ed e LI 25 8372 D PC27 1 AD Rate ecan E 58 62557 T 8358 511 co 8s cre Q Sooo 260 7 T 3 H 5 18357 eco 8 CEPS R366 8 8 E 3 8 R277 5 276 5 Hg 8 z 284 2 m 17290 OS PC294 285 2 R303 Te28 S g tr Oo Ore 8 R301 1 290 5 S TP289 O ss 2 TP279 Sr 2 TP288 2 218 Hass 5 8251 822 925 R343 C24 reae 2 250 R342 C240 3 2 R341 C239 8 oS thoes 8945 6238 i 3 TP268 TP263 8296 2 O 3 LI R225 T z HHH 88 S 54 c219 T 2 S 358 8 55 8294 5 5557 2270 H TI Tyres 999 mum pp C218 5888 ZLLELLLLL TP241TP231 TP230 338 c FUE TsO Or R 108352 Ld 8 LL C1 268 245 E mm O30 2 25 mu PC246 em 208 5 5 5 OR 8 Bi H 225 LT 862337 Crease 207 23588 5 C243 5 6206 LI 1 R266 L a216 IS C205 8265 R223 R337 c235 82908289 C20 83360234 224411 LL 216 6203 Qrezie
92. 4 PUMP TIMES 9134 times 3 38 20 Move the Head Carriage by hand to the lock position HEAD CARRIAGE 01 Fix the 1 5 Cover SCREW I S COVER 3 39 3 8 INK TUBE REPLACEMENT 1 Turn on the sub power while pressing the left right and down keys to enter the Service Mode 2 Select SERVICE MENU SUB MENU PUMP UP and remove ink by following the sequence 3 Turn off the sub power and then turn off the main power v v MENU 4 SERVICE MENU SERVICE MENU 49 SUB MENU 4 gt SUB MENU 43 gt DRAIN BOTTLE 4 1 ENTER REMOVE SOL CRT 1234 PUMPING UP gt gt gt MAIN POWER SW SUB POWER SW 4 Remove the following covers 15 Cover MaintenanceCover Left Side Cover Front Cover Top Cover Right Top Cover LEFTSIDECOVER MAINTENANCECOVER TOPCOVER RIGHT TOP COVER I S COVER 3 40 5 Remove the Cut Cable Guide lt VP 300 gt 1 Remove the 3 screws to remove the Cut Cable Guide a CUT CABLE GUIDE VP 540 1 Remove the 3 screws
93. 688410 amp S 60841 Qocedl 202410 21041 L0eH 12240 LES BED Sn 8 9895 EE Q GEedl MN 7519 1 9224 S bonos E bead 5559 Qu P S D P 960 88 maama gozal S eJ 2 8 E S 5 gocu 88641 0028 ed s 6024 Lo __ 1 0 2 80 e 029 pied coloo V s 5 10800 s gt 0020 2 102H Lo 226089 1 S Z j SENTO 202 eJ 6 22 SD I eeed1Q 0028 Sev amp 1 eS 002031 002ul 1 5 1 1 i e Hic Lt a 5 102N2 02 5 2 CN700 E 5 gt 02 521 0 SS 7 U S 5 3 5 B9 mcg paw n D500 R505 1 04 0 MADE IN JAPAN 5 0501 LINEAR ENCODER BOARD 3 3 8 8 2 2 S LO oo e 9000002163 9 gpl 48 of 11234561783 8 cc 0123456789 Si g 0500 5 8 D O S 10500 2 7 NS ERE CUT CARRIAGE BOARD Bs 5 221 UL 7 2 dt 94V 0 A30C5 MADE IN JAPAN CN504 It indicates the version of the Carriage Board
94. 7 84547 aor 7 7 6 140088 Sea 12 1581 257088 campis 1900 88 5532 7 7 Eurus bui CABLE CARD 36PT 20001 88 sP 200 _ 140 000002166 ASSv CORDHEATERve s00 000002183 CABLEASSYHEATERVP s0 Hiooonozrss 00 essere 5 1000004205 _ CABLE ASSY FRONT COVER 2 2 2 2 MAIN BOARD Arrangement Diagram Component Side It indicates the version of the Main Board
95. 9 Pump Times trip total clear 1 703 1 703 Maintenance group Mainte count 0 times Total time 483 hours Printing time 8 hours Wiper group Wiping count 86 times Rubbing count 6 times Wiper replace count 0 times Head group Shot Cnt 1 trip total clear 2 697 2 697 Shot Cnt 2 trip total clear 2 701 2 701 Shot Cnt 3 trip total clear 10 361 10 361 Shot Cnt 4 trip total clear 10 357 10 357 Shot Cnt 5 trip total clear 12 166 12 166 Shot Cnt 6 trip total clear 12 137 12 137 Shot Cnt 7 trip total clear 4 786 4 786 Shot Cnt 8 trip total clear 4 767 4 767 H1 H2 H3 H4 Wiping count for head 43 43 43 43 times Rubbing count for head 3 3 3 3 times Headrank set count 0 0 0 0 times Auto cleaning count 17 17 17 17 times Normal cleaning count 4 4 4 4 times Medium cleaning count 0 0 0 0 times Powerful cleaning count 1 1 1 1 times Print group Printing time 6 hours Print pages 34 pages Ink group Cartridge change 1 4 0 1 2 0 times Change ink type 0 times Error group Service call count 0 times Service call history kkkk k kk Motor error feed 0 times Motor error scan 2 times Low temperature error 0 times High temperature error 0 times Emergency capping 0 times Start uncapped 2 times Heater group PRINT DRYER Heater used time 6 6 hours System group Power on count Power on time Sleep time Shee
96. CASTER BWS 50BN 3000000036 SET SQUARE M5 8 5 8 5 2 3 100PCS 1000002618 LEVER BRAKE VP 540 31049157 SCREW CAP 6 20 3CBC PW SW 1000002149 5 VP 540 1000002678 STAY STAND VP 300 1000002635 STAY STAND VP 540 1000001579 STOPPER SHAFT XC 540 1 10 TOOL CARRIAGE PARTS LIST Main Parts Parts No 22805292 Parts Name ASSY CLAMP BLADE CM 500 Parts No 22175155 Parts Name SPRING SCREW CM 500 22805291 ASSY HOLDER BLADE CM 500 22715168 STAY AUTO CUTTER 2 CM 500 22805287 ASSY PLATE CAM SLIDE CM 500 1000002531 STAY CUT CARRIAGE BOARD VP 540 22805571 ASSY CARRIAGE SP 300 1000002540 STAY HOLDER BELT VP 540 W700461250 ASSY CROP SENSOR BOARD VP 540 22535287 LABEL CAUTION CARRIAGE LA266 W700461120 ASSY CUT CARRIAGE BOARD VP 540 W700461290 ASSY FLEX1 VP 540 1000002674 PLATE CABLE CUT VP 300 1000002613 PLATE CABLE CUT VP 540 7488739000 BASE CUTTER CJ 500 1000002530 CARRIAGE VP 540 1000002185 CABLE ASSY PINCH SENSOR VP 540 23475207 CABLE CARD 15P1 19001 BB For VP 300 23475238 CABLE CARD 15P1 25701 BB HIGH V For VP 540 1000002187 CABLE ASSY CROP SENSOR VP 540 PARTS LIST Supplemental Parts Parts No Parts Name 31029801AS
97. COUNT MENU gt MAINTENANCE gt CLEANING has been performed Unit Reference times This value is cleared automatically after carrying out the Head Maintenance This value is cleared automatically after carrying out the Head Maintenance TOTAL TIME Lapsed time from the last Head Maintenance PRINTING TIME Printing time from the last Head Maintenance CLEAR ALL Clear all the value in the MAINTENANCE GROUP WIPE GROUP Clear all the value in the WIPE GROUP PRINT GROUP Number of pages printed CUTTING GROUP CUTTING TIME Total time of cutting performed DISCONNECT Number of times the carriage has been disconnected CLEAR ALL Clear all the value in the CUTTING GROUP hour Unit imes imes imes Reference his value is cleared automatically after replacing it his value is cleared automatically after replacing it o c p Unit test print time is excluded ges Unit Reference Test print time is excluded Disconnection of Tool Carriage and Head Carriage imes INK GROUP CARTRIDGE 1 Number of times the Ink Cartridge 1 has been changed CARTRIDGE 2 Number of times the Ink Cartridge 2 has been changed CARTRIDGE 3 Number of times the Ink Cartridge 3 has been changed Unit Reference times times times times CARTRIDGE 4 Number of times the Ink Cartridge 4 has been changed CHANGE INK Number of times the Ink type has been changed CLEAR ALL
98. Clear all the value in the INK GROUP ERROR GROUP times Unit imes Reference LOW TEMP ERR Number of times the Low Temperature Error has occurred HIGH Number of times the High Temperature Error has occurred S imes imes ro gt 5 Djo c 5 5 times Number of times of forced capping for Head dry prevention that works when cap is left open for 3 minutes or more due to cover open or other reasons When cap is left open it is detected when machine is started times EMERG CAPPING Number of times the Emergency Capping Error has occurred TART UNCAPPED Number of times the machine has started uncapped CLEAR ALL Clear all the value in the ERROR GROUP HEATER GROUP PRINT USE TIME Total time of Print Heater used DRY USE TIME Total time of Dryer used CLEAR ALL Clear all the value in the HEATER GROUP times Unit Reference gt ojo GIS SYSTEM GROUP Unit POWER ON COUNT Number of times Sub Power has been turned on imes ui POWER ON TIME Total time of Sub Power ON our Sleep time is excluded pT 4 SLEEP TIME Total time of the machine in Sleep Mode SHEETCUT COUNT of times the Sheet Cut has been performed times It counts Auto Sheet Cut performed by both printer and RIP o CLEAR ALL Clear all the value in the SYSTEM GROUP es 4 9 Service Report SERVICE REPORT
99. E 51 I 1 62800 4 2 1 P 900 gooey i S 4 2 1n z a 64 08 st 5 e el Et me 18 5 0 Av6 0 Av6 i ED 7912000001 er e 2 222 2 2 1n 2 2 1n zat 7912000001 NI 7912000001 N d r NI 30vW 11 5 2 91 6 QBYOB 21 901818 2 2 91 6 08408 21 3901018V2 N 2 i n 2 o MT Ets al zal ZOBINJ g 100802 RUND g 1 OOLINDe o mL Sa 3120 t 2 Sel 20 27 61812181 8 Eme i O 5 5 8 95522 58552 o 61814 918 6 11 O i PES cj 1 GQdVOH 13NYd Puejoy ie 2 5 SUB BOARD SUB BOARD Arran TANVd 1 4 t Diagram SUB BOARD C DUXI d SFCLOHAFL T WON MOOI L019 mii Ir XT E
100. Feed Motor has been rotated MOTOR SCAN Total time that the Scan Motor has been rotated Reference ife 1500 hours ife 200 000 times PUMP TIMES Total time that the Pump Motor has been rotated CLEAR ALL Clear all the value in the Motor Group HEAD GROUP Contents Reference SHOT COUNT 1 Number of shots fired from the nozzle H1 left Shots 1000 Life 6 billion Shots nozzle Number of shots fired from the nozzle H1 right Number of shots fired from the nozzle H2 left Number of shots fired from the nozzle H2 right Number of shots fired from the nozzle H3 left Number of shots fired from the nozzle H3 right Number of shots fired from the nozzle H4 left SHOT COUNT 8 Number of shots fired from the nozzle H4 right WIPE H1 Number of times the Wiping has been performed H1 WIPE H2 Number of times the Wiping has been performed H2 WIPE H3 Number of times the Wiping has been performed H3 Number of times the Wiping has been WIRE TIS performed H4 RUB H4 Number of times the Rubbing has been performed H1 RUB H2 Number of times the Rubbing has been performed H2 RUB H3 Number of times the Rubbing has been performed H3 RUB H4 Number of times the Rubbing has been performed H4 NORMAL CL H1 Number of times the Normal Cleaning has been performed H1 NORMAL CL H2 Number of times the Normal Cleaning has been performed H2 NORMAL CL H3 Number of times the Normal Cleaning has been performed H3 NORMAL CL H4 Number of tim
101. IC chip on it No information is written on IC chip during this check ry Normally the count of the cartridge installation is CHECK written However the count of the installation in this COMPLETED 4 check is not written Before this IC CHECK make sure Cartridge Sensor is working properly RI A lt Serial No of the Ink Cartridge IC is displayed 4 SLOT 1 4 1402A30C010000A5 AY 1 5 a SEL gt INK TYPEWT Ink type of the Ink Cartridge IC is displayed 4 v 511 CAPACITY 4 Ink capacity of the Ink Cartridge IC is displayed 4 200cc AY A gt 811 LOT NO 4 Lot No of the Ink Cartridge IC is displayed 4 40216A AY AY 5 811 CONSUM 4 Ink consumption of the Ink Cartridge is displayed 4 100 000cc AY 511 4 The used time of the Ink Cartridge is displayed 4 0 000400 00 00 Av Av 5 SLI GINSERT 4 The insert count of the Ink Cartridge is displayed 4 1 times Av av 511 FLAG 4 TAE The Flag information of the Ink Cartridge is displayed 4 000000000 av It reads the information written on the IC of each carriage CARTRIDGE 4 Following messages displayed when some error is found 4 SLOT 2 Ink cartridge is not inserted 7 SLOT 4 NO CARTRIDGE av CARTRIDGE A cartridge with no IC is inserted wire break or short 4 5 0 4 SLOT 4 NO IC CHIP System error due to the trouble such as a da
102. INK INSTALL SET SOL CRT E SOL Max4COLOR4 DRAIN BOTTLE 1234 1 Goes next when cartridge is set mur EARN OE EAR RESELLER p FILLING INK CHECK DRAIN BOTTLE E Goes next when completed ay t SUB MENU 45 REMOVE SOL CRT PUMPING UP PUMP UP b 4 DRAIN BOTTLE 4 1234 Goes next when cartridge is removed Goes next when completed NN CHECK 4 SUB MENU lt 4 1 Cleaning and ink filling for after head replacement HEAD REPLACE 4 DRAIN P AY Lp SET SOLCL LIQUID gt FILLING INK REMOVE SOL CL FILLING INK 1234 1234 Goes next when cleaning cartridge is set Goes next when cleaning cartridge is removed P CHECK SET SOL CRT FILLING INK CHECK DRAIN BOTTLE 4 1234 DRAIN BOTTLE 4 Goes next when cartridge is set 2 SUB MENU 4 4 gt REMOVE SOL CRT SET SOLCL LIQUID HEAD WASH 4 DRAIN BOTTLE 1234 1234 Goes next when cartridge is removed Goes next when cleaning cartridge is set gt WASHING HEAD REMOVE SOL CL WASHING HEAD 1234 Goes next Goes next when completed when cleaning cartridge is removed v SUB MENU lt lt gt PERIODIC CL 4 This is for selecting a cleaning type for PERIODIC function PERIODIC CL 4 LIGHT LIGHT 4 Options WIPE LIGHT NORMAL MEDIUM Default NORMAL Aw WIPE Wiping and Flushing only LIGHT Wiping and light evacuation ligh
103. Never use gasoline alcohol thinner or any other flammable materials Cleaning using the cleaning kit IMPORTANT This is very important work for maintaining the heads in good condition and must be done periodically Replacing the wipers Replacing the blade Replacing the separating knife Explain the following items referring to the Setup Guide L Temperature and humidity Specified 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 While in use Temperature 20 to 32 Humidity 35 to 80 Non condensing While not in use Temperature 5 to 40 C Humidity 20 to 80 Non condensing When not in use for a prolonged period Transporting the unit When transporting the unit head cleaning is required and you need 2 cleaning cartridges for it HIMPORTANT Fill ink within one week after transporting If the machine is left without ink the nozzles on the heads may get clogged Explain to refer to the User s Manual when a error message is displayed And also explain to switch off and on the machine and check what happens before calling for inquiry when SERVICE CALL is displayed since it occasionally solves the problem just by restarting Explain the procedure of capping the print heads referring to the User s Manual 5 5 The Print Heads Stopped Moving
104. PRINT and press ENTER key 12 Test pattern as shown in the figure will be printed 13 Loosen the 3 screws fixing the head SERVICE MENU PRINT MENU PRINT MENU HEAD ADJUST 4 gt 4 gt v HEAD ADJUST 4 BIAS 4P BIAS 4 TEST PRINT 4 4 SERVICE MENU 49 RINT MENU RINT MENU EAD ADJUST m EAD ADJUST ERTICAL 4 gt ERTICAL EST PRINT 4 lt H gt v gt v Loosen the screws fixing the head for 1 2 turn If the screws are loosened too much the alignment cannot be done correctly E 4 27 OF OO Oo oS L o S ml Ld 4 15 16 Turn the Adjustment Screw to make the lines of each color in the test pattern straight E Position of the printing moves 1 line by turning the screw 1 6 turn 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
105. PRINT P 4 Test pattern will be printed u Find the position where the two lines are overlapping and check the number of each color In case of having problem selecting i one between two numbers 1 2 is also available when setting up the Head Position Hi h DT3 High 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 50 value 19 VP 540 only The number with is the current setting H2 H1 DTi High 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 rum 29 30 31 32 50 H4 H3 H2 H1 Head Position DT3 Low 10 11 12 13 nm 22 23 24 25 26 27 28 29 30 31 32 50 Low H4 H3 H1 L DT1 Low 10 11 12 13 14 15 16 19 20 21 22 23 24 25 26 27 28 29 30 31 32 50 4 30 Select DT1 Low DT3 Low 22 BI DIR DEFAULT 48 DT1 HIGH and DT3 HIGH in the TEST PRINT HEAD ADJUST menu enter ix the parameters checked at step 21 BI DIR DEFAULT lt zi 34 lt DT1 Low 4 1 4 4 2 with and V keys 27 AY Press ENTER key to save the BI DIR DEFAULT 48 Hi H2 mas 4 settings DT3 Low 4 2 1 3 4 2 4 AY MICI We eet deve 2 d Br DrR DEFAULT 42 H2 mB 451 lt gt Ij
106. PRINT during automatic Crop Mark detection It prints a 4 F square Crop Mark and cuts the contour after b detecting the mark CROP CUT ADJ 4 0 30 gt 0 3 When it shows 1 it means that it has never 4 SETTING 0 40 0 40mm 4 been setup and it needs to be set In this case even 5 if adjustment is unnessesary due to the test result Returns to menu with MENU key 0 must be set here CROP CUT ADJ 4 PERFORMING This test pattern is for adjusting the cut position 4 TEST PRINT 2 TEST PRINT during automatic Crop Mark detection It prints a square Crop Mark and continuously prints 0 1 scales for both scan and feed direction and then cuts crosswise after detecting the mark ay gt 4 PRINT CUT ADJ 4 l PERFORMING This test pattern is for adjusting the print amp cut PRINT CUT ADJ b 4 TEST PRINT 4 TEST PRINT position It prints 3 square Crop Marks along the scan direction and cuts the contours of the marks PRINT CUT ADJ 4 gt F 0 30b 0 30mm When it shows it means that it has never 4 SETTING gt 0 40 0 40mm i been setup and it needs to be set In this case eve z if adjustment is unnessesary due to the test result v Returns to menu with MENU key 0 must be set here m RINT CUT 4 p PERFORMING This test pattern is for adjusting the print amp cut 4 TEST PRINT 2 TEST PRINT position It prints 0 1mm sca
107. Supplemental Parts 21545160 PAD WIPER TRAY SJ 540 1 31289109 5 21975124 PULLEY T14P284 GEAR S53 S2 3104917145 21975123 PULLEY WD6 94S9 S3 31049170 5 1000002575 RAIL GUIDE WIPER VP 540 S4 3119970145 15229506 SENSOR INTERRUPTER GP1A05A5 5 31249952 22295132 SHAFT IDLE PULLEY STX 7 S6 3128910245 22155961 SHAFT WIPER FJ 540 56 31289102 5 22175140 SPRING TENSIONER STX 7 S7 31289112AS Parts Name 11379105 WIPER HEAD ASP FJ 50 1000002573 COVER SCRAPER VP 540 1000002571 HOLDER SCRAPER VP 540 1000001658 WIPER SCRAPER 540 1000002186 CABLE ASSY WIPER SENSOR VP 540 1000002182 CABLE ASSY WIPER MOTOR VP 540 1 22 1 12 PUMP SYSTEM Cut to 215mm when using 1 23 1 12 PUMP SYSTEM PARTS LIST Main Parts PARTS LIST Supplemental Parts pene 1000002794 55 XC 540 1000002564 COUPLING PUMP VP 540 22025671 COVER CAP CASE FJ 540 1000002536 FRAME BACK UP CAP VP 540 1000002580 FRAME BASE CAP VP 540 21685122 GEAR S10S20 22135616 GUIDE CAP CASE FJ 540 11659249 HOLDER RING FJ 540 OINI OIA 22435106 MOTOR 103 593 1041 1000002595 PLATE P BEARING VP 540 1000001585 PLATE P MOTOR XC 540 1000002539 SHAFT CAP VP 540 1000002563 SHAFT PUMP VP 540 22175334 _ SPRING CAP HE
108. VP 540 Above ZW65383 VP 300 Above ZW61510 am ES V 14 M s da 1 2 FRAME VP 540 Above ZW65383 VP 300 Above ZW61510 PARTS LIST Main Parts Parts No Parts Name 21905192 ADAPTER CLAMP MEDIA 540 PARTS LIST Supplemental Parts Parts No Parts Name 31029101 BUSH NB 19 7520501000 ASSY CAP BOTTLE 2 FJ 52 31029106 BUSH SQUARE SB 6025 W700461240 ASSY FAN JUNCTION BOARD VP 540 31289111AS CUPSCREW SET M4 6 NI 100 PCS 1000002653 BASE BOTTOM VP 300 31289109AS CUPSCREW 5 374 NI 100 PCS 1000002527 BASE BOTTOM VP 540 31119904 PIN SPRING 2 5 8 SUS STRAIGHT 50 PCS 1000002589 VP 540 31129101 PIPE SET POLYCA 3 6 8 20PCS 21985140 BRACKET INK CATCH TANK SP 540V 31149706AS RING SET E RING ETW 10 SUS 20 PCS 12159573 BUSH 80F 0603 31149705 RING SET E RING ETW 7 SUS 50PCS 12159563 BUSH 80F 1006 31409702 SADDLE SET LOCKING WIRE LES 1010 20P 12159508 BUSH SHAFT OILES 80F 1206 31409801AS SADDLE LOCKING WIRE LWS 0711Z 20P 1000002176 CABLE ASSY PINCH U D SENSOR VP 540 31049171AS SCREW SET CAP M3 12 NI 50 PCS 21745109 COLLAR LEVER FJ 540 31049142AS SCREW M3 6 NI MEC 20 PCS 1000002630 COVER SCAN MOTOR VP 540 31049173AS SCREW M4 10 NI 50 PCS 1000002528 FRAME MIDDLE L VP 540 310491
109. are shown on the lower LCD On the left it displays the check sum in hexadecimal of v 2 digits On the right it displays the input data byte in decimal of max 10 digits They Receiving data from network are cleared when ENTER key is pressed The input data byte overflows at 4GB 4294967296B and is reset to 0 2 NETWORK 4 3 1073741624 4 SUB MENU 45 MSG 45 This is for setting the timing to show the message for maintenance It displays the 4 MAINTE MSG 4 NONE gt 100 hours 4 message suggesting to perform maintenance when the total print time reaches the specified hours Range NONE 10 to 999 hours in 10 hour unit Default NONE SERVICE MENU 4 MOTOR MENU 45 4 SCAN SCAN Aging for Scan Motor AGING 4 5 AGING The Head Carriage runs max printing width in Scan direction AY AY ww 1 1 FEED Aging for Feed Motor a 14 Grit Roller runs 100mm back and forth 1 P lt gt BOTH The Head Carriage runs max printing width 4 in Scan direction and at the same time Grit Roller t v runs 100 back and forth a CUTTING The Tool Carriage runs max printing width AGING 4 BOTH in Scan direction and at the same time Grit Roller 2 runs the half of max printing width back and forth 4 BOTH AGING a at AGING 4 C
