1 technical training presented by lars hanson. 2 machine specification chapter 2page 2-7...

1

Technical Training

Presented by Lars Hanson

2

Machine Specification Chapter 2 Page 2-7

Resolutions: D600dpi models & 300dpi models

“D” = Device 300 x 600dpi

Machine Types: 600dpi - A3 model

300dpi - A4 model

Operation Panel: LED display

Original Type: Book & sheet

Printing Speed: 5 speeds (Approx. 60, 80, 100, 120, 130)

Image Processing Mode: Line, Photo, Duo, Pencil

Ink Cartridge: 1,000 millilitres per cartridge

Only for 600dpi machine

From now on the term 600dpi

will be used

3

Optional Accessories Chapter 2 Page 2-6

Available Options

Colour Cylinder (Drum)

Auto Document Feeder AF-V

Feeds up to 50 originals automatically

Job Separator IV:N

Key Card Counter IV:N

Special Paper Feed Kit

Use for thick paper such as cards and envelopes. Replace with this when thick paper needs to pass through the machine.

Stand

Printer Control Board RISORINC3N

Use to connect a computer to the machine using a parallel cable.

RISO PRINTER Network Interface Card RISORINC-NET

Use to directly connect the machine to the network.

This comes with RISO-MONITOR software.

4

Machine Installation

Notice Sheet

Following two steps are un-necessary

1. Unlocking the scanner lock screw.

2. Scanner carriage test mode release.

5

Specifications Chapter 2

See Specification Sheet Page 2-7

Preparing to Print

1. Power Switch.

2. Open and set paper feed tray.

3. Load paper & position the guides.

4. Paper feed pressure adjustment. Normal / Card

5. Open paper receiving tray.

Basic Operation

1. How to scan originals. Line / Photo / Duo

2. Reduce & Enlargement.

3. Print Positioning.

4. Consumable replacement.

5. Drum removal.

6. Master making unit release.

6

Speed

DensityPrint Position

RZ370 Conpane

Reduce/Enlarge

Ink Saving Mode

Pencil ModeProof Copy

Master Making/Print Mode

7

Main Drive Chapter 3 Page 3-1

Main Motor

Print Drum

Air Pump

1st & 2nd Paper FeedGear

(Paper Separation)

Timing Belt

Gear

Printing Speed: 60cpm to 130cpm in 5 steps

8

Print Drum

(Main Pulley / Main Shaft)

Timing Belt

Air Pump Main Motor

Paper Feed Area

9

Main Drive

Position B Machine home position

1. Paper Feed Section

2. Printing Section

3. Air Pump unit

4. Position B sensor

TM 801 & 892

1

2

3

4

Timing Positions

Disassemble & Reassemble Main Drive

Please Note:

Position B = Drum Release

10

2Pos B Printing section

Markings on the plastic gearsAlign – marking against = markings on the two gears

1 Pos B Paper feed section

Markings on plastic gearsAlign dots together

4

Pos B sensor

Position B sensor actuator

3Pos B Air pump

11

Main Motor Safety Switches Page 3-4

1. Rear Cover Safety Switch (L & R) (TM 005)

2. Master Removal Box Safety Switch (TM 423)

3. Master Making Unit Safety Switch (TM 409)

4. Print Drum Safety Switch (TM 820)

Stops the four following motors:

• Main Motor

• Clamp motor

• Master compression motor

• Master disposal motor

12

1 1

4 3

2

Rear Cover Safety Switch (L) Rear Cover Safety Switch (R)

Print Drum Safety Switch Master Making Unit Safety Switch

Master Removal Box Safety Switch

13

Paper Feeding Section Chapter 4 Page 4-1

Paper Feed Tray Area Page 4-2

1. Paper detection sensor (TM 600)

2. Paper width potentiometer (TM 9874 + 1102 & 1103)

3. Paper size detection sensor (TM 601)

4. Upper limit sensor A 600dpi only (TM 602) (TM 740)

5. Upper limit sensor B (TM603)

6. Lower limit sensor (TM 604)

7. Paper feed pressure sensor 600dpi only (TM 614)

8. Paper feed tray upper safety switch (TM 607)

9. Paper feed tray lower safety switch (TM 608)

10.Paper feed tray button (TM 609)

