E D D - Hewlett Packardwhp-aus1.cold.extweb.hp.com/pub/scitex/HP_Scitex_Fresco...International...

PRODUCT:

NUR Fresco HiQ

PART/ASSEMBLY:

Fresco HiQ 8C Upgrade

ISSUE DATE:

6-Feb-03

DESCRIPTION OF CHANGE:

Fresco 4-Color to 8-Color Printing Capability

OPTIONAL UPGRADE KIT:

NUR Fresco HiQ 3200

P/N: 10-0808

NUR Fresco HiQ 1800

P/N: 10-0591

SOFTWARE AFFECTED:

YES NO

IMPLEMENTATION:

ON REQUEST IMMEDIATE

NEXT CALL ON FAILURE

PREPARED BY:

Alex Davidson

TYPE OF CHANGE:

MANDATORY CONDITIONAL

MATERIAL DISPOSITION:

N/A

USE AS SPARE

DISCARD ALL

DISCARD SELECTIVELY (refer to Mat’l Disposition)

SEND BACK FOR REWORK

PROJECT MANAGER:

SIGNATURE/DATE

ENGINEERING MANAGER:

SIGNATURE/DATE

ICS MANAGER:

SIGNATURE/DATE

OOPP TT

II OONN

AA LL

UUPP GG

RR AA DD

EE

Read this document carefully before implementing the upgrade!

FC10-0808 Rev. D of 117

International Customer Support Optional Upgrade

Table of Contents 1. General .............................................................................................................................. 6 2. Estimated Installation Time .............................................................................................. 6 3. Additional Required Tools................................................................................................ 6 4. Preparation for Upgrade.................................................................................................... 6 5. Replacing the Print Head Carriage Plates......................................................................... 7 6. Replacing the Current 4C-SIT with the 8C SIT................................................................ 9 7. Purge Manifold Relocation ............................................................................................. 13 8. Replacing the 5-Micron Filter Bracket with the 8C Filter Bracket ................................ 16 9. IGUS Replacement – Fresco HiQ 3200.......................................................................... 18 10. IGUS Replacement – Fresco HiQ 1800.......................................................................... 26 11. Tubes (Hydraulic) Connection for IGUS........................................................................ 37 12. Installing the Switch-Blocks ........................................................................................... 38 13. Installing the Light Main Ink Tanks Assembly .............................................................. 41 14. Switch Block Hydraulic Connections............................................................................. 44 15. Screwing the 8C Filter Bracket to the Chassis Wall....................................................... 50 16. Connecting Filter Ink Inlet Tubes ................................................................................... 51 17. Installation of the 8C Ink Pump Control (IPC) and Ink I/O Board................................. 51 18. Cable Installation ............................................................................................................ 58 19. Installing the Dell 530 Workstation................................................................................ 63 20. FPP Board and Driver Installation.................................................................................. 65 21. Installing the PrinTop Application.................................................................................. 76 22. Final Tasks ...................................................................................................................... 76 23. Installing NUR Flash 1.2 ................................................................................................ 77 24. Testing............................................................................................................................. 77 25. Logistics.......................................................................................................................... 83 26. Material Disposition........................................................................................................ 89 27. Table of Appendixes ....................................................................................................... 90 Appendix A: Ink Flushing System.......................................................................................... 91 Appendix B: Print Heads Replacement .................................................................................. 96 Appendix C: Print Head Plate Calibration............................................................................ 101 Appendix D: Schematic Drawings........................................................................................ 117

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Optional Upgrade International Customer Support

Table of Figures Figure 1: Crimping Tool ................................................................................................6 Figure 2: Removing the Print Head Cover Shield .........................................................7 Figure 3: Print Head Cover Shield Assembly................................................................8 Figure 4: Print Head Plate From Kit ..............................................................................8 Figure 5: Cable FW52A Female Plug in Print Head Carriage Assembly......................9 Figure 6: Removing SIT Block from the Print Head Carriage ....................................10 Figure 7: Print Heads and 8C Secondary Ink Tanks (SIT) ..........................................11 Figure 8: 8C SIT Assembled........................................................................................12 Figure 9: Distance between the Top of the SIT and the Top of the Print Head Plate..12 Figure 10: Purge Manifold...........................................................................................13 Figure 11: New Purge Valve Bracket ..........................................................................14 Figure 12: the New Bracket Position (Above Cable Duct)..........................................14 Figure 13:Purge Manifold Mounted on New Bracket and at New Location (1800) ...15 Figure 14:Purge Manifold Mounted on New Bracket and at New Location (3200) ...15 Figure 15: Ink Filters and Old Bracket ........................................................................16 Figure 16: Bracket with Dark and Light Filters...........................................................17 Figure 17: Protective Plate on Printing Carriage Unit and IGUS Starting Point.........18 Figure 18: Protective Cover under Cable Chain Tray .................................................19 Figure 19: Bracket at Center of Cable Chain Tray ......................................................20 Figure 20: Adaptor Brackets (from Kit) on Print Head Carriage ................................22 Figure 21: F-shaped Brackets (from kit)......................................................................22 Figure 22: Shelving Separator Unit .............................................................................24 Figure 23: Snapping Lids on IGUS .............................................................................24 Figure 24: New IGUS Secured on Cable Chain Tray..................................................25 Figure 25: IGUS Cable Carrier Print Head Connection (Before Upgrade) .................27 Figure 26: IGUS Cable Carrier Tray Connection (Before Upgrade)...........................27 Figure 27: IGUS Tube Carrier Print Head Connection (Before Upgrade) ..................28 Figure 28: IGUS Tube Carrier Tray Connection (Before Upgrade)............................29 Figure 29: 8C IGUS-Print Head Carriage Adaptor Brackets.......................................30 Figure 30: 8C IGUS-Tray Adaptor Bracket – Left Side..............................................30 Figure 31: 8C IGUS-Tray Adaptor Bracket – Right Side............................................30 Figure 32: 8C IGUS-Tray Adaptor Bracket – Left Side Screw Holes ........................32 Figure 33: 8C IGUS Cable Carrier Cable Tray Connection ........................................32 Figure 34: 8C IGUS-Print Head Carriage Adaptor Bracket – Screw Holes................33 Figure 35 IGUS Cable Carrier Print Head Carriage Connection.................................33 Figure 36: 8C IGUS-Tray Adaptor Bracket – Right Side Screw Holes ......................34 Figure 37: 8C IGUS Right Side – Carriage Tray.........................................................35 Figure 38: 8C IGUS Right Side – Print Head..............................................................36 Figure 39: 8C IGUS – Carriage Tray Installation........................................................36 Figure 40: Jig Location ................................................................................................38 Figure 41: Adaptor Bracket .........................................................................................39 Figure 42: Rivet Gun and Rivets .................................................................................39 Figure 43: Left (C and M) Switch-Block for Installation Purpose Only .....................40

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Figure 44: Switch Block Y and K on Adaptor Bracket ...............................................40 Figure 45: Cabinet Floor Location of Light Main Ink Tanks ......................................41 Figure 46: Light Ink Tanks Front View.......................................................................42 Figure 47: Light Main Ink Tanks Side View...............................................................42 Figure 48: Front View of the Service Cabinet after Installation..................................43 Figure 49: Switch Block Electro-Valves Location ......................................................44 Figure 50: Switch Block Bottom View........................................................................45 Figure 51: Right Switch-Block Bottom View—Black and Yellow Colors.................46 Figure 52: Bracket with Dark and Light Filters...........................................................47 Figure 53: Light Ink Tanks Front View.......................................................................48 Figure 54: Right Switch Block Top View—Black and Yellow Colors.......................49 Figure 55: Two Level Filter Bracket Screw Holes ......................................................50 Figure 56: Ink Control Card with New Labels ............................................................52 Figure 57: IPC Board in Service Cabinet ....................................................................52 Figure 58: GI/O#1 Board Box with New Labels in Service Cabinet ..........................53 Figure 59: GI/O#1 Board Box Schematics ..................................................................53 Figure 60: Cable Duct Top Covers Below Purge Valves (Rubber Bumper on Edges)54 Figure 61: CB and HTB on Rail ..................................................................................55 Figure 62: Light IPC Board and Labeled Cables.........................................................55 Figure 63: Light and Dark IPC Boards ........................................................................56 Figure 64: Rail and Ink I/O Board Location................................................................56 Figure 65: Longer Rail (P/N: 17-1237) .......................................................................57 Figure 66: I/O Ink Board and Accessories...................................................................57 Figure 67: IPC and I/O Ink Boards ..............................................................................62 Figure 68: Y-adaptor Connecting Monitor to PC ........................................................63 Figure 69: Mouse Shelf Location ................................................................................64 Figure 70: New Bracket ...............................................................................................65 Figure 71: Green Latch and D-types Connection ........................................................66 Figure 72: FPP Board and Parts from Kit ....................................................................66 Figure 73: FPP Board with Bracket .............................................................................66 Figure 74: FPP Board installed with Nut from Kit ......................................................67 Figure 75: Nut and Screw from Kit .............................................................................67 Figure 76: Install Window ...........................................................................................68 Figure 77: Choose Search and Install Option Window ...............................................68 Figure 78: Hardware Type Window ............................................................................69 Figure 79: Device Driver Window ..............................................................................69 Figure 80: Install from Disk Dialog Box .....................................................................70 Figure 81: Locate File Dialog Box ..............................................................................70 Figure 82: Select Device Driver Window....................................................................71 Figure 83: System Properties Window with Device Manager Tab .............................72 Figure 84: Device Manager Window...........................................................................73 Figure 85: Update Driver Window ..............................................................................73 Figure 86: Hardware Update Wizard...........................................................................74 Figure 87: Installation Options Window......................................................................74

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Figure 88: Select Device Driver Window....................................................................75 Figure 89: Install From Disk Dialog Box ....................................................................75 Figure 90: Locate File Dialog Box ..............................................................................75 Figure 91: New label to Add below Existing Label on Printer....................................77 Figure 92: Calibration of the SIT Assembly................................................................79 Figure 93: Main Ink Tanks ..........................................................................................93 Figure 94: Five-Microns Filter.....................................................................................93 Figure 95: SIT Draining...............................................................................................93 Figure 96: Disconnecting the Print Head.....................................................................98 Figure 97: Print Head Protective Cover (Securing Screws Encircled) ........................98 Figure 98: Removing the Print Head Protective Cover ...............................................98 Figure 99: Print Head Plate..........................................................................................99 Figure 100: Unscrewing the Print Head Allen Screw..................................................99 Figure 101: Removing the Print Head .........................................................................99 Figure 102: Print Head...............................................................................................100 Figure 103: Removing the Print Head Protective Cover Shields ..............................103 Figure 104: Rulers......................................................................................................103 Figure 105: Eight Adjustments Assemblies...............................................................104 Figure 106: Adjustment Assembly ............................................................................104 Figure 107: 6 mm Distance between the Plate and Carriage .....................................105 Figure 108: Indicator Holders A and B......................................................................106 Figure 109: Arm for Indicator....................................................................................106 Figure 110: Micrometer Indicator..............................................................................106 Figure 111: Indicator Holder B, Arm, and Micrometer IdicatorAssembled..............107 Figure 112: Back Right Screw that Secures Print Head Carriage to its Base............107 Figure 113: Front Left Screw that Secures the Print Head carriage to its Base.........108 Figure 114: Calibrating the Minimum Distance ........................................................109 Figure 115: Indicator Holder A, Arm, and Micrometer IdicatorAssembled .............111 Figure 116: Two Micrometers Pointing to the Print Head Plate Face.......................112 Figure 117: Micrometer Calibration ..........................................................................112 Figure 118: Horizontal Calibration............................................................................115

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1. General The 8C Optional Upgrade kit allows the Fresco HiQ to print in either 8 or 4-color mode. This document describes how to install the 8C Upgrade kit on NUR Fresco HiQ printers (1800 and 3200).

2. Estimated Installation Time The upgrade requires that two Field Service Engineers (FSEs) perform the upgrade for a period of three days, and that one FSE remains on-site for an additional two days of on-site training and accompanied production.

3. Additional Required Tools

• Crimping tool for pin terminals. An example of a crimping tool is displayed below.

• Calibration Kit (P/N: 200-60-00-002)

• Drill

Figure 1: Crimping Tool

4. Preparation for Upgrade

IMPORTANT!!

Perform the Wake-Up procedure, and Print the "All Nozzles" Pattern

before beginning the upgrade installation. Show the printout to the

customer and save this pattern as proof of the print heads’ condition prior

to the upgrade!!! 1. Make sure that no substrate is loaded on the printer.

2. Empty all the Main Ink Tanks into separate empty containers for reuse.

3. Perform the Ink System Flushing Procedure (refer to Appendix A).

4. Power down the machine and cut the air pressure.

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5. Replacing the Print Head Carriage Plates Since the 8C upgrade uses a new Print Head setup, you must replace of the Print Head carriage plates.

Replace the Print Head plates as follows:

1. Remove three M5 screws from the Print Head cover shield using a 4 mm Allen key and remove Print Head cover shield (refer to Figure 2). See Appendix B on page 96 for details.

PH Plate toReplace

Locating Pin

PH Cover Shield Removed

Rulers

Figure 2: Removing the Print Head Cover Shield

2. Disassemble the Print Head cover shield, that was removed above, as follows:

• Remove the 22 screws (do not discard) (using a Phillips screwdriver) to remove the frame from the Print Head shield (refer to Figure 3). Do not discard the frame. Discard the shield.

• Clean the frame thoroughly with solvent.

3. Mount the new Print Head cover shield (from kit) on the frame that was removed in the previous step, and secure it with the original 22 screws. Ensure to tighten the screws in a cris-cross pattern.

4. Remove the Motherboard cover.

5. Remove all the Print Heads (See Appendix B on page 96 for details).

6. Remove the Print Head plate and its locating pins from the Print Head carriage as follows:

Warning: Keep all parts of the eight adjustment assemblies, as these parts will be used later.

• Remove the eight adjustment assemblies.

• Remove the Print Head plate from the Print Head carriage.

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7. Remove the two-sided rulers from the Print Head plate.

8. Secure the rulers removed in step 6 to the new Print Head plate (from kit PN: 10-0810).

9. Use the eight adjustment assemblies to secure the new plate with rulers to the Print Head carriage (refer to Appendix C on page 101 and Figure 4).

10. Do not calibrate the Print Head plate yet; this will be done at a later stage (see Appendix C, on page 101 for details).

PH Shield

Frame

AdjustmentAssemblies(8 Total)

Pin (4 Total)

Figure 3: Print Head Cover Shield Assembly Figure 4: Print Head Plate From Kit

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6. Replacing the Current 4C-SIT with the 8C SIT A Secondary Ink Tank (SIT) unit is required for each ink color. Therefore, when upgrading to 8 colors, you need to replace the 4C SIT block with the 8C SIT block.

Removing the Current 4C SIT Block

1. Disconnect cable FW52A (the SIT floaters sensor cable) from the female plug, as displayed below.

Cable FW52A Female Plug

Figure 5: Cable FW52A Female Plug in Print Head Carriage Assembly - Disconnected

2. Disconnect all tubes leading to the current SIT block before removing it, as follows:

Note: When disconnecting tubes, use the silicon caps provided in your kit (P/N: 200-60-00-004 and 200-60-00-005) to cap the tubes and corresponding fittings on the SITs.

• Disconnect the four vacuum tubes using a 7 mm wrench.

• Disconnect the four pressure tubes from the SIT block using a 10 mm wrench.

• Disconnect all purge tubes from the SIT block.

• Disconnect the PHs’ 16 tubes that run from the manifold the SITs using a 7 mm wrench.

Note: Make sure to label each Print Head tube before disconnecting it from its SIT.

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3. Unscrew the four M6 screws on the back of the Print Head carriage plate using a 5 mm Allen key.

Caution: Be careful when unscrewing the SIT since it could tip forward.

4. Remove the SIT block.

Figure 6: Removing SIT Block from the Print Head Carriage

Installing the New 8C SIT Block

1. In the kit, locate the new 8C SIT block (P/N: 10-0595).

2. Secure the new 8C SIT (from kit) to the Print Head carriage plate using the four M6 screws removed in step 3 above.

3. Connect cable FW52A to the female plug where the previous plug was removed (see Figure 5).

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4. Remove the silicon caps and use a 7 mm wrench to connect the Print Head outlets tubes from the flushing manifold, as follows:

• Connect Print Heads 7,8 and 6,5 to the dark SIT and Print Heads 4,3 and 2,1 to the light SIT (see Figure 7 and Figure 7).

• Repeat for the remaining three colors.

5. Before tightening the SIT screws, make sure that the distance between the SIT wall and the Print Head carriage plate is exactly 81.5 mm (see Figure 9).

7,8

6,5 4,3 2,1

7,8

6,54,3

2,1

PH Outlets Dark K (7,8/6,5) Light K (4,3/2,1)

Dark SIT Light SIT

Y-ConnectorPurge Outlet

Pressure Outlet

PH Outlets

14-Micron Filter

Vacuum Outlet

Restrictor M

C

Y

K

Figure 7: Print Heads and 8C Secondary Ink Tanks (SIT)

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K

C

M

Y

Dark SITLight SIT

Purge Outlet Connector Dark

Y-Connector and Purge Outlet

Purge Connector Light

14 MicronFilter

Pressure Inlet

Restrictors (2)

PH Outlets Tubes Circled

Vacuum Outlet

Figure 8: 8C SIT Assembled

Distance from A to B Should be 81.5 mm

Figure 9: Distance between the Top of the SIT and the Top of the Print Head Plate

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7. Purge Manifold Relocation The Purge Valves Manifold must be relocated because the current location of the Purge Manifold is required for installing the new filter bracket.

