Read this document carefully before implementing the upgrade!

Transcription

1 PRODUCT: NUR Fresco HiQ PART/ASSEMBLY: Fresco HiQ 8C Upgrade OPTIONAL UPGRADE KIT: NUR Fresco HiQ 3200 ISSUE DATE: 6-Feb-03 DESCRIPTION OF CHANGE: Fresco 4-Color to 8-Color P/N: NUR Fresco HiQ 1800 P/N: Printing Capability SOFTWARE AFFECTED: IMPLEMENTATION: PREPARED BY: YES NO ON REQUEST IMMEDIATE Alex Davidson NEXT CALL ON FAILURE TYPE OF CHANGE: MANDATORY CONDITIONAL MATERIAL DISPOSITION: N/A USE AS SPARE DISCARD ALL DISCARD SELECTIVELY (refer to Mat l Disposition) SEND BACK FOR REWORK PROJECT MANAGER: SIGNATURE/DATE ENGINEERING MANAGER: SIGNATURE/DATE ICS MANAGER: SIGNATURE/DATE Read this document carefully before implementing the upgrade! OPTIONAL UPGRADE FC Rev. D Page 1 of 117

2 Table of Contents 1. General Estimated Installation Time Additional Required Tools Preparation for Upgrade Replacing the Print Head Carriage Plates Replacing the Current 4C-SIT with the 8C SIT Purge Manifold Relocation Replacing the 5-Micron Filter Bracket with the 8C Filter Bracket IGUS Replacement Fresco HiQ IGUS Replacement Fresco HiQ Tubes (Hydraulic) Connection for IGUS Installing the Switch-Blocks Installing the Light Main Ink Tanks Assembly Switch Block Hydraulic Connections Screwing the 8C Filter Bracket to the Chassis Wall Connecting Filter Ink Inlet Tubes Installation of the 8C Ink Pump Control (IPC) and Ink I/O Board Cable Installation Installing the Dell 530 Workstation FPP Board and Driver Installation Installing the PrinTop Application Final Tasks Installing NUR Flash Testing Logistics Material Disposition Table of Appendixes Appendix A: Ink Flushing System Appendix B: Print Heads Replacement Appendix C: Print Head Plate Calibration Appendix D: Schematic Drawings Page 2 of 117 FC Rev. D

3 Table of Figures Figure 1: Crimping Tool...6 Figure 2: Removing the Print Head Cover Shield...7 Figure 3: Print Head Cover Shield Assembly...8 Figure 4: Print Head Plate From Kit...8 Figure 5: Cable FW52A Female Plug in Print Head Carriage Assembly...9 Figure 6: Removing SIT Block from the Print Head Carriage...10 Figure 7: Print Heads and 8C Secondary Ink Tanks (SIT)...11 Figure 8: 8C SIT Assembled...12 Figure 9: Distance between the Top of the SIT and the Top of the Print Head Plate..12 Figure 10: Purge Manifold...13 Figure 11: New Purge Valve Bracket...14 Figure 12: the New Bracket Position (Above Cable Duct)...14 Figure 13:Purge Manifold Mounted on New Bracket and at New Location (1800)...15 Figure 14:Purge Manifold Mounted on New Bracket and at New Location (3200)...15 Figure 15: Ink Filters and Old Bracket...16 Figure 16: Bracket with Dark and Light Filters...17 Figure 17: Protective Plate on Printing Carriage Unit and IGUS Starting Point...18 Figure 18: Protective Cover under Cable Chain Tray...19 Figure 19: Bracket at Center of Cable Chain Tray...20 Figure 20: Adaptor Brackets (from Kit) on Print Head Carriage...22 Figure 21: F-shaped Brackets (from kit)...22 Figure 22: Shelving Separator Unit...24 Figure 23: Snapping Lids on IGUS...24 Figure 24: New IGUS Secured on Cable Chain Tray...25 Figure 25: IGUS Cable Carrier Print Head Connection (Before Upgrade)...27 Figure 26: IGUS Cable Carrier Tray Connection (Before Upgrade)...27 Figure 27: IGUS Tube Carrier Print Head Connection (Before Upgrade)...28 Figure 28: IGUS Tube Carrier Tray Connection (Before Upgrade)...29 Figure 29: 8C IGUS-Print Head Carriage Adaptor Brackets...30 Figure 30: 8C IGUS-Tray Adaptor Bracket Left Side...30 Figure 31: 8C IGUS-Tray Adaptor Bracket Right Side...30 Figure 32: 8C IGUS-Tray Adaptor Bracket Left Side Screw Holes...32 Figure 33: 8C IGUS Cable Carrier Cable Tray Connection...32 Figure 34: 8C IGUS-Print Head Carriage Adaptor Bracket Screw Holes...33 Figure 35 IGUS Cable Carrier Print Head Carriage Connection...33 Figure 36: 8C IGUS-Tray Adaptor Bracket Right Side Screw Holes...34 Figure 37: 8C IGUS Right Side Carriage Tray...35 Figure 38: 8C IGUS Right Side Print Head...36 Figure 39: 8C IGUS Carriage Tray Installation...36 Figure 40: Jig Location...38 Figure 41: Adaptor Bracket...39 Figure 42: Rivet Gun and Rivets...39 Figure 43: Left (C and M) Switch-Block for Installation Purpose Only...40 FC Rev. D Page 3 of 117

4 Figure 44: Switch Block Y and K on Adaptor Bracket...40 Figure 45: Cabinet Floor Location of Light Main Ink Tanks...41 Figure 46: Light Ink Tanks Front View...42 Figure 47: Light Main Ink Tanks Side View...42 Figure 48: Front View of the Service Cabinet after Installation...43 Figure 49: Switch Block Electro-Valves Location...44 Figure 50: Switch Block Bottom View...45 Figure 51: Right Switch-Block Bottom View Black and Yellow Colors...46 Figure 52: Bracket with Dark and Light Filters...47 Figure 53: Light Ink Tanks Front View...48 Figure 54: Right Switch Block Top View Black and Yellow Colors...49 Figure 55: Two Level Filter Bracket Screw Holes...50 Figure 56: Ink Control Card with New Labels...52 Figure 57: IPC Board in Service Cabinet...52 Figure 58: GI/O#1 Board Box with New Labels in Service Cabinet...53 Figure 59: GI/O#1 Board Box Schematics...53 Figure 60: Cable Duct Top Covers Below Purge Valves (Rubber Bumper on Edges)54 Figure 61: CB and HTB on Rail...55 Figure 62: Light IPC Board and Labeled Cables...55 Figure 63: Light and Dark IPC Boards...56 Figure 64: Rail and Ink I/O Board Location...56 Figure 65: Longer Rail (P/N: )...57 Figure 66: I/O Ink Board and Accessories...57 Figure 67: IPC and I/O Ink Boards...62 Figure 68: Y-adaptor Connecting Monitor to PC...63 Figure 69: Mouse Shelf Location...64 Figure 70: New Bracket...65 Figure 71: Green Latch and D-types Connection...66 Figure 72: FPP Board and Parts from Kit...66 Figure 73: FPP Board with Bracket...66 Figure 74: FPP Board installed with Nut from Kit...67 Figure 75: Nut and Screw from Kit...67 Figure 76: Install Window...68 Figure 77: Choose Search and Install Option Window...68 Figure 78: Hardware Type Window...69 Figure 79: Device Driver Window...69 Figure 80: Install from Disk Dialog Box...70 Figure 81: Locate File Dialog Box...70 Figure 82: Select Device Driver Window...71 Figure 83: System Properties Window with Device Manager Tab...72 Figure 84: Device Manager Window...73 Figure 85: Update Driver Window...73 Figure 86: Hardware Update Wizard...74 Figure 87: Installation Options Window...74 Page 4 of 117 FC Rev. D

5 Figure 88: Select Device Driver Window...75 Figure 89: Install From Disk Dialog Box...75 Figure 90: Locate File Dialog Box...75 Figure 91: New label to Add below Existing Label on Printer...77 Figure 92: Calibration of the SIT Assembly...79 Figure 93: Main Ink Tanks...93 Figure 94: Five-Microns Filter...93 Figure 95: SIT Draining...93 Figure 96: Disconnecting the Print Head...98 Figure 97: Print Head Protective Cover (Securing Screws Encircled)...98 Figure 98: Removing the Print Head Protective Cover...98 Figure 99: Print Head Plate...99 Figure 100: Unscrewing the Print Head Allen Screw...99 Figure 101: Removing the Print Head...99 Figure 102: Print Head Figure 103: Removing the Print Head Protective Cover Shields Figure 104: Rulers Figure 105: Eight Adjustments Assemblies Figure 106: Adjustment Assembly Figure 107: 6 mm Distance between the Plate and Carriage Figure 108: Indicator Holders A and B Figure 109: Arm for Indicator Figure 110: Micrometer Indicator Figure 111: Indicator Holder B, Arm, and Micrometer IdicatorAssembled Figure 112: Back Right Screw that Secures Print Head Carriage to its Base Figure 113: Front Left Screw that Secures the Print Head carriage to its Base Figure 114: Calibrating the Minimum Distance Figure 115: Indicator Holder A, Arm, and Micrometer IdicatorAssembled Figure 116: Two Micrometers Pointing to the Print Head Plate Face Figure 117: Micrometer Calibration Figure 118: Horizontal Calibration FC Rev. D Page 5 of 117

6 1. General The 8C kit allows the Fresco HiQ to print in either 8 or 4-color mode. This document describes how to install the 8C Upgrade kit on NUR Fresco HiQ printers (1800 and 3200). 2. Estimated Installation Time The upgrade requires that two Field Service Engineers (FSEs) perform the upgrade for a period of three days, and that one FSE remains on-site for an additional two days of on-site training and accompanied production. 3. Additional Required Tools Crimping tool for pin terminals. An example of a crimping tool is displayed below. Calibration Kit (P/N: ) Drill 4. Preparation for Upgrade Figure 1: Crimping Tool IMPORTANT!! Perform the Wake-Up procedure, and Print the "All Nozzles" Pattern before beginning the upgrade installation. Show the printout to the customer and save this pattern as proof of the print heads condition prior to the upgrade!!! 1. Make sure that no substrate is loaded on the printer. 2. Empty all the Main Ink Tanks into separate empty containers for reuse. 3. Perform the Ink System Flushing Procedure (refer to Appendix A). 4. Power down the machine and cut the air pressure. Page 6 of 117 FC Rev. D

7 5. Replacing the Print Head Carriage Plates Since the 8C upgrade uses a new Print Head setup, you must replace of the Print Head carriage plates. Replace the Print Head plates as follows: 1. Remove three M5 screws from the Print Head cover shield using a 4 mm Allen key and remove Print Head cover shield (refer to Figure 2). See Appendix B on page 96 for details. Rulers PH Plate to Replace Locating Pin PH Cover Shield Removed Figure 2: Removing the Print Head Cover Shield 2. Disassemble the Print Head cover shield, that was removed above, as follows: Remove the 22 screws (do not discard) (using a Phillips screwdriver) to remove the frame from the Print Head shield (refer to Figure 3). Do not discard the frame. Discard the shield. Clean the frame thoroughly with solvent. 3. Mount the new Print Head cover shield (from kit) on the frame that was removed in the previous step, and secure it with the original 22 screws. Ensure to tighten the screws in a cris-cross pattern. 4. Remove the Motherboard cover. 5. Remove all the Print Heads (See Appendix B on page 96 for details). 6. Remove the Print Head plate and its locating pins from the Print Head carriage as follows: Warning: Keep all parts of the eight adjustment assemblies, as these parts will be used later. Remove the eight adjustment assemblies. Remove the Print Head plate from the Print Head carriage. FC Rev. D Page 7 of 117

8 7. Remove the two-sided rulers from the Print Head plate. 8. Secure the rulers removed in step 6 to the new Print Head plate (from kit PN: ). 9. Use the eight adjustment assemblies to secure the new plate with rulers to the Print Head carriage (refer to Appendix C on page 101 and Figure 4). 10. Do not calibrate the Print Head plate yet; this will be done at a later stage (see Appendix C, on page 101 for details). PH Shield Frame Pin (4 Total) Adjustment Assemblies (8 Total) Figure 3: Print Head Cover Shield Assembly Figure 4: Print Head Plate From Kit Page 8 of 117 FC Rev. D

9 6. Replacing the Current 4C-SIT with the 8C SIT A Secondary Ink Tank (SIT) unit is required for each ink color. Therefore, when upgrading to 8 colors, you need to replace the 4C SIT block with the 8C SIT block. Removing the Current 4C SIT Block 1. Disconnect cable FW52A (the SIT floaters sensor cable) from the female plug, as displayed below. Cable FW52A Female Plug Figure 5: Cable FW52A Female Plug in Print Head Carriage Assembly - Disconnected 2. Disconnect all tubes leading to the current SIT block before removing it, as follows: Note: When disconnecting tubes, use the silicon caps provided in your kit (P/N: and ) to cap the tubes and corresponding fittings on the SITs. Disconnect the four vacuum tubes using a 7 mm wrench. Disconnect the four pressure tubes from the SIT block using a 10 mm wrench. Disconnect all purge tubes from the SIT block. Disconnect the PHs 16 tubes that run from the manifold the SITs using a 7 mm wrench. Note: Make sure to label each Print Head tube before disconnecting it from its SIT. FC Rev. D Page 9 of 117

10 3. Unscrew the four M6 screws on the back of the Print Head carriage plate using a 5 mm Allen key. Caution: Be careful when unscrewing the SIT since it could tip forward. 4. Remove the SIT block. Figure 6: Removing SIT Block from the Print Head Carriage Installing the New 8C SIT Block 1. In the kit, locate the new 8C SIT block (P/N: ). 2. Secure the new 8C SIT (from kit) to the Print Head carriage plate using the four M6 screws removed in step 3 above. 3. Connect cable FW52A to the female plug where the previous plug was removed (see Figure 5). Page 10 of 117 FC Rev. D

11 4. Remove the silicon caps and use a 7 mm wrench to connect the Print Head outlets tubes from the flushing manifold, as follows: Connect Print Heads 7,8 and 6,5 to the dark SIT and Print Heads 4,3 and 2,1 to the light SIT (see Figure 7 and Figure 7). Repeat for the remaining three colors. 5. Before tightening the SIT screws, make sure that the distance between the SIT wall and the Print Head carriage plate is exactly 81.5 mm (see Figure 9). 7,8 Dark SIT Light SIT 6,5 4,3 2,1 PH Outlets Dark K (7,8/6,5) Light K (4,3/2,1) 7,8 K 6,5 4,3 M 2,1 14-Micron Filter Restrictor C Pressure Outlet PH Outlets Y-Connector Purge Outlet Y Vacuum Outlet Figure 7: Print Heads and 8C Secondary Ink Tanks (SIT) FC Rev. D Page 11 of 117

12 Dark SIT Purge Outlet Connector Dark Light SIT Y-Connector and Purge Outlet Purge Connector Light K M C Y 14 Micron Filter PH Outlets Tubes Circled Vacuum Outlet Pressure Inlet Restrictors (2) Figure 8: 8C SIT Assembled Distance from A to B Should be 81.5 mm Figure 9: Distance between the Top of the SIT and the Top of the Print Head Plate Page 12 of 117 FC Rev. D

13 7. Purge Manifold Relocation The Purge Valves Manifold must be relocated because the current location of the Purge Manifold is required for installing the new filter bracket. Removing the Purge Manifold Bracket Remove the old purge manifold bracket as follows: 1. Cut the tie-wraps of the Inlet purge valves and the outlets tubes (to Print Head Carriage) (see Figure 10). Tube Connector Inlet Tube Two M8 Allen Screws Hidden Purge Bracket Purge Tubes Four M5 Allen Screws Outlet Tube Figure 10: Purge Manifold 2. Disconnect all purge tubes leading to the purge valves with the exception of the outlet tube using a 12 mm wrench (see Figure 10). 3. Remove the four M5 screws (two on each side) from the bracket using a 4 mm Allen key. Save the screws (see Figure 10). 4. Remove the two M8 screws that secure the old bracket to the wall using a 6 mm Allen key. Save the screws and discard the bracket (see Figure 10). FC Rev. D Page 13 of 117