110. be a cause of missing dots When printing is paused the coloring at the seam may be altered when printing resumes Before you perform lengthy printing check the amount of ink remaining in the ink cartridges Never store ink at any locations where high temperature may occur or exposed to open flame Performing a cutting Test Cut CUTTING PRIOR menu Adjusting the cutting conditions Blade Force Cutting Speed Blade Offset Tool up Speed 7 6 E Job outputting from Roland VersaWorks Explain each procedure as follows on a job outputting from Roland VersaWorks IMPORTANT Never use the Media Clamps during cutting Printing and cutting During a print amp cut the cap of the cutter holder may scratch and damage the printed surface Turn the cap of the blade holder to adjust the amount of blade extension or use the Dry Time setting on RIP as necessary Printing and cutting using Crop Marks Refer to the User s Manual 4 9 Performing Printing and Cutting Separately Automatic alignment with Crop Marks Manual alignment with Crop Marks When printing and cutting are performed using Crop Marks misalignment of cutting caused by media stretch shrinkage can be avoided Adding Media Profiles Explain the procedure of adding Media Profiles of third party media Downloading Media Profiles from the website Adding Media Profiles to Roland VersaWorks 77 Functions for o
111. connected to Tool Carriage Also lock the connected carriages if they are not locked IE After locking the carriages push them lightly towards left to confirm it is locked and also to eliminate looseness 4 32 SCREWs I S COVER YO LIMIT INITIALIZE MENU 4 Confirm that the head is certainly capped and press ENTER key The Tool Carriage gets separated from the Head Carriage and it starts limit position initialize EMIT 4 After the completion of the initialize the message is 4 displayed as shown in the figure SETTING UP CUTTER DOWN POS 4 DETECTING Move the Tool Carriage with your hand until it makes full contact with the Left Frame with Cut Down status 6 Perform the Cut Down Position Initialize by pressing ENTER key SETTING UP After the completion of the initialize the message is CUTTER DOWN POS 4 displayed as shown in the figure 9 Perform the following adjustment 4 7 FLUSHING POSITION ADJUSTMENT INITIALIZATION COMPLETED 4 33 4 6 LINEAR ENCODER SETUP Referential Time 5min This is for checking the reading of the linear encoder and for calibrating its expansion contraction caused by the operation environment This operation is required when Lim
112. correction value for the scan direction is 0 3 E amagnifier If itis difficult to see the cut line visually use Select CUTTING MENU CROP CUT ADJ SETTING and enter the correction values found in the test pattern for both Feed and Scan F Feed direction S Scan direction Left Current value Right New value Setting range 2 00mm 0 01mm unit C W Value of F towards key Value of F towards gt key Value of S towards lt j key Value of S towards ENTER key Saves new setting MENU key Moves out SETTING menu lt TEST PATTERN gt Correction value scale CUTTING MENU 4 CROP CUT ADJ gt 19 v CROP CUT ADJ 45 SETTING Select CUTTING MENU CROP CUT ADJ TEST PRINT and press ENTER key The test print and cut will be performed A Crop Mark is printed and detected by the Crop Mark Sensor and its contour is cut Confirm the cut line position on the print visually E a magnifier If it is difficult to see the cut line visually use 4 41 CUTTING MENU 4 CROP CUT ADJ CROP CUT ADJ 4 TEST PRINT J 4 Broken line is indicating the cut line Adjustment is completed if the position error of cut line is within 0 1 If not select SETTING menu again for further adjustment IE W key key gt key 4 key
113. d LIS 2 P nin ast ES A i wh ima oss 104 f SIVE 1 ogiscviyova m ERA 22A 20A gt XJ rego o NT oan Pip ien 7 tr zu WD S rs NON ru 03 sora Lr ove sony tiaa d PLE Nas sa aN LU p Ra Mau J09 S 1 vel Progo eron 1 9 L i LE n XV 9 A m 1 55 88 Im ss S oni 55 T xa 3 Over eL 28 30v vaavi 20A T 22959 od Lag T 5 T card 1 TEND NON 2 2 5 i Els O i 3 FIL 55 xy vaavi ep ES 4 227 LH LH GL UU 1 sro ero yy Td 2d 2 8 Lt
114. gvu 292 EJ gt F4 9291 a R124 af Qre o 8241 05302 5 E OLLI R 672 mE OCO re 36 oj 2 w54 OLLI gt ef 28 T Orso I pos LED Seu SSU 625 o 2 6 TP420 170 R318 TP418 E s cse do e R43 TP43 R42 8 a res wes E TP42 z OLD rs 62 FLO 7 8 EP 0 Qress 5 CTI 56 7 59 T 9 67 2 Oria 2 O CJ Qui 8012 LI 215 RI gu Lu 8113 8841 2 7641 gt 291 5 72 5 2 Si 169 O a CE TP80 25 9 22 Oo 3 TP83 33 13 58555 8 58884 2 15 7082 699 2125 bs 1 4 it Diagram SERVO BOARD C
115. ii of the stop position of Motor Encoder and Grit Encoder at each Error beeps 2 times time The result is judged by the last Encoder coordinates G ENC CHECK 4 A FAILED v A v SERVICE MENU SVC MODE 4 lt he 4 The heater does operate when the machine is started in Service Mode Set START here HEATER MENU 4 SVC MODE HEAT 4 STOP gt STOP 4 when the heater needs to be on START is canceled once the Sub Power is turned off and AY the setting is back to STOP when entering the Service Mode next time a v HEATER MENU 2 e m gt HEATER ADJUST 4 gt PRINT This is for setting the offset of heater temperature 4 HEATER ADJUST 4 PRINT gt 4 ob 34 The heater is controlled with this offset value added to the temperature displayed on the LCD Range 5 5 Default 0 a HEATER ADJUST 4 DRYER 4 DRYER 4 3 A v HEATER MENU 4 PREHEAT 4 This is for setting the heater temperature for PREHEATING under the gt o HEATER MENU in the User Menu TEMP 4 35 C p 35 C Range 20 to 40 C Default 30 C v a lt 4 gt TI
116. in the figure will be printed 4 25 Loosen the 3 screws fixing the head IE Loosen the screws fixing the head for 1 2 turn If the screws are loosened too much the alignment cannot be done correctly Insert the 1 5 mm Hexagonal Wrench through the hole of ADJUSTMENT the Head Carriage then turn the Adjustment Screw to SCREW make the lines of each color in the test pattern straight IE Position of the printing moves 1 line by turning the screw 2 3 turn Hole for inserting the Hexagonal Wrench When the upper lines are shifting towards the left of the lower lines turn the screw CW When the upper lines are shifting towards the right of the lower lines turn the screw CCW T Tighten the screws fixing the head in order as shown in the figure using the Torque Driver ST 056 IE Torque for tightening is 2kgf cm 20cNm Make sure not to tighten the screws too strong 4 26 1 Print the test pattern again If the result is not satisfactory repeat step 5 to 9 E The shifting of lines should be smaller than 1 2 dot 11 VERTICAL ADJUSTMENT Select PRINT MENU HEAD ADJUST gt VERTICAL TEST
117. it 2 CM Sule cdit cean EM Guide affect the printing at the position where there is dirt and the vertical banding may appear When there are foreign substances on the teeth of the gear 3 There is dirt in the teeth Cleanthe the movement of the Head Carriage changes at the position of the gear 9 where there is dirt And it results in the periodical vertical banding 6 6 MISSING DOT OR DEFLECTED FIRED DOT APPEARS WHEN PERFORMING PRINTING WITH LONG DELAY NO CHECKINGPOINT ACTION REFERENCE OUTLINE When the main power is off the maintenance flushing is not Clean Replace Encoder 3 12 ENCODER SCALE Encoder Scale is dirty REPLACEMENT Check the main power Do not switch off the performed and may cause the Head nozzle clogging Make lt User s Manual 7 switch main power sure to power on off with only the sub power switch for daily use 6 3 6 7 Print amp Cut Misalignment Ideal Conditions Ae Ae Ke 0 0 0 9 6 Se Ae Ae The above illustration shows the ideal print and cut conditions where the red stars signify the printed image and the black lines signify the cut path Since the actions to be taken are different depending on the conditions of shifting check how cutting is shifted first and take appropriate actions Most of the actions can be done by users Symptom 1 Cut is Shifted in the Same Direction for the Same Amount dedo dex
118. it with the other hand and remove it IE 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 o Remove the Top together with the tube Fix the new Cap Top Make sure to fix it so that the tube side faces the front IE Note the following contents 1 Do not touch the tip of rubber on the Cap Top 2 The spring is properly fixed under the Cap Top 3 Do not bend the tubes Fix the Cap Frame 3 14 Y TUBE JOINT Connect the tube of the Cap Top to the tube of the Pump using the Y tube joint Fix the Pump Cover A 21512677 10 PUMPCOVER Move the Head Carriage by hand to the lock position 11 Fix the 1 5 Cover N 1 Perform the following adjustment 1 4 7 FLUSHING POSITION ADJUSTMENT 3 15 3 4 TOOL CARRIAGE REPLACEMENT 1 Remove the following covers Cover MaintenanceCover Left Side Cover Front Cover Top Cover LEFTSIDE COVER TOPCOVER MAINTENANCE COVER FRONT COVER COVER 3 Remove the Tool Carriage Cover the Tool Carriage Board Cover 2 Separate the Tool Carri
119. of the target device during the lt gt Roland DG Corporation Be 4 yew Qe Q 33 6 2 3 amp n 192 1681000 100 fag Update of the Grrware has been completed Turn off the power supply of the target device 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 fine lines and gap between bands could The is required for this alignment Please DO NOT use Take Up Unit for this alignment 1 Remove the 1 5 Cover SCREWs I S COVER 2 Remove the Carriage Cover and Right Top Cover 3 Remove the Damper Plate 4 24 on the Sub Power SW while pressing lt q and gt keys to enter the Service Mode Set up the PET G on the machine 4 MENU 4 SERVICE MENU v BIAS ADJUSTMENT SERVICE MENU 4 Select PRINT MENU HEAD ADJUST gt BIAS and PRINT MENU press ENTER key 4 gt v PRINT MENU 4 HEAD ADJUST 4 gt v HEAD ADJUST 45 BIAS 4 gt BIAS 4 TEST PRINT J 4 Test pattern as shown
120. pen tip leaves the ST 002 57 v bed v Adjust the parameter 2009 menu with and V ENTER keys for the pressure to be 195 to 20501 1 9N to 2 0N Press ENTER key to save the settings plum hrs 11 Select 3091 menu under FORCE ADJUST menu Confirm that the force is 25 to 35gf 0 25N to 0 35N when the tip of the pen leaves the bed by lifting the Tool Holder with the Dial Tension Meter ST 013 Ifthe value of the force is not proper repeat the adjustment again 4 52 4 14 BELT TENSION ADJUSTMENT them to the right in the lock position 2 Remove the Covers in order 1 I S Cover 2 Maintenance Cover 3 Left Cover 4 Front Cover 5 Top Cover 3 VP 540 Measure the tension of the belt at the position above the center of the 4th Grit Roller from the left using Tension Gauge ST 001 1 Pull up the belt until its inside comes to the top surface of the Cable Guide when you see it from the machine front 2 The tension is proper if the measured value is 0 82kgf to 0 90kgf If the tension is improper move on to the next step and adjust the belt tension 1 Connect the Tool Carriage to the Head Carriage and move Referential Time 20min 5 0 9 TOP COVER MAINTE
121. range refferring to step 3 IE Turn the screw CW Tension is increased Turn the screw CCW Tension is decreased Tighten the 2 Fixing Screws shown in the figure and again confirm that the tension is within the proper value Tighten the 2 screws shown in the figure to slightly contact with Idle Pulley Holder Move on to 4 15 BELT POSITION ADJUSTMENT IE Make sure not to tighten the screws too tight It may move the fixed Idle Pulley Holder accidentally 4 55 IDLE PULLEY HOLDER 4 15 BELT POSITION ADJUSTMENT Referential Time 30min is necessary This adjustment is to prevent the belt wear which is caused by the belt contacting with the pulley flanges excessively The belt position needs to be confirmed after the Belt Tension Adjustment and adjusted if it 1 Remove the Covers in order 1 1 5 Cover 2 Right Top Cover 3 Maintenance Cover 4 Left Cover 5 Front Cover 6 Top Cover MAINTENANCE COVER FRONT NAR p 7 RIGHT TOP COVER I S COVER 2 Turn on the Sub Power SW while pressing lt q V and gt keys to enter the Service Mode 3 ADJUSTMENT ON THE DRIVE PULLEY SIDE Perform the Aging test for the belt Select MOTOR MENU AGING SCAN and press ENTER key 4 56 MENU 4 SERVICE MENU SERVICE MENU 45
122. replacement An error occurs while downloading a program for sub CPU An error occurs when trying to connect with An error occurs while sending a command There is a problem with synchronizing serial communication to Sub CPU Limit Position Initialize in the Service Mode has not been done Even though the machine carries out the regular movement the output of Head Lock Sensor does not reach the expected value Even though the machine carries out the regular movement the output of Limit Sensor does not reach the expected value Tool Carriage Connection Error Machine fails to disconnect the Tool Carriage from the Head Carriage Linear Encoder Setup has not been done Servo Board does not work correctly Sub CPU does not work correctly There is a bad connection between Main Board and Servo Board A noise on a signal A noise on a signal while sending a command Sub CPU was reset to default Tried to communicate when Sub CPU was reset to default Servo Board does not work correctly Sub CPU does not work correctly There is a bad connection between Main Board and Servo Board A noise on a signal while sending a command Sub CPU was reset while sending a command Servo Board does not work correctly Sub CPU does not work correctly There is a bad connection between Main Board and Servo Board A noise on signal Limit Position Initialize has not been done Limit Position Initialize is ended be
123. returns to the former menu by pressing 4 key when the cursor is on the head 1 BI DIR DEFAULT4 H1 H2 H3 4 H4 45 4 DT1 Low 4 2 1 3 4 2 P AY Av BI DIR DEFAULT P 4 H2 H3 4 H4 45 4 DT3 Low 4 2 1 3 4 2 AY Only for VP 540 1 BI DIR DEFAULT 42 H1 H2 H3 43 43 5 4 DT1 High 4 2 1 3 4 2 4 1 1 BI DIR DEFAULT4 H2 H3 4 4 4 4 DT3 High 4 2 1 3 4 2 Cursor be moved with 4 and gt keys and value can be selected with a and keys ENTER key for saving the setting The value being selected is marked with an under bar It returns to the former menu by pressing 4 key when the cursor is the head of the left end Default 0 It can be changed starting from the standard value 15 with A keys Range 0 to 60401 changeable by 0 5dot which is indicated as 1 2 This menu is hidden normally HEAD ADJUST 4 STANDARD HEAD 4 It appears when Base Head Menu is enabled STANDARD HEAD gt 1 gt 1 of PAGE2 SYSTEM SWITCH menu this menu is used for adjusting Head Alignment Refer to 4 4 HEAD ALIGNMENT 3 Normal beeps 1 time 00000000 PRINT MENU 4 PROCESSING LINEAR ENCODER 4 4 LINEAR ENCODER 4 POS 1361 00 SETUP COMPLETED v 4 Thi
124. right and down keys to enter the Service Mode 4 v A SERVICE MENU Select SERVICE MENU gt SUB MENU gt PUMP 2 SERVICE MENU 4 UP and remove ink by following the sequence SUB MENU 4 gt SUB MENU PUMP UP gt 4 DRAIN BOTTLE 1 v v v REMOVE SOL CRT 1234 PUMPING UP 3 In PRINT MENU gt HEAD RANK menu select the HEAD RANK SERVICE MENU 49 head No of the head that you are going to replace and PRINT MEN input the Head Rank written on the new head gt Input Head Rank by selecting the digit with the left PRINT MENU 44 and right keys and changing the parameters with the up HEAD RANK and down keys gt Press the ENTER key to save the settings HEAD RANK 44 The head at the left end is HEAD1 and HEAD2 to HEAD 2 HEAD4 in order to the right gt HEAD RANK 1 43 TE Make sure to input the Head Rank before 1234567 1 5 4 replacing the head because the sticker which ENTER the head rank is written on will be hidden once the head is installed Turn off the sub power and then turn off the power MAIN POWER SW Be sure to turn off the main power when replacing the head The head or Main Board could break otherwise It is recommende
125. s Manual may fail to reach the preset temperature Suggest using the machine under the environment from 20 to 32 C Environmental Raise the environmental temperature is low temperature NO 1 5 The voltage or power Check the voltage If the voltage is unstable the heater cannot function fully supply is unstable Bad contact or cut line on the cable between the Re fix Replace the Heater Unit and Main cable Board If the cable between the Heater unit and Main Board is broken the Heater temperature does not rise Check the connection of the each cable or replace it if it is broken The temperature of the Heater does not rise if the Fuse FS300 or FS301 on the power board is burned out FS300 is for the print heater and FS301 for the dryer Fuse on the power board Replace the fuse on the is broken power board The Heater does not work correctly because the signal to the Power Board is broken Replace the power board Heater is not transferred correctly 6 12 PROBLEM IN NETWORK RIP DOES NOT RECOGNIZE THE PRINTER REFERENCE NO Turn off the main power It can be solved by restarting the printer with the main power and restart the printer Try it several times Refix the cable E be solved by refixing the network cable Try it several Network problem with a crossover cable the printer or the network by connecting the PC and the printer directly with a crossover cable Main board is damaged Replace the main bo
126. the new ink tubes to the tube joints Cartridge Side and fix them to the Clamps Connect the tubes to the tube joints in the fixed positions with K on top as shown in the figure 3 42 anno 1 JOINTs Upper CARTRIDGE Side CARRIAGE Side gt Lower Front View JOINTs CLAMPs M Y Left Side 11 12 Make sure that the fixing direction of the Holder Cable Plate is correct HOLDER CABLE PLATE Rear View HOLDER CABLE SHEET NG HOLDER CABLE PLATE r M OK _ FLEXIBLE CABLE CABLE HOLDER N CABLE HOLDER HOLDER CABLE PLATE TUBE lt Cross Section gt Cross the tubes Carriage Side two by two as shown in the figure and fix them to the Clamps 157 lt Rear View gt EX Connect the tubes to the Y tube joints Carriage Side 3 43 13 Fixthe Carriage Cover CARRIAGE COVER 14 Fix the Cut Cable Guide lt VP 300 gt 1 Fix the Cut Cable Guide with the 3 screws a
127. 0 COVER RAIL B VP 300 1000002651 COVER RAIL B RIGHT VP 540 1000004207 F TYPE2 VP 540 1000004208 COVER RAIL TYPE2 VP 300 PLATE COVER VP 540 1000004204 1000004204 PLATECOVER 300 27 22535390 _ LABELEMERGENCY STOP 34406 28 22535286 LABEL CAUTION COVER LA265 B PLATE COVER F 540 roses SET J roses SCREW SET CAP si pemenows urscnEWSETMS ON 1000004203 1000004203 PLATE NUT COVER F VP 300 3 FRAME COVER F VP 540 a H 11000004202 FRAME COVER VP 300 724 1000004361 COVER INT SwvP 540 T 55 11879107 2 13169102 COVER SW AVT32344 1000004200 _ HOOK INT SW 540 22535287 LABEL CAUTION CARRIAGE 1 266 1 2 FRAME VP 540 Below ZW65382 VP 300 Below ZW61509 ES 8 814 817 517 73 11 Ws wi 32 10320 5 1711 6 4 24 54 eal EA nes oN li 29 ir dos I 207 28 8 58 1 2 FRAME VP 540 Below ZW65382 VP 300 Below ZW61509 PARTS LIST Main Parts 195140 BRACKETJNKCATCHTANKSP S4Uv s 2150563 9 2155508 BUSH SHAFT OES 80 1208 PARTS LIST Supplemental Parts Parts Name 1 2 FRAME
128. 00 PCS 6700460220 ASSY PINCHROLL VP 540 31019702AS SCREW SET BIND P TIGHT M3 6 3C 100P 6700460300 ASSY PINCHROLL C VP 540 31249211AS WASHER SET PLAIN 4 3 7 0 5 NI 100P 21745101 COLLAR P ROLLER PNC 960 22195153 FRAME PINCH ROLL SP 540V 22145416 LEVER P ROLLER PNC 960 11539104 PIN 3 35 SUS M6 22145831 PIN NO 1 214 831 22145832 PIN NO 2 214 832 INI aJa AJOIN 22055264 PLATE GUIDE P PNC 960 21565103 P ROLLER 016 4 10 21565102 P ROLLER TD16S4 B10 22625101 SPRING PINCH LEFT SP 300 Co 1000002648 SPRING PINCH LEFT VP 540 22625102 SPRING PINCH RIGHT 300 1000002649 SPRING PINCH RIGHT VP 540 22715461 STAY PINCH CENTER SP 540V N 1000003028 STAY PINCH SENSOR VP 540 1000002973 LABEL PINCH SENSOR VP 540 979 31249303 WASHER SET SPRING NI 100 PCS 1 9 STAND E nium PARTS LIST Main Parts 1000002578 ARM L VP 540 1000002577 ARM R VP 540 7498805000 ASSY STOPPER SCREW PNS 501 1000002636 ASSY BASE STAND VP 540 1000002153 55 5 SHEET VP 300 1000001611 ASSY SHAFT SHEET XC 540 PARTS LIST Supplemental Parts 21815106 BOLT SHOULDER PNS 501 12329505
