Durst Rho 600 Pictor SM 5-Adjustments V1.0

oSMM=m= =
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RK=^=
RKN b~=~ KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK O

RKO f=q~=`KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK P
RKP s~KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK Q
RKQ _=^=p KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK R
RKR m=KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK R
RKS b KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK T
RKT j~=aL=p=p KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK U
RKU e~=j~=a~ KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKNM
RKV wJj KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKNN
RKNM `~=pKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKNQ
RKNN jJaKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKNU
RKNO m=p~=` KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKOM
RKNP c=f=q KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKOP
RKNQ rs=p KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKOS
RKNR s~=c~ KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKOT
RKNS r=m=r KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKOT
=
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oSMM=m=pj~~=L=afqJpaK= `~=R=^===============================
= NLPM=
s=NKM==J==ONLMSLOMMT=
RKN b~=~=
qW=
=
1. Safety test unit GLP2 1431
2. Adapter f. 3x400VAC, EU ELE_AD_02
3. Adapter f. 230 - VAC external supply ELE_AD_04
p~=W=
=
1. Safety check can only be done from trained staff.
2. In the area from 2 m around the machine is not allowed to stay during
the test is running.
3. Use a yellow tape to block off this area.
mW=
=
Attention: disconnect the main power supply from SpiiPlus (J18)
otherwise this unit get damaged!!
Other equipment what needs to be disconnected:

All electrical connections from Microlynx
All electrical connections from linear controller SpiiPlus
Remove all PCBs from rack
1. Shutdown machine. Shutdown workstation. Disconnect power supply from

monitor and workstation.
2. Bypass all 3 phases from main power filter L1.
3. Connect on the low power trigger from main switch the adapter for
230VAC external supply (ELE_AD_04) and plug it to a power socket.
4. Rho-main switch connected with adapter (ELE_AD_02) to safety test
unit.
5. Switch on the main switch from Rho600 Pictor switch must stay ON!
6. Load program "Rho160" and follow the program steps.
Used measurement points:

Aluminium plate left
Steel frame, zinc coated pins for metal covers
Metal plate connection unit
Metal plate power unit
Metal plate UV unit
Print sledge carriage support (middle position)
7. Disconnect power supply at low power trigger and adapter. Fasten

screws at clamp.
8. Remove bypasses at main power filter L1.
9. Connect workstation and monitor.
10. Store the printed protocol at the machine papers.
= OLPM=
Program data RHO160:
1. Isolation check between phase L1, L2,L3 and PE

a. Rmin = 2 MOhm
2. leakage current cold
b. I max = 20 mA
3. High voltage check
c. Rise time = 5 sec
d. Test cycle = 2 sec
e. Test voltage 2100V
f. Voltage = DC +
g. max. current = 3 mA
1. Safety test check:
a. Test current = 25 A, Rmax = 0,1 Ohm
RKO f=q~=`=
Wiring of Transformer and Main switch like shown in the following pictures.
Main Input Inside Transformer
Connect both earth All earth cables are

cables on this connected on this point
connector!!
Switch adjustment
to transformer
1. Use at the transformer the connections what are the nearest to

the main power supply voltage.(e.g. 210V for USA)
Connect to the
right main input
voltage!
= PLPM=
2. Check now the main voltage at the main connector from Pictor. Do
not switch on machine! The voltage must be in the range from
380 and 430V. If this is not given, connect the cables at the
transformer to an other position! (other input voltage). Is the
voltage too low it needs to connect to the next lower clamp from
the input voltage or converse.
3. Main switch adjust current on the used input voltage:
Main voltage (V) Current (A)

190 32
200 30
210 29
220 27
230 26
240 25
RKP s~=
Disconnect the power supply before switching on the machine first time.
Backplane X1100 +12V, -12V, 5V

X1101 +24V
Head Power 1 X2150 +24V disconnect all connections
Head Power 2 X2150 +24V disconnect all connections
ACS Controller Spii+ J17 +24V
J18 ~230V
Security Control
Connector X88 +24V
Ink Pump Control X3040 +24V
UV Lamp Unit X100 +24V
Fan Unit Control X2180 +24V
HeadDriver X2117 +155V
HeadHeater Control X2100 +60V
X2000 +24V
Adjust the 5V power supply on the backplane. Turn the potentiometer on the
Sunpower main power supply the there are 5V (+0,2V)on the PCBs.
= QLPM=
RKQ _=^=p=
`=~=~=
Dip Switch 4321