Removing the Purge Manifold Bracket

Remove the old purge manifold bracket as follows:

1. Cut the tie-wraps of the Inlet purge valves and the outlets tubes (to Print Head Carriage) (see Figure 10).

Tube Connector

Purge Tubes

Purge Bracket

Outlet Tube

Inlet Tube

Four M5 Allen Screws Two M8

Allen Screws Hidden

Figure 10: Purge Manifold

2. Disconnect all purge tubes leading to the purge valves with the exception of the outlet tube using a 12 mm wrench (see Figure 10).

3. Remove the four M5 screws (two on each side) from the bracket using a 4 mm Allen key. Save the screws (see Figure 10).

4. Remove the two M8 screws that secure the old bracket to the wall using a 6 mm Allen key. Save the screws and discard the bracket (see Figure 10).

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Installing the New Purge Manifold Bracket

Install the new purge manifold bracket as follows:

1. Locate the purge manifold bracket in the kit (P/N: 17-0623).

Figure 11: New Purge Valve Bracket

2. Locate the four bores above the cable duct (see Figure 12).

Figure 12: the New Bracket Position (Above Cable Duct)

3. Secure the new bracket above the cable duct as far to the right as possible using two M8x10 screws from the kit (P/N: 12-0148) and two washers (P/N: 0061-30-009) (see Figure 12 and Figure 13).

4. Carefully, lift the purge valve manifold and secure it to the new bracket with the Allen screws that were previously removed (refer to Figure 13 for Fresco HiQ 1800 and Figure 14 for Fresco HiQ 3200).

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S crew s

Figure 13:Purge Manifold Mounted on New

Bracket and at New Location (Fresco HiQ 1800)

Figure 14:Purge Manifold Mounted on New

Bracket and at New Location (Fresco HiQ 3200)

Screws Circled

5. Reconnect the air inlet tube only and shorten it to fit.

Note for Fresco HiQ 3200: The spittoon 10 mm nylon tube is too short for the new setup and may get caught in the purge valve unit. The longer nylon tube included in the kit solves this problem.

Make sure that the spittoon tube is empty of ink before disconnecting and replacing it.

6. Disconnect both ends of the current 10 mm nylon tube from the spittoon using a 14 mm wrench and replace with the one from kit (P/N: 000-14-01-013).

7. If necessary, cut the tube to adjust its length.

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8. Replacing the 5-Micron Filter Bracket with the 8C Filter Bracket The 8C upgrade requires nine 5-micron filters. You must install a new filter bracket to hold the additional filters.

Removing the 5-Micron Filter Bracket

Note: Make sure to wear protective gloves and to place cloths on the Service Cabinet floor to collect the ink dripping from the filter/quick connectors.

1. Push on the quick connector of the filter inlet to release the inlet tubes (refer to Figure 15).

2. To release the filters, push on the release button of the filter outlet quick connectors and remove them (refer to Figure 15). Discard these filters.

3. Disconnect the outlet tubes from the filter's quick connectors using an 11 mm wrench. Insert a silicon cap on each tube to prevent dripping (refer to Figure 15).

4. Disconnect all ink pressure tubes from the 5-micron filter’s quick connectors (refer to Figure 15). Do not discard the quick connectors. You will need to connect them later to the new filter bracket.

5. Remove the two M6 screws securing the bracket to the chassis using a 5 mm Allen key, and remove the bracket (refer to Figure 15). Do not discard the screws; you will use these at a later stage.

6. Remove the nuts from the quick connectors using 19 mm (on top) and 21 mm (bottom) wrenches, and remove the quick connectors (refer to Figure 15). Do not discard; you will use these at a later stage.

7. Remove the five nuts on the filter outlets from the upper section of old bracket using an 11 mm wrench (refer to Figure 15). Do not discard; you will use these at a later stage.

19 mm Nut

21 mm Nut

Draining Cap

Filter Inlet Quick Connector

5 Micron Ink Filter

Filter Outlet Quick Connector

Release Knob

M6 Screw

11 mm Nut (Remove & Save)

Figure 15: Ink Filters and Old Bracket

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Note: At the end of this process, you should have 10 quick connectors for later use.

Note: An extra quick connector (PN: 200-40-05-311) is supplied in the kit, if required.

Installing the 8C Filter Bracket

1. In the kit, locate the filters assembly bracket (P/N: 10-0802) and the nine new 5-micron filters (P/N: 200-40-05-309).

2. Connect the nine new 5-micron filters to each quick connector on the bracket (refer to Figure 16)

3. Plug-in nine quick connectors that were removed above to the filter inlets.

Light Ink Filters

Dark Ink Filters

Solvent Filter

Draining Cap Circled

Figure 16: Bracket with Dark and Light Filters

Note: The 8C Filter Bracket is installed onto the chassis only after the hydraulics are connected, to enable easier hydraulic connection. See section 15 on page 50 on for details.

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9. IGUS Replacement—Fresco HiQ 3200 Both the Left Side IGUS Cable Carrier and the Right Side IGUS Tube Carrier must be replaced. For the Left Side IGUS Cable Carrier, the IGUS is removed without the cables that it encases—the cables remain attached to the printer while the cable chain is replaced. For the Right Side IGUS Tube Carrier, the IGUS is removed with its tubes—the tubes are removed with the IGUS. The new Right Side IGUS Tube Carrier comes equipped with the tubes inside.

Note: This section refers to the Fresco HiQ 3200 only. If you are upgrading Fresco HiQ 1800 skip to section 10 on page 26.

Note: Refer to Logistics on page 83 throughout this process for a listing of material disposition.

The following terminology for the IGUS is used in this section:

Complete Name Name Used in this Section Left Side IGUS Cable Carrier IGUS Cable Carrier Right Side IGUS Tube Carrier IGUS Tube Carrier

Removing the IGUS Cable Carrier (Fresco HiQ 3200)

1. Position the Print Head Carriage as far right as possible.

2. Remove the cables from the Cable Carrier as follows:

• Start with the side connected to the Print Head carriage (refer to Figure 17).

IGUS Cable Carrier Outer Lids Base of the PH Carriage IGUS Tube Carrier

IGUS Cable Carrier Adaptor Bracket

IGUS Tube Carrier Adaptor Bracket

Two Screws on Each Side Circled

Figure 17: Protective Plate on Printing Carriage Unit and IGUS Starting Point

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• Position a flat screwdriver inside the lid's two openings and push slightly down to open the outer lids. Start from the left side to last lid on the outer radius of the IGUS Cable Carrier. Do not discard (refer to Figure 17).

• Pull all the cables out of the IGUS Cable Carrier and lay them down away from the linear encoder scale.

3. Remove the four screws that secure the IGUS Cable Carrier to the adaptor bracket on the left side of the Print Head carriage using a 4 mm Allen key (refer to Figure 17). Do not discard.

4. Remove the two M5 screws that secure the adaptor bracket to the right side of the Print Head carriage using a 4 mm Allen key. Do not discard (refer to Figure 17).

5. Loosen the four protective cover nuts under the cable chain tray using an 8 mm wrench. Disconnect the air gun tube from the quick-connector (refer to Figure 18).

Air Gun Quick Connector

Four 8 mm Nuts Circled

Protective Cover

Figure 18: Protective Cover under Cable Chain Tray

6. Remove the four M5 screws that secure the IGUS Cable Carrier end to the cable chain tray using a 4 mm Allen key.

Caution: Remove the IGUS Cable Chain carefully. Avoid hitting or damaging the Linear Encoder Scale.

7. Remove the IGUS Cable Carrier.

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8. Remove the two M6 screws on the bracket (left side) from the center of the cable chain tray using a 4 mm Allen key, while holding the nut beneath it with a 10 mm wrench (refer to Figure 19). Do not remove the bracket.

IGUS Cable Carrier

Two Left M6 Screws

Two RightM6 Screws

8 mm Nut Below M6 Screw

Bracket at Center of Cable Chain Tray

Figure 19: Bracket at Center of Cable Chain Tray

Removing the IGUS Tube Carrier (Fresco HiQ 3200)

Note: When disconnecting tubes, use the silicon caps provided in your kit (P/N: 200-60-00-004 and 200-60-00-005) to cap all end tubes and SIT inlets.

1. Position the Print Head carriage as far left as possible.

2. Disconnect all remaining tubes, in the IGUS Tube Carrier, as follows:

• Disconnect the solvent tube from the 14-micron filter and from the flushing manifold using a 10 mm Allen key.

• Disconnect the air flush inlet tube from the air flush valve assembly and from the air flush gauge inside the pneumatics cabinet.

3. Remove the four M5 screws that secure the IGUS Tube Carrier, to the adaptor plate on the right side of the Print Head carriage using a 4 mm Allen key (refer to Figure 17).

4. Remove the two M5 screws that secure the adaptor plate to the right side of the Print Head carriage using a 4 mm Allen key. Do not discard (refer to Figure 17).

5. Remove the four M5 screws that secure the IGUS Tube Carrier end to the cable chain tray using a 4 mm Allen key.

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Caution: Remove the IGUS Cable Chain carefully. Avoid hitting or damaging the Linear Encoder Scale.

6. Remove the IGUS Tube Carrier.

7. Remove the two M6 screws on the bracket (left side) from the center of the cable chain tray using a 4 mm Allen key, as you hold the nut below with a 10 mm wrench (refer to Figure 18). Do not remove the bracket.

Installing the 8C IGUS Adaptor Brackets (Fresco HiQ 3200)

1. In the Kit, locate the following IGUS brackets:

• The left IGUS F-shaped bracket (P/N: 17-1376) and the right IGUS F-shaped bracket (P/N: 17-1379), for the center of the cable chain tray.

• The left IGUS bracket (P/N: 17-1381) and the right IGUS bracket (P/N: 17-1380) for the Print Head carriage.

2. In the kit, locate the two IGUS cable chains:

• The IGUS Cable Carrier assembly (P/N: 10-0755).

• The IGUS Tube Carrier assembly (P/N: 10-0806).

3. Secure the left and right adaptor brackets on the left and right sides of the Print Head carriage, in place of the removed bracket, using a 4 mm Allen key and the screws removed from the previous Print Head carriage bracket (refer to Figure 20).

4. Secure the F-shaped brackets to the 2 new IGUS assemblies using for each bracket:

• A 4 mm Allen key

• Four M5x20 screws (P/N: 000-61-10-066)

• Four spring washers (P/N: 000-61-30-005)

• Four flat washers (P/N: 000-61-30-023)

Note: Secure the F-shaped brackets to the IGUS cable chain away from the printer.

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5. Cut a section from the rubber bumper (P/N: 000-62-00-038) to insert in the outer edge of the F-shaped brackets (refer to Figure 21).

Left Bracketon PH Carriage

Right Bracket on PH Carriage

M6 screws secure bracket to PH carriage

Four M6x16 screws secure IGUS to bracket

Figure 20: Adaptor Brackets (from Kit) on Print Head Carriage

Left Bracket on Cable Chain Tray

Right Bracket on Cable Chain Tray

Four M5x16 Screws to Secure IGUS to Bracket (Circled)

Two M6x20 Screws Secure Bracket to X-axis

Insert Rubber Bumper at Edges

Figure 21: F-shaped Brackets (from kit).

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Installing the IGUS Cable Carrier (Fresco HiQ 3200)

Caution: When installing the IGUS Cable Carrier, carefully avoid hitting or damaging the Linear Encoder Scale.

1. Place the new IGUS Cable Carrier along the cable chain tray on the left of the Print Head carriage.

2. Secure the left F-shaped bracket (previously connected to the IGUS) to the left side cable chain tray using a 4 mm Allen key and the two M5x20 screws (P/N: 12-0076) (refer to Figure 21 and Figure 24).

3. Remove the snap-on upper lids all along the IGUS using a flat screwdriver.

4. Place the electrical cables that were removed from the previous IGUS Cable Carrier into the open new IGUS Cable Carrier.

5. Secure the cables along the IGUS Cable Carrier using the eleven shelving separators (from kit, P/N 19-0104) (refer to Figure 22) as follows:

Note: Make sure to install a shelving separator unit at both ends of the IGUS cable chain.

• Starting from the side of the cable chain tray, insert the shelving separator, one at a time, at a slight angle, inside the IGUS Cable Carrier and snap it on the lower lid.

• Push the shelving separator’s vertical separators together to ensure that there is enough room to insert cables in the outer chambers.

• Insert the cables in the right and left compartments of the shelving separators, each in its own chamber.

• Ensure that cables FW30A and FW30B are inserted in the two lower compartments.

Note: No cables should be inserted in the middle vertical chambers.

• Repeat the bulleted steps above, at an interval of eight snap-on lids.

Caution: Do not create pressure between the cables and the sidewalls of the IGUS Cable Carrier (refer to Figure 22).

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Vertical Separator

Horizontal Shelf

Tilt and Snap-on

Thicker Cable

Thinner Cable

Figure 22: Shelving Separator Unit

6. Reassemble the snap-on lids all along the IGUS Cable Carrier. You may need to use a pair of pliers to assist you in this task (refer to Figure 23).

Pair of Pliers

Snap-on Lids

Figure 23: Snapping Lids on IGUS

Caution: Do not use a hammer to force the snap-on lids back on the IGUS cable chain.

7. Secure the IGUS Cable Carrier to the adaptor bracket on the Print Head carriage using:


• Four M6x16 screws (P/N: 000-61-10-050)


Note: Use tie wraps to secure the cables to the IGUS walls at both ends of the IGUS Cable Carrier (P/N:000-50-15-042 and 000-50-15-096).

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Installing the IGUS Tube Carrier (Fresco HiQ 3200)

Caution: When installing the IGUS Tube Carrier, carefully avoid hitting or damaging the Linear Encoder Scale.

1. Place the new IGUS Tube Carrier along the cable chain tray on the right of the Print Head carriage.

2. Lift the new IGUS Tube Carrier onto the cable chain tray and insert the hydraulic tubes (bundled up) into the cable duct, under the cable chain tray.

3. Route the tubes from the cable duct through the opening in the service cabinet above the Main Ink Tanks and secure the tubes with tie-wraps. You will connect the tubes at a later stage.

4. Secure the left F-shaped bracket (previously connected to the IGUS) to the right side cable chain tray using a 4 mm Allen key and the two M5x20 screws (P/N: 12-0076) (refer to Figure 21 and Figure 24). You will connect the hydraulic tubes on the IGUS Tube Carrier to the new SIT at a later stage.

5. Reconnect the air gun tube to the quick connector (removed in step 5/page 19) and reinstall the protective cover back in its original location (refer to Figure 18).

6. Secure the Right Side Tube IGUS to the adaptor bracket on the Print Head carriage using:


• Four M6x16 screws (P/N: 000-61-10-050)

• Spring washers (P/N: 000-61-30-006)

Once installed, the IGUS appears as follows.

Cable Chain Tray

F-Shaped Bracket Secured on Top of Existing Bracket

M6x204 Total

M5x16 Circled 8 Total

IGUS Cable Carrier IGUS Tube Carrier

Figure 24: New IGUS Secured on Cable Chain Tray

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10. IGUS Replacement—Fresco HiQ 1800 Both the Left Side IGUS Cable Carrier and the Right Side IGUS Tube Carrier must be replaced. For the Left Side IGUS Cable Carrier, the IGUS is removed without the cables that it encases—the cables remain attached to the printer while the cable chain is replaced. For the Right Side IGUS Tube Carrier, the IGUS is removed with its tubes—the tubes are removed with the IGUS. The new Right Side IGUS Tube Carrier comes equipped with the tubes inside.

Note: This section refers to the Fresco HiQ 1800 printer only. If you are upgrading Fresco HiQ 3200, refer to section 9 on page 18.

Note: Refer to Logistics on page 83 throughout this procedure for a listing of material disposition.

The following terminology for the IGUS is used in this section:

Complete Name Name Used in this Section Left Side IGUS Cable Carrier IGUS Cable Carrier Right Side IGUS Tube Carrier IGUS Tube Carrier

Removing the IGUS Cable Carrier (Fresco HiQ 1800)

1. Position the Print Head Carriage as far right as possible.

2. Remove the cables from the IGUS Cable Carrier as follows:

• Start with the side connected to the Print Head carriage (refer to Figure 17).

• Position a flat screwdriver inside the lid's two openings and push slightly down to open the outer snap-on lids. Start from the left side to last snap-on lid on the outer radius of the IGUS Cable Carrier. Do not discard.

• Pull all the cables out of the IGUS Cable Carrier and lay them down.

3. Remove the four screws that secure the IGUS Cable Carrier to the left side of the Print Head Carriage using a 4 mm Allen key (see Figure 25).

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4. Remove the two screws that secure the IGUS Cable Carrier to the IGUS tray at the center of the cable chain tray using a 4 mm Allen key (see Figure 26). Do not discard

5. Remove the IGUS Cable Carrier.

Figure 25: IGUS Cable Carrier Print Head Connection (Before Upgrade)

Figure 26: IGUS Cable Carrier Tray Connection (Before Upgrade)

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Removing the IGUS Tube Carrier (Fresco HiQ 1800)

Note: When disconnecting tubes, use the silicon caps provided in your kit (P/N: 200-60-00-004 and 200-60-00-005) to cap all end tubes and SIT inlets.

1. Position the Print Head Carriage as far left as possible.

2. Disconnect the remaining tubes in the IGUS Tube Carrier, as follows:

• Disconnect the solvent tube from the 14-micron filter and from the flushing manifold using a 10 mm Allen key.

• Disconnect the air flush inlet tube from the air flush valve assembly. Inside the pneumatic cabinet, disconnect the air flush gauge.

3. Remove the two M5 screws that secure the IGUS Tube Carrier to the right side of the Print Head carriage using a 4 mm Allen key (see Figure 27).