129. 00002178 CABLE ASSY PRI CAR ORG VP 540 22175134 SPRING A CJ 70 1000002188 CABLE ASSY SCAN MOTOR VP 540 22175122 SPRING BACKUP PNC 960 23475213 CABLE CARD 36P1 2000L BB 22175157 SPRING C P ROLLER CM 500 23475240 CABLE CARD 36P1 2670L BB HIGH V 1000002596 STAY G ENCODER SENSOR VP 540 1000002167 CABLE ASSY CUT CAR ORG VP 540 1000002602 STAY GUIDE FLEX VP 540 21365103 CASE LOCK CJ 70 22715469 STAY HOLD SHAFT SQUARE SP 500 1000002646 COVER ENCODER VP 540 1000002597 STAY RAILGUIDE L VP 540 1000002592 COVER FEED GEAR VP 540 1000002534 STAY SHAFT DRIVE PULLEY VP 540 1000002711 COVER INK CARTRIDGE FLEX VP 300 1000002554 STAY SUPPORT RAIL L VP 540 1000002708 CARTRIDGE FLEX VP 540 22135346 STOPPER CAM CM 500 1000002647 COVER INNER VP 540 1000002594 STOPPER GRIT ENCORDER VP 540 1000003037 COVER JUNCTION BOARD VP 540 22135439 STOPPER LINEAR SCALE FJ 540 1000002710 COVER RAIL SIDE VP 540 1000003036 SUPPORT CABLE 1000002593 FLANGE GRIT ENCORDER VP 540 1000003823 FLANGE MOTOR SCAN VP 540 Revised 6 1000002552 FRAME FEED MOTOR VP 540 1000002549 FRAME SUPPORT AUTO CUTTER VP 540 1000002660 FRAME SUPPORT RAIL VP 300 1000002546 FRAME SUPPORT RAIL VP 540 1000003086 FILTER E RAIL SHIELD VP 540 1000001905
130. 01 CLAMP SET INSULOK 185 100 PCS 6085393800 ASSY INK DAMPER L 4 SJ 1000 31289109AS CUPSCREW SET M3 4 NI 100 PCS W700461130 ASSY LINEAR ENCODER BOARD VP 540 31289102 CUPSCREW 5 3 6 NI 50 PCS W700461110 ASSY PRINT CARRIAGE BOARD VP 540 31149703AS SET E RING ETW 4 100 PCS 1000002519 BASE CARRIAGE AL VP 540 31299102AS SET NYLON P2655B 20 PCS 1000002520 BASE HOLDER CARRIAGE VP 540 31409801AS SADDLE LOCKING WIRE LWS 0711Z 20 21775103 CAM CARRIAGE FJ 540 31679902 SCREW SET C SEMS 2 8 NI 100 PCS COIN IO 43 10 NN 11769118 2 56 14 31019148 5 SCREW SET BINDING 2 6 4 NI 100 PCS 1000002588 COVER HEAD BOARD VP 540 31049173AS SCREW SET CAP 4 10 NI 50 PCS 1000002632 COVER PRINT CARRIAGE VP 540 31049169AS SCREW SET CAP M4 8 3CBC PW 20PCS 1000002652 COVER PRINT JUNCTION VP 540 31049169 SCREW SET CAP M4 8 3CBC PW 20PCS 1000002523 FRAME CARRIAGE U D VP 540 31089121 SCREW SET PAN 2 3 8 NI PW 100 1000003076 GUIDE CARRIAGE CAP VP 540 31179908 5 SCREW SET UREA M3 20 N 1 WH 50PCS 22135440 GUIDE HEAD AL FJ 540 1000003293 GUIDE TUBE VP 540 31239125 SCREW SET W SEMS M3 8 SUS 50 PCS 31799103 SCREW SET CAP M3 15 NI 20PCS 1000002201 ASSY HEAD INKJET SOL XC 540 1000002587 LEVER CARRIAGE VP 540
131. 01 Fix the Grit Encoder Board together with the stay so that the Grit Encoder is in between the gap of sensor IE Adjust the position of the sensor so that the clearance with the Grit Encoder is around 1mm SENSOR lt Top View gt 22 Rotate the Shaft to check that the Grit Encoder does not touch the sensor In case that the Grit Encoder touches the sensor loosen the screw as shown in the figure to adjust the sensor by moving right and left GRIT ENCODER ENCODER BOARD SENSOR lt Top View gt 23 Connect the connector of the Motor Cable and fix it to the Clamp 24 Fix Cutter Frame IE When fixing the Cutter Frame fix the sensor cable on the back side to the Clamp 7 5 3 30 25 26 Connect the connector of the sensor cable to the Feed Motor Board 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 27 In MOTOR MENU SERVO LOCK menu select F Rotate the Grit Roller back and forth by hand and make sure the value on the LCD changes depending on the movements 28 Press the ENTER key to excite the motor Check the Grit Roller can not be rotated easily by hand an
132. 02 DR 1000003015 FUSE 1543 15DR 13429702 INLET PO1CFO01 15A250V 22535257 LABEL CAUTION VOLTAGE LA167 1000002682 LABEL LAN VP 540 LA964 PAR 1000002043 CABLE ASSY 230V SELECTOR XC 540 For 230V TS LIST Supplemental Parts Parts No Parts Name 31029106 BUSH SQUARE SB 6025 22535117 LABEL POWER CM 500 NO 893 31329601AS CLAMP SET INSULOK 18 100 PCS 13129170 POWER SW AJ7201B 31289111AS CUPSCREW SET M4 6 NI 100 PCS 12429114 POWER UNIT ZWS150PAF 36J 31289109AS CUPSCREW SET M3 4 NI 100 PCS 1000002579 STAY CABLE VP 540 31279116 LABEL EARTH MARK 1 NO E 580 1000002566 STAY CHASSIS FAN VP 540 31279121 LABEL FLASH LIGHTING NO E 582 1000002189 CABLE ASSY JUNBI A VP 540 31279191 LABEL WARNING FUSE REPLACE 347 23415116 CABLE ASSY JUNBI D SP 300 31409801AS SADDLE LOCKING WIRE LWS 0711Z 20P 23415117 CABLE ASSY POWER MAIN SP 300 31019124 SCREW SET BINDING M3 35 NI 50 PCS 23475197 CABLE CARD 25P1 105L BB FJ 540 31169103AS SCREW SET FLAT M3 6 3CBC 100 PCS 23415268 CABLE ASSY AC GROUND GREEN SP 540 31369102 SPACER PCB SUPPORT 8 1 8 PINCH ROLLER PARTS LIST Main Parts Parts No Parts Name 6700460210 ASSY PINCHROLL L VP 540 31149702AS PARTS LIST Supplemental Parts Parts No Parts Name RING SET E RING ETW 3 1
133. 07 _ 15199237 C22 _ 1000001098 Function V RGL L4960 5V Regulator C E09A54RA D A Converter for Head BK C21 C E09A54RA C26 C E09A54RA C25 R14 25 4131 GB R10 2541746 OY 2 R6 R 25 4131 GB R1 R 2541746 OY R2 R 25 4131 GB R7 R 2541746 OY R11 2804131 GB Transistor for Driving HEAD YE R15 R 2541746 OY 2 USE 01543 15DR 1 000000659 FUSE 01543 15DR 3 000003014 FUSE 154002 DR S Parts No Description Function C17 C14 C10 C207 1 POWER BOARD 5 Description 300 2559105 FUSE 5X20 021706 3MXP 6 3A 250V Fuse for Print Heater 5301 2559105 FUSE 5X20 021706 3MXP 6 3A 250V SR300 100000016 RELAY SSR G3M 205P VD 1 DC24V LF Relay for Print Heater SSR301 1100000016 RELAY SSR G3M 205P VD 1 DC24V LF Relay for Dryer 2 28 3 Replacement of Parts 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 5 CROP CUT ADJUSTMENT 6 PRINT CUT POSITION ADJUSTMENT Adj Time 65min Total Time 85min TOOL CARRIAGE REPLACEMENT 20 min 1 LIMIT amp CUT DOWN POSITION ADJUSTMENT 2 FLUSHING POSITION ADJUSTMENT 3 TOOL HEIGHT ADJUSTMENT 4 TOOL PRESSU
134. 1 RM BIS iiis TAAI EOISIAH _ 48 os abs lt WTS VITIN Me sra S TE dL 208 E OS 5 TVOTINOXS EEEEEEEEEEEEEE NO ANOS 1 E oa sd cl Od hhbhbh WIG TW lt AAA EEEEEEREREEREE E DIES lt SERE E ix dorad lt EER SEE OINO 117 60 So bi EETA 602 SOIN VO 14 LLL 117 WZ Us vaa IE 5 vag NI wed z HEB ED aS 55555555555555 2 a c H was Rro ESSO o T ii xi 2 5 H a 9 2 VAS L Sova E SZ Obs 2 amos C 550 ve ODS Cras yrs Pi ve 15 a T cH IS ds V9 NONE 082 ETC sn 305785 BOS as I VN CVE BIS p 1 DOS a ETT 1 VA DIOS INOX3 5 lt 9 Canis kan ny 01 5 sv on DOS ISL TW ao i TOVITI 20 XU IS SAN TOR TRIN qe ory S eld 9 6 ISL L 4 TOMUS HX TILES TIROX N LV
135. 1000002970 LABEL G ROLLER 50 VP 540 LA977 31409801AS SADDLE LOCKING WIRE LWS 0711Z 20P 1000002685 LABEL PINCH ROLL VP 540 LA968 31019149 SCREW SET BINDING M2 3 8 3CBC 100PCS 1000002196 L BEARING SSR15XW1GGE W2GE 1440L 31049155AS SCREW SET CAP M3 12 BC PW 20 PCS 1000002145 L BEARING SSR15XW1GGE W2GE 2050L 31049171AS SCREW SET CAP M3 12 NI 50 PCS 1000002535 LOCK STAY VP 540 31049170AS SCREW SET CAP 3 8 NI 50 PCS 1000002581 PLATE CUT ORIGIN VP 540 31049173AS SCREW SET CAP M4 10 NI 50 PCS 1000002675 PLATE HOLDER CABLE VP 300 31049174AS SCREW SET CAP M4 15 NI 20 PCS 1000002612 PLATE HOLDER CABLE VP 540 31049137AS SCREW SET CAP M4 25 3CBC 20 PCS 22055316 PLATE LINEAR SCALE CJ 70 31049169AS SCREW SET CAP M4 8 3CBC PW 20PCS 1000002672 PLATE RAIL REAR VP 300 31199701AS SCREW SET SET WP M3 3 NI 20 PCS 1000002615 PLATE RAIL REAR VP 540 31229103AS SCREW SET TRUSS M2 6 NI 100 PCS 1000002658 RAIL GUIDE VP 300 31239103AS SCREW SET W SEMS M3 8 NI PW 50 PCS 1000002525 1000002659 RAIL GUIDE VP 540 RAIL LINEAR SCALE VP 300 31019703 SCREW BINDING P TIGHT M3 8 3C 100P 31049117 SCREW CAP M4 12 NI PW 4 9 0 8 20PCS 1000002543 RAIL LINEAR SCALE VP 540 1 9 31069104 SCREW CAP M4 6 FL NI 1 3 DRIVE UNIT VP 540 Above ZW65383 VP 300 Above ZW61510
136. 1029101 BUSH NB 19 1000002553 APRON B VP 540 31329501 CLAMP SET PUSH MOUNT RT30SSF5 20 1000002152 APRON F AL VP 300 31289109AS CUPSCREW SET M3 4 NI 100 PCS 1000002148 APRON F AL VP 540 31289102 CUPSCREW 6 NI 50 PCS 1000002655 APRON F UNDER VP 300 31279106 LABEL CAUTION HOT SURF NO 778 1000002542 APRON F UNDER VP 540 31299102 SET NYLON P2655B 20 PCS 1000002166 ASSY CORD HEATER VP 300 31409702 SADDLE SET LOCKING WIRE LES 1010 20P 1000002165 ASSY CORD HEATER VP 540 31409801AS SADDLE LOCKING WIRE LWS 0711Z 20 W700461270 ASSY THERMISTOR BOARD VP 540 31019124 SCREW SET BINDING M3 35 NI 50 PCS 1000002151 BED VP 300 31019115AS SCREW SET BINDING M3 4 3CBC 100 PCS 1000002147 BED VP 540 31049170AS SCREW SET CAP 3 8 50 PCS 1000000764 FAN A35577 55ROL 31049173AS SCREW SET CAP M4 10 NI 50 PCS 1000002584 FRAME SIDE BED L VP 540 31049169AS SCREW SET CAP M4 8 3CBC PW 20PCS 1000002657 PLATE SHUTTER VP 300 31019703 SCREW BINDING P TIGHT M3 8 3C 100P 1000002541 PLATE SHUTTER VP 540 15099124 SENSOR US 602SXTLAS 650FF 50 15099115 SENSOR INTERRUPTER GP2A25NJ 1000002600 SHUTTER BED L VP 540 1000002599 SHUTTER BED R VP 540 21625103 SHUTTER HEATER CORD SP 300 1000002582 SPACER BED LOWER VP 540
137. 1289112 5 CUPSCREW SET M3 10 NI 100 PCS S7 131289109 8 CUPSCREW SET M3 4 NI 100 PCS S8 3128910245 CUPSCREW SET M3 6 NI 50 PCS S9 131119904 PIN SPRING 2 5 8 SUS STRAIGHT 50 PCS 31129102 PIPE SET POLYCA 4 8 10 20PCS 31149704AS IRING SET E RING ETW 6 SUS 100 PCS 31299102AS SET NYLON P2655B 20 PCS 31409702 SADDLE SET LOCKING WIRE LES 1010 20P 3140980145 SADDLE LOCKING WIRE LWS 0711Z 20 31019149 SCREW SET BINDING M2 3 8 100PCS 31049155 SCREW SET CAP M3 12 BC PW 20 PCS 3104917145 SCREW SET CAP M3 12 NI 50 PCS 31049170AS SCREW SET CAP M3 8 NI 50 PCS 31049173AS SCREW SET CAP 4 10 NI 50 PCS 3104917445 SCREW 4 15 NI 20 PCS 31049137AS SCREW SET CAP M4 25 3CBC 20 PCS 31049169 SCREW SET CAP M4 8 3CBC PW 20PCS 31199701 5 SCREW SET SET WP M3 3 NI 20 PCS 31229103AS SCREW SET TRUSS 276 NI 100 PCS 3123910345 SCREW SET W SEMS M3 8 NI PW 50 PCS 31019703 SCREW BINDING P TIGHT M3 8 3C 100P 31049117 SCREW CAP M4 12 NI PW 4 9 0 8 20PCS 31069104 SCREW CAP M4 6 FL NI 1 4 HEAD CARRIAGE VP 540 N 36 38 Cut to 110mm 38 Cut to 130mm when using 372 when using 1 12 1 4 HEAD CARRIAGE VP 540 PARTS LIST Main Parts Parts No Parts Name 21905166 ADAPTER HEAD FJ 540 PARTS LIST Supplemental Parts Parts No Parts Name 313296
138. 187520 8 1000004142 SUPPORT GUIDE CABLE 2 VP 540 1000003151 PAD GUIDE TUBE VP 540 12399352 1000003821 1000003822 FILTER E FRC 45 12 6 5 Revised 2 SPACER FLANGE VP 540 BASE FLANGE VP 540 PARTS LIST Supplemental Parts Parts No Parts Name 21685128 GEAR H300 510 6 16 1000003084 FILTER E SFT 36SN 31029101 BUSH NB 19 31029106 BUSH SQUARE SB 6025 1000002673 GUIDE CUT CABLE VP 300 31329501AS CLAMP SET PUSH MOUNT RT30SSF5 20P 1000002616 GUIDE CUT CABLE VP 540 1000003293 GUIDE TUBE TYPE3 VP 540 3000000033 CLAMP WIRE PLESS RFC 45VO 31289111AS CUPSCREW SET M4 6 NI 100 PCS 1000002603 HOLDER BACKUP SHAFTSQUARE VP 540 31289112AS CUPSCREW SET M3 10 NI 100 PCS 1000002666 HOLDER CABLE VP 300 31289109AS CUPSCREW SET M3 4 NI 100 PCS 1000002562 HOLDER CABLE VP 540 31289102AS CUPSCREW SET M3 6 NI 50 PCS 1000001555 HOLDER IDLE PULLEY XC 540 31119904 PIN SPRING 2 5 8 SUS STRAIGHT 50 PCS 21655131 HOLDER LINEAR SCALE CJ 70 31129102 PIPE SET POLYCA 4 8 10 20PCS 22115121 HOUSING R BEARING FRAME FJ 540 31149704AS RING SET E RING ETW 6 SUS 100 PCS 22535287 LABEL CAUTION CARRIAGE LA266 31299102AS RIVET SET NYLON P2655B 20 PCS 1000002971 LABEL G ROLLER 170 VP 540 LA978 31409702 SADDLE SET LOCKING WIRE LES 1010 20P
139. 3 32 SERVICE MENU 4 MOTOR MENU 4 gt MOTOR MENU AGING gt 4 AGING 43 FEED al SERVICE MENU 4 HITORY MENU gt 4 gt HITORY MENU 4 MOTOR GROUP 4 gt MOTOR HOURS 4 1653 hours 4 1 MOTOR HOURS F 4 CLEAR d ENTER 3 7 PUMP REPLACEMENT 1 Turn off the sub power and then turn off the main power c MAIN POWER SW Rear View 2 Remove the 1 5 Cover SCREW I S COVER 3 Unlock the Head Carriage and move it leftward by hand 4 Remove the Pump Cover and Panel Cover IE When removing the Panel Cover remove the sensor on the back side of the Panel Cover and flexible cable on the Panel Board SENSOR 1 FLEXIBLE CABLE 2 A lt Back Side gt PUMPCOVER 3 33 Remove the connector of the motor MOTOR CONNECTOR 6 Disconnect the tubes of the Cap Top and the tubes of the Drain from the pumps Remove the 2 screws as shown in the figure to remove the Pump Unit SCREW PUMPUNIT Remove the 4 screws as shown in the figure to remove the Pump Unit Stay 3 34 9 Separate the 2 pumps
140. 37 SCREW SET CAP 4 25 20 PCS 1000002529 FRAME MIDDLE VP 540 31799107 SCREW SET CAP M4 6 NI 20PCS 1000002548 FRAME SCAN MOTOR VP 540 31049169AS SCREW 5 4 8 3CBC PW 20PCS 1000002518 FRAME SIDE L VP 540 31239125AS SCREW SET W SEMS M3 8 SUS 50 PCS 1000002545 FRAME SIDE R VP 540 31179106 SCREW JACK UP SP 540V 22305101 GUIDE LEVER SP 300 22485104 KNOB FJ 50 1000002556 LEVER CAM PINCH VP 540 22155763 OILES BUSH 80 0806 22175105 PINCH ROLL SPRING 22055474 PLATE INK CATCH TANK FJ 52 1000002609 PLATE LEVER LINK VP 540 15229506 SENSOR INTERRUPTER GP1A05A5 22145393 SHAFT JOINT PNC 960 22295270 SHAFT SQUARE SP 300 1000002526 SHAFT SQUARE VP 540 22035196 STAND LEVER SP 300 1000002629 STAY COVER UNDER VP 540 1000002558 STAY FRAME SIDE R VP 540 1000002555 STAY LEVER SENSOR VP 540 1000002631 STAY PINCH LEVER ADJUST VP 540 1000002551 STAY PINCH LEVER VP 540 1000002569 STAY SUPPORT INKCARTRIDGE VP 540 1000004193 SUPPORT FRAME R TYPE2 VP 540 1000003088 PAD BASE BOTTOM VP 540 1000003087 PAD SUPPORT FRAME R VP 540 1000002168 CABLE ASSY FAN VP 540 1 7 31069104 SCREW CAP M4 6 FL NI 1 3 DRIVE UNIT VP 540 Below ZW65382 VP 300 Below ZW61509 51222 S28 22 e 8
141. 5 aas sidas vidas aas ovaas svas 1 ovas svas pvas evas was Ivas ovas ro 001 970 sow 5 TET SON 1 aya ELEMIS B SEC TUNES Td 1 D anm ova mmy l oaa 5 rsa SS Pecan cars 5 T FEROX nm ova ii 1 wave T Sava 2 15 ave i sava ttava sava H 2 Bru Teava 5 ava slave Siva dale 9rava dava 1 grava ova SIT 8 ava 5 EV i grava 5 E 5 ava ru E ma cova sva Ta sav 81 dva save sara sava 6012 sava 8 tova fave ava imos 5 zava 9 19 s iva Tava Aa 2 10 79 ircuit Diagram MAIN BOARD C 00111
142. 5 6 20 High 540 only 1111 1 MN DT1 High 20 6 5 3 2 1 0 41 2 3 4 45 6 20 H4 111 2 Head Position DT3 Low 20 6 5 3 2 1 0 1 2 3 4 45 6 20 Low H4 1 LU 11111 DTi Low 20 6 5 3 2 1 0 1 2 3 4 45 6 20 HORIZONTAL 4 TEST PRINT HORIZONTAL H2 44 DT1 Low 4 2 1 3 4 1 HORIZONTAL s H2 44 DT3 Low 4 2 1 4 w HORIZONTAL 4 H2 H3 H4 45 DT1 High 4 2 1 3 4 E HORIZONTAL 4s H2 H3 HA 44 bd lt gt 45 1 High gt 2 1 3 540 only BIDIRECTIONAL ADJUSTMENT SERVICE MENU 45 Select PRINT MENU gt HEAD ADJUST gt PRINT MEND DIR DEFAULT TEST PRINT and press ENTER key INE PRINT MENU 45 HEAD ADJUST INE HEAD ADJUST 4 BI DIR DEFAUL 4 gt BI DIR DEFAULT 4 TEST
143. 55 555 555559 955 2555559 55 5 55553 555555 233833 geg 23888 ZER 25552984 88 8 SEREF 888888 888888 SES 82858 882 380860 ES 85 E 52255 42423 g 45225552 252 223208 sies 8522558 53 88 BIS de 522552214424029229222 202252 225722 909 2858555855528 z5 SESS 5 SE LS SAE SSH TDA FP ia oviva dou dadapa DINOS o DANOJ PPP aaa Be ANOD Noa INO 4 x L 3 LSTA D i el 8 1 f 8 iL B EE z 5 3 wa EE B Ha Sy viva EBEN 2 yv XD 2 7 4 9 it Diagram MAIN BOARD C EEADIZOIDLAD ONZE 0D
144. 7 eer i OO st 0E 1 E 8 A i o 9 a 671 T Hl 8 FE SOO OOs zi s 0924 eel 5 BEEF 22 ero o e _ 5 oe p 188 1 4 A eel B o E a 2 93 3 8 as 2 si 62139 c 888 s d gg a wu 1221 011 e 5113 TR coi 8 a 8 CT 21 oe os D er a Szy 11 Tou MG 925 LL co 00 9833 m mH m full LUL UUL G SIUL LL Le 11 Lr 21 E 4 e a trs 5 8213 a gt Lt13 2 7 921 c 71145214 e 2 51137219 1156273 11132213 2 1214 8 2 0213 981 rae 131 18 lt 8 H 88H um HH 955 068 Tore sa z ea ee 8 op Mc ou oL z 60 SUL 8 CUL 5 lt 5 o N DP SW 54 VP 30 MAIN BOARD_ Arrangement Diagram Soldering Side
145. 74 CUT CABLE GUIDE 2 the Cable Support with the 3 screws as shown in the figure 17 18 19 Move the Head Carriage in a whole width of the machine manually to make sure that there is no noise Confirm the cable assemblies when it makes abnormal noise After turning on the main power turn on the sub power while pressing the left right and down keys to enter the Service Mode Select SERVICE MENU gt SUB MENU gt FILL INK and perform Ink Filling by following the sequences 3 78 SCREW CABLE SUPPORT lt Top View gt lt q HJ MENU 4 SERVICE MENU SERVICE MENU 4 SUB MENU SUB MENU 44 FILL INK gt DRAIN BOTTLE 4 ENTER FILLING INK gt gt gt CHECK DRAIN BOTTLE 4 4 1 SERVICE MODE
146. AD FJ 540 1000002561 SPRING CAP SWING VP 540 1000002565 STAY PUMP ASSY VP 540 1000002019 STOPPER PUMP XC 540 1000002645 STOPPER SHAFT CAP VP 540 6700319010 ASSY PUMP SUB XC 540 1000002095 FITTING TUBE PP VFY206 1000002119 TUBE EPDM ID2 OD4 310MM 1000003033 STAY GUIDE CAP CASE VP 540 1000003104 SHEET BASE CAP VP 540 1000002179 CABLE ASSY PUMP MOTOR VP 540 1000003383 ASSY TUBING 2 30MM VP 540 1 24 1 13 INK SYSTEM E 2 A amp y 5 gt 9 2 Cut to 110mm when using 28 Cut to 170mm when using 1 3 PARTS LIST Main Parts Parts No Parts Name 11909133 ADAPTER SCREW 2FAI FJ 50 1000001589 2 3FAI XC 540 W700461280 ASSY CARTRIDGE IC BOARD VP 540 W700461230 ASSY FEED MOTOR BOARD VP 540 1000002423 ASSY TUBING 2 210MM XC 540 1000002568 BASE INKCARTRIDGE VP 540 1000002172 CABLE ASSY INK CARTRIDGE VP 540 11659218 HOLDER I C SC 500 11659149 HOLDER RING 2 FJ 50 PARTS LIST Supplemental Parts 22055435 _____ 500 PartsNo _ ParsName 1000002560 PLATE INK JOINT VP 540 1 1000001473 PLATE HOLDER XC 540 2 21475153 SHEET INKCARTRIDGE SP 300 S3 22625103 SPRING PRESS CARTRIDGE SP 300 4 1000002640 SUPPORT TUBE VP 540 5 1 25 Parts No Parts Name 21435109 TUBE SILICONE 3 5 8 1000002680 ADAPTER JOINT VPI336 11909167 ADAPTER SCREW 3FAI FJ 540
147. AIN 3 CSS JJ UBE CAP TOP STOPPER 7 AAA U 5 SCREW LL PUMPUNIT 1 TUBE DRAIN 15 Connect the connector of the motor 3 37 CONNECTOR Ser MOTOR 16 Fix the Pump Cover and Panel Cover When fixing the Panel Cover fix the sensor on the back side of the Panel Cover and connect the flexible cable on the E Panel Board FLEXIBLE CABLE Back Side 2 7 PUMPCOVER PANEL COVER HIER TOT Service Mode Clear the pump times press the ENTER key 17 Turn on the main power then turn on the sub power while pressing the left right and down keys to enter the 18 Select SERVICE MENU gt 1 5 MENU gt PUMP CHECK and perform PUMP SUCTION and PUMP RELEASE to check the pumps work correctly OW 2 9 4 SERVICE MENU SERVICE MENU 42 I S MENU gt 4 I S MENU 44 gt PUMP CHECK 4 PUMP CHECK gt PUMP SUCTION 4 44 4 PUMP RELEASE 19 Select SERVICE MENU gt HISTORY MENU gt MOTOR GROUP PUMP TIMES CLEAR and SERVICE MENU 4 HITORY MENU gt gt HITORY MENU 4 MOTOR GROUP gt
148. BUSH SET ROLL 2 4 3 100 5 22025646 COVER BELT HOLDER EGX 600 31029803AS BUSH SET ROLL 3 5 3C 20PCS 1000002570 COVER CARRIAGE BOARD VP 540 31329601AS CLAMP SET INSULOK 185 100 PCS 22025269 COVER CARRIAGE CM 500 31289109AS CUPSCREW SET M3 4 NI 100 PCS 1000002667 GUIDE CABLE FLEX CUT VP 300 31289102AS CUPSCREW 5 376 NI 50 PCS 1000002591 GUIDE CABLE FLEX CUT VP 540 31299102AS SET NYLON P2655B 20 PCS 21655232 HOLDER BELT EGX 600 31019148AS SCREW SET BINDING M2 6 4 NI 100 PCS Revised 6 22285503 NUT PENHOLDER 31019118AS SCREW SET BINDING M3 10 3CBC 100PCS 21495115 SCREW BLADE SET CM 500 31019116AS SCREW SET BINDING M3 6 3CBC 100 PCS 15099115 SENSOR INTERRUPTER GP2A25NJ 31069104 SCREW CAP M4 6 FL NI 21475148 SHEET FILTER CROP CJ 500 31169103AS SCREW SET FLAT M3 6 3CBC 100 PCS 22175122 SPRING BACKUP PNC 960 31089110AS SCREW SET PAN M3 4 NI PW 100 PCS 22175154 SPRING BLADE UP CM 500 31229103AS 1 21 SCREW SET TRUSS 2 6 NI 100 PCS 1 11 WIPER SYSTEM PARTS LIST Main Parts Parts Name 1000002576 BASE WIPER MOTOR VP 540 11929138 BELT 408P2M4 530 12159536 BUSH B S6 17 1000002572 COVER WIPE VP 540 21995104 FLANGE PULLEY STX 7 1000002574 FRAME WIPER VP 540 21685144 GEAR S53S5 B15 FJ 540 21655245 HOLDER WIPER FJ 540 PARTS LIST
