atd-tc-l-03 service manual of tc prototype 6h 9 carriage transmission belt adjustment ... step motor...

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SERVICE MANUAL

Legal Notices

The information contained in this document is subject to change without notice.

No part of this document can be distributed, copied or translated without the prior written

consent of Inkcups Now (ICN).

ICN makes no warranty of the veracity and reliability of the content in this document,

including, but not limited to, the warranties of merchantability and/or fitness for a particular

purpose.

ICN shall not be liable for errors contained in this document, or for any direct, indirect,

incidental or other consequential damages resulted from using this material.

ICN owns the properties of trademarks, photographs and technical terms in this document,

which would not be transferred because of OEM, distribution, rent, and borrow.

ICN is the owner of patents related to this product; the ownership would not be transferred

because of OEM, distribution, rent, and loan.

ICN shall not be liable for any damages or injuries resulted from improper operation or

ignoring warnings in this document.

INKCUPS NOW SERIES INKJET PRINTERS XJET

All rights reserved by Inkcups Now Corporation Rev: SC71112

Page 1 of 100

Table of Contents

LEGAL NOTICES ..................................................................................................................... 2

Electrical Safety ............................................................................................................................................... 7

Mechanical Safety ........................................................................................................................................... 7

General Warning ............................................................................................................................................. 7

General Cautions ............................................................................................................................................. 8

Handling precautions ....................................................................................................................................... 9

Working Environment ...................................................................................................................................... 9

CHAPTER 1 PRINTER’S MAIN STRUCTURE ...................................................................... 10

1-1 Front View ...................................................................................................................................... 10

1-2 Back View ...................................................................................................................................... 11

1-3 Carriage ......................................................................................................................................... 12

CHAPTER 2 CONTROL SYSTEM ......................................................................................... 13

2-1 Power Supply ................................................................................................................................. 13

2-1-1 Main Power Control (Strong Current) ........................................................................ 13

2-1-2 DC Power Distribution ................................................................................................ 15

2-2 SYSTEM REQUIREMENTS .......................................................................................................... 16

2-3 PCB Boards ................................................................................................................................... 17

2-3-1 Board List ................................................................................................................... 17

2-3-2 Head Board (4 Colors + W) ........................................................................................ 18

2-3-3 IS Main Board (V4.6) .................................................................................................. 20

2-3-4 PWC Motion Board V1.3 ............................................................................................ 24

2-3-5 Power Control Board .................................................................................................. 25

2-3-6 UV Adapter Board ...................................................................................................... 26

2-3-7 Negative Pressure Control Board .............................................................................. 28

2-3-8 Step Driver Board ....................................................................................................... 29



Page 2 of 100

2-3-9 Fan & SMC Board ...................................................................................................... 30

2-4 Motion Control ............................................................................................................................... 31

2-4-1 Head Carriage’s Movement in X Direction ................................................................. 31

2-4-2 Printing Gantry’s Movement in Y Direction ................................................................ 33

2-4-3 Printing Platen’s Movement in Z Direction ................................................................. 35

2-4-4 Conveyor’s Movement in Y Direction ......................................................................... 37

CHAPTER 3 INK SYSTEM ..................................................................................................... 38

3-1 Ink System Diagram ...................................................................................................................... 38

3-2 Components .................................................................................................................................. 39

CHAPTER 4 MENISCUS SYSTEM ........................................................................................ 41

4-1 Meniscus System Diagram ............................................................................................................ 41

4-2 Components .................................................................................................................................. 41

4-3 Workflow ........................................................................................................................................ 43

4-4 Setting Negative Pressure Value ................................................................................................... 44

CHAPTER 5 PRINTER CONTROL INTERFACES ................................................................ 45

5-1 Printer Control Software ................................................................................................................ 45

5-2 Using LCD Control Panel ............................................................................................................... 47

CHAPTER 6 PREPARATION AND PRINTER SETUP .......................................................... 49

6-1 Operation Requirements ................................................................................................................ 50

6-2 Cable Connection .......................................................................................................................... 51

6-3 Power on ........................................................................................................................................ 52

6-4 Check Motion Control .................................................................................................................... 52

6-5 Checking and Setting Negative Pressure ...................................................................................... 53

6-5-1 Check the Negative Pressure .................................................................................... 53

6-5-2 Setting the Negative Pressure ................................................................................... 53

6-6 Filling Ink ........................................................................................................................................ 54

6-6-1 Fill Ink for the First Time ............................................................................................. 54



Page 3 of 100

6-6-2 Adding Ink .................................................................................................................. 55

6-7 Setting Platen Height for Printing .................................................................................................. 56

6-8 Install Print Heads .......................................................................................................................... 57

6-9 Install LED UV Lamps .................................................................................................................... 58

6-10 Settings Printing Origin .................................................................................................................. 60

6-10-1 Setting a Casual Position ........................................................................................... 60

6-10-2 Setting Printing Origin on PCS ................................................................................... 60

6-11 Print Head Calibration .................................................................................................................... 61

6-12 Power Off ....................................................................................................................................... 61

CHAPTER 7 PRINT HEAD INSTALLATION ......................................................................... 62

7-1 Warning:......................................................................................................................................... 62

7-2 Tools Need: ................................................................................................................................... 62

7-3 Preparation .................................................................................................................................... 62

7-4 Illustration of Head Plate Assembly ............................................................................................... 63

7-5 Assemble Print Heads with Ink Tubes ........................................................................................... 65

7-6 Install Assembled Print Heads on Head Plate ............................................................................... 66

7-7 Installing the Head Plate onto Carriage ......................................................................................... 68

7-8 Connect Print Heads to the Ink System ......................................................................................... 71

7-9 Print Head Calibration .................................................................................................................... 74

7-9-1 Calibration Workflow .................................................................................................. 74

7-9-2 Mechanical Alignment of the Print Head .................................................................... 75

7-9-3 Step Calibration .......................................................................................................... 76

7-9-4 Vertical Alignment ...................................................................................................... 79

7-9-5 Step Pass Calibration ................................................................................................. 82

7-9-6 Horizontal Alignment .................................................................................................. 85

CHAPTER 8 PWC MODULE .................................................................................................. 90

8-1 Using PWC Function ..................................................................................................................... 90



Page 4 of 100

8-2 Setting PWC Parameters ............................................................................................................... 90

8-3 PWC Workflow ............................................................................................................................... 92

8-3-1 Printer Initialization ..................................................................................................... 92

8-3-2 Auto Clean after Printer is Ready .............................................................................. 94

8-3-3 Before Carriage Movement and Purge ...................................................................... 95

8-3-4 Before Printer Power Off ............................................................................................ 96

CHAPTER 9 CARRIAGE TRANSMISSION BELT ADJUSTMENT ....................................... 97

9-1 Checking the Tension of Carriage Transmission Belt ................................................................... 97

9-2 Adjusting Carriage Transmission Belt ........................................................................................... 98

APPENDIX A PRINT WORKFLOW AT RUN MODE ............................................................. 99

APPENDIX B LCD MENU .................................................................................................... 100



Page 5 of 100

To Ensure Safety

ELECTRICAL SAFETY

The printer should be in a ventilated environment to prevent from humidity and heating.

Operate the machine with dry hands.

Check power supply voltage and grounding by an authorized electrician.

Power supply input requirement is 115VAC/60Hz. Check the input voltage switches of the four power supplies in the

front electrical cabinet.

MECHANICAL SAFETY

Move the machine with forklift.

Ground the printer on a flat place in a dry environment.

Make working place clean and in order.

Use emergency stop button to stop every moving part of the printer immediately and cut off all power supply.

GENERAL WARNING

Electrical Danger

- Use the power supply voltage specified on the nameplate. Avoid overloading the printer’s electrical outlet with multiple

devices.

- Be sure the printer is well-grounded. Failure to ground the printer may result in electrical shock, fire, and susceptibility

to electromagnetic interference.

- Use only the electrical cord supplied with the printer. Do not damage, cut, or repair the power cord. A damaged power

cord has risk of fire and electric shock. Replace a damaged power cord with an manufacturer approved one.

- Cut power off and unplug the power cable in any of the following cases:

1) When placing your hands inside the printer.

2) When there is smoke or an unusual smell coming from the printer.

3) When the printer is making an abnormal noise.

4) When a piece of metal or a liquid (no part of cleaning and maintenance routines) touches internal parts of the

printer.

5) During an electrical (thunder/lightning) storm.

6) During a power failure.

Danger of Fire

- Do not operate printer within 8 meters (25 feet) of open flames, sparks, or other sources of ignition. Do not SMOKE

within 8 meters (25 feet) of the printer.



Page 6 of 100

Danger of Ink

- Avoid contact between ink and skin, eyes, and clothing.

- Wash skin immediately with soapy water when it has contact with ink.

- Remove clothing soaked with ink to avoid contact with skin.

- Use an approved eye wash station if ink is splashed into eyes and consult a doctor if necessary.

Note: If an approved eye wash station is unavailable, cleaning fluid eyes with cold water and consult a doctor if

necessary.

- Do not swallow ink. If swallowed, do not induce vomiting, but seek immediate medical attention.

- Keep ink cartridges, cleaning kits, and waste ink bottles out of the reach of children.

- Be sure all operators are trained to use emergency equipments such as eye wash stations and fire extinguishers; and

know where they are located.

Others

- Do not disassemble or repair the printer yourself. Do not reinstall the printer in a new location. Call your manufacturer

approved service technicians for service.

- Install and operate the printer in a well-ventilated area.

- The printer installation must meet local, state, and federal regulations on the emissions of volatile organic compounds

in the workplace. It is the responsibility of users to comply with these regulations. Manufacturer recommends installing

with an ink vapor extraction and exhausting system or a certified air purification system. Before installing a system

exhausting ink vapors to the outside atmosphere, consult with your local air quality control authorities. It is your

responsibility to comply with all local, state, and federal air pollution control regulations and building codes.

GENERAL CAUTIONS

Allow and maintain adequate space around printer for immediate access to safety equipment such as eye wash

stations, fire extinguishers, gloves and safety glass dispensers, and fireproof waste storage containers.

If an Air Purification System is installed, leave adequate space for exhaust hoses from the printer. Locate these hoses

and the Air Purification System so that they do not pose a trip hazard or interfere with the operation of the printer such

as loading and unloading media, replacing ink cartridges, inspecting and replacing the waste ink tank.

Always hold the power cord by the plug when connecting and disconnecting from the power outlet. Never pull on the

cord because this may damage it and create risk of fire and electric shock.