4. Remove the two M5 screws that secure the IGUS Tube Carrier to the cable chain tray using a 4 mm Allen key (see Figure 28). Do not discard.

5. Remove the IGUS Tube Carrier.

Figure 27: IGUS Tube Carrier Print Head Connection (Before Upgrade)

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Figure 28: IGUS Tube Carrier Tray Connection (Before Upgrade)

Installing the 8C Adaptor Brackets (Fresco HiQ 1800)

1. In the Kit, locate the IGUS brackets:

• Left and right IGUS-Print Head carriage adaptor brackets, which will be connected to the Print Head carriage, (17-1402).

• Left and right IGUS-tray adaptor brackets (P/N: 17-1403), which will be connected to the center of the cable chain tray.

2. Install the IGUS-Print Head carriage adaptor brackets on the Print Head carriage, as follows:

• Position the adaptor brackets on the Print Head carriage, where the previous IGUS was connected. Ensure that the bottoms of the adaptors are facing you as you place them on the Print Head carriage, as displayed in Figure 29.

• Secure the adaptor brackets to each side of the Print Head carriage using a 4 mm Allen key and four M5x16 screws (P/N: 12-0085) (refer to Figure 29).

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Figure 29: 8C IGUS-Print Head Carriage Adaptor Brackets

3. Install the IGUS-cable chain tray adaptor brackets as follows:

• Position the brackets on the cable chain tray, where the previous IGUS was connected. Ensure that the outer sides of the adaptors as displayed in Figure 30 and Figure 31 are facing away from the tray funnel.

• Secure the adaptor brackets to each side of the IGUS cable chain tray using the two slotted flat screws from the previous IGUS and a 4 mm Allen key.

Figure 30: 8C IGUS-Tray Adaptor Bracket – Left

Side Figure 31: 8C IGUS-Tray Adaptor Bracket – Right

Side

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Installing the IGUS Cable Carrier (Fresco HiQ 1800)

1. In the kit, locate the IGUS Cable Carrier (P/N: 10-0812).

2. Place the IGUS Cable Carrier on the cable chain tray.

3. Secure the cables along the IGUS Cable Carrier using the eleven shelving separators (from kit, P/N 19-0104) to (refer to Figure 22) as follows:

Note: Make sure to install a shelving separator unit at each end of the IGUS Cable Carrier.

• Starting from the side of the cable chain tray, insert the shelving separator, one at a time, at a slight angle, inside the IGUS Cable Carrier and snap it on the lower lid.

• Push the shelving separator’s vertical separators together to ensure that there is enough room to insert cables in the outer chambers.

• Insert the cables in the right and left compartments of the shelving separators, each in its own chamber.

• Ensure that cable FW30A and cable FW30B are inserted in the two lower compartments.

Note: No cables should be inserted in the middle vertical chambers.

• Place shelving units in the IGUS Cable Carrier at an interval one shelving unit every eight snap-on lids.

Caution: Do not create pressure between the cables and the sidewalls of the IGUS cable chain (refer to Figure 22).

4. Put back the snap-on lids all along the IGUS Cable Carrier. You may need to use a pair of pliers to assist you in this task (refer to Figure 23).

Caution: Do not use a hammer to force the snap-on lids back on the IGUS Cable Carrier.

5. Secure the tray end of the IGUS Cable Carrier to the four holes of the IGUS-tray adaptor bracket using:

• Four socket screws (P/N: 000-61-10-066)


• Four flat washers (P/N: 000-61-30-023) (refer to Figure 32)

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Figure 32: 8C IGUS-Tray Adaptor Bracket – Left Side Screw Holes

Once installed, the IGUS Cable Carrier appears as follows.

Figure 33: 8C IGUS Cable Carrier Cable Tray Connection

6. Secure the Print Head carriage end of the IGUS Cable Carrier to the four holes of the IGUS-Print Head carriage adaptor bracket using:


• Four M5x16 screws (P/N: 000-61-10-066)

• Four Spring washers (P/N: 000-61-30-005)


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Figure 34: 8C IGUS-Print Head Carriage Adaptor Bracket – Screw Holes

Once installed, the IGUS Cable Carrier appears as follows.

Figure 35 IGUS Cable Carrier Print Head Carriage Connection

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Installing the IGUS Tube Carrier (Fresco HiQ 1800)

1. In the kit, locate the IGUS Tube Carrier assembly (P/N: 10-0813).

2. Place the IGUS Tube Carrier on the IGUS tray.

3. Route the IGUS tubes through the tray funnel under the X-axis into the Service Cabinet (see section 12.11 for details on tube connections).

4. Secure the tray end of the IGUS Tube Carrier to the four holes of the IGUS-tray adaptor bracket using the using:


• Four M6x16 screws (P/N: 000-61-10-066)



Figure 36: 8C IGUS-Tray Adaptor Bracket – Right Side Screw Holes

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Once installed, the IGUS Tube Carrier appears as follows.

Figure 37: 8C IGUS Right Side – Carriage Tray

5. Secure the Print Head carriage end of the IGUS Tube Carrier to the four holes of the IGUS-Print Head carriage adaptor bracket using:


• Four M5x16 screws (P/N: 000-61-10-066)


• Four flat washers (P/N: 000-61-30-23) (refer to Figure 34).

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Once installed, the IGUS Tube Carrier appears as follows.

Figure 38: 8C IGUS Right Side – Print Head

Both sides of the new IGUS-cable chain tray installation appear as follows: Left Side IGUS Right Side IGUS

Figure 39: 8C IGUS – Carriage Tray Installation

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11. Tubes (Hydraulic) Connection for IGUS

Note: You may need to shorten the tubes to fit them into their respective locations.

Caution: Although the hydraulic tubes are labeled, make sure to verify that you connect each tube to its proper location.

1. Connect all tubes leading to the SIT as follows:

• Connect the eight pressure tubes (labeled, from IGUS) to the 8C SIT using a wrench (refer to Figure 8).

• Connect the eight vacuum tubes to the 8C SIT vacuum tubes connectors using a wrench (refer to Figure 8).

• Reconnect the four purge tubes to the Y-connector of the 8C SIT (refer to Figure 8).

2. Reconnect the solvent tube to the flushing manifold.

3. Reconnect the air flush tube to the air flush assembly.

4. Reconnect the four purge tubes to the purge valve manifold (refer to Figure 10).

5. Reconnect the solvent tube to the solvent 14-micron filter.

6. Reconnect the air flush tube to air flush valve, in the pneumatic panel.

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12. Installing the Switch-Blocks In the 8C upgrade, both 8 color and 4 color printing is possible. The Switch Blocks enable you to switch between the two color settings.

Drilling Holes in Service Cabinet Wall

1. Tape the jig (from kit, P/N: 17-1545) to the wall of the service cabinet so that the bottom left corner is approximately 1 cm above the cable opening and approximately 1 cm to the right of the cable opening, as displayed in Figure 40.

Figure 40: Jig Location

2. Drill four holes through the jig holes using a drill and 4 mm drill bit (P/N: 90-0046).

3. Remove the jig.

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Installing the Switch Blocks

The Switch Blocks (P/N: 10-0830) arrive connected to cable # 23-0399 and to 6 mm tubing.

Install the Switch Blocks as follows:

1. Position the adaptor bracket with the hole facing up, onto the wall of the service cabinet so that the adaptor holes (see Figure 41) align with the holes on the wall.

Figure 41: Adaptor Bracket

Hole Facing Up

2. Secure the Switch Blocks to the upper holes (refer to Figure 42) using the rivet gun (P/N: 90-0047) and the rivets (P/N: 000-62-00-057) as follows:

• Insert a rivet into the rivet gun, with the long end in first (refer to Figure 42).

Figure 42: Rivet Gun

• Align the rivet gun with the upper left hole on the adaptor bracket, and squeeze the gun several times until the rivet is firmly inside the hole and the gun is freed (refer to Figure 43).

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Rivets Cable # 23-0393 Adaptor Bracket

Holes to Support Switch-Block

Figure 43: Left (C and M) Switch-Block for Installation Purpose Only

3. Repeat the above steps for the right hole.

4. Drill the two bottom holes directly through the adaptor plate using a drill and 4 mm drill bit (P/N: 90-0046).

5. Repeat step 2 above to insert the rivets into bottom holes (refer to Figure 43).

6. Secure the Black (K) and Yellow (Y) Switch Block to the right side of the adaptor bracket using the screws (P/N: 12-0077), spring washers (P/N: 000-61-30-006) and flat washers (P/N: 000-61-30-022) (refer to Figure 44).

Adaptor Bracket

Hole on Adaptor Bracket

Switch Block Y and K

Figure 44: Switch Block Y and K on Adaptor Bracket

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7. Secure the Cyan (C) and Magenta (M) Switch Block to the left side of the adaptor bracket as described in step 6.

13. Installing the Light Main Ink Tanks Assembly 1. Unscrew the four M5 screws from the floor of the service cabinet using a 4 mm Allen

key. The location of the screws is indicated in Figure 45 below. Do not discard the screws.

Back Screw 4

2

1

3

Figure 45: Cabinet Floor Location of Light Main Ink Tanks

Note: Make sure that the drainage valve bracket on the light Main Ink Tank (MIT) assembly is facing out (refer to Figure 46).

2. Position the new light MIT assembly onto the floor, across from the existing one. Make sure to lift the new tank unit high enough to insert the back screw into the back hole of the Main Ink Tanks (refer to Figure 45).

3. Secure light MIT assembly onto the floor with the screws removed in step 1 above using an Allen key, as follows:

• Remove the cable duct cover, on the light ink tank (refer to Figure 46).

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Vacuum Fitting

Cable Duct

Y C M K

Cable Duct Cover

Pressure Fitting

Figure 46: Light Ink Tanks Front View

• Since the M5 screw is too short, you must first secure the screw (1) and its washers with white tape to the Allen key, then insert into hole of cable duct and tighten (refer to Figure 45 and Figure 47).

Screws Location Circled

Cable Duct Cover

Cable Duct

Screw to Secure Light Ink Tanks

Draining Manifold

YC

MK

Back Screw Hidden 4

1

2

3

Figure 47: Light Main Ink Tanks Side View

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• Tighten screws 2 and 3 back in place to secure the light MIT assembly (refer to Figure 45 and Figure 47).

• Tighten the fourth screw (4) behind the light MIT assembly using an L-shaped Allen key. Secure with tape as above (refer to Figure 45 and Figure 47).

Figure 48 displays the service cabinet after installing the light MITs.

Purge Valve Bracket

Light MITs

Cable Duct

Dark SIT

Drainage

Dark Filters

Light Filters

Duct

Figure 48: Front View of the Service Cabinet after Installation

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14. Switch Block Hydraulic Connections The steps below described the hydraulic connections of all tubes leading in and out from the Switch Blocks. The order described below is from the right Switch Block—Black (BK) and Yellow (YL) colors, to the left Switch Block—Magenta (M), and Cyan (C) colors.

Preparation

Note: Place several cloths on the Service Cabinet floor to absorb all spilled ink.

Note: Make sure to use tie-wraps to secure all tubes leading in and out of the Switch Blocks.

1. Remove electro valve 5C, 6C, 7C, and 8C, from the Yellow and Black Switch Block, to create easier access to the SIT outlet fittings (refer to Figure 49).

2. Remove electro valves 1B, 2B, 3B, and 4B from the Yellow and Black Switch Block, to create easier access to the SIT outlet fittings (refer to Figure 49).

Figure 49: Switch Block Electro-Valves Location

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Figure 50: Switch Block Bottom View

Connecting the Pressure Tubes to Light and Dark Filter Outlets

1. Locate the tube, labeled "Dark K P Filter" (A) on the bottom Black (K) section of the Switch Block, and connect it to the bottom of the dark black filter outlet using an 11 mm wrench (refer to Figure 51 and Figure 52).

2. Locate the tube, labeled "Light K P Filter" (B) on the bottom Black (K) section of the Switch-Block, and connect it to the bottom of the light black filter outlet using an 11 mm wrench (refer to Figure 51 and Figure 52).

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3. Repeat the steps above for the remaining three colors (refer to Figure 51 and Appendix D, DRW# 60-0110).

B: Light K P Filter

E: Light K P Outlet to SIT

A: Dark K P Filter

C: Light K V Pump

H: Light K V Inlet to SIT

E: Light Y P Outlet to SIT

Electro Valve

H: Light Y V Inlet to SIT

A: Dark Y P Filter

C: Light Y V P

B: Light Y P Filter

Definition: P=Pressure V=Vacuum K=Black Y=Yellow

Bottom Right Side Switch-block Black (K) Color

Bottom Left Side Switch-block Yellow (Y) Color

Figure 51: Right Switch-Block Bottom View—Black and Yellow Colors

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Light Ink Filters

Dark Ink Filters

Solvent Filter

Draining Cap Circled

Figure 52: Bracket with Dark and Light Filters

Note: Before connecting any tubes to its fitting, make sure to remove the 10 mm nut from that fitting, insert the nut into the tube then use an 10 mm wrench to secure the tube (and nut) to the fitting.

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Connecting the Vacuum Tubes to Light and Dark Main Ink Tanks

1. Locate the tube, labeled "Light K V Pump" (C) on the bottom Black (K) section of the Switch Block, and connect it to the vacuum fitting (T-connection), of the Black Light Main Ink Tanks (refer to Figure 51 and Figure 53).

Vacuum Fitting T-connection

Cable Duct

Y C M K

Cable Duct Cover

Pressure FittingT-connection

Figure 53: Light Ink Tanks Front View

2. Locate the tube, labeled "Dark K V Pump" (D) on the top Black (K) section of the Switch Block, and connect it to the Black Dark Main Ink Tank’s vacuum pump (T-connection fitting) (refer to Figure 51, Figure 53, and Appendix D, DRW# 60-0110).

3. Repeat the above steps for the remaining three colors (refer to Figure 51 and Appendix D, DRW# 60-0110).

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Connecting the Pressure Tubes to Light Secondary Ink Tanks (SIT)

1. Locate the IGUS chain tube labeled "Light K P SIT" (E) and connect it to the Switch Block fitting behind the electro valve (refer to Figure 54).

D: Dark K V Pump Outlet to Dark Main Ink Tanks

J: Dark Y V Pump Inlet to Dark Main Ink Tanks

J: Dark K V Inlet From Dark SIT

F: Dark K Pressure Outlet to Dark

F: Dark Y Pressure Outlet to Dark

D: Dark Y V Inlet From Dark SIT

Top Right SideSwitch-block Black (K) Color

Top Right Side Switch-block Yellow (Y) Color

Figure 54: Right Switch Block Top View—Black and Yellow Colors

2. Repeat the above step for the remaining three colors (refer to Appendix D, DRW # 60-0110).

Connecting the Vacuum Tubes to the Dark SITs

1. Locate the tube from the IGUS chain, labeled "Dark K V SIT" (J) and connect the tube to its fitting on the top section of the Switch Block (refer to Figure 53 and Figure 54).


Connecting the Pressure Tubes to the Dark SITs

1. Locate the tube from the IGUS chain, labeled "Dark K P SIT" (F) and connect the tube to its fitting on the top section of the Switch Block (refer to Figure 54).


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Connecting the Vacuum Tubes to the Light SITs

1. Locate the tube, from the IGUS chain, labeled "Light K V SIT" (H) and connect the tube to its fitting behind the electro valve (refer to Figure 51).


Reconnect all Electro Valves Previously Removed

1. Connect electro valve 5C, 6C, 7C, and 8C, from the Yellow and Black switch-block (refer to Appendix D, DRW 60-0098).

2. Connect electro valves 1B, 2B, 3B, and 4B from the Yellow and Black switch-block (refer to Appendix D, DRW 60-0098).

15. Screwing the 8C Filter Bracket to the Chassis Wall Secure the 8C Filter Bracket to the chassis wall where the old bracket was mounted using an Allen key, the screws removed from the previous bracket (refer to Figure 48) and two spring washers from the kit (P/N: 000-61-30-009). Use the screw holes specific to your printer, as indicated in Figure 55.

Fresco HiQ 3200

Fresco HiQ 1800 (first models)

Fresco HiQ 1800

Figure 55: Two Level Filter Bracket Screw Holes

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16. Connecting Filter Ink Inlet Tubes 1. Locate the ink pressure tubes that are connected to the pressure pump (lower) at the base

of each MIT.

2. Connect the tube to the inlet quick connector at the top of each 5-micron filter using an 11 mm wrench. Ensure to connect each to tube to its proper color filter.

3. Repeat steps 1 and 2 for each color.

17. Installation of the 8C Ink Pump Control (IPC) and Ink I/O Board

Note: Refer to the Logistic Section on Page 83 throughout the implementation of this upgrade to correctly identify the parts that need to be removed and/or replaced, as well as, the correct screws needed to perform the procedure.

Labeling and Preparation

1. In the kit locate the following labels:

P/N Description 61-0022 DARK IPC LABEL 12X20 BLACK FOR CABLE 61-0023 LIGHT IPC LABEL 12X20 BLACK FOR CABLE 61-0026 DARK PUMPS LABEL 12X50 BLACK FOR CABLE 61-0027 LIGHT PUMPS LABEL 12X50 BLACK FOR CABLE 61-0029 LABEL FOR GI/O 61-0028 12345678 LABEL (FOR GI/O) 12X50 BLACK FOR CABLE

2. Label the existing Ink Pump Control (IPC) Board and its cables with new labels (from kit) as follows (refer to Figure 57):

• Label the Ink Vacuum and Pressure cable # 23-0011 as "Dark Pump" at the three cable endings (refer to Figure 57).

• Label the IPC Board as "Dark" placing the label on the right lower corner (refer to Figure 57).