149. ENU 4 SERVICE MENU 1 A In MOTOR MENU gt SERVO LOCK menu select S Move the Head Carriage left and right by hand and make sure the value on the LCD changes depending on the head position 15 Press the ENTER key to excite the motor Check the Head Carriage can not be moved easily by hand and the value on the LCD doesn t change 16 17 Perform the AGING Go back to the MOTOR MENU and select AGING gt SCAN and press the ENTER key Make sure the machine performs AGING and then finish it by pressing ENTER key IE Do not load any media when performing AGING Clear the motor working hours Go back to the Service Menu and select HISTORY MENU gt MOTOR GROUP gt MOTOR HOURS S gt CLEAR and press the ENTER key The motor working hours will be reset to O 3 24 SERVICE MENU 4 MOTOR MENU 1 gt 4 SERVO LOCK gt gt SERVO LOCK 43 8 4 SERVO LOCK 43 5 1688 4 1 SERVO LOCK S 1688 SERVICE MENU 4 AGING gt 4 AGING SCAN 4 SERVICE MENU 4 HISTORY MENU HISTORY MENU 4 MOTOR GROUP gt Y MOTOR HOURS S 1653 hours gt Yo MOTOR HOURS 5 45 CLEAR ENTER 3 6 FEED MOTOR REPLACEMENT 1 Turn off the sub power and th
150. ENU 45 FLUSHING ADJ 4 19 FLUSHING ADJ SET POSITION ______ The left end cap does not necessarily touch first HEAD 2 N CAP 4 37 4 8 CROP MARK SENSOR ADJUSTMENT Referential Time 10min cases This adjustment is for adjusting the sensitivity of the Crop Mark Sensor If not adjusted the crop marks cannot be read correctly and it results in an error of cut position to the print This adjustment is required under following Crop Mark Sensor or Tool Carriage Board is replaced or adjusted The VR for adjusting the voltage is unexpectedly moved The distance between Crop Mark Sensor and the bed surface is changed When it needs to be adjusted for a particular media use the media instead of SV GG However in this case the adjustment is to be optimized for the media and it may affect the crop mark detection on other media The result of the crop mark recognition on Roland media is not assured when any media other than SV GG is used for this adjustment The Print Heater and Dryer must be off during this adjustment 1 Remove the Covers in order 1 1 5 Cover 2 Maintenance Cover 3 Left Cover 4 Front Cover 5 Top Cover Cover gt keys to enter the Service Mode Setup the SV GG on the machine MAINTENANCE TOP COVER COVER I S COVER 2 Remove the Tool Carriage Cover and Tool Carriage Board
151. ETWORK CONTROLLER Referential Time 5min Turn on the Main Power SW and Sub Power SW then press MENU key Select SYSTEM INFO gt NETWORK IP ADDRESS and set the IP address 17 pe MENU 43 ok SYSTEM INFO gt 4 Piivi SYSTEM INFO 4 NETWORK gt V IH NETWORK IP ADDRESS gt gt IP ADDRESS 4 192 168 000 100 2 2 Open browser and enter the IP address which is set at step 1 Currentfirmware version appears Sc Internet Explorer is recommended 3 Click Update 4 22 4 Specify the target file for upgrade and click Update The progress is shown in percentage while upgrading S Do not turn off the power or press any keys while upgrading When upgrade is completed the version of upgraded firmware appears Turn off the Sub Power SW and Main Power SW once 4 23 pi Mee 08 Ho O Q ADH 6 0 3 amp rro 182 163000 Yo ce odo ny Current firmware version Print Server 1 1 Tue May 30 14 40 26 JST 2006 Specify the for update and click Update Q Q 9 4 G dieses 182168 00100 6 0 The firmware bemg updated Do not care eff the power supply
152. Electrical Section 2 1 2 2 2 3 2 4 2 5 2 6 WIRING MAP MAIN BOARD SERVO BOARD CARRAGE BOARD SUB BOARD MAINTENANCE PARTS LIST 2 28 3 Replacement of Main Parts 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 10 3 11 3 12 3 13 3 14 3 15 HEAD REPLACEMENT WIPER REPLACEMENT CAP TOP REPLACEMENT TOOL CARRIAGE REPLACEMENT CARRIAGE MOTOR REPLACEMENT FEED MOTOR REPLACEMENT PUMP REPLACEMENT INK TUBE REPLACEMENT BOARD REPLACEMENT MAIN BOARD SW POWER SUPPLY BATTERY REPLACEMENT CARRIAGE BELT REPLACEMENT ENCODER SCALE REPLACEMENT GRIT ENCODER REPLACEMENT PINCH ROLLER REPLACEMENT CUTTER PROTECTION REPLACEMENT 4 Adjustment 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 12 4 13 4 14 4 15 4 16 SERVICE MODE gU II ILU IE HOW TO UPGRADE FIRMWARE INSTALL FIRMWARE HOW TO UPGRADE FIRMWARE OF THE NETWORK CONTROLLER HEAD ALIGNMENT LIMIT POSITION amp CUT DOWN POSITION INITIALIZE LINEAR ENCODER SETUP FLUSHING POSITION ADJUSTMENT CROP MARK SENSOR ADJUSTMENT CROP CUT ADJUSTMENT PRINT CUT POSITION ADJUSTMENT CALIBRATION FEEDING DIRECTION TOOL HEIGHT ADJUSTMENT TOOL PRESSURE ADJUSTMENT BELT TENSION ADJUSTMENT BELT POSITION ADJUSTMENT TAKE UP UNIT OPERATION CHECK
153. Fist of oe It starts loading the firmware The firmware installation is completed when NG COMPLETED message is displayed Turn off the Sub Power ERASING NG DEVICE ERROR WRITING NG DEVICE ERROR E COMPLETED 4 19 10 1 Turn on the Sub Power SW while pressing V 1 and ENTER keys to enter INITIALIZE ALL SYS PARAMETER menu Select the model by pressing and V keys and press ENTER key to start initialization The Sub Power turns off automatically when it is completed 20 6 INITIALIZE ALL SYS PARAMETER J p SELECT MODEL 4 VP 540 INITIALIZATION COMPLETED Turn on the Sub Power SW while pressing 4 and gt keys to enter the Service Mode 002 MENU lt SERVICE MENU Enter the NETWORK menu and input IP ADDRESS SUBNET MASK and MENU GATEWAY ADDR Turn off the Sub Power when the network setting is completed MENU NETWORK NETWORK SERVICE MENU SYSTEM INFO 4 gt v SYSTEM INFO NETWORK gt lt ADDRESS gt 168 000 NETWORK 4 gt SUBNET mask 48 7 SUBNET MASK gt P 255 255 255 000 J ADDR 4 4 gt IP ADDRESS 192 168 000 100 4 42 GATEWAY ADDR 4 000 000 000 000 2 4 20
154. ISER QUE DES FUSIBLES DE LA TAILLE ET DU TYPE SPECIFIES fj F80L HS Electric charge Do not touch when power is on The wiring terminal untended for connec tion of the protective earthing conductor associated with the supply wiring HIGH VOLTAGE HANDLING ATTENTION Do not touch during power on Electric shock Compornents damage Do not repair Replace power unit Do not replace fuse Can not be recovered met Hui RB MRADI Do not disconnect the cable of this termi nal except the time of replacement 1 Structure amp Spare Parts 1 1 COVER VP 540 Below ZW65382 VP 300 Below ZW61509 PARTS LIST Main Parts 1 1 1 Ne 24 passsaaa 23475212 CABLE CARD 24P1 600L BB PARTS LIST Supplemental Parts Posno jPaisNam CUPSCREW SET M4 6 NI 100 PCS CUPSCREW SET M3 4 NI 100 PCS PLAPOINT FE4 6 WH RING SET PUSH ON CS CSTW 3 100 PCS SCREW SET BINDING M2 3 8 3CBC 100PCS SCREW BINDING P TIGHT M3 8 3C 100P SCREW PLAPOINT M4 6 BK FE 1 1 COVER VP 540 Above ZW65383 VP 300 Above ZW61510 S1 1 1 COVER VP 540 Above ZW65383 VP 300 Above ZW61510 PARTS LIST Main Parts PARTS LIST Supplemental Parts Parts Name Parts Name 6 1000002620 0 COVER RAIL B VP 54
155. L SPAN 8 1000000065 ASSY FLANGE GUIDE veao Ls e700s6s040_ ASSY MEDIA CLAMP LLONG PARTS LIST Supplemental Parts 0 31049157 SCREW CAP 6 20 3CBC PW SW 31139104 SCREW PLAPOINT M4 6 BK FE 31229103 5 SCREW SET TRUSS 2 6 NI 100 PCS 1 29 Section 2 Electrica 2 1 WIRING MAP 144015 W3MOd MS 22222222222222222222222222222222222222222222223 AIONATOS 5 mio m 2 mia osx o Wd ou 2 ar 8 8 WAV 4080 1 2 o Cis s rp quel eomer NVA HONId LIND J 0 AYALLVE Lx z YOLOW dWid G M YOLON NHdTA 4 2 gt as ST onl EE 2 SI 2 2 1 1 68 2 SOSNHS 1 HONWNALNIVIAG QNVOS YOLON 4384 m WOSN3S 1 a S resa nnitibi i 5 es E SOSNHS quvog quVOS 21 YAONA S85dTNINVO YOSNaS 1159 SOGTHINVO YNI VP 540 300 WIRING MAP Cable List PetsNo 00000 PatsNeme Fe 2177 rower ves ______ Fs oos moror veso _______ 2180 cABLE ASsy RELAY JUNCTION 7 7 7 1000002043 cweassvzxwsmecronxos
156. LER 9 SENSOR CHECK It can be performed in the Sensor Check 10 CROP MARK SENSOR ADJUSTMENT 11 CROP CUTADJUSTMENT Necessary when the voltage is adjusted in the CROP MARK SENSOR ADJUSTMENT 3 51 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 gt SUB MENU gt CLOCK Set the DATE in order of the Year Month Day 6 IP ADDRESS SETTING Start the machine with the Service Mode and set in the User Menu 7 FIRMWARE VERSION CONFIRMATION OF NETWORK CONTROLLER 8 HEAD RANK SETTING 9 SERIAL NUMBER INPUT 10 INK TYPE SETTING 11 SENSOR CHECK It can be performed in the Sensor Check 12 LIMIT amp CUT DOWN POSITION INITIALIZE 13 FLUSHING POSITION ADJUSTMENT 14 LINEAR ENCODER SETUP 14 TOOL PRESSURE ADJUSTMENT 16 HEAD ALIGNMENT Only Horizontal and Bidirectional Adjustments are required 17 CALIBRATION 18 CROP MARK SENSOR ADJUSTMENT 19 CROP CUTADJUSTMENT 20 PRINT CUT POSITION ADJUSTMENT 3 52 SW POWER SUPPLY REPLACEMENT 41V SW POWER SUPPLY CONNECTOR LAYOUT Connected to the CN1 on the SERVO BOARD Connected to the CN302 on the POWER BOARD 1 Turn off the sub power and then turn off the main power and pull out the AC cord
157. MENU 43 4 This is for checking the operation of panel keys It shows NONE on the lower LCD gt 4 gt before pressing any key It shows the key name when key is pressed it shows 4 4 the message KEY ERROR when 2 or more keys are pressed at the same time and itis considered that no buttons are pressed You can exit this menu with 44 key Therefore 4 key needs to be the last button to be pressed in order to check all keys No operations for 10 seconds or pressing 44 key let it exit this menu When exiting the names of the keys that never been pressed are displayed with a buzzer This means that if a buzzer does not go off when exiting all keys are checked properly The power cannot be turned off with the Sub Power SW while performing this menu SUB MENU 4 Abbreviated This is for checking LCD LED and buzzer When this menu is selected it s guentialty performs the functions of LCD LED and buzzer The functions are as follows ON OFF 4 LCD LED BUZ CHK4 of LCD contrast LCD back light ON OFF of buzzer display and move of cursor on av Returns when completed LCD and display of all characters available on LCD Confirm that all functions operate properly visually and by the sound J ay Waiting for incoming data SUB MENU 45 DETECTING 4 This is for checking the data input from network The check sum and input data bye 4 PORT CHECK 4 00 084
158. MEOUT lt This is for setting the time to show the confirmation message when controlling heater 4 HEAT TIMEOUT 4 OFF p 10min 4 temperature before printing It shows the message of HEATING TIMEOUT CONTINUE when the temperature controll is not completed at the specified timing when controlling the heater temperature before printing Range OFF 10 to 30 min by 10 min Default 20 min A V Print Heater OFF Print Heater ON HEATER MENU 4 PRINT _ 25 4 PRINT x 40 4 4 HEATER CHECK 4 DRYER 25 DRYER 25 C 4 is for checking the heaters and thermistors While in this menu it shows ON OFF status and the temperatures read from the thermistors of Print heater and Dryer A v keys are for selecting the heater or dryer and ENTER key is for turning ON OFF the selected heater or dryer ON OFF mentioned here only means to power on or off manually and not to control the temperature Be aware that the temperature keeps rising while it is ON It turns off automatically when exiting the menu Check if the temperature rises when the heater or dryer is ON and also if the temperature decreases to the room temperature when it is OFF Kom temperature is displayed in Celsius only av SERVICE MENU 4 SYSTEM SWITCH 4 1 4 mis is the software switch for switching the setting of supporting functions Normally it is not necessary I to change Each bit can be selected by 4 and gt keys and switched
159. MPLETED G ENC CHECK FAILED E ETITITITTTTTITITITITITI LEFT COVER LEFT SIDE COVER lt Left Side gt MAINTENANCE COVER 3 14 PINCH ROLLER REPLACEMENT 1 Conical type is used on both left amp right Pinch Rollers and flat type is used for the Middle Pinch Rollers Left Pinch Roller Right Pinch Roller E Red marking is done on the outer side of left amp right Pinch Rollers There is no marking on the middle Pinch Rollers Red marking Remove the E Ring on one side of the Pinch Roller and pull out the Shaft Make sure not to lose the washers which are fixed at both sides of the Pinch Roller Put the new Pinch Roller with washers and insert the Shaft into the Pinch Roller Fixing operation becomes easy when you put the washers to the Pinch Roller with grease 4 Fix the E Ring and check that the Pinch Roller rotates smoothly 3 70 3 15 CUTTER PROTECTION REPLACEMENT 1 Remove the Cutter Protection CUTTER PROTECTION 2 Wipe the adhesive on the Bed with alcohol 3 Install the Cutter Protection from 1mm from right edge of the Bed CUTTER PROTECTION 4 Make sure that the Cutter Protection is not bumpy 3 71
160. NANCE COVER I S COVER BELT 9 V T E 4 Se CABLE GUIDE 4 53 VP 300 Measure the tension of the belt at the empty screw hole of the LM Guide between the 2nd and 3rd Grit Rollers from the left using Tension Gauge ST 001 1 Pull up the belt until its inside comes to the top surface of the Cable Guide when you see it from the machine front 2 The tension is proper if the measured value is 1 25kgf to 1 40kgf If the tension is improper move on to the next step and adjust the belt tension lt 2 gt BELT CABLE GUIDE Loosen the 2 Fixing Screws which is located on the left end of the belt halfway round FIXINGSCREW IE Be careful with the sharp edges around the belt when loosening the screws It may cause injury 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 The belt tension cannot be adjusted higher when the screw contacts with Idle Pulley Holder IE The gap between the screws and Idle Pulley can be seen from both front side and rear side of the machine IDLE PULLEY HOLDER 4 54 Turn the Adjustment Screw as shown the figure to adjust the value of the tension gauge within acceptable
161. NSOR LIMIT SENSOR Ine raar edge al tie media andaliga It detects the limit positon of the head carriage in the scan whether the media is loaded or not direction IS COVER SENSOR It detects whether the IS Cover is opened or closed HEAD LOCK SENSOR It detects whether the HEAD CARRIAGE is at the lock position or not THERMOSTAT HEATER If the Heater exceeds the limit temperature it stops the power supply HERMOSTAT DRYER If the Dryer exceeds the limit temperature it stops the power supply FRONT PAPER SENSOR It detects the front edge of the media THERMISTOR DRYER It takes the temperature of the Dryer THERMISTOR HEATER It takes the temperature of the Heater Left side of the machine MAINTENANCE COVER SENSOR detects whether the Maintenance Cover is set lt EE or not FEED ENCODER MODULE It detects the rotation position of the Grit Roller SHEET LOAD SENSOR It detects whether the Sheet Loading Lever is UP or DOWN 5 2 5 Supplemental Information oc 2 m 0 oc 0 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 D Z N z O a 2 a lt 1O gt 5 T c c 9 2
162. OATEL wilden a 53 8 421 g 7 or v 4L LOEN SIEN WTA Mor doi gt axien PIDAL FIOATEL 0650 3665 E a II 9 D E zi TAMT 4 VLEDI IWAT oa ANAT 5 0 STEN 1 089 TIND ODA 019d 4 1 1 8DNVO MAIN BOARD C 2 12 Qvi or 001 vasvn VOS OL roga 180473 m TROD cora NONMASVGIG Disis Lvan vars von 9 DO 5 visa ININA OL 2 ol o HAVSd 5 Ed Oo G x um UNIS LYaH 5 SA 9 THO PENAT aovnnivo E idi el OL lt a
163. POOR CUTTING QUALITY STITCH CUT DISTORTED CUT MISMATCHED START AND END POINTS NO CHECKINGPOINT ACTION REFERENCE loose tightly not correct correctly meme correct adjustment ADJUSTMENT When using only left and right pinch rollers middle part of the media won t follow both edges when the media is fed and this may affect the cutting quality Depending on the surface condition or the types of media Blade Holder tip gets caught by the vinyl and it results in stitch cut Bearing Blade Replace the Blade Holder doesn t rotate Holder smoothly Scratch in Cutter Replace the Cutter Protection Protection 4 12 TOOL HEIGHT EX Tool height is not correct Adjust the tool height ADJUSTMENT 10 Tool doesn t move Replace the Tool 3 4 TOOL CARRIAGE up down smoothly Carriage REPLACEMENT 11 Tool Carriage is loose Replace the Tool 3 4 TOOL CARRIAGE 9 Holder part of Tool Replace the Tool 3 4 TOOL CARRIAGE Carriage is loose Carriage REPLACEMENT When there is a backlash at the Scan motor or Feed 43 Backlash of Motor Gear Adiust Backlash motor Tool Carriage and Grit Roller will be driven unstable and results in symptoms such as mismatched start and Middle Pinch Rollers are Use the Middle Pinch Blade Holder tip is Don t use the Blade caught by the media Holder tip When the driver IC that drives solenoid is d
164. Preheating Preheat Up velocity 30 cm s Bi dir simple 0 Vacuum power AUTO Bi dir Adjust No 1 0 0 0 0 No 3 f 0 4 X 4 9 No 2 0 0 0 0 No 4 0 0 0 Preset name PRESETTING2 Calibration 0 00 85 Scan interval 0 0 sec Force 50 gf Cutting calib F S 0 00 0 00 Heater setting PRINT 35 94 F Edge detection Enable Velocity 30 cm s Print cut adjust F S 0 00 0 00 mm Heater setting DRYER 40 104 Full width S FULL Offset 0 250 mm Crop cut adjust F S 0 00 0 00 mm Feed for dry Disable Preheating Preheat Up velocity 30 cm s Bi dir simple 0 Vacuum power AUTO Bi dir Adjust No 1 0 o o 9 No 3 0 0 0 0 No 2 0 0 0 0 No 4 0 0 0 0 Preset name PRESETTING8 Calibration 0 00 85 Scan interval 0 0 sec Force 50 gf Cutting calib F S 0 00 0 00 Heater setting PRINT 35 94 F Edge detection Enable Velocity 30 cm s Print cut adjust F S 0 00 0 00 mm Heater setting DRYER 40 104 Full width S FULL Offset 0 250 mm Crop cut adjust F S 0 00 0 00 mm Feed for dry Disable Preheating Preheat Up velocity 30 cm s Bi dir simple 0 Vacuum power AUTO Bi dir Adjust No 1 o 0 No 3 0 0 0 0 No 2 0 0 0 0 No 4 0 0 0 4 10 HISTORY REPORT History Report Model VP 540 Serial No Version 1 00 Date Motor group Motor feed trip total clear 0 0 Motor scan trip total clear 9
165. R335C233 m R334 C232 Fern 202 R333 C231 LT CL e264 5 R32 230 R281 T 1263 TP302 2 a 8 ezzaL 1 6215 M R28 TP303 0104282 amp 2228 7T samt r32 222111 Ora C228 R284 TP244 6229 LL 5260 R330 R28 LT 2259 6329 101 213 2214582 233 TP312 8324 LI CO R323 R258 16310 0 nR251 ms TP309 ET CLI TP318 cn ce 317 TP307 1 216 Orato TP30 Orense TP30 Te238 Orr208 TP222 Qrezo wO mO 18315 Qrezos 301 25 TP324 3 298 PC249 PC230 19231 8 TP 204 19323 297 2100 O 20 O O 21 203 TP320 712212 TP319 257 PC235 1 220 24 1 9 ircuit Diagram MAIN BOARD C
166. RE ADJUSTMENT 5 CROP MARK SENSOR ADJUSTMENT 6 CROP CUT ADJUSTMENT 7 PRINT CUT POSITION ADJUSTMENT Adj Time 45min Total Time 65min CAP TOP REPLACEMENT 20 min 4pcs 1 FLUSHING POSITION ADJUSTMENT Adj Time 5min Total Time 25min CARRIAGE MOTOR REPLACEMENT 20 min 1 SERVO LOCK CHECK 2 AGING It can be performed in the MOTOR MENU gt AGING gt SCAN 3 MOTOR HOURS CLEAR Adj Time 5min Total Time 25min FEED MOTOR REPLACEMENT 30 min 1 SERVO LOCK CHECK 2 AGING It can be performed in the MOTOR MENU gt AGING gt FEED 3 GRIT ENCODER CHECK 4 MOTOR HOURS CLEAR Adj Time 6min Total Time 36min GRIT ENCODER REPLACEMENT 10 min 1 GRIT ENCODER CHECK Adj Time 2min Total Time 12min PUMP REPLACEMENT 20 min 2 pcs 1 PUMP CHECK 2 PUMP TIMES CLEAR Adj Time 2min Total Time 22min MAIN BOARD REPLACEMENT In case that the parameters cannot be transferred by Peck 35 min 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 gt SUB MENU gt CLOCK Set the DATE in order of the Year Month Day 6 IP ADDRESS SETTING Start the machine with the Service Mode and set in the User Menu 7 FIRMWARE VERSION CONFIRMATION OF NETWORK CONTROLLER 8 HEAD RANK SETTING 9 SERIAL NUMBER INPUT 10 INK TYPE SETTING 11 SENSOR CHECK It can be perform
167. RRIAGE VP 300 X 26 36 7 ee Cut to 110mm when using AM il Li m x SAT 1 __ 19 S y a 0 gt gt 27 ez 227 ss d 1 31 28 K p s4 p _ ee dd 25 S4 L7 M Re 1 n lt i lt 25 5 1 Xs f 51 3 ASSA 7 A 2 12 552 18 3 9 Cut to 130mm when using 45 9214 4 BN gt U MJ 1 14 1 5 HEAD CARRIAGE VP 300 PARTS LIST Main Parts PARTS LIST Supplemental Parts 21905166 ADAPTER HEAD 540 31289109 CUPSCREW 5 3 4 NI 100 PCS 1000002679 ADAPTER JUNCTION VPY306 31289102AS CUPSCREW SET M3 6 NI 50 PCS 11909167 ADAPTER SCREW FJ 540 31299102AS RIVET SET NYLON P2655B 20 PCS 6085393800 ASSY INK DAMPER 3FAI 4 SJ 1000 Revised 1 31409801 SADDLE LOCKING WIRE LWS 0711Z 20P W700461130 ASSY LINEAR ENCODER BOARD VP 540 31679902 SCREW SET C SEMS 2 8 NI 100 PCS W700461110 ASSY PRINT CARRIAGE BOARD VP 540 31019148 SCREW SET BINDING M2 6 4 NI 100 PCS 1000003136 ASSY TUBING 3 150MM VP 540 31049169 SCREW M4 8 3CBC PW 20PCS 1000002661 BASE CARRIAGE AL VP 300 31089121AS SCREW 5 M2 3 8 NI PW 100 5 1000003032 BASE CARRIAGE SIDE AL VP 540 31179908 5 SCREW SET UREA M3 20 1 50 5 1000002662 BASE HOLDER CARRIAGE VP 300 31239125 SCREW SET W