Page 7 of 100

HANDLING PRECAUTIONS

These precautions are recommended to avoid damage to your printer and its components.

Power supply

- Use the power supply voltage specified on the nameplate.

- Check the printer electrical outlet for proper polarity and grounding before connecting printer. Failure to do so may

result in fire and electric shock hazards.

- Be sure the printer is well-grounded. Failure to ground the printer may result in electrical shock, fire, and susceptibility

to electromagnetic interference.

- Avoid overloading the printer’s electrical outlet with multiple devices.

- Use only the electrical cord supplied by manufacturer with the printer.

Printer

- Wipe the printer clean with a soft cloth that is moistened with a neutral detergent. Do not allow liquid to enter the

printer. Or it may create risk of fire and electrical shock and cause malfunction. Do not clean the printer with benzene

or paint thinner, which may damage the paint.

- Never touch the print head nozzles. They can be easily damaged or clogged.

Regular Inspection and Maintenance

- Clean the ink system before leaving the printer for a long time (two weeks or more with the power off).

- Clean the ink system before charging ink after leaving the printer for a long time (two weeks or more with the power

off).

WORKING ENVIRONMENT

Before opening the machine box, please prepare a space more than 12m2 (3mx4m) (the machine should be put in

the center);

Temperature of printer’s working environment should be between 16℃ and 28℃;

Space must be clean and dry, not including anything that may cause crumble;

Good ventilation to draw heat, moisture and dust out of the environment;

Good lighting for the maintenance of printer and checking print quality



Page 8 of 100

CHAPTER 1 PRINTER’S MAIN STRUCTURE

1-1 FRONT VIEW

PWC Device

For automatic purging,

wiping and capping of

the heads

Head Carriage

Carry heads, sub

ink tanks, head

board, etc.

LED UV Lamps

Light during

printing to cure

printouts

LCD Control

Panel

Left Electric Cabinet

Step motor and belt pulley

for carriage transmission

are installed

Printing Gantry

The whole gantry

moves in Y direction

during printing.

Adjustable Foot

Hold the printer and

make sure printer’s

base is horizontal

Caster

Facilitates printer’s

movement in short

distance

Converyor

For sending substrates

to the printing area

Front Electric Cabinet

Contains control boards

(PCBs), power supplies,

motor drivers, power

distribution, etc.



Page 9 of 100

1-2 BACK VIEW

Power Socket and

Power Switch

Waste Ink Tank Ink Supply Cabinet

Includes main ink tanks,

ink filters and ink pumps

Conveyor Control

Drive the rolling of

conveyor, including belt

roller, motor, reducer

and a rotary encoder

Meniscus Control Cabinet

Includes NP Control Board,

air pumps, air valves, air

cylinder, etc.

All rights reserved by Inkcups Now Corporation



Page 10 of 100

1-3 CARRIAGE

Warning: During printing, the cover of the carriages should be closed and screws on them should be tightened,

especially the two hand screws of the front cover. Otherwise, the covers may strike the printer; screws may drop in

the carriage’s moving path and scratch print heads.

3-way E-valves

Sub-ink-tanks

Equipped with two-level

sensor and heater

Linear Encoder

Monitor carriage’s

position & give

feedback

Transmission Belt

Drives the carriage

moving in X axis

PWC

Automatic wiping and

capping unit for print

head maintenance

LED UV Lamps

Light during

printing to cure

printouts

Head Plate with Ricoh

Gen 4 Print Heads

Linear Guide

Guide the movement

of carriage in X axis

Conveyor

It supports substrates

and conveys them to the

printing area

Manual 3-way Valve

It supports auto

height movement

Through-beam Photoelectric Sensors

To check if the height of substrate to

make sure it does not get over printhead

nozzle plates



Page 11 of 100

CHAPTER 2 CONTROL SYSTEM 2-1 POWER SUPPLY

Warning:

Please make sure the input power meets with the specification of the four Power Supplies,

Relay and Power Control Board.

The power supplies can be supplied with either 110V or 220V power. Before connecting the

printer with power, please check the following items:

- The switch on the four power supplies are correclty switched.

- Pease check with your technical support or sales if the Relay installed on the printer is for

220V (P/N: ECPS0087) or 110V (P/N: ECPS0190).

- Please check with your technical support or sales if the Power Control Board installed on

the printer is for 220V (P/N: RBOT0077) or 110V (P/N: RBOT0097).

GND of the three switching power supplies should be connected together, and be connected to

the Earth Ground

2‐1‐1 MAIN POWER CONTROL (STRONG CURRENT)

Diagrams



Page 12 of 100

Connection Illustration



Page 13 of 100

2‐1‐2 DC POWER DISTRIBUTION

The NuviJet control system for TL2024 has four power supplies: 24V for IS Main Board, PWC Board, Negative

Pressure Control Board, UV Adapter Board, and platen fans; 36V for X, Y and Z servo motors; ±12V for the head

board; 48V for the two LED UV lamps.



Page 14 of 100

2-2 SYSTEM REQUIREMENTS

Please configure your computer with the following as minimal requirements:

Processor (CPU) Core I3, 3.3GHz

RAM 4 GB

Hard Disk 230 GB

Operating System Windows 7 (64 bit)

Monitor 1024x768 Pixels

USB port High speed USB 2.0 port

USB cable High grade USB 2.0 cable

We recommend you to use NTFS file system to deal with files larger than 2GB.



Page 15 of 100

2-3 PCB BOARDS

2‐3‐1 BOARD LIST

Board Name Qty. Image

Head Board (6H-V6.0) 1

IS Main Board (V4.6) 1

Negative Pressure control

board (V2.0)

1

UV Adapter Board (V2.4) 1

PWC Board (V1.3) 1



Page 16 of 100

Step Driver Board (PWC) 1

Fan and SMC Board (V2.2) 1

Power Control Board 1

LCD Board (V3.1) 1

2‐3‐2 HEAD BOARD (4 COLORS + W)

Head Board is installed on the top of print head carriage. It connects and send orders to printheads through

printhead adaptor cables; communicates with IS main board; and receive signals of ink level in sub-tanks.

JP613~

JP617

W Y

M C

K

Even ODD

Head K

Even ODD

Head C

Even ODD

Head M

Even ODD

Head Y

Even ODD

Head W1

Even ODD

Head W2

Ink 8~Ink3

W2 W1 Y M C K

JP501

Power Supply

JP603 Linear

Encoder

JP301 Main Board



Page 17 of 100

Socket Connection Socket Connection

JP205A Printhead K (EVEN) JP206A Printhead K (ODD)

JP205B Printhead C (EVEN) JP206B Printhead C (ODD)

JP205C Printhead M (EVEN) JP206C Printhead M (ODD)

JP205D Printhead Y (EVEN) JP206D Printhead Y (ODD)

JP205E Printhead W1 (EVEN) JP206E Printhead W1 (ODD)

JP205F Printhead W2 (EVEN) JP206F Printhead W2 (ODD)

Note: Plug printheads’ connectors to the corresponding sockets. Do NOT switch the connectors; otherwise,

it will not print correctly.

Warning: Make sure the plugging cards of print head data cables are fully plugged into the corresponding

sockets and locked; otherwise, print head may get burned.

Socket Connection Note

JP301 To JP601 of IS Main Board

JP501 Power cable from electronic box

+12V G G -12V G +24V

JP603 To linear encoder reader

JP605~JP610

(Ink3~Ink8)

Sub-tank level sensors of K, C, M,

Y, W1 and W2 respectively

JP613~JP618 To 3-way E-valves of K, C, M, Y,

W1 and W2 respectively

+24V GND

Ink Level Low

Ink Level High

+5V



Page 18 of 100

2‐3‐3 IS MAIN BOARD (V4.6)

IS Main Board is installed on the door of Left Electronic Cabinet. It communicats with head board and step driver

board, controls X, Y and Z motion, supplies ink, and at the same time controls other peripheral functions.

Slot Connection Note

Mode and Tooling Control

MS1, MS3,

MS4

To the 3-way mode switch:

MS1: Move Checking IO,

MS3: Setup and Run socket

MS4: Fixture socket

P15, P16,

P17

To the motor for the loading of

fixture

Arm232 to Step Driver Board

CANBUS to

NP Board

J401

Power Supply

P3-P8

Ink Pumps

P18 P Pump

P19~20 Buzzer

P13, P14 Ink Pumps

Z to Z limit

sensors

X/Y Step

X-org

X-end

MS4 MS3

B2 PW2 to Relay

of Platen Fan

PS4 to Power

Control Board Panel to

LCD Board

J601 to Head Board

Sen5 Sen 6 Sen7

Y-org Y-end

Z S

ervo

PS3 PS2 PS1 to JP301

of UV Control Board

P9-P12 to JP301 of

UV Control Board

BD SF F1 F2 to JP301

of UV Control Board

To compurter

MS1

P15, P16, P17 to Fixture’s Motor



Page 19 of 100

Motion Control

X-step To step motor of carriage

movement

Y-step To step motor of media feeding

X-Org To carriage origin sensor

X-End To carriage end sensor

Y-Org To Y direction origin sensor

Y-End To Y direction end sensor

Y-encoder

Z To Z direction origin and end

sensor

Z-Servo To linear encoder and motor

driver of platen movement in Z

axis; and also the through-beam

photoelectric sen

Ink Supply and Meniscus System

CANBUS To JP205 of NP board and JP205

of PWC Motion Board V1.3



Page 20 of 100

P3~P14 To ink pumps and white ink’s

re-wind pumps

P18 To positive pump

Sen7 From Main Ink Tank of White 1

Sen8 From Main Ink Tank of White 2

UV Lamp Control

PS1 To JP301 of UV Control Board

PS2

PS3

P9-P12 To JP301 of UV Control Board

BD SF F1 F2 To JP301 of UV Control Board

Power Control



Page 21 of 100

J401 Power Supply

Sen5 To the button Emergency Stop

Sen6 To foot panel

PS4 To JP4 of Power-off sequence

board

SF & F1 To JP1 of Power-off sequence

board

Z & FD

Others

ARM232 To JP211 of Step Driver Board

JP601 To JP301 of head board

P19, P20 To Buzzer

Panel To JP2 of LCD Board

Simple Panel To JP4 of Fan & SMC Board

USB To computer installed with Printer

Control Software



Page 22 of 100

2‐3‐4 PWC MOTION BOARD V1.3


JP101 From power supply

JP401 To the step motor driver of conveyor

Z-Servo From the rotary encoder of conveyor

Z-Servo

JP101

JP205

JP401



Page 23 of 100

2‐3‐5 POWER CONTROL BOARD


JP1 To SF & F1 of IS Main Board

JP2 Wire 01 to Stop button, wire L1 to

relay.