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“Dark Pumps” Label on Cable #23-0011 (Vacuum & Pressure Pumps)

8C COMM Cable # 23-0381

Cable DuctsCovers

Cable # 23-0375

“Dark” Label on Dark IPC Board

Figure 56: Ink Control Card with New Labels

IPC Board

CB, HTB and Timer

Orange Mount

Rail Hole for New RailCircled

Plastic Duct

Figure 57: IPC Board in Service Cabinet

3. Apply label # 61-0028 on the GI/O # 1 board box above the LEDs and above label # 60-0029 (refer to Figure 58 and Figure 59).

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Figure 58: GI/O#1 Board Box with New Labels in Service Cabinet

Figure 59: GI/O#1 Board Box Schematics

4. Remove all the cable duct plastic covers on the panel (refer to Figure 57).

5. Remove the top cover of the aluminum cable duct above the purge valve manifold and replace with the three-section wall profile (P/N: 19-0090).

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6. Cut small sections to fit each end of the cable duct top-cover (from step above) using the long rubber bumper/gasket (P/N: 000-62-00038) to (refer to Figure 60).

Note: Older printers do not have aluminum cable ducts. Therefore, users of these printers can ignore steps 5 and 6.

Figure 60: Cable Duct Top Covers Below Purge Valves (Rubber Bumper on Edges)

Installing the Light IPC Board

1. In the kit, locate the following:

P/N Description 20-0042 LIGHT IPC BOARD 10-0756 EXTRUDED PROFILE FOR INK CONTROL ASSY 17-1237 DIN RAIL FOR FRESCO 8C

The Extruded Profile for the IPC Board assembly kit (P/N: 10-0756) contains the following:

P/N Description 000-50-16-046 END PLATE PLASTIC,POLYAMID 000-50-16-047 MOUNTING FOOT PLASTIC,POLYAMID 17-0632 EXTRUDED PROFILE PLASTIC RS-SP1 (TAPUZ) 0.25M

2. Mount the Light IPC board and its orange frame as follows:

• Turn the orange frame of the light IPC Board on its back and insert the two snap-on clips. Make sure that the hollow ends are up.

• Slide the Light IPC Board (from kit) into the orange frame. Secure the Light IPC Board by inserting both end sections into the orange frame.

3. Verify that the existing rail that holds the Circuit Breaker (CB) is long enough to support the new Light IPC Board (refer to Figure 57).

4. If the current rail is too short, you must replace it with the new longer rail (from kit, P/N: 17-1237) as follows:

• Remove the Terminal Block (TB) fixture on each side of the CB and the TB using a flat screwdriver to (refer to Figure 62).

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• Remove the CB, timer, and the TB from the rail. You may need to use a flat screwdriver for the yellow TB (refer to Figure 62).

• Remove M4 screws that secure the short rail to the wall using a 3 mm Allen key (refer to Figure 57). Discard short rail and keep the screws for later use.

• Attach the long rail (from kit) in place of the previous one using:

• A 4 mm Allen key to screw in the two screws from the step above

• One M5x10 screw from the kit (P/N: 12-0090)

• A spring washer (P/N: 000-61-30-305)

• A flat washer (P/N: 000-61-30-023) (refer to Figure 62).

5. Position the CB, Timer, and the TB on the new rail at the same location they were at when removed from the previous rail.

6. Reinstall the two TB fixtures from the above step (refer to Figure 61).

TB Fixture Unit

Circuit Breaker

Timer

Hydraulic Tunnel Block (HTB)

Yellow TB

Figure 61: CB and HTB on Rail

7. Snap the assembled Light IPC Board onto the existing rail, next to the CB and Hydraulic Terminal Block (HTB) (refer to Figure 62).

Light IPCLabel

Cable #23-0011

Five Pins Terminal

24VDC TB

Cable Duct Long Rail (From kit)

Screw From Ki Ci l d

Figure 62: Light IPC Board and Labeled Cables

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8. Use the label (from kit) to label the IPC Board as "Light."

Once installed and labeled, both IPC Boards appear as follows.

Figure 63: Light and Dark IPC Boards

Installing the Ink I/O Board

1. Locate the Ink I/O Board Location, displayed in Figure 64.

Rail with Two M5 Screws(Hidden Behind Dark IPC)

Bores Ink I/O Board Location

Figure 64: Rail and Ink I/O Board Location

2. Remove the Dark IPC Board from its rail.

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3. Replace the half length rail with the full length rail from the kit P/N: 17-1237 (see Figure 65) as follows:

Note: This step can be ignored if you already have the full-length rail installed on your printer.

• Remove the short rail from the wall using a 3 mm Allen key to unscrew the screws. Discard the short rail and retain the screws.

Figure 65: Longer Rail (P/N: 17-1237)

• Secure the long rail from the kit in place of the old one using the 3 mm Allen key the two screws from the step above.

4. Locate the I/O Ink Board and Accessories, displayed in the Figure 66. The Ink I/O Board and accessories comprises the following parts: P/N Description 20-0054 INK I/O 24 BOARD ASSEMBLY 10-0756 EXTRUDED PROFILE FOR INK CONTROL ASSY 000-50-16-046 END PLATE PLASTIC,POLYAMID 000-50-16-047 MOUNTING FOOT PLASTIC,POLYAMID

Extruded Plastic Profile

Mounting

I/O Ink Board

End Plates

Figure 66: I/O Ink Board and Accessories

5. Mount the Ink I/O Board in its plastic base, as follows:

• Slide the Ink I/O Board onto the Extruded Plastic Profile.

• Locate the Ink I/O Board and slide both Mounting Feet on its back.

• Snap the End Plates on each end of the I/O Ink profile.

6. Snap the Dark IPC Board on to the right side of the rail.

7. Snap the Ink I/O Board on to the left side of the rail.

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18. Cable Installation Refer to the relevant schematic drawings in Appendix D throughout the cable connection process.

Note: Make sure that you secure all cables with tie-wraps as often as necessary, use tie wraps (P/N:000-50-15-042 and 000-50-15-096) from kit.

Cable # 23-0375: 24 VDC Power Input to the IPC Board

Connect the new cable # 23-0375 as follows:

1. Disconnect the FW91 wires from TB (J3) in the dark IPC Board using a flat screwdriver.

2. Disconnect the wire pins from Hydraulic Terminal Block (HTB) using a flat screwdriver.

3. Cut the tie-wraps securing the FW91 cable; pull the cable out, and discard.

4. Connect the cable # 23-0375 to HTB as follows (refer to Appendix D):

• Red wire to the +24V TB # 4.

• Black wire to the 0/24V TB # 1.

5. Connect the cable # 23-0375 to the two IPC boards as follows:

• Red wire to +24 V (first pin from right).

• Black wire to 0/24 V (second pin from right).

• Make sure to connect the shorter cable to the light IPC board J 3 terminal and the longer cable to the dark IPC board J 3 terminal.

6. Route the cable throughout the cable duct.

Connecting Cable # 23-0395 Communications Cable


1. Disconnect the FW29 communications cable as follows:

• Remove the two screws securing the D-Type connector of the existing FW29 cable on the dark IPC Board using a flat screwdriver, and cut the tie-wraps to free the cable.

• Route and secure the FW29 cable through the open cable ducts closer to the light IPC Board (refer to DRW # 23-0396 in Appendix D). This cable will be connected at a later stage.

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2. Connect the 8C Communications Cable # 23-0395 to both light and dark IPCs and I/O Ink boards as follows (refer to DRW # 23-0396 and the drawings entitled ‘8C Dark Ink Control Board Wiring’ and ‘8C Light Ink Control Board Wiring’ in Appendix D):

• Connect the D-type connector, labeled "23-0395 I/O to Comm, J2" to the Ink I/O board (P1) connector using a flathead screwdriver.

• Connect the D-type connector labeled "23-0395 IPC Dark P3" to the dark IPC board (P3) connector using a flathead screwdriver.

• Connect the D-type connector labeled "23-0395 IPC Light P3" to the light IPC board (P3) connector using a flathead screwdriver.

3. Connect the D-type connector labeled " 23-0395 FW 29" to the D-type connector of the cable FW 29 you disconnected in Step 1 above using a flathead screwdriver.

Connecting Cable # 23-0380 Main Ink Tanks Float Sensors


1. Disconnect the current FW71 cable, Main Ink Tanks float sensor as follows:

• Use a flat screwdriver to unscrew the two screws securing the D-Type connector to GIO-1 board (J1) (refer to Appendix D).

Note: Cut the tie-wraps as required to free the cable.

• Locate cable FW71 in the cable duct, at the base of the dark MITs.

• Disconnect cable FW71’s Molex connectors from cable FW71A’s (K and M) Molex connector (refer to Appendix D).

• Disconnect cable FW71’s Molex connectors from cable FW71B’s (Y and C) Molex connector (refer to Appendix D).

2. Disconnect the current FW75 cable, Main Ink Tanks float sensor 24V power supply cable, as follows:

• Locate cable FW75 in the cable duct, at the base of the dark MITs.

• Disconnect cable FW75’s 2-pin Molex connector.

• Route the Molex connector through the cable duct near the light MITs and secure with tie-wrap near the purge valve (refer to Appendix D).

• You will connect the 2-pins Molex connector to cable #23-0380 in the next step.

3. Connect the new cable # 23-0380 (from kit) as follows:

• Use a flat screwdriver to connect the D-Type connector of the new cable # 23-0380 to GIO-1 board J1 port, in place of the previous cable (refer to Appendix D).

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• Secure the cable # 23-0380 with tie-wraps and route it through the plastic cable (below GIO-1 board) and left side cable ducts.

• Route the longer section of the cable # 23-0380 (see labels on cable) towards the cable duct at the base of the dark MITs and connect the two 6-pin female Molex connectors to the FW71A (K and M ports) and FW71B cables (C and Y ports), respectively (refer to Appendix D).

• Route and secure the shorter end of cable # 23-0380 (see labels on cable) towards the cable duct at the base of the light MITs and connect the two 6-pin female Molex connectors to the FW71A (K and M ports) and FW71B cable (C and Y ports), respectively (refer to Appendix D).

• Connect the 2-pin Molex connector of the FW75 to the cable wire # 23-0380 2-pin Molex connector.

Connecting Cable # 23-0011 to the Light IPC Board Pressure and Vacuum Pumps Input

Connect the new cable # 23-0011 (from kit) as follows:

1. Connect the D-Type connector of the new cable # 23-0011 to the P2 of light IPC Board and secure with tie-wrap the far end close to the light ink tanks.

2. Label the cable (from kit) at both ends, as "Light Pumps."

3. Route the cable to the cable duct at the base of the light MITs.

4. Open the cable duct if it is not already opened.

5. Connect cable #23-0011 labeled “Pres” to the four light Pressure Pumps as follows:

• Connect the 4 Molex connectors on the branch to each of the 4 Molex connectors connected to the Pressure Pumps, according to the color of the isolation tube.

6. Connect the branch of cable # 23-0011 labeled “Vac” to the newly installed light vacuum pumps, as follows:

• Connect each of the 4 Molex connectors on the branch to the Vacuum Pumps according to the color of the isolation tube.

7. Close the cable duct.

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Connecting Cable # 23-0384


Note: Make sure that the color wires connected from one end of the cable to the light IPC board J1 terminal match the wires connected at the other end to the dark IPC board J1 terminal.

1. Connect the 8C Input from the SIT float sensor to Light IPC cable # 23-0384 as follows:

Note: Do this procedure one color wire at a time on the dark IPC board.

• Disconnect the green wire from the J1 terminal on the dark IPC board.

• Locate the green wire (GN) on the cable # 23-0384 labeled "23-0384 IPC Dark J1" (refer to DRW 23-0384 in Appendix D).

• Cut the pin terminal from the wire.

• Insert both green wires from above into the pin terminal and use the crimping tool to tighten the wires and the pin together. Insert the pin terminal back into the J1 terminal of the dark IPC board (refer to DRW # 23-0384 and DRW # 60-0098 in Appendix D).

2. Repeat the above procedure for the remaining Brown (BR), Pink, Grey (GR), and Yellow (YL) colored wires. Again, perform the connection one-color wire at a time.

3. Connect the distal end of cable # 23-0384 to the J1 terminal on the light IPC board. Make sure to connect the wires in the same order as the ones on the dark IPC board (refer to DRW # 23-0384 in Appendix D).

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Cable #23-0399 (P4)

Cable #23-0395 (P1)

Cable #23-0381 Light (P3)

Cable #23-0375 Light (J3)

Light IPC

Cable FW52 Light (J2)

Cable #23-0011 Light (P2)

Cable FW92 Dark (J2)

Cable FW52 Dark (J1)

Cable #23-0001 Dark (P2)

Cable #23-0381 Dark (P3)

Cable #23-0375 Dark (J3)

Dark IPC

Ink I/O

Figure 67: IPC and I/O Ink Boards

Connecting Cable # 23-0399 from the Switch Blocks to I/O Ink Board and HTB

Note: Refer to Appendix D, DRW # 60-0094, DRW # 60-0098, DRW # 23-0399, and DRW # to connect cable # 23-0399.

Cable #23-0399, which arrives connected to the Switch Blocks, must be connected to the I/O Ink Board and to the Hydraulic TB (HTB).

Connect Cable # 23-0399 to the I/O Ink Board and to the Hydraulic TB (HTB) as follows:

1. Connect the main (gray) cable # 23-0399 to the I/O Ink Board’s P4 terminal.

2. Connect cable # 23-0399’s thin red and black wires to the HTB as follows:

• Red wire labeled ‘+24V TB Hydr’ to +24V on the TB #1 (from Switch Block CM).

• Red wire labeled ‘TB’ to +24V on the TB#3 (from Switch Block YK).

• Black wire labeled ‘TB’ to 0/24V, on the TB # 2 (from Switch Block YK).

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19. Installing the Dell 530 Workstation The Fresco 8C upgrade requires a new Dell workstation running the Windows XP operating system. This replaces the existing Fresco Dell workstation.

Install the new Dell 530 Workstation as follows:

1. Remove the currently installed Dell workstation from the printer.

2. In the kit, locate the new Dell 530Workstation - Dell 530 Dual CPU Xenon 1.7 GHz with Windows XP Pro Operating system (P/N: 20-0039).

3. Remove the Dell workstation and its accessories from the box and place it at the same location where the previous workstation was installed.

4. Connect all cables to the new Dell workstation 530 that were disconnected from the previous Dell workstation, including:

• FW30A and FW30B

• Com 1—FW26 to Galil controller

• Com 2—PC Com Interface, (RS 232) to ADAM communication converter board

• Network com

• Monitor

• Keyboard and mouse (new)

• Use the Y-adaptor to connect the monitor to the new PC (refer to Figure 68)

Y-Adaptor Connector

Monitor to PC Connection Circled

Figure 68: Y-adaptor Connecting Monitor to PC

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5. Install the mouse shelf (from kit, P/N: 17-0313) as follows:

• Lift up the front hood of the operator console to access the rail where the mouse pad bracket is to be installed.

• Unscrew the right most screw using a 3 mm Allen key to (refer to Figure 69).

• Align the mouse pad bracket to the hole and tighten the screw.

Mouse Pad Bracket

Allen Screw Encircled

Figure 69: Mouse Shelf Location

6. Pack the removed Dell workstation in the box that the new workstation was shipped in (refer to Material Disposition on page 89).

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20. FPP Board and Driver Installation

Removing the Previous FPP Board

1. Unplug the Dell workstation then use a flat screwdriver to unscrew the FPP board’s two D type connection screws from the previous Dell PE1300 PC

2. Open the Dell workstation’s cover to remove the FPP board.

Caution: Hold the FPP Board from its outside edges (as you would hold a picture) to avoid any Electrostatic Discharges (ESD) that may damage the FPP board.

3. Use a Phillips screwdriver to unscrew the four 3/16" Phillips screw on the FPP board and pull the FPP board from its bracket. Do not discard.

Installing the New FPP board

1. Insert the new bracket (P/N 10-0801, from kit) into the FPP board. Make sure the LED is inside its appropriate hole within the bracket (refer to Figure 70, Figure 72, and Figure 73).

Slot LED's Hole Bracket P/N # 17-0620 (from Kit)

D-Type Connection Slots

Figure 70: New Bracket

2. Make sure the Dell workstation is unplugged and lay it on its side. Slide the handle to open the protective side cover.

3. Open the green latch to access the FPP board (refer to Figure 71).

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Green Latch

D-Type Connection Slot

Figure 71: Green Latch and D-types Connection

4. Insert the four 3/16" socket screws (from old FPP board) into the new FPP board's bracket and tighten (refer to Figure 70, Figure 72 and Figure 73).

SlotFPP Board LED

Bracket From Kit

LED's Slot

Four 3/16 Screws

Figure 72: FPP Board and Parts from Kit

Correct BracketAssembly LED

Figure 73: FPP Board with Bracket

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Note: Verify that the FPP board's LED is inside the hole of the bracket (from kit) (refer to Figure 73).

5. Pull on the green latch to release the covers and lift up (refer to Figure 71).

6. Remove the third cover from top (refer to Figure 71).

7. Insert the FPP board into the slot and push to lock the pin within the bracket (refer to Figure 74).

PC Bracket

Nut Under Phillips Screw From Kit

Pin in Slot

Push on the Side of the PC's Frame to Align Pin with Slot

Figure 74: FPP Board installed with Nut from Kit

Note: Make sure that the pin is aligned with the slot (refer to Figure 74).

8. Insert the nut (from kit, refer to Figure 75) from the D-type location slots, to align the nut with the FPP board's bracket. Use a Phillips screwdriver to screw in the Phillips screw as you push sideways on the Dell workstation’s bracket (refer to Figure 74).