14 Installing the New Purge Manifold Bracket Install the new purge manifold bracket as follows: 1. Locate the purge manifold bracket in the kit (P/N: ). Figure 11: New Purge Valve Bracket 2. Locate the four bores above the cable duct (see Figure 12). Figure 12: the New Bracket Position (Above Cable Duct) 3. Secure the new bracket above the cable duct as far to the right as possible using two M8x10 screws from the kit (P/N: ) and two washers (P/N: ) (see Figure 12 and Figure 13). 4. Carefully, lift the purge valve manifold and secure it to the new bracket with the Allen screws that were previously removed (refer to Figure 13 for Fresco HiQ 1800 and Figure 14 for Fresco HiQ 3200). Page 14 of 117 FC Rev. D

15 Screws Screws Circled Figure 13:Purge Manifold Mounted on New Bracket and at New Location (Fresco HiQ 1800) Figure 14:Purge Manifold Mounted on New Bracket and at New Location (Fresco HiQ 3200) 5. Reconnect the air inlet tube only and shorten it to fit. Note for Fresco HiQ 3200: The spittoon 10 mm nylon tube is too short for the new setup and may get caught in the purge valve unit. The longer nylon tube included in the kit solves this problem. Make sure that the spittoon tube is empty of ink before disconnecting and replacing it. 6. Disconnect both ends of the current 10 mm nylon tube from the spittoon using a 14 mm wrench and replace with the one from kit (P/N: ). 7. If necessary, cut the tube to adjust its length. FC Rev. D Page 15 of 117

16 8. Replacing the 5-Micron Filter Bracket with the 8C Filter Bracket The 8C upgrade requires nine 5-micron filters. You must install a new filter bracket to hold the additional filters. Removing the 5-Micron Filter Bracket Note: Make sure to wear protective gloves and to place cloths on the Service Cabinet floor to collect the ink dripping from the filter/quick connectors. 1. Push on the quick connector of the filter inlet to release the inlet tubes (refer to Figure 15). 2. To release the filters, push on the release button of the filter outlet quick connectors and remove them (refer to Figure 15). Discard these filters. 3. Disconnect the outlet tubes from the filter's quick connectors using an 11 mm wrench. Insert a silicon cap on each tube to prevent dripping (refer to Figure 15). 4. Disconnect all ink pressure tubes from the 5-micron filter s quick connectors (refer to Figure 15). Do not discard the quick connectors. You will need to connect them later to the new filter bracket. 5. Remove the two M6 screws securing the bracket to the chassis using a 5 mm Allen key, and remove the bracket (refer to Figure 15). Do not discard the screws; you will use these at a later stage. 6. Remove the nuts from the quick connectors using 19 mm (on top) and 21 mm (bottom) wrenches, and remove the quick connectors (refer to Figure 15). Do not discard; you will use these at a later stage. 7. Remove the five nuts on the filter outlets from the upper section of old bracket using an 11 mm wrench (refer to Figure 15). Do not discard; you will use these at a later stage. Filter Inlet Quick Connector Draining Cap Release Knob 19 mm Nut 5 Micron Ink Filter 21 mm Nut 11 mm Nut (Remove & Save) M6 Screw Filter Outlet Quick Connector Figure 15: Ink Filters and Old Bracket Page 16 of 117 FC Rev. D

17 Note: At the end of this process, you should have 10 quick connectors for later use. Note: An extra quick connector (PN: ) is supplied in the kit, if required. Installing the 8C Filter Bracket 1. In the kit, locate the filters assembly bracket (P/N: ) and the nine new 5-micron filters (P/N: ). 2. Connect the nine new 5-micron filters to each quick connector on the bracket (refer to Figure 16) 3. Plug-in nine quick connectors that were removed above to the filter inlets. Solvent Filter Draining Cap Circled Dark Ink Filters Light Ink Filters Figure 16: Bracket with Dark and Light Filters Note: The 8C Filter Bracket is installed onto the chassis only after the hydraulics are connected, to enable easier hydraulic connection. See section 15 on page 50 on for details. FC Rev. D Page 17 of 117

18 9. IGUS Replacement Fresco HiQ 3200 Both the Left Side IGUS Cable Carrier and the Right Side IGUS Tube Carrier must be replaced. For the Left Side IGUS Cable Carrier, the IGUS is removed without the cables that it encases the cables remain attached to the printer while the cable chain is replaced. For the Right Side IGUS Tube Carrier, the IGUS is removed with its tubes the tubes are removed with the IGUS. The new Right Side IGUS Tube Carrier comes equipped with the tubes inside. Note: This section refers to the Fresco HiQ 3200 only. If you are upgrading Fresco HiQ 1800 skip to section 10 on page 26. Note: Refer to Logistics on page 83 throughout this process for a listing of material disposition. The following terminology for the IGUS is used in this section: Complete Name Left Side IGUS Cable Carrier Right Side IGUS Tube Carrier Name Used in this Section IGUS Cable Carrier IGUS Tube Carrier Removing the IGUS Cable Carrier (Fresco HiQ 3200) 1. Position the Print Head Carriage as far right as possible. 2. Remove the cables from the Cable Carrier as follows: Start with the side connected to the Print Head carriage (refer to Figure 17). Outer Lids IGUS Cable Carrier Base of the PH Carriage IGUS Tube Carrier Two Screws on Each Side Circled IGUS Cable Carrier Adaptor Bracket IGUS Tube Carrier Adaptor Bracket Figure 17: Protective Plate on Printing Carriage Unit and IGUS Starting Point Page 18 of 117 FC Rev. D

19 Position a flat screwdriver inside the lid's two openings and push slightly down to open the outer lids. Start from the left side to last lid on the outer radius of the IGUS Cable Carrier. Do not discard (refer to Figure 17). Pull all the cables out of the IGUS Cable Carrier and lay them down away from the linear encoder scale. 3. Remove the four screws that secure the IGUS Cable Carrier to the adaptor bracket on the left side of the Print Head carriage using a 4 mm Allen key (refer to Figure 17). Do not discard. 4. Remove the two M5 screws that secure the adaptor bracket to the right side of the Print Head carriage using a 4 mm Allen key. Do not discard (refer to Figure 17). 5. Loosen the four protective cover nuts under the cable chain tray using an 8 mm wrench. Disconnect the air gun tube from the quick-connector (refer to Figure 18). Air Gun Quick Connector Protective Cover Four 8 mm Nuts Circled Figure 18: Protective Cover under Cable Chain Tray 6. Remove the four M5 screws that secure the IGUS Cable Carrier end to the cable chain tray using a 4 mm Allen key. Caution: Remove the IGUS Cable Chain carefully. Avoid hitting or damaging the Linear Encoder Scale. 7. Remove the IGUS Cable Carrier. FC Rev. D Page 19 of 117

20 8. Remove the two M6 screws on the bracket (left side) from the center of the cable chain tray using a 4 mm Allen key, while holding the nut beneath it with a 10 mm wrench (refer to Figure 19). Do not remove the bracket. IGUS Cable Carrier Two Left M6 Screws Two Right M6 Screws Bracket at Center of Cable Chain Tray 8 mm Nut Below M6 Screw Figure 19: Bracket at Center of Cable Chain Tray Removing the IGUS Tube Carrier (Fresco HiQ 3200) Note: When disconnecting tubes, use the silicon caps provided in your kit (P/N: and ) to cap all end tubes and SIT inlets. 1. Position the Print Head carriage as far left as possible. 2. Disconnect all remaining tubes, in the IGUS Tube Carrier, as follows: Disconnect the solvent tube from the 14-micron filter and from the flushing manifold using a 10 mm Allen key. Disconnect the air flush inlet tube from the air flush valve assembly and from the air flush gauge inside the pneumatics cabinet. 3. Remove the four M5 screws that secure the IGUS Tube Carrier, to the adaptor plate on the right side of the Print Head carriage using a 4 mm Allen key (refer to Figure 17). 4. Remove the two M5 screws that secure the adaptor plate to the right side of the Print Head carriage using a 4 mm Allen key. Do not discard (refer to Figure 17). 5. Remove the four M5 screws that secure the IGUS Tube Carrier end to the cable chain tray using a 4 mm Allen key. Page 20 of 117 FC Rev. D

21 Caution: Remove the IGUS Cable Chain carefully. Avoid hitting or damaging the Linear Encoder Scale. 6. Remove the IGUS Tube Carrier. 7. Remove the two M6 screws on the bracket (left side) from the center of the cable chain tray using a 4 mm Allen key, as you hold the nut below with a 10 mm wrench (refer to Figure 18). Do not remove the bracket. Installing the 8C IGUS Adaptor Brackets (Fresco HiQ 3200) 1. In the Kit, locate the following IGUS brackets: The left IGUS F-shaped bracket (P/N: ) and the right IGUS F-shaped bracket (P/N: ), for the center of the cable chain tray. The left IGUS bracket (P/N: ) and the right IGUS bracket (P/N: ) for the Print Head carriage. 2. In the kit, locate the two IGUS cable chains: The IGUS Cable Carrier assembly (P/N: ). The IGUS Tube Carrier assembly (P/N: ). 3. Secure the left and right adaptor brackets on the left and right sides of the Print Head carriage, in place of the removed bracket, using a 4 mm Allen key and the screws removed from the previous Print Head carriage bracket (refer to Figure 20). 4. Secure the F-shaped brackets to the 2 new IGUS assemblies using for each bracket: A 4 mm Allen key Four M5x20 screws (P/N: ) Four spring washers (P/N: ) Four flat washers (P/N: ) Note: Secure the F-shaped brackets to the IGUS cable chain away from the printer. FC Rev. D Page 21 of 117

22 5. Cut a section from the rubber bumper (P/N: ) to insert in the outer edge of the F-shaped brackets (refer to Figure 21). M6 screws secure bracket to PH carriage Left Bracket on PH Carriage Right Bracket on PH Carriage Four M6x16 screws secure IGUS to bracket Figure 20: Adaptor Brackets (from Kit) on Print Head Carriage Two M6x20 Screws Secure Bracket to X-axis Left Bracket on Cable Chain Tray Insert Rubber Bumper at Edges Right Bracket on Cable Chain Tray Four M5x16 Screws to Secure IGUS to Bracket (Circled) Figure 21: F-shaped Brackets (from kit). Page 22 of 117 FC Rev. D

23 Installing the IGUS Cable Carrier (Fresco HiQ 3200) Caution: When installing the IGUS Cable Carrier, carefully avoid hitting or damaging the Linear Encoder Scale. 1. Place the new IGUS Cable Carrier along the cable chain tray on the left of the Print Head carriage. 2. Secure the left F-shaped bracket (previously connected to the IGUS) to the left side cable chain tray using a 4 mm Allen key and the two M5x20 screws (P/N: ) (refer to Figure 21 and Figure 24). 3. Remove the snap-on upper lids all along the IGUS using a flat screwdriver. 4. Place the electrical cables that were removed from the previous IGUS Cable Carrier into the open new IGUS Cable Carrier. 5. Secure the cables along the IGUS Cable Carrier using the eleven shelving separators (from kit, P/N ) (refer to Figure 22) as follows: Note: Make sure to install a shelving separator unit at both ends of the IGUS cable chain. Starting from the side of the cable chain tray, insert the shelving separator, one at a time, at a slight angle, inside the IGUS Cable Carrier and snap it on the lower lid. Push the shelving separator s vertical separators together to ensure that there is enough room to insert cables in the outer chambers. Insert the cables in the right and left compartments of the shelving separators, each in its own chamber. Ensure that cables FW30A and FW30B are inserted in the two lower compartments. Note: No cables should be inserted in the middle vertical chambers. Repeat the bulleted steps above, at an interval of eight snap-on lids. Caution: Do not create pressure between the cables and the sidewalls of the IGUS Cable Carrier (refer to Figure 22). FC Rev. D Page 23 of 117

24 Vertical Separator Thinner Cable Horizontal Shelf Tilt and Snap-on Thicker Cable Figure 22: Shelving Separator Unit 6. Reassemble the snap-on lids all along the IGUS Cable Carrier. You may need to use a pair of pliers to assist you in this task (refer to Figure 23). Pair of Pliers Snap-on Lids Figure 23: Snapping Lids on IGUS Caution: Do not use a hammer to force the snap-on lids back on the IGUS cable chain. 7. Secure the IGUS Cable Carrier to the adaptor bracket on the Print Head carriage using: A 5 mm Allen key Four M6x16 screws (P/N: ) Four spring washers (P/N: ) Note: Use tie wraps to secure the cables to the IGUS walls at both ends of the IGUS Cable Carrier (P/N: and ). Page 24 of 117 FC Rev. D

25 Installing the IGUS Tube Carrier (Fresco HiQ 3200) Caution: When installing the IGUS Tube Carrier, carefully avoid hitting or damaging the Linear Encoder Scale. 1. Place the new IGUS Tube Carrier along the cable chain tray on the right of the Print Head carriage. 2. Lift the new IGUS Tube Carrier onto the cable chain tray and insert the hydraulic tubes (bundled up) into the cable duct, under the cable chain tray. 3. Route the tubes from the cable duct through the opening in the service cabinet above the Main Ink Tanks and secure the tubes with tie-wraps. You will connect the tubes at a later stage. 4. Secure the left F-shaped bracket (previously connected to the IGUS) to the right side cable chain tray using a 4 mm Allen key and the two M5x20 screws (P/N: ) (refer to Figure 21 and Figure 24). You will connect the hydraulic tubes on the IGUS Tube Carrier to the new SIT at a later stage. 5. Reconnect the air gun tube to the quick connector (removed in step 5/page 19) and reinstall the protective cover back in its original location (refer to Figure 18). 6. Secure the Right Side Tube IGUS to the adaptor bracket on the Print Head carriage using: A 5 mm Allen key Four M6x16 screws (P/N: ) Spring washers (P/N: ) Once installed, the IGUS appears as follows. IGUS Cable Carrier IGUS Tube Carrier F-Shaped Bracket Secured on Top of Existing Bracket Cable Chain Tray M6x20 4 Total M5x16 Circled 8 Total Figure 24: New IGUS Secured on Cable Chain Tray FC Rev. D Page 25 of 117

26 10. IGUS Replacement Fresco HiQ 1800 Both the Left Side IGUS Cable Carrier and the Right Side IGUS Tube Carrier must be replaced. For the Left Side IGUS Cable Carrier, the IGUS is removed without the cables that it encases the cables remain attached to the printer while the cable chain is replaced. For the Right Side IGUS Tube Carrier, the IGUS is removed with its tubes the tubes are removed with the IGUS. The new Right Side IGUS Tube Carrier comes equipped with the tubes inside. Note: This section refers to the Fresco HiQ 1800 printer only. If you are upgrading Fresco HiQ 3200, refer to section 9 on page 18. Note: Refer to Logistics on page 83 throughout this procedure for a listing of material disposition. The following terminology for the IGUS is used in this section: Complete Name Left Side IGUS Cable Carrier Right Side IGUS Tube Carrier Name Used in this Section IGUS Cable Carrier IGUS Tube Carrier Removing the IGUS Cable Carrier (Fresco HiQ 1800) 1. Position the Print Head Carriage as far right as possible. 2. Remove the cables from the IGUS Cable Carrier as follows: Start with the side connected to the Print Head carriage (refer to Figure 17). Position a flat screwdriver inside the lid's two openings and push slightly down to open the outer snap-on lids. Start from the left side to last snap-on lid on the outer radius of the IGUS Cable Carrier. Do not discard. Pull all the cables out of the IGUS Cable Carrier and lay them down. 3. Remove the four screws that secure the IGUS Cable Carrier to the left side of the Print Head Carriage using a 4 mm Allen key (see Figure 25). Page 26 of 117 FC Rev. D

27 4. Remove the two screws that secure the IGUS Cable Carrier to the IGUS tray at the center of the cable chain tray using a 4 mm Allen key (see Figure 26). Do not discard 5. Remove the IGUS Cable Carrier. Figure 25: IGUS Cable Carrier Print Head Connection (Before Upgrade) Figure 26: IGUS Cable Carrier Tray Connection (Before Upgrade) FC Rev. D Page 27 of 117

28 Removing the IGUS Tube Carrier (Fresco HiQ 1800) Note: When disconnecting tubes, use the silicon caps provided in your kit (P/N: and ) to cap all end tubes and SIT inlets. 1. Position the Print Head Carriage as far left as possible. 2. Disconnect the remaining tubes in the IGUS Tube Carrier, as follows: Disconnect the solvent tube from the 14-micron filter and from the flushing manifold using a 10 mm Allen key. Disconnect the air flush inlet tube from the air flush valve assembly. Inside the pneumatic cabinet, disconnect the air flush gauge. 3. Remove the two M5 screws that secure the IGUS Tube Carrier to the right side of the Print Head carriage using a 4 mm Allen key (see Figure 27). 4. Remove the two M5 screws that secure the IGUS Tube Carrier to the cable chain tray using a 4 mm Allen key (see Figure 28). Do not discard. 5. Remove the IGUS Tube Carrier. Figure 27: IGUS Tube Carrier Print Head Connection (Before Upgrade) Page 28 of 117 FC Rev. D