JP3 From L1 and N terminals of

terminal block

JP4 To PS4 of IS Main Board

JP1

JP4

JP3

JP2



Page 24 of 100

2‐3‐6 UV ADAPTER BOARD

UV Adapter Board controls the two LED UV lamps.


JP1 Power supply

JP301 LED UV lamps PIN1 +24V(VDD24)

PIN2 Remote UV Ready

PIN3 Lamp 1 Fault

Pin5 Lamp 1 On

Pin6 Lamp 2 On

Pin7 Lamp 1 Set Power Bit1


Pin9 GND

Pin11 Lamp1 shutter open

Pin12 Lamp 2 Fault

Pin13 Lamp 1 Shutter Run / LED EN A In

Pin14 GND


Pin22 Lamp 2 Set Power Bit 0

JP1

JP301

JP601

JP602



Page 25 of 100

Pin28 Lamp 1 Shutter Open Feedback

Pin29 Lamp 1 Shutter Closed Feedback

Pin30 Lamp 2 Shutter Open Feedback

Pin31 Lamp 2 Shutter Closed Feedback


JP601 To LED UV lamp 1

JP602 To LED UV lamp 2



Page 26 of 100

2‐3‐7 NEGATIVE PRESSURE CONTROL BOARD

Negative pressure board controls the negative pressure system, which is important for high-speed printing.


JP101 Power supply

JP205 To socket Panel of IS Main Board

JP301

(KCMY)

Pin 1, 3, 5: +24V

Pin 2: to positive 3-way EM valve

Pin 4: to negative 3-way EM valve

Pin 6: to negative pump

JP302

(White)

U301 Negative pressure sensor of Meniscus system of KCMY

U302 Negative pressure sensor of Meniscus system of white ink

JP101

JP301

JP302

U301

U302

JP205



Page 27 of 100

2‐3‐8 STEP DRIVER BOARD

Step Driver Board control the operation of PWC device that is used for automatice purge, wipe and capping of

printheads.


JP101 From 24V power supply

JP1A To the PWC’s motor of Y direction

movement

A+ A- B+ B-

JP1B To the PWC’s motor of X direction

movement

JP201 From the down sensor of PWC

JP202 From the up sensor of PWC

JP203 From X-origin sensor of PWC

JP204 From X-end sensor of PWC

JP211 From socket ARM232 of IS Main

Board



Page 28 of 100

2‐3‐9 FAN & SMC BOARD


JP4 To the socket Simple Panel of IS

Main Board

JP5 From main ink tanks of K and C JP5 JP6

GND K C GND M Y Waste F

JP6 From main ink tanks of M, Y, flushing

fluid and waste ink



Page 29 of 100

2-4 MOTION CONTROL

Head Carriage’s movement in X direction, platen’s movement in Y direction (media feeding) and Z direction

(printing height adjustment) are reallized with motors, motor dirvers, linear encoders, sensors and other parts. All

the motion related electric parts are connected to Main Board, which process the motion signals and orders.

This section introduces motions’ main parts, workflows, and setups.

2‐4‐1 HEAD CARRIAGE’S MOVEMENT IN X DIRECTION

Main Parts Included

1. DC Motor: It is installed at the left end of carriage’s guide beam.

2. DC Motor Driver: It sits in the front electric cabinet. It controls and drives the DC motor.

Three connectors are plugged on the DC motor driver. The signal cables (PUL+, PUL-, DIR+ and DIR-)

go to the main board, encoder and high voltage cables (EB+, EB-, EA+, EA-, +5V and GND) come from

the motor.

3. Linear Encoder: It goes along the top of carriage’s guide beam, monitors the position of carriage and

gives feedbacks.

4. Transmission Belt: It pulls the carriage and enables it from moving. The belt is fastened to the back of

carriage.



Page 30 of 100

Initialization Workflow

During printer initialization after power on, carriage will take several seconds to initialize and search for the

origin position.

Power ON

PWC Initialization

Z (Printing Platen) Axis Initialization

Error! Carriage Stops Moving

Carriage moves right-ward and check if the origin sensor is effective

No

Continue searching for origin sensor

15S

Carriage Stops Moving

Yes

Y (Gantry) Initialization

End

Printing Speed (600dpi)

Speed Small Dot Middle Dot Large Dot

High 1.27m/s 1.06m/s 0.84m/s

Low 1.06m/s 0.84m/s 0.63m/s



Page 31 of 100

2‐4‐2 PRINTING GANTRY’S MOVEMENT IN Y DIRECTION

Main Parts Included

1. Step Motor: It generates the rotation of leading screw.

2. Leading Screw: It leads the movement of printing gantry, which is bound to two plates that are fixed on the

bearing brackets of the leading screw.

3. Linear Guide and Guide Slider: Two linear guides are installed, one on each side of the leading screw to

guide the movement of printing gantry and make sure its passage is linear. One each linear guide, there

are four guide sliders, two for each connecting plate.

4. Step Motor Driver: It sits in the front electric cabinet. It controls and drives the step motor of printing

gantry’s movement in Y direction.

1) Two connectors are plugged on the step motor driver. The signal cables (PUL+, PUL-, DIR+ and DIR-)

go to the main board, encoder and high voltage cables (EB+, EB-, EA+, EA-, +5V and GND) come

from the step motor.

2) Dial Switch:

SW8 ON

SW7 OFF

SW6 ON

SW5 OFF

SW4 OFF

SW3 OFF

SW2 ON

SW1 ON



Page 32 of 100


During printer initialization after power on, platen will move forward, closer to the operator, and stops at the

terminal position.

Power ON

PWC Initialization

Z Axis Initialization

Error! Printing Gantry Stops Moving

Printing gantry moves backwardand check if the Y origin sensor is

effective

No

Continue searching for Y origin sensor

Printing Gantry Stops at the Y original position

Yes

X Axis Initialization

15S

End



Page 33 of 100

2‐4‐3 PRINTING PLATEN’S MOVEMENT IN Z DIRECTION

Main Parts Included

1. Step Motor: It generate the rotation of leading screw at the backside of the printer.

2. Leading Screw: It leads the movement of printing platen’s movement in Z-axis. It is connected to the

reducer at the backside of the printer.

3. Reducers: Two reducers are installed beneath the front and end of printing platen’s holder. The one at the

front is connected to the motor; the one at the back is connected to the leading screw. They are

connected with a shaft and couplings.

4. Pneumatic Supports and Shafts: They hold the printing platen and make printing platen’s movement in

Z-axis possible and stable. There are two pneumatic supports and two shafts at each end.

5. Step Motor Driver: It sits in the front electric cabinet. It controls and drives the step motor for printing

platen’s movement in Z-axis.

1) Two connectors are plugged on the step motor driver. The signal cables (PUL+, PUL-, DIR+ and

DIR-) go to the main board, encoder and high voltage cables (EB+, EB-, EA+, EA-, +5V and GND)

come from the step motor.

2) Dial Switch:

SW8 ON

SW7 ON

SW6 OFF

SW5 OFF

SW4 OFF

SW3 OFF

SW2 ON

SW1 ON



Page 34 of 100


During printer initialization after power on, platen will move forward, closer to the operator, and stops at the

terminal position.

Power ON

PWC Initialization

Error! Platen Stops Moving

Printing platen moves down and Check if the Z origin sensor is effective

No

Continue searching for Z origin sensor

Printing platen stops at the Z origin position

Yes

X Axis Initialization

15s

Y Axis Initialization

End



Page 35 of 100

2‐4‐4 CONVEYOR’S MOVEMENT IN Y DIRECTION

Main Parts Included

1. Step Motor: It generates the rotation of conveyor’s roller.

2. Coveyor Roller: Two conveyor rollers in total; one at the back end and connects to the step motor, the

other at the front end.

3. Step Motor Driver: It sits in the front electric cabinet. It controls and drives the step motor of printing

gantry’s movement in Y direction.

1) Two connectors are plugged on the step motor driver. The signal cables (PUL+, PUL-, DIR+ and

DIR-) go to the main board, encoder and high voltage cables (EB+, EB-, EA+, EA-, +5V and GND)

come from the step motor.

2) Dial Switch:

SW8 OFF

SW7 ON

SW6 ON

SW5 ON

SW4 OFF

SW3 OFF

SW2 ON

SW1 ON

Workflow

- Run Mode: The conveyor runs only after the tooling template arrives at the top position.

- Fixture Mode: The conveyor can run freely with options in LCD menu.



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CHAPTER 3 INK SYSTEM

3-1 INK SYSTEM DIAGRAM

The ink system of TCL1818 not only supplies ink for printing, but also provides positive pressure for printhead

maintenance and negative pressure to stablize ink supply for high speed printing. The positive and negative

pressures are controlled by the air system, which is introduced in Chapter 4.

Please see the following Ink System diagram:



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3-2 COMPONENTS

Main Ink Tank: Seven main ink tanks are provided; please clean it with your inks’ flushing fluid and dry it

with air before pour ink into it.

Ink and Flush Pumps: There’s one pump for each ink channel and flushing fluid channel.They are used to

pump ink from main ink tanks to sub-ink-tanks when the two-level sensors in the latter detect ink low. For

each white ink channel, there’s one extra pump for ink circulation.

The order of the ink pumps from right to left is: K, C, M, Y, White1, F, Re-W1.

Filters: In the ink system, two kinds of filters are adopted: Disk Filter and Needle Filter. One air disk filter is

installed on the main ink tank to prevent any dust from getting in. Two Ink disk filters are also required before

the ink getting into sub-ink-tank and printheads to filter any dust and air. And the needle filters are installed

between ink pumps and sub-ink-tanks to filtrate impurities.

Manual 3-way Valve: There’s one manual 3-way valve in each channel; they are installed at the ink outlets

of sub-ink-tanks. The valves are used to print heads’ connection with sub-ink-tanks and flushing fluid tank.

Valve Positions of Manual 3-way Valves:

K C M Y W F

Sub-ink-tank

INK Handle Flush

Print Head

Flush

Handle

Flush

Sub-ink-tank

Print Head

OFF Flush

Sub-ink-tank

Print Head

Handle

Main Ink Tanks

Needle Filters

Ink & Flush Pumps



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Valve Position OFF: Ink channel is closed; ink cannot flow to the print head.

Valve Position INK: Ink channel is open; ink flows to the print head.

Valve Position Flush: Flushing fluid flows to the print head.