11.Elevator motor (TM 682 & 683)

14

107

11

3

2

1

10 8

5

4

6

9

Paper feed tray buttonPaper feed Pressure sensor

Paper feed tray button

Paper feed trayUpper safety SW

Upper limit Sensor A

Upper limit Sensor B

Horizontal print position Knob

Paper detection sensor

Paper width potentiometer

Paper size detection sensor

Elevator motor Paper feed tray lower limit sensor

Paper feed trayLower safety SW

15

Paper Feeding Section

First Paper Feed

1. Three paper feed positions: Card 600 dpi only, Normal, Custom 600dpi only.

2. No double feed detection sensor or stack feed switch.

3. Paper feed clutch (TM688)

3 Paper feed clutch

Disassemble & Reassemble Paper Feed & Drive Assy

16

Paper Feeding Section Chapter 5 Page 5-1

Second Paper Feed Page 5-2

1. Paper sensor (TM 605)

1

Guide roller

Timing roller

Timing roller

Paper sensor

Disassemble & Reassemble Second Paper Feed

17

Paper Feeding Section

Vertical Print Positioning Page 5-4

1. Print positioning pulse motor (TM 900 & 901)

2. Vertical centreing sensor (TM 831)

2

1

• Positions printed image up or down

Print positioning Pulse motor

Vertical centreing sensor

Disassemble & Reassemble Vertical Print Drive

18

Image UP

Image DOWN

Print positioning pulse motor

• CW Image DOWN

• CCW Image UP

Print positioning wheel assy

Vertical centreing sensor

19

Printing Section Chapter 6 Page 6-1

Printing Pressure Page 6-2

1. Print pressure pulse motor 600dpi only (TM 904, 905 & 908)

2. Print pressure HP sensor 600dpi only (TM 830)

3. Pressure solenoid (TM 886)

• Print pressure pulse motor rotates for set pulses from the HP sensor position according to the selected printing density.

• Pressure solenoid stays activated (stays on) all through the printing job until the machine stops.

Disassemble & Reassemble Press Section

20

Pressure solenoid is OFF(Pressure roller is DOWN)

Pressure solenoid is ON (Pressure roller is UP)

1

2

3

Print pressurePulse motor

Print pressureHP sensor

Pressuresolenoid

Levers Engaged Levers disengaged

Pressure cam

Pressure solenoid

Hook lever Pressure lever

21

300 dpi machine 600 dpi machine

Printing pressureManually Adjusted

Printing pressurePulse motor Adjusted

22

Printing Section Chapter 8

Print Drum Lock Mechanism, etc. Page 8-6

1. Print drum lock solenoid (TM 885)

2. Print drum safety switch (TM 820)

3. Print drum lock sensor (TM 807)

4. Print drum release button (TM 818)

5. Front door set switch (TM 817)

• The print drum can be manually pulled out from the machine by a serviceman with the machine power off

Disassemble & Reassemble Lock Mechanism

23

2

1

3

4

5

3

1

2

4

5

Print drum safety SW

Print drum safety SW

Print drum lock solenoid

Print drum lock sensor

Print drum lock solenoid

Print drum lock sensor

Print drum Release button

Print drum Release button

Front door safety SW

Front door set SW

24

How to release the Print Drum manually from the machine.

1.Confirm that the print drum is at Position B

(If not, bring the drum to Position B)

2. Push in a screw driver in the hole indicated below.

3. The print drum disengages from the lock.

Push screw driver through the hole.

IMPORTANT:

Please ensure print drum is in Position B before removing.

25

Printing Section Chapter 8 Page 8-1

Print Drum Page 8-2

1. Print drum position B lock release lever

2. Ink sensor (TM 809)

3. Overflow sensor (TM 810)

4. Ink pump unit (TM 887 & 888)

5. Ink bottle set switch (TM 811)

6. Rollers & Ink blocking plates

Disassemble & Reassemble Print Drum

26

1

Print drum position B lock release lever

Push the lever down to release the print drum from position B.

