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RKN
bäÉÅíêáÅ~ä=ë~ÑÉíó KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKO
RKO fåéìí=qê~åëÑçêãÉê=`çååÉÅíáçåëKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKP
RKP sçäí~ÖÉëKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKQ
RKQ
_ìë=^ÇÇêÉëë=pïáíÅÜÉë KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK R
RKR mêáåí=ëäÉÇÖÉKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKR
RKS båÅçÇÉêKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKT
RKT jÉÇá~=aÉíÉÅíL=píçé=pÉåëçêKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKU
RKU
eÉ~Ç=jÉÇá~=aáëí~åÅÉ KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKNM
RKV wJjçíçêKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKNN
RKNM `ê~ëÜ=pÉåëçêKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKNQ
RKNN jJaêáîÉKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKNU
RKNO
máäò=p~ÑÉíó=`çåíêçääÉê KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKOM
RKNP cáêÉ=fãéìäë=qçïÉêëKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKOP
RKNQ rs=póëíÉãKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKOS
RKNR
RKNS
s~Åììã=c~åë KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKOT
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NLPM=

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RKN bäÉÅíêáÅ~ä=ë~ÑÉíó=

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  • 1. Safety test unit

GLP2

1431

  • 2. Adapter f. 3x400VAC, EU

ELE_AD_02

  • 3. Adapter f. 230 - VAC external supply

ELE_AD_04

 

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  • 1. Safety check can only be done from trained staff.

 
  • 2. In the area from 2 m around the machine is not allowed to stay during the test is running.

  • 3. Use a yellow tape to block off this area.

 

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Attention: disconnect the main power supply from SpiiPlus (J18)

 

otherwise this unit get damaged!!

 

Other equipment what needs to be disconnected:

All electrical connections from Microlynx

All electrical connections from linear controller SpiiPlus

Remove all PCBs from rack

  • 1. Shutdown machine. Shutdown workstation. Disconnect power supply from monitor and workstation.

  • 2. Bypass all 3 phases from main power filter L1.

  • 3. Connect on the low power trigger from main switch the adapter for 230VAC external supply (ELE_AD_04) and plug it to a power socket.

  • 4. Rho-main switch connected with adapter (ELE_AD_02) to safety test unit.

  • 5. Switch on the main switch from Rho600 Pictor switch must stay ON!

  • 6. Load program "Rho160" and follow the program steps. Used measurement points:

Aluminium plate left

Steel frame, zinc coated pins for metal covers

Metal plate connection unit

Metal plate power unit

Metal plate UV unit

Print sledge carriage support (middle position)

  • 7. Disconnect power supply at low power trigger and adapter. Fasten screws at clamp.

  • 8. Remove bypasses at main power filter L1.

  • 9. Connect workstation and monitor.

10. Store the printed protocol at the machine papers.

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`Ü~éíÉê=R=^ÇàìëíãÉåí===============================

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Program data RHO160:

  • 1. Isolation check between phase L1, L2,L3 and PE

    • a. Rmin = 2 MOhm

  • 2. leakage current cold

    • b. I max = 20 mA

  • 3. High voltage check

Rise time

  • c. = 5 sec

  • d. Test cycle = 2 sec

  • e. Test voltage 2100V

  • f. = DC +

Voltage

  • g. max. current = 3 mA

  • 1. Safety test check:

    • a. Test current = 25 A, Rmax = 0,1 Ohm

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Wiring of Transformer and Main switch like shown in the following pictures.

Main Input

Inside Transformer

Connect both earth cables on this connector!! Switch adjustment to transformer
Connect both earth
cables on this
connector!!
Switch adjustment
to transformer
All earth cables are connected on this point
All earth cables are
connected on this point

1. Use at the transformer the connections what are the nearest to the main power supply voltage.(e.g. 210V for USA)

Program data RHO160: 1. Isolation check between phase L1, L2,L3 and PE a. Rmin = 2

Connect to the right main input voltage!

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2. Check now the main voltage at the main connector from Pictor. Do not switch on machine! The voltage must be in the range from 380 and 430V. If this is not given, connect the cables at the transformer to an other position! (other input voltage). Is the voltage too low it needs to connect to the next lower clamp from the input voltage or converse.

3. Main switch – adjust current on the used input voltage:

Main voltage (V)

Current (A)

190

32

200

30

210

29

220

27

230

26

240

25

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Disconnect the power supply before switching on the machine first time.

Backplane

X1100

+12V, -12V, 5V

 

X1101

+24V

Head Power 1

X2150

+24V

disconnect all connections

Head Power 2

X2150

+24V

disconnect all connections

ACS Controller Spii+ J17

+24V

 

J18

~230V

Security Control Connector X88

+24V

Ink Pump Control

X3040

+24V

UV Lamp Unit

X100

+24V

Fan Unit Control

X2180

+24V

HeadDriver

X2117

+155V

HeadHeater Control

X2100

+60V

 

X2000

+24V

Adjust the 5V power supply on the backplane. Turn the potentiometer on the Sunpower main power supply the there are 5V (+0,2V)on the PCBs.

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RKQ _ìë=^ÇÇêÉëë=pïáíÅÜÉë=

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Dip Switch

4321

Block Valve Control

2 (F5)

0000

Meniscus Valve Control

0100

Head Heater Control 1

0000

Head Heater Control

0001

Ink Pump Control

1000

Fan Unit Control

0111

UV Lamp Control L1

0000

UV Lamp Control L2

0001

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The tolerances from the voltages are always written into the right box.