Nut (from Kit)P/N # 17-0619

Phillips ScrewP/N # 12-0089

Figure 75: Nut and Screw from Kit

9. Make sure the bracket is correctly positioned then push the green latch down and close the Dell workstation cover.

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FPP Driver Installation

1. Once the FPP board is installed, turn on the Dell workstation.

2. The Found New Hardware wizard is activated and the Install window appears.

Note: If the pop-up window fails to appear click Start > Settings > Control Panels > Add Hardware to access the window.

Figure 76: Install Window

3. Select Install from a list or specific location (Advanced) and click Next. The Choose Search and Install Option window is displayed.

Figure 77: Choose Search and Install Option Window

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4. Select Don't search, I will choose the driver to install and click Next. The Hardware Type window is displayed.

Figure 78: Hardware Type Window

5. Ensure that Show All Devices is selected and click Next. The Device Driver window is displayed.

Figure 79: Device Driver Window

6. Insert the PrinTop ver. 1.51 CD (P/N: 51-0015) into the CD ROM drive.

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7. Select {Standard CD-Rom drives} and click Have Disk. The Install from Disk dialog box is displayed.

D:\

Figure 80: Install from Disk Dialog Box

8. Click Browse The Locate File dialog box is displayed.

Figure 81: Locate File Dialog Box

9. Select Plotpro.inf, and click Open. The Select Device Driver window is displayed.

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Figure 82: Select Device Driver Window

10. Click Next.

11. Click Finish and restart the computer.

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Updating the FPP Driver (Plotpro.inf)

Once installed, the FPP driver must be updated.

To update the FPP driver: 1. Click Start > Settings > Control Panel > System. The System Properties window is

displayed with the General tab selected.

2. Click the Hardware tab.

Figure 83: System Properties Window with Device Manager Tab

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3. Click Device Manager. The Device Manager window is displayed.

Figure 84: Device Manager Window

4. Select Plotpro. The Plotpro Properties window is displayed with the General tab selected.

Figure 85: Update Driver Window

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5. In the Driver tab, click Update Driver. The Hardware Update Wizard begins running.

Figure 86: Hardware Update Wizard

6. Select Install from a list or specific location (Advanced), and click Next. The Search Installation Options window is displayed.

Figure 87: Installation Options Window

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7. Select Don't search, I will choose the driver to install, and click Next. The Select Device Driver window is displayed.

Figure 88: Select Device Driver Window

8. Click Have Disk. The Install From Disk dialog box is displayed.

Figure 89: Install From Disk Dialog Box

9. Click Browse. The Locate File dialog box is displayed.

Figure 90: Locate File Dialog Box

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10. In the Plotpro Drive folder, select Plotpro, and click Open.

11. Click OK > Next > Finish to complete the installation.

12. Restart the workstation.

21. Installing the PrinTop Application 1. In the kit, locate PrinTop ver. 1.51 for Fresco HiQ SW Package (P/N: 51-0015).

2. Insert the PrinTop CD into the CD ROM drive and follow the installation instructions.

22. Final Tasks 1. Discard unnecessary parts (refer to Material Disposition section page 89).

2. Clean the printer and its surrounding environment.

3. Close all cable ducts cover in the service cabinet.

Calibrating the Print Head Plate

1. Use the calibrating kit to calibrate the Print Head plate as described in Appendix C.

2. Reinstall the spittoon.

Installing the Print Heads

1. Reinstall all the Print Heads as described in Appendix B.

2. Install the new Print Head cover shield (from kit, P/N: 17-0680).

System Flushing

1. Fill each light MIT with 1 liter (0.25 gallons) of solvent (flushing fluid) and continue with the rest of the procedure as described in Appendix A: Ink Flushing System on page 91. To flush the dark MITs, you may use the solvent that remains in the dark MITs from the flushing procedure performed at the beginning of the upgrade.

2. In PrinTop, change the print mode to 8C.

3. Circulate solvent in the system and flush the system with solvent as described in the Ink System Flushing in Appendix A.

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New Printer's Label

Place the new label (from kit) below the existing label as show below (refer to Figure 91).

Existing Label on Printer

New Label (from kit)

Figure 91: New label to Add below Existing Label on Printer

23. Installing NUR Flash 1.2 Install the NUR Flash software at the customer’s RIPping station as described in the NUR Flash Release Notes (P/N: 68-5005 and P/N: 68-5006) provided in the kit.

24. Testing

System Check

The following steps should be performed after completing the upgrade:

1. Check the Light Main Ink Tank Floats as follows:

• Fill each ink tank with its respective color.

• Verify that the corresponding LED is ON (on GI/O #1).

2. Check that all hydraulic tubes are connected to their respective location as follows:

• In PrinTop, select the Ink tab.

• Select C (cyan) to activate the dark cyan pump.

• Verify that cyan ink fills the pressure tube and that cyan ink is present in the vacuum tube.

• Repeat this test for all remaining seven colors, one at a time.

3. Press each purge valve and verify that the proper ink comes out of the Print Head.

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4. Manually move the Print Head carriage to check if the electrical cables on the left IGUS cable chain are pinched, entangled, or obstructed.

Caution: Before switching on the 24V ink system powers supply CB, verify that all connections and changes specified in this FCO have been performed correctly.

IPC Board Diagnostics LEDs

The following table explains the meanings of the LEDs on the IPC board. Each group of indicators includes four LEDs, one for each color.

LED System Status when Lit Vacuum Ink Pumps Vacuum Ink Pumps are operating. Pressure Ink Pumps Pressure Ink Pumps are operating. Purge Valves Purge is taking place. Secondary Ink Tank Floats Ink in Secondary Ink Tanks has reached maximum

level.

Testing the SIT Assembly’s Height

Verify that the Ink level at the SIT tanks is up to spec, as follow:

1. Activate the ink system and verify that ink is moving in and out of the SIT.

2. Connect a 4 mm tube (P/N: 000-14-01-002) using quick male connectors (P/N: 000-14-02-030) to the Ink Outlet of black Print Head’s #7,8.

3. Place the tube in front and parallel to the black Print Head #8.

4. Verify that the distance between the lower nozzle of the Print Head and ink level in the tube is no more than 13 mm (refer to Figure 92)

5. If the level is lower than 13 mm, check other elements that could affect the ink pressure (IPC board, filters, restrictors and tubes).

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Figure 92: Calibration of the SIT Assembly.

Checking Transistor Voltages

1. Switch on the 24V Ink System CB.

2. Using a voltmeter, place one of the voltage probes on the 0V terminal (W92 BR).

3. Place the other probe at the following transistors on the IPC board. The readings should appear according to the following table:

Transistor Voltages Check Enter Measured Value Transistor Desired Value

C M Y K Vacuum +6 volt ±10% Pressure +10 volt ±10% Purge +24 volt

Checking Purge Valve Outlets

The system should perform purges at regular intervals according to software settings. Verify that the system performs purge correctly for each color and that purge LEDs on IPC board are lit during the purge.

Purge Check C M Y K Purge Occurs Purge LEDs

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Checking Secondary Ink Tank Float

When the float in each reserve ink tank reaches its highest point, the appropriate indicator light on the IPC board should light up and three seconds later, the corresponding ink pressure pump motor should be automatically switched off.

Note: Before performing the following check procedure; disconnect all air pressure tube from Print Head carriage to avoid ink flooding.

To check ink float logic, perform the following procedure for each of the four ink colors separately:

1. Ensure that the 24V power supply is switched on.

2. Disconnect the connection to vacuum pump motor (upper connection).

3. Verify that the ink reserve tank fills up. Verify that when the float reaches its maximum height, the appropriate LED on IPC board is lit.

4. Verify that the pressure pump motor for the color being tested switches off automatically after 3 seconds.

5. Repeat steps 2–4 for each ink color.

6. Reconnect the connection to vacuum pump motor.

Color LED Pressure Pump

Stops C M Y K

Ink I/O Switch Block Test: Using the Debug Software

Note: If the Switch Blocks Debug Software is not activated properly, it can cause color-mixing problems. Make sure to follow the instructions described below carefully to ensure proper software implementation.

Preparation and Software Installation Before installing the software, perform the following:

1. Shut down PrinTop.

2. Turn off the 24V CB.

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3. Disconnect the float cables from the J3 port on both IPC board terminal blocks to cut off the IPC boards’ power (see Appendix D).

4. Turn ON the 24V CB.

Install the Ink I/O Switch Block Test software as follows:

1. On the Testing CD, locate and select GioDebug.

2. Double-click Setup. The Setup of the Ink I/O Switch Block software begins running.

3. Click OK. The Ink I/O Switch Block software is now installed on your workstation.

Activating the Software 1. On the Testing CD, double click SwitchInkIO. The following window is displayed.

Note: Make sure to work with the Ink I/O Switch Block software only. Any other Switch Block debugger that may be installed refers for the TNK card, and is therefore not relevant to the current upgrade.

2. Check that @5b00 is displayed in the top-right corner of the window, as displayed in the example above. If not, there is a communication problem with the Switch Blocks.

Electro Valve Locating and Functionality Test This test ensures that the Ink I/O Board is properly connected to the Switch Blocks electro-valves and checks that the electro-valves are working properly.

1. In the field, enter ‘#5M00’ and press ENTER to check that all valves on the Switch Blocks are closed.

2. Check that the value ‘#5M00’ is returned in the top-right corner of the window.

3. Select the ByPass checkbox.

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4. In the Values Block CM area, click each button to turn ON the corresponding valve on the switch block, and then click it again to turn the valve OFF. Ensure that you hear a click when you switch ON and OFF each valve, as the click indicates that the valve is working.

5. When each button is ON, check that the valve LED that lights up on the Switch Block corresponds to valve indicated by the software.

6. Repeat the test for all valves on both Switch Blocks.

7. Turn OFF all valve buttons.

8. Clear the ByPass checkbox.

Switch Block Coordination Test Using the Switch Block Coordination Test software, you can simulate commands from the I/O INK BOARD to the Switch Block, as follows:

1. In the field, enter ‘#5M11’ to activate the top level of valves on both Switch Blocks. Check that the LEDs on the top level of electro-valves are lit.

2. In the field, enter ‘#5M22’ to activate the second from top level of valves on the both Switch Blocks. Check that the LEDs on the second from top level of electro-valves are lit. After approximately 10 seconds, this level of LEDs is turned OFF and the top level of LEDs are lit.

3. In the field, enter ‘#5M44’ to activate the second from bottom level of valves on the both Switch Blocks. Check that the LEDs on the second from bottom level of electro-valves are lit. After approximately 10 seconds, this level of LEDs is turned OFF and the bottom level of LEDs are lit.

4. In the field, enter ‘#5M88’ to activate the bottom level of valves on both Switch Blocks. Check that the LEDs on the bottom level of electro-valves are lit.

Note: Make sure that after entering each full string and pressing ENTER, the same string is displayed in the right corner of the window (If not, the command is illegal or there is communication problem).

5. To turn OFF all valves and enter the string ‘#5M00’ in the field.

Finishing the Debug Process 1. Close the program and turn OFF the 24V CB.

2. Reconnect the float cables from the J3 ports on both IPC board terminal blocks.

Notes:

• When you finish the testing process, uninstall the Switch Blocks Debug Software from the computer.

• PrinTop cannot run simultaneously with the Switch Block Debug Software.

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25. Logistics

8 COLOR ASSY KIT FRESCO 3200, P/N 10-0808

COMPONENT DESCRIPTION QTY

10-0751 KIT UPGRADE-8 COLOR FRESCO 3200 1 10-0220 INK CELL ASSY PRINTING CARRIAGE, 8 COLORS 1 10-0595 INK TANK ASSY FOR 8C 1 10-0755 IGUS FOR 3200 1 10-0756 EXTRUDED PROFILE FOR INK CONTROL ASSY 1 10-0799 LABELS FOR CABELS FRESCO 8 COLOR 1 10-0800 ACCESSORIES KIT FOR UPGRADE 8C FRESCO 3200 1 10-0802 FILTERS KIT ASSY 8 COLOR 1 10-0806 IGUS TUBE ASSY FRESCO 3200 8C 1

10-0810 PRINT HEAD PLATE ASSY 8 COLOR (CARRAGE) FOR KIT 8C 1

10-0830 SWITCH BLOCK ASSY 1 10-0831 ACCESSORIES FOR SWITCH BLOCK ASSY 1 17-0623 8 COLORS PURGE VALVES BRACKET 1 17-1376 IGUS BRACKET RIGHT 1 17-1379 IGUS BRACKET LEFT 1 17-1380 PRINT HEAD BRACKET IGUS RIGHT 1 17-1381 PRINT HEAD BRACKET FOR IGUS LEFT 1 20-0039 WS,DELL 530 DUAL CPU XENON 1.7 GHZ WIN XP PRO 1 20-0042 INK CONTROL LIGHT ASSY BOARD (IPC L) 1 200-40-05-309 FILTER,CAPSULE,5U WITH QUICK CONN. MALE 9

23-0011 CABLE ASSY,INK CONTROL VACUUM & PRESSURE PUMPS. 1

23-0375 24V FROM TBH TO INK CONTROL PCB 1 23-0379 INK CONTROL 8 COLOR WIRING 1

23-0380 GI/O #1 INPUTS FROM MAIN INK TANKS SENSORS (6 PIN 1

23-0384 8C INPUTS FROM SECONDARY INK TANKS LEVEL SNS 1 50-0008D KIT,SOFTWARE RIP, NUR FLASH V1.2, SUPPORT 8C 1 90-0055 SWITCH BLOCK PACKAGE 1 70-0034 8 COLOR PACKING BOX 1

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ACCESSORIES KIT FOR UPGRADE 8C FRESCO 3200, P/N: 10-0800


000-14-00-170 GASKET FOR D33XXGLO VALVE 1 000-14-01-013 TUBE,NYLON,DO=10 MM DI=8 MM,WHITE 0.8

000-50-15-042 TIE WRAP,CABLE,L=100MM BUNDLE MAX D=23MM,NYLON 1


000-61-10-050 SCREW,SOCKET HEAD CAP HEX,ST.ST.,M6X16,FULL TH 8

000-61-10-066 SCREW SOCKET HEX CAP M5*16 S.S. 8 000-61-30-005 WASHER SPRING M5 DIN 127B,ST.ST. 8 000-61-30-006 WASHER,SPRING,M6 DIN 127-B,A2,ST.ST. 8 000-61-30-009 WASHER,SPRING,M8 DIN 127,A2,ST.ST. 2 000-61-30-021 WASHER,FLAT,M8 DIN 125 A,A2,ST.ST. 2 000-61-30-023 WASHER,FLAT,M5 DIN 125 A,A2,ST.ST. 9 000-61-30-305 WASHER SPRING M5 S.S. 1 000-62-00-038 GASKET,EPDM 0.8-2.5 1 000-62-00-057 RIVET 4X10 MM 10 10-0801 KIT FPP BRACKET FOR DELL WS530 1 12-0076 SCREW,SOCKET HEAD CAP M6X20,DIN 912,A2,ST.ST 4

12-0090 SCREW,SOCKET BUTTON HEAD M5X10,ISO 7380,A2,ST.ST. 1

12-0148 SCREW,SOCKET HEAD CAP M8X10,DIN 912,A2,ST.ST. 2 15-0146 O RING BETWEEN THE PLATE AND THE BOLCK 5 15-0147 PLATE OPERATOR FOR SWITCH BLOCK 1 15-0148 6.5W COIL 24VDC FOR SWITCH BLOCK 1 15-0149 PLUG FOR COIL FOR SWITCH BOX 1 17-0313 BRACKET,PAD,MOUSE MOUNTED 1 17-1237 RAIL DIN FRESCO 8C 1 17-1545 JIG FOR SWITCH BLOCK 1

19-0077 TIE MOUNT,28X28MM,NYLON ADHESIVE,WITH HOLE 5.0MM 1

19-0090 WALL PROFILE 80X320MM 3 19-0096 O RING 10X1 EPDM 5 200-40-05-311 FAST CONN. FEMALE FOR CAPSULE FILTER 5U 1 200-60-00-004 SILICON CAP ID=3.48 FOR 4MM PIPE 50 200-60-00-008 SILICON CAP ID=4.37 FOR HEAD 50

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50-0029 KIT,S/W PRINTOP VER.1.5 FRESCO 8C KIT 1 61-0030 LOGO FRESCO HIQ 8C 3200 1 90-0012 NUT DRIVER,FLUSHING MANIFOLD 1 90-0046 DRILL 4MM 1 90-0047 RIVET GUN 1 FC10-0808 FRESCO HIQ 8C FCO 1

FC10-0808 Rev. D of 117


KIT UPGRADE 8 COLOR FRESCO 1800, P/N: 10-0591


10-0220 INK CELL ASSY PRINTING CARRIAGE, 8 COLORS 1 10-0553 ACCESSORIES FOR KIT 8C FRESCO 1800 1 10-0595 INK TANK ASSY FOR 8C 1 10-0756 EXTRUDED PROFILE FOR INK CONTROL ASSY 1 10-0799 LABELS FOR CABLES FRESCO 8 COLOR 1 10-0802 FILTERS KIT ASSY 8 COLOR 1

10-0810 PRINT HEAD PLATE ASSY 8 COLOR (CARRIAGE) FOR KIT 8C 1

10-0812 IGUS FOR FRESCO 1800 8C 1 10-0813 IGUS TUBE ASSY FRESCO 1800 8C 1 10-0830 SWITCH BLOCK ASSY 1 10-0831 ACCESSORIES FOR SWITCH BLOCK ASSY 1 17-0623 8 COLORS PURGE VALVES BRACKET 1 17-1402 PRINT HEAD IGUS ADAPTOR FRESCO 1800 8C 2 17-1403 IGUS BASE ADAPTOR FRESCO 1800 8C 2 20-0039 WS,DELL 530 DUAL CPU XENON 1.7 GHZ WIN XP PRO 1 20-0042 INK CONTROL LIGHT ASSY. BOARD (IPC L) 1 200-40-05-309 FILTER,CAPSULE,5U WITH QUICK CONN. MALE 9