27

5

23

4Ink bottle set SW

Overflow sensorInk sensor

Ink pump unit

28

6 Rollers & Ink blocking plate

Ink blocking plate

Fixed position No adjustment

Ink blocking plate

Doctor roller adjustment

Gap adjustment between Squeegee roller and drum body

Doctor roller Squeegee roller Driven roller

29

Squeegee Pressure = 0.2 plus/minus 0.05 A3

0.3 plus/minus 0.05 A4/B4

Squeegee Gap Adjustment = 0.06 plus/minus 0.02 A3

0.08 plus/minus 0.02 A4/B4

Adjustments page 8-27

30

Paper Receiving Area Chapter 7 Page 7-1

Paper Separation, Suction Unit & Receiving Tray Page 7-2

1. Separator

2. Separator Arm

3. Air Pump Unit Air blow timing fixed by Position B setting

4. Separation Fan (TM 662)

5. Suction Fan (TM 661)

6. Paper Ejection Motor (TM 660)

7. Paper Ejection Encoder Sensor (TM 612)

8. Paper Ejection Sensor (TM 606)

9. Paper Ejection Wing Reflecting type sensor

10.Paper Receiving Tray Paper Arrangers 400dpi Corrugators 300dpi

Disassemble & Reassemble Suction Unit & Paper Separation

31

1 3 2Separator Air pump unit Separator arm

32

4

Separation fan

33

TOP View

BOTTOM View

8

Paper ejection sensor

7

5

6

Paper ejection motor

Paper ejection encoder sensor

Suction fan

34• Fixed Position

• Manually adjustable

300dpi machine

600dpi machine

Adjust paper ejection wing dial according to the type & size of paper

Metric Machine

Paper Ejection Wings

For ordinary paper widths equal to or larger than B4, set to A3 B4

Metric Machine

For ordinary paper widths equal to or smaller than B4, set to A4 B5

Metric Machine

For thick paper, set to

35

Paper Receiving Tray

Paper GuidesThe paper guide positions must be readjusted if the horizontal print position is adjusted by sliding the paper feed tray.

Paper ArrangersAvailable only on 600dpi machines

36

Paper Receiving Tray

CorrugatorsThe corrugators are available only on the 300dpi machines.

Note:

Normal Paper Corrugators in position (DOWN)

Thick Paper Corrugators put away (UP)

37

Master Making Section Chapter 14 Page 14-1

Pulling the Master Making Unit out1. Master making unit removal button (TM 410)

2. Master making unit safety switch (TM 409)

3. Master making unit set sensor (TM 408)

4. Master making unit solenoid (TM 488)

• The Master making unit can be manually pulled out from the machine by a serviceman with the machine power off.

38Press the master making unit release button to pull the unit out of the machine.

39

Pulling out the master making unit manually

Push screw driver through the hole.

Note: Master making unit can be released manually by serviceman

40

32

3

4

1

2

41

Master making unitSafety switch

Master making unitSet sensor

Master making unitSafety switch

Master making unitRelease button

Master making unitSet sensor

Master making unitRelease button

Master making unitSolenoid

Master making unitSolenoid

41

Master Making Section

Write Pulse Motor, Load Pulse Motor & Cutter Unit Page 14-

4

1. Write pulse motor (TM 462 & 463)

TM 466

2. Load pulse motor (TM 464)

3. Cutter unit (TM 480) TM 486 & 487 Disc blade shuttle cutter unit only

4. Cutter HP switch (TM 403)

5. Cutter stop position switch (TM 404) Disc blade shuttle cutter unit only

Disassemble & Reassemble Master Making Section

Remove Master Making Unit & place on table. Please Note:

Drum & Master making unit is not to be out of machine at the same time. (machine may tip over)

42

2 3 1 Write pulse motor

Cutter unit

Load pulse motor

43

Rotary blade type cutter unit used on A3 machines

Shuttle type blade type cutter unit used on A4/B4 machines

Rotary blade

Disc blade shuttle

3

4

4

Cutter HP switch

Cutter unit

Cutter HP switch

2

Cutter stop position switch

44

Master Making Section

Master Making Unit Page 14-31

1. Master making unit

Master making unit is removable from the machine by detaching flat cable wire harness from the unit and removing four mounting screws.