Block Valve Control 0000
Meniscus Valve Control 0100
Head Heater Control 1 0000
Head Heater Control 2 (F5) 0001
Ink Pump Control 1000
Fan Unit Control 0111
UV Lamp Control L1 0000
UV Lamp Control L2 0001
RKR m==
The tolerances from the voltages are always written into the right box.
OQs=s~==uONRO= +- 1 V DC
1. Disconnect X2034-CK/MY Head Interface, X2034-YM/KC Head Interface,

X2160 Block Valve Control, X2180 Meniscus Valve Control.
2. Connect X2152 on Head Power PCB-2.
3. Check on all above mentioned connectors the poling and measure the
voltage (24V DC).
4. Connect all connectors to the PCBs again.
5. The power LED on the PCB must light up green now.
NOs=~==m=e~= +- 0,5V DC
1. Disconnect all Molex - connector J8 on the print head.

2. Connect connector X2156 on Head Power PCB-2.
3. Check on all 4pol. Molex connector J8 the poling and measure the
voltage (12V DC).
OQs=~===e~=e~= +- 1 V DC
1. Disconnect X2000/1 Head Heater1 (and X2000/2 Head Heater2 at F5).

2. Connect connector X2151 on Head Power PCB-2.
3. Check on all Panduid connector the poling and measure the voltage
(24V DC).
= RLPM=
j=L=m=s~==
1. Check the function from the valves Meniscus/Purge.

2. Press the button in Testcom under the text Meniscus valves (C1/3 ,
C2/4 , M1/2 , M2/4 , Y1/2 , Y2/4 , K1/2 , K2/4, depending on the
color options) after each other. If the button is active the green
LED on the Meniscus Control PCB must light up. The function of the
valves can be tested only with an air flow.
3. After that press the button in Testcom under the text Blocking valves
(CK1, CK2, depends on options) after each other. If the button is
active the green LED on the Blocking valve PCB lights up. The
funktion of the valves can be tested only with an ink flow.
m=~=~=
1. Switch on in Testcom the heating control

2. All connected print heads must heat up now.
3. Check temperature in Testcom with a click on the right button
(47C +/-1C)
ilfp=l=~=
1. Print heads must be empty otherwise do 2x Long Purge in Testcom.

2. Switch on heating for all print heads and wait that it reached 47C
+/- 1C on all print heads.
3. wait another 15 min to stabilize the temperature.
4. check and write down actual LOIS value.
5. Calculate offset and program it into the machine.
Info: The LOIS value is read out as usual. Also when e.g. the KC print head
is rotated with 180 is tank1 K and tank 2 C!
calculation:
LOIS Offset = actual value -318
e.g.:
actual value from CK1C at 47C = 287
LOIS Offset = 287-318 = -31
Now the value from CK1C is programmed with -31
Programming:
1. Set data at DurstPrinter.setup file

2. Send to Rho (Write - Read from Rho - no " * " should appear in the
display box)
= SLPM=
RKS b=
Check all encoders that they count in both ways. The Head Media Distance
Encoder must be moved manually. For this connect the Z-hub adapter. This
adapter is connected instead of the meniscus PCB.
Exchange (change poling) the cables on the motor controller clamp if the
sledge moves to the wrong side.
Attention: check at first that the sledge is not totally down (lower
mechanical limit Stop). If that happens, move at first up. If the sledge is
up (upper mechanical limit stop) converse situation.
Note: If the upper electrical limit Stop is active, there is no movement to
an upper position possible. Sledge can only move down until the limit
switch is not active any more. With the lower limit switch converse.
= TLPM=
RKT j~=aL=p=p=
Mechanical Adjustment!
Positioning device must be aligned with the 2 bore holes as shown in the
picture. The dimensions of the adjustment tool you find in the drawing
pic.11.
The mark of the positioning device is

eccentric. The positioning must be
done so that the mark for the light
beam is as close as possible to the
belt.
pic.10
pic.11
cut out for sensor