29 Figure 28: IGUS Tube Carrier Tray Connection (Before Upgrade) Installing the 8C Adaptor Brackets (Fresco HiQ 1800) 1. In the Kit, locate the IGUS brackets: Left and right IGUS-Print Head carriage adaptor brackets, which will be connected to the Print Head carriage, ( ). Left and right IGUS-tray adaptor brackets (P/N: ), which will be connected to the center of the cable chain tray. 2. Install the IGUS-Print Head carriage adaptor brackets on the Print Head carriage, as follows: Position the adaptor brackets on the Print Head carriage, where the previous IGUS was connected. Ensure that the bottoms of the adaptors are facing you as you place them on the Print Head carriage, as displayed in Figure 29. Secure the adaptor brackets to each side of the Print Head carriage using a 4 mm Allen key and four M5x16 screws (P/N: ) (refer to Figure 29). FC Rev. D Page 29 of 117

30 Figure 29: 8C IGUS-Print Head Carriage Adaptor Brackets 3. Install the IGUS-cable chain tray adaptor brackets as follows: Position the brackets on the cable chain tray, where the previous IGUS was connected. Ensure that the outer sides of the adaptors as displayed in Figure 30 and Figure 31 are facing away from the tray funnel. Secure the adaptor brackets to each side of the IGUS cable chain tray using the two slotted flat screws from the previous IGUS and a 4 mm Allen key. Figure 30: 8C IGUS-Tray Adaptor Bracket Left Side Figure 31: 8C IGUS-Tray Adaptor Bracket Right Side Page 30 of 117 FC Rev. D

31 Installing the IGUS Cable Carrier (Fresco HiQ 1800) 1. In the kit, locate the IGUS Cable Carrier (P/N: ). 2. Place the IGUS Cable Carrier on the cable chain tray. 3. Secure the cables along the IGUS Cable Carrier using the eleven shelving separators (from kit, P/N ) to (refer to Figure 22) as follows: Note: Make sure to install a shelving separator unit at each end of the IGUS Cable Carrier. Starting from the side of the cable chain tray, insert the shelving separator, one at a time, at a slight angle, inside the IGUS Cable Carrier and snap it on the lower lid. Push the shelving separator s vertical separators together to ensure that there is enough room to insert cables in the outer chambers. Insert the cables in the right and left compartments of the shelving separators, each in its own chamber. Ensure that cable FW30A and cable FW30B are inserted in the two lower compartments. Note: No cables should be inserted in the middle vertical chambers. Place shelving units in the IGUS Cable Carrier at an interval one shelving unit every eight snap-on lids. Caution: Do not create pressure between the cables and the sidewalls of the IGUS cable chain (refer to Figure 22). 4. Put back the snap-on lids all along the IGUS Cable Carrier. You may need to use a pair of pliers to assist you in this task (refer to Figure 23). Caution: Do not use a hammer to force the snap-on lids back on the IGUS Cable Carrier. 5. Secure the tray end of the IGUS Cable Carrier to the four holes of the IGUS-tray adaptor bracket using: Four socket screws (P/N: ) Four spring washers (P/N: ) Four flat washers (P/N: ) (refer to Figure 32) FC Rev. D Page 31 of 117

32 Figure 32: 8C IGUS-Tray Adaptor Bracket Left Side Screw Holes Once installed, the IGUS Cable Carrier appears as follows. Figure 33: 8C IGUS Cable Carrier Cable Tray Connection 6. Secure the Print Head carriage end of the IGUS Cable Carrier to the four holes of the IGUS-Print Head carriage adaptor bracket using: A 4 mm Allen key Four M5x16 screws (P/N: ) Four Spring washers (P/N: ) Four flat washers (P/N: ) (refer to Figure 34) Page 32 of 117 FC Rev. D

33 Figure 34: 8C IGUS-Print Head Carriage Adaptor Bracket Screw Holes Once installed, the IGUS Cable Carrier appears as follows. Figure 35 IGUS Cable Carrier Print Head Carriage Connection FC Rev. D Page 33 of 117

34 Installing the IGUS Tube Carrier (Fresco HiQ 1800) 1. In the kit, locate the IGUS Tube Carrier assembly (P/N: ). 2. Place the IGUS Tube Carrier on the IGUS tray. 3. Route the IGUS tubes through the tray funnel under the X-axis into the Service Cabinet (see section for details on tube connections). 4. Secure the tray end of the IGUS Tube Carrier to the four holes of the IGUS-tray adaptor bracket using the using: A 5 mm Allen key Four M6x16 screws (P/N: ) Four spring washers (P/N: ) Four flat washers (P/N: ) (refer to Figure 36) Figure 36: 8C IGUS-Tray Adaptor Bracket Right Side Screw Holes Page 34 of 117 FC Rev. D

35 Once installed, the IGUS Tube Carrier appears as follows. Figure 37: 8C IGUS Right Side Carriage Tray 5. Secure the Print Head carriage end of the IGUS Tube Carrier to the four holes of the IGUS-Print Head carriage adaptor bracket using: A 4 mm Allen key Four M5x16 screws (P/N: ) Four spring washers (P/N: ) Four flat washers (P/N: ) (refer to Figure 34). FC Rev. D Page 35 of 117

36 Once installed, the IGUS Tube Carrier appears as follows. Figure 38: 8C IGUS Right Side Print Head Both sides of the new IGUS-cable chain tray installation appear as follows: Left Side IGUS Right Side IGUS Figure 39: 8C IGUS Carriage Tray Installation Page 36 of 117 FC Rev. D

37 11. Tubes (Hydraulic) Connection for IGUS Note: You may need to shorten the tubes to fit them into their respective locations. Caution: Although the hydraulic tubes are labeled, make sure to verify that you connect each tube to its proper location. 1. Connect all tubes leading to the SIT as follows: Connect the eight pressure tubes (labeled, from IGUS) to the 8C SIT using a wrench (refer to Figure 8). Connect the eight vacuum tubes to the 8C SIT vacuum tubes connectors using a wrench (refer to Figure 8). Reconnect the four purge tubes to the Y-connector of the 8C SIT (refer to Figure 8). 2. Reconnect the solvent tube to the flushing manifold. 3. Reconnect the air flush tube to the air flush assembly. 4. Reconnect the four purge tubes to the purge valve manifold (refer to Figure 10). 5. Reconnect the solvent tube to the solvent 14-micron filter. 6. Reconnect the air flush tube to air flush valve, in the pneumatic panel. FC Rev. D Page 37 of 117

38 12. Installing the Switch-Blocks In the 8C upgrade, both 8 color and 4 color printing is possible. The Switch Blocks enable you to switch between the two color settings. Drilling Holes in Service Cabinet Wall 1. Tape the jig (from kit, P/N: ) to the wall of the service cabinet so that the bottom left corner is approximately 1 cm above the cable opening and approximately 1 cm to the right of the cable opening, as displayed in Figure 40. Figure 40: Jig Location 2. Drill four holes through the jig holes using a drill and 4 mm drill bit (P/N: ). 3. Remove the jig. Page 38 of 117 FC Rev. D

39 Installing the Switch Blocks The Switch Blocks (P/N: ) arrive connected to cable # and to 6 mm tubing. Install the Switch Blocks as follows: 1. Position the adaptor bracket with the hole facing up, onto the wall of the service cabinet so that the adaptor holes (see Figure 41) align with the holes on the wall. Hole Facing Up Figure 41: Adaptor Bracket 2. Secure the Switch Blocks to the upper holes (refer to Figure 42) using the rivet gun (P/N: ) and the rivets (P/N: ) as follows: Insert a rivet into the rivet gun, with the long end in first (refer to Figure 42). Figure 42: Rivet Gun Align the rivet gun with the upper left hole on the adaptor bracket, and squeeze the gun several times until the rivet is firmly inside the hole and the gun is freed (refer to Figure 43). FC Rev. D Page 39 of 117

40 Holes to Support Rivets Cable # Switch-Block Adaptor Bracket Figure 43: Left (C and M) Switch-Block for Installation Purpose Only 3. Repeat the above steps for the right hole. 4. Drill the two bottom holes directly through the adaptor plate using a drill and 4 mm drill bit (P/N: ). 5. Repeat step 2 above to insert the rivets into bottom holes (refer to Figure 43). 6. Secure the Black (K) and Yellow (Y) Switch Block to the right side of the adaptor bracket using the screws (P/N: ), spring washers (P/N: ) and flat washers (P/N: ) (refer to Figure 44). Hole on Adaptor Bracket Adaptor Bracket Switch Block Y and K Figure 44: Switch Block Y and K on Adaptor Bracket Page 40 of 117 FC Rev. D

41 7. Secure the Cyan (C) and Magenta (M) Switch Block to the left side of the adaptor bracket as described in step Installing the Light Main Ink Tanks Assembly 1. Unscrew the four M5 screws from the floor of the service cabinet using a 4 mm Allen key. The location of the screws is indicated in Figure 45 below. Do not discard the screws. 4 1 Back Screw 3 2 Figure 45: Cabinet Floor Location of Light Main Ink Tanks Note: Make sure that the drainage valve bracket on the light Main Ink Tank (MIT) assembly is facing out (refer to Figure 46). 2. Position the new light MIT assembly onto the floor, across from the existing one. Make sure to lift the new tank unit high enough to insert the back screw into the back hole of the Main Ink Tanks (refer to Figure 45). 3. Secure light MIT assembly onto the floor with the screws removed in step 1 above using an Allen key, as follows: Remove the cable duct cover, on the light ink tank (refer to Figure 46). FC Rev. D Page 41 of 117

42 Y C M K Vacuum Fitting Cable Duct Cover Pressure Fitting Cable Duct Figure 46: Light Ink Tanks Front View Since the M5 screw is too short, you must first secure the screw (1) and its washers with white tape to the Allen key, then insert into hole of cable duct and tighten (refer to Figure 45 and Figure 47). Back Screw Hidden 4 Draining Manifold Y C M K Cable Duct Cover Cable Duct Screw to Secure Light Ink Tanks 3 1 Screws Location Circled 2 Figure 47: Light Main Ink Tanks Side View Page 42 of 117 FC Rev. D

43 Tighten screws 2 and 3 back in place to secure the light MIT assembly (refer to Figure 45 and Figure 47). Tighten the fourth screw (4) behind the light MIT assembly using an L-shaped Allen key. Secure with tape as above (refer to Figure 45 and Figure 47). Figure 48 displays the service cabinet after installing the light MITs. Purge Valve Bracket Cable Duct Dark Filters Light MITs Dark SIT Drainage Duct Light Filters Figure 48: Front View of the Service Cabinet after Installation FC Rev. D Page 43 of 117

44 14. Switch Block Hydraulic Connections The steps below described the hydraulic connections of all tubes leading in and out from the Switch Blocks. The order described below is from the right Switch Block Black (BK) and Yellow (YL) colors, to the left Switch Block Magenta (M), and Cyan (C) colors. Preparation Note: Place several cloths on the Service Cabinet floor to absorb all spilled ink. Note: Make sure to use tie-wraps to secure all tubes leading in and out of the Switch Blocks. 1. Remove electro valve 5C, 6C, 7C, and 8C, from the Yellow and Black Switch Block, to create easier access to the SIT outlet fittings (refer to Figure 49). 2. Remove electro valves 1B, 2B, 3B, and 4B from the Yellow and Black Switch Block, to create easier access to the SIT outlet fittings (refer to Figure 49). Figure 49: Switch Block Electro-Valves Location Page 44 of 117 FC Rev. D

45 Figure 50: Switch Block Bottom View Connecting the Pressure Tubes to Light and Dark Filter Outlets 1. Locate the tube, labeled "Dark K P Filter" (A) on the bottom Black (K) section of the Switch Block, and connect it to the bottom of the dark black filter outlet using an 11 mm wrench (refer to Figure 51 and Figure 52). 2. Locate the tube, labeled "Light K P Filter" (B) on the bottom Black (K) section of the Switch-Block, and connect it to the bottom of the light black filter outlet using an 11 mm wrench (refer to Figure 51 and Figure 52). FC Rev. D Page 45 of 117

46 3. Repeat the steps above for the remaining three colors (refer to Figure 51 and Appendix D, DRW# ). Definition: P=Pressure V=Vacuum K=Black Y=Yellow Electro Valve E: Light Y P Outlet to SIT E: Light K P Outlet to SIT C: Light Y V P H: Light Y V Inlet to SIT H: Light K V Inlet to SIT B: Light Y P Filter A: Dark Y P Filter B: Light K P Filter A: Dark K P Filter C: Light K V Pump Bottom Left Side Switch-block Yellow (Y) Color Bottom Right Side Switch-block Black (K) Color Figure 51: Right Switch-Block Bottom View Black and Yellow Colors Page 46 of 117 FC Rev. D

47 Solvent Filter Draining Cap Circled Dark Ink Filters Light Ink Filters Figure 52: Bracket with Dark and Light Filters Note: Before connecting any tubes to its fitting, make sure to remove the 10 mm nut from that fitting, insert the nut into the tube then use an 10 mm wrench to secure the tube (and nut) to the fitting. FC Rev. D Page 47 of 117

48 Connecting the Vacuum Tubes to Light and Dark Main Ink Tanks 1. Locate the tube, labeled "Light K V Pump" (C) on the bottom Black (K) section of the Switch Block, and connect it to the vacuum fitting (T-connection), of the Black Light Main Ink Tanks (refer to Figure 51 and Figure 53). Y C M K Vacuum Fitting T-connection Cable Duct Cover Pressure Fitting T-connection Cable Duct Figure 53: Light Ink Tanks Front View 2. Locate the tube, labeled "Dark K V Pump" (D) on the top Black (K) section of the Switch Block, and connect it to the Black Dark Main Ink Tank s vacuum pump (T-connection fitting) (refer to Figure 51, Figure 53, and Appendix D, DRW# ). 3. Repeat the above steps for the remaining three colors (refer to Figure 51 and Appendix D, DRW# ). Page 48 of 117 FC Rev. D

49 Connecting the Pressure Tubes to Light Secondary Ink Tanks (SIT) 1. Locate the IGUS chain tube labeled "Light K P SIT" (E) and connect it to the Switch Block fitting behind the electro valve (refer to Figure 54). D: Dark Y V Inlet From Dark SIT J: Dark Y V Pump Inlet to Dark Main Ink Tanks F: Dark Y Pressure Outlet to Dark D: Dark K V Pump Outlet to Dark Main Ink Tanks J: Dark K V Inlet From Dark SIT F: Dark K Pressure Outlet to Dark Top Right Side Switch-block Yellow (Y) Color Top Right Side Switch-block Black (K) Color Figure 54: Right Switch Block Top View Black and Yellow Colors 2. Repeat the above step for the remaining three colors (refer to Appendix D, DRW # ). Connecting the Vacuum Tubes to the Dark SITs 1. Locate the tube from the IGUS chain, labeled "Dark K V SIT" (J) and connect the tube to its fitting on the top section of the Switch Block (refer to Figure 53 and Figure 54). 2. Repeat the above step for the remaining three colors (refer to Appendix D, DRW # ). Connecting the Pressure Tubes to the Dark SITs 1. Locate the tube from the IGUS chain, labeled "Dark K P SIT" (F) and connect the tube to its fitting on the top section of the Switch Block (refer to Figure 54). 2. Repeat the above step for the remaining three colors (refer to Appendix D, DRW # ). FC Rev. D Page 49 of 117

50 Connecting the Vacuum Tubes to the Light SITs 1. Locate the tube, from the IGUS chain, labeled "Light K V SIT" (H) and connect the tube to its fitting behind the electro valve (refer to Figure 51). 2. Repeat the above step for the remaining three colors (refer to Appendix D, DRW # ). Reconnect all Electro Valves Previously Removed 1. Connect electro valve 5C, 6C, 7C, and 8C, from the Yellow and Black switch-block (refer to Appendix D, DRW ). 2. Connect electro valves 1B, 2B, 3B, and 4B from the Yellow and Black switch-block (refer to Appendix D, DRW ). 15. Screwing the 8C Filter Bracket to the Chassis Wall Secure the 8C Filter Bracket to the chassis wall where the old bracket was mounted using an Allen key, the screws removed from the previous bracket (refer to Figure 48) and two spring washers from the kit (P/N: ). Use the screw holes specific to your printer, as indicated in Figure 55. Fresco HiQ 1800 (first models) Fresco HiQ 1800 Fresco HiQ 3200 Figure 55: Two Level Filter Bracket Screw Holes Page 50 of 117 FC Rev. D