1

Master making unit

Master making unit has been removed and placed on table.

45

Master Making Section

Sensors to detect the Master Material, etc.1. Master detection sensor (TM 401)

2. Master end sensor (TM 402)

3. Master positioning sensor (TM 400)

4. Master making upper unit set sensor (TM 407)

5. Master flanges F & R Built on the machine

46

3 2

1

5

2

4

Master making upper unit set sensor

Master positioning sensor

Bottom View

Master end sensor (Rcv.)

Master detection sensor

Master end sensor (Send)Master flanges F & R

47

Master Making Section

Thermal Print Head (TPH) Area Page 14-12

1. TPH (TM 9874 + 1234) (TM 80 to 85) 300 dpi machine = 80 & 81 only

2. Thermal Pressure Motor (TM 460 & 461)

3. TPH Pressure Sensor (TM 406)

• The TPH comes down against the Write Roller only during the

master-making process.

Disassemble & Reassemble TPH Assy

48

1

TPH

Springs to pull down the TPH

23

Thermal Pressure MotorTPH Pressure Sensor

Eccentric Cam to

Raise the TPH

49

Master Making Section

Master Transfer Rollers Page 14-20

1. Write Roller

2. Master Stocker Roller

3. Load Roller

4. Clamping Guide Roller

5. Stocker Solenoid (TM 489)

• Stocker solenoid activates only when the leading edge of the master

material transfers to the Load roller.

• Master making starts before the leading edge of the master material

is clamped on the print drum.

Driven by Write Pulse Motor

Driven by Write Pulse Motor

Please Note:

Position A = Master Loading

50

Master Making Unit

1

Write roller2

Master stocker roller

Stocker solenoid

5

3

Load roller

4

Clamping guide roller

Metal Shaft

Master positioning sensor

Cutter unitTPH

Master Roll

51

5

Stocker solenoid

The cover plate lifts up to close the Stocker entrance when the solenoid activates.

52

Master Making Section Chapter 9 Page 9-1

Master Clamp Unit Page 9-2

1. Clamp motor (TM 863, 864, 883 & 884)

2. Clamp sensor A (TM 803)

3. Clamp sensor B (TM804)

4. Clamp guiding plate

5. Position A compensator arm

6. Clamp plate

7. Master ejection plate

Disassemble & Reassemble Master Clamp Unit

53

13 2

5

4

Clamp motorClamp sensor B

Clamp sensor A

Position A compensator arm

Clamp guiding plate

• Master removal action is made while the print drum is rotating

• Master clamping action is made when the print drum is stationary with the

position A compensator arm holding the print drum in the position A

position.

FRONT view BACK view

54

• Master removal action is made

the print drum is rotating.

• Master clamping action is made when the

print drum is stationary with the Position

A compensator arm holding the print drum

in the Position A position. 7

6

Position A compensator block

Master ejection plate

Clamp plate

Roller for master ejection plate

Roller for clamp plate

55

The RISOiQualitySystem built into all new RZ series models is a radical new way to ensure that the users of RISO printers get the very best performance from their RISO printers, automatically.

The System allows two-way communication between RISOiQualitySystem

equipped printers and their supplies - ink and masters – via tiny integrated RF-tags

Embedded in the ink bottle and master roll.

This two-way communication provides a host of important benefits that include :

Assurance of optimum print quality

Prevention of operator error for supplies

Warning of shortage in remaining volume

Minimal paper waste

56

The RISO i Quality System – real time control for ultimate quality

What is an RF-tag?

An RF-tag (= Radio Frequency-tag) is a film that contains an IC chip and an antenna.

Various data for activating the RISOiQualitySystem are stored in the IC chip, and this data is sent to and received from the RISO printer via the antenna.

About Supplies…

Each Riso ink has its own character and viscosity, requiring individual and precise adjustment of print pressure, idling time and operating speed to obtain maximum print quality. In addition, the sensitivity of masters varies between the start and the end of the roll. Current RISO printers adjust for these parameters

but only to a limited extent. The RISOiQualitySystem not only offers real-time adjustment all of the time, it also achieves improved print quality.