light beam
media direction
mark
Mark (beam)
device
pic.12
= ULPM=
First of all remove the old reflector!
When you mount the new holder (10% angle) for the reflector, you have to make sure that the
adjustment of the new holder is done like shown in the drawing (pic.13).
Sledge
direction
Printing direction
pic.13
Alignment of the chamfer
Next step is mounting the reflector onto the holder.
pic.14
chamfer for base from

reflector (LE2020227)
=
base for reflector film
= (LE2020228)
= Reflector film (ibwJcqacMOMcMOM)
b~=~=W= Printing direction
Adjust the voltage on the sensor interface PCB. Turn the potentiometer and
measure the voltage between P0 and P14. The voltage must be 10V +/-0,2V.
Adjustment
potentiometer
Measure point P14, P0
= VLPM=
RKU e~=j~=a~=
Printhead
Measuring Slots
hole Sledge
plate
15mm
Measuring
distance HMD
Transport
belt
Do the Measurement in the middle from the transport belt. Use a calliper
and measure through the measuring hole 2 (front hole) down to the transport
belt.
Adjustment point Measuring HMD Tolerance

distance
Reference switch 62mm 47mm +/- 1,2mm
lower electrical 16mm 1mm +/- 0,1mm
limit switch
Lower mechanical 15,8mm 0,8mm +/-
limit stop 0,05mm
Upper electrical 64mm 49mm +/- 0,5mm
limit switch
Description from Init cycle:
1. Sledge moves up with a high speed until it hits the upper reference
switch.
2. Sledge moves down with a low speed until it does not switch the
reference switch any more.
3. Sledge moves still down until it reach the Index position from the
HMD encoder.
4. After the encoder reached the Index position the Encoder PCB sets the
Encoder to 0 HMD is initialized.
= NMLPM=
RKV wJj=
Adjustment:
4. Adjust turning speed from Z-hub motor
Light barrier plate must be mounted (not accuracy adjusted yet)

and the mechanical limit stop is turned out.
Attention: check that the light barrier plate does not touch the
light barrier itself (it moves smoothly into the gap). Also the
upper electrical limit switch is not allowed to switch on until
the plate has not reached the light barrier!
Do a rough adjustment from the 2 potentiometer as seen in the
picture below.
potentiometer slow
potentiometer fast
Send following commands to the machine:
./serial c .10YHMSA0 for slow speed

./serial c .10YHMSA1 for fast speed
With this command the sledge moves up to the reference switch

and from there a definite time down. The software calculates
from the moved way and the time the speed. The result is
displayed on the monitor.
= NNLPM=
The following values must be reached (last 3 numbers):
130 +/-5 at fast speed

060 +/-5 at low speed
Is this not given the speed needs to be adjusted. Turn the poti
to the left side the speed gets lower for the next move. And
faster with a turn to the right hand side. This procedure must
be down until the right speed is set.
5. Adjust reference switch (light barrier)
1. Move with Z-hub adapter to the measuring distance (62mm)

for reference switch.
2. Move sensor plate from above down until the switch is not
switching on any more.
3. Initialize in Testcom with Go Init and read encoder
steps. The value must be in the range from 300 and 700.
Is this given go to the next point. Is the value not in
the range than move the sensor plate more up or down.
Recheck the value and repeat again or go on.
2.
1.
6. Parameter RhoHMDistance rough adjustment:
1. Initialize with Go Init

2. Measure distance to transport belt
3. Write the value into Durstprinter.setup. Set the
parameter RhoHMDistance = measured distance -15mm in
tenth part mm without comma (rounded).
e.g.: measured= 61,87

61,87-15=46,87
RhoHMDistance = 469
= NOLPM=
7. Parameter RhoHMDistance fine adjustment:
1. Initialize with Go Init

2. Set HMD = 10mm (motor moves to that distance)
3. Measure distance to transport belt (e.g.: 25,2)
4. Set parameter RhoHMDistance (e.g. value parameter +2
( +/- 0,1mm tolerance)
8. Check distances:
Move in Testcom to following distances:
HMD in Testcom Measuring Tolerance

distance
40 55mm +/-0,2mm
15 30mm +/-0,2mm
5 20mm +/-0,1mm
9. Adjust mechanical limit Stop
Move manual to a distance from 15,8mm and fix the limit stop
screw.
10. Mount lower electrical limit switch
Attention: mechanical limit Stop must be more down!