51 16. Connecting Filter Ink Inlet Tubes 1. Locate the ink pressure tubes that are connected to the pressure pump (lower) at the base of each MIT. 2. Connect the tube to the inlet quick connector at the top of each 5-micron filter using an 11 mm wrench. Ensure to connect each to tube to its proper color filter. 3. Repeat steps 1 and 2 for each color. 17. Installation of the 8C Ink Pump Control (IPC) and Ink I/O Board Note: Refer to the Logistic Section on Page 83 throughout the implementation of this upgrade to correctly identify the parts that need to be removed and/or replaced, as well as, the correct screws needed to perform the procedure. Labeling and Preparation 1. In the kit locate the following labels: P/N Description DARK IPC LABEL 12X20 BLACK FOR CABLE LIGHT IPC LABEL 12X20 BLACK FOR CABLE DARK PUMPS LABEL 12X50 BLACK FOR CABLE LIGHT PUMPS LABEL 12X50 BLACK FOR CABLE LABEL FOR GI/O LABEL (FOR GI/O) 12X50 BLACK FOR CABLE 2. Label the existing Ink Pump Control (IPC) Board and its cables with new labels (from kit) as follows (refer to Figure 57): Label the Ink Vacuum and Pressure cable # as "Dark Pump" at the three cable endings (refer to Figure 57). Label the IPC Board as "Dark" placing the label on the right lower corner (refer to Figure 57). FC Rev. D Page 51 of 117

52 8C COMM Cable # Cable # Dark Label on Dark IPC Board Cable Ducts Covers Dark Pumps Label on Cable # (Vacuum & Pressure Pumps) Figure 56: Ink Control Card with New Labels IPC Board Plastic Duct Hole for New Rail Circled Orange Mount CB, HTB and Timer Rail Figure 57: IPC Board in Service Cabinet 3. Apply label # on the GI/O # 1 board box above the LEDs and above label # (refer to Figure 58 and Figure 59). Page 52 of 117 FC Rev. D

53 Figure 58: GI/O#1 Board Box with New Labels in Service Cabinet Figure 59: GI/O#1 Board Box Schematics 4. Remove all the cable duct plastic covers on the panel (refer to Figure 57). 5. Remove the top cover of the aluminum cable duct above the purge valve manifold and replace with the three-section wall profile (P/N: ). FC Rev. D Page 53 of 117

54 6. Cut small sections to fit each end of the cable duct top-cover (from step above) using the long rubber bumper/gasket (P/N: ) to (refer to Figure 60). Note: Older printers do not have aluminum cable ducts. Therefore, users of these printers can ignore steps 5 and 6. Figure 60: Cable Duct Top Covers Below Purge Valves (Rubber Bumper on Edges) Installing the Light IPC Board 1. In the kit, locate the following: P/N Description LIGHT IPC BOARD EXTRUDED PROFILE FOR INK CONTROL ASSY DIN RAIL FOR FRESCO 8C The Extruded Profile for the IPC Board assembly kit (P/N: ) contains the following: P/N Description END PLATE PLASTIC,POLYAMID MOUNTING FOOT PLASTIC,POLYAMID EXTRUDED PROFILE PLASTIC RS-SP1 (TAPUZ) 0.25M 2. Mount the Light IPC board and its orange frame as follows: Turn the orange frame of the light IPC Board on its back and insert the two snap-on clips. Make sure that the hollow ends are up. Slide the Light IPC Board (from kit) into the orange frame. Secure the Light IPC Board by inserting both end sections into the orange frame. 3. Verify that the existing rail that holds the Circuit Breaker (CB) is long enough to support the new Light IPC Board (refer to Figure 57). 4. If the current rail is too short, you must replace it with the new longer rail (from kit, P/N: ) as follows: Remove the Terminal Block (TB) fixture on each side of the CB and the TB using a flat screwdriver to (refer to Figure 62). Page 54 of 117 FC Rev. D

55 Remove the CB, timer, and the TB from the rail. You may need to use a flat screwdriver for the yellow TB (refer to Figure 62). Remove M4 screws that secure the short rail to the wall using a 3 mm Allen key (refer to Figure 57). Discard short rail and keep the screws for later use. Attach the long rail (from kit) in place of the previous one using: A 4 mm Allen key to screw in the two screws from the step above One M5x10 screw from the kit (P/N: ) A spring washer (P/N: ) A flat washer (P/N: ) (refer to Figure 62). 5. Position the CB, Timer, and the TB on the new rail at the same location they were at when removed from the previous rail. 6. Reinstall the two TB fixtures from the above step (refer to Figure 61). Circuit Breaker TB Fixture Unit Timer Figure 61: CB and HTB on Rail Yellow TB Hydraulic Tunnel Block (HTB) 7. Snap the assembled Light IPC Board onto the existing rail, next to the CB and Hydraulic Terminal Block (HTB) (refer to Figure 62). 24VDC TB Screw From Ki Ci l d Long Rail (From kit) Five Pins Terminal Cable # Light IPC Label Cable Duct Figure 62: Light IPC Board and Labeled Cables FC Rev. D Page 55 of 117

56 8. Use the label (from kit) to label the IPC Board as "Light." Once installed and labeled, both IPC Boards appear as follows. Figure 63: Light and Dark IPC Boards Installing the Ink I/O Board 1. Locate the Ink I/O Board Location, displayed in Figure 64. Bores Ink I/O Board Location Rail with Two M5 Screws (Hidden Behind Dark IPC) 2. Remove the Dark IPC Board from its rail. Figure 64: Rail and Ink I/O Board Location Page 56 of 117 FC Rev. D

57 3. Replace the half length rail with the full length rail from the kit P/N: (see Figure 65) as follows: Note: This step can be ignored if you already have the full-length rail installed on your printer. Remove the short rail from the wall using a 3 mm Allen key to unscrew the screws. Discard the short rail and retain the screws. Figure 65: Longer Rail (P/N: ) Secure the long rail from the kit in place of the old one using the 3 mm Allen key the two screws from the step above. 4. Locate the I/O Ink Board and Accessories, displayed in the Figure 66. The Ink I/O Board and accessories comprises the following parts: P/N Description INK I/O 24 BOARD ASSEMBLY EXTRUDED PROFILE FOR INK CONTROL ASSY END PLATE PLASTIC,POLYAMID MOUNTING FOOT PLASTIC,POLYAMID Extruded Plastic Profile I/O Ink Board Mounting End Plates Figure 66: I/O Ink Board and Accessories 5. Mount the Ink I/O Board in its plastic base, as follows: Slide the Ink I/O Board onto the Extruded Plastic Profile. Locate the Ink I/O Board and slide both Mounting Feet on its back. Snap the End Plates on each end of the I/O Ink profile. 6. Snap the Dark IPC Board on to the right side of the rail. 7. Snap the Ink I/O Board on to the left side of the rail. FC Rev. D Page 57 of 117

58 18. Cable Installation Refer to the relevant schematic drawings in Appendix D throughout the cable connection process. Note: Make sure that you secure all cables with tie-wraps as often as necessary, use tie wraps (P/N: and ) from kit. Cable # : 24 VDC Power Input to the IPC Board Connect the new cable # as follows: 1. Disconnect the FW91 wires from TB (J3) in the dark IPC Board using a flat screwdriver. 2. Disconnect the wire pins from Hydraulic Terminal Block (HTB) using a flat screwdriver. 3. Cut the tie-wraps securing the FW91 cable; pull the cable out, and discard. 4. Connect the cable # to HTB as follows (refer to Appendix D): Red wire to the +24V TB # 4. Black wire to the 0/24V TB # Connect the cable # to the two IPC boards as follows: Red wire to +24 V (first pin from right). Black wire to 0/24 V (second pin from right). Make sure to connect the shorter cable to the light IPC board J 3 terminal and the longer cable to the dark IPC board J 3 terminal. 6. Route the cable throughout the cable duct. Connecting Cable # Communications Cable Connect the new cable # as follows: 1. Disconnect the FW29 communications cable as follows: Remove the two screws securing the D-Type connector of the existing FW29 cable on the dark IPC Board using a flat screwdriver, and cut the tie-wraps to free the cable. Route and secure the FW29 cable through the open cable ducts closer to the light IPC Board (refer to DRW # in Appendix D). This cable will be connected at a later stage. Page 58 of 117 FC Rev. D

59 2. Connect the 8C Communications Cable # to both light and dark IPCs and I/O Ink boards as follows (refer to DRW # and the drawings entitled 8C Dark Ink Control Board Wiring and 8C Light Ink Control Board Wiring in Appendix D): Connect the D-type connector, labeled " I/O to Comm, J2" to the Ink I/O board (P1) connector using a flathead screwdriver. Connect the D-type connector labeled " IPC Dark P3" to the dark IPC board (P3) connector using a flathead screwdriver. Connect the D-type connector labeled " IPC Light P3" to the light IPC board (P3) connector using a flathead screwdriver. 3. Connect the D-type connector labeled " FW 29" to the D-type connector of the cable FW 29 you disconnected in Step 1 above using a flathead screwdriver. Connecting Cable # Main Ink Tanks Float Sensors Connect the new cable # as follows: 1. Disconnect the current FW71 cable, Main Ink Tanks float sensor as follows: Use a flat screwdriver to unscrew the two screws securing the D-Type connector to GIO-1 board (J1) (refer to Appendix D). Note: Cut the tie-wraps as required to free the cable. Locate cable FW71 in the cable duct, at the base of the dark MITs. Disconnect cable FW71 s Molex connectors from cable FW71A s (K and M) Molex connector (refer to Appendix D). Disconnect cable FW71 s Molex connectors from cable FW71B s (Y and C) Molex connector (refer to Appendix D). 2. Disconnect the current FW75 cable, Main Ink Tanks float sensor 24V power supply cable, as follows: Locate cable FW75 in the cable duct, at the base of the dark MITs. Disconnect cable FW75 s 2-pin Molex connector. Route the Molex connector through the cable duct near the light MITs and secure with tie-wrap near the purge valve (refer to Appendix D). You will connect the 2-pins Molex connector to cable # in the next step. 3. Connect the new cable # (from kit) as follows: Use a flat screwdriver to connect the D-Type connector of the new cable # to GIO-1 board J1 port, in place of the previous cable (refer to Appendix D). FC Rev. D Page 59 of 117

60 Secure the cable # with tie-wraps and route it through the plastic cable (below GIO-1 board) and left side cable ducts. Route the longer section of the cable # (see labels on cable) towards the cable duct at the base of the dark MITs and connect the two 6-pin female Molex connectors to the FW71A (K and M ports) and FW71B cables (C and Y ports), respectively (refer to Appendix D). Route and secure the shorter end of cable # (see labels on cable) towards the cable duct at the base of the light MITs and connect the two 6-pin female Molex connectors to the FW71A (K and M ports) and FW71B cable (C and Y ports), respectively (refer to Appendix D). Connect the 2-pin Molex connector of the FW75 to the cable wire # pin Molex connector. Connecting Cable # to the Light IPC Board Pressure and Vacuum Pumps Input Connect the new cable # (from kit) as follows: 1. Connect the D-Type connector of the new cable # to the P2 of light IPC Board and secure with tie-wrap the far end close to the light ink tanks. 2. Label the cable (from kit) at both ends, as "Light Pumps." 3. Route the cable to the cable duct at the base of the light MITs. 4. Open the cable duct if it is not already opened. 5. Connect cable # labeled Pres to the four light Pressure Pumps as follows: Connect the 4 Molex connectors on the branch to each of the 4 Molex connectors connected to the Pressure Pumps, according to the color of the isolation tube. 6. Connect the branch of cable # labeled Vac to the newly installed light vacuum pumps, as follows: Connect each of the 4 Molex connectors on the branch to the Vacuum Pumps according to the color of the isolation tube. 7. Close the cable duct. Page 60 of 117 FC Rev. D

61 Connecting Cable # Connect the new cable # as follows: Note: Make sure that the color wires connected from one end of the cable to the light IPC board J1 terminal match the wires connected at the other end to the dark IPC board J1 terminal. 1. Connect the 8C Input from the SIT float sensor to Light IPC cable # as follows: Note: Do this procedure one color wire at a time on the dark IPC board. Disconnect the green wire from the J1 terminal on the dark IPC board. Locate the green wire (GN) on the cable # labeled " IPC Dark J1" (refer to DRW in Appendix D). Cut the pin terminal from the wire. Insert both green wires from above into the pin terminal and use the crimping tool to tighten the wires and the pin together. Insert the pin terminal back into the J1 terminal of the dark IPC board (refer to DRW # and DRW # in Appendix D). 2. Repeat the above procedure for the remaining Brown (BR), Pink, Grey (GR), and Yellow (YL) colored wires. Again, perform the connection one-color wire at a time. 3. Connect the distal end of cable # to the J1 terminal on the light IPC board. Make sure to connect the wires in the same order as the ones on the dark IPC board (refer to DRW # in Appendix D). FC Rev. D Page 61 of 117

62 Ink I/O Cable # (P4) Cable # (P1) Cable # Light (P3) Cable # Light (J3) Light IPC Cable # Dark (J3) Cable # Dark (P3) Cable # Dark (P2) Dark IPC Cable FW52 Dark (J1) Cable FW92 Dark (J2) Cable FW52 Light (J2) Cable # Light (P2) Figure 67: IPC and I/O Ink Boards Connecting Cable # from the Switch Blocks to I/O Ink Board and HTB Note: Refer to Appendix D, DRW # , DRW # , DRW # , and DRW # to connect cable # Cable # , which arrives connected to the Switch Blocks, must be connected to the I/O Ink Board and to the Hydraulic TB (HTB). Connect Cable # to the I/O Ink Board and to the Hydraulic TB (HTB) as follows: 1. Connect the main (gray) cable # to the I/O Ink Board s P4 terminal. 2. Connect cable # s thin red and black wires to the HTB as follows: Red wire labeled +24V TB Hydr to +24V on the TB #1 (from Switch Block CM). Red wire labeled TB to +24V on the TB#3 (from Switch Block YK). Black wire labeled TB to 0/24V, on the TB # 2 (from Switch Block YK). Page 62 of 117 FC Rev. D

63 19. Installing the Dell 530 Workstation The Fresco 8C upgrade requires a new Dell workstation running the Windows XP operating system. This replaces the existing Fresco Dell workstation. Install the new Dell 530 Workstation as follows: 1. Remove the currently installed Dell workstation from the printer. 2. In the kit, locate the new Dell 530Workstation - Dell 530 Dual CPU Xenon 1.7 GHz with Windows XP Pro Operating system (P/N: ). 3. Remove the Dell workstation and its accessories from the box and place it at the same location where the previous workstation was installed. 4. Connect all cables to the new Dell workstation 530 that were disconnected from the previous Dell workstation, including: FW30A and FW30B Com 1 FW26 to Galil controller Com 2 PC Com Interface, (RS 232) to ADAM communication converter board Network com Monitor Keyboard and mouse (new) Use the Y-adaptor to connect the monitor to the new PC (refer to Figure 68) Y-Adaptor Connector Monitor to PC Connection Circled Figure 68: Y-adaptor Connecting Monitor to PC FC Rev. D Page 63 of 117

64 5. Install the mouse shelf (from kit, P/N: ) as follows: Lift up the front hood of the operator console to access the rail where the mouse pad bracket is to be installed. Unscrew the right most screw using a 3 mm Allen key to (refer to Figure 69). Align the mouse pad bracket to the hole and tighten the screw. Allen Screw Encircled Mouse Pad Bracket Figure 69: Mouse Shelf Location 6. Pack the removed Dell workstation in the box that the new workstation was shipped in (refer to Material Disposition on page 89). Page 64 of 117 FC Rev. D

65 20. FPP Board and Driver Installation Removing the Previous FPP Board 1. Unplug the Dell workstation then use a flat screwdriver to unscrew the FPP board s two D type connection screws from the previous Dell PE1300 PC 2. Open the Dell workstation s cover to remove the FPP board. Caution: Hold the FPP Board from its outside edges (as you would hold a picture) to avoid any Electrostatic Discharges (ESD) that may damage the FPP board. 3. Use a Phillips screwdriver to unscrew the four 3/16" Phillips screw on the FPP board and pull the FPP board from its bracket. Do not discard. Installing the New FPP board 1. Insert the new bracket (P/N , from kit) into the FPP board. Make sure the LED is inside its appropriate hole within the bracket (refer to Figure 70, Figure 72, and Figure 73). Slot LED's Hole D-Type Bracket P/N # Connection Slots (from Kit) Figure 70: New Bracket 2. Make sure the Dell workstation is unplugged and lay it on its side. Slide the handle to open the protective side cover. 3. Open the green latch to access the FPP board (refer to Figure 71). FC Rev. D Page 65 of 117