168. SEMS M3 8 SUS 50 PCS 23475206 CABLE CARD 21P1 330L BB 31199905 SCRW SET SET CONE M3 16 NI 20 PCS 11769118 2 56 14 1000002588 COVER HEAD BOARD VP 540 1000002632 COVER PRINT CARRIAGE VP 540 COIN ODO o NN 1000002652 COVER PRINT JUNCTION VP 540 1000003076 GUIDE CARRIAGE CAP VP 540 22135440 GUIDE HEAD AL FJ 540 1000003293 GUIDE TUBE VP 540 1000002201 ASSY HEAD INKJET SOL XC 540 11659249 HOLDER RING FJ 540 1000002753 LABEL READ MANUAL VP 540 LA969 21345105 LOCK CJ 500 22395108 MAGNET CJ 500 1000003075 PAD PRINT CARRIAGE L VP 540 1000003074 PAD PRINT CARRIAGE R VP 540 1000002664 PLATE DAMPER VP 300 22055547 PLATE GND FJ 540 22175520 SPRING HEAD ADJUST 500 FJ 540 22175519 SPRING HEAD PRESS 500 FJ 540 1000003863 STAY CARRIAGE TUBE 2 VP 540 1000000417 STAY ENCORDER SENSOR SP 540V 1000002524 STAY HOLDER CARRIAGE BOARD VP 540 1000003031 SUPPORT ADJUST SCREW VP 540 1000002663 SUPPORT CARRIAGE BOARD VP 300 1000002643 SUPPORT DAMPER VP 540 1000002670 TUBE SJ RDG3 4 4LINK VP 300 1000002174 CABLE ASSY LINEAR ENCODER VP 540 1 6 1 16 1 6 PARTS LIST Main Parts Parts No Parts Name 1000002654 APRON B VP 300 PARTS LIST Supplemental Parts Parts No Parts Name 3
169. The length of printing or cutting is subject to the limitations of the program 2 W ith Roland PET film print travel 1 m Temperature 25 C 77 F humidity 50 7 13 Exclusive stands power cord blade blade holder media clamps media flanges replacement blade for separating knife cleaning kit software RIP User s M anual 53 Not assured when the print heater or dryer is used 4 The following conditions must be met Media type Media specified by Roland DG Corp Roll media must be loaded on the shaft PREFEED menu item must be set to EN ABLE Side margins 25 mm or more for both the left and right margins Front margin 35 mm or more Excluding expansion contraction of the media Range for assured repetition accuracy 54 inch model For media with a width exceeding 610 mm Length 4 000 mm For media with a width of 610 mm or less Length 8 000 mm 30 inch model Length 3 000 mm 5 Provided that media length is under 3 000 mm Temperature 25 77 F Excluding possible shift caused by expansion contraction of the media and or by reloading the media 6 Media type Roland PET film D ata size 1 000 mm in the media feed direction 1 346 mm 54 inch model or 736 mm 30 inch model in the carriage move ment direction N o lamination Automatic detection of crop marks at 4 points when media is reloaded D uring cutting PREFEED menu item must be set to EN ABLE Temperature 25 C 77 F Excludes the effec
170. UTTING 2 stop Aging press ENTER key The Head Carriage N lt gt automatically returns to capping position and it returns to the 4 CUTTING 4 NOW AGING 4 former menu after the Head is capped Make sure not to perform Aging for excessive time when the head has ink in order to prevent the head from being damaged by dried ink When Aging is performed with ink filled it runs while performing the Flushing operation No Flushing when ink is not A A Y Servo Motor LOCKED p MOTOR MENU 4 P gl SERVO LOCK SERVO LOCK lt mis is for checking whether Servo Motor can be locked N 4 SERVO LOCK 8 100 4 0 0 properly While in this menu Servo Motor is free When the 4 Carriages are moved by hands the displayed values change as long as the feed back is proper Servo Motor FREE Servo Motor can be locked by pressing ENTER key Fe When it is locked while the motor is in pause the power 5 SERVO LOCK 45 SERVO LOCK 4 controlled normally E 5 As for F Feed direction the value displayed on the left changes 240 20 4 F 0 0 4 Grid Encoder and the right changes by Motor Encoder E Normal beeps 1 time MOTOR MENU 4 4 M ENC 6654 M G ENC CHECK 4 This is for checking whether the Grit Encoder functions 4 G ENC CHECK 6653 COMPLETED Be careful with the Feed Motor which drives as executing this menu The motor drives about 4 times and it displays the coordinates
171. Vinyl media is recommended for this adjustment 5 4 4 MENU 4 gt 2 Perform Bidirectional Adjustment referring to 4 4 HEAD SERVICE MENU 4 ALIGNMENT PRINT MENU 15 v PRINT MENU 45 HEAD ADJUST v HEAD ADJUST 45 BI DIR DEFAULT p gt 3 Select CUTTING MENU gt PRINT CUT ADJ gt TEST PRINT 2 and press ENTER key SERVICE MENU 45 CUTTING MENU The test print and cut will be performed Iv CUTTING MENU 4 IE Bidirectional adjustment and this step must be done by using the same media v PRINT CUT ADJ 4 TEST PRINT 2 4 4 43 From the test pattern find the value where the print line matches the cut line In this case the correction value for the scan direction is 0 3 If it is difficult to see the cut line visually use a magnifier Select CUTTING MENU gt PRINT CUT ADJ SETTING and enter the correction values found in the test pattern for both Feed and Scan S F Feed direction S Scan direction Left Current value Right New value Setting range 5 00mm 0 01mm unit Value of F towards Value of F towards gt key Value of S towards key Value of S towards ENTER key Saves new setting MENU key Moves out SETTING menu
172. age and lock the connected carriages IE The right end is the highest position of the bed Ne 1 Turn on the Sub Power SW while pressing lt d V and gt keys to enter the Service Mode Select CUTTING MENU FORCE ADJUST Only the Tool Carriage can be moved FORCE ADJUST menu OQO v b Select FORCE ADJUST 30gf and press PAUSE key to move the Tool Carriage down 4 51 MENU 4 SERVICE MENU MENU 4 SERVICE MENU v SERVICE MENU 4 CUTTING MENU v CUTTING MENU 4 FORCE ADJUST CUTTING MENU 45 FORCE ADJUST FORCE ADJUST 45 X 30gf 2 30gf 45 17 16 J PAUSE 8 Lift up the Tool Holder with the Dial Gauge ST 013 and measure the pressure when the pen tip leaves the bed Adjust the parameter 309 menu with A and keys for the pressure to be 25 to 35gf 0 25N to 0 35N Press ENTER key to save the settings 9 Select FORCE ADJUST 200gf and press PAUSE CUTTING MENU 4 key to move the Tool Carriage down FORCE ADJUST v FORCE ADJUST 4 200gf m 200gf lt 56 gt 57 PAUSE 10 Lift up the Tool Holder with the Tension Gauge ST 002 4 and measure the pressure when the
173. age from the Head Carriage Remove the 4 rivets as shown in the figure to remove TOOLCARRIAGE RIVETs fal 9 Tb PL e z gl gear caue 88 gt Laaa _ 7 RE E NE TOOL CARRIAGE BOARD COVER 3 16
174. ain When it is proper press ENTER key to cancel Aging 20 SCAN 4 4 04 Fix the Right Side Frame by sliding it from behind to hook the tab as shown in the figure 4 61 4 16 TAKE UP UNIT OPERATION CHECK Referential Time 2min This is to check whether Take up Unit operates properly 1 Confirm that the cable of Take up unit is connected to the connector and turn on the Main Power SW REAR VIEW Turn on the Sub Power SW while pressing 4 V and keys to enter the Service Mode v v MENU 4 SERVICE MENU 3 Select SUB MENU TU TU SERVICE MENU lt gt gt i gt v SUB MENU 45 gt i gt TU CHECK 4 4 gt TU 4 START gt START 8 4 4 62 4 Confirm that START is selected and press ENTER key to turn on the Take up Unit IE START or STOP can be selected with TU 4 land keys START START y The current setting is displayed on the left and the new setting is diplayed on the right 2 Set the AUTO switch of the Take up Unit to either FORWARD or BACKWARD AUTO MANUAL BACKWARD BACKWARD FORWARD FORWARD Move the Dancer Roller up and down by hand and con
175. amaged rarely Solenoid IC on Servo Replace 1 23 on the abnormal tool pressure is given In this case the blade hits Board is damaged Servo Board the bed and jumps when it goes down and it results in stitch cutting end points LM A Belt Tension Ajustment correct 6 9 MEDIA SKEW CHECKING POINT REFERENCE Media Flanges are fixed with the stoppers If they are not User s Manual fixed Media roll shifts left and right while it is fed and it may result in media skew NO 2 Flanges are not set Set the Media Flanges User s Manual When the flanges are not fully put in the media tube correctly to the Media Media is fed tilted and it may result in Media shifting The most effective measure against Media shifting is to set 3 Media is not set straight Setup Media again teers Manual Media straight to the machine Especially on lengthy Media Flanges are not Fix the Flanges with the fixed by the stoppers stopper to the machine printing small tilt of Media setup results in big Media shifting while printing When dust such as pieces of vinyl is stuck to the Grit Grit Roller is dirty Clean the Grit Roller Roller ability to hold Media decreases and it results in Media shifting Use a brush to clean the Grit Roller When pinch rollers wear out ability to hold media decreases and it results in media shifting Referential time for replacing Pinch Roller is 24 months 3 14 PINCH ROLLER Pinch Roller is worn out Replace the P
176. and Idle Pulley Holder IE The gap between the screws and Idle Pulley can be seen from both front side and rear side of the machine 16 Press ENTER key to restart Aging 17 Insert a wrench through the holes on the Side Frame and adjust the belt position turning the screw 1 and 2 as follows Belt leans to the front side of the machine Turn the screw 1 carefully in CW to press it to the Idle Pulley Holder Make sure to have a gap of 3mm between the screw 2 and Idle Pulley Holder when turning the screw 1 Belt leans to the rear side of the machine Turn the screw 2 carefully in CW to press it to the Idle Pulley Holder Make sure to have a gap of 3mm between the screw 1 and Idle Pulley Holder when turning the screw 2 4 60 IDLE PULLEY HOLDER 4 Lm 1 Tighten one of the screws that has no contact with the Idle Pulley Holder to slightly touch the Idle Pulley Holder IE Make sure not to tighten the screws too tight It may move the Idle Pulley Holder accidentally 19 Tighten the 2 fixing screws as shown in the figure IE Be careful with the moving Carriages during the work and also with the sharp edges of the mechanical parts around it Confirm that the belt is not touching the Pulley Flanges excessively When the belt is in improper position adjust it ag
177. and it backs out the menu For backing out the menu without saving the position press MENU key without pressing ENTER key A Y Normal E E ME FIL 214 m SERVICE MENU 4 I S MENU 45 NOW PROCESSING gt I S CHECK 4 This is for checking the I S MENU 4 1 5 4 COMPLETED operation of the wiper motor Checking Error and sensor Make sure not to have the Head Carriage I S CHECK ERROR 4 4 and Tool Carriage above the WIPER wiper unit during the check A In I S MENU 4 PUMP CHECK 44 NOW PROCESSING checking the pump 4 PUMP CHECK 4 PUMP SUCTION motor The rotation for both ink AY v suction and release can be checked Pump motor rotates PUMP CHECK dle NOW PROCESSING for 5 seconds and stop 4 PUMP RELEASE The wiper can be moved N ay manually Option FRONT REAR I S MENU lt gt I S CONTROL 4 WIPER 4 rots Bias 1 4 9 gt aution Make sure not to have 4 5 CONTROL 4 WIPER 4 FRONT AY carriage above the wiper unit during this operation Normal I S MENU 4 NOW PROCESSING WIPER AGING 414 4 WIPER AGING d COMPLETED This is for confirming that v Error beeps 2 times wiper is operated properly E NN WIPER AGING 4 4 FAILED Remove all cartridges mi cartridges must be removed before entering IC N
178. ard Main board may be damaged if the problem is not solved by the measures above 1 The problem may be in the network when they are connected 3 Connect them directly through LAN It can be identified whether the problem is on 4 6 9 6 13 ERROR MESSAGE NO 1 CHECKING ACTION Restart the machine service call Refer to 6 14 SERVICE CALL Restart the machine Internal Error Upgrade the firmware to the latest version 6 14 SERVICE CALL Disorder of communication with Sub CPU This occurs when the Sub CPU is not detected after turning on the machine REFERENCE OUTLINE Restart the machine and see if the same error occurs again Servo Board does not work correctly Sub CPU does not work correctly There is a bad connection between Main Board and Servo Board Restart the machine and see if the same error occurs again Check the revision record of the firmware version and upgrade it if the error has been solved in the firmware Check cable connection between Main Board and Servo Board Check the other cable connections of Servo Board Servo Board replacement Main Board replacement Flexible cable replacement 0004 Sub CPU SRAM error SRAM is broken Servo Board replacement 0005 0006 0007 0008 0010 Network I F Initialize has not been Network I F does not work correctly Check the firmware is installed into Network I F completed Firmware for Network I F is not installed Main Board
179. by a and v keys SYSTEM SWITCH b 4 1 4 00000000 Pes ENTER key to save the settings There are 16 pages of 8 bit System Switches v bit 87654321 1 ay Bit Contents Meanings Default SYSTEM SWITCH 4 PAGE16 2 m Reflection of the heater related 1 enables the settings of FULL WIDTH S and lt gt lt PAGE1 Bit4 Parameters to the test pattern PERIODIC CL for all test patterns 0 4 PAGE16 4 00000000 4 PAGE1 Bit7 Periodic flushing of MAX ink Enables with 0 Disables with 1 0 587654321 2 6 Base Head Menu With 1 STANDARD HEAD menu is added 0 to the Service Menu All the default of the items not shown here is 0 CAUTION The machine may make unexpected move when the Bits not shown here are changed SERVICE MENU 4 HISTORY MENU 4 MOTOR HOURS F44 MOTOR HOURS 45 HISTORY MENU 4 MOTOR GROUP 4 3 hours 4 CLEAR 4 v In History Menu the parameters are separated in groups CATEGORIES MOTOR GROUP HEAD GROUP MAINTE GROUP by categories The parameters can be displayed or cleared WIPE GROUP PRINT GROUP CUTTING GROUP by selecting the group INK GROUP HEATER GROUP ERROR GROUP SYSTEM SERVICE MENU 4 4 REPOR 4 4 SERVICE REPORT 4 Reports be printed The head to print the report i
180. by pressing Y A W keys while TEST PRINT menu by VERTICAL 4 pressing keys again after feeding media returns m WISH to the original position HEAD ADJUST 4 HORIZONTAL 4519 PERFORMING 4 HORIZONTAL 4 TEST PRINT 4 TEST PRINT av HORIZONTAL 45 2 H4 45 4 DT1 Low 4 2 1 3 4 av HORIZONTAL 4 H2 H3 H4 45 4 PT3 Low 4 2 1 4 Av 1 Only for VP 540 z AY 1 1 HORIZONTAL 4 H2 H3 H4 4 High 4 2 1 3 4 i Av 1 HORIZONTAL P H3 49 4 High 4 2 1 1 Cursor be moved with 4 and gt keys and value can be selected with A keys ENTER key for saving the setting The value being selected is marked with an under bar It returns to the former menu by pressing 4 key when the cursor is on the head of the left end It starts with H2 when H1 is defined as the standard head Default 0 Range 30 to 30dot changeable by 0 5dot 0 5dot is indicated as 1 2 HEAD ADJUST 44 BI DIR DEFAULT4 TEST PRINT 4 6 PERFORMING lt gt 4 gt m 4 BI DIR DEFAULT gt 4 5 PRINT 4 1234 TEST PRINT AY Cursor can be moved with 4 and gt keys and the heads can turned ON OFF with A and keys Press ENTER key to start the test print of the selected heads It
181. cel done 06 01 11 17 14 27 Print done Testpattern 06 01 10 12 53 26 Cancel start Pinch lever up 06 01 11 17 13 27 Print start Testpattern 06 01 10 12 53 26 Setup done Width 1222mm Env 0 010 06 01 11 17 11 27 Print done Testpattern 06 01 10 12 52 26 Cancel done 06 01 11 17 09 28 Print start Testpattern 06 01 10 12 52 26 Cancel start Pinch lever up 06 01 11 17 09 28 Print done Testpattern 06 01 10 12 50 26 Print done Testpattern 06 01 11 17 06 28 Print start Testpattern 06 01 10 12 49 26 Print start Testpattern 06 01 11 17 06 28 Setup done Width 932mm Env 0 028 06 01 10 12 48 26 Setup done Width 1222mm Env 0 011 06 01 11 17 05 28 Sub power on Service mode 06 01 10 12 46 26 Sub power on Service mode 06 01 11 15 59 27 Sub power off 06 01 10 12 46 26 Main power on Normal 06 01 11 15 56 27 Print done Testpattern 06 01 10 12 46 26 Sub power off 06 01 11 15 54 28 Print start Testpattern 06 01 10 12 08 26 Setup done Width 1222mm Env 0 012 06 01 11 15 53 27 Setup done Width 932mm Env 0 028 06 01 10 12 07 26 Cancel done 06 01 11 15 52 27 Sub power on Service mode 06 01 10 12 07 26 Cancel start Pinch lever up 06 01 11 15 13 28 Sub power off 06 01 10 12 07 26 Setup done Width 1315mm Env 0 012 06 01 11 15 00 28 Print done Testpattern 06 01 10 12 05 26 Cancel done 06 01 11 14 59 28 Print start Testpattern 06 01 10 12 05 26 Cancel start Pinch lever up 06 01 11 14 57 28 Print done Testpattern 06 01 10 12 03 27 Print done Testpattern 06 01 11 14 55 28 Print
182. culate the calibration amount with the formula shown at step 4 Test pattern is always printed with offset 0 0096 Even if a correction is made in the SETTING menu the test pattern is not g changed 5 500 Scan 4 46 4 Calculate the amount to be calibrated with the formula as shown in the figure 5 Select PRINT MENU CALIB DEFAULT gt SETTING and enter the calibration value with and V keys Press ENTER key to save the setting Calibration Value Measured 400 Length Measured Length x 100 IE Parameters can be entered with an increment of 0 01 MAX 2 00 to MIN 2 00 4 47 SERVICE MENU 45 PRINT MENU v gt v PRINT MENU 4 CALIB DEFAULT Y gt v CALIB DEFAULT 4 SETTING gt SETTING lt 0 00 0 15 J 4 4 12 TOOL HEIGHT ADJUSTMENT Referential Time 5min Carriage 1 Install the White Dummy Pen ST 006 to the Tool eee NT WHITE DUMMY PEN E 2 Move the Pinch Rollers at the positions as shown in the figure and lower them PINCH ROLLER VP 300 GRIT ROLLER 3 Remove the 1 5 Cover 4 Remove the Tool Carriage Cover 4 SCREWs I S COVER COVER Y
183. d the value on the LCD doesn t change FEED MOTORBOARD MENU 4 SERVICE MENU SERVICE MENU 4 MOTOR MENU 4 gt MOTOR MENU 43 SERVO LOCK gt SERVO LOCK 43 140 140 4 3 31 80 80 i ENTER SERVO LOCK G F 80 80 27 30 31 Check the Grit Encoder Go back to the MOTOR MENU and select G ENC CHECK and press the ENTER key Make sure the Grit Encoder functions correctly by confirming the display to show G ENC CHECK COMPLETED In case that G ENC CHECK FAILED appears check the followings 1 Grit Encoder is fixed correctly 2 Feed Motor is fixed correctly 3 There are no scratches or fingerprints Perform AGING Go back to the MOTOR MENU and select AGING gt FEED and press the ENTER key Make sure the machine performs AGING and then finish it by pressing ENTER key SERVICE MENU 4 MOTOR MENU gt 1 gt livl MOTOR MENU 4 G ENC CHECK 4 1 ENTER M ENC 6654 G ENC 6653 4 COMPLETED G ENC CHECK FAILE E Do not load any media when performing AGING Clear the motor working hours Go back to the Service Menu and select HISTORY MENU gt MOTOR GROUP gt MOTOR HOURS gt CLEAR and press the ENTER key The motor working hours will be reset to O
184. d to disconnect the AC code SUB POWER SW Remove the 1 5 Cover SCREW I S COVER Remove the Right Top Cover and Carriage Cover Remove the 2 screws to remove the Damper Plate And remove the 2 Ink Dampers from the head which will be replaced Do not hold both sides of the Ink Damper tight It could break Be sure to remove and fix the Ink Damper with the Head Board Cover fixed It prevents the ink from dropping on the Head Board 3 5 IE There is a tab on the left side of the Head Board 10 Remove the 2 screws fixing the Head Board Cover and move it upward Cover HEAD BOARD COVER SCREW 2 2 2 Ceg 00O Disconnect the 2 flexible cables from the head FLEXIBLE CABLE SY E Remove the Spring and remove the 3 screws fixing the head Then pull the head towards the front and pull it up to remove it 2 5 2 11 12 14 Remove the head from the adapter and fix the new head to the adapter E