Move with Z-hub adapter to 16mm measuring distance and fix the
part so that the switch is on.
Move the sledge up and the switch is off. Move again down. As
soon the switch is on the sledge stops. Check distance, if
necessary readjust the switch position and redo the procedure.
11. Mount upper electrical limit switch
Move with Z-hub adapter to the distance and follow the

instruction as above.
= NPLPM=
RKNM `~=p=
1. Mount the electrical crash switch like shown on the photo below.
Black holding
metal
Mounting part
Switching
part
2. Switch ON the machine:

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

Place the print sledge in the centre of the belt table.
Set the Head Media Distance HMD=4,8mm (in Testcom).
Put a Media with 5mm thickness (Kapa) underneath the sensor. Move
the switching
part down until it is set flat to the Media. Fix the switching
part with the set screws
on the side).
Switch
Switch part
Media 5mm
Black
transport
belt
5mm
= NQLPM=
4. Adjustment of the switching point:
Bend the switching part against the UV-lamp until you have a
distance of 10mm.
press the SET-button for min. 1 second
When the LED on the switch is blinking with high frequency then the
new switching point is set.
10mm SET-button
5. Check of the switching point:

5.1 Manual test
set the HMD to 4mm and put a plate with 5mm inside
move the print sledge over the Media >> the sensor must be activated
before the UV-lamp is reaching the media.
Automatic test
Initialise the machine and set the HMD to 4mm
Put the Media with 5mm again
Testcom: Press the button Security Move
This starts the security move procedure. The print sledge is passing
the Media with slow motion. The switch should be activated and the
print sledge should be stopped before the UV-lamp is reaching the
media.
5.9.1 New settings of crash switches and printing distance

=
5.9.1.1 New setting of the media crash switches
=
Durst has decided to change the setting of the media crash switches. This
change is valid for all machines build at Durst Phototechnik Austria with
Quadro Array Printheads (Rho600, RhoPac, RhoPictor, Rho800).
From now on all machines are shipped out with these new settings and we
strongly recommend to do this change also on all machines in the field.
With the new adjustment tool LE3099008 can be ordered at Durst and is the
same for Rho600, RhoPac, RhoPictor and Rho800.
=
= NRLPM=
Adjustment tool LE3099008:
=
=
mN=
mO=
= =
=
How to do the adjustment:
=
Place the adjustment tool LE3099008 like shown in the photos below and
press it against the crash switch bar.
~==~=
i^PMVVMMU=
MJi=
MIT= MIR=
mP= mQ=
= =
Adjust the height of the crash switch unit so that the switch bar touches
the 0,7mm step of the tool LE3399008. Take care that the crash switch bar
is not lower than the 0,7mm step of the adjustment tool.
When you change from 0,7mm to 0,5mm step you should hear the micro-switches
clicking. Make sure that the switches are activated between 0,5mm and
0,7mm.
Info: 0,5mm means that the crash switch is activated 0,5mm before touching
the printheads.
Check the electrical function of the switch bar:
Press against the switch bar on both edges by hand and check if you can see
the ON/OFF-signal on the Optoisolator-PCB in the electronic rack. When
crash switch is not activated the LED on the Optoisolator PCB is ON (when
switch pressed OFF).
When you press against the bar with the 0,5mm step at least 1 micro-switch
must be activated (you will hear the switching of the micro-switch). Check
the adjustment on the two edge positions (in the centre it can happen that
the crash switch bar is a little bit higher or deeper.
=
= NSLPM=
O=K=== mR=
=
New setting of the minimum Printing Distance
According to the change of the media crash switch settings Durst has also
decided not to allow a printing distance smaller as 1,5mm any longer. To
change this in the software following entry in the DurstPrinter.setup-
file must be modified:
NIR=
=
=
RhoMediaMinHeadDistanceCM 0.150000
=
=
Important Information:
We can only handle returned printheads that have been damaged by a
crash under warranty if following steps have been performed:
New setting of the Media crash switches (0,5-0,7mm) has been done.
Minimum printing distance must be set to 1,5mm.
Session-Log-File of the crash day must be sent to Durst.
The media where the crash happened must be sent to Durst together
with the printhead.
=
= NTLPM=
RKNN jJa=
d~==
M-Drive is a stepper motor drive with build in power electronics. This