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+- 1 V DC
+- 1 V DC
  • 1. Disconnect X2034-CK/MY Head Interface, X2034-YM/KC Head Interface, X2160 Block Valve Control, X2180 Meniscus Valve Control.

  • 2. Connect X2152 on Head Power PCB-2.

  • 3. Check on all above mentioned connectors the poling and measure the voltage (24V DC).

  • 4. Connect all connectors to the PCBs again.

  • 5. The power LED on the PCB must light up green now.

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+- 0,5V DC
+- 0,5V DC
  • 1. Disconnect all Molex - connector J8 on the print head.

  • 2. Connect connector X2156 on Head Power PCB-2.

  • 3. Check on all 4pol. Molex connector J8 the poling and measure the voltage (12V DC).

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+- 1 V DC
+- 1 V DC
  • 1. Disconnect X2000/1 Head Heater1 (and X2000/2 Head Heater2 at F5).

  • 2. Connect connector X2151 on Head Power PCB-2.

  • 3. Check on all Panduid connector the poling and measure the voltage (24V DC).

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  • 1. Check the function from the valves Meniscus/Purge.

  • 2. Press the button in Testcom under the text Meniscus valves (C1/3 , C2/4 , M1/2 , M2/4 , Y1/2 , Y2/4 , K1/2 , K2/4,… depending on the color options) after each other. If the button is active the green LED on the Meniscus Control PCB must light up. The function of the valves can be tested only with an air flow.

  • 3. After that press the button in Testcom under the text Blocking valves (CK1, CK2,… depends on options) after each other. If the button is active the green LED on the Blocking valve PCB lights up. The funktion of the valves can be tested only with an ink flow.

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  • 1. Switch on in Testcom the heating control

  • 2. All connected print heads must heat up now.

  • 3. Check temperature in Testcom with a click on the right button (47°C +/-1°C)

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  • 1. Print heads must be empty otherwise do 2x Long Purge in Testcom.

  • 2. Switch on heating for all print heads and wait that it reached 47°C +/- 1°C on all print heads.

  • 3. wait another 15 min to stabilize the temperature.

  • 4. check and write down actual LOIS value.

  • 5. Calculate offset and program it into the machine.

Info: The LOIS value is read out as usual. Also when e.g. the KC print head is rotated with 180° is tank1 K and tank 2 C!

calculation:

LOIS Offset =

actual value -318

e.g.:

actual value from CK1C at 47°C = 287 LOIS Offset = 287-318 = -31

Now the value from CK1C is programmed with -31

Programming:

  • 1. Set data at DurstPrinter.setup file

  • 2. Send to Rho (Write - Read from Rho - no " * " should appear in the display box)

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Check all encoders that they count in both ways. The Head Media Distance Encoder must be moved manually. For this connect the Z-hub adapter. This adapter is connected instead of the meniscus PCB.

Exchange (change poling) the cables on the motor controller clamp if the sledge moves to the wrong side. Attention: check at first that the sledge is not totally down (lower mechanical limit Stop). If that happens, move at first up. If the sledge is up (upper mechanical limit stop) converse situation. Note: If the upper electrical limit Stop is active, there is no movement to an upper position possible. Sledge can only move down until the limit switch is not active any more. With the lower limit switch converse.

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Mechanical Adjustment!

Positioning device must be aligned with the 2 bore holes as shown in the picture. The dimensions of the adjustment tool you find in the drawing

pic.11.

RKT jÉÇá~=aÉíÉÅíL=píçé=pÉåëçê= Mechanical Adjustment! Positioning device must be aligned with the 2 bore holes as shown

The mark of the positioning device is

eccentric. The positioning must be done so that the mark for the light beam is as close as possible to the belt.

RKT jÉÇá~=aÉíÉÅíL=píçé=pÉåëçê= Mechanical Adjustment! Positioning device must be aligned with the 2 bore holes as shown

pic.10

RKT jÉÇá~=aÉíÉÅíL=píçé=pÉåëçê= Mechanical Adjustment! Positioning device must be aligned with the 2 bore holes as shown

pic.11

pic.12

cut out for sensor light beam media direction mark Mark (beam) device
cut out for sensor
light beam
media direction
mark
Mark (beam)
device

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First of all remove the old reflector! When you mount the new holder (10% angle) for the reflector, you have to make sure that the adjustment of the new holder is done like shown in the drawing (pic.13).

Sledge Printing direction pic.13 Alignment of the chamfer
Sledge
Printing direction
pic.13
Alignment of the chamfer

Next step is mounting the reflector onto the holder.

pic.14

First of all remove the old reflector! When you mount the new holder (10% angle) for

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First of all remove the old reflector! When you mount the new holder (10% angle) for

chamfer for base from reflector (LE2020227)

base for reflector film

(LE2020228)

Reflector film (ibwJcqacMOMcMOM)

First of all remove the old reflector! When you mount the new holder (10% angle) for
First of all remove the old reflector! When you mount the new holder (10% angle) for

Printing direction

Adjust the voltage on the sensor interface PCB. Turn the potentiometer and measure the voltage between P0 and P14. The voltage must be 10V +/-0,2V.