23-0011 CABLE ASSY,INK CONTROL VACUUM&PRESSURE PUMPS. 1

23-0375 24V FROM TBH TO INK CONTROL PCB 1 23-0379 INK CONTROL 8 COLOR WIRING 1

23-0380 GI/O #1 INPUTS FROM MAIN INK TANKS SENSORS (6 PIN 1

23-0384 8C INPUTS FROM SECONDARY INK TANKS LEVEL SNS 1 50-0008D KIT,SOFTWARE RIP, NUR FLASH V1.2, SUPPORT 8C 1 90-0055 SWITCH BLOCK PACKAGE 1

ACCESSORIES FOR KIT 8C FRESCO 1800, P/N: 10-0553


000-14-00-170 GASKET FOR D33XXGLO VALVE 1 000-14-01-013 TUBE,NYLON,DO=10 MM DI=8 MM,WHITE 0.8


000-50-15-096 TIE WRAP,CABLE,L=203MM BUNDLE MAX 1

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D=55MM,NYLON

000-61-10-050 SCREW,SOCKET HEAD CAP HEX,ST.ST.,M6X16,FULL TH 8

000-61-10-066 SCREW SOCKET HEX CAP M5*16 S.S. 16 000-61-30-005 WASHER SPRING M5 DIN 127B,ST.ST. 16 000-61-30-006 WASHER,SPRING,M6 DIN 127-B,A2,ST.ST. 8 000-61-30-009 WASHER,SPRING,M8 DIN 127,A2,ST.ST. 3 000-61-30-021 WASHER,FLAT,M8 DIN 125 A,A2,ST.ST. 3 000-61-30-023 WASHER,FLAT,M5 DIN 125 A,A2,ST.ST. 17 000-61-30-034 WASHER,SPRING, 25X12.2X0.9 DIN 2093 B 2 000-61-30-305 WASHER SPRING M5 S.S. 1 000-62-00-038 GASKET,EPDM 0.8-2.5 1 000-62-00-057 RIVET 4X10 MM 10 10-0801 KIT FPP BRACKET FOR DELL WS530 1 12-0085 SCREW,SOCKET FLAT HEAD M6X16,DIN 7991,A2,ST.ST 4

12-0090 SCREW,SOCKET BUTTON HEAD M5X10,ISO 7380,A2,ST.ST. 1

12-0148 SCREW,SOCKET HEAD CAP M8X10,DIN 912,A2,ST.ST. 2 15-0146 O RING BETWEEN THE PLATE AND THE BOLCK 5 15-0147 PLATE OPERATOR FOR SWITCH BLOCK 1 15-0148 6.5W COIL 24VDC FOR SWITCH BLOCK 1 15-0149 PLUG FOR COIL FOR SWITCH BOX 1 17-0313 BRACKET,PAD,MOUSE MOUNTED 1 17-1237 RAIL DIN FRESCO 8C 1 17-1545 JIG FOR SWITCH BLOCK 1

19-0077 TIE MOUNT,28X28MM,NYLON ADHESIVE,WITH HOLE 5.0MM 1

19-0090 WALL PROFILE 80X320MM 3 19-0096 O RING 10X1 EPDM 5 200-40-05-311 FAST CONN. FEMALE FOR CAPSULE FILTER 5U 1 200-60-00-004 SILICON CAP ID=3.48 FOR 4MM PIPE 50 200-60-00-008 SILICON CAP ID=4.37 FOR HEADE 50 50-0029 KIT,S/W PRINTOP VER.1.5 FRESCO 8C KIT 1 61-0031 LOGO FRESCO HIQ 8C 1800 1 90-0012 NUT DRIVER,FLUSHING MANIFOLD 1 90-0046 DRILL 4MM 1 90-0047 RIVET GUN 1

FC10-0808 Rev. D of 117



FC10-0808 FRESCO HIQ 8C FCO 1

ACCESSORIES FORSWITCH BLOCK ASSY, P/N: 10-0831


000-50-16-046 END PLATE PLASTIC,POLYAMID 2 000-50-16-047 MOUNTING FOOT PLASTIC,POLYAMID 2 000-61-30-006 WASHER,SPRING,M6 DIN 127-B,A2,ST.ST. 4 000-61-30-022 WASHER,FLAT,M6 DIN 125 A,A2,ST.ST. 4 000-62-00-057 RIVET 4X10 MM 10 12-0077 SCREW,SOCKET HEAD CAP M6X30,DIN 912,A2,ST.ST 4 12-0119 SCREW,CROSS RECESSED SUNK,M3X8,S.S,DIN 965 A2 5 15-0142 SWIVEL ELBOW MALE ADAPTOR 6/4X1/8 NBR+EPDM 8 17-1237 RAIL DIN FRESCO 8C 1 17-1373 INTERFACE PLATE ASSY 1 17-1701 EXTRUDED PROFILE PLASTIC RS-SP1 1 20-0054 INK I/O 24 BOARD ASSEMBLY 1 23-0395 CABLE,8C COMM FROM FW29 TO IPCS&INK I/O BOARD. 1

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26. Material Disposition The table below instructs you on the action required for items removed during the upgrade.

PN PART DESCRIPTION QTY ACTION

00-53-00-054 DELL POWEREDGE 1300* 3 SEND BACK 200-40-01-140 PRINT HEAD COVER SHIELD 1 SEND BACK 10-0087 IGUS 1 DISCARD 10-0147 SIT 4 C 1 SEND BACK 200-52-00-090 CABLE FW91 1 DISCARD 200-52-00-075 CABLE FW71 1 DISCARD 200-40-05-307 FILTER BRACKET 1 DISCARD 200-40-07-100 PURGE BRACKET 1 DISCARD 000-51-30-000 DIN RAIL 1 DISCARD

* Refer to the Dell PowerEdge 1300 Return Form, the last page of this document, for details on returning the Dell workstation. This form must be filled in, cut out from the book, and sent to the IT department of your local subsidiary along with the Dell PowerEdge 1300. Ensure to fill in the personal details and customer support representative sections of the form only. The IT sections are to be filled in by the IT department of your local subsidiary.

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27. Table of Appendixes Appendix A: Ink Flushing System.......................................................................................... 91

Appendix B: Print Heads Replacement .................................................................................. 96

Appendix C: Print Head Plate Calibration............................................................................ 101

Appendix D: Schematic Drawings........................................................................................ 117

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Appendix A: Ink Flushing System

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Ink System Flushing Appendix A describes ink system flushing, which includes the following procedures:

• Draining ink from the tubes that returns ink to the MITs.

• Draining ink from the MITs.

• Draining ink from the SITs.

• Flushing the Ink System.

• Circulating solvent.

• Draining solvent from the MITs.

• Draining solvent from the SITs.

• Refilling the Ink Circuit with Ink.

Step A: Draining Ink from MIT Return Tubes 1. Shut down procedure to the NUR Fresco HiQ printer.

2. Turn ON 24V DC power supply circuit breaker.

3. Activate PrinTop.

4. In PrinTop, open the INK window and deactivate all pressure pumps.

5. Wait about two minutes while the vacuum pumps drains the remaining ink from the return pipes into the main tanks.

6. Turn OFF 24V DC power supply circuit breaker.

Step B: Draining Ink from the MITs Repeat the following for all four colors.

1. Unscrew the four bolts securing the MIT to the cabinet floor (see Figure 93).

2. Drain the MIT by removing the draining cap and opening the draining valve.

3. Tilt the MIT carefully to obtain maximum drainage and clean the MIT walls by squirting solvent inside the tank while tilted.

Note: Avoid damaging the MIT wires while tilting the MITs.

4. Drain the 5-micron filter by disconnecting the lower quick connector and opening the white cap (see Figure 94).

5. After the 5-micron filter is drained, close the white cap and reconnect the quick connector.

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6. Close the MIT draining valve and close the draining cap.

Figure 93: Main Ink Tanks Figure 94: Five-Microns Filter

Step C: Draining Ink from the SITs Repeat the following step for all four colors.

• Disconnect the Print Head feeding tube from the SIT and open the Print Head outlet (see Figure 95).

14–Micron Filter Purge Outlet

Vacuum Outlet

PH Outlet (4)

Restrictor Cover

Pressure Inlet

Figure 95: SIT Draining

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Step D: Flushing the Ink System 1. Fill each main tank with 2.5 liters (0.7 gallon) of solvent (flushing fluid).

2. Turn ON the 24 V DC power supply circuit breaker.

3. In PrinTop, open the INK window and activate all the pressure pumps.

Note: Repeat steps 4 through 10 for all four colors.

4. Open the restrictor cover for PHs 7 and 8 that are located under the pressure gauge.

5. In the Ink window, activate the pressure pump.

6. Once solvent starts flowing out from the restrictor outlet, deactivate the pressure pump in the Ink window.

7. Close the restrictor cover.

8. In the Ink window, activate the pressure pump again.

9. Once solvent starts flowing from the SIT outlet, deactivate the pressure pump in the Ink window.

10. Close the SIT outlet.

Step E: Circulating Solvent 1. In the Ink window, activate all the pressure pumps and let the remaining solvent circulate

for 10 minutes.

2. In the Ink window, deactivate all the pressure pumps.

3. Wait 2 minutes while the vacuum pumps drain the solvent from the MIT return tube.

4. Turn OFF the F5 24V DC power supply circuit breaker.

Step F: Draining Solvent from the MITs Repeat the following steps for all four colors.

1. Drain the MIT.

2. Tilt the MIT to obtain maximum drainage.

Note: Avoid damaging the MIT wires while tilting the MITs.

3. Replace the 5-micron filter.

4. Close the MIT drain.

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Step G: Draining Solvent from the SITs Repeat the procedure described in ‘Step C: Draining Ink from the SITs’ on page 93 and leave the Print Head outlets open.

Step H: Filling the Ink Circuit with Ink 1. Turn ON the F5 24V DC power supply circuit breaker.

2. Fill each main tank with 2.5 liters (0.7 gallon) of ink.

Note: Repeat steps 3 through 12 for all four colors.

3. Unscrew the four bolts securing the ink inlet (14-micron filter cover) to the secondary tank block using a 2.5 mm Allen key.

4. Replace the 14-micron filter and filter’s O-ring.

5. Point the ink inlet tube towards the Print Head carriage sink.

6. In the Ink window, activate the pressure pump.

7. Once pure ink starts flowing from the inlet tube, deactivate the pressure pump in the Ink window.

8. Close the ink inlet (14-micron filter cover); leave the new filter inside.

9. In the Ink window, reactivate the pressure pump.

10. Once pure ink starts flowing from the SIT outlet (which is still open – refer to step 7), deactivate the pressure pump in the Ink window.

11. Close the SIT outlet.

12. In the Ink window, activate all the pressure pumps and let the ink circulate for five minutes.

13. Check the ink system for leakage.

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Appendix B: Print Heads Replacement

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Print Head Replacement Print Head replacement involves the following tasks:

• Removing the previous Print Head.

• Installing a new Print Head.

Step A: Removing a Print Head Remove a Print Head (Print Head) as follows:

1. Move the Print Head carriage to the service position.

Caution: Turn OFF the Print Head power supply (PS) circuit breaker located in the drying and pneumatic cabinet.

2. Flush the faulty Print Head with solvent (flushing fluid).

3. Close the flushing manifold valve.

Note: Label the Print Head electric flat cable before disconnecting it.

Note: Inspect the Print Head flat cable visually. Remove and replace the ones that are splattered with ink. (refer to Figure 96).

4. Disconnect the Print Head flat cable from the Print Head (and from the Motherboard if needed) by pushing the two connectors’ grip arms away from each other (refer to Figure 102).

Note: To make reconnecting the ink pipe to the flushing manifold, attach a lead (rope or pipe) at the end of the ink pipe to provide you with slack by disconnecting the Print Head ink pipe from the flushing manifold. Pull the lead when reconnecting the ink pipe to its original location (see Figure 96).

FC10-0808 Rev. D of 117


Disconnected PH Ink Pipe from the Flushing Manifold

PH Flat Cable

PH Ink Pipe Attach a pipe or

thin Rope to ease reconnection

Figure 96: Disconnecting the Print Head

5. Remove the Print Head protective cover by releasing the three Allen screws using a 5 mm Allen (see Figure 97 and Figure 98).

Screws to Remove

Figure 97: Print Head Protective Cover

(Securing Screws Encircled)

PH Plate

Locating Pin

PH ProtectivePlate

Figure 98: Removing the Print Head Protective Cover

Caution: Be very careful not to damage the PHs orifices.

6. Remove the Print Head from the Print Head Plate by releasing the two Allen screws

using a 2.5 mm Allen key (see Figure 100).

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Figure 99: Print Head Plate

2.5 mm Allen Key

Figure 100: Unscrewing the Print Head Allen Screw

7. Carefully, remove the Print Head from the Print Head plate pins as displayed below.

PH Locating Pins

PH Locating Bores

Figure 101: Removing the Print Head

8. Disconnect the ink pipe from the Print Head using a 7 mm wrench key (refer to Figure 102)

Note: If the ink pipe or the flat cable is crimped and worn, replace it as well.

9. Tag the Print Head with a detailed repair tag and a section of its “All Nozzle” test pattern. Pack the Print Head package and send it to your local NUR service center.

FC10-0808 Rev. D of 117


Step B: Installing a New Print Head Install the new Print Head as follows:

1. Use solvent (flushing fluid) to remove any ink residue around the Print Head locating pins.

2. Remove the silicon cap from the new PHs ink pipe inlet (see Figure 102).

Flat Cable Connector

Ink Pipe Connector Covered with Silicon Cap

Head Adaptor (HAD) Board

Connector Grip Arm

Figure 102: Print Head

3. Reconnect the ink pipe and the flat cable to the new Print Head.

4. Reconnect the Print Head ink pipe to the flushing manifold.

Note: Verify that the flat cable connector is fully locked by closing the grip arms firmly until you hear a click.

5. Carefully, place the Print Head on to the two Print Head Plate locating pins, while making sure not to break the bores’ thin metal plates when inserting the Print Head (see Figure 101).

6. Reconnect the Print Head to the Print Head plate by screwing in the two Allen screws using a 2.5 mm Allen key (see Figure 100).

7. Reconnect the Print Head protective cover on the Print Head plate using the locating pins (first locate the bottom side and then the upper) (see Figure 101).

8. Secure the Print Head protective plate using a 5 mm Allen key and three Allen screws that (see Figure 96).

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Appendix C: Print Head Plate

Calibration

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Print Head Plate Calibration Keep in mind the following general principles when calibrating the Print Head Plate:

• Perform this procedure exactly and in the stipulated order.

• Accurate Print Head (printing head) plate calibration creates a uniform parallel distance between the substrate and all the Print Heads, guaranteeing a high quality printing result.

• Print Head plate calibration is performed mainly by referencing the Print Heads to the vacuum plate.

Calibrating the Print Head Plate includes the following procedures:

• Preparing for Print Head Plate Calibration.

• Setting the PH Plate and PH Carriage to be Parallel.

• Locating the Closest Distance between the VP and the Print Head Carriage.

• Adjusting the Minimum Distance between the VP and the Print Head Cover Shield.

• Installing the two Micrometers for the Print Head Plate Vertical Adjustment.

• Calibrating the Micrometer.

• Finding the Reference Point.

• Vertically Calibrating the Print Head Plate.

• Horizontally Calibrating the Print Head Plate.

Preparing for Print Head Plate Calibration 1. Shut down the printer.

2. Turn off the main electric power switch.

3. Close the main air pressure inlet to the printer.

4. Remove the service spittoon.

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5. Remove the Print Head protective cover by releasing the three Allen screws using a 5 mm Allen, as indicated below.

Screws to Remove

Figure 103: Removing the Print Head Protective Cover Shields

6. Remove the rulers connected to both sides of the Print Head plate (see Figure 104).

Rulers

Figure 104: Rulers

7. The Print Head plate is connected to the Print Head carriage by two pins, one on each side of the plate and by the eight adjustable assemblies (see Figure 105 and Figure 106). One pin is inserted into a round bore and the other is inserted into an elliptical bore. Verify that the pin from the elliptic bore has been removed.

If the pin is still in the elliptical bore, remove it as follows:

• Remove the eight adjustable assemblies (see Figure 105 and Figure 106).

• Remove the Print Head plate from the Print Head carriage.

• Remove the pin from the elliptic bore.

Note: Do not remove the pin from the round bore.

• Restore both the Print Head plate and the eight adjustable assemblies.

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Step A: Setting the PH Plate and PH Carriage to be Parallel Eight adjustment assemblies connect the Print Head plate to the Print Head carriage (refer to Figure 105).

2

6

8

4

7

5

3

1

Figure 105: Eight Adjustments Assemblies

Each adjustment assembly includes the following parts (refer to Figure 106):

A: Two slip washers

B: Adjustment Screw

C: M4 Allen Locking Bolt

D: 14 mm Lock nut

Figure 106: Adjustment Assembly

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Set the distance between the Print Head Plate and Print Head Carriage to be parallel, as follows:

1. Verify that the space between the Print Head plate and the Print Head carriage is 6 mm. Measure the distance at the Four Corners of the plate, at the location of the two slip-washers (see Figure 107).