Warning:

Before printing, do remember to adjust the handle of manual three-way valve to position INK, so that ink can

flow into heads; otherwise, air may get into heads when they run out of ink.

Everyday after work, make sure the manual three-way valve handles of the areat position OFF.

One Way Valve: To avoid ink from flowing back.

Sub-ink-tanks: It is designed for stable ink supply. Two level sensor is installed in each sub-tank. When the

sensors detect that ink level is low, ink pumps will pump ink from main ink tank to them. Negative pressure is

provided here to keep pressure inside stable to keep ink stays at the surface of nozzle plate. That is to

ensure good printing quality.

Printhead: TCL1818 printer is designed for six printheads printing. Install your printheads onto the carriage

according to the section Installing Ricoh Gen 4 Heads. Then, connect the print heads to the control system.



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CHAPTER 4 MENISCUS SYSTEM The meniscus system for inks in TCL1818 printer can be divided into two parts: negative pressure system and

positive pressure system. Negative Pressure System provides negative pressure to control the ink level inside

print heads so as to achieve high speed printing. It hold ink back to avoid flowing freely during printing and when

print heads are idle. The negative pressure for KCMY and white ink is controlled separately. Positive Pressure

System to generate positive pressure for purging to clean heads and avoid nozzle jam.

4-1 MENISCUS SYSTEM DIAGRAM

4-2 COMPONENTS

Negative Pressure

Negative Pump: It provides negative pressure required by the printing operation. It is connected to JP301 of

Negative Pressure Control Board that gives orders.

Inflation Valve: It triggers the negative pressure pump to pump. It connects to JP301 or JP302 on negative

pressure control board that orders the valve to inflate when it detects abnormal low pressure in the air

cylinder.

Deflation Valve: It is used to trigger the Adjustable Restrictive Valve to deflate. It connects to JP301 or

JP302 on negative pressure control board that orders the valve to deflate when it detects abnormal high

pressure in the air cylinder.

Adjustable Restrictive Valve: It is used to obtain optimized target pressure value and it helps to stabilize

the pressure. It releases air when there’s too much pressure, the order of which is given by three-way

e-valve (Deflation).

Negative Pressure for

KCMY Channels

Negative Pressure for

White Ink Channels

Positive

Pressure



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Air Cylinder: With air cylinder being installed, the negative pressure can be more stabilized.

Sensor: It is installed on the Negative Pressure Control Board; it is U301.

Positive Pressure

Positive Pump: It creates positive pressure required by purging ink or solvent. It is connected to purge

button.

Adjustable Restrictive Valve: It is used to obtain optimized target pressure value and it helps to stabilize

the pressure. It releases air when there’s too much pressure, the order of which is given by three-way

e-valve (Deflation).

Switch Valve

For each ink channel there’s a switch valve, which is used to switch between negative pressure and

possitive pressure.



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4-3 WORKFLOW

Negative Pressure

When the printer is in the status of “Ready” after initializing, negative pressure control board check

the negative pressure in the air system with sensors (U301 and U302) that is connected to the air

guide and air cylinder.

When the negative pressure value is beyond the range that is set on LCD panel or PCS, the board

sends orders to the inflation or deflation three-way e-valve.

If the negative pressure is lower than the preset value, the board sends order to the deflation 3-way

e-valve, so negative air pump is connected and it starts to work. If the pump sucks too much air, the

board sends order to the inflation 3-way e-valve so that the throttle valve is connected and starts to

release air into the system.

If the negative pressure is higher than preset value, the board sends order to open the 3-way e-valve

to air. And if the pump pumps too much air, the inflation 3-way e-valve triggers the adjustable

restrictive valve to absorb some air.

Positive Pressure

When you press purge on LCD, the negative control board orders the 6H three-way e-valves, which

connect to positive pump through air guide, to switch from negative pressure to positive pressure.

The valves are separated so that you can purge the channels one by one.

Once purging is stopped, the leak valve will release the positive pressure in the air system; then

negative pressure parts will start to work.



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4-4 SETTING NEGATIVE PRESSURE VALUE

Users should be very clear about the negative pressure value of their printers. Before printing, proper

negative pressure value should be set on the software Negative Pressure Control for the system to control it.

Mainly there are two steps to get an accurate negative pressure value:

- Calculate: get a range of the value through a formula;

- Alignment: get the accurate value by tests;

Calculate Negative Pressure Value Range

The negative pressure value is decided by the distance between sub-ink-tank and print heads;

please calculate the theoretical negative value according to the following diagram

Alignment

1. Input any value in the range got according to the method above;

2. Press buttons on Panel Board to purge ink from one print head, either head 1 or head 2.

3. Observe the nozzles and check if nozzles spray normally.

4. Wipe the print head with a piece of Cleanroom wiper (in one direction only).

5. Check the nozzle plate.

If there is bleeding (small drop of ink) over the nozzle, reduce 0.1Kpa of the pressure (as the value

is negative, reduce means to increase the ABSOLUTE value). If there is no bleeding, increase

0.1kpa of the pressure, then repeat step 2 to step 5 until you get the threshold pressure value (in

which the bleeding is almost unobservable).



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CHAPTER 5 PRINTER CONTROL INTERFACES The printer can be controlled with two interfaces: the Printer Control Software (PCS) and the LCD control panel.

With PCS, users can set printing settings, printer parameters and control printer remotely; while the LCD control

panel allows user to do basic printer settings and control the printer closely.

5-1 PRINTER CONTROL SOFTWARE

With Printer Control, you can check printer's real time status, set printer parameters and control the printing

process.

1. General Introduction

Remotely control the printer through USB connection, switching printer’s online/offline status, clean

print head, move print head and media.

Monitor and control the printing process. Send print jobs to the printer and pause/resume/abort job

during printing.

Set printhead parameters, align the printer, and modify printing settings.

Setup user permissions. Normal user cannot modify advanced settings, for safety consideration.

2. Main Interface

Peripheral Status Panel

Tool Bar Operation PanelPrinting Setting Panel Status Panel



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You can use menu, buttons to control the printers and check the status from the status windows in the main

user interface. Please go to the user’s manual of Printer Control Software for detailed information about its

usages and functions.

3. Update The Firmware

Follow these steps when you need to update the firmware of the Printer Control Software:

1. Turn on the printer and open Printer Control Software;

2. Select Update Firmware < Update < Tools menu;

3. Select the firmware file for your printer type and click OK to update;

4. If you are using Windows XP and it prompts up the following dialog, click the “Continue Anyway”

button:

5. Power off the printer when the computer prompts you to restart the printer;

6. Turn on the printer after 3 seconds.



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9 7

1 2 3 4

5 6 8 10

Run/Set Up\Fix

5-2 USING LCD CONTROL PANEL

The LCD control panel locates at the front of the printer; with keys on it, users can set up and control the printer.

There are five buttons next to the LCD panel, which are used to power on/off the printer, move platen in Z

direction and start printing.

1. Main Parts

No. Button Function

1 Emergency Stop Cut off power of the complete printer

2 Mode Switch To switch mode among Fixture, Set Up and Run (see note

2 in page 48)

3 Printer OFF Button Turn off the printer

4 Printer ON Button Turn on the printer

5 LCD Panel It’s the interface of setting printing parameters.

Error Power

Abort Pause Menu



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6 Abort Key Press this key to stop the printing job.

7 Pause/Resume Key Press this key to stops the printing job; press the button

again to resume print.

8 Menu Key Press the key to toggle between the display of menu and

the display of the printer status.

9 Arrow Keys Use these keys to select settings, change parameter,

move media and other like operations.

10 Enter Key Press this key to accept changes of setting, move media

and do other like operations.

Note 1: See Appendix B for the detailed menu list.

2. Mode Switch

This 3-way switch enables you to switch between three modes, which are Run mode, set up mode and

fixture mode.

- RUN Mode: The motions of the tooling template are included in the printing workflow. See Appendix A

for the printing workflow at run mode.

- Set Up Mode: To set up and down positions of the tooling template with options under Set Load Device

Position of LCD control panel.

The options under Set Load Device Position are only effective at Set Up Mode.

The setting of up and down postions should be down every time after turning on the printer.

Every time after turning on the printer, press the foot panel to initialize the template.

After capture and log, pressing the foot panel to test and check if the two positions of the tooling

panel are OK.

- Fixture Mode: NuviJet printing control system ignores the tooling system. But the foot panel should be

pressed everytime after PCS sending job to the printer to start printing.



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CHAPTER 6 PREPARATION AND PRINTER SETUP After unpacking the printer (check Appendix A for detailed information), please prepare and set up the

printer to get the printer ready for printing according to the workflow that is to connect the printer to a

computer, connect the power cable, turn on the printer, check and set negative pressure, fill ink, load media,

set printing origin, and align the printer.

This chapter explains all the detailed procedures of these preparations. It includes:

Operation Requirements

Cable Connection

Power On

Check Motion Control

Check and Setting Negative Pressure

Fill Ink

Set Platen Height for Printing

Install Print Heads

Install LED UV Lamps

Set Printing Origin

Print Head Calibration

Please follow this order to get the printer ready for printing.



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6-1 OPERATION REQUIREMENTS

Before you unpack the printer, please choose a proper location for it, and make sure all the following electrical and

environmental requirements are fulfilled.

Electrical

The electrical requirements should be met to avoid electronic shock or interference that may cause bad print

quality.

1). Please make sure the input power meets with the specification of the four Power Supplies, Relay and Power

Control Board.

The power supplies can be supplied with either 110V or 220V power. Before connecting the printer

with power, please check the following items:

- The switch on the four power supplies are correclty switched.

- Pease check with your technical support or sales if the Relay installed on the printer is for 220V

(P/N: ECPS0087) or 110V (P/N: ECPS0190)

- Please check with your technical support or sales if the Power Control Board installed on the

printer is for 220V (P/N: RBOT0077) or 110V (P/N: RBOT0097).

2). GND of the three switching power supplies should be connected together, and be connected to the Earth

Ground

3). Use the supplied power cord and plug it into a well grounded electrical outlet.

4). Avoid overloading the printer’s electrical outlet with multiple devices.

5). Make sure the electrical outlet of the printer is well grounded.

Environmental

Choose a place with proper temperature and ventilation condition for the printer to avoid dust from getting into

the printheads and ensure all the parts work in its best condition.

6). Before opening the machine box, please prepare a space more than 12m2 (3mx6m).

7). Good ventilation to draw heat, moisture and dust out of the environment.

8). Good lighting for the maintenance of printer and checking print quality.

9). Temperature of printer’s working environment should be between 16℃ and 28℃.

10). Space must be clean and dry, not including anything that may cause crumble.