Adjustment

potentiometer

Measure point P14, P0
Measure point P14, P0
First of all remove the old reflector! When you mount the new holder (10% angle) for

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RKU eÉ~Ç=jÉÇá~=aáëí~åÅÉ=

Measuring hole Measuring
Measuring
hole
Measuring
Printhead
Printhead

Sledge

RKU eÉ~Ç=jÉÇá~=aáëí~åÅÉ= Measuring hole Measuring Printhead Sledge HMD 15mm Transport Do the Measurement in the middle
HMD
HMD
RKU eÉ~Ç=jÉÇá~=aáëí~åÅÉ= Measuring hole Measuring Printhead Sledge HMD 15mm Transport Do the Measurement in the middle

15mm

RKU eÉ~Ç=jÉÇá~=aáëí~åÅÉ= Measuring hole Measuring Printhead Sledge HMD 15mm Transport Do the Measurement in the middle
RKU eÉ~Ç=jÉÇá~=aáëí~åÅÉ= Measuring hole Measuring Printhead Sledge HMD 15mm Transport Do the Measurement in the middle
Transport
Transport

Do the Measurement in the middle from the transport belt. Use a calliper and measure through the measuring hole 2 (front hole) down to the transport belt.

Adjustment point

Measuring

HMD

Tolerance

distance

Reference switch

62mm

47mm

+/- 1,2mm

lower electrical limit switch

16mm

1mm

+/- 0,1mm

Lower mechanical

15,8mm

0,8mm

+/-

limit stop

0,05mm

Upper electrical limit switch

64mm

49mm

+/- 0,5mm

Description from Init cycle:

  • 1. Sledge moves up with a high speed until it hits the upper reference switch.

  • 2. Sledge moves down with a low speed until it does not switch the reference switch any more.

  • 3. Sledge moves still down until it reach the Index position from the HMD encoder.

  • 4. After the encoder reached the Index position the Encoder PCB sets the Encoder to 0 HMD is initialized.

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NMLPM=

RKV wJjçíçê=

Adjustment:

4. Adjust turning speed from Z-hub motor

Light barrier plate must be mounted (not accuracy adjusted yet)

and

the mechanical limit stop is turned out.

Attention: check that the light barrier plate does not touch the light barrier itself (it moves smoothly into the gap). Also the upper electrical limit switch is not allowed to switch on until the plate has not reached the light barrier! Do a rough adjustment from the 2 potentiometer as seen in the picture below.

RKV wJjçíçê= Adjustment: 4. Adjust turning speed from Z-hub motor Light barrier plate must be mounted
RKV wJjçíçê= Adjustment: 4. Adjust turning speed from Z-hub motor Light barrier plate must be mounted

potentiometer slow

  • potentiometer fast

RKV wJjçíçê= Adjustment: 4. Adjust turning speed from Z-hub motor Light barrier plate must be mounted

Send following commands to the machine:

./serial –c .10YHMSA0 for slow speed ./serial –c .10YHMSA1 for fast speed

With this command the sledge moves up to the reference switch and from there a definite time down. The software calculates from the moved way and the time the speed. The result is displayed on the monitor.

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The following values must be reached (last 3 numbers):

  • 130 at fast speed

+/-5

  • 060 at low speed

+/-5

Is this not given the speed needs to be adjusted. Turn the poti to the left side the speed gets lower for the next move. And faster with a turn to the right hand side. This procedure must be down until the right speed is set.

5. Adjust reference switch (light barrier)

  • 1. Move with Z-hub adapter to the measuring distance (62mm) for reference switch.

  • 2. Move sensor plate from above down until the switch is not switching on any more.

  • 3. Initialize in Testcom with Go Init and read encoder steps. The value must be in the range from 300 and 700. Is this given go to the next point. Is the value not in the range than move the sensor plate more up or down. Recheck the value and repeat again or go on.

2. 1. 6. Parameter RhoHMDistance rough adjustment:
2.
1.
6. Parameter RhoHMDistance rough adjustment:
  • 1. Initialize with Go Init

  • 2. Measure distance to transport belt

  • 3. Write the value into Durstprinter.setup. Set the parameter RhoHMDistance = measured distance -15mm in tenth part mm without comma (rounded).

e.g.: measured= 61,87

61,87-15=46,87 RhoHMDistance = 469

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`Ü~éíÉê=R=^ÇàìëíãÉåí===============================

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NOLPM=

  • 7. Parameter RhoHMDistance fine adjustment:

    • 1. Initialize with Go Init

    • 2. Set HMD = 10mm (motor moves to that distance)

    • 3. Measure distance to transport belt (e.g.: 25,2)

    • 4. Set parameter RhoHMDistance (e.g. value parameter +2 ( +/- 0,1mm tolerance)

  • 8. Check distances:

  • Move in Testcom to following distances:

    HMD in Testcom

    Measuring

    Tolerance

    distance

     
    • 40 +/-0,2mm

    55mm

     
     
    • 15 +/-0,2mm

    30mm

     

    5

    20mm

    +/-0,1mm

    • 9. Adjust mechanical limit Stop

    Move manual to a distance from 15,8mm and fix the limit stop screw.

    • 10. Mount lower electrical limit switch

    Attention: mechanical limit Stop must be more down! Move with Z-hub adapter to 16mm measuring distance and fix the part so that the switch is on. Move the sledge up and the switch is off. Move again down. As soon the switch is on the sledge stops. Check distance, if necessary readjust the switch position and redo the procedure.

    • 11. Mount upper electrical limit switch

    Move with Z-hub adapter to the distance and follow the instruction as above.

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    NPLPM=

    RKNM `ê~ëÜ=pÉåëçê=

    • 1. Mount the electrical crash switch like shown on the photo below.