66 Green Latch D-Type Connection Slot Figure 71: Green Latch and D-types Connection 4. Insert the four 3/16" socket screws (from old FPP board) into the new FPP board's bracket and tighten (refer to Figure 70, Figure 72 and Figure 73). Bracket From Kit Four 3/16 Screws LED's Slot FPP Board LED Slot Figure 72: FPP Board and Parts from Kit Correct Bracket Assembly LED Figure 73: FPP Board with Bracket Page 66 of 117 FC Rev. D

67 Note: Verify that the FPP board's LED is inside the hole of the bracket (from kit) (refer to Figure 73). 5. Pull on the green latch to release the covers and lift up (refer to Figure 71). 6. Remove the third cover from top (refer to Figure 71). 7. Insert the FPP board into the slot and push to lock the pin within the bracket (refer to Figure 74). Push on the Side of the PC's Frame to Align Pin with Slot Nut Under Phillips Screw From Kit PC Bracket Pin in Slot Figure 74: FPP Board installed with Nut from Kit Note: Make sure that the pin is aligned with the slot (refer to Figure 74). 8. Insert the nut (from kit, refer to Figure 75) from the D-type location slots, to align the nut with the FPP board's bracket. Use a Phillips screwdriver to screw in the Phillips screw as you push sideways on the Dell workstation s bracket (refer to Figure 74). Nut (from Kit) P/N # Phillips Screw P/N # Figure 75: Nut and Screw from Kit 9. Make sure the bracket is correctly positioned then push the green latch down and close the Dell workstation cover. FC Rev. D Page 67 of 117

68 FPP Driver Installation 1. Once the FPP board is installed, turn on the Dell workstation. 2. The Found New Hardware wizard is activated and the Install window appears. Note: If the pop-up window fails to appear click Start > Settings > Control Panels > Add Hardware to access the window. Figure 76: Install Window 3. Select Install from a list or specific location (Advanced) and click Next. The Choose Search and Install Option window is displayed. Figure 77: Choose Search and Install Option Window Page 68 of 117 FC Rev. D

69 4. Select Don't search, I will choose the driver to install and click Next. The Hardware Type window is displayed. Figure 78: Hardware Type Window 5. Ensure that Show All Devices is selected and click Next. The Device Driver window is displayed. Figure 79: Device Driver Window 6. Insert the PrinTop ver CD (P/N: ) into the CD ROM drive. FC Rev. D Page 69 of 117

70 7. Select {Standard CD-Rom drives} and click Have Disk. The Install from Disk dialog box is displayed. D:\ Figure 80: Install from Disk Dialog Box 8. Click Browse The Locate File dialog box is displayed. Figure 81: Locate File Dialog Box 9. Select Plotpro.inf, and click Open. The Select Device Driver window is displayed. Page 70 of 117 FC Rev. D

71 10. Click Next. 11. Click Finish and restart the computer. Figure 82: Select Device Driver Window FC Rev. D Page 71 of 117

72 Updating the FPP Driver (Plotpro.inf) Once installed, the FPP driver must be updated. To update the FPP driver: 1. Click Start > Settings > Control Panel > System. The System Properties window is displayed with the General tab selected. 2. Click the Hardware tab. Figure 83: System Properties Window with Device Manager Tab Page 72 of 117 FC Rev. D

73 3. Click Device Manager. The Device Manager window is displayed. Figure 84: Device Manager Window 4. Select Plotpro. The Plotpro Properties window is displayed with the General tab selected. Figure 85: Update Driver Window FC Rev. D Page 73 of 117

74 5. In the Driver tab, click Update Driver. The Hardware Update Wizard begins running. Figure 86: Hardware Update Wizard 6. Select Install from a list or specific location (Advanced), and click Next. The Search Installation Options window is displayed. Figure 87: Installation Options Window Page 74 of 117 FC Rev. D

75 7. Select Don't search, I will choose the driver to install, and click Next. The Select Device Driver window is displayed. Figure 88: Select Device Driver Window 8. Click Have Disk. The Install From Disk dialog box is displayed. Figure 89: Install From Disk Dialog Box 9. Click Browse. The Locate File dialog box is displayed. Figure 90: Locate File Dialog Box FC Rev. D Page 75 of 117

76 10. In the Plotpro Drive folder, select Plotpro, and click Open. 11. Click OK > Next > Finish to complete the installation. 12. Restart the workstation. 21. Installing the PrinTop Application 1. In the kit, locate PrinTop ver for Fresco HiQ SW Package (P/N: ). 2. Insert the PrinTop CD into the CD ROM drive and follow the installation instructions. 22. Final Tasks 1. Discard unnecessary parts (refer to Material Disposition section page 89). 2. Clean the printer and its surrounding environment. 3. Close all cable ducts cover in the service cabinet. Calibrating the Print Head Plate 1. Use the calibrating kit to calibrate the Print Head plate as described in Appendix C. 2. Reinstall the spittoon. Installing the Print Heads 1. Reinstall all the Print Heads as described in Appendix B. 2. Install the new Print Head cover shield (from kit, P/N: ). System Flushing 1. Fill each light MIT with 1 liter (0.25 gallons) of solvent (flushing fluid) and continue with the rest of the procedure as described in Appendix A: Ink Flushing System on page 91. To flush the dark MITs, you may use the solvent that remains in the dark MITs from the flushing procedure performed at the beginning of the upgrade. 2. In PrinTop, change the print mode to 8C. 3. Circulate solvent in the system and flush the system with solvent as described in the Ink System Flushing in Appendix A. Page 76 of 117 FC Rev. D

77 New Printer's Label Place the new label (from kit) below the existing label as show below (refer to Figure 91). Existing Label on Printer Figure 91: New label to Add below Existing Label on Printer New Label (from kit) 23. Installing NUR Flash 1.2 Install the NUR Flash software at the customer s RIPping station as described in the NUR Flash Release Notes (P/N: and P/N: ) provided in the kit. 24. Testing System Check The following steps should be performed after completing the upgrade: 1. Check the Light Main Ink Tank Floats as follows: Fill each ink tank with its respective color. Verify that the corresponding LED is ON (on GI/O #1). 2. Check that all hydraulic tubes are connected to their respective location as follows: In PrinTop, select the Ink tab. Select C (cyan) to activate the dark cyan pump. Verify that cyan ink fills the pressure tube and that cyan ink is present in the vacuum tube. Repeat this test for all remaining seven colors, one at a time. 3. Press each purge valve and verify that the proper ink comes out of the Print Head. FC Rev. D Page 77 of 117

78 4. Manually move the Print Head carriage to check if the electrical cables on the left IGUS cable chain are pinched, entangled, or obstructed. Caution: Before switching on the 24V ink system powers supply CB, verify that all connections and changes specified in this FCO have been performed correctly. IPC Board Diagnostics LEDs The following table explains the meanings of the LEDs on the IPC board. Each group of indicators includes four LEDs, one for each color. LED Vacuum Ink Pumps Pressure Ink Pumps Purge Valves Secondary Ink Tank Floats System Status when Lit Vacuum Ink Pumps are operating. Pressure Ink Pumps are operating. Purge is taking place. Ink in Secondary Ink Tanks has reached maximum level. Testing the SIT Assembly s Height Verify that the Ink level at the SIT tanks is up to spec, as follow: 1. Activate the ink system and verify that ink is moving in and out of the SIT. 2. Connect a 4 mm tube (P/N: ) using quick male connectors (P/N: ) to the Ink Outlet of black Print Head s #7,8. 3. Place the tube in front and parallel to the black Print Head #8. 4. Verify that the distance between the lower nozzle of the Print Head and ink level in the tube is no more than 13 mm (refer to Figure 92) 5. If the level is lower than 13 mm, check other elements that could affect the ink pressure (IPC board, filters, restrictors and tubes). Page 78 of 117 FC Rev. D

79 Figure 92: Calibration of the SIT Assembly. Checking Transistor Voltages 1. Switch on the 24V Ink System CB. 2. Using a voltmeter, place one of the voltage probes on the 0V terminal (W92 BR). 3. Place the other probe at the following transistors on the IPC board. The readings should appear according to the following table: Transistor Voltages Check Transistor Desired Value Enter Measured Value Vacuum +6 volt ±10% Pressure +10 volt ±10% Purge +24 volt C M Y K Checking Purge Valve Outlets The system should perform purges at regular intervals according to software settings. Verify that the system performs purge correctly for each color and that purge LEDs on IPC board are lit during the purge. Purge Check C M Y K Purge Occurs Purge LEDs FC Rev. D Page 79 of 117

80 Checking Secondary Ink Tank Float When the float in each reserve ink tank reaches its highest point, the appropriate indicator light on the IPC board should light up and three seconds later, the corresponding ink pressure pump motor should be automatically switched off. Note: Before performing the following check procedure; disconnect all air pressure tube from Print Head carriage to avoid ink flooding. To check ink float logic, perform the following procedure for each of the four ink colors separately: 1. Ensure that the 24V power supply is switched on. 2. Disconnect the connection to vacuum pump motor (upper connection). 3. Verify that the ink reserve tank fills up. Verify that when the float reaches its maximum height, the appropriate LED on IPC board is lit. 4. Verify that the pressure pump motor for the color being tested switches off automatically after 3 seconds. 5. Repeat steps 2 4 for each ink color. 6. Reconnect the connection to vacuum pump motor. Color LED Pressure Pump Stops C M Y K Ink I/O Switch Block Test: Using the Debug Software Note: If the Switch Blocks Debug Software is not activated properly, it can cause color-mixing problems. Make sure to follow the instructions described below carefully to ensure proper software implementation. Preparation and Software Installation Before installing the software, perform the following: 1. Shut down PrinTop. 2. Turn off the 24V CB. Page 80 of 117 FC Rev. D

81 3. Disconnect the float cables from the J3 port on both IPC board terminal blocks to cut off the IPC boards power (see Appendix D). 4. Turn ON the 24V CB. Install the Ink I/O Switch Block Test software as follows: 1. On the Testing CD, locate and select GioDebug. 2. Double-click Setup. The Setup of the Ink I/O Switch Block software begins running. 3. Click OK. The Ink I/O Switch Block software is now installed on your workstation. Activating the Software 1. On the Testing CD, double click SwitchInkIO. The following window is displayed. Note: Make sure to work with the Ink I/O Switch Block software only. Any other Switch Block debugger that may be installed refers for the TNK card, and is therefore not relevant to the current upgrade. 2. Check is displayed in the top-right corner of the window, as displayed in the example above. If not, there is a communication problem with the Switch Blocks. Electro Valve Locating and Functionality Test This test ensures that the Ink I/O Board is properly connected to the Switch Blocks electrovalves and checks that the electro-valves are working properly. 1. In the field, enter #5M00 and press ENTER to check that all valves on the Switch Blocks are closed. 2. Check that the value #5M00 is returned in the top-right corner of the window. 3. Select the ByPass checkbox. FC Rev. D Page 81 of 117

82 4. In the Values Block CM area, click each button to turn ON the corresponding valve on the switch block, and then click it again to turn the valve OFF. Ensure that you hear a click when you switch ON and OFF each valve, as the click indicates that the valve is working. 5. When each button is ON, check that the valve LED that lights up on the Switch Block corresponds to valve indicated by the software. 6. Repeat the test for all valves on both Switch Blocks. 7. Turn OFF all valve buttons. 8. Clear the ByPass checkbox. Switch Block Coordination Test Using the Switch Block Coordination Test software, you can simulate commands from the I/O INK BOARD to the Switch Block, as follows: 1. In the field, enter #5M11 to activate the top level of valves on both Switch Blocks. Check that the LEDs on the top level of electro-valves are lit. 2. In the field, enter #5M22 to activate the second from top level of valves on the both Switch Blocks. Check that the LEDs on the second from top level of electro-valves are lit. After approximately 10 seconds, this level of LEDs is turned OFF and the top level of LEDs are lit. 3. In the field, enter #5M44 to activate the second from bottom level of valves on the both Switch Blocks. Check that the LEDs on the second from bottom level of electro-valves are lit. After approximately 10 seconds, this level of LEDs is turned OFF and the bottom level of LEDs are lit. 4. In the field, enter #5M88 to activate the bottom level of valves on both Switch Blocks. Check that the LEDs on the bottom level of electro-valves are lit. Note: Make sure that after entering each full string and pressing ENTER, the same string is displayed in the right corner of the window (If not, the command is illegal or there is communication problem). 5. To turn OFF all valves and enter the string #5M00 in the field. Finishing the Debug Process 1. Close the program and turn OFF the 24V CB. 2. Reconnect the float cables from the J3 ports on both IPC board terminal blocks. Notes: When you finish the testing process, uninstall the Switch Blocks Debug Software from the computer. PrinTop cannot run simultaneously with the Switch Block Debug Software. Page 82 of 117 FC Rev. D

83 25. Logistics 8 COLOR ASSY KIT FRESCO 3200, P/N COMPONENT DESCRIPTION QTY KIT UPGRADE-8 COLOR FRESCO INK CELL ASSY PRINTING CARRIAGE, 8 COLORS INK TANK ASSY FOR 8C IGUS FOR EXTRUDED PROFILE FOR INK CONTROL ASSY LABELS FOR CABELS FRESCO 8 COLOR ACCESSORIES KIT FOR UPGRADE 8C FRESCO FILTERS KIT ASSY 8 COLOR IGUS TUBE ASSY FRESCO C PRINT HEAD PLATE ASSY 8 COLOR (CARRAGE) FOR KIT 8C SWITCH BLOCK ASSY ACCESSORIES FOR SWITCH BLOCK ASSY COLORS PURGE VALVES BRACKET IGUS BRACKET RIGHT IGUS BRACKET LEFT PRINT HEAD BRACKET IGUS RIGHT PRINT HEAD BRACKET FOR IGUS LEFT WS,DELL 530 DUAL CPU XENON 1.7 GHZ WIN XP PRO INK CONTROL LIGHT ASSY BOARD (IPC L) FILTER,CAPSULE,5U WITH QUICK CONN. MALE CABLE ASSY,INK CONTROL VACUUM & PRESSURE PUMPS V FROM TBH TO INK CONTROL PCB INK CONTROL 8 COLOR WIRING GI/O #1 INPUTS FROM MAIN INK TANKS SENSORS (6 PIN C INPUTS FROM SECONDARY INK TANKS LEVEL SNS D KIT,SOFTWARE RIP, NUR FLASH V1.2, SUPPORT 8C SWITCH BLOCK PACKAGE COLOR PACKING BOX 1 FC Rev. D Page 83 of 117

84 ACCESSORIES KIT FOR UPGRADE 8C FRESCO 3200, P/N: COMPONENT DESCRIPTION QTY GASKET FOR D33XXGLO VALVE TUBE,NYLON,DO=10 MM DI=8 MM,WHITE TIE WRAP,CABLE,L=100MM BUNDLE MAX D=23MM,NYLON 1 TIE WRAP,CABLE,L=203MM BUNDLE MAX D=55MM,NYLON 1 SCREW,SOCKET HEAD CAP HEX,ST.ST.,M6X16,FULL TH SCREW SOCKET HEX CAP M5*16 S.S WASHER SPRING M5 DIN 127B,ST.ST WASHER,SPRING,M6 DIN 127-B,A2,ST.ST WASHER,SPRING,M8 DIN 127,A2,ST.ST WASHER,FLAT,M8 DIN 125 A,A2,ST.ST WASHER,FLAT,M5 DIN 125 A,A2,ST.ST WASHER SPRING M5 S.S GASKET,EPDM RIVET 4X10 MM KIT FPP BRACKET FOR DELL WS SCREW,SOCKET HEAD CAP M6X20,DIN 912,A2,ST.ST SCREW,SOCKET BUTTON HEAD M5X10,ISO 7380,A2,ST.ST SCREW,SOCKET HEAD CAP M8X10,DIN 912,A2,ST.ST O RING BETWEEN THE PLATE AND THE BOLCK PLATE OPERATOR FOR SWITCH BLOCK W COIL 24VDC FOR SWITCH BLOCK PLUG FOR COIL FOR SWITCH BOX BRACKET,PAD,MOUSE MOUNTED RAIL DIN FRESCO 8C JIG FOR SWITCH BLOCK TIE MOUNT,28X28MM,NYLON ADHESIVE,WITH HOLE 5.0MM WALL PROFILE 80X320MM O RING 10X1 EPDM FAST CONN. FEMALE FOR CAPSULE FILTER 5U SILICON CAP ID=3.48 FOR 4MM PIPE SILICON CAP ID=4.37 FOR HEAD 50 Page 84 of 117 FC Rev. D