PH Carriage PH Plate

Figure 107: 6 mm Distance between the Print Head Plate and the Print Head Carriage

If any adjustments are necessary, see Figure 105 and Figure 106 and perform the following:

2. Remove the 14 mm lock nut (part D) from the 8 adjustment assemblies.

3. Release the M4 Allen locking bolt (part C) and adjustment assemblies 5,6,7 and 8.

4. Release the adjustment screw (part B) at adjustment assemblies 5,6,7 and 8, so that the screw creates neither tension nor pressure between the Print Head plate and the Print Head Cover shield.

5. At the corners where the distance is not 6 mm, perform the following for each corner:

• Release the M4 Allen locking bolt (part C).

• Adjust to a 6 mm distance by screwing or unscrewing the Adjustment screw (part B).

• Tighten the M4 Allen locking bolt (part C).

Note: Take into account that the distance may be affected while you tighten the Allen locking bolt.

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Step B: Locating the Closest Distance between the Vacuum Plate and the Print Head Carriage 1. Reassemble the Print Head cover shield (refer to Figure 103).

2. Remove the two ink-flushing manifolds from the Print Head carriage side.

3. Unscrew two screws at the left side of the Print Head carriage, to the left of the manifolds.

4. In the Calibration kit, locate Indicator Holder B (P/N: 000-60-01-016) and an Arm for Indicator (P/N: 000-61-01-020), and the Micrometer Indicator (P/N: 000-60-01-018) (see Figure 108, Figure 109, and Figure 110).

B A

Figure 108: Indicator Holders A and B

Bolt to Remove

Figure 109: Arm for Indicator

Figure 110: Micrometer Indicator

Note: You may use also the Magnetic Base (P/N: 000-60-01-011) in this process.

5. Secure the Arm for Indicator to Indicator Holder B by screwing it into the smaller of its middle holes.

6. Remove the bolt and one of the washers from the Arm for Indicator (see Figure 109).

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7. Insert the Micrometer Indicator on to the Arm in the location where the bolt and washer were removed.

8. Replace the bolt and washer. The Indicator Holder B, Arm, and Micrometer appear as follows:

Figure 111: Indicator Holder B, Arm, and Micrometer IdicatorAssembled

9. In the Calibration kit, locate the two M8x20 screws (P/N: 000-61-10-005).

10. Secure the Micrometer assembly (Indicator Holder B, Arm, and Micrometer Indicator) on the Print Head carriage using the two socket head screws (P/N: 000-61-10-005) and an Allen key, in the location from which you removed the two screws (see Figure 114).

11. Verify that the four screws (two at the front and two at the back) that secure the Print Head carriage to the base plate of the X-beam are tight (see Figure 112 and Figure 113).

Figure 112: Back Right Screw that Secures Print Head Carriage to its Base (view from ink cabinet)

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Figure 113: Front Left Screw that Secures the Print Head carriage to its Base (view from the front of

printer)

12. Find the minimum distance between the Print Head carriage and the vacuum plate using the micrometer, as follows (see Figure 114):

• Use the Left side of the vacuum plate as a reference (zero point).

• Move the Print Head carriage from left to right and find the minimum distance.

• Repeat this step for the top, center and bottom of the vacuum plate.

• Record the minimum distance at each position & mark it on the vacuum plate.

Note: An acceptable distance deviation is up to 0.5mm.

Note: Move the Print Head carriage by pulling and pushing the IGUS to ensure that measurement is not affected. If the distance deviates by more than 0.5 mm, you must adjust the vacuum plate. Inserting one or more spacers behind one or more VP corners will adjust the VP by extending the specific corner.

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Micrometer Indicator

Arm for Indicator

Indicator Holder B

Figure 114: Calibrating the Minimum Distance, Top, Center and Bottom, between the Print Head

Carriage and the VP Plate

Step C: Adjusting the Minimum Distance between the Vacuum Plate and the Print Head Cover Shield 1. Verify that the Print Head cover shield is on.

2. Move the Print Head carriage to the service side (left side).

3. Remove the four screws (two at the front & two at the back) that secure the Print Head carriage to the base plate of the X-beam (see Figure 112 and Figure 113).

4. Move the Print Head carriage to the point you recorded in step 2 (the minimum distance point).

5. In the kit, locate the two L-shaped 1.5 mm thick spacer rulers (P/N: 200-60-00-007).

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6. At the recorded point, insert the two L-shaped spacer rulers between the VP and the Print Head cover, placing them specifically at the two edges of the Print Head cover.

7. Push the Print Head carriage from its base against the Vacuum Plate.

8. Hold the Print Head carriage from its base and verify the two gauges can move yet touch the two plates.

9. Re-secure the four screws tightly.

Step D: Installing the two Micrometers for the Print Head Plate Vertical Adjustment 1. Remove the Print Head plate cover (see Figure 103).

2. In the Calibration kit, locate Indicator Holder A (P/N: 000-60-01-017) and an Arm for Indicator (P/N: 000-61-01-020), and the Micrometer Indicator (P/N: 000-60-01-018) (see Figure 108, Figure 109, and Figure 110).

Note: You may use also the Magnetic Base (P/N: 000-60-01-011) in this process.

3. Secure the Arm for Indicator to Indicator Holder A by screwing it into the hole in which it fits.

4. Remove the bolt and one of the washers from the Arm for Indicator (see Figure 109).

5. Insert the Micrometer Indicator on to the Arm in the location where the bolt and washer were removed.

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6. Replace the bolt and washer. The Indicator Holder A, Arm, and Micrometer appear as follows:

Figure 115: Indicator Holder A, Arm, and Micrometer IdicatorAssembled

7. Secure Indicator Holder A on the Print Plate using the two M8x20 screws (P/N: 000-61-10-092) and an Allen key (see Figure 108 and Figure 116).

8. Move the Print Head carriage to the service location, keeping the micrometers’ pointers away from the carriage.

9. Adjust the two micrometers’ pointers to touch the bottom and top of the Print Head plate.

10. Place the two micrometers’ pointers in a straight path on the Print Head plates’ face without using holes or pins.

11. Move the carriage left and right and verify that the two micrometers’ pointers are indeed in a straight path, on the Print Head plates’ face, without using holes or pins. (see Figure 114).

12. Verify that the two micrometers arms are stable.

13. Move the Print Head carriage to the right side of the vacuum plate, ensuring that the Print Head plate is not touching the micrometers’ pointers.

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Step E: Micrometer Calibration Use the aluminum ruler from the calibration kit (P/N: 000-60-01-019) to calibrate the two micrometers, as follows:

1. Press the ruler against the vacuum plate while pushing in the micrometers’ pointer (see Figure 114).

2. While holding the ruler against the vacuum plate adjust the micrometer to 20 mm (with the dial’s small hand pointing to 20 and the big hand pointing to 0—see Figure 116).

Indicator Holder A

Figure 116: Two Micrometers Pointing to the Print Head Plate Face

3. Repeat these steps for both the upper and lower micrometer.

4. Move the Print Head Carriage to the right and to the left to verify that the two micrometers’ pointers have a clear path on the Print Head plates’ face, checking that there are no holes or pins in the path.

Figure 117: Micrometer Calibration

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Step F: Finding the Reference Point 1. Move the Print Head carriage to the service side while ensuring that the Print Head plate

does not touch the micrometers’ pointers.

2. Locate the two micrometers’ pointers against the Print Head plate.

3. Move the Print Head carriage left and right against the two micrometers. The micrometers’ pointer should be at about 7 mm, according to the following calculations:

• The micrometer was calibrated to 20 mm (as a reference).

• The distance to the Print Head cover shield is about 1.5 mm (see step 3 above).

• The width of the Print Head cover shield includes the distance between the Print Head cover shield and the Print Head carriage (11.5 mm). This means that the distance to the Print Head plate (without the shield) is: 20 – (1.5+11.5) = 7 mm.

4. Observe the two micrometers’ pointers for the corner at which the pointer is closest to 7 mm.

Note: It is preferable to select the corner at which the pointer is slightly over 7 mm.

5. Select this corner as your reference point.

Step G: Vertically Calibrating the Print Head Plate Adjusting the Print Head plate vertically involves only adjusting two corners in relation to the third corner (the reference point you set in step 5 above). Refer to Figure 105 and Figure 106 throughout the procedure.

1. Verify the following:

• The 14 mm Lock Nuts (part D) from the 8 adjustment assemblies have been removed.

• The M4 Allen locking bolts (part C) at adjustment assemblies 5,6,7 and 8 have been released.

• The adjustment screws (part B) at adjustment assemblies 5,6,7 and 8 are released, so that the screw creates neither tension nor pressure between the Print Head plate & the Print Head cover shield.

2. Release the M4 Allen locking bolts (part C) at adjustment assemblies at the three corners, which do not include the reference point corner.

3. Adjust the three corners, one by one, using the reference point found earlier in Step G, as follows:

• Move the Print Head carriage to the point at which the corner needs to be adjusted while facing the micrometer.

• Adjust the distance of the adjustment assembly’s corner by turning the adjusting screw, using a wide flat metal plate, while watching the micrometers’ reading.

FC10-0808 Rev. D of 117


• Lock the M4 Allen locking bolt after each adjustment.

• Recheck the micrometer’s reading.

• If more adjustment is required, adjust the screw again and lock the M4 Allen locking bolt.

• Repeat the previous steps until you obtain an acceptable measurement. An acceptable measurement deviation is up to 0.5 mm.

• Perform the same adjustment on all three corners.

• Once the distance is the same as measured at the reference point, fix the adjustment assembly by restoring the 14 mm Lock Nuts (part D), and tighten the nut, while you steadily hold the M4 Allen locking bolt.

Note: Take into account that while you tighten the Allen locking bolt, the distance may be affected.

4. Fix the adjustment assembly at the remaining corners, as follows:

• Lock the M4 Allen locking bolt (part C).

• Fix the adjustment assembly by restoring the 14 mm Lock Nuts (part D), tighten the nut while you hold the M4 Allen locking bolt steady.

5. Recheck the vertical calibration, by moving the Print Head carriage left and right while watching the micrometer’s reading.

6. If the distance changes from corner to corner, readjust the three corners again (see Step C).

Step H: Horizontally Calibrating the Print Head Plate 1. Connect the magnet base to the printer chassis.

2. Use the magnet to assemble the micrometer on the chassis and above the Print Head plate.

3. Move the Print Head carriage from its base, right and left, checking that the micrometer’s gauge is at the same level both at the right top point and left top point of the Print Head plate (see Figure 117).

4. If the level is incorrect, adjust the Print Head plate.

5. Loosen all the M4 Allen locking bolts at the three corners, except for the one near the remaining pin (in the round bore), which will be used as an axis for the Print Head plate.

6. Verify that the adjustment screws do not move as you unscrew the M4 Allen locking bolts.

7. Slightly loosen the M4 Allen locking bolts at the remaining pin’s corner adjustment assemblies.

of 117 FC10-0808 Rev. D


8. Gently raise the plate from its bottom by inserting any tool under the Print Head plate to adjust the Print Head plate horizontally.

9. Adjust the Print Head height, locking the M4 Allen three locking bolts, one by one, while watching the micrometer’s reading.

10. Perform the previous steps until you obtain a satisfactory measurement.

Note: After adjustment is complete, do not attempt to restore the pin that was removed.

11. Fix the adjustment assembly for the remaining corners:

• Lock the M4 Allen locking bolt (part C).

• Fix the adjustment assembly by restoring the 14 mm lock nuts (part D). Tighten the nut while you firmly hold the M4 Allen locking bolt.

12. Move the Print Head carriage left and right while watching the micrometers’ reading to recheck the horizontal calibration.

Figure 118: Horizontal Calibration

Step I: Final Tasks 1. Remove all the micrometers and Jigs from the chassis and Print Head carriage.

2. Restore the two rollers to the Print Head plate.

3. Restore the Print Head cover shield.

4. Restore the ink-flushing manifold.

5. Restore the spittoon.

FC10-0808 Rev. D of 117


Calibration Kit Logistics Calibration Print Head plate Kit, PN: 200-60-00-002 PN PART DESCRIPTION QTY

000-60-01-011 MAGNETIC BASE W/8 MM 1

000-60-01-016 INDICATOR HOLDER-2 M10/M8 1

000-60-01-017 INDICATOR HOLDER M10/ M8 2

000-60-01-018 INDICATOR 0.01 MM 0-30 MM 2

000-60-01-019 RULER FOR CALIBRATION HEADS PLATE (SMOOTH) 700 MM 1 000-60-01-020 ARM FOR MAGNETIC BASE M8 2

000-61-10-005 SCREW SOCKET HEX CAP M425 2

000-61-10-092 SCREW HEX CAP M8X20 2

200-60-00-007 1.5 MM RULER FOR HEADS PLATE ADJUSTMENT 1

of 117 FC10-0808 Rev. D


FC10-0808 Rev. C of 117

Appendix D: Schematic Drawings

ApprovedDateDescriptionRev

NURMacroprinters LTD.

Design

Name Date

Drawn

Approve

Engr.

TITLE:

DRW. No: 23-0383 Rev:Sheet of Scale:Page Size:

Used OnNext Assy

35cm

5cmToFW52

yellow

Magenta

Cyan

Black

5

2

3

4

1 0/VBR

GR

PINK

GN

YL

1 3 2

Magenta input

Black input

Cyan input

yellow input

0/V0/V 0/V0/V

FW 52A

44A

N.C

N.C

N.C

N.CSoldering point

N.C-Normally closed

solderingpoints

CYAN

YELLOW

MAGENTA

BLACK

Extenuation Cables

10cm

FLOATTANK

5

66A

FLOATTANK

CYAN

YELLOW

MAGENTA

BLACK

DARKColors

LIGHTColors

8cm

8cm

8cm

Nataly 24.04.02 FRESCO 1 . 8 Colors.FW52ADark&Light Floats

Sensors Wiring.

Yellow light

Magenta light

Cyan light

Black light

N.C

N.C

N.C

N.C

A


Design

Name Date

Drawn

Approve

Engr.

TITLE:

DRW. No: Rev:Sheet 1 of 1 Scale: nonePage Size: A4Used OnNext Assy


Fr 1 18008 color s

08/08/02

GIO Panel Layout Fresco 8 colors

Fr 1 32008 color s

60-0095B AVI.F

G I/O 1 G I/O 2

TB Hydraulic

C.B

SO

LVE

NT

+24V 0/V SOLVENTPULSES(TIMER) ST

OPP

ER

GN

D

Wiri

ng D

uct

Wiri

ng D

uct

Wiring Duct

Wiring Duct

INK CONTROLDark

INK CONTROL Light ST

OPP

ER

INK I/0

SWITCH BOXCM

SWITCH BOXYK

Adding Switch BoxC

AVI.F08/08/02

INK I/O Replacing TNK cardC 20/10/02 AVI.F


Design

Name Date

Drawn

Approve

Engr.

TITLE:

DRW. No: Rev: ASheet 1 of 1 Scale: nonePage Size: A4Used OnNext Assy

AVI.F

AVI.F

24/01/02

30/07/02

FR1- 32008 Colors


J6

J7

J3 J5

J1G I/O 1

J6

J7

J3 J5

J1G I/O 2W63

W54 (RS 485)

23-0380

TEMP.SENSORS Vaccume PlateINPUTS

W50

W28 - RS 485.From PC COMM INTERFACE

Outputs : Heating System,purge,vuccum pump,cooling fans

Ink Level Sensors main tanksINPUTS

IR Temp.Sensors -Top& Botton Rollers INPUTS.

AN.Output.ForProportional Valve.

GI/O CONNECTIONSFresco 8 Colors

INPUTS OF: AIR FLOW SENSOR TEMP CONTROLL- OVER IR HEAT

W72

OUTPUT - IR heatrs

IR SENSORS (Input)SUBSTRATE

IR HEATERLEDS

W63

W11

1

W79 - RS 485 (Standard cable) To Watchdog Board (P1)

GIO1Jumpers Setting

GIO2Jumpers Setting

60-0096

FR1 -18008 Colors


Design

Name Date

Drawn

Approve

Engr.

TITLE:

DRW. No: Rev:Sheet 1 of 2 Scale: nonePage Size:

Used OnNext Assy


GN

YL

GREY

BR

PINK

0V

INPUT

INPUT

INPUT

INPUT

CYAN

MAGENTA

BLACK

YELLOWLIG

HT

IPC

PC

B J

1

4

523-0384 IPC

Light J123-0384 IPC

Dark J1

33A2 23

3B

NOTES: Do Not Assemble the Ferrules Pos1 to the cable but provide them separately in the same packing cable.

110 CM15cm 15cm

DA

RK

IPC

PC

B J1

1

Cable 23-03848C Inputs From Secondary

Ink Tanks Level Sns To Light IPC.23-0384 A

29.05.02NATALY

AVI.F 25.07.02

A4

Fr 1-18008C

Fr 1-32008C

0V

25/9/02Removing The TNK Card And Adding The Ink I/O CardBApprove

dDateDescriptionRev


Design

Name Date

Drawn

Approve

Engr.