    RKNM `ê~ëÜ=pÉåëçê= 1. Mount the electrical crash switch like shown on the photo below. Black holding
    Black holding
    Black holding
    RKNM `ê~ëÜ=pÉåëçê= 1. Mount the electrical crash switch like shown on the photo below. Black holding
    Mounting part
    Mounting part
    RKNM `ê~ëÜ=pÉåëçê= 1. Mount the electrical crash switch like shown on the photo below. Black holding
    Switching part
    Switching
    part
    • 2. Switch ON the machine:

    Switch not activated: LED on the switch must blink with approx. 1Hz and the LED on the relais should be ON all the time. Switch activated: If you activate the switch the LED on the switch must be ON all the time and the LED on the relais is OFF.

    • 3. Height adjustment of the Media Security Switch Place the print sledge in the centre of the belt table. Set the Head Media Distance HMD=4,8mm (in Testcom). Put a Media with 5mm thickness (Kapa) underneath the sensor. Move the switching part down until it is set flat to the Media. Fix the switching part with the set screws on the side).

    Switch Switch part Media 5mm Black transport belt 5mm
    Switch
    Switch part
    Media 5mm
    Black
    transport
    belt
    5mm

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    `Ü~éíÉê=R=^ÇàìëíãÉåí===============================

    =

    sÉêëáçå=NKM==J==ONLMSLOMMT=

    NQLPM=

    4. Adjustment of the switching point:

    Bend the switching part against the UV-lamp until you have a distance of 10mm. press the SET-button for min. 1 second When the LED on the switch is blinking with high frequency then the new switching point is set.

    10mm
    10mm

    5. Check of the switching point:

    5.1 Manual test

    SET-button
    SET-button

    set the HMD to 4mm and put a plate with 5mm inside move the print sledge over the Media >> the sensor must be activated before the UV-lamp is reaching the media.

    Automatic test

    Initialise the machine and set the HMD to 4mm Put the Media with 5mm again Testcom: Press the button “Security Move” This starts the security move procedure. The print sledge is passing the Media with slow motion. The switch should be activated and the print sledge should be stopped before the UV-lamp is reaching the media.

    5.9.1 New settings of crash switches and printing distance

    =

    5.9.1.1 New setting of the media crash switches

    =

    Durst has decided to change the setting of the media crash switches. This change is valid for all machines build at Durst Phototechnik Austria with Quadro Array Printheads (Rho600, RhoPac, RhoPictor, Rho800). From now on all machines are shipped out with these new settings and we strongly recommend to do this change also on all machines in the field. With the new adjustment tool LE3099008 can be ordered at Durst and is the same for Rho600, RhoPac, RhoPictor and Rho800.

    =

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    =

    sÉêëáçå=NKM==J==ONLMSLOMMT=

    NRLPM=

    Adjustment tool LE3099008:

    = = máÅíìêÉN= máÅíìêÉO= = = = How to do the adjustment: =
    =
    =
    máÅíìêÉN=
    máÅíìêÉO=
    =
    =
    =
    How to do the adjustment:
    =

    Place the adjustment tool LE3099008 like shown in the photos below and press it against the crash switch bar.

    Åê~ëÜ=ëïáíÅÜ=Ä~ê= MJiÉîÉä= MITãã= MIRãã= máÅíìêÉP= =
    Åê~ëÜ=ëïáíÅÜ=Ä~ê=
    MJiÉîÉä=
    MITãã=
    MIRãã=
    máÅíìêÉP=
    =
    i^PMVVMMU= máÅíìêÉQ= =
    i^PMVVMMU=
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    =

    Adjust the height of the crash switch unit so that the switch bar touches the 0,7mm step of the tool LE3399008. Take care that the crash switch bar is not lower than the 0,7mm step of the adjustment tool. When you change from 0,7mm to 0,5mm step you should hear the micro-switches clicking. Make sure that the switches are activated between 0,5mm and

    0,7mm.

    Info: 0,5mm means that the crash switch is activated 0,5mm before touching the printheads. Check the electrical function of the switch bar:

    Press against the switch bar on both edges by hand and check if you can see the ON/OFF-signal on the Optoisolator-PCB in the electronic rack. When crash switch is not activated the LED on the Optoisolator PCB is ON (when switch pressed OFF). When you press against the bar with the 0,5mm step at least 1 micro-switch must be activated (you will hear the switching of the micro-switch). Check the adjustment on the two edge positions (in the centre it can happen that the crash switch bar is a little bit higher or deeper.

    =

    oÜçSMM=máÅíçê=pÉêîáÅÉj~åì~ä=L=afqJpÉêîáÅÉaÉéíK=

    `Ü~éíÉê=R=^ÇàìëíãÉåí===============================

    =

    sÉêëáçå=NKM==J==ONLMSLOMMT=

    NSLPM=

    O=éçëK=íç=ÅÜÉÅâ= máÅíìêÉR=
    O=éçëK=íç=ÅÜÉÅâ=
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    = New setting of the minimum Printing Distance According to the change of the media crash
    =
    New setting of the minimum Printing Distance
    According to the change of the media crash switch settings Durst has also
    decided not to allow a printing distance smaller as 1,5mm any longer. To
    change this in the software following entry in the “DurstPrinter.setup”-
    file must be modified:
    NIRãã=
    =
    =
    RhoMediaMinHeadDistanceCM
    0.150000
    =
    Important Information:
    We can only handle returned printheads that have been damaged by a
    crash under warranty if following steps have been performed:
    ► New setting of the Media crash switches (0,5-0,7mm) has been done.
    ► Minimum printing distance must be set to 1,5mm.
    ► Session-Log-File of the crash day must be sent to Durst.
    ► The media where the crash happened must be sent to Durst together
    with the printhead.
    =

    oÜçSMM=máÅíçê=pÉêîáÅÉj~åì~ä=L=afqJpÉêîáÅÉaÉéíK=

    `Ü~éíÉê=R=^ÇàìëíãÉåí===============================

    =

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    NTLPM=

    RKNN jJaêáîÉ=

    dÉåÉê~ä==

    M-Drive is a stepper motor drive with build in power electronics. This motor is triggered from the linear motor controller Spii+. On Spii+ Controller must be installed the software LE2011.1Z or higher!