185. e 10min Total Time 20min PANEL BOARD REPLACEMENT 7min 1 LCD LED BUZ CHECK It can be performed in the SUB MENU LCD LED BUZ CHK 2 KEY CHECK It can be performed in the SUB MENU gt KEY CHECK Adj Time 3min Total Time 10min SERVO BOARD REPLACEMENT 18min 1 1 5 CHECK It can be performed in the 5 MENU gt 1 5 CHECK 2 IC CHECK It can be performed in the I S MENU gt CARTRIDGE gt IC CHECK 3 FAN CHECK It can be performed in the SUB MENU gt FAN CHECK gt VACUUM FAN to check that there is a operation sound of the vacuum fans 4 PUMP CHECK It can be performed in the 5 MENU gt PUMP CHECK gt PUMP SUCTION to check the pumps work correctly 5 SENSOR CHECK It can be performed in the SENSOR CHECK 6 HEATER CHECK It can be performed in the HEATER MENU gt HEATER CHECK 7 GRIT ENCODER CHECK It can be performed in the MOTOR MENU gt G ENC CHECK 8 AGING It can be performed in the MOTOR MENU gt AGING gt BOTH 9 TOOL UP DOWN CHECK It can be performed by PAUSE key in the CUTTING MENU gt FORCE ADJUST 10 TOOL PRESSURE ADJUSTMENT 11 CROP MARK SENSOR ADJUSTMENT 12 CROP CUT ADJUSTMENT Adj Time 40min Total Time 58min CARRIAGE BELT REPLACEMENT 35min 1 BELT TENSION ADJUSTMENT 2 BELT POSITION ADJUSTMENT 3 LIMIT amp CUT DOWN POSITION INITIALIZE 4 FLUSHING POSITION ADJUSTMENT 5 CUTTING QUALITY CHECK Adj Time 25min Total Time 60min ENCODER SCALE REPLACEMENT
186. e BELT gt And loosen the Adjustment Screw ADJUSTMENT SCREW FIXINGSCREW 10 Loosen the 4 screws as shown in the figure Remove the Carriage Belt from the plate and connect the new belt with the scotch tape 11 3 62 1 Slowly pull the belt end which is not connected the new belt until the new one reaches to the Belt Stay Check that the belt is not twisted IE Apply adequate quantity of grease P 39008297 FLOIL 902 14KG to pulleys BELT STAY lt Left Side lt Right Side Tighten the screws as shown in the figure to fix both ends of the Carriage Belt to the Belt Holder with the plastic plate and metal plate 1 When fixing the Carriage Belt make sure the ends of the Carriage Belt are not overlapped Be careful with the fixing direction of the plastic plate and the fixing order of the plates Cross section diagram OK SCREW METAL PLATE PLASTIC PLATE CARRIAGE BELT BELT HOLDER Tighten the Adjustment Screw to have tension on the belt And tighten the 2 Fixingscrews as shown in the 14 figure IE Do not tighten the Adjustment Screw tight 3 63 Cross section diagram OK SCREW CARRIAGE BELT CARRIAGE BELT ETAL PLAT PLASTIC PLATE BELT HOLDER NG
187. e cable Replacement Confirm whether Encoder Scale is between the slit of Encoder Module in a whole width of the machine Check cable connection between Linear Encoder Board and Main Board Confirm connection between Belt and Carriage Linear Encoder replacement Scan Motor replacement Main Board replacement Ink cartridge IC sensor replacement Check cable connection around Thermistor Thermistor replacement Check Thermostat Check Thermistor Check cable connection around Thermistor Thermistor replacement Check Dryer Check Thermostat Check Thermistor 7 1 INSTALLATION CHECK LIST VP 540 300 INSTALLATION CHECK LIST Date User Name Serial Number E Checking for Installing Place There is a space necessary for installing the machine as follows 2400mm 8 ft VP 540 3300mm 11ft VP 300 2700mm 9 ft Install the machine a location that is level stable and able to bear the weight of the machine The total weight of the machine may reach 160 kg 353 Ib or more 120 kg 265 Ib or more for the 30 inch model Installation in an unsuitable location may cause a major accident including tipover fall or collapse Never install out of doors or in any location where exposure to water or high humidity may occur Current leakage may cause electrical shock electrocution or combustion and fire Never install close t
188. ed from the outlet In addition to the ANWARNING and NCAUTION symbols the symbols shown below are also used Tips and advise before the adjustment About the Labels Affixed to the Unit These labels are af xed to the body of this product The following gure describes the location Ag x unm WI NY OM Flammable Ink and discharged uid are ammable Keep away from open ame Ink Is Toxic Ink and discharged uid are toxic Avoid contact with the body Use only in a well ventilated area 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 ngers to become pinched rsult ing in injury Flammable Ink and discharged uid are ammable Keep away from open ame Ink Is Toxic Ink and discharged uid are toxic Avoid contact with the body Use only in a well ventilated area Caution High Temperature The platen and dryer become hot Exer cise caution to avoid re or burns E b WARNING FOR CONTINUED PROTECTION AGAINST RISK OF FIRE REPLACE ONLY WITH FUSE OF THE SPECIFIED TYPE AND CURRENT RATING ATTENTION AFIN D VITER TOUT RISQUE D INCENDIE N UTIL
189. ed in the SENSOR CHECK 12 LIMIT POSITION amp CUT DOWN POSITION INITIALIZE 13 FLUSHING POSITION ADJUSTMENT 14 LINEAR ENCODER SETUP 15 TOOL PRESSURE ADJUSTMENT 16 HEAD ALIGNMENT Only Horizontal and Bidirectional Adjustments are required 17 CALIBRATION 18 CROP MARK SENSOR ADJUSTMENT 19 CROP CUT ADJUSTMENT 20 PRINT CUT POSITION ADJUSTMENT Adj Time 130min Total Time 165min MAIN BOARD REPLACEMENT case that the parameters can be transferred by Peck 35 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 in the User Menu 6 PUT PARAMETER 7 TIME AND DATE SETTING Set the date and time in the SERVICE MENU gt SUB MENU gt CLOCK DATE in order of the Year Month Day 8 FIRMWARE VERSION CONFIRMATION OF NETWORK CONTROLLER 9 SENSOR CHECK It can be performed in the SENSOR CHECK 10 CROP MARK SENSOR ADJUSTMENT 11 CROP CUT ADJUSTMENT Necessary when the voltage is adjusted in the CROP MARK SENSOR ADJUSTMENT Adj Time 40min Total Time 75min CUTTING CARRIAGE BOARD REPLACEMENT 7min 1 TOOL UP DOWN CHECK 2 PINCH ROLLER SENSOR CHECK 3 CROP MARK SENSOR ADJUSTMENT 4 CROP CUT ADJUSTMENT Adj Time 23min Total Time 30min CARRIAGE BOARD REPLACEMENT 10min 1 HEAD UP DOWN SENSOR CHECK Only VP 540 2 THERMISTER CHECK 3 LINEAR ENCODER SETUP Adj Tim
190. efective 3 9 BOARDS There might be a problem with the other devices on the Main Broken Main Board Main Board Replacement REPLACEMENT Board if the Fuses are not defective 3 1 HEAD Broken Head Head Replacement REPLACEMENT 6 3 SHIFTING IN PRINTING COLOR SHIFTING REFERENCE If media is not set straight it comes loose on the Platen and The media is set tilted Set the media correctly User s Manual it wrinkles and results in shifting Set the media straight referring to the User s Manual Encoder Scale is Clean or replace Encoder 3 12 ENCODER SCALE When Encoder Scale is not read correctly printing position dirty broken REPLACEMENT may shift If the Heads are not aligned or Horizontal adjustment is not performed properly the color shifting occurs Head is out of adjustment Head Alignment 4 4 HEAD ALIGNMENT Bad contact of Flexible Replace the If the Flexible cable is not fixed correctly the Head moves cable Flexible cable incorrectly and results in the shifting in printing NO 1 Encoder Module is Clean or replace Encoder When Encoder Scale is not read correctly printing position 3 dirty broken Module may shift 6 2 6 4 INK DROPS ON THE MEDIA 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 If media tends to curl or become b
191. en turn off the main power MAIN POWER SW Rear View 2 Remove the following covers CARTRIDGE COVER MaintenanceCover Left Side Cover LeftCover Ink Cartridge Cover LEFT COVER LEFTSIDE COVER MAINTENANCECOVER lt Left Side gt 3 Disconnect the connector of the sensor cable from the Feed Motor Board FEED MOTOR BOARD 4 Remove the Cutter Frame When removing the Cutter Frame remove the CUm Sensor Cable on the back side from the Remove the connector of the Motor Cable Remove the screw as shown in the figure to remove the Grit Encoder Board together with the stay Remove the 3 screws as shown in the figure to remove Grit Encoder Stopper Remove the Grit Encoder ENCODER BOARD 1 a GRIT ENCODER _ IE Make sure not to scratch or leave any fingerprints on the Grit Encoder 3 26 Remove the 4 rivets as shown in the figure and slide the Gear Cover to the front side and remove it 10 Remove the spring SPRING Remove the 3 screws fixing the Flange and remove the motor together with the Flange 11
192. eplacement Cycle 12 months Good Replacement Done Wiper Scraper Replace it as necessary Replacement Done Good Lithium Battery Replacement Cycle 24 months MA Replacement Done Check if the carriage belt doesn t touch the the flanges of the drive Good pulley and idle pulley when the head carriage moves in the full width Carriage Belt Adjust the belt position if necessary Check the belt tension and adjust it if necessary Good 0 Adjustment Done Check A Check if it is not worn out it does not have dirt on it and it rotates Good Mechanical Pinch Roller smoothly L Replacement Done Parts Grit Roller Remove foreign substances stuck on it by using a brush Good Replacement Done Check printin Check that there is no problem with the printing operation and ome 9 printing result Check cuttin Check that there is no problem with the cutting operation and Done 9 cutting result Get report with Get Report of the Peck or print ALL Report in the Service menu Clean it manually using the Roland cleaning stick and cleaning liquid Cleaning Done L Adjustment Done Cutter Protection Replace it depending on degree of scratches on it Output Get report after maintenance 7 12 7 3 Specifications Main unit specification 30 Printing technology Piezoelectric inkjet Media W idth 210 to 1 371 mm 8 3 to 54 in 182 to 762 mm 7 2 to 30 in Thickness Maximum
193. er s interview Replacement Done Reset Replacement Cycle 6 billion shots Nozzle Perform a manual cleaning by using cleaning sticks and cleaning Cleaning Done liquid Output the test patterns for BIAS VERTICAL HORIZONTAL and Good DIR DEFAULT to check the error and perform adjustment if necessary Adjustment Determine if it should be replaced based on MOTOR ERROR and Good MOTOR HOURS S in the History Report the motor sound heard while Carriage Motor printing the report and the customer s interview Put some grease 0 Replacement Done FLOIL G902 on the gear if you replace the motor Replacement Cycle 1 500 hours L Reset Determine if it should be replaced based on the deformation or the time Cleaning Done period from the last replacement If replacement is unnecessary clean them manually using the Roland Replacement Done cleaning stick and cleaning liquid Replacement Cycle 6 months Wiping count 3 000 times or Rubbing count 100 times Check Consumable Cleaning Wiper Parts Determine if it should be replaced based on the performance of the Good cleaning or the time period from the last replacement Cleaning Done If replacement is unnecessary clean them manually using the Roland cleaning stick and cleaning liquid Replacement Cycle 6 months Replacement Done Determine if it should be replaced based on its appearance Sponge for Wiper or the time period from the last replacement R
194. er to 4 11 CALIBRATION v v at When it shows it means CALIB DEFAULT 45 SETTING 4 that it has never been setup and it 5 2 needs to be set In this case even if 4 SETTING 4 0 05 b 0 108 adjustment is unnecessary by the test result 0 must be set here PRINT MENU 45 PATTERN 4 PERFORMING This is for checking the Head 4 TEST PATTERN HORIZONTAL EST PRIN Alignment in Horizontal E ay TEST PATTERN 4 4 PERFORMING zm is for checking the Head N 4 BI DIR 4 ES PRIN oin Ad in Bidirectional 2 v prints on the entire print range N TEST PATTERN 4 PERFORMING with solid single color by each 4 FILL EST PRIN head Print mode is fixed at 720 dpi and 8 pass v 2 TEST PATTERN 4 PERFORMING This print pattern is for checking a m ES PRIN shifting error in Bidirectional and 4 BI DIR CHECK zs also for confirming the mechanical tendency ay PRINT MENU 4 NOW PROCESSING FLUSHING ADJ 4 NOW PROCESSING 4 FLUSHING ADJ 4 SET POSITION This is for adjusting the flushing position For VP 540 set the head height to LOW As entering the menu the Head Carriage moves to the current flushing position With left and right keys move the Head Carriage to the position where the surface of the leftmost Cap Top slightly touches the Head Surface and press ENTER key to save the position As ENTER key is pressed the head is automatically capped
195. ern 06 01 10 13 03 26 Print start Testpattern 06 01 10 11 38 26 Print done Testpattern 06 01 10 13 02 26 Print done Testpattern 06 01 10 11 37 26 Print start Testpattern 06 01 10 13 01 26 Print start Testpattern 06 01 10 11 36 26 Setup done Width 1315mm Env 0 017 06 01 10 13 01 26 Print done Testpattern 06 01 10 11 33 26 Sub power on Service mode 06 01 10 13 00 26 Print start Testpattern 06 01 10 11 29 25 Sub power off 06 01 10 12 59 26 Print done Testpattern 06 01 10 11 28 26 Sub power on Service mode 06 01 10 12 59 26 Print start Testpattern 06 01 10 11 27 25 Main power on Normal 06 01 10 12 58 26 Print done Testpattern 06 01 10 11 27 25 Sub power off 06 01 10 12 58 26 Print start Testpattern 06 01 10 11 27 25 Error Scan motor 00500 06 01 10 12 57 26 Print done Testpattern 06 01 10 11 36 25 Print start Testpattern 4 12 Other Factory Mode 9 INITIALIZE ALL SYS PARAMETER J p SELECT MODEL 540 2 p INITIALIZATION COMPLETED eO SYSTEM PARAMETER INITIALIZE All parameters will be initialized Turn on the Sub Power SW while pressing V and ENTER keys to start the machine in system parameter initialize mode Select the model by pressing and keys Press ENTER key to initialize the system parameter or press the Sub Power SW more than 1 second to cancel it The machine turns off automatically when the initialization is completed All the parameters are reset to the default It is nece
196. es the Normal Cleaning has been performed H4 MEDIUM CL H1 Number of times the Medium Cleaning has been performed H1 MEDIUM CL H2 Number of times the Medium Cleaning has been performed H2 MEDIUM CL H3 Number of times the Medium Cleaning has been performed H3 MEDIUM CL H4 Number of times the Medium Cleaning has been performed H4 POWERFUL CL H1 Number of times the Powerful Cleaning has been performed H1 POWERFUL CL H2 Number of times the Powerful Cleaning has been A performed H2 POWERFUL CL H3 Number of times the Powerful Cleaning has been performed H3 POWERFUL CL H4 Number of times the Powerful Cleaning has been performed H4 AUTO Number of times the Automatic Cleaning has been performed H1 AUTO CL H2 Number of times the Automatic Cleaning has been performed H2 AUTO CL H3 Number of times the Automatic Cleaning has been performed H3 AUTO Number of times the Automatic Cleaning has been performed H4 Clear all the value of the H4 Clear all the value of the H3 Clear all the value of the H2 Clear all the value of the H1 Clear all the value of all the Head CICIT Shots 1007 Life 6 billion Shots nozzle o o ex ex ih o o times times times times er er ex ex o o o o o o o 3 times ex ER ex o o o o o MAINTENANCE GROUP Number of times the Head Maintenance SUB MAINTE
197. firm that the drive part rotates Drive Part IE The operation status of Take up Unit can be confirmed also on the LCD is diplayed on the right side of upper LCD while driving and not displayed while not driving Select STOP with and keys and press ENTER key TU 4 START STOP Jg 4 4 63 Move the Dancer Roller and down by hand and confirm that the drive part does not rotate IE The setting of STOP is canceled when exiting the menu The initial setting is START every time entering TU menu 4 64 5 Supplemental Information 5 1 Special Tools Table shows a list of special tools recommended by Roland DG Corp TORQUE DRIVER N6 HEAD ALIGNMENT TENSION GAUGE 3009 3N TOOL PRESSURE ADJUSTMENT Tool No ST 006 WHITE DUMMY PEN TOOL HEIGHT USTMENT TOOL PRESSURE ADJUSTMENT Tool No 57 013 DIAL TENSION METER DT 100 1009 10 TOOL PRESSURE ADJUSTMENT TENSION GAUGE 2000GF 2000CN BELT TENSION ADJ USTMENT CLEAN STICK TX712A HEAD CLEANING Tool No 21755107 CLEANING LIQUID SL 500ML HEAD CLEANING SOL Tool No 22085118 KIT CLEANING SL HEAD CLEANING SOL Cleaning Liquid Cleaning Sticks 10 pcs 5 Supplemental Information 5 2 SENSOR MAP REAR PAPER SE
198. fore it is completed Check cable connection between Main Board and Servo Board Check the other cable connections of Servo Board Servo Board replacement Main Board replacement Flexible cable replacement Check cable connection between Main Board and Servo Board Check the other cable connections of Servo Board Servo Board replacement Main Board replacement Flexible cable replacement Check cable connection between Main Board and Servo Board Check the other cable connections of Servo Board Servo Board replacement Main Board replacement Flexible cable replacement Check cable connection between Main Board and Servo Board Check the other cable connections of Servo Board Servo Board replacement Main Board replacement Flexible cable replacement Complete Limit Position Initialize correctly Head Lock Sensor does not work correctly or Head Lock Sensor replacement is broken Limit Sensor does not work correctly or is broken Fault of Tool Carriage Connection Loose of Connection Part Fault of the Limit Position Initialize value Limit Sensor does not work correctly or is broken Fault of Tool Carriage Connection Loose of Connection Part Fault of the Limit Position Initialize value Limit Sensor does not work correctly or is broken Linear Encoder Setup has not been done Linear Encoder Setup is ended before it is completed 6 10 Check the mechanical backlash or loose with the scan axis related pa
199. g Screws for the bottom of the screw head to slightly contact with the Stay 2 111 Lt IE Make sure not to tighten the screws too tight accidentally It may move the fixed Drive Pulley Holder 4 58 11 12 13 14 Confirm that the belt is not touching the pulley flanges excessively When the belt is in improper position adjust it again When itis proper leave the belt aging on and go to the following ADJUSTMENT ON THE IDLE PULLEY SIDE ADJUSTMENT ON THE IDLE PULLEY SIDE Confirm the position of the belt The position is proper when the belt is not touching the flanges excessively When the position is proper close this BELT POSITION ADJUSTMENT When itis improper make adjustment as follows IE Belt partly touching the flange is acceptable Press ENTER key to cancel Aging Loosen the 2 Fixing Screws located at the left end of the belt eighth to quarter round IE When the screw is loosen more than necessary it gives difficulty in adjusting the belt Also you need to be careful with the sharp edges around it when turning the screws It may cause injury 4 59 FIXINGSCREW 9 FIXINGSCREW 15 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
200. he figure appears FINISHED d 4 Using the tweezers grasp the bottom portion of the wiper and unhook it WIPERCARRIAGE SCRAPER IE Clean the Wiper Carriage and Scraper using the cleaning stick if they need to be cleaned 3 11 Remove the wiper and install the new one jE Make sure to fix the Wiper so that the rubber side faces the front Use the tweezers to press the area shown in the figure and engage the wiper on the hook S Make sure to engage it on the hook If the wiper is not hooked it may fall off during use Fix the 1 5 Cover and press the ENTER key The Head Carriage moves back to the standby position SCREW and the Head Cleaning starts automatically When the ISCOVER Head Cleaning finishes the screen shown in the figure appears MAINTENANCE 43 REPLACE WIPER 3 12 3 3 CAP TOP REPLACEMENT 1 Remove the 1 5 Cover Move the Head Carriage slowly leftwards to the position where it is not above the Capping Unit 3 Remove the Pump Cover Disconnect the tube the Cap Top from the tube of the 9 Y TUBE JOINT Pump Save the Y tube joint to use later for connecting the tube ofthe new Cap Top 3 13 Unhook the Cap Frame while holding