INK

The RF-tag embedded on the ink bottle communicates data such as colour, viscosity, etc. to the printer, preventing the selection of the incorrect colour and assuring optimum print quality.MASTERThe RF-tag in the master roll stores and communicates data including master character and position on the roll for real-time adjustment of the master making parameters. This allows optimum print quality.

57

OPTIMUM PRINT PRESSURE CONTROL

Print pressure is automatically optimised based on data received from the RF-tag in the ink bottle and the master roll to assure optimum results.

OPTIMUM TPH POWER CONTROL

Information from the RF-tag in the master roll is used to optimise the power of the thermal head based on the real-time condition of the master materials.

The RISO i Quality System – Functions and Features

1. Ink colour indication Thanks to the The RISOiQualitySystem, printers with

LCD panels now can show the ink colour on the control panel.

2. Prevention of mis-insertion of ink bottle If the user tries to insert an ink bottle of the wrong colour – for instance placing a RED ink bottle in a drum used for BRIGHT RED – the machine returns an error message and prevents mis-operation. This assures reliable and consistent colour reproduction.

3. Thermal head energy auto adjustment Data stored in the master rolls RF-tag includes the date of manufacture, position on the roll and master character. This information is used to automatically adjust the power of the thermal head to suit, resulting in optimised masters, every time and best possible print quality.

58

4. Idling time auto adjustment by interval from previous use ink character

The RISOiQualitySystem automatically adjusts idling time according to the combination of time elapsed since last use, ink colour and ink characteristics, to assure optimum quality from the start of a print run and to minimise paper wastage.

5. Print press roller auto adjustment to optimise first print quality

The RISOiQualitySystem combines information on ink viscosity, character and colour with details on master characteristics and data as to when the printer was last used to adjust warm up action and optimise pressure of the print roller for maximum quality from the beginning of the print run, to minimise paper wastage.

6. Print press roller auto adjustment for superior output The printer reads information on master character and ink viscosity, character and colour from the

RISOiQualitySystem and uses this to automatically set the optimum print pressure of the print roller for maximum output quality.

7. Precise, real-time feedback on remaining supplies A further advantage of the RISOiQualitySystem is precise real-time feedback on the amount of ink and masters remaining. When the remaining volume of supplies is near to the end, the RISO printer indicates the caution display so that the users need never run out of ink or masters un-expectedly.

59

Manual data input procedure for LED modelsTo optimise print quality, the printer receives information from supplies via the RF-tag. If that data is un-available for any reason, the

“i” indicator fails to light and an “H” is shown in the print quantity display.

Step 1: Enter a parameter using the print quantity keys.

Manual input parameters

H1 : Ink colour setting

Select the same colour as that of the currently installed drum.

1: Black 2: Colour

H2 : Print density adjustment (ink)

Perform fine adjustment to optimise print density according to ink.

1 (Light) to 5 (Dark)

H3 : Test printing print density adjustment (ink)

Perform adjustment of print density for test printing according to ink type and colour. This adjustment is independent to H2.

1 (Light) to 5 (Dark)

60

H4 : Master making density setting

Set the reference density for the master making process

1 (Light) to 10 (Dark)

H5 : Print density adjustment (master)

Perform fine adjustment to optimise print density for testing according

master.

1 (Light) to 5 (Dark)

H6 : Test printing print density adjustment (master)

Perform adjustment of print density for test printing according to

master. This adjustment is independent of H5.

1 (Light) to 5 (Dark)

Step 2 : Press the start key to complete entry.

If the next number appears, repeat steps 1 and 2.

Step 3 : When all data necessary is input, the print quantity display

returns to normal and is available for standard operations.