    m~ê~ãÉíÉê=mêçÖê~ããáåÖ=

    • 1. Connect Notebook with the programming cable „IMS MD-CC300-000” and the MDM Line Receiver PCB (ZW2063A).

    • 2. Activate the Safety relais in Testcom

    • 3. Start IMS SPI Interface Program

    RKNN jJaêáîÉ= dÉåÉê~ä= = M-Drive is a stepper motor drive with build in power electronics. This
    • 4. Click on the following window „File/Open“ to load the actual parameter file (e.g.: …\ACS Controller SpiiPlus\ LE2012P_XZ- MDM34ACplus.mot).

    RKNN jJaêáîÉ= dÉåÉê~ä= = M-Drive is a stepper motor drive with build in power electronics. This

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    =

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    NULPM=

    • 5. Check the parameter, use the same settings as shown below.

    5. Check the parameter, use the same settings as shown below. 6. Click onto „View/IO Settings“
    • 6. Click onto „View/IO Settings“ and check also the settings on the 2.page.

    5. Check the parameter, use the same settings as shown below. 6. Click onto „View/IO Settings“
    5. Check the parameter, use the same settings as shown below. 6. Click onto „View/IO Settings“
    • 7. Click on „Set“ to program the parameter into the controller. After that click on

    „Recall“ and the data is read from the

    controller. Now check the settings from point 5 and 6.

    2. 1.
    2.
    1.
    • 8. Is now everything ok, the program can be closed with „Exit“ and the programming cycle is done. (the message if it should be saved needs to click „NEIN“) Disconnect programming cable!

    =

    oÜçSMM=máÅíçê=pÉêîáÅÉj~åì~ä=L=afqJpÉêîáÅÉaÉéíK=

    `Ü~éíÉê=R=^ÇàìëíãÉåí===============================

    =

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    RKNO máäò=p~ÑÉíó=`çåíêçääÉê=

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    Check cable connection as shown in Wiring Diagram LE2000006 sheet 6.

    Input – Output:

    clamp

    description

    I/O

    X1/ T0

    Safety switch cover hood and emergency circle 1

    O

    X1/ T1

    Safety switch cover hood and emergency circle 2

    O

    X1/ T2

    Safety switch light trap 1

    O

    X1/ T3

    Safety switch light trap 2

    O

         

    X2/O1

    Emergency relais K10 (Connection Unit)

    O

    X2/O2

    Emergency relais K11 (Connection Unit)

    O

    X2/O2

    Security Control PCB internal (Relais

    O

    K2)

    X2/O3

    Security Control PCB internal (Relais

    O

    K3)

         

    X3/13

    +24V

    I

    X3/24

    UV-Safety relais K4 (Connection Unit)

    O

         

    X5/I0

    Security Control PCB internal (C1)

    I

    X5/I1

    Sensor A

    I

    X5/I2

    Sensor B

    I

    X5/I3

    Sensor C2

    I

    X5/I4

    UV Standby

    I

    X5/I5

    Sensor D2

    I

    X5/I6

    Sensor D1

    I

    X5/I7

    Sensor C1

    I

         

    X6/I8

    Reserve

    I

    X6/I9

    Reserve

    I

    X6/I10

    Emergency circle1

    I

    X6/I11

    Emergency circle2

    I

    X6/I12

    Safety switch light trap 1

    I

    X6/I13

    Safety switch light trap 2

    I

    X6/I14

    Safety switch cover hood 1

    I

    X6/I15

    Safety switch cover hood 2

    I

    X6/I16

    Temperature warning

    I

    X6/I17

    Temperature early warning

    I

    X6/I18

    +24V, at Crash 0V

    I

    X6/I19

    Reserve

    I

         

    X7/A1

    Security Control PCB internal (C2)

    I

    X7/A1

    +24V

    I

    X7/A2

    GND

    I

    X7/A2

    GND

    I

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    =

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    OMLPM=

    pÉåëçê=^ÇàìëíãÉåí=

    Sensor A, B (backside on top of sledge)

    Check distance with thickness gauge!! Perforated plate on support 0,3 - 0,6mm
    Check distance with thickness gauge!!
    Perforated plate on
    support
    0,3 -
    0,6mm

    In the case of doubt check the impulse length with an oscilloscope:

    the minimum pulse width (and break time) must be 14ms. (13ms = Guarantee from Pilz impulse detection)

    Sensor C1, C2, D1, D2

    Check distance with thickness gauge!! Always both sensors C1, C2 and D1, D2 must be ON or OFF at the same time (optical check from the LED´s is enough)

    pÉåëçê=^ÇàìëíãÉåí = ∑ Sensor A, B (backside on top of sledge) Check distance with thickness gauge!!

    pí~êí=ìé=

    0,4 - 1.0mm
    0,4 -
    1.0mm

    1. Measure input voltage:

    Pilz Unit X2:

    Pin 0V Pin +24V (Tolerance: 22 - 26V) = voltage value A:

    2. Check sensor A and B:

    move the sledge, the red LED lights up on every fin

    voltage measurement:

    This applies for all voltage measurements: GND = Pin 0V at X2 (Pilz-Module)

    X5 at Pilz-Module:

    Sensor

    A

    B

    LED light

    Pin I1

    Pin I2

    voltage value A + 0 - 3V

    LED dark

    Pin I1

    Pin I2

    voltage value = 0 - 2V

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    =

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    3.