201. ichever is greater ting when reloading media 3 6 Print heater setting range for the preset temperature 30 to 45 C 86 to 112 F Media heating system 7 Dryer setting range for the preset temperature 30 to 50 C 86 to 122 F Connectivity Ethernet LOBASE T 100BASE TX automatic switching Power saving function Automatic sleep feature Power requirements 100 10 120V 10 8 3A 50 60 Hz or 220 to 240V 10 4 3 50 60 Hz AC100to 120V 10 5 8 50 60 Hz 220 to 240V 10 3 0 A 50 60 Hz Power consumption During operation Approx 1 110 W Approx 780 W Sleep mode Approx 34 W Approx 33W Acoustic noise level During operation 64 dB A or less according to ISO 7779 64 dB A or less according to 150 7779 D uring standby 40 dB A or less according to ISO 7779 40 dB A or less according to ISO 7779 Dimensions with stand 8 2 310 W x 740 D x 1 125 H mm 90 9 W 29 1 D x 44 3 in 1 700 W x 740 D x 1 125 H mm 66 9 W x 29 1 D x 44 3 H in W eight with stand 109 kg 240 Ib 87 5 kg 193 Ib Environmental Power on 9 Temperature 15 to 32 59 to 90 F 20 C 68 F or more recommended humidity 35 to 80 RH non condensing Power off Temperature 5 to 40 C 41 to 104 F humidity 20 to 80 RH non condensing Accessories etc
202. in for confirmation Adjustment is completed if the position of cut line is satisfactory If not repeat the adjustment again TREND Right Base 0 3mm Broken line is indicating the cut line 4 45 4 11 CALIBRATION FEEDING DIRECTION Referential Time 20 This adjustment is for calibrating the feed amount of media It allows the media to be fed proper amount by calibrating the variation in Grit Roller diameter Calibration is made based on the value in feeding media PET G Without proper calibration it may cause misalignment in the feed amount of media and it results in the problems such as white banding banding of overlap or the dimension error of print result compared to the original data Take up Unit must not be used during this adjustment 1 Turn on the Sub Power SW while pressing lt d V and gt keys to enter the Service Mode 4 gt o Setup the PET G on the machine MENU 4 SERVICE MENU 2 Select PRINT MENU CALIB DEFAULT gt TEST SERVICE MENU 4 PRINT and press ENTER key PRINT MENU Test Pattern will be printed 2 v PRINT MENU 45 E Test print requires 510mm or more of the CALIB DEFAULT media setup width Y CALIB DEFAULT 49 TEST PRINT J 4 Measure the length of the feed direction and use the value to cal
203. inch Roller REPLACEMENT 6 7 6 10 MOTOR ERROR NO CHECKING POINT ACTION There is a dirt in teeth of When the Drive Gear has some dirt on its teeth and cannot Clean Drive Gear Drive Gear rotate Motor Error occurs Back tension of media is When using hard to unroll or too heavy media Motor Error too high occurs due to the too much load for feeding the media REPLACEMENT follow the order from the CPU and it results in a Motor Error When the Motor Driver is broken the power supply voltage for Broken Servo Board Servo Board replacement the motor is not supplied and the motor cannot move It results in a Motor Error Power Supply for Motor is Replace the switching 3 9 BOARDS When the Power Supply voltage for the Motor is not supplied power supply REPLACEMENT the Motor cannot move and it results in a Motor Error Broken life of the Motor Motor replacement 3 5 CARRIAGE MOTOR When the Motor is broken or reaches its life the Motor cannot ERROR DESCRIPTION SCAN MOTOR ERROR CODE 0000 0000 Error detected at first Error detected as a result No v MEANNG Feed Motor Deviation Error 0001 The order from the CPU does not match the lt External factors gt feedback of the Feed Motor 1 Media Jamming Feed Motor Overcurrent Error 1 2 Carriage is moved by hands 0004 Big load is put on the motor movement 3 Carriage runs into a thing hand instantane
204. isalignment of printing and cutting This calibration is to be used only when performing cutting only Preset function 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 EDGE DETECTION SCAN INTERVAL VACUUM POWER FULL WIDTH S FEED FOR DRY CALIBRATION in the CUTTING Cutting conditions ADJUST BI DIR CALIBRATION for printing PRINT CUT ADJ CROP CUT ADJ PREHEATING Maintenance Explain the following items referring to the User s Manual LI Disposing of discharged ink CHECK DRAIN BOTTLE message appears when a certain amount of discharged fluid collects in the bottle IMPORTANT When you dispose of discharged ink make sure to reset the discharged fluid count from MENU gt SUB MENU gt MAINTENANCE gt DRAIN BOTTLE and press the ENTER key Otherwise CHECK DRAIN BOTTLE message appears at the inappropriate timing Never place discarded fluid in the location close to fire To store discharged fluid temporarily use the included drain bottle or durable sealed container such as a metal can or polyethylene tank and cap it tightly Dispose of discharged fluid properly in accordance with your local laws 7 9 Cleaning the parts other than the print heads Pinch Rollers Grit Rollers Platen
205. it Sensor Encoder Scale or Encoder Module is replaced or the position is adjusted 1 Turn on the Sub Power SW while pressing lt q and gt keys to enter the Service Mode 4 gt v e v MENU 4 SERVICE MENU 2 Lower the Pinch Rollers Make sure to unload the media when it is set on the machine Also the Media Clamps must be removed 3 Select PRINT MENU LINEAR ENCODER and press ENTER key SERVICE MENU 4 PRINT MENU v PRINT MENU lt LINEAR ENCODER 4 NOW PROCESSING POS 1361 00mm 4 34 One of the messages appears at the completion of the set up In case of Setup error check the followings Dirt Scratch on the Encoder Scale Dirt Scratch on the Encoder Module Encoder Scale is not between the Encoder Module Backlash of the Carriage Motor Gear and the Drive Gear Fixation between the Carriage and the Carriage Belt Bad Contact in the cables When LINEAR ENCODER SETUP is completed perform the LINEAR CALIB in the Service Menu In case of an error check the followings Dirt Scratch on the Encoder Scale Dirt Scratch on the Encoder Module Encoder Scale is not between the Encoder Module Backlash of the Carriage Motor Gear and the Drive Gear Fixation between the Carriage and the Carriage Belt Bad Contact in the cables 4 35
206. key lt TEST PATTERN gt Correction value scale Cutline CUTTING MENU 45 PRINT CUT ADJ v PRINT CUT ADJ 4 SETTING gt Select PRINT CUT ADJ gt TEST PRINT and press ENTER key The test print and cut will be performed 3 marks are printed at the left end right end and the center of the media and each mark is cut Confirm the cut line positions on the marks visually If it is difficult to see the cut line visually use a magnifier 4 44 CUTTING MENU 4 PRINT CUT ADJ D PRINT CUT ADJ 4 TEST PRINT J 4 Broken line is indicating the cut line 8 Adjustment is completed if the position error of cut line is within the range below If not select SETTING menu CUTTING MENU 4 again for further adjustment PRINT CUT ADJ p gt v Mark on the right Within 0 1mm Mark on the left Within 0 PRINT CUT ADJ 42 Make an adjustment based on the mark on the SETTING right key M t ition t ds front F 0 30 0 30mm Moves position towards fron 8 0 40 0 40mm J key Moves cut position towards rear key Moves cut position towards right 9 4 Moves cut position towards left ENTER key Saves new setting Fine Adjustment MENU key Moves out SETTING menu Perform the test print aga
207. les for both scan and feed direction and then cuts crosswise ay SERVICE MENU 4 FRSHODPULWwab 4 234 4 4 gt I SENSOR CHECK 4 nee H 4 EC AY This menu displays the real time status of each sensor It shows when the sensor is ON The first page shows the status of each sensor Each alphabet stands for as follows ch F Front Paper Sensor U Head Up Down Sensor Head Up Down Sensor VP 300 Fixed Each color has 2 positions and the left side R Rear Paper Sensor L Sheet Load Sensor H Head HIGH on the display shows the left side head S Crop Mark Sensor W Pinch Roller Sensor L Head LOW H Head Lock Sensor w Wiper Sensor Blank Cartridge not inserted Ink remains imit Sensor a TU Motor Drive Sensor TU Motor Drive Sensor C Cartridge inserted Ink remains D Side Cover Sensor When TU is connected Driving E Cartridge not inserted Ink empty P Maintenance Cover Sensor b Not in use Blank Not driving Cartridge inserted Ink empty b SERVICE MENU 4 THERMISTOR This is for checking Thermistor It displays the temperature read from the thermistor placed on the board of the Head1 THERMISTOR HEAD 25 Qf TIF The temperature on the left is in Celsius and the right is in Fahrenheit Av Since the temperature of the device possibly rises it normally shows higher temperature than the room temperature v
208. m User s Manual ink drys too fast it may result in banding because the dots heater is inappropriate temperature stay small afetr landing on media Bi directinal adjustment is setting for 4 KORR User s Manual not correct Bidirectional Printing Feed Calibration is not Apply Calibration Users Manual If the calibration is not correct white fine line caused by gaps correct or dark line caused by overlapping appears Scanning distance of the Set the FULL WIDTH S Set FULL WIDTH S to FULL to uniform the heating time on User s Manual os Head Carriage to FULL each pass This may improve printing quality Set PERIODIC to When this is set to to 990 min self cleaning is 7 PERIODIC CL setting User s Manual performed while a printing is paused And it may cause NONE or Page An 3 uneven printing at the part before and after cleaning 3 1 HEAD Head Rank setting affects the amount of the fired Ink If it is Set lead Rank REPLACEMENT not set properly the ink dots are not fired in appropriate sizes Check whether each BIAS VERTICAL HORIZONTAL Head is out of adjustment Head Alignment 4 4 HEAD ALIGNMENT and BI DIR DEFAULT settings are correct 11 Foreign substances stuck Manual Users Manual Nozzle condition becomes poor due to the foreign substances on the head 9 stuck on the surface of the Head 42 Wiper wears out Widerreplacement 3 2 WIPER Wipi
209. mage of driver IC placed on Ink Tank Board SLOTI 4 SYSTEM ERROR Data error SLOTI 4 DATA ERROR S M ec uf gt SERVICE MENU 4 CUTTING MENU 4 CROPMARK SENSE 444 MIN 0 7V MAX2 3 4 m gt gt CUTTING MENU 4 CROPMARK SENSE p 4 OUTLEVEL CHECK 4 4 2 0V v This is for adjusting the level of Crop Mark Sensor Refer to 4 8 CROP MARK SENSOR ADJUSTMENT CROPMARK SENSE 49 ADJUST 4 ADJUST 4 2 1 This is for adjusting the Crop Mark Sensor sensitivity There are 3 levels of sensitivity O 1 2 This adjustment may help when Crop Mark detection is failed with the default level setting Default 0 av CUTTING MENU 4 FORCE ADJUST 4 30gf 45 7 lt gt 74 g This is for adjusting the Tool Pressure FORCE ADJUST 4 305 4 17 gt 16 4 Refer to 4 13 TOOL PRESSURE ADJUSTMENT AY 30gf Range 0 to 30 Default 17 200gf Range 31 to 80 Default 56 FORCE ADJUST 4 200gf 4 4 200gf 4 56 57 4 CUTTING MENU 4 CROP CUT ADJ 4 PERFORMING This test pattern is for adjusting the cut position UN CROP CUT ADJ 4 TEST
210. n 1 00 Subnet Mask 255 255 255 000 Ink remain 1 4 76 62 59 73 Serial No XXXXXXX Gateway Address 000 000 000 000 Date 2007 01 11 14 19 MAC Address 00 40 00 0 1 Head Temperature 27 82 4 F Heater temp PRINT 2870 89 F Heater temp DRYER 26 78 F Menu language Japanese Calibration 1 00 Vacuum power Auto Length unit mm Full width scanning FULL Set remain at loading Disable Temperature unit Scan interval 0 0 sec Heater setting PRINT 35 C 94 F Head height Low Sleep Enable Heater setting DRYER 40 104 F Edge detection Enable Sleep interval 30 min Feed for dry Disable Empty mode Stop Sheet remain 0 0m Preheating PREHEAT Bi dir simple 0 Periodic cleaning NONE Media clamp SHORT H1 H2 H3 H4 H1 H2 H3 H4 Bi dir adjust No 1 4 5 4 3 5 3 5 No 3 5 4 4 4 5 No 2 i 0 0 0 0 No 4 2 2 2 5 2 Tool parameter Force 90 gf Cutting calib F S 0 00 0 00 Cutting priority Command Velocity 30 cm s Print cut adjust F S 0 00 0 05 mm Prefeed Disable Offset 0 250 mm Crop cut adjust F S 0 10 0 05 mm Auto Env Match Enable Up velocity 30 cm s Preset name PRESETTING1 Calibration 0 00 8 Scan interval 0 0 sec Force 50 gf Cutting calib F S 0 00 0 00 Heater setting PRINT 35 C 94 F Edge detection Enable Velocity 30 cm s Print cut adjust F S 0 00 0 00 mm Heater setting DRYER 40 C 104 F Full width S FULL Offset 0 250 mm Crop cut adjust F S 0 00 0 00 mm Feed for dry Disable
211. n of the Flange Fix the Flange with the 3 screws temporarily 3 21 Fix the spring 9 Check the gears mesh without backlash in the following procedure 1 Unlock the Head Carriage 2 Turn the Drive Gear by hand and check there is no backlash all the way around 3 Move the Head Carriage by hand to the lock position 3 22 SPRING 10 11 Tighten up the 3 screws to fix the Flange in the order shown in the figure Apply proper quantity of grease FLOIL 5902 between gears Connect the connector of the Motor Cable 12 E 13 Fixthe Chassis Cover Right Top Cover and Panel Cover When fixing the Panel SENSOR Cover fix the sensor on the back side of the Panel Cover and connect the flexible cable to the Panel Board FLEXIBLE CABLE Back Side lt gt RIGHT TOP COVER PANEL COVER CHASSIS COVER 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 3 23 v v M
212. ng does not work effectively and foreign substances left REPLACEMENT on the head surfaces cannot be removed completely Cleaning does not work effectively and the nozzle condition 1 Defect of Cap Top Cap Top replacement BS CAF TOF cannot be improved Also if the head is not capped correctly REPLACEMENT the head dries and may cause the head nozzle clogging 3 Ciean the head sudace Generally we do not recommend to wipe the surface of Head 14 Head nozzle is clogged using the cleaning stick with a cleaning stick Howerver it s worth trying before Manual Cleaning replacing the Head Soak the cleaning stick in cleaning liquid 9 fully and then tap and scrub the surface of Head with it 3 1 HEAD Broken Head Head replacement REPLACEMENT 16 Broken Pump Pump replacement Ink suction during cleanings does not work and the nozzle condition cannot be improved 6 1 6 2 PARTICULAR COLOR IS NOT PRINTED ALL When the machine keeps printing with ink cartridge almost Ink Cartridge is almost Check remaining Ink saris anual empty the negative pressure delivered in the ink tube causes empty Replace the Ink Cartridge the improper ink supplying and the head cannot fire the ink correctly If the cartridge tab does not stick out when it is empty it cannot detect it empty and printing is continued without firing ink Also if the sensor is not working Ink Empty cannot be detected even if the cartridge tab sticks out
213. ng the Encoder Plate Move the Head Carriage in a whole width of the machine Make sure that the Encoder Scale doesn t make contact with the Encoder Module and also Encoder Scale is between the slit of the Encoder Module Carry out the 4 6 LINEAR ENCODER SETUP 3 66 3 13 GRIT ENCODER REPLACEMENT 1 Turn off the sub power and then turn off the main power 2 Remove the following covers MaintenanceCover Left Side Cover LeftCover Remove the screw as shown in the figure to remove the Grit Encoder Board together with the stay Remove the 3 screws as shown in the figure to remove Grit Encoder Stopper 3 67 c MAIN POWER SW Rear View LEFTCOVER LEFTSIDE COVER MAINTENANCE COVER lt Left Side gt ENCODER BOARD GRITENCODERSTOPPER 7 Replace with the new Grit Encoder The both sides of the Grit Encoder is the same When fixing the Grit Encoder make sure not to scratch or leave any fingerprints on the Grit Encoder Fixthe Grit Encoder Stopper with the 3 screws as shown in the figure by holding the Shaft Fix the Grit Encoder Board together with the stay so that
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215. o any flammable object or in a gas filled location It causes a risk of combustion or explosion Install in a clean brightly lit location Conduct operations in a clean brightly lit location Working in a location that is dark or cluttered may lead to an accident such as becoming caught in the machine as the result of an inadvertent stumble Position so that the power plug is within immediate reach at all times This is to enable quick disconnection of the power plug in the event of an emergency Install the machine next to an electrical outlet Also provide enough empty space to allow immediate access to the electrical outlet Ensure adequate ventilation for the work area Failing to perform ventilation may result in a health hazard or danger of combustion due to ink fumes Ki Checking the Accessories K Power cord 1 Arm right 1 Arm left 1 Casters 2 Stand leg 1 Shafts 2 Stoppers 2 3 Bolts 26 49 1 Short media clamps 2 Long media clamps 2 Media wrench 1 left and right left and right flanges 2 Installed on the machine Nera vv nk cartridge Middle pinch rollers 1 Blade holder 1 1 5 540 Pin 1 blade for separa 2 VP 300 ting knife 1 Installed on the machine gos 2 E SOL INK cleaning Software RIP 1 U
216. orks Install Roland VersaWorks in reference to the Quick Start Guide System requirements for installing the software Operating system Windows XP Professional Service Pack 1 or later or Windows 2000 Service Pack 4 or later CPU Pentium 4 2 0 GHz or faster Memory RAM 512MB and above 1GB or more recommended Monitor High resolution SXGA 1 280 x 1 024 pixels or better display recommended Free hard disk space required as a working space 40 GB or more recommended Hard disk file system NTFS format Make the setting for Select the check box Download Updates Automatically and Notify if the customer accepts it Power saving setting on PC Turn off the PC s Power saving functions which make the PC goes stanby or sleep It may stop a job being output ES 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 Leave the power on at times Maintenance operation is automatically carried out every 24 hours while the machine is not in use Use the sub power switch for the daily powering on and off 7 5 Loading and cutting off media For the stable media feeding place the middle pinch rollers above all the grit rollers that lie between the left and right pinch rollers T PORTANT Perfo
217. ould break lt Do not hold both sides of the Damper Make sure not to press it to the Dampers Dampers could break Fix the screws at the lower end of the long screw hole 416 lt 540 gt lt 300 gt 16 Fix the Damper Plate and then turn on the sub power right and down keys to enter the m 5 D E cg 35 c 8 92 3 C e 0 18 19 Select SERVICE MENU gt SUB MENU gt HEAD REPLACE and perform Head Cleaning and filling ink by following the sequences f you dispose of the drained ink the drain counter needs to be reset Select SUB MENU gt MAINTENANCE RESET DRAIN COUNTER in the User s menu and press the ENTER key Enter the Service Mode and perform the following adjustments 1 THERMISTER CHECK 2 4 4 HEAD ALIGNMENT 3 4 7 FLUSHING POSITION ADJUSTMENT 4 4 9 CROP CUT ADJUSTMENT 5 4 10 PRINT CUT POSITION ADJUSTMENT 3 9 SERVICE MENU 4 SUB MENU gt SUB MENU 4 HEAD REPLACE p gt gt CHECK DRAIN BOTTLE 4 SET SOLCL LIQUID lC 2 2 FILLING INK gt gt gt EMOVE SOL CL 1234 FILLING INK gt gt gt DRAIN BOTTLE 4 ENTER SET SOL CRT 1234 FILLING INK
218. ously 4 Media is stuck because it is caught by the paper pipe 5 Media is pulled forcedly Feed Motor Overcurrent Error 2 6 Loaded Media is too heavy 0008 A little load is put on the motor movement for a long time lt Machine factors gt 0005 0001 and 0004 occurred at the same time 1 The grease lubrication of the motor gear is not enough 2 Motor is broken Life 0001 and 0008 d h 3 Servo Board is broken 0009 an occurred at the same time 4 Tool Carriage fixation to the belt is loose Scan Motor Deviation Error 0010 The order from the CPU does not match the feedback of the Scan Motor Scan Motor Overcurrent Error 1 0040 Big load is put on the motor movement instantaneously Scan Motor Overcurrent Error 2 0080 A little load is put on the motor movement for a long time 0050 0010 and 0040 occurred at the same time 0090 0010 and 0080 occurred at the same time 6 11 HEATER DRYER TEMPERATURE DOES GO UP REFERENCE The media is loaded Set up the media User s Manual 277 Inappropriate temperature is set on the machine When the setting of print heater dryer is off the Heater does not operate Check the temperature User s Manual setting When media is narrow the air cooling effect by the vacuum fan increases and it takes time for the heater temperature to go up Media width is too small Use a wider media In cold environment it may take a long time or the Heater User