85 COMPONENT DESCRIPTION QTY KIT,S/W PRINTOP VER.1.5 FRESCO 8C KIT LOGO FRESCO HIQ 8C NUT DRIVER,FLUSHING MANIFOLD DRILL 4MM RIVET GUN 1 FC FRESCO HIQ 8C FCO 1 FC Rev. D Page 85 of 117

86 KIT UPGRADE 8 COLOR FRESCO 1800, P/N: COMPONENT DESCRIPTION QTY INK CELL ASSY PRINTING CARRIAGE, 8 COLORS ACCESSORIES FOR KIT 8C FRESCO INK TANK ASSY FOR 8C EXTRUDED PROFILE FOR INK CONTROL ASSY LABELS FOR CABLES FRESCO 8 COLOR FILTERS KIT ASSY 8 COLOR PRINT HEAD PLATE ASSY 8 COLOR (CARRIAGE) FOR KIT 8C IGUS FOR FRESCO C IGUS TUBE ASSY FRESCO C SWITCH BLOCK ASSY ACCESSORIES FOR SWITCH BLOCK ASSY COLORS PURGE VALVES BRACKET PRINT HEAD IGUS ADAPTOR FRESCO C IGUS BASE ADAPTOR FRESCO C WS,DELL 530 DUAL CPU XENON 1.7 GHZ WIN XP PRO INK CONTROL LIGHT ASSY. BOARD (IPC L) FILTER,CAPSULE,5U WITH QUICK CONN. MALE CABLE ASSY,INK CONTROL VACUUM&PRESSURE PUMPS V FROM TBH TO INK CONTROL PCB INK CONTROL 8 COLOR WIRING GI/O #1 INPUTS FROM MAIN INK TANKS SENSORS (6 PIN C INPUTS FROM SECONDARY INK TANKS LEVEL SNS D KIT,SOFTWARE RIP, NUR FLASH V1.2, SUPPORT 8C SWITCH BLOCK PACKAGE 1 ACCESSORIES FOR KIT 8C FRESCO 1800, P/N: COMPONENT DESCRIPTION QTY GASKET FOR D33XXGLO VALVE TUBE,NYLON,DO=10 MM DI=8 MM,WHITE TIE WRAP,CABLE,L=100MM BUNDLE MAX D=23MM,NYLON TIE WRAP,CABLE,L=203MM BUNDLE MAX 1 Page 86 of 117 FC Rev. D

87 COMPONENT DESCRIPTION QTY D=55MM,NYLON SCREW,SOCKET HEAD CAP HEX,ST.ST.,M6X16,FULL TH SCREW SOCKET HEX CAP M5*16 S.S WASHER SPRING M5 DIN 127B,ST.ST WASHER,SPRING,M6 DIN 127-B,A2,ST.ST WASHER,SPRING,M8 DIN 127,A2,ST.ST WASHER,FLAT,M8 DIN 125 A,A2,ST.ST WASHER,FLAT,M5 DIN 125 A,A2,ST.ST WASHER,SPRING, 25X12.2X0.9 DIN 2093 B WASHER SPRING M5 S.S GASKET,EPDM RIVET 4X10 MM KIT FPP BRACKET FOR DELL WS SCREW,SOCKET FLAT HEAD M6X16,DIN 7991,A2,ST.ST SCREW,SOCKET BUTTON HEAD M5X10,ISO 7380,A2,ST.ST SCREW,SOCKET HEAD CAP M8X10,DIN 912,A2,ST.ST O RING BETWEEN THE PLATE AND THE BOLCK PLATE OPERATOR FOR SWITCH BLOCK W COIL 24VDC FOR SWITCH BLOCK PLUG FOR COIL FOR SWITCH BOX BRACKET,PAD,MOUSE MOUNTED RAIL DIN FRESCO 8C JIG FOR SWITCH BLOCK TIE MOUNT,28X28MM,NYLON ADHESIVE,WITH HOLE 5.0MM WALL PROFILE 80X320MM O RING 10X1 EPDM FAST CONN. FEMALE FOR CAPSULE FILTER 5U SILICON CAP ID=3.48 FOR 4MM PIPE SILICON CAP ID=4.37 FOR HEADE KIT,S/W PRINTOP VER.1.5 FRESCO 8C KIT LOGO FRESCO HIQ 8C NUT DRIVER,FLUSHING MANIFOLD DRILL 4MM RIVET GUN 1 FC Rev. D Page 87 of 117

88 COMPONENT DESCRIPTION QTY FC FRESCO HIQ 8C FCO 1 ACCESSORIES FORSWITCH BLOCK ASSY, P/N: COMPONENT DESCRIPTION QTY END PLATE PLASTIC,POLYAMID MOUNTING FOOT PLASTIC,POLYAMID WASHER,SPRING,M6 DIN 127-B,A2,ST.ST WASHER,FLAT,M6 DIN 125 A,A2,ST.ST RIVET 4X10 MM SCREW,SOCKET HEAD CAP M6X30,DIN 912,A2,ST.ST SCREW,CROSS RECESSED SUNK,M3X8,S.S,DIN 965 A SWIVEL ELBOW MALE ADAPTOR 6/4X1/8 NBR+EPDM RAIL DIN FRESCO 8C INTERFACE PLATE ASSY EXTRUDED PROFILE PLASTIC RS-SP INK I/O 24 BOARD ASSEMBLY CABLE,8C COMM FROM FW29 TO IPCS&INK I/O BOARD. 1 Page 88 of 117 FC Rev. D

89 26. Material Disposition The table below instructs you on the action required for items removed during the upgrade. PN PART DESCRIPTION QTY ACTION DELL POWEREDGE 1300* 3 SEND BACK PRINT HEAD COVER SHIELD 1 SEND BACK IGUS 1 DISCARD SIT 4 C 1 SEND BACK CABLE FW91 1 DISCARD CABLE FW71 1 DISCARD FILTER BRACKET 1 DISCARD PURGE BRACKET 1 DISCARD DIN RAIL 1 DISCARD * Refer to the Dell PowerEdge 1300 Return Form, the last page of this document, for details on returning the Dell workstation. This form must be filled in, cut out from the book, and sent to the IT department of your local subsidiary along with the Dell PowerEdge Ensure to fill in the personal details and customer support representative sections of the form only. The IT sections are to be filled in by the IT department of your local subsidiary. FC Rev. D Page 89 of 117

90 27. Table of Appendixes Appendix A: Ink Flushing System Appendix B: Print Heads Replacement Appendix C: Print Head Plate Calibration Appendix D: Schematic Drawings Page 90 of 117 FC Rev. D

91 Appendix A: Ink Flushing System FC Rev. D Page 91 of 117

92 Ink System Flushing Appendix A describes ink system flushing, which includes the following procedures: Draining ink from the tubes that returns ink to the MITs. Draining ink from the MITs. Draining ink from the SITs. Flushing the Ink System. Circulating solvent. Draining solvent from the MITs. Draining solvent from the SITs. Refilling the Ink Circuit with Ink. Step A: Draining Ink from MIT Return Tubes 1. Shut down procedure to the NUR Fresco HiQ printer. 2. Turn ON 24V DC power supply circuit breaker. 3. Activate PrinTop. 4. In PrinTop, open the INK window and deactivate all pressure pumps. 5. Wait about two minutes while the vacuum pumps drains the remaining ink from the return pipes into the main tanks. 6. Turn OFF 24V DC power supply circuit breaker. Step B: Draining Ink from the MITs Repeat the following for all four colors. 1. Unscrew the four bolts securing the MIT to the cabinet floor (see Figure 93). 2. Drain the MIT by removing the draining cap and opening the draining valve. 3. Tilt the MIT carefully to obtain maximum drainage and clean the MIT walls by squirting solvent inside the tank while tilted. Note: Avoid damaging the MIT wires while tilting the MITs. 4. Drain the 5-micron filter by disconnecting the lower quick connector and opening the white cap (see Figure 94). 5. After the 5-micron filter is drained, close the white cap and reconnect the quick connector. Page 92 of 117 FC Rev. D

93 6. Close the MIT draining valve and close the draining cap. Figure 93: Main Ink Tanks Figure 94: Five-Microns Filter Step C: Draining Ink from the SITs Repeat the following step for all four colors. Disconnect the Print Head feeding tube from the SIT and open the Print Head outlet (see Figure 95). 14 Micron Filter Purge Outlet Pressure Inlet Restrictor Cover PH Outlet (4) Vacuum Outlet Figure 95: SIT Draining FC Rev. D Page 93 of 117

94 Step D: Flushing the Ink System 1. Fill each main tank with 2.5 liters (0.7 gallon) of solvent (flushing fluid). 2. Turn ON the 24 V DC power supply circuit breaker. 3. In PrinTop, open the INK window and activate all the pressure pumps. Note: Repeat steps 4 through 10 for all four colors. 4. Open the restrictor cover for PHs 7 and 8 that are located under the pressure gauge. 5. In the Ink window, activate the pressure pump. 6. Once solvent starts flowing out from the restrictor outlet, deactivate the pressure pump in the Ink window. 7. Close the restrictor cover. 8. In the Ink window, activate the pressure pump again. 9. Once solvent starts flowing from the SIT outlet, deactivate the pressure pump in the Ink window. 10. Close the SIT outlet. Step E: Circulating Solvent 1. In the Ink window, activate all the pressure pumps and let the remaining solvent circulate for 10 minutes. 2. In the Ink window, deactivate all the pressure pumps. 3. Wait 2 minutes while the vacuum pumps drain the solvent from the MIT return tube. 4. Turn OFF the F5 24V DC power supply circuit breaker. Step F: Draining Solvent from the MITs Repeat the following steps for all four colors. 1. Drain the MIT. 2. Tilt the MIT to obtain maximum drainage. Note: Avoid damaging the MIT wires while tilting the MITs. 3. Replace the 5-micron filter. 4. Close the MIT drain. Page 94 of 117 FC Rev. D

95 Step G: Draining Solvent from the SITs Repeat the procedure described in Step C: Draining Ink from the SITs on page 93 and leave the Print Head outlets open. Step H: Filling the Ink Circuit with Ink 1. Turn ON the F5 24V DC power supply circuit breaker. 2. Fill each main tank with 2.5 liters (0.7 gallon) of ink. Note: Repeat steps 3 through 12 for all four colors. 3. Unscrew the four bolts securing the ink inlet (14-micron filter cover) to the secondary tank block using a 2.5 mm Allen key. 4. Replace the 14-micron filter and filter s O-ring. 5. Point the ink inlet tube towards the Print Head carriage sink. 6. In the Ink window, activate the pressure pump. 7. Once pure ink starts flowing from the inlet tube, deactivate the pressure pump in the Ink window. 8. Close the ink inlet (14-micron filter cover); leave the new filter inside. 9. In the Ink window, reactivate the pressure pump. 10. Once pure ink starts flowing from the SIT outlet (which is still open refer to step 7), deactivate the pressure pump in the Ink window. 11. Close the SIT outlet. 12. In the Ink window, activate all the pressure pumps and let the ink circulate for five minutes. 13. Check the ink system for leakage. FC Rev. D Page 95 of 117

96 Appendix B: Print Heads Replacement Page 96 of 117 FC Rev. D

97 Print Head Replacement Print Head replacement involves the following tasks: Removing the previous Print Head. Installing a new Print Head. Step A: Removing a Print Head Remove a Print Head (Print Head) as follows: 1. Move the Print Head carriage to the service position. Caution: Turn OFF the Print Head power supply (PS) circuit breaker located in the drying and pneumatic cabinet. 2. Flush the faulty Print Head with solvent (flushing fluid). 3. Close the flushing manifold valve. Note: Label the Print Head electric flat cable before disconnecting it. Note: Inspect the Print Head flat cable visually. Remove and replace the ones that are splattered with ink. (refer to Figure 96). 4. Disconnect the Print Head flat cable from the Print Head (and from the Motherboard if needed) by pushing the two connectors grip arms away from each other (refer to Figure 102). Note: To make reconnecting the ink pipe to the flushing manifold, attach a lead (rope or pipe) at the end of the ink pipe to provide you with slack by disconnecting the Print Head ink pipe from the flushing manifold. Pull the lead when reconnecting the ink pipe to its original location (see Figure 96). FC Rev. D Page 97 of 117

98 PH Flat Cable PH Ink Pipe Disconnected PH Ink Pipe from the Flushing Manifold Attach a pipe or thin Rope to ease reconnection Figure 96: Disconnecting the Print Head 5. Remove the Print Head protective cover by releasing the three Allen screws using a 5 mm Allen (see Figure 97 and Figure 98). Screws to Remove PH Plate Locating Pin PH Protective Plate Figure 98: Removing the Print Head Protective Cover Figure 97: Print Head Protective Cover (Securing Screws Encircled) Caution: Be very careful not to damage the PHs orifices. 6. Remove the Print Head from the Print Head Plate by releasing the two Allen screws using a 2.5 mm Allen key (see Figure 100). Page 98 of 117 FC Rev. D

99 2.5 mm Allen Key Figure 99: Print Head Plate Figure 100: Unscrewing the Print Head Allen Screw 7. Carefully, remove the Print Head from the Print Head plate pins as displayed below. PH Locating Bores PH Locating Pins Figure 101: Removing the Print Head 8. Disconnect the ink pipe from the Print Head using a 7 mm wrench key (refer to Figure 102) Note: If the ink pipe or the flat cable is crimped and worn, replace it as well. 9. Tag the Print Head with a detailed repair tag and a section of its All Nozzle test pattern. Pack the Print Head package and send it to your local NUR service center. FC Rev. D Page 99 of 117

100 Step B: Installing a New Print Head Install the new Print Head as follows: 1. Use solvent (flushing fluid) to remove any ink residue around the Print Head locating pins. 2. Remove the silicon cap from the new PHs ink pipe inlet (see Figure 102). Head Adaptor (HAD) Board Connector Grip Arm Figure 102: Print Head Flat Cable Connector 3. Reconnect the ink pipe and the flat cable to the new Print Head. 4. Reconnect the Print Head ink pipe to the flushing manifold. Ink Pipe Connector Covered with Silicon Cap Note: Verify that the flat cable connector is fully locked by closing the grip arms firmly until you hear a click. 5. Carefully, place the Print Head on to the two Print Head Plate locating pins, while making sure not to break the bores thin metal plates when inserting the Print Head (see Figure 101). 6. Reconnect the Print Head to the Print Head plate by screwing in the two Allen screws using a 2.5 mm Allen key (see Figure 100). 7. Reconnect the Print Head protective cover on the Print Head plate using the locating pins (first locate the bottom side and then the upper) (see Figure 101). 8. Secure the Print Head protective plate using a 5 mm Allen key and three Allen screws that (see Figure 96). Page 100 of 117 FC Rev. D

101 Appendix C: Print Head Plate Calibration FC Rev. D Page 101 of 117

102 Print Head Plate Calibration Keep in mind the following general principles when calibrating the Print Head Plate: Perform this procedure exactly and in the stipulated order. Accurate Print Head (printing head) plate calibration creates a uniform parallel distance between the substrate and all the Print Heads, guaranteeing a high quality printing result. Print Head plate calibration is performed mainly by referencing the Print Heads to the vacuum plate. Calibrating the Print Head Plate includes the following procedures: Preparing for Print Head Plate Calibration. Setting the PH Plate and PH Carriage to be Parallel. Locating the Closest Distance between the VP and the Print Head Carriage. Adjusting the Minimum Distance between the VP and the Print Head Cover Shield. Installing the two Micrometers for the Print Head Plate Vertical Adjustment. Calibrating the Micrometer. Finding the Reference Point. Vertically Calibrating the Print Head Plate. Horizontally Calibrating the Print Head Plate. Preparing for Print Head Plate Calibration 1. Shut down the printer. 2. Turn off the main electric power switch. 3. Close the main air pressure inlet to the printer. 4. Remove the service spittoon. Page 102 of 117 FC Rev. D