motor is triggered from the linear motor controller Spii+.
On Spii+ Controller must be installed the software LE2011.1Z or higher!
m~~=m~=
1. Connect Notebook with the programming cable IMS MD-CC300-000

and the MDM Line Receiver PCB (ZW2063A).
2. Activate the Safety relais in Testcom
3. Start IMS SPI Interface Program
4. Click on the following window File/Open to load the actual

parameter file (e.g.: \ACS Controller SpiiPlus\ LE2012P_XZ-
MDM34ACplus.mot).
= NULPM=
5. Check the parameter, use the same settings as shown below.
6. Click onto View/IO Settings and check also the settings on the
2.page.
7. Click on Set to program the parameter into the controller.

After that click on Recall and the data is read from the
controller. Now check the settings from point 5 and 6.
2.
1.
8. Is now everything ok, the program can be closed with Exit and
the programming cycle is done. (the message if it should be
saved needs to click NEIN) Disconnect programming cable!
=
= NVLPM=
RKNO m=p~=`=
d~=
Check cable connection as shown in Wiring Diagram LE2000006 sheet 6.
Input Output:
clamp description I/O

X1/ T0 Safety switch cover hood and O
emergency circle 1
X1/ T1 Safety switch cover hood and O
emergency circle 2
X1/ T2 Safety switch light trap 1 O
X1/ T3 Safety switch light trap 2 O
X2/O1 Emergency relais K10 (Connection O

Unit)
X2/O2 Emergency relais K11 (Connection O
Unit)
X2/O2 Security Control PCB internal (Relais O
K2)
X2/O3 Security Control PCB internal (Relais O
K3)
X3/13 +24V I
X3/24 UV-Safety relais K4 (Connection Unit) O
X5/I0 Security Control PCB internal (C1) I

X5/I1 Sensor A I
X5/I2 Sensor B I
X5/I3 Sensor C2 I
X5/I4 UV Standby I
X5/I5 Sensor D2 I
X5/I6 Sensor D1 I
X5/I7 Sensor C1 I
X6/I8 Reserve I
X6/I9 Reserve I
X6/I10 Emergency circle1 I
X6/I11 Emergency circle2 I
X6/I12 Safety switch light trap 1 I
X6/I13 Safety switch light trap 2 I
X6/I14 Safety switch cover hood 1 I
X6/I15 Safety switch cover hood 2 I
X6/I16 Temperature warning I
X6/I17 Temperature early warning I
X6/I18 +24V, at Crash 0V I
X6/I19 Reserve I
X7/A1 Security Control PCB internal (C2) I

X7/A1 +24V I
X7/A2 GND I
X7/A2 GND I
= OMLPM=
p=^=
Sensor A, B (backside on top of sledge)
Check distance with thickness gauge!!
Perforated plate on
0,3 - support
0,6mm
In the case of doubt check the impulse length with an oscilloscope:

the minimum pulse width (and break time) must be 14ms. (13ms =
Guarantee from Pilz impulse detection)
Sensor C1, C2, D1, D2
Check distance with thickness gauge!!

Always both sensors C1, C2 and D1, D2 must be ON or OFF at the same
time (optical check from the LEDs is enough)
0,4 -
1.0mm
p~==
1. Measure input voltage:
Pilz Unit X2:

Pin 0V
Pin +24V (Tolerance: 22 - 26V) = voltage value A:
2. Check sensor A and B:

move the sledge, the red LED lights up on every fin
voltage measurement:
This applies for all voltage measurements: GND = Pin 0V at X2
(Pilz-Module)
X5 at Pilz-Module:
Sensor A B
LED light Pin I1 Pin I2 ... voltage value A + 0 - 3V
LED dark Pin I1 Pin I2 ... voltage value = 0 - 2V
= ONLPM=
3. Check C1,C2 (left) and D1,D2 (right):
The sensors must switch ON and OFF at same time when the sledge
moves. A check with the eyes is enough. Is the time difference
bigger than 140ms is a problem with the Pilz controller.
Voltage measurement:
X5 at Pilz-Modul:
Sensor C1 C2 D1 D2
LED light Pin I7 Pin I3 Pin I6 Pin I5... voltage value A + 0 - 3V
LED dark Pin I7 Pin I3 Pin I6 Pin I5... voltage value = 0 - 2V
c===
1. Check temperature control at linear motor:

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

adjustment
T1 (520) dark dark normal
T2 (600) dark light Temperature early
warning
T3 (1,2k) light light Over temperature
2. Initialize sledge contactor K4 must switch on.