    Check C1,C2 (left) and D1,D2 (right):

    The sensors must switch ON and OFF at same time when the sledge

    A check with the eyes is enough. Is the time difference bigger than 140ms is a problem with the Pilz controller.

    moves.

    Voltage measurement:

    X5 at Pilz-Modul:

    Sensor

    C1

    C2

    D1

    D2

    LED light

    Pin I7 Pin I3 Pin I6 Pin I5

    ...

    voltage value A + 0 - 3V

    LED dark

    Pin I7 Pin I3 Pin I6 Pin I5

    ...

    voltage value = 0 - 2V

    cìåÅíáçå=Åçåíêçä==

    1.

    Check temperature control at linear motor:

     

    Connect linear motor temperature simulation at X327. Check the Pilz outputs I16, I17 as shown below.

     

    Simulator

    I16

    I17

    Operating status

     

    adjustment

    T1 (520)

    dark

    dark

    normal

    T2 (600)

    dark

    light

    Temperature early warning

    T3 (1,2k)

    light

    light

    Over temperature

    2.

    Initialize sledge contactor K4 must switch on.

     

    3.

    Sensor C1, C2, D1,D2:

     
     

    Sledge is at park position or right side Simulate the 4 situations:

     

    C1

    C2

    D1

    D2

    K4 - status

    disconnected

     

    connected

    connected

    connected

    drops off

    connected

     

    disconnected

    connected

    connected

    drops off

    connected

     

    connected

    disconnected

    connected

    drops off

    connected

     

    connected

    connected

    disconnected

    drops off

    4.

    Push the emergency Stop during the sledge moves sledge Stops and machine is OFF!

    5.

    Switch on UV lamps and open the cover hood in park position lamps are still on and the sledge must be possible to move by hand.

    6.

    Switch on UV lamps and open the cover hood during the sledge moves lamps are OFF and sledge must stop. Now possible to move the sledge by hand.

    7.

    Switch on UV lamps and pull out the purge tray lamps are OFF and sledge must be possible to move (If the purge tray is in purge position the lamps are ON)

    8.

    Disconnect during printing the sensor A at X80 from the Security PCB K4 drops off (UV-lamps OFF)

    9.

    Disconnect during printing the sensor B at X81 from the Security PCB K4 drops off (UV-lamps OFF)

    10. Switch on the UV lamps in park position with intensity 10 -> UV lamps must switch off after approx. 2 min. (over temperature)

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    RKNP cáêÉ=fãéìäë=qçïÉêë=

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    • 1. The cable X2023 for the addressing must be connected on the right position. See Wiring Diagram.

    • 2. Do addressing from towers. Head Driver(cooling tower) CK,KC:

    gìãéÉê=pN=

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    gìãéÉê=pN

    `äçëÉ=

    `äçëÉ `äçëÉ===

    `äçëÉ

    gìãéÉê=pO=

    gìãéÉê=pO

    gìãéÉê=pO===

    gìãéÉê=pO

    `äçëÉ=

    `äçëÉ `äçëÉ===

    `äçëÉ

    Head Driver(cooling tower) F5:

    gìãéÉê=pN=

    gìãéÉê=pN

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    gìãéÉê=pN

    `äçëÉ=

    `äçëÉ `äçëÉ===

    `äçëÉ

    gìãéÉê=pO=

    gìãéÉê=pO

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    gìãéÉê=pO

    léÉå=

    léÉå léÉå===

    léÉå

    ãÉ~ëìêÉãÉåí=

    • 1. Click in Testcom on button „Testmode“.

     

    MY,YM:

    gìãéÉê=pN=

    gìãéÉê=pN

    gìãéÉê=pN===

    gìãéÉê=pN

    léÉå=

    léÉå léÉå===

    léÉå

    gìãéÉê=pO=

    gìãéÉê=pO

    gìãéÉê=pO===

    gìãéÉê=pO

    `äçëÉ=

    `äçëÉ `äçëÉ===

    `äçëÉ

     

    F6:

    gìãéÉê=pN=

    gìãéÉê=pN

    gìãéÉê=pN===

    gìãéÉê=pN

    léÉå=

    léÉå léÉå===

    léÉå

    gìãéÉê=pO=

    gìãéÉê=pO

    gìãéÉê=pO===

    gìãéÉê=pO

    léÉå=

    léÉå léÉå===

    léÉå

    • 2. Check that V14 on the Head Interface-PCB lights red.

    • 3. Measure with the oscilloscope on the Head Driver PCB (cooling tower), V124 Pin18 (measurement point see photo) to ground (measurement point P0).