103 5. Remove the Print Head protective cover by releasing the three Allen screws using a 5 mm Allen, as indicated below. Screws to Remove Figure 103: Removing the Print Head Protective Cover Shields 6. Remove the rulers connected to both sides of the Print Head plate (see Figure 104). Rulers Figure 104: Rulers 7. The Print Head plate is connected to the Print Head carriage by two pins, one on each side of the plate and by the eight adjustable assemblies (see Figure 105 and Figure 106). One pin is inserted into a round bore and the other is inserted into an elliptical bore. Verify that the pin from the elliptic bore has been removed. If the pin is still in the elliptical bore, remove it as follows: Remove the eight adjustable assemblies (see Figure 105 and Figure 106). Remove the Print Head plate from the Print Head carriage. Remove the pin from the elliptic bore. Note: Do not remove the pin from the round bore. Restore both the Print Head plate and the eight adjustable assemblies. FC Rev. D Page 103 of 117

104 Step A: Setting the PH Plate and PH Carriage to be Parallel Eight adjustment assemblies connect the Print Head plate to the Print Head carriage (refer to Figure 105) Figure 105: Eight Adjustments Assemblies Each adjustment assembly includes the following parts (refer to Figure 106): A: Two slip washers B: Adjustment Screw C: M4 Allen Locking Bolt D: 14 mm Lock nut Figure 106: Adjustment Assembly Page 104 of 117 FC Rev. D

105 Set the distance between the Print Head Plate and Print Head Carriage to be parallel, as follows: 1. Verify that the space between the Print Head plate and the Print Head carriage is 6 mm. Measure the distance at the Four Corners of the plate, at the location of the two slip-washers (see Figure 107). PH Plate PH Carriage Figure 107: 6 mm Distance between the Print Head Plate and the Print Head Carriage If any adjustments are necessary, see Figure 105 and Figure 106 and perform the following: 2. Remove the 14 mm lock nut (part D) from the 8 adjustment assemblies. 3. Release the M4 Allen locking bolt (part C) and adjustment assemblies 5,6,7 and Release the adjustment screw (part B) at adjustment assemblies 5,6,7 and 8, so that the screw creates neither tension nor pressure between the Print Head plate and the Print Head Cover shield. 5. At the corners where the distance is not 6 mm, perform the following for each corner: Release the M4 Allen locking bolt (part C). Adjust to a 6 mm distance by screwing or unscrewing the Adjustment screw (part B). Tighten the M4 Allen locking bolt (part C). Note: Take into account that the distance may be affected while you tighten the Allen locking bolt. FC Rev. D Page 105 of 117

106 Step B: Locating the Closest Distance between the Vacuum Plate and the Print Head Carriage 1. Reassemble the Print Head cover shield (refer to Figure 103). 2. Remove the two ink-flushing manifolds from the Print Head carriage side. 3. Unscrew two screws at the left side of the Print Head carriage, to the left of the manifolds. 4. In the Calibration kit, locate Indicator Holder B (P/N: ) and an Arm for Indicator (P/N: ), and the Micrometer Indicator (P/N: ) (see Figure 108, Figure 109, and Figure 110). A B Bolt to Remove Figure 108: Indicator Holders A and B Figure 109: Arm for Indicator Figure 110: Micrometer Indicator Note: You may use also the Magnetic Base (P/N: ) in this process. 5. Secure the Arm for Indicator to Indicator Holder B by screwing it into the smaller of its middle holes. 6. Remove the bolt and one of the washers from the Arm for Indicator (see Figure 109). Page 106 of 117 FC Rev. D

107 7. Insert the Micrometer Indicator on to the Arm in the location where the bolt and washer were removed. 8. Replace the bolt and washer. The Indicator Holder B, Arm, and Micrometer appear as follows: Figure 111: Indicator Holder B, Arm, and Micrometer IdicatorAssembled 9. In the Calibration kit, locate the two M8x20 screws (P/N: ). 10. Secure the Micrometer assembly (Indicator Holder B, Arm, and Micrometer Indicator) on the Print Head carriage using the two socket head screws (P/N: ) and an Allen key, in the location from which you removed the two screws (see Figure 114). 11. Verify that the four screws (two at the front and two at the back) that secure the Print Head carriage to the base plate of the X-beam are tight (see Figure 112 and Figure 113). Figure 112: Back Right Screw that Secures Print Head Carriage to its Base (view from ink cabinet) FC Rev. D Page 107 of 117

108 Figure 113: Front Left Screw that Secures the Print Head carriage to its Base (view from the front of printer) 12. Find the minimum distance between the Print Head carriage and the vacuum plate using the micrometer, as follows (see Figure 114): Use the Left side of the vacuum plate as a reference (zero point). Move the Print Head carriage from left to right and find the minimum distance. Repeat this step for the top, center and bottom of the vacuum plate. Record the minimum distance at each position & mark it on the vacuum plate. Note: An acceptable distance deviation is up to 0.5mm. Note: Move the Print Head carriage by pulling and pushing the IGUS to ensure that measurement is not affected. If the distance deviates by more than 0.5 mm, you must adjust the vacuum plate. Inserting one or more spacers behind one or more VP corners will adjust the VP by extending the specific corner. Page 108 of 117 FC Rev. D

109 Indicator Holder B Arm for Indicator Micrometer Indicator Figure 114: Calibrating the Minimum Distance, Top, Center and Bottom, between the Print Head Carriage and the VP Plate Step C: Adjusting the Minimum Distance between the Vacuum Plate and the Print Head Cover Shield 1. Verify that the Print Head cover shield is on. 2. Move the Print Head carriage to the service side (left side). 3. Remove the four screws (two at the front & two at the back) that secure the Print Head carriage to the base plate of the X-beam (see Figure 112 and Figure 113). 4. Move the Print Head carriage to the point you recorded in step 2 (the minimum distance point). 5. In the kit, locate the two L-shaped 1.5 mm thick spacer rulers (P/N: ). FC Rev. D Page 109 of 117

110 6. At the recorded point, insert the two L-shaped spacer rulers between the VP and the Print Head cover, placing them specifically at the two edges of the Print Head cover. 7. Push the Print Head carriage from its base against the Vacuum Plate. 8. Hold the Print Head carriage from its base and verify the two gauges can move yet touch the two plates. 9. Re-secure the four screws tightly. Step D: Installing the two Micrometers for the Print Head Plate Vertical Adjustment 1. Remove the Print Head plate cover (see Figure 103). 2. In the Calibration kit, locate Indicator Holder A (P/N: ) and an Arm for Indicator (P/N: ), and the Micrometer Indicator (P/N: ) (see Figure 108, Figure 109, and Figure 110). Note: You may use also the Magnetic Base (P/N: ) in this process. 3. Secure the Arm for Indicator to Indicator Holder A by screwing it into the hole in which it fits. 4. Remove the bolt and one of the washers from the Arm for Indicator (see Figure 109). 5. Insert the Micrometer Indicator on to the Arm in the location where the bolt and washer were removed. Page 110 of 117 FC Rev. D

111 6. Replace the bolt and washer. The Indicator Holder A, Arm, and Micrometer appear as follows: Figure 115: Indicator Holder A, Arm, and Micrometer IdicatorAssembled 7. Secure Indicator Holder A on the Print Plate using the two M8x20 screws (P/N: ) and an Allen key (see Figure 108 and Figure 116). 8. Move the Print Head carriage to the service location, keeping the micrometers pointers away from the carriage. 9. Adjust the two micrometers pointers to touch the bottom and top of the Print Head plate. 10. Place the two micrometers pointers in a straight path on the Print Head plates face without using holes or pins. 11. Move the carriage left and right and verify that the two micrometers pointers are indeed in a straight path, on the Print Head plates face, without using holes or pins. (see Figure 114). 12. Verify that the two micrometers arms are stable. 13. Move the Print Head carriage to the right side of the vacuum plate, ensuring that the Print Head plate is not touching the micrometers pointers. FC Rev. D Page 111 of 117

112 Step E: Micrometer Calibration Use the aluminum ruler from the calibration kit (P/N: ) to calibrate the two micrometers, as follows: 1. Press the ruler against the vacuum plate while pushing in the micrometers pointer (see Figure 114). 2. While holding the ruler against the vacuum plate adjust the micrometer to 20 mm (with the dial s small hand pointing to 20 and the big hand pointing to 0 see Figure 116). Indicator Holder A Figure 116: Two Micrometers Pointing to the Print Head Plate Face 3. Repeat these steps for both the upper and lower micrometer. 4. Move the Print Head Carriage to the right and to the left to verify that the two micrometers pointers have a clear path on the Print Head plates face, checking that there are no holes or pins in the path. Figure 117: Micrometer Calibration Page 112 of 117 FC Rev. D

113 Step F: Finding the Reference Point 1. Move the Print Head carriage to the service side while ensuring that the Print Head plate does not touch the micrometers pointers. 2. Locate the two micrometers pointers against the Print Head plate. 3. Move the Print Head carriage left and right against the two micrometers. The micrometers pointer should be at about 7 mm, according to the following calculations: The micrometer was calibrated to 20 mm (as a reference). The distance to the Print Head cover shield is about 1.5 mm (see step 3 above). The width of the Print Head cover shield includes the distance between the Print Head cover shield and the Print Head carriage (11.5 mm). This means that the distance to the Print Head plate (without the shield) is: 20 ( ) = 7 mm. 4. Observe the two micrometers pointers for the corner at which the pointer is closest to 7 mm. Note: It is preferable to select the corner at which the pointer is slightly over 7 mm. 5. Select this corner as your reference point. Step G: Vertically Calibrating the Print Head Plate Adjusting the Print Head plate vertically involves only adjusting two corners in relation to the third corner (the reference point you set in step 5 above). Refer to Figure 105 and Figure 106 throughout the procedure. 1. Verify the following: The 14 mm Lock Nuts (part D) from the 8 adjustment assemblies have been removed. The M4 Allen locking bolts (part C) at adjustment assemblies 5,6,7 and 8 have been released. The adjustment screws (part B) at adjustment assemblies 5,6,7 and 8 are released, so that the screw creates neither tension nor pressure between the Print Head plate & the Print Head cover shield. 2. Release the M4 Allen locking bolts (part C) at adjustment assemblies at the three corners, which do not include the reference point corner. 3. Adjust the three corners, one by one, using the reference point found earlier in Step G, as follows: Move the Print Head carriage to the point at which the corner needs to be adjusted while facing the micrometer. Adjust the distance of the adjustment assembly s corner by turning the adjusting screw, using a wide flat metal plate, while watching the micrometers reading. FC Rev. D Page 113 of 117

114 Lock the M4 Allen locking bolt after each adjustment. Recheck the micrometer s reading. If more adjustment is required, adjust the screw again and lock the M4 Allen locking bolt. Repeat the previous steps until you obtain an acceptable measurement. An acceptable measurement deviation is up to 0.5 mm. Perform the same adjustment on all three corners. Once the distance is the same as measured at the reference point, fix the adjustment assembly by restoring the 14 mm Lock Nuts (part D), and tighten the nut, while you steadily hold the M4 Allen locking bolt. Note: Take into account that while you tighten the Allen locking bolt, the distance may be affected. 4. Fix the adjustment assembly at the remaining corners, as follows: Lock the M4 Allen locking bolt (part C). Fix the adjustment assembly by restoring the 14 mm Lock Nuts (part D), tighten the nut while you hold the M4 Allen locking bolt steady. 5. Recheck the vertical calibration, by moving the Print Head carriage left and right while watching the micrometer s reading. 6. If the distance changes from corner to corner, readjust the three corners again (see Step C). Step H: Horizontally Calibrating the Print Head Plate 1. Connect the magnet base to the printer chassis. 2. Use the magnet to assemble the micrometer on the chassis and above the Print Head plate. 3. Move the Print Head carriage from its base, right and left, checking that the micrometer s gauge is at the same level both at the right top point and left top point of the Print Head plate (see Figure 117). 4. If the level is incorrect, adjust the Print Head plate. 5. Loosen all the M4 Allen locking bolts at the three corners, except for the one near the remaining pin (in the round bore), which will be used as an axis for the Print Head plate. 6. Verify that the adjustment screws do not move as you unscrew the M4 Allen locking bolts. 7. Slightly loosen the M4 Allen locking bolts at the remaining pin s corner adjustment assemblies. Page 114 of 117 FC Rev. D

115 8. Gently raise the plate from its bottom by inserting any tool under the Print Head plate to adjust the Print Head plate horizontally. 9. Adjust the Print Head height, locking the M4 Allen three locking bolts, one by one, while watching the micrometer s reading. 10. Perform the previous steps until you obtain a satisfactory measurement. Note: After adjustment is complete, do not attempt to restore the pin that was removed. 11. Fix the adjustment assembly for the remaining corners: Lock the M4 Allen locking bolt (part C). Fix the adjustment assembly by restoring the 14 mm lock nuts (part D). Tighten the nut while you firmly hold the M4 Allen locking bolt. 12. Move the Print Head carriage left and right while watching the micrometers reading to recheck the horizontal calibration. Step I: Final Tasks Figure 118: Horizontal Calibration 1. Remove all the micrometers and Jigs from the chassis and Print Head carriage. 2. Restore the two rollers to the Print Head plate. 3. Restore the Print Head cover shield. 4. Restore the ink-flushing manifold. 5. Restore the spittoon. FC Rev. D Page 115 of 117

116 Calibration Kit Logistics Calibration Print Head plate Kit, PN: PN PART DESCRIPTION QTY MAGNETIC BASE W/8 MM INDICATOR HOLDER-2 M10/M INDICATOR HOLDER M10/ M INDICATOR 0.01 MM 0-30 MM RULER FOR CALIBRATION HEADS PLATE (SMOOTH) 700 MM ARM FOR MAGNETIC BASE M SCREW SOCKET HEX CAP M SCREW HEX CAP M8X MM RULER FOR HEADS PLATE ADJUSTMENT 1 Page 116 of 117 FC Rev. D

117 Appendix D: Schematic Drawings FC Rev. C Page 117 of 117

118 5 Extenuation Cables 35cm 6 6A soldering points To FW52 5cm FW 52A 10cm 1 3 4A 2 4 8cm BLACK BLACK yellow input YL Cyan input GN Magenta input PINK GR Black input 8cm 8cm MAGENTA CYAN MAGENTA CYAN 1 BR 0/V 0/V N.C N.C-Normally closed Soldering point Black 0/V 0/V 0/V N.C Magenta N.C Cyan N.C Black light N.C Magenta light Cyan light Yellow light N.C N.C N.C YELLOW DARK Colors FLOAT TANK FLOAT TANK YELLOW LIGHT Colors yellow Drawn Name Date NUR Macroprinters LTD. Next Assy Used On Design Approve Engr. Nataly TITLE: FRESCO 1. 8 Colors. FW52ADark&Light Floats Sensors Wiring. Rev Description Date Approved Page Size: Sheet of Scale: DRW. No: Rev: A

119 G I/O 1 G I/O 2 Wiring Duct INK I/0 Wiring Duct INK CONTROL Dark Wiring Duct INK CONTROL Light STOPPER C.B SOLVENT TB Hydraulic +24V 0/V SOLVENT GND PULSES (TIMER) STOPPER Wiring Duct SWITCH BOX CM SWITCH BOX YK C INK I/O Replacing TNK card 20/10/02 AVI.F B Adding Switch Box 08/08/02 AVI.F Rev Description Date Approved Next Assy Fr colors Fr colors Used On Page Size: A4 Name Date Drawn Design Approve Engr. AVI.F 08/08/02 Sheet 1 of 1 Scale: none TITLE: DRW. No: NUR Macroprinters LTD. GIO Panel Layout Fresco 8 colors Rev: C

120 Outputs : Heating System,purge,vuccum pump,cooling fans W63 IR SENSORS (Input) SUBSTRATE IR Temp.Sensors -Top& Botton Rollers INPUTS. OUTPUT - IR heatrs TEMP.SENSORS Vaccume Plate INPUTS AN.Output.For Proportional Valve. W111 INPUTS OF: AIR FLOW SENSOR TEMP CONTROLL- OVER IR HEAT Ink Level Sensors main tanks INPUTS J6 W50 J6 IR HEATER LEDS G I/O 1 J G I/O 2 J1 W72 W63 J7 J7 J3 J5 J3 J5 W54 (RS 485) W79 - RS 485 (Standard cable) To Watchdog Board (P1) GIO1 Jumpers Setting GIO2 Jumpers Setting W28 - RS 485.From PC COMM INTERFACE Rev Description Date Approved Next Assy FR Colors FR Colors Used On Page Size: A4 Name Date Drawn Design AVI.F 24/01/02 Approve Engr. AVI.F 30/07/02 Sheet 1 of 1 Scale: none TITLE: DRW. No: NUR Macroprinters LTD. GI/O CONNECTIONS Fresco 8 Colors Rev: A