3. Sensor C1, C2, D1,D2:
Sledge is at park position or right side

Simulate the 4 situations:
C1 C2 D1 D2 K4 - status
disconnected connected connected connected drops off
connected disconnected connected connected drops off
connected connected disconnected connected drops off
connected connected connected disconnected drops off
4. Push the emergency Stop during the sledge moves sledge Stops and
machine is OFF!
5. Switch on UV lamps and open the cover hood in park position lamps
are still on and the sledge must be possible to move by hand.
6. Switch on UV lamps and open the cover hood during the sledge moves
lamps are OFF and sledge must stop. Now possible to move the sledge
by hand.
7. Switch on UV lamps and pull out the purge tray lamps are OFF and
sledge must be possible to move (If the purge tray is in purge
position the lamps are ON)
8. Disconnect during printing the sensor A at X80 from the Security PCB
K4 drops off (UV-lamps OFF)
9. Disconnect during printing the sensor B at X81 from the Security PCB
K4 drops off (UV-lamps OFF)
10. Switch on the UV lamps in park position with intensity 10 -> UV

lamps must switch off after approx. 2 min. (over temperature)
= OOLPM=
RKNP c=f=q=
^=
1. The cable X2023 for the addressing must be connected on the right
position. See Wiring Diagram.
2. Do addressing from towers.
Head Driver(cooling tower) CK,KC: MY,YM:
g=pN=
g=pN= `=
`= g=pN=
g=pN= l=
l=
g=pO==
g=pO `==
` g=pO=
g=pO= `=
`=
Head Driver(cooling tower) F5: F6:
g=pN=
g=pN= `=
`= g=pN=
g=pN= l=
l=
g=pO==
g=pO l=
l= g=pO=
g=pO= l=
l=
~=
1. Click in Testcom on button Testmode.

2. Check that V14 on the Head Interface-PCB lights red.
3. Measure with the oscilloscope on the Head Driver PCB (cooling tower),
V124 Pin18 (measurement point see photo) to ground (measurement point
P0).
= OPLPM=
5V rectangle impulse:
5VDC +- 0,5V
9s
+- 0,05s
Attention: calibrate
probe first! (otherwise
wrong measurement)
4. Do this measurement on all Head Driver PCBs.

5. Deactivate Testmode in Testcom.
Measure Fireimpuls:
1. Switch on control pulse Head Voltage ON/OFF in Testcom.

2. V133 on all Head Driver PCB must light up.
3. Click on Set Head Voltage 100
4. Click on Testmode in Testcom.
5. Measure the pulse with the oscilloscope on the Head Driver PCB from
the cooling towers.
This must be done on all test points (Fire1-8) on all PCBs.
6. Save the oscilloscope screen. (store in on an external database)
Open oscilloscope default settings fire_100
measurements:
rise time
puls width
fall time
Vp-p (Voltage Peak to Peak)
= OQLPM=
Attention: Do not forget to
rise time = 3,2 +- 0,4s
calibrate the probe! puls width = 5,8 +- 0,4s
fall time = 0,8 +- 0,2s
(otherwise wrong measurement) Vamptd = 100V +-2,5V
7. Change voltage to 120V. For this click Set Head Voltage 120. Same
measurement as with 100V. Do it for all printheads.
rise time = open
puls width = open
fall time = open
Vamptd= 120V +-3V
=
8. At first deactivate Testmode and than Set Head Voltage.
= ORLPM=
RKNQ rs=p=
ibhp=j==
LEKS is a module to control the UV-Fans.
Fan overrun-time
LED red
No speed signal
(Fan off) Temperature set point
LED yellow LED red

Fan on Temp. warning
LED green
Picture 1
UV ready
message
p~==
1. Threshold adjustment or checking from temperature warning.

- Turn the potentiometer CCW to the left limit
- As seen in the picture, turn potentiometer exactly 2 mark
lines clockwise.
Arrow must be
exactly in the
middle from the
2.mark line
2. During the initialization the contactor K4 switches on.