TITLE:

Rev:Sheet of Scale: nonePage Size:

Used OnNext Assy

Ink Pump ControlDark

Ink Pump ControlLight

P3 P3J3 J3

J2 J2J1 J1P2 P2

DY DC DM DK LY LC LM LK

GI/O#1

J1

HYDRAULIKTB+24 V 0/24V

MOLEX 2W/W

FRESCO 1

8 Colors Wiring.

MOLEX6W/W

D type 9

FW75

FW71 AFW71 AFW71 B FW71 B

Cyan & MagentaSwitch Block

Yellow & BlackSwitch Block

P4

Cable: 23-0399 Outputs From Ink I/O To Switch Blocks CM&YK

CAVI.F 08/08/02

A3 1 1

Fr1-32008 ColorsFr1-18008 Colors

DRW. No. 60-0098

1A 2A 3A 4A

5A 6A 7A 8A

1B

3B

2B

4B

1C 2C 3C 4C

5C 6C 7C 8C

5B

7B

6B

8B

P1P2

P3

Ink I/O Card

C 02/10/02Replacing cables 23-0396/7/8 with 23-0399

Y C KM

Cable: 23-0375 8C DC IN 24VFrom TBH To IPCS

FW92

. Out

puts

Fro

m IP

C T

o A

ir Pu

rge

Valv

es

Cabl

e: 2

3- 0

380

8C In

puts

Fro

m M

ain

Ink

Tank

sLe

vel S

enso

rs to

GI/O

#1

Cable: 23-0011 Ink Pumps Control Dark

FW29 COMM. Cable From PC Com. Interface To Cable 23-0395

Cabl

e: 2

3-00

11 I

nk P

umps

Con

trol

Lig

ht

FW52- Inputs From SITLevel Sensors To Dark IPC

Cable: 23-0395 8C COMM CableFrom FW29 To IPCS & Ink I/O Board

Cable: 23-0384 8C Inputs FromSIT Level Sensors To Light IPC

+ 24 V 0/24V

J3

J2 J1

P3

P2

Cable 23-0011 - Ink Pumps Control Dark.

FW52 - Inputs From SITLevel Sensors To Dark IPC

CMYK

0/24

+24vBR

BK

WH

RD

GN

GN

Pink

YL

GR

BR

FW92 - Outputs From Dark IPCTo Air PurgeValves

+24v

0/24

Cable 23-0395 8C COMM CableFrom FW29 To IPCS & Ink I/O Board


Design

Name Date

ofer m

11/12/01AVI.F

Drawn

Approve

Engr.

TITLE: 8C Dark Ink Control Board Wiring.

DRW. No: Rev:Sheet 1 of 1 Scale: none

FR 1 32008C

Page Size: A4

Used OnNext Assy


NATALY 11.07.01

WH BK

To Hydraulic T.B

To Light IPC

To Dark Pressure & Vacuum INK Pumps

To SIT Level Sensors

To CMYK Purge Air Valves

INK CONTROLCARD

PURGELEDS

Pressure Ink Pump LEDS

K Y M CK Y M C

Vacuum Ink Pump LEDS

Pressure TransistorsVacuum Transistors

SecondaryTank float

LEDS

U5M

icro

cont

rolle

r

FUSE- 8A. SB

F1

CMYK

0/24

To Ink I/O Card

Cable 23-0375 8C DC IN 24V From TBH TO IPCS

Cable 23-0384 8C Inputs FromSIT Level Sensors To Light IPC

To Light IPC

Dar

k

FR 1 18008C

J3

J2 J1

P3

P2

Cable 23-0011 - Ink Pumps Control Dark.

0/24

+24vGN

Pink

YL

GR

BR

+24v

0/24

Cable 23-0395 8C COMM CableFrom FW29 To IPCS & Ink I/O Board


Design

Name Date

ofer m

11/12/01AVI.F

Drawn

Approve

Engr.

TITLE: 8C Light Ink Control Board Wiring.

DRW. No:

FR1 18008C

Rev:Sheet 1 of 1 Scale: nonePage Size: A4

Used OnNext Assy

FR1 32008C


NATALY 11.07.01

BK

To Hydraulic T.B

To Dark IPC

To Dark Pressure & Vacuum INK Pumps

INK CONTROLCARD

Pressure Ink Pump LEDS

K Y M CK Y M C

Vacuum Ink Pump LEDS

Pressure TransistorsVacuum Transistors

SecondaryTank float

LEDS

U5M

icro

cont

rolle

r

FUSE- 8A. SB

F1

CMYK

0/24

To FW29 COMM Cable

Cable 23-0375 8C DC IN 24V From TBH TO IPCS

Cable 23-0384 8C Inputs FromSIT Level Sensors To Light IPC

To Dark IPC

RD

Ligh

t

23-0395 FW 29 23-0395 IPC Light P3

33A

167

2 4 33B

2

35cm

+ DATA- DATA

+24V0/24V

33C

587

105

cm

3 cm

23-0

395

IPC

Dar

KP31

2

63

12

63

WHBK

RDGN

12

63

16/10/02Changing Cable LengthB


Design

Name Date

Drawn

Approve

Engr.

TITLE:

Rev: BSheet of Scale: nonePage Size:

Used OnNext Assy


Cable: 23-03958C COMM Cable From FW29

To IPCS & INK I/O Board.

NATALY 11.07.02

1 2

Fr 1 18008 color s

DRW: 23-0395

FW 29

1

2

3

INK I/OComm. P1

987

33D

2 55 c

m

5 cm

3 cm

3 cm

pin 1

pin 1

23-0

395

Ink

I/O

Com

m p

1

Fr 1 32008 color s

A4

WH

BK

GN

RD

WH

BK

RDGN

7

8

5

IPC "Light"Comm .P3

IPC "Dark"Comm. P3

pin 1

AVI.F 16.10.02AVI.F


Design

Name Date

Drawn

Approve

Engr.

TITLE:

DRW. No: Rev:Sheet 1 of 1 Scale: nonePage Size:Used OnNext Assy


Main InkTank

DARK

Main InkTank

LIGHT

SITDark

SITLight/Dark

Pre

ssur

e

Vacu

um

Pressure

Vacuum

Vacuum

VL

VD

PD

PL L

D

Vacu

um

SWITCH BOX INK FLOW DIAGRAM

Filter P. Pump

V. Pump

P. Pump

V. Pump

Filter

SWITCHBOX

PrintingCarriage

Connector from Switch Boxto Main Tank.

Connector from Switch Box to SIT.

Electro Valve.

Symbols:

SIT = Secondary Ink Tank.D = DarkL= LightPD = Pressure Dark.PL = Pressure Light.VD = Vacuum Dark.VL = Vacuum Light.

Ink Line.

A

AVI.F

AVI.F

18/08/02

18/08/02A4

Fresco-18008 Colors

Fresco-32008 Colors

60-0110


23-0399 switchblock YK

1C-Y

2C-Y

5B-Y

7B-Y

5C-Y

6C-Y

7C-K

3C-K

4C-K

6B-K

8B-K

8C-K

X cm

1C-Y2C-Y5B-Y

7B-Y

5C-Y

6C-Y

7C-K

3C-K

4C-K

6B-K

8B-K

8C-K

15 cm 13 cm22 cm13 cm25 cm15 cm37 cm22 cm37 cm25 cm37 cm37 cm

Cable Length - X

126

1C-Y

2C-Y

5B-Y

3C-K

7B-Y

4C-K

5C-Y

6B-K

6C-Y

8B-K

7C-K

8C-K

10 cm


Design

Name Date

Drawn

Approve

Engr.

TITLE:

Scale: none

Used OnNext Assy

FR 1 - 32008 color s

NATALY 19.08.02 Cable: 23-0399 Outputs From INK I/O To Switch

Blocks CM&YKSheet 1 of 3Page Size: A3

FR 1 - 18008 color s

AVI.F 25.09.02DRW. No: 23-0399

1A-C

2A-C

1B-C

3B-C

5A-C

6A-C

7A-M

3A-M

4A-M

2B-M

4B-M

8A-M

X cm

126

3

1B-C

3A-M

4A-M

2B-M

6A-C

4B-M

7A-M

8A-M

5A-C23-0399 switchblock CM

8

LABEL

7

4514

+ 24V TB Hydr

TB Hydr+ 24V0/24V

9 1010A

12

11

23-0399INK I/O

P4

3

1313A

1313B 10 cm

4 cm3 cm

TB Hydr

37 cm TB Hydr

NOTES -C1. for single wire use Item 1.2. for 2 or 3 wires use item 2.

See Note B

NOTE-AShrink Position

6 cm 4 cm

73

See Note A

3 cm 4 cm+24V

TB Hydr

1A-C

2A-C

3B-C

NOTES-C1. for single wire use Item 1.2. for 2 or 3 wires use item 2.

6 cm

1A-C2A-C1B-C

3B-C

5A-C

6A-C

7A-M

3A-M

4A-M

2B-M

4B-M

8A-M

15 cm 13 cm22 cm13 cm25 cm15 cm37 cm22 cm37 cm25 cm37 cm37 cm

Cable Length - X59 cm+24V TB Hydr

Rev: BB Changing Wires and Labels Position. 25.09.02

7

8

LABEL

6 cm 4 cm

73

NOTE-BShrink Position

1C-Y

2C-Y

5B-Y

7B-Y

5C-Y

6C-Y

7C-K

3C-K

4C-K

6B-K

8B-K

8C-K

RD

BK

WH

GNORBU

WH/BK

GN

/BK

OR

/BK

BU

/BK

BK

/WH

GN

/WH

BU

/WH

RDRDRDRDRDRDRDRDRDRDRD

L = 32 cm

L = 41 cm

L = 30 cm

L =51 cm

L =32 cm

L =66 cm

L =41 cm

L =78 cm

L =51 cm

L =78 cm

L =78 cm

+ 24V

ApprovedD

ateD

escriptionRev

NU

RM

acroprinters LTD.

Design

Nam

eD

ate

Drawn

Approve

Engr.

TITLE:

Scale: none

Used O

nN

ext Assy

FR 1 - 3200

8 colors

NATALY

22.08.02

Sheet 2 of 3

Page Size: A3 FR 1 - 1800

8 colors

AV

I.F25.09.02

1A-C

2A-C

1B-C

3B-C

5A-C

6A-C

7A-M

3A-M

4A-M

2B-M

4B-M

8A-M

RD

RDRDRDRD RDRDRDRDRDRD RD

WH

GNORBU

WH/BK

GN

/BK

OR

/BK

BU

/BK

BK

/WH

GN

/WH

BU

/WH

L = 32 cm

L = 41 cm

L = 30 cm

L =51 cm

L =32 cm

L =66 cm

L =41 cm

L =78 cm

L =51 cm

L =78 cm

L =78 cm

+ 24V

9213822071519146181325512424111723161022

TB Hydr

RD

1

RD

TB Hydr

0/24V

L = 56 cm

0/24V

POU

T16

POU

T17

POU

T12

POU

T18

POU

T14

POU

T19

POU

T20

POU

T13

POU

T21

POU

T15

POU

T22

POU

T23

POU

T0

POU

T1

POU

T8

POU

T2

POU

T10

POU

T3

POU

T4

POU

T9

POU

T5

POU

T11

POU

T6

POU

T7

L =78 cm

Cable: 23-0399

Outputs From

INK I/O

To Switch

Blocks C

M&YK

DR

W. N

o: 23-0399R

ev: BB

Changing W

ires and Labels Position.

25.09.02

+24V GND

W90: 24V From Systems Power Supply

BK2BK1 GN/YL

To LIGHT IPCW 77To Comm Interace

W 75_b

ToCable 23-0380Level sensor

Main Ink Tanks

BKRD

Hydraulic TB

To C.B SOLVENT

To Solvent pulses Flow (pin A2)

To Solvent Pump (com)

BK BKRD

RD BK

FW117 :


Desi gn

Name Date

Drawn

Approve

Engr.

TITLE:

DRW. No:

Fr 1 18 0 08 colors

Rev: DSheet 1 of 1 Scale: nonePage Size: A4

Used OnNext Assy AVI F. 25/07/01


Hydraulic T.B Fresco 8 colors

Fr 1 32 0 08 colors

60-0094

RD BK

To DARK IPC

BKRD

B Adding TNK for Switcher box 4/8 colors. AVI.F25/07/01

0/24V

1 2 3 4 1 2 3 4

1 2 3 4 1 2 3 4

Cable 23-0375

BKRDRD

Cable 23-0399 To Switch Block YK

Cable 23-0399 To Switch Block CM

C 25/09/01Removing TNK Cable 23-0391 & Adding 23-0398/7/6.

02/10/02Removing Cables 23-0398/7/6 & Adding 23-0399.D

0.9 METER

3cm 10cm

+24VJ3

TBH4 8

8A2

1

33A

5

7

23-0375TBH

23-0375 Dark IPC J3

33B

2

0V

J3

1

2

1

2

Dark Ink INK Control

Light InkINK Control

BK

RD

BK

RD

6

23-0375 Light IPC J3


Design

Name Date

Drawn

Approve

Engr.

TITLE:Fr 1 -1800

8 color s

Rev: BSheet of Scale: nonePage Size:

Used OnNext Assy


Cable: 23-0375 8C DCIN +24Vs From TBH to IPCS

NATALY 27.01.02

1 2 DRW. No: 23-0375

0.5 METER

TBH

3cm

Fr 1 -32008 color s

AVI.F 25.07.01A4

PIN 4

PIN 1

23-0380GI/O #1 J1

11

1212A

5

44A

33A

1213

5 cm50 cm

89

67

GI/O #1J1

23-0380Main Light Ink Tanks

1012

12B

1114


Design

Name Date

Drawn

Approve

Engr.

TITLE:Fr 1 18008 color s


Used OnNext Assy


Cable: 23-0380 8 C. Inputs From Main Ink Tanks Level

Sensors to GI/O #1

NATALY

1 4

12.03.02

FW71 B - Y,C

1616A

FW71

A -

M,K

1616B

15

1616A

1616B

FW 75

1717A

23-0380Main Dark Ink Tanks

FW71 B - Y,C

FW71

A -

M,K

5 cm

50 cm5 cm

DRW. No: 23-0380 A

Fr 1 32008 color s

AVI.F 25.07.02A4

BK

RD

GN

BR

BU

OR

YL

VIOL.

WH

SHIELD

IN 1

IN 2

IN 3

IN 4

IN 5

IN 6

IN 7

IN 8

24Vh

Light Magenta Low Level

Dark Magenta Low Level

Light Yellow Low Level

Dark Yellow Low Level

Light Black Low Level

Dark Black Low Level

Light Cyan Low Level

Dark Cyan Low Level

18

21

8

20

7

19

65

17

4

16

3

15

2

14

1 12

GI/O #1

J1

GN

WH

BK2

136

2

136

2

136

2

136


Design

Name Date

Drawn

Approve

Engr.

TITLE:


Used OnNext Assy


NATALY

2 3

12.03.02

FW75

FW71 B -Y,C

FW71 B -Y,C

FW71 A -M,K

FW71 A -M,K

DRW. No: 23-0380

Cable: 23-0380 8 C. Inputs From Main Ink Tanks Level

Sensors to GI/O #1

Note: FoldingPoint In Item

11

Note:Soldering

Point In Item 3

A4A4AVI.F 25.07.02

Fr 1 18008 color s

Fr 1 32008 color s

23-0011INK CONTROL

P2

VACUUMPUMPS

PRESS.PUMPS

2

1

2

1

2

1

2

1

1

2

1

2

1

2

1

2

7cm

60cm

3.5Meter

3 44A

77A

8

77B

5

6

910

11

12

13

14

11

12

13

14


Design

Name Date

6/8/01nataly

ofer m.

04/11/01

Drawn

Approve

Engr.

TITLE: CABLE 23-0011. INK CONTROL PUMPS.DRW. No: Rev:Sheet 1 of 4 Scale: none

Fresco13200

Page Size: A4

Used OnNext Assy

Fresco11800 6/8/01

Avi.f


5cm

1215

23-0011

11

114

215

316

417

518

720

821

922

1023

619

24122513

+M1-M1

+M2-M2

+M3-M3

+M4-M4

+M6-M6

+M7-M7

+M8-M8

+M9-M9

BLACK

MAGENTA(Red)

CYAN(Blue)

YELLOW

BLACK

MAGENTA(Red)

CYAN(Blue)

YELLOW

VACUUMPUMPS

PRESSINGPUMPS

RD/BK

WH/BKWH

RD

BU/BK

BU

OR/BK

OR

WH/BKWH

RD/BKRD

BU/BKBU

OR/BKOR

1

2

1

2

1

2

1

2

1

2

1

2

1

2

1

2


Design

Name Date

6/8/01nataly

ofer .m

04/11/01AVI.F

Drawn

Approve

Engr.

TITLE: INK CONTROL Cable

DRW. No: Rev:Sheet 2 of 4 Scale: nonePage Size: A4

Used OnNext AssyFR.1 1800

FR.1 3200

ApprovedDateDescriptionRev 23-0011

INKCONTROL

P2

Purge Valves

Dark IPCOverflow Tanks Floats

Motor Pumps

OutputsInputs

Comm.interfacePC

Pressure

DC DKDYDM

KYMC

DKDYDMDC

Vacuum

DC DKDYDM

Light IPCOverflow Tanks Floats

Motor Pumps

OutputsInputs

Pressure

LC LKLYLM

LKLYLMLC

Vacuum

LC LKLYLM

8 Color Electrical Ink Block Diagram


DELL Power Edge 1300 Work Station Return Form Customer Name:

Contact Person Name:

Address:

Country:

City:

State:

Zip Code:

Tel:

Fax:

E-Mail:

Printer S/N:

Customer

Support Representative

IT Notes

Dell S/N (DSN)

CPU No / One / Two

_________ MHZ No / One / Two

_________ MHZ

Memory _________ MB _________ MB

Hard Drive _________ GB _________ GB

CD-ROM No / One / Two No / One / Two

JAZ Drive No / One / Two No / One / Two

Network Card No / One / Two No / One / Two

IT Infrastructure Department


IT Infrastructure Department

Customer Support Representative Name: ___________________ Date: ____________________ Signature: ________________ IT Representative Name: ___________________ Date: ____________________ Signature: ________________ Customer Support Representative Notes:

IT Representative Notes:

E D D - Hewlett Packardwhp-aus1.cold.extweb.hp.com/pub/scitex/HP_Scitex_Fresco...International...

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Transcript of E D D - Hewlett Packardwhp-aus1.cold.extweb.hp.com/pub/scitex/HP_Scitex_Fresco...International...