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6-2 CABLE CONNECTION

To run the printer, you need to connect it to a computer, on which the Printer Control Software and your RIP

software run, with the USB cable provided; and connect power cord to give power supply.

1. Connect the printer to the computer that the Printer Control Software and your RIP software are installed with

the USB cable provided. Please see the image above for the position of the USB socket.

2. Connect one end of the power cable provided to the power supply socket of the printer and the other end to the

electrical outlet. Please see the image above for the position of the power supply socket.

3. Press the red power switch to connect power to the printer.

Warning:

Before connecting power cord, read the Electrical Requirements carefully and thoroughly;

If you are not sure how to accommodate the circuit to the printer, please consult a qualified

electrician.

Make sure the electrical outlet and the printer are well grounded.

Power Switch

USB Socket

Power Supply Socket

To foot pedal



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6-3 POWER ON

When the printer is connected to a computer on which the Printer Control Software or your RIP software is installed,

it is ready to power on. But before that, please check the grounding and power supply of the printer again to make

sure it is safe and the environment is qualified.

1. Turn on the computer connecting to the printer. The computer needs to be installed with Printer Control

Software and RIP software

2. After the computer is ready, press the Power ON button (the blue button at the front right side of the printer).

Please see the image in section 5-2 Using LCD Control Panel.

3. Start the Printer Control Software.

4. The printer will start to initialize, PWC, carriage, and platen will move toward the origin position and stop there.

Please see the section 2-4 Motion Control for the initialization workflow.

Note: Every time after you send printing job order from either PCS or RIP software, you need to press the Print

button (the blue button at the front left side of the printer) to start printing. Please see the image in section 5-2

Using LCD Control Panel.

Once the printer has done initialization, the LCD panel will display “Ready”.

6-4 CHECK MOTION CONTROL

Before installing print heads, we need to check printer’s motion control so as to prevent any accident.

Please press the arrow buttons on the LCD control panel or those on PCS to move carriage and platen to check if

they are well controlled.

- Press the left and right arrow buttons to check if carriage moves accordingly; release the buttons to check if

carriage stops moving right away.

- Press the up and down arrow buttons to check if printing gantry moves back and forth accordingly; release the

buttons to check if printing gantry stops moving right away.

- Select up and down options on LCD control panel or on PCS to check if printing platen goes up and down

accordingly; release the buttons to check if platen stops moving right away.



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6-5 CHECKING AND SETTING NEGATIVE PRESSURE

Negative Pressure System provides negative pressure to control the ink level inside printheads and keep ink

from flowing out through the nozzles, and positive pressure for purge ink or cleaning fluid for heads’

maintenance and avoiding nozzle jam. Improper negative pressure value will cause nozzle failure and the

printing quality will be bad. When negative pressure level is too high, it draws ink back and stops ink from

getting out of the printheads; nozzles will starves out and fail to print. When negative pressure level is too low,

ink will escape from printheads and accumulate around nozzles; ink drops fired by the printheads may be

absorbed by the accumulation and cannot arrive at the media, nozzles will fail to print. Thus, it is important to

check the negative pressure when the printer is just turned on.

6-5-1 CHECK THE NEGATIVE PRESSURE

After turning the printer on, please check the negative pressure value displayed on the negative pressure value

display or LCD panel (Menu>Ink Pressure Setup>Pressure Value). Before filling ink, we need to make sure the

negative pressure is acceptable. The negative pressure value normally is -2.2kPa.

When the printer is turned on, the value displayed may be beyond the range (-2.0KPA~-2.5KPA). But during

the initialization, the negative pressure system adjusts the negative pressure by itself until it gets to the value

set on the LCD panel. When the printer is ready after initializing, please read the value displayed on the LCD

panel.

6-5-2 SETTING THE NEGATIVE PRESSURE

When the negative pressure value displayed on LCD panel is not -2.2kPa, it needs to be set.

Method: Go to LCD panel and set the negative pressure value under Menu>Ink Pressure Setup>Pressure

Value with LCD panel buttons.



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6-6 FILLING INK

The ink system has 6 main ink tanks and one main tank for cleaning fluid. In each tank there’s a sensor; when the

ink or flush in the tank is not enough, the printer will beep and shows an error message on LCD panel.

6-6-1 FILL INK FOR THE FIRST TIME

When you receive the printer, all the ink system components are well installed and tested. But dust may get into

the ink system during shipment. Therefore, you need to clean the ink system with flushing fluid before filling ink

for the first time. Not until the ink system has been cleaned thoroughly can you fill ink to the system.

Warning: The procedure is only applicable when your ink is the same with that used by the manufacturer.

Otherwise, the ink system should be cleaned thoroughly with the flushing fluid of your ink and let it circulate in the

ink system for about 2 hours.

Cleaning the Ink System with Flushing Fluid

1 Screw the main ink tanks off the printer.

2 Clean the main tanks with flushing fluid. Then pour some flushing fluid in each main tank; 1/4 of

the tank will be enough.

3 Install the main ink ink tanks filled with flushing fluid back to the printer.

4 Turn on the printer, set the negative pressure values to -2.2kPa.

5 Check the handle position of manual 3-way valves. Make sure the fluid can go to the

sub-ink-tanks. (Please check the section 3-2 for detailed information of using manual 3-way

valve)

6 Switch the ink supply mode from Manual to Auto on LCD panel (Menu > Ink Supply Setup > Ink

Supply Mode). By default, Manual is selected.

7 Pumps start to pump cleaning fluid into sub-ink-tanks.

8 Press the button Purge Ink on PCS or LCD control panel or the button to the right of carrige’s

home station. Flushing fluid will come out from the outlets of manual 3-way valves.

9 Keep pressing the button until all the flushing fluid in the main ink tanks is purged out.

10 Power off the printer by pressing the button Power Off at the front.

Now the ink system should be clean and ready for ink introduction.



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Fill Ink for the First Time

As long as the ink system is clean, you can fill ink to the ink system according to the following procedure.

1. Fill main tank with ink:

1) Pour one color of ink into its corresponding main ink tank.

2) Install the main ink tank back to the printer; pay attention to the color channel.

Warning: The four ink channels should be supplied one by one; please install the second main

ink tank after the sub-ink-tank of first ink channel is full.

2. Fill sub-ink-tank with ink:

3) Select Auto as ink supply mode from LCD panel and set 20sec as the supply time.

The ink will be pumped into the sub-ink-tanks, during which the LCD will indicate the

corresponding ink channel is supplying ink; by flashing the sub-ink-tank symbol on the LCD. It

stops flashing when the sub-tank is full.

4) Repeate steps 1 to 3 to fill other ink channels.

6-6-2 ADDING INK

When the ink level in main ink tank is low, the printer will beep and at the same time send a warning message

“Main Tank [K, C, M, Y, flush] Ink Low” to LCD panel. Please add the corresponding ink as soon as possible to

ensure the printing job can be finished with good quality.

Warning:

Do not add the ink of different brand, use the same ink only! If you need to use ink of the other

kind or brand, clean the ink system with cleaning fluid thoroughly before changing ink.



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6-7 SETTING PLATEN HEIGHT FOR PRINTING

The distance between print head (nozzles) and media should be proper. The printing quality will not be good if the

distance is too big. While if too small, carriage could have crash with the media. According to our long time

experience, 1.7mm is a proper distance for printing.

Here’s the procedure of setting platen’s height for printing with options on PCS:

1. Switch to Fixture Mode, in which the auto measurement of Z-axis height is enabled.

2. Move the carriage to the printing platen.

3. Keep clicking the Up arrow button on PCS or pressing the Up arrow button next to the LCD control panel until

the platen stops moving. A warning message will pop up on PCS:

4. Go to the Z-axis setting pane in Options tab and set parameters

a. Click the button Get to the right of Z-axis Height to get current position of platen; and set the current

platen’s height as Z-axis Height. The following warning message will pop up, please click button Yes.



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b. In the numeric box of Z-axis height, it will display the value of the platen’s position.

c. Input the Media thickness and Head-Media distance values into the numeric boxes next to them.

It is recommended to set the Head-Media distance as 1.7mm.

d. Input the distance between nozzle plate and platen into the Head-Platform Offset numeric box. You can

get this value when installing head plate on the carriage.

6-8 INSTALL PRINT HEADS

Please see Chapter 7 Print Head Installation for detailed procedures.



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6-9 INSTALL LED UV LAMPS

Each LED UV lamp is fixed on carriage with two holding plates; please see the images below as reference. UV

Lamp Holder 1 is fixed on carriage; UV lamp is fixed on Holder 2. Hook holder 2 on holder 1 and fix them on the

carriage with screws.

Please follow steps below to install the LED UV lamp on the carriage.

1. Remove the top 2pcs M5 cross-recessed pan head screws that are used to fix the UV Lamp Holder 1 on

carriage.

Note: Before shipment, UV Lamp Holder 1 is fixed on the carriage with 4pcs M5 screws. Please remove the two

at the top. Do NOT remove the two screws at the bottom.

2. Put the metal plate on the backside of the LED UV lamp; match the four long screw holes of Holder 2 to the

screw holes on the LED UV lamp. Fix Holder 2 on the LED UV lamp with 4pcs M3 cross-recessed pan head

screws.

UV Lamp Holder 1

UV Lamp Holder 1

UV Lamp Holder 2



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Note: Pay attention to the direction of Holder 2; please take the image below as reference.The bended side of

Holder 2 should be closer to the emitting window.

3. Hook and hang UV lamp holder 2 on holder 1.

4. Fix UV lamp holder 2 and UV lamp holder 1 on carriage with the 2pcs M5 cross-recessed pan head screws

removed in step 1.

5. Plug the connector of UV Lamp Control cable to the socket on the top of corresponding UV lamp.

Note: The two cables are labeled as UV Lamp 1 and UV Lamp 2. Plug the connector of cable UV Lamp 1 to the

UV lamp on the right side of the carriage (facing the printer). Plug the connector of cable UV Lamp 2 to the UV

lamp on the left side of the carriage.

Emitting Window

Bended Side

UV Lamp Holder 2



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6-10 SETTINGS PRINTING ORIGIN

Printing Origin is the position where the print job starts; two methods are provided for setting the origin according

different types of origin.

6-10-1 SETTING A CASUAL POSITION

Origin: a casually specified target position

Method: Move the platen and carriage at the same time until getting to the target printing origin with

arrow buttons; then press button Enter. The carriage will go back to the right home station.

6-10-2 SETTING PRINTING ORIGIN ON PCS

Origin: a precisely specified target position

Method: Go to PCS>Printer>Media Setting pane; input the distance values.