3. Switch on lamp 1. Check if correct lamp starts up and the fan turns
into the right direction (airflow out of lamp).
During the start up the intensity goes up to 80% for approx. 45
seconds. After that the lamp is ready (green LED on LEKS Module)
and now goes to standby (20% power)
= OSLPM=
4. Switch on lamp 2. Check if correct lamp starts up and the fan
turns into the right direction (airflow out of lamp). And also that
UV lamp ready appears after 45 seconds.
5. Check temperature reference preset or maybe recalibrate.

Measure voltage on the LEKS module between PIN2 and PIN10 (lamps
are turn on). Reference value = 2,50V +/-0,01 lack the
potentiometer after calibration
6. Check intensity adjustment on both lamps. With Set Intensity
decrease or increase the power check lamp light or lighter or
darker)
7. Check cooling down from fans. After switching off the UV lamps the
fan speed must increase. After approx. 4min +0.5 fan switches off.
If this is not given adjust the potentiometer lack the
potentiometer after calibration.
RKNR s~=c~=
1. Activate in Testcom TableFan.
2. Both fans must turn.
3. Operate the controller on the Fan Unit Control PCB (potentiometer).
4. Fans must turn faster with a turn CW and converse.
RKNS r=m=r=
o=
1. LA2050400 Meniscus under pressure unit must be assembled together and

proved from the components before (also electrical).
2. Over pressure connection done on machine.
3. Unit with pressure control, filter and over pressure valve (Purge)
already mounted.
4. Hoses connected to the tanks.
5. hoses connected up to sledge (L-M-P block (LF2020540) connected,
print heads not connected)
6. Meniscus and Purge hose capped on sledge.
7. disconnect lung hose from external lung and cap it.
8. capping from Meniscus- vacuum pump must be removed!
Attention: Take care the hoses and openings are clean all the time
during the start-up procedure below.
= OTLPM=
i===
1. connect pressure metre to connector Y2012 (measure unit must be set

to zero).
If there is a voltage on the under pressure unit a negative pressure
from >-580mbar will be generated from the pump and pump switch off
itself. If there is a leakage to pump is running continuously and the
need negative pressure can never be reached. With a time measurement
the period must be shorter than 200sec.
2. Open Y2016 and check at which pressure the pump starts again. This
pressure must be higher than -580mbar.
3. At the right pressure send this command and check the receive
message.
command Receive message

./serial -c .01YPSxyz , z= 0 = OK
.10YPS
4. Check at the hose from the external lung the pressure. There must be
min -580mbar.
5. Open Y2012 and let the vacuum go down. Take care not to get pollution
into that opening. When the pressure is zero send the command and
check the receive message.

./serial c .01YPSxyz , z = 1 =
.10YPS NOT OK
Cap Y2012 again.
6. Long-term leakage test:

Vacuum must be reached and measure unit connected to Y2012.
Maximum pressure reduction from 3bar over a period from 3 min.
Attention: pump not powered up and not allowed to switch on during
this measurement
j===
1. Connect pressure metre to Y2006 (measure unit must be set to zero).

If there is a voltage on the under pressure unit a negative pressure
from 10,5mbar 0,8mbar will be generated from the pump and the pump
switch off itself. If there is a leakage to pump is running
continuously and the need negative pressure can never be reached.
2. At the right pressure send this command and check the receive
message.

./serial c .01YPSxyz , y = 0 =
.10YPS OK
With a time measurement the period must be shorter than 50sec.

3. Open Y2006 and immediately the pump starts to run.
4. Check on the print sledge on all 8 fittings at the L-M-P block

(LF2020540) the negative pressure. This pressure must be in the range
from 9,2 and -11,2mbar.
5. Now create a negative pressure from 20mbar (bypass between P0 and P1,
or squeeze the silicon tube what is connect on the PCB and Y2008
several times for short time). Disconnect X3028 after 2min and the
LED V30 lights up red.
Check with the command the receive message.
= OULPM=
./serial c .01YPSxyz , y = 1 =
.10YPS NOT OK
Connect X3028 and check the time to reach a pressure from -10,5mbar +-
0,8mbar.
This time must be shorter than 150sec.
6. Disconnect X3029 connector and open Y2009 the pressure goes down to
zero. Take care not to get pollution into that opening! CAP Y2006.
After 2 min. waiting the LED V31 lights up red.