219. ptimizing printing and cutting Explain the following items referring to the User s Manual Optimizing printing to match Media thickness Head height VP 540 only Bi direction adjustment Feed calibration IMPORTANT These adjustments are required for each Media individually If you are setting Feed Calibration on your machine check in advance that Use Printer Settings is set on Roland VersaWorks Feed Calibration Controls Use Printer Settings Y Optimizing printing and cutting to match Media thickness Bi direction adjustment Print Cut position adjustment IMPORTANT These adjustments are required for each media and also when the head height is changed Make sure to perform Bi direction adjustment before Print Cut position adjustment Correcting misalignment for printing and cutting when using Crop Marks Bi direction adjustment Crop Cut adjustment These adjustments are required when printing and cutting using Crop marks are not aligned Make sure to perform Bi direction adjustment before Crop Cut adjustment AUTO ENV MATCH function IMPORTANT This function is for correcting the Print amp Cut misalignment caused by the stretch shrinkage of Encoder Scale Make sure to set it to ENABLE at all times 7 8 Calibration for cutting IMPORTANT During Print amp Cut CALIBRATION in the CUTTING MENU is to be set to 0 It may cause a m
220. rming a sheet cut when the long media clamps are installed causes interference with the separating knife which may result in malfunction or damage to the machine When you use the long media clamps set the MEDIA CLAMP menu item to LONG to disable the sheet cut Settings for the Media Heating System PORTANT Do not set the print heater temperature too high If the ink dries too fast the diameter of the ink dots land on the media cannot expand enough and it may result in bandings Starting printing or cutting Pausing and canceling a printing or cutting Setting a starting position of printing or cutting Base posint setting Printing test and cleanings Test print Normal cleaning Medium cleaning Powerful cleaning E Large amount of ink is consumed for the Powerful cleaning Checking for remaining Ink Explain the EMPTY MODE T ORTANT The remaining ink amount shown on the machine and RIP is only an approximate guide which may differ somewhat from the actual amount remaining Installation amp Handling of the ink cartridges Shake the cartridge gently before installing a ECO SOL MAX ink cartridge Be sure to replace with an item of identical type Never mix items of different types Never leave the machine with any ink cartridge removed The print heads may become clogged Never frequently insert and remove an ink cartridge Air may leak into the ink tube and
221. rts Limit Sensor replacement Check the mechanical backlash or loose with the scan axis related parts Check the mechanical Backlash or loose with the Tool Carriage part Connection Part Replacement Limit Position Initialize Check the mechanical Backlash or loose with the Tool Carriage part Connection Part Replacement Limit Position Initialize Carry out Linear Encoder Setup in service menu Even though the machine carries out the regular movement the output of the Wiper Sensor does not reach the expected value Input value from Linear Encoder is not Wiper Motor error Defect of Wiper Unit Defect of Wiper Sensor Cut line or short circuit of cable and Flexible cable Read error of Linear Encoder changed by the Linear Encoder origin setup Read error of Encoder on Scan Motor side When Motor stops during printing expected Belt is not fixed to Head Carriage firmly movement is not completed on some head Dryer temperature has reached 80 C and above Cartridge IC driver cable has short circuited or cut line Thermistor cable has short circuited or cut line Thermistor has a problem Thermostat has a problem Thermistor has a problem Thermistor cable has short circuited or cut line Thermistor has a problem Dryer cable connection has a problem Thermostat has a problem Thermistor has a problem Wiper Motor Replacement Wiper Unit Replacement Wiper Sensor Replacement Cable and Flexibl
222. s 1 1 HOLDER CABLE SHEET 2 1 1 1 1 4 1 FLEXIBLE CABLE x 3 CABLE HOLDER 1 1 o o HOLDER CABLE PLATE 5 5 1 TUBEGUIDE 3 75 TUBE CABLE HOLDER E Make sure that the fixing direction of FLEXIBLE CABLE CABLE HOLDER the Holder Cable Plate is correct HOLDER CABLE SHEET HOLDER CABLE PLATE NG HOLDER CABLE PLATE OK Fix the 2 Tube Guides Connect the flexible cables to the Carriage Board and fix them to the clamps In case of replacing the tube guides cross the tubes two by two as shown in the figure when fixing the tubes to the tube guides lt Back Side gt TUBEG DES CARRIAGE BOARD FLEXIBLE CABLE Make sure that the tubes do not touch the plate and Cable Guide Support Cross PLATE CABLE GUIDE SUPPORT m Cross the tubes two by two as shown in the figure and fix them to the Clamps Back Side 3 76 1 Connect the tubes to the Y tube joints Fix them to the Clamps 15 Fixthe Carriage Cover 16 Fix the Cut Cable Guide VP 300 1 Fix the Cut Cable Guide with the 3 screws as shown in the figure lt VP 540 gt 1 Fix the Cut Cable Guide with the 3 screws as shown in the figure 3 77 ray NR
223. s is for checking the installation and Error beeps 2 times LINEAR ENCODER 4 Eroris found on Linear operation of Linear Encoder and Scale SETUP FAILED Encoder and Scale Refer to 4 6 LINEAR ENCODER SETUP Normal beeps 1 time PRINT MENU 42 NOW PROCESSING ILINEAR CALIB 4 4 LINEAR CALIB 4 SETUP COMPLETED 1 24 LINEAR CALIB lt 4 0 18 1 This is calibrating the cutting size in the scan direction by calculating the expansion and contraction amount of the Encoder Scale Error beeps 2 times LINEAR CALIB 4 FAILED TO SETUP aw 4 c PRINT MENU 4 CALIB DEFAULT 4 PERFORMING This menu is used for Calibration 4 CALIB DEFAULT b 41 EST PRINT TEST PRINT Ref
224. s selectable considering the case of head REPORT SERVICE REPORT 4 HEAD H1 trouble Select a head with keys and press ENTER key to start printing AY H1 H2 H3 H4 SERVICE Service Report is printed It prints the Service Information additionally to the System Y Report of the standard menu HISTORY History Report is printed REPORT 4 HISTORY REPORT 4 CARTRIDGE Ink Cartridge IC Report is printed It lists the information written on the IC of the Ink I e Cartridges installed on the machine 4 HISTORY REPORT 4 HEAD H1 EVENT LOG Event Log Report is printed The number of Event to be printed is selectable from AY P 100 200 ALL 400 H1 H2 H3 H4 ALL All Reports are printed together System Report Service Report History Report AY Ink Cartridge IC Report Event Log Report SERIAL Service Report and History Report can be sent to RS 232C Serial using special tool REPORT 4 CARTRIDGE 45 9600bps N81 X ON OFF 4 CARTRIDGE 4 HEAD H1 H1 H2 H3 H4 REPORT 4 SELECT MAXIMUM4 EVENT LOG 45 gt lt equired Printing Area 4 EVENT LOG 4100 LOGS HEAD 1 Pr 4 Av Options 100LOGS 200LOGS ALL ME CARTRIDGE W180 L35mm EVENT LOG 100 LOGS W280 L155mm REPORT lt 24 EVENT LOG 200 LOGS W280 L285mm 4 SERIAL 4 EVENT 1 400 W280 L545mm 4 7 HISTORY MENU MOTOR GROUP Contents MOTOR FEED Total time that the
225. s shown in the figure lt VP 540 gt 1 Fix the Cut Cable Guide with the 3 screws as shown in the figure pel CUT CABLE GUIDE 2 Fixthe Cable Support with the 3 screws as shown in the figure SCREW CABLE SUPPORT Top View 3 44 15 Adjust the position of the flexible cable so that it comes in the middle of the Protection Plates PROTECTIONPLATE FLEXIBLE CABLE 1 After turning the main power turn on the sub power 0 while pressing the left right and down keys to enter the oco Service Mode v MENU 4 SERVICE MENU 17 Select SERVICE MENU gt SUB MENU gt FILL INK and perform Ink Filling by following the sequences SUB MENU
226. ser s Manual 1 cartridges 2 Cleaning kit L Cleaning sticks 10 Tweezers 1 Replacement Setup Guide 1 wipers 2 7 3 Installation and Preparation Set up following items in reference to the Setup Guide 3 Assembling and Installing to 7 Network Settings Assemble the Stand Attach the Shafts Install the Drain Bottle Revised 1 careful to pinch the drain tube Drain Tube Drain Tube NG OK Cable tie Drain Bottle Drain Bottle Drain Bottle VP 540 ZV71196 and below VP 540 ZV71197 and above VP 300 ZV70554 and below VP 300 ZV70555 and above Attach the Ink cartridge Tray Remove the Packing Materials Connect the Cables Install the Ink Cartridges IMPORTANT Shake the Ink Cartridge a few times gently before installing to the machine Install the Blade Make the Network Settings IP address of PC Revised 1 IP address of VP 540 300 Upgrading the Firmware Upgrade the firmware to the latest version Revised 5 Setting Date and Time Go to SERVICE MENU gt SUB MENU gt CLOCK and set date and time to the local time SERVICE MENU 49 SUB MENU DATE DATE SUB MENU CLOCK 05 09 10 05 09 10 Year Month Day Year Month Day TIME TIME 01 01 59 01 501 59 7 4 Installing Roland Versaw
227. ssary to initialize the limit position after this initialization SERVICE CALL 0101 occurs without initializing the limit position LANGUAGE UNIT SELECTION e v Roland DG Corp VP 540 MENU LANGUAGE amp ENGLISH 4 Y 4 LENGTH UNIT mm gt INCH y Y 4 TEMP UNIT OC Um CBE ao SERVICE REPORT PRINTING Turn on the Sub Power SW while pressing W key to start the machine in the service report printing mode The service report will be printed automatically when the media is set v up It prints with Black ink Printing Area W270 L360mm The machine turns to be the normal mode after printing 4 13 Key Combinations Function for Service Combination Key Selection 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 F W Installation Mode for a brand new Main Board SUM ERROR will be displayed POWER Press ENTER to upgrade F W System Parameter Ve All parameters will be initialized Initialize Press ENTER to start initialize Limit Position Cut Down A Press ENTER to initialize Limit Position Initialize gt 2 Then set Cut Down Position Service Report will be printed Service Report It is the same as the Service Report
228. start Testpattern 06 01 10 12 03 27 Print start Testpattern 06 01 11 14 55 28 Setup done Width 932mm Env 0 034 06 01 10 12 02 26 Print done Testpattern 06 01 11 14 54 28 Sub power on Service mode 06 01 10 12 01 26 Print start Testpattern 06 01 11 14 39 28 Sub power off 06 01 10 12 01 26 Print done Testpattern 06 01 11 14 38 28 Print done Testpattern 06 01 10 12 00 26 Print start Testpattern 06 01 11 14 36 28 Print start Testpattern 06 01 10 11 59 26 Print done Testpattern 06 01 11 14 36 28 Print done Testpattern 06 01 10 11 59 26 Print start Testpattern 06 01 11 14 36 28 Print start Testpattern 06 01 10 11 50 26 Setup done Width 1217mm Env 0 014 06 01 11 14 35 28 Print done Testpattern 06 01 10 11 49 26 Sub power on Service mode 06 01 11 14 33 28 Print start Testpattern 06 01 10 11 48 26 Sub power off 06 01 11 14 32 28 Setup done Width 932mm Env 0 031 06 01 10 11 47 26 Print done Testpattern 06 01 11 14 28 28 Sub power on Service mode 06 01 10 11 47 26 Print start Testpattern 06 01 10 23 57 28 Sub power off 06 01 10 11 45 26 Print done Testpattern 06 01 10 13 10 26 Print done Testpattern 06 01 10 11 44 26 Print start Testpattern 06 01 10 13 10 26 Print start Testpattern 06 01 10 11 42 26 Print done Testpattern 06 01 10 13 06 26 Print done Testpattern 06 01 10 11 40 26 Print start Testpattern 06 01 10 13 04 26 Print start Testpattern 06 01 10 11 39 26 Print done Testpattern 06 01 10 13 04 26 Print done Testpattern 06 01 10 11 39 26 Print start Testpatt
229. t In this case SW Power Supply will output the voltage by rotating the volume counterclockwise When the protection circuit works SW Power Supply may not output for a while Measure the voltage some time later again 9 Put back the Chassis CHASSIS 10 Fix the Chassis with the 4 screws as shown in the figure 11 Connect all the cables to the SW Power Supply FLEXIBLE CABLE 3 56 3 10 BATTERY REPLACEMENT CAUTION Danger of explosion if battery is incorrectly replaced Replace only with the same or equivalent type recommended by the manufacturer Dispose of used batteries according to the manufacturer s instructions ATTENTION Il y a danger d explosion s il y a remplacement incorrect de la batterie Remplacer uniquement avec une batterie du m me type ou d un type quivalent recommand par le constructeur Mattre au rebut les batteries usag es conform ment aux instructions du fabricant ADVARSEL Lithiumbatteri Eksplosionsfare ved fejlagtig handtering Udskiftning ma kun ske med batteri af samme fabrikat og type Lev r det brugte batteri tilbage til laverangren Z WARNING Do not recharge short circuit disassembly the lithium battery nor put it into fire It may cause heat explosion and fire Q Put tape around the lithium battery for insulation for disposal or preservation It may cause heat
230. t Peck used count Cutting group Cutting time Disconnect carr cut count count 97 times 37 hours 2 hours 33 times 0 times 0 hours 67 times 4 11 hours hours times XXXXXXX 2007 01 11 14 24 0 0 0 INK CARTRIDGE REPORT Ink Cartridge Report Model VP 540 Serial No Version 0 50 No SERIAL INK TYPE CAP LOT No CONSUM TIME INS FLAG 1 14d178b002000071 eSOL K 200cc 60907A 47 879cc 0y015d04h14m08s 1 00000000 2 000000018ebb7700 eSOL C 200cc 61004A 75 914cc 0y015d04h14m03s 1 00000000 3 000000018ef67200 eSOL M 200cc 61021A 81 901cc 0y015d04h13m58s 1 00000000 4 000000018f613b00 eSOL Y 200cc 61026A 53 789cc 0y015d04h13m52s 1 00000000 EVENT LOG REPORT Event log Report Model VP 540 Serial No XXXXXXX Version 0 50 Date 2007 01 11 17 20 Date Time Temp Event Information Date Time Temp Event Information 07 01 11 17 20 27 Print start Testpattern 07 01 10 1 26 Print start Testpattern 06 01 11 17 19 27 Print done Testpattern 07 01 10 12 56 26 Print done Testpattern 06 01 11 17 18 27 Print start Testpattern 06 01 10 12 55 26 Print start Testpattern 06 01 11 17 17 27 Print done Testpattern 06 01 10 12 55 26 Setup done Width 926mm Env 0 038 06 01 11 17 14 27 Print start Testpattern 06 01 10 12 53 26 Can
231. ter than regular cleaning only NORMAL MEDIUM The regular NORMAL MEDIUM cleaning Ay SUB MENU 4 This is for checking the operation of fans Press ENTER key for ON OFF of fans 4 FAN CHECK 4 VACUUM FAN Fan turns off automatically as exiting this menu Av av 2 aj SUB MENU 4 4 gt TU lt Selecting START the operation of TU can be 4 TU CHECK 410 gt gt STOP 4 confirmed by manually moving the dancer roller of TU Aw The driving status of TU is indicated on the upper right PM E apa as woe oe Bg of the display It shows while driving and it is blank When Take Up unit is not connected when not driving Also selecting STOP make sure TU IS does not drive when the dancer roller is moved Once back out this menu the initial status here is always NOT CONNECTED 4 1 START despite what is selected before 1 Y 207777777770 y SUB MENU 45 CLOCK DATE 4 DATE 45 k Revised 4 4 CLOCK 4105 09 10
232. to remove the Cable Support 12 Pull the flexible cable to access the screw FLEXIBLE CABLE dd CABLE SUPPORT lt Back 5 gt lt gt 2 Remove the 3 screws to remove the Cut Cable Guide CUT CABLE GUIDE 6 Remove the Carriage Cover CARRIAGE COVER 3 41 10 Disconnect the ink tubes Carriage Side from the Y tube joints and put the scotch tape at the tip of the ink tube to prevent the ink from coming out E It is not necessary to replace the ink tubes of the other side Carriage Side of the joints Disconnect the ink tubes Cartridge Side from the tube joints and put the scotch tape at the tip of the ink tube to prevent the ink from coming out E It is not necessary to replace the ink tubes of the other side Cartridge Side of the joints Pull out the ink tubes and put the new ink tubes in the Tube Guides Each four tubes are connected and the lengths of both ends are different Be careful with the fixing direction of tubes P No P Name 1000002670 TUBE SJ RDG3 4 4 VP 300 1000002681 TUBE SJ RDG3 4 4LINK VP 540 Connect
233. ts of slanted movement and of expansion and contraction of the media W arm up is required after powerup T his may require 5 to 20 minutes depending on the operating environment D epending on the ambient temperature and media width the preset temperature may fail to be reached 8 D epth when the included ink cartridge tray is installed is 1 000 mm 9 O perating environment Humidity 95 no condensation 80 j Op Use in an operating environment with this range 85 i i 0 1520 27 32 F 59 68 80 6 89 6 Temperature 7 14
234. umpy due to the Ink absorption the Head sometimes strikes the media while printing and it causes the Ink dropping problem If media produces static electricity easily the ink tends to remain on the head surface while printing and results in ink User s Manual Use the media clamps Media strikes Head Replace with a suitable media Static electricity of the media Perform PERIODIC CL dropping When this is set to 1 min to 990 min automatic cleaning is performed while printing and it may prevent the ink dropping NO 1 Cleaning does not work effectively with worn wiper Therefore foreign substances stuck the head surface cannot 1 Wiper wears gut Wiper Replacement Meere Manual removed completely and the ink flows through it and results in ink dropping 3 8 INK TUBE When the ink tube is broken it is not possible to keep the ink Broken Ink Tube Replacement REPLACEMENT line air tight and results in ink dropping 3 1 HEAD When a head is broken mechanically such as a crack it is not Broken Head Head Replacement REPLACEMENT keep the ink line air tight and results in the ink 6 5 VERTICAL BANDING When there is scratch or dirt on the Encoder Scale the printing image could be affected and the vertical bandings appear at the position where there is scratch or dirt NO 1 When the sliding resistance with the moving Head Carriage increases partly due to some dirt on the LM Guide
235. waiting mode for receiving the firmware by pressing ENTER key IE The setting made here is only temporary for the firmware installation and it is not saved WAITING 000 000 000 000 IP ADDRESS 45 192 168 000 100 2 l 4 SUBNET MASK o gt 255 255 255 000 4 4 GATEWAY ADDR 4 000 000 000 000 4 WAITING 192 168 000 100 4 Start the Peck4 on PC Peck4 screen is displayed and click Select Port button 4 0 1 Select Port D nn Get Report Get Parameters Put Parameters Set Head Rank Firmware Upgrade Exit Select Type3 Prolll etc from Product Also select Via Network and input IP address of VP 540 300 Select Port Product C C Select C via Parallel Click OK button ia Network via USB ProII SP serise AJ 1000 etc ProlII etc Delete Host Restart 1182 168 0 100 Cox po 4 18 Peck4 screen is displayed again Click Firmware Upgrade button Passus Get Report Bet Parameters Put Parameters Set Head Rank 2 Exit OPEN screen is displayed Select the firmware file and click Open 58 It starts to send the firmware to VP 540 300 227 Record Docuneni D Fie ATI mee lm e
236. ws to remove the Cut Cable Guide CUT CABLE GUIDE 6 Remove the Carriage Cover CARRIAGE COVER 3 73 Disconnect the ink tubes from the Y tube joints and put the scotch tape at the tip of the ink tube to prevent the ink from coming out And remove them from the Clamps Open the clamp and disconnect the 3 flexible cables from the Carriage Board Remove the Cable Holders and Holder Cable Sheets from the Tube Guides leaving the flexible cables and Holder Cable Plates 3 74 HOLDER CABLE SHEET CABLE HOLDER HOLDER CABLE PLATE FLEXIBLE CABLE TUBEGUIDEs 1 Replace the tube guides if they are not following tube guide TUBEGUIDEs S Parts 1000003293 Parts Name GUIDE TUBE VP 540 11 Fix the new Cable Holders and Holder Cable Sheets to the Tube Guides with reference to the following figures TUBEGUIDEs IE Make sure that the cable s fit in the grooves of the tube guides CABLES TUBES TUBEGUIDE lt Cross section gt careful that lt Fixing Position gt 1 the fixing order EE E CABLE HOLDER rA Lt L

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