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6-11 PRINT HEAD CALIBRATION

Calibrate the print heads both mechanically and from the software so that they are well aligned. Please see the

section 7-9 Print Head Calibration for detailed information.

6-12 POWER OFF

1. Switch manual three-way valve handles’ position so that the either the ink channel or flushing fluid channel are

shut off.

2. Keep pressing the Abort button on the LCD panel, a warning message will pop to for you to confirm if you’d like

to turn off the printer. Select Yes. The carriage will go back to the home station and the PWC will cap the

heads.

3. Press the Power OFF button (the red button above the LCD control panel). Please see the image in section 5-2

Using LCD Control Panel.

4. Quit the Printer Control Software or your RIP software.

Note:

It is not necessarily to turn off the printer if it will be idle for only a few hours and safety can be guaranteed.

When the printer is idle, make sure the printheads spit ink



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CHAPTER 7 PRINT HEAD INSTALLATION This chapter introduces procedures to install Ricoh Gen4 print heads onto the head plate and fix the plate on the carriage.

7-1 WARNING:

A specialized personnel is required to assemble the head plate.

Head plate should be assembled in a dust free environment; any dust getting into the ink channel may cause nozzle jam.

Operate with plastic gloves on.

Carefully handle all the parts; any scratch or hit is forbidden.

All the screws on the head plate should be tightened. Otherwise, they may get loose and drop during printing; that may scratch and damage print heads.

After assembly, the head plate with print heads should be well kept; any scratch or hit is forbidden.

7-2 TOOLS NEED:

A. Syringe B. Hex Key Driver C. Ink Tube (Φ4) D. Side-cutting Pliers E. Gloves

7-3 PREPARATION

1. Prepare a clean space in a dust free environment; spread a piece of material (1m×1m) that will prevent the parts from getting hit or scratched (sponge or air bubble film).

Note: Make sure the material (sponge or air bubble film) is dust-free.

2. Check if all the parts for head installtion are available. Please see section 7-4 Illustration of Head Plate Assembly for the parts list.

3. Cleaning

Before installation, you need to clean all the parts with a piece of Cleanroom wiper dipped with flushing fluid. Please pay more attention to the slots on head plate; there shouldn’t be any ashes or other impurities, otherwise heads’ physical position will not be precise.

Clean ink tubes and ink filters with flushing fluid by purging flushing fluid into them with a syringe.



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7-4 ILLUSTRATION OF HEAD PLATE ASSEMBLY

1 Head Plate The head plate can hold 6 Ricoh Gen 4 print heads. It is precisely designed so that the print heads on it are horizontally and vertically parallel to the largest extent.

2 Front Adjusting Bar Hold the five Y Adjustment Pins (item 4)

3 Y Adjustment Pin (M4) Adjust the corresponding print head’s position in Y direction.

4 Front Adjusting Bar Fixing Screw (M4)

Fix the front adjusting bar (item 2)

5 Fixing Hexagon Socket Head Cap Screw (M3X10)

Two screws used to fix the reference print head (item 11)

6 Adjustable Print Head (total: 5) Gen 4 head that are adjustable



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7 Fixing Hexagon Socket Head Cap Screw (M3X10)

Each adjustable print head is fixed on the Head plate by a pair of these two screws. Only the left side head (reference head) has two fixing screws (and no pre-fixing screw). The pre-fixing screw includes a spring, which enables the screw to press down the print head and at the same time make sure the head is movable

9 Pre-fixing Hexagon Socket Head Cap Screw (M3X16)

8 Rear Adjusting Bar Hold the 5 adjustment spring (item 10)

10 Adjustment Spring It provides spring force so that print heads are physically adjustable in Y direction.

11 Reference Print Head (total 1) Gen 4 head taken as the reference for other print heads during installation or position adjustment



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7-5 ASSEMBLE PRINT HEADS WITH INK TUBES

Note: The following procedures take water-based print heads as example; the installation procedures of installing print heads on UV system are exactly the same, except that the ink tubes and connectors should be for UV ink.

1 Cut the long ink tube (Φ4) into 24 sections of short tubes whose length is about 3.8cm and 12 sections of long tubes whose length is about 10cm.

2 Plug one short tube onto each ink inlet of print head. Make sure the tube gets to the bottome of the inlet.

3 Then connect every two short tubes at the same side with a Y-shape connector. Make sure the tubes

get to the bottom of the connector’s two outlets. Please see the image below:

4 Install a long section of tube to the inlet of each Y-shape connector.

5 Now please differentiate the front and end sides of the print head. Check the two holes at the ends of nozzle line; one is a long one, the other a round one. The side with the long hole is the front side of the print head.

6 Install a luer connector and a luer lock on long tube at the end side of the print head.



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7-6 INSTALL ASSEMBLED PRINT HEADS ON HEAD PLATE


7 Remove two fixing and pre-fixing hexagon socket head cap screws (item 7, 9) from the head plate (item1).

8 Put the reference print head (item11) into the right slot on head plate (item1).

Note: Pay attention to the direction of the print head. There are two positioning pins at the bottom of the print head, please match the two pins with holes on the two ends of the slot. See the image below:

Warning: Handle the print head carefully. Avoid anything sharp to touch, scratch, or hit the nozzle plate.

9 Fix the reference print head (item11) on the head plate (item1) by installing the two hexagon socket head cap screw (item 5).

10 Loosen the 5 Y Adjustment Pins (item3) until they don’t stick out the back side of front adjusting bar.

11 Put the 5 adjustable print heads (item6) into the five slots on head plate.

- Pay attention to the direction of the print head. There are two positioning pins at the bottom of the print head, please match the two pins with holes on the two ends of the slot.

- Push the print head against the spring.

12 Fix each adjustable print head on head plate with a pre-fixing screw (item9) and a fixing screw (item7).

- Tighten the pre-fixing screw (item9) a little bit; make sure the print head is pressed down by the screw while the print head is still movable. At the same time, make sure the screw does not stick out the bottom of head plate.

- You do not need to tighten the fixing screw (item7), because you’ll adjust the print head position before printing.



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Warning: The Fixing Hexagon Socket Head Cap Screw (item9) should be exactly M3X10 and the Pre-fixing Hexagon Socket Head Cap Screw be M3X16.



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7-7 INSTALLING THE HEAD PLATE ONTO CARRIAGE


Now you can fix the head plate on the carriage; at the same time connect the print heads to the control system.

1 Move the carriage from its home station to the platen and put a piece of Cleanroom wiper or a piece of protective film beneath the carriage.

2 Raise the platen until the platen touches the carriage.

3 Remove carriage’s four covers by unscrewing them: top cover, up-front cover, manual 3-way valve cover and front cover. The manual 3-way valve cover is connected to the up-front cover.

The top cover is fixed with four screws, the up-front cover together with the manual 3-way valve cover are fixed with eight screws, and the front cover is fixed with four screws.

Warning: During printing, the cover of the carriages should be closed and screws on them should be

tightened, especially the two hand screws of the front cover. Otherwise, the covers may strike the printer;

screws may drop in the carriage’s moving path and scratch print heads.

4 Put several pieces of Cleanroom Wiper beneath the carriage.

5 Place the assembled head plate on platen to the front of carriage. Make sure there’s Cleanroom Wiper beneath it.

Pay attention to the direction of the head plate; the reference head should be on the right-hand side of operator.

Top Cover

Up-front Cover

Manual 3-way

Valve Cover

Front Cover



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Carefully handle the head plate and avoid any harsh mechanical contact with the print heads.

6 Thread the data cables of the four print head go beneath the sub-ink-tanks; and take them out from the back of sub-ink-tanks.

Warning: Handle the data cables with care; do NOT fold, cut to tear the cables, which are fragile.

7 Push the head plate into the carriage. At the same time, pull the data cables a little bit, in case the cables are stuck in the carriage and get folded or even torn apart.

8 Adjust the position of head plate so as to match the screw holes for fixing the head plate on carriage (3 on each side of the carriage and head plate).

9 Install hexagon socket head cap screws (M4×12) into the matched holes. Do not tighten them but screw them half way.

10 Press the four angles of the head plate with your hands to make it touch the platen completely.

11 Tighten screws on each side of the carriage by turns: tighten the middle two screws a little, then two screws on the cross that is the left front screw and right back screw, and then the last two screws on the cross. Repeat this step until all the screws are fully tightened.

Note: Make sure the tightness of the two back screws is a little slighter than other four screws; but at the same time, all of them should be tightened.

12 Organize the data cables and plug the plugging cards into corresponding sockets on the headboard. Please go to section 2-3-2 Head Board for detailed connecting information.

Warning:

- Please differentiate the data cables of each print head.



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- Please pay attention to the direction of the plugging card.

- Plug each card into corresponding ejector header firmly, then lock it with the header’s two ears.

- Printhead will be burned if the cards are not well plugged.



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7-8 CONNECT PRINT HEADS TO THE INK SYSTEM


1. Connect a disc filter to the outlet of manual 3-way valve.

- Please differentiate disc filter’s ink inlet and outlet. Connect the ink inlet to the luer lock at the ink outlet of manual 3-way valve. The ink inlet side is marked as “IN”; please see the image below:

- The luer lock assembly at the ink outlet of manual 3-way valve constitutes of two luer locks. Please insert the inlet of disc filter to the luer lock at the bottom; then rotate the luer lock anti-clockwise and tighten it.

2. Screw a luer adapter (Φ4) on the ink outlet of disc filter.

3. Check the distance between disc filter’s ink outlet and print head’s front ink inlets.

Disc Filter

Luer Lock

Luer Lock Fittings

Disc Filter

Manual 3-way Valve

Print Head

Male Luer Connector



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4. Cut the ink tube on print head’s ink inlets accordingly.

Note: The ink tube on print head’s front ink inlets shouldn’t be either too long or too short, since the space

between disc filter and print head is limited.

5. Connect the ink tube to the luer adapter at disc filter’s outlet.

6. Follow the above procedures to connect the rest print heads.

7. Fill print head with ink:

1) Turn on the printer by pressing the button Power On at the front.

For brand new print heads, they are filled with Dowanal, which needs to be purged out with flushing fluid

before filling ink.

2) Please adjust the handle position of manual three-way valve of one ink channel so that the print

head is connected with flushing fluid. (Please check the section 3-2 for detailed information of using

manual 3-way valves)

Warning: The four ink channels should be supplied one by one.

3) Purge flushing fluid together with air out from the ink outlets at the back of print head.