    RKNP cáêÉ=fãéìäë=qçïÉêë= ^ÇÇêÉëëáåÖ = 1. The cable X2023 for the addressing must be connected on the

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    =

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    5V rectangle impulse:

    5VDC +- 0,5V 9µs +- 0,05µs Attention: calibrate probe first! (otherwise wrong measurement)
    5VDC +- 0,5V
    9µs
    +- 0,05µs
    Attention: calibrate
    probe first! (otherwise
    wrong measurement)
    • 4. Do this measurement on all Head Driver PCBs.

    • 5. Deactivate „Testmode“ in Testcom.

    Measure Fireimpuls:

    • 1. Switch on control pulse „Head Voltage ON/OFF“ in Testcom.

    • 2. V133 on all Head Driver PCB must light up.

    • 3. Click on „Set Head Voltage 100“

    • 4. Click on „Testmode“ in Testcom.

    • 5. Measure the pulse with the oscilloscope on the Head Driver PCB from the cooling towers. This must be done on all test points (Fire1-8) on all PCBs.

    • 6. Save the oscilloscope screen. (store in on an external database)

    Open oscilloscope default settings „fire_100“

    measurements:

    rise time

    puls width

    fall time

    Vp-p (Voltage Peak to Peak)

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    =

    sÉêëáçå=NKM==J==ONLMSLOMMT=

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    Attention: Do not forget to

    calibrate the probe!

    (otherwise wrong measurement)

    rise time

    = 3,2

    +- 0,4µs

    puls width = 5,8

    +- 0,4µs

    fall time

    = 0,8

    +- 0,2µs

    Vamptd

    = 100V +-2,5V

    Attention: Do not forget to calibrate the probe! (otherwise wrong measurement) rise time = 3,2 +-
    Attention: Do not forget to calibrate the probe! (otherwise wrong measurement) rise time = 3,2 +-

    7. Change voltage to 120V. For this click „Set Head Voltage 120“. Same measurement as with 100V. Do it for all printheads.

    rise time =

    open

    puls width = open

    fall time =

    open

    Vamptd=

    120V +-3V

    =

    8. At first deactivate „Testmode“ and than „Set Head Voltage“.

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    =

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    ORLPM=

    RKNQ rs=póëíÉã=

    ibhp=jçÇìäÉ=ÇÉëÅêáéíáçå=

    LEKS is a module to control the UV-Fans.

    RKNQ rs=póëíÉã= ibhp=jçÇìäÉ=ÇÉëÅêáéíáçå = LEKS is a module to control the UV-Fans. Fan overrun-time LED red

    Fan overrun-time

    RKNQ rs=póëíÉã= ibhp=jçÇìäÉ=ÇÉëÅêáéíáçå = LEKS is a module to control the UV-Fans. Fan overrun-time LED red

    LED red No speed signal (Fan off)

    RKNQ rs=póëíÉã= ibhp=jçÇìäÉ=ÇÉëÅêáéíáçå = LEKS is a module to control the UV-Fans. Fan overrun-time LED red
    • Temperature set point

    LED yellow Fan on
    LED yellow
    Fan on
    RKNQ rs=póëíÉã= ibhp=jçÇìäÉ=ÇÉëÅêáéíáçå = LEKS is a module to control the UV-Fans. Fan overrun-time LED red
    • LED red Temp. warning

    RKNQ rs=póëíÉã= ibhp=jçÇìäÉ=ÇÉëÅêáéíáçå = LEKS is a module to control the UV-Fans. Fan overrun-time LED red
    LED green UV ready
    LED green
    UV ready

    Picture 1

    pí~êí=ìé=

    • 1. Threshold adjustment or checking from temperature warning.

      • - Turn the potentiometer CCW to the left limit

      • - As seen in the picture, turn potentiometer exactly 2 mark lines clockwise.

    RKNQ rs=póëíÉã= ibhp=jçÇìäÉ=ÇÉëÅêáéíáçå = LEKS is a module to control the UV-Fans. Fan overrun-time LED red

    Arrow must be exactly in the middle from the 2.mark line

    • 2. During the initialization the contactor K4 switches on.

    • 3. Switch on lamp 1. Check if correct lamp starts up and the fan turns into the right direction (airflow out of

    lamp).

    During the start up the intensity goes up to 80% for approx. 45 seconds. After that the lamp is ready (green LED on LEKS Module) and now goes to standby (20% power)

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    `Ü~éíÉê=R=^ÇàìëíãÉåí===============================

    =

    sÉêëáçå=NKM==J==ONLMSLOMMT=

    OSLPM=

    4.

    Switch on

    lamp 2. Check if correct lamp starts up and the fan

    turns into the right direction (airflow out of lamp). And also that

    UV lamp ready appears after 45 seconds.

    • 5. Check temperature reference preset or maybe recalibrate. Measure voltage on the LEKS module between PIN2 and PIN10 (lamps

    are turn on). Reference value = 2,50V +/-0,01 lack the potentiometer after calibration

    • 6. Check intensity adjustment on both lamps. With „Set Intensity“ decrease or increase the power darker)

    check lamp light or lighter or

    • 7. Check cooling down from fans. After switching off the UV lamps the fan speed must increase. After approx. 4min +0.5 fan

    switches off.

    If this is not given adjust the potentiometer lack the potentiometer after calibration.

    RKNR

    s~Åììã=c~åë=

    • 1. Activate in Testcom „TableFan“.

    • 2. Both fans must turn.

    • 3. Operate the controller on the Fan Unit Control PCB (potentiometer).

    • 4. Fans must turn faster with a turn CW and converse.