61

Master Disposal Area Chapter 10 Page 10-1

Master Disposal Unit Page 10-2

1. Master disposal box safety switch (TM 423)

2. Master disposal motor (TM470)

3. Master disposal motor encoder sensor (TM 426)

4. Master disposal jam sensor (TM 420)

5. Master compression motor (TM 490, 491 & 493)

6. Master compression motor encoder sensor (TM 425)

7. Master compression plate HP sensor (TM 421)

8. Master loading sensor (TM 806)

9. Master disposal roller release lever

10. Master disposal roller lock lever Removing jammed master on the disposal rollers.

(For the machine operator)

Disassemble & Reassemble Master Disposal Section

62

1Master disposal box safety switch

10Master disposal roller

lock lever

9 Master disposal rollerRelease lever

63

3

2 7

5 6Master compression motor Master compression motorencoder sensor

Master disposal motorencoder sensor

Master disposal motorMaster compression plate HP sensor

64

48 Master loading sensor Master disposal jam sensor

Master making unit (BOTTOM View)

65

Master Disposal Area

Master Disposal Box Full Detection

1. Disposal box capacity Approx. 100 masters

2. Removed master Not counted

3. Full detection Master compression motor encoder sensor

END POSITION of the Master compression plate

Preset pulse count of the Master compression motor encoder sensor.

FULL POSITION of the Master compression plate

Preset pulse count of the Master compression motor encoder sensor.

BOX FULL MESSAGE

Speed of the Master compression motor encoder sensor disc.

FULL indication display When the encoder disc rotation slows down to a preset speed Per one rotation before the master compression plate arrives to the FULL POSITION

66

Original Scanning Section Chapter 11 Page 11-1

Flat Bed Scanning Page 11-2

1. Scanner carriage HP sensor (TM 200)

2. Original detection sensor (TM 201)

3. Stage cover sensor (TM 209)

4. Scanner carriage (TM 280, 281, 282, 283 & 284)

5. Scanner lamp (TM 260) 600 dpi only

• Shading compensation Both 600 dpi & 300dpi.

• ABC (Auto Base Control) 600dpi machine only.

• Different scanner unit between 600 dpi & 300 dpi.

• No original size detection sensor.

Image making area is set by:

1. Paper size detected on the paper feed tray.

2. Original size detected by the optional auto feeder (AF) original size detection sensor.

Disassemble & Reassemble Scanning Section

300dpi

600dpi

Main Scan

Sub Scan

= D600dpi

67

1 Scanner carriage HP sensor

2Original detection sensor

4Scanner carriage 5

Scanner lamp

3 Stage cover sensor

68

Test Mode Chapter 17 Page 17-1

Important Test Modes Page 17-2

1. REv information extract onto CF card (TM 099)

2. Jam message clear (TM 110)

3. User area memory clear (TM 111)

4. Normal area test mode data clear (TM 112)

5. Protected area test mode entering (TM 9874)

The existing setting should be noted down on a piece of paper before activating these to test

modes. Activating these two test modes will reset the settings back to program default settings.

Note: Factory default setting differs from the program default settings Factory adjusts each

machine before shipment.

There is a plan for the future that existing normal area test mode settings can be downloaded onto

CF card.

69

Test Mode

Starting up the Test Mode

To access Test Mode, press the two print position keys at the same time and turn the machine power ON.

Standard Test Mode: No. 0001 - 0999

Options Test Mode: No. 3000 - 3599

Protected Test Mode: No. 1900 - 1999

An access code of No. 9874 needs to be input in order to get into the Protected area Test Mode.

70

Test Mode

Activation & Exit

Normal Area

Test Mode

71

Panel Messages CHAPTER 16 Page 16-1

72

Panel Messages CHAPTER 16 Page 16-2

73

Other Precautions Chapter 18 Page 18-1

1. Power saving (Low power) mode.

With no error status on the machine, if no operation is made on the machine for 30 seconds, the

24 volt supply to the machine components is terminated. There is no sign for this power saving mode, so when using a multi-meter to check 24 volts on the machine this must be kept in mind.

Also when servicing machine, NO DRUM FREE ROTATION (FREE SWITCH) is accessible when in power saving mode. TO ACTIVATE 24 VOLTS, TOUCH KEYPAD.

2. Battery replacement

Replace the battery on the mechanical PCB with the machine power ON. (RZ3 series only)

3. Replacement of the mechanical control PCB

When the mechanical control PCB is replaced, it is necessary to record all the user mode and test mode settings. Therefore it is important to memo down all the user mode settings prior to the replacement of the mechanical control PCB.

The protected area test mode (those test modes which needs 9874 to be activated in advance)

are memorised in the EEPROM, so these do not need to be re-entered.