Remove the cap that is plugged on the ink tube at the ink outlet of the print head. Press Purge

Flush button to the right of carriage’s home station, flushing fluid will be purged out from the ink

tube instead of the nozzles. Stop purging until there’s no air bubbles coming out from the ink tube.



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4) Screw the cap back and keep purge flushing fluid, which will come out from the nozzles.

5) Repeat step 8 and 9 to clean the print head thorougly with flushing fluid.

Not we can fill the print head with ink.

6) Switch the handle of manual 3-way valve so that ink is connected to the print head.

7) Purge ink together with air out from the ink outlets at the back of print head.

Remove the cap that is plugged on the ink tube at the ink outlet of the print head. Press Purge Ink

button to the right of carriage’s home station, ink will be purged out from the ink tube instead of

the nozzles. Stop purging until there’s no air bubbles coming out from the ink tube.

Note: Purge ink for 2-3 seconds; air in the head will be purged out completely. Do NOT purge ink

more than 5 seconds, otherwise the sub-ink-tank will be empty and air will get into the head

again.

8) Screw the cap back and keep purging ink, which will come out from the nozzles.

9) Adjust the handle position of manual three-way valve of the ink channel that has finished

supplying ink and open another ink channel.

10) Repeat steps 7 and 14 to supply ink for all the channels.



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7-9 PRINT HEAD CALIBRATION

Every time the printer is moved, printhead is replaced, parts are replaced or adjusted, or any other mechanical

operations are done, or printing parameters are changed, the printer should be aligned to achieve good and

accurate print. PCS provides options to help you do the alignment, including step calibration, step pass calibration,

vertical alignment, and horizontal alignment. Before that, the mechanical alignment of the five heads should be

done.

7-9-1 CALIBRATION WORKFLOW

Mechanical Alignment

PCS>Adjust>Step Calibration

PCS>Adjust>Vertical Calibration

PCS>Adjust>Step Pass Calibration

PCS>Adjust>Horizontal Calibration

End



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7-9-2 MECHANICAL ALIGNMENT OF THE PRINT HEAD

After the all the Gen 4 heads are installed onto the printer and ink are supplied. You need to align the mechanical position of the five print heads according to the CheckNozzle pattern, so that they cooperate well.

1. Print the CheckNozzle test pattern (see image below).

When the five printheads are well aligned, the lines printed by the first nozzles of heads C, M, Y and W should overlap with the long black line on the top printed by the first nozzle of head K.

2. Check if the long black line overlaps with the first line of WHITE. If not, rotate the Y adjustment screw of head K a little bit with a hex driver. Clockwise rotation will push the head forward; anti-clockwise rotation will pull the head backward.

Note: A magnifier (10X or higher) is required to check the alignment.

3. Repeat step 1 and 2 until the line printed by the first nozzle of the white head overlaps with the long black line printed by the first nozzle of head K.

4. Now you can take the head K as the reference to adjust other heads. Check if the lines printed by the first nozzles of head C, M and Y overlap with the long black line. If not, rotate the Y adjustment screw of corresponding head with the method described in step 2.



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7-9-3 STEP CALIBRATION

This command will do a step calibration for 4 passes. This calibration is the basis for other steps alignment and

other printing passes.

1. Select Step Calibration from the Adjust Menu; the Step Calibration dialogue pops up, which shows the step

value.

This dialogue is for you to check the step value; click button Calibrate to do the calibration if you are not

satisfied with the value, and click OK if the value is acceptable. In the following image, the steps value of 4

passes is 832.



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2. Clicking button Calibrate will pop up the Media Calibration dialogue. With the options in the dialogue, users

can print a test pattern and enter the calibration value according to the pattern.

Click button Print to print the test pattern, which has 41 groups of lines labeled with numbers from 20 to -20.

Each group has two rows of lines. Check the pattern thoroughly; find out the group in which the two rows of

lines are best aligned. For example in the following image group “0” is best aligned.

Enter the number below the group into the numeric box of Calibration Value in the dialogue. Take the

following image as an example. The number you should enter into the Calibration Value box is 0, because

the group labeled “0” is best aligned.

Click button Next to continue.

… 2 1 0 -1 -2 … -20 20



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3. The dialogue updated will show the present Media Step value after calibration and provides options for

further calibration.

4. Click button Print, the test chart will be sent to the printer to print as a job automatically. The following

image will be printed:

5. Check the test chart and select the best aligned group.

Note:

In this test chart the best aligned group for each color may differ; you need to select the group that most

colors are best aligned. For example, in the chart above, the best aligned group for all the colors in general

is group “1”.

6. Add the value of best-aligned group number to the current value in the dialog box, e.g., if the value is 845

and the best-aligned group number in the test chart printed is 1, you should update the value from 845 to

846.

0

1

2

‐1

‐2



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7. Click button Apply.

Note: Long-range Calibration function is not applicable to TL series printer.

8. Click button Finish to end the calibration and close the dialogue; click button Back to go back the last step;

and click button Cancel to close the dialogue without saving any setting.

7-9-4 VERTICAL ALIGNMENT

Vertical alignment can help to make sure the all the printheads are well aligned in the vertical direction, which

means the first nozzles of all printheads are in one line.

Follow these steps to do the vertical alignment:

1. Choose the Vertical Alignment command from the Adjust menu, the Vertical Alignment dialogue pops up.

Note:

The values of the colors displayed are the current calibration value.



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2. Click the button CheckPrint to see the current printheads’ status. Following test pattern will be printed:

Note:

When all the printheads are well aligned, the lines of C, M and Y will be printed in the same line of K as

the above image shows; otherwise lines of C, M and Y will stagger with lines of K.

You should print the check print after alignment to make sure the result is good; otherwise you have to

do the calibration (physical or by software) again.

3. Click the Calibration button to calibration the printheads if the test pattern in step 2 does not look good.

4. Click the Print button, the following test chart will be printed. Enter the CMYK value of the best-aligned

groups in the Group1 and Group 2 fields.

Note:

For each printhead of C, M, Y amd W, 41 groups of lines labeled with numbers from -20 to 20 will be

printed.

To the left of the lines printed by each printhead there are labels telling you the printhead that prints

G1C4D1

G1C3D1

G1C2D1

… 2 1 0 -1 -2 …20 -20

G1C5D1



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the lines. Enter the value of the best aligned group into the numeric up down box according to the

labels.

If the settings are not correct, add the value of best-aligned group number to the current value in the

dialog box, e.g., if the setting at step 3 for Group1 M is 4 (A), and the best-aligned group number in the

test chart printed in step 4 is 1 (B), then you should update the Group 1 M value from 4 (A) to 5 (A+B).

5. Press button Apply to save the calibration and press button Finish to close this dialogue;

6. The PCS will show the dialogue in step 1. Press button CheckPrint to check the calibration.



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7-9-5 STEP PASS CALIBRATION

Because each media has different thickness, one media feed command will result in different actual media

feed lengths. If printed image has horizontal banding or when using new type of media, it is recommended to

do a media calibration.

When doing a media calibration, a test chart will be printed, you should check the test chart and input the value

of the best-aligned group number, and then the Printer Control Software can compute how much

compensation should be made when feeding this type of media.

Follow the steps below to do the calibration:

1. Select Step Pass Calibration from the Adjust Menu; the Step Calibration dialogue pops up, which shows

the step value.

This dialogue is for you to check the step value; click button Calibrate to do the calibration if you are not

satisfied with the value, and click OK if the value is acceptable.

2. Clicking button Calibrate pops up the Media Calibration dialogue. With the options in the dialogue, users can

print a test pattern and enter the calibration value read from the pattern.



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Click button Print to print the test pattern; each color has 41 groups of lines labeled with numbers from 20 to

-20. Each group has two rows of lines. Check the pattern through, find out the group in which most colors

are best aligned. For example in the following image group “0” is best aligned.

… 2 1 0 -1 … -20 20 -2



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Enter the value below the group into the numeric box of Calibration Value in the dialogue. Take the image

above as an example. The number you should enter into the Calibration Value box is 0, because the group

labeled “0” is best aligned.

Click button Next to continue.

3. The dialogue updated will show the present Media Step value after calibration and provides options for

further calibration.

4. Click button Print, the test chart will be sent to the printer to print as a job automatically. The following image

will be printed:

5. Check the test chart and select the best aligned group; for example, in the chart above, the best aligned

group for all the colors in general is group “1”.

6. Add the value of best-aligned group number to the current value in the dialog box, e.g., if the value is 845

and the best-aligned group number in the test chart printed is 1, you should update the value from 845 to

0

1

2

‐1

‐2



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846.

7. Click button Apply at the bottom left of the dialogue to apply the modification.

Note: Long-range Calibration function is not applicable to TL series printer.

8. Click button Finish to end the calibration and close the dialogue; click button Back to go back the last step;

and click button Cancel to close the dialogue without saving any setting.

7-9-6 HORIZONTAL ALIGNMENT

Horizontal alignment can help to make sure the print heads print at precise horizontal position. This is mostly

related to the print head Scan direction from left to right. If printed image looks blurred in uni-directional printing,

you should consider doing a horizontal alignment to the print heads.

Bi-direction alignment is also included in horizontal alignment. If printed image is good in uni-directional

printing, but looks blurred in bi-directional printing, you should do a bi-direction alignment.

This option also allows users to calibrate the mechanical error of the platen; the platen may not be completely

even. Follow these steps to do the horizontal alignment:

1. Choose the Horizontal Alignment command from the Adjust menu, the Horizontal Alignment dialog

；appears



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2. Select the resolution and speed you want to calibrate from the combo box on the top of the dialogue (each

combination of resolution and speed has to be aligned separately).

3. Click the “Check Print” button to see the current result of calibration.

4. Click the “Calibration” button to calibrate if the test pattern printed is not good; the Origin to End Alignment

dialogue appears.

5. Click the Print button, the test chart for Origin to End Alignment will be printed, the following image is part of

it:

The first printheads of each color print groups of lines and long lines of dots. Shorter groups of black lines

and short lines of black dots by printhead K1 are printed at the same position. They are used for contrast.

The groups of lines and lines of dots printed by the second and third printheads of each color are

compared to the groups printed by the first heads.

For general adjustment of printheads, check the groups of lines printed and compare them with the short

groups of lines, either black or other colors. Select the group that short group overlaps with long group.

While for more accurate adjustment, especially when jobs have thin lines that have higher requirement of

accuracy, the lines of dots should be checked.