./serial c .02YPSxyz, y = 1 =
.10YPS NOT OK
Connect X3029 again.
7. Long-term leakage test:

At first create a negative pressure from 20mbar (bypass P0 and P1,
or squeeze the silicon tube what is connect on the PCB and Y2008
several times for short time). Disconnect X3028. Vacuum must be
reached and the pressure metre connected to Y2006. Check the pressure
reduction over 1 hour. Max. 1mbar over the period from 1 hour.
Switch off the pressure metre during the measure period.
m===
1. Check the over pressure valve, this must open between 0,5 and 1,0bar.
2. Connect at switch S31 Pin2 and 3 the Ohmmeter. Switch must be highly
resistive with environment pressure (Feedback for Unix workstation).
Connect at Y2002 the pressure metre.
Now open the filter reduction valve (near pressure controller) at
Y2001 and adjust a pressure from 250mbar (+30mbar).
Adjust over pressure sensor (Purge Pressure Sensor) that the switch
just close. Ohmmeter still connect and a resistor from less than 1 Ohm
must be displayed. Now its save that over pressure sensor can
recognize a pressure higher 250mbar.
3. Adjust purge pressure with the filter regulation valve (near pressure
controller) to 300 up to 330mbar.
4. This pressure must be also at the test point from the sledge when the
Purge Ambient Valve is open.
5. Check with the command the receive message.

./serial c .01YPSxyz , x = 0 =
.10YPS OK
6. Close the filter regulation valve that no over pressure exists.

./serial c .01YPSxyz, x = 1 =
.10YPS NOK
= OVLPM=
7. Check the breather from the valve.
Testcom: Purge/ Ambient Valve
If Purge / Ambient Valve is open the over pressure must move out
of the hole next to Y2004.
= PMLPM=

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oSMM=m= =

RKN b~=~ KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK O

Other equipment what needs to be disconnected:

1. Shutdown machine. Shutdown workstation. Disconnect power supply from

Used measurement points:

7. Disconnect power supply at low power trigger and adapter. Fasten

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

Main Input Inside Transformer

Connect both earth All earth cables are

1. Use at the transformer the connections what are the nearest to

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

Main voltage (V) Current (A)

Backplane X1100 +12V, -12V, 5V

Dip Switch 4321

1. Disconnect X2034-CK/MY Head Interface, X2034-YM/KC Head Interface,

1. Disconnect all Molex - connector J8 on the print head.

1. Disconnect X2000/1 Head Heater1 (and X2000/2 Head Heater2 at F5).

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

1. Switch on in Testcom the heating control

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

LOIS Offset = actual value -318

Now the value from CK1C is programmed with -31

1. Set data at DurstPrinter.setup file

The mark of the positioning device is

cut out for sensor

Alignment of the chamfer

Next step is mounting the reflector onto the holder.

chamfer for base from

= Reflector film (ibwJcqacMOMcMOM)

b~=~=W= Printing direction

Measure point P14, P0

Adjustment point Measuring HMD Tolerance

Description from Init cycle:

4. Adjust turning speed from Z-hub motor

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

Send following commands to the machine:

./serial c .10YHMSA0 for slow speed

With this command the sledge moves up to the reference switch

130 +/-5 at fast speed

5. Adjust reference switch (light barrier)

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

6. Parameter RhoHMDistance rough adjustment:

1. Initialize with Go Init

e.g.: measured= 61,87

1. Initialize with Go Init

Move in Testcom to following distances:

HMD in Testcom Measuring Tolerance

9. Adjust mechanical limit Stop

10. Mount lower electrical limit switch

Attention: mechanical limit Stop must be more down!

11. Mount upper electrical limit switch

Move with Z-hub adapter to the distance and follow the

2. Switch ON the machine:

3. Height adjustment of the Media Security Switch

5. Check of the switching point:

5.9.1 New settings of crash switches and printing distance

M-Drive is a stepper motor drive with build in power electronics. This

1. Connect Notebook with the programming cable IMS MD-CC300-000

4. Click on the following window File/Open to load the actual

7. Click on Set to program the parameter into the controller.

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

clamp description I/O

X2/O1 Emergency relais K10 (Connection O

X5/I0 Security Control PCB internal (C1) I