    RKNS råÇÉê=mêÉëëìêÉ=råáí=

    oÉèìáêÉãÉåíë=

    • 1. LA2050400 Meniscus under pressure unit must be assembled together and proved from the components before (also electrical).

    • 2. Over pressure connection done on machine.

    • 3. Unit with pressure control, filter and over pressure valve (Purge) already mounted.

    • 4. Hoses connected to the tanks.

    • 5. hoses connected up to sledge (L-M-P block (LF2020540) connected, print heads not connected)

    • 6. Meniscus and Purge hose capped on sledge.

    • 7. disconnect lung hose from external lung and cap it.

    • 8. capping from Meniscus- vacuum pump must be removed!

    Attention: Take care the hoses and openings are clean all the time during the start-up procedure below.

    oÜçSMM=máÅíçê=pÉêîáÅÉj~åì~ä=L=afqJpÉêîáÅÉaÉéíK=

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    =

    sÉêëáçå=NKM==J==ONLMSLOMMT=

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    • 1. connect pressure metre to connector Y2012 (measure unit must be set to zero). If there is a voltage on the under pressure unit a negative pressure from >-580mbar will be generated from the pump and pump switch off itself. If there is a leakage to pump is running continuously and the need negative pressure can never be reached. With a time measurement the period must be shorter than 200sec.

    • 2. Open Y2016 and check at which pressure the pump starts again. This pressure must be higher than -580mbar.

    • 3. At the right pressure send this command and check the receive message.

    command

    Receive message

    ./serial -c

    .01YPSxyz , z= 0 = OK

    .10YPS

    • 4. Check at the hose from the external lung the pressure. There must be min -580mbar.

    • 5. Open Y2012 and let the vacuum go down. Take care not to get pollution into that opening. When the pressure is zero send the command and check the receive message.

    command

    Receive message

    ./serial –c

    .01YPSxyz , z = 1 =

    .10YPS

    NOT OK

    Cap Y2012 again.

    • 6. Long-term leakage test: Vacuum must be reached and measure unit connected to Y2012. Maximum pressure reduction from 3bar over a period from 3 min. Attention: pump not powered up and not allowed to switch on during this measurement

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    • 1. Connect pressure metre to Y2006 (measure unit must be set to zero). If there is a voltage on the under pressure unit a negative pressure from –10,5mbar ±0,8mbar will be generated from the pump and the pump switch off itself. If there is a leakage to pump is running continuously and the need negative pressure can never be reached.

    • 2. At the right pressure send this command and check the receive message.

    command

    Receive message

    ./serial –c

    .01YPSxyz , y = 0 =

    .10YPS

    OK

    With a time measurement the period must be shorter than 50sec.

    • 3. Open Y2006 and immediately the pump starts to run.

    • 4. Check on the print sledge on all 8 fittings at the L-M-P block (LF2020540) the negative pressure. This pressure must be in the range from –9,2 and -11,2mbar.

    • 5. Now create a negative pressure from 20mbar (bypass between P0 and P1, or squeeze the silicon tube what is connect on the PCB and Y2008 several times for short time). Disconnect X3028 after 2min and the LED V30 lights up red. Check with the command the receive message.

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    command

    Receive message

    ./serial –c

    .01YPSxyz , y = 1 =

    .10YPS

    NOT OK

    Connect X3028 and check the time to reach a pressure from -10,5mbar +-

    0,8mbar.

    This time must be shorter than 150sec.

    • 6. Disconnect X3029 connector and open Y2009 the pressure goes down to zero. Take care not to get pollution into that opening! CAP Y2006. After 2 min. waiting the LED V31 lights up red. Check with the command the receive message.

    command

    Receive message

    ./serial –c

    .02YPSxyz, y = 1 =

    .10YPS

    NOT OK

    Connect X3029 again.

    • 7. Long-term leakage test: At first create a negative pressure from –20mbar (bypass P0 and P1, or squeeze the silicon tube what is connect on the PCB and Y2008 several times for short time). Disconnect X3028. Vacuum must be reached and the pressure metre connected to Y2006. Check the pressure reduction over 1 hour. Max. 1mbar over the period from 1 hour. Switch off the pressure metre during the measure period.

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    • 1. Check the over pressure valve, this must open between 0,5 and 1,0bar.

    • 2. Connect at switch S31 Pin2 and 3 the Ohmmeter. Switch must be highly resistive with environment pressure (Feedback for Unix workstation). Connect at Y2002 the pressure metre. Now open the filter reduction valve (near pressure controller) at Y2001 and adjust a pressure from 250mbar (+30mbar). Adjust over pressure sensor (Purge Pressure Sensor) that the switch just close. Ohmmeter still connect and a resistor from less than 1 Ohm must be displayed. Now it’s save that over pressure sensor can recognize a pressure higher 250mbar.

    • 3. Adjust purge pressure with the filter regulation valve (near pressure controller) to 300 up to 330mbar.

    • 4. This pressure must be also at the test point from the sledge when the Purge Ambient Valve is open.

    • 5. Check with the command the receive message.

    command

    Receive message

    ./serial –c

    .01YPSxyz , x = 0 =

    .10YPS

    OK

    • 6. Close the filter regulation valve that no over pressure exists. Check with the command the receive message.

    command

    Receive message

    ./serial –c

    .01YPSxyz, x = 1 =

    .10YPS

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    7. Check the breather from the valve. Testcom: „Purge/ Ambient Valve“ If Purge / Ambient Valve is open the over pressure must move out of the hole next to Y2004.

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