…

…

…

…

…

…

… …

20 … 2 1 0 -1 -2 … -20

L1G2C4D1

L1G1C4D1

L1G2C1D1

L1G1C1D1



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6. Check the test chart and find out the best aligned group for each printhead; enter the value into the numeric

up and down boxes in the Original to End Alignment dialogue.

Note: The value to enter to the dialog field should always be added to the value that is already in the field.

For instance if the Value that is already in the M = 2, if the reading from the printed pattern gives –1 as the

best value then M = 2 –1 which gives M = 1.

7. Click the button Next in the bottom of the dialogue; the Bi-direction dialogue shows up:

8. Click the Print button, the test chart for Bi-direction Alignment will be printed, the following image is part of

it:

Note:

G1C1D0

20 … 2 1 0 -1 -2 … -20



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The long lines are printed by K1 when the carriage moves from origin to end and the short lines are

printed when the carriage moves back from end to origin.

9. Check the test chart printed and input the value of the best aligned group into the numeric up and down box

into the Bi-direction Alignment dialogue.

Note:

You should print at the left, right and middle of the printable area respectively to check the result of the

bi-direction alignment. If the pattern looks different, you should adjust the mechanical parts of the carriage

rail to reduce the Parallel errors (see Parallel Check command in Adjust menu).

10. Click the button Next in the bottom of the dialogue; the End to Original Alignment dialogue shows up:

11. Click the button Print, the test pattern of End to Original Alignment which is the same with that of Original to

End Alignment will be printed (see the image in step 5).

12. Check the test chart and find out the best aligned group for each printhead; enter the values into the

numeric up and down boxes in the End to Original Alignment dialogue accordingly.

13. Click the button Next, the Platen Level Calibration dialogue shows up:

The Platen Level Calibration dialogue is for you to check the status of the platen and do adjustment to

compensate any mechanical error.



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14. Check the Platen Level Calibration option to enable the adjustment.

Sample point: Select the number of test chart you want to print. For example, 3 points means three test

charts will be evenly printed on three points of the platen.

Begin/End: Define the range of the platen you want to check.

1，2，3 …: The numeric up and down boxes on the left shows the position of the sample points; the

numeric up and down boxes in the middle are the ones you need to enter the calibration value.

15. Click the Print button to print the following test charts on each point:

16. Check the test charts and find the best aligned groups; enter the values into the numeric up and down

boxes of the middle column in the dialogue.

17. Click Finish to end the calibration and close the Platen Level Calibration dialogue.

Note:

Clicking the Reset button will set all settings on this tab to default value.

Clicking the Apply button to save and apply the settings.

Clicking the Cancel button to quit the alignment and close the dialogue without saving any

change.

G1C1D1

20 … 2 1 0 -1 -2 … -20



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CHAPTER 8 PWC MODULE PWC is short for purging, wiping, and capping. The PWC module is installed at the home station of carriage and used for automatic head maintenance before, during and after printing.

8-1 USING PWC FUNCTION

The PWC module works in following conditions:

1. Printer Initialization: PWC will uncap the print heads, purge ink and wipe nozzle plates. Only when the Power ON Clean option is checked in PWC clean dialogue, will print heads be purged after initialization; otherwise, purge and wipe will not be carried out.

2. Auto Clean: Click the Auto Clean button on PCS to purge all the print heads with ink and wipe nozzle plates automatically. The auto clean parameters can be set in PCS. Please see section 8-2 Setting PWC Parameters for detailed information setting PWC setups.

3. Movement of PWC Module before Carriage Movement (including printing) and Purge when Print Heads are Capped: Capping plate and wiping plate move to origin positions.

4. Before Printer Power off: Wiping plate and wiping plate move to their end positions.

5. Manual Wipe: This option is only enabled when the printer is ready and in idle mode. Click Wipe button in Manual Clean dropdown list on PCS. Wiping plate moves from the origin position to end position to wipe the nozzle plates.

6. Manual Cap: This option is only enabled when the printer is ready and in idle mode. Click Cap On or Cap off button in Manual Clean dropdown list. Capping plate moves accordingly.

Please see section 8-3 PWC workflow for detaild procedure.

8-2 SETTING PWC PARAMETERS

Printer Control Software (PCS) enable users to set auto clean parameters of PWC: options in the PWC Clean Dialogue (Service Tab) and Cleaning Setting in Printer Tab.

PWC Clean Dialogue



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The PWC Clean dialogue is in the Service tab, which can be opened after selecting the User Management option in Tools menu of PCS and login. Then click the PWC Clean button.

- Purge Duration: Set the purge ink time for each auto clean.

- Wipe Times: Set the number of wiping times after purging ink. Currently only once is supported.

- Wait Capup Time: Define the idle time of printer before automatic capping. That means print heads will be capped automatically after the printer is idle for a period of time.

- Power On Clean: When this option is being checked, print head will be purged with ink when printer is initializing.

Cleaning Setting

Here only the option Interval is effective, which is to the interval for auto clean. For example, when we set 20passes as the interval, print heads will be purged and wiped everytime after printing 20 passes.



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8-3 PWC WORKFLOW

Here are the workflows of PWC module, including Printer Initialization, Auto Clean after Printer is ready, before Carriage Movement (including printing) and Purge, and Printer Power off.

8-3-1 PRINTER INITIALIZATION

When the printer is turned on, it needs several seconds to initialize, during which the PWC module will operate automatically to purge ink and wipe the heads.

When Power On Clean is checked:



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When Power On Clean is not checked



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8-3-2 AUTO CLEAN AFTER PRINTER IS READY

After the printer is turned on and get ready, please press the button Purge either on LCD or on PCS to purge ink or flushing fluid out from nozzles when necessary. The PWC will wipe the heads automatically.

Click the Auto Clean button on PCS:

Start

End

Switch 3-way E-valve so that sub-tanks are connected to ink pumps

Purge ink; purge time can be set on PCS

Wiping plate moves to end to wipe the heads.

Carriage moves to the origin

Carriage moves out

Wiping plate moves to the origin



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8-3-3 BEFORE CARRIAGE MOVEMENT AND PURGE

When print heads are capped, before carriage movement (including printing) and purge, the wiping plate and capping plate will move to get the carriage ready.

Start

Capping plate moves down to the lowest position

Carriage moves out

Wiping plate moves to the origin

Carriage moves to origin

Carriage move\Purge ink\Printing



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8-3-4 BEFORE PRINTER POWER OFF

In order to cap the heads with PWC module before turning off the printer, please keep pressing the Abort

button on the LCD panel, a warning message will pop to for you to confirm if you’d like to turn off the printer.

Select Yes. The carriage will go back to the home station and the PWC will cap the heads.

Warning:

Before turning off the printer, please switch manual three-way valves’ position so that either the

ink channels or flushing fluid channel is shut off.

Start

Carriage moves to origin

Wiping plate moves to the end

Capping plate moves down to the highest position

End



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CHAPTER 9 CARRIAGE TRANSMISSION BELT

ADJUSTMENT

9-1 CHECKING THE TENSION OF CARRIAGE TRANSMISSION BELT

The tightness of carriage transmission belt must be proper; being too tight, the belt is easy to break

and other parts that relating to it will be bended; being too loose, it is likely to slip when moving the

carriage and the carriage will move inaccurately. Thus, it needs to be checked periodically, whenever

the belt is loose, every time the belt is adjusted, changed or when there is banding on printouts. Then

adjust the belt accordingly.

Tool needed: Analog Force Pull/Push Gauge

1. Assemble the Belt Pull Clamp at the Analog Pull Force Gauge; please install the belt pull clamp.

2. Check the initial tension of the Carriage Belt at the center of the Beam. Hook the belt at the middle

of the printer with the belt pull clamp on the gauge; set the gauge pointer to zero. Use the steel rule

to measure the distance of belt and belt groove when it is being pulled. Check the distance and

tension at the same time; when the distance between 60-65mm, the tension should be within

1.30-1.50kg. Get the peak value as the belt tension reading. Please take the image below as

reference:

Belt Pull Clamp



Page 96 of 100

If the tension is beyond 1.30-1.50kg when the distance is between 60-65mm, then belt tension needs to

be adjusted according to the following section.

9-2 ADJUSTING CARRIAGE TRANSMISSION BELT

Tools needed: hex key wrenches of 5mm

After opening the cabinet to the right of carriage’s origin position, you’ll find the belt pulley, its holder with two

adjusting screws. Please see the image below:

Adjusting Method: Tightening the two adjustment screws to move the belt pulley rightward so as to tighten

the belt; loosening the two adjustment screws to loosen the belt.

If the value is larger than 1.50kg, loosen the two belt tension adjustment screws accordingly. If the

value is smaller than 1.30kg, tighten the two screws accordingly.

Note: Tighten or loosen the screws little by lttile and check belt tension at the same time.

Belt Adjustment ScrewsBelt Pulley



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APPENDIX A PRINT WORKFLOW AT RUN MODE

PCS sends job to printer

Press foot pedal to start print

Tooling template moves up

Conveyor moves to printing origin

Is the template at the top position?

Print

Conveyor rolls for one cycle to clear printouts from printing

platen.

Yes

Is it the last template?

Yes

Is the template at the top position?

Move tooling template down

End

No

Move tooling template down

No

The template keeps in top postion

Yes

Is conveyor in printing origin?

Yes

No

No



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APPENDIX B LCD MENU Menu Check Nozzle Manual Clean K C M Y W1 W2 Flush Wipe Cap Uncap Move Z up or down This menu, keys function (key

pressed start move, key up stop move): Up key = Move Z Up Down key = Move Z Down Enter key = Exit this menu Menu key = Return Status UI

Move Conveyor Menu This menu, keys function (key pressed start move, key up stop move): Up key = Move it forward Down key = Move it backwardEnter key = Exit this menu Menu key = Return Status UI

Set Load Device Postion Jog Capture Ink Supply Setup Supply Mode Manual Auto Pump Time Limit (if mode is auto) Off（no limit) 10 Sec 20 Sec 30 Sec Manual Supply Ink (if mode is

manual)

K C M Y W Flush Ink Pressure Setup NP1 Value NP2 Value NP1 Pressure Reset NP2 Pressure Reset System Factory Default



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Language English 中文简体中文繁体 Uint Feet Millimeters Centimeters Meters Color Seting Background Color Front Color Beep Button Pressed Start Print End Print

Spit Sound Start Move Alarm Type Sound Light Sensor Switch Main Tank Waste Tank Z Height Protect

Sensor

White ink circulation pump

Diagnose Negative System Start Motion General

Check Aging About Printer

Ink Supply Warning



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atd-tc-l-03 service manual of tc prototype 6h 9 carriage transmission belt adjustment ... step motor...

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