121 110 CM 15cm 15cm IPC Light J IPC Dark J A 4 3B 2 NOTES: Do Not Assemble the Ferrules Pos1 to the cable but provide them separately in the same packing cable. LIGHT IPC PCB J1 0V INPUT INPUT INPUT INPUT 0V CYAN MAGENTA BLACK YELLOW BR GN PINK GREY YL DARK IPC PCB J1 Rev Description Date Approved Next Assy Page Size: Fr C Fr C Used On A4 Name Date Drawn Design NATALY Approve Engr. AVI.F Sheet 1 of 2 Scale: none NUR Macroprinters LTD. TITLE: Cable C Inputs From Secondary Ink Tanks Level Sns To Light IPC. DRW. No: Rev: A

122 Cable: C COMM Cable From FW29 To IPCS & Ink I/O Board D type 9 FW29 COMM. Cable From PC Com. Interface To Cable GI/O#1 J1 P1 P2 Ink I/O Card P3 P4 J2 J3 Ink Pump Control Dark J1 P3 P2 J2 J3 P3 Ink Pump Control Light J1 P2 Cable: C DC IN 24V From TBH To IPCS V 0/24V HYDRAULIK TB Cable: C Inputs From Main Ink Tanks Level Sensors to GI/O #1 Y C FW92. Outputs From IPC To Air Purge Valves M K Cable: C Inputs From SIT Level Sensors To Light IPC FW52- Inputs From SIT Level Sensors To Dark IPC Cable: Ink Pumps Control Light FW75 MOLEX 2W/W FW71 B FW71 A FW71 B FW71 A DY DC DM DK LY LC LM LK MOLEX 6W/W Cable: Outputs From Ink I/O To Switch Blocks CM&YK 1A 2A 3A 4A 1C 2C 3C 4C Cable: Ink Pumps Control Dark 1B 2B 5B 6B 3B 4B 7B 8B 5A 6A 7A 8A 5C 6C 7C 8C Cyan & Magenta Switch Block Yellow & Black Switch Block C Replacing cables /7/8 with /10/02 B Rev Removing The TNK Card And Adding The Ink I/O Card Description 25/9/02 Date Approve d Next Assy Page Size: Fr Colors Fr Colors Used On Drawn Design Approve Engr. Name Date AVI.F 08/08/02 A3 Sheet 1 of 1 Scale: none NUR Macroprinters LTD. TITLE: DRW. No FRESCO 1 8 Colors Wiring. Rev: C

123 Cable C DC IN 24V From TBH TO IPCS To Hydraulic T.B To Ink I/O Card WH BK Cable C COMM Cable From FW29 To IPCS & Ink I/O Board To Light IPC FUSE- 8A. SB F1 0/24 J3 +24v P3 Vacuum Ink Pump LEDS K Y M C Pressure Ink Pump LEDS K Y M C BR +24v U5 Vacuum Transistors Pressure Transistors PURGE LEDS BK WH RD GN 0/24 K Y M C J2 Microcontroller Dark GN Pink YL GR BR C M Y K 0/24 J1 Secondary Tank float LEDS P2 INK CONTROL CARD Rev Description FW92 - Outputs From Dark IPC To Air PurgeValves Date FW52 - Inputs From SIT Level Sensors To Dark IPC Approved Next Assy FR C FR C Used On Page Size: A4 Drawn Design Approve Engr. Cable Ink Pumps Control Dark. Cable C Inputs From SIT Level Sensors To Light IPC Sheet 1 of 1 Name ofer m AVI.F Date NATALY /12/01 Scale: none To Dark Pressure & Vacuum INK Pumps To SIT Level Sensors To Light IPC To CMYK Purge Air Valves NUR Macroprinters LTD. TITLE: 8C Dark Ink Control Board Wiring. DRW. No: Rev:

124 Cable C DC IN 24V From TBH TO IPCS To Hydraulic T.B To FW29 COMM Cable RD BK Cable C COMM Cable From FW29 To IPCS & Ink I/O Board To Dark IPC FUSE- 8A. SB F1 0/24 J3 +24v P3 Vacuum Ink Pump LEDS K Y M C Pressure Ink Pump LEDS K Y M C +24v U5 Vacuum Transistors Pressure Transistors 0/24 Microcontroller Light GN Pink YL GR C M Y K Secondary Tank float LEDS P2 J2 BR 0/24 J1 INK CONTROL CARD Cable Ink Pumps Control Dark. To Dark Pressure & Vacuum INK Pumps Cable C Inputs From SIT Level Sensors To Light IPC To Dark IPC Next Assy FR C FR C Used On Drawn Design Approve Engr. Name Date NATALY ofer m AVI.F 11/12/01 NUR Macroprinters LTD. TITLE: 8C Light Ink Control Board Wiring. Rev Description Date Approved Page Size: A4 Sheet 1 of 1 Scale: none DRW. No: Rev:

125 35cm 5 cm 3 cm FW IPC Light P3 3 3A B pin 1 FW DATA - DATA 0/24V +24V WH BK GN RD IPC "Light" Comm.P3 3 cm 3 3C IPC DarK P cm WH BK GN RD 3 3D Ink I/O Comm p1 2 pin 1 55 cm INK I/O Comm. P1 B Rev RD GN BK WH Changing Cable Length Description 16/10/02 Date AVI.F Approved IPC "Dark" Comm. P3 Next Assy Page Size: Fr colors Fr colors Used On A4 3 cm Drawn Design Approve Engr Name Date NATALY Sheet 1 of 2 Scale: none pin 1 AVI.F NUR Macroprinters LTD. TITLE: Cable: C COMM Cable From FW29 To IPCS & INK I/O Board. DRW: Rev: B

126 Symbols: Vacuum SIT Dark SIT Light/Dark Printing Carriage Connector from Switch Box to Main Tank. Connector from Switch Box to SIT. Pressure Vacuum Electro Valve. Ink Line. P D VD VL P L D L Vacuum SWITCH BOX Vacuum Pressure SIT = Secondary Ink Tank. D = Dark L= Light PD = Pressure Dark. PL = Pressure Light. VD = Vacuum Dark. VL = Vacuum Light. V. Pump Main Ink Tank V. Pump Main Ink Tank Filter P. Pump LIGHT Rev Filter P. Pump Description DARK Date Approved Next Assy Page Size: Fresco Colors Fresco Colors Used On A4 Name Date Drawn Design AVI.F 18/08/02 Approve Engr. AVI.F 18/08/02 Sheet 1 of 1 Scale: none TITLE: DRW. No: NUR Macroprinters LTD. SWITCH BOX INK FLOW DIAGRAM Rev: A

127 NOTE-B Shrink Position 6 cm 4 cm TB Hydr 3 cm 4 cm + 24V 0/24V TB Hydr 1C-Y 1C-Y 2C-Y 2C-Y 3 7 5B-Y 5B-Y 6 cm A 10 cm 3C-K 7B-Y 4C-K 3C-K 7B-Y 4C-K NOTE-A Shrink Position 6 cm 4 cm INK I/O P A 11 Cable Length - X +24V TB Hydr 59 cm 1A-C 15 cm 2A-C 1B-C 3A-M 3B-C 4A-M 5A-C 2B-M 6A-C 4B-M 7A-M 8A-M 13 cm 22 cm 13 cm 25 cm 15 cm 37 cm 22 cm 37 cm 25 cm 37 cm 37 cm 13 13B switch block CM See Note A LABEL 10 cm 8 Rev V TB Hydr 1A-C 2A-C 1B-C 3A-M 3B-C 4A-M 5A-C 2B-M 6A-C 4B-M 7A-M 8A-M X cm Description 3 cm 4 cm 1A-C 2A-C 1B-C 3A-M 3B-C 4A-M 5A-C 2B-M 6A-C 4B-M 7A-M 8A-M B Changing Wires and Labels Position Date switch block YK See Note B + 24V TB Hydr Approved 7 3 LABEL 8 NOTES-C 1. for single wire use Item for 2 or 3 wires use item 2. Next Assy Page Size: A3 FR colors FR colors Used On 5C-Y 6B-K 6C-Y 8B-K 7C-K 8C-K X cm Drawn Design Approve Name 5C-Y 6B-K 6C-Y 8B-K 7C-K 8C-K Cable Length - X TB Hydr 37 cm 1C-Y 15 cm 2C-Y 5B-Y 3C-K 7B-Y 4C-K 5C-Y 6B-K 6C-Y 8B-K 7C-K 8C-K Date 13 cm 22 cm 13 cm 25 cm 15 cm 37 cm 22 cm 37 cm 25 cm 37 cm 37 cm NUR Macroprinters LTD. NATALY TITLE: Cable: Engr. AVI.F Sheet 1 of 3 Scale: none DRW. No: NOTES -C 1. for single wire use Item for 2 or 3 wires use item 2. Outputs From INK I/O To Switch Blocks CM&YK Rev: B

128 1 0/24V BK 9 POUT16 RD 21 POUT17 WH 3 POUT12 GN 8 POUT18 OR 2 POUT14 BU 20 POUT19 WH/BK 7 POUT20 GN/BK 15 POUT13 OR/BK 19 POUT21 BU/BK 14 POUT15 BK/WH 6 POUT22 GN/WH 18 POUT23 BU/WH 13 POUT0 RD 25 POUT1 WH 5 POUT8 GN 12 POUT2 OR 4 POUT10 BU 24 POUT3 WH/BK 11 POUT4 GN/BK 17 POUT9 OR/BK 23 POUT5 BU/BK 16 POUT11 BK/WH 10 POUT6 GN/WH 22 POUT7 BU/WH B Changing Wires and Labels Position Rev Description Date L = 56 cm L = 32 cm L = 41 cm L = 30 cm L =51 cm L =32 cm L =66 cm L =41 cm L =78 cm L =51 cm L =78 cm L =78 cm L =78 cm L = 32 cm L = 41 cm L = 30 cm L =51 cm L =32 cm L =66 cm L =41 cm L =78 cm L =51 cm L =78 cm L =78 cm Approved Next Assy Page Size: A3 FR colors FR colors Used On 0/24V RD TB Hydr + 24V 1C-Y RD 2C-Y RD 5B-Y RD 3C-K RD 7B-Y RD 4C-K RD 5C-Y RD 6B-K RD 6C-Y RD 8B-K RD 7C-K RD 8C-K RD + 24V TB Hydr 1A-C RD 2A-C RD 1B-C RD 3A-M RD 3B-C RD 4A-M RD 5A-C RD 2B-M RD 6A-C RD 4B-M RD 7A-M RD 8A-M Drawn Design Approve Engr. Sheet 2 of 3 Name Date NATALY AVI.F Scale: none NUR Macroprinters LTD. TITLE: Cable: Outputs From INK I/O To Switch Blocks CM&YK DRW. No: Rev: B

129 W 77 To Comm Interace Cable To DARK IPC To LIGHT IPC W 75_b To Cable Level sensor Main Ink Tanks RD RD RD RD BK BK BK BK V 0/24V GND Hydraulic TB Cable To Switch Block CM RD RD RD BK1 BK2 BK BK BK GN/YL To C.B SOLVENT Cable To Switch Block YK FW117 : To Solvent Pump (com) W90: 24V From Systems Power Supply To Solvent pulses Flow (pin A2) D Rev Removing Cables /7/6 & Adding Description 02/10/02 C 25/09/01 Removing TNK Cable & Adding /7/6. B Adding TNK for Switcher box 4/8 colors. 25/07/01 AVI.F Date Approved Fr colors Fr colors Drawn Desi gn Approve Name Date Next Assy Used On Engr. AVI F. 25/07/01 Page Size: A4 Sheet 1 of 1 Scale: none TITLE: DRW. No: NUR Macroprinters LTD. Hydraulic T.B Fresco 8 colors Rev: D

130 0.9 METER 3cm 10cm Dark IPC J TBH A A 5 TBH Light IPC J3 3cm 3 3B 0.5 METER 7 Dark Ink INK Control J3 1 2 RD BK +24V 0V PIN 4 PIN 1 TBH Light Ink INK Control J3 1 2 RD BK Rev Description Date Approved Next Assy Page Size: Fr colors Fr colors Used On A4 Drawn Name Date NUR Macroprinters LTD. Design NATALY TITLE: Cable: Approve 8C DCIN +24Vs From TBH to IPCS Engr. AVI.F Sheet 1 of 2 Scale: none DRW. No: Rev: B

131 17 17A 11 5 cm 12 12A 50 cm FW GI/O #1 J1 3 3A GI/O #1 J1 4 4A Main Light Ink Tanks Main Dark Ink Tanks 16 16B 16 16A 14 FW71 B - Y,C FW71 A - M,K 50 cm FW71 B - Y,C 5 cm 5 cm B 16 16B 16 16A FW71 A - M,K 15 Rev Description Date Approved Next Assy Page Size: Fr colors Fr colors Used On A4 Name Date Drawn Design NATALY Approve Engr. AVI.F Sheet 1 of 4 Scale: none NUR Macroprinters LTD. TITLE: Cable: C. Inputs From Main Ink Tanks Level Sensors to GI/O #1 DRW. No: Rev: A

132 Note: Soldering Point In Item 3 GI/O #1 J Vh IN 1 IN 5 IN 3 IN 7 SHIELD IN 2 IN 6 Light Cyan Low Level Light Yellow Low Level Light Magenta Low Level Light Black Low Level Dark Cyan Low Level Dark Yellow Low Level RD GN 1 1 BK WH OR BR VIOL GN BK YL FW75 FW71 B -Y,C FW71 A -M,K Note: Folding Point In Item 11 FW71 B -Y,C IN 4 IN 8 Dark Magenta Low Level Dark Black Low Level BU WH FW71 A -M,K Rev Description Date Approved Next Assy Page Size: Fr colors Fr colors Used On A4 Name Date Drawn Design NATALY Approve Engr. AVI.F Sheet 2 of 3 Scale: none NUR Macroprinters LTD. TITLE: Cable: C. Inputs From Main Ink Tanks Level Sensors to GI/O #1 DRW. No: Rev: A4

133 3.5Meter 5cm cm INK CONTROL P2 4 4A B 7 7A VACUUM PUMPS PRESS. PUMPS cm Rev Description Date Approved Next Assy Fresco Fresco1 Name Date Drawn nataly 6/8/01 Design 1800 Approve ofer m. 6/8/01 Used On Engr. Avi.f 04/11/01 Page Size: A4 Sheet 1 of 4 Scale: none TITLE: DRW. No: NUR Macroprinters LTD. CABLE INK CONTROL PUMPS Rev:

134 INK CONTROL P M1 -M1 +M2 -M2 +M3 -M3 +M4 -M4 +M6 -M6 +M7 -M7 +M8 -M8 +M9 -M9 Next Assy WH/BK WH OR/BK OR RD/BK RD BU/BK BU WH/BK WH OR/BK OR RD/BK RD BU/BK BU Drawn Design Approve Engr. BLACK YELLOW MAGENTA (Red) CYAN (Blue) BLACK YELLOW MAGENTA (Red) CYAN (Blue) Name nataly ofer.m AVI.F Date 6/8/01 04/11/01 VACUUM PUMPS PRESSING PUMPS NUR Macroprinters LTD. TITLE: INK CONTROL Cable Rev Description Date Approved Page Size: A4 Sheet 2 of 4 Scale: none DRW. No: FR FR Used On Rev:

135 Inputs 8 Color Electrical Ink Block Diagram Outputs Overflow Tanks Floats DC DM DY DK Dark IPC Vacuum DC DM DY DK Motor Pumps Pressure DC DM DY DK PC Comm. interface C M Y K Purge Valves Inputs Outputs Overflow Tanks Floats LC LM LY LK Light IPC Vacuum LC LM LY LK Motor Pumps Pressure LC LM LY LK

136 DELL Power Edge 1300 Work Station Return Form Customer Name: Contact Person Name: Address: Country: City: State: Zip Code: Tel: Fax: Printer S/N: Customer Support Representative IT Notes Dell S/N (DSN) CPU No / One / Two MHZ No / One / Two MHZ Memory MB MB Hard Drive GB GB CD-ROM No / One / Two No / One / Two JAZ Drive No / One / Two No / One / Two Network Card No / One / Two No / One / Two IT Infrastructure Department

137 Customer Support Representative Name: Date: Signature: IT Representative Name: Date: Signature: Customer Support Representative Notes: IT Representative Notes: IT Infrastructure Department