HP Designjet L65500 service manual part 1-2
1 Printer systems
• Electrical system.....................................................................................................4
• Ecabinet.........................................................................................................5
• E-Box ........................................................................................................... 19
• ECabinet Circuit Diagrams ..................................................................... 10
• PCA Boards and connections..........................................................................20
• Formatter PCA...................................................................................... 20
• Hard disc drive..................................................................................... 20
• Upper and Lower Engine PCI Board ........................................................ 20
• Printmech Board ................................................................................... 21
• Main Interconnect Board connections ...................................................... 22
• Substrate path ..................................................................................................... 28
• Ink System........................................................................................................... 39
• Scan Axis ........................................................................................................... 45
• Carriage............................................................................................................. 57
• Printhead Cleaning System.................................................................................... 61
• Heating and Curing .............................................................................................66
• User Interface ...................................................................................................... 74
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Electrical system
The electrical system is primarily housed in the electrical cabinet, inside this is the electronics box.
Electronics overview diagram
The following diagram explains the connections between components and electronic boards, the voltage,
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or the type of data line.
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Ecabinet
The ECabinet
ACB-3
ACB-2
ACB-1
3 phase
Circuit
breaker
Single phase
Circuit breaker
RCD-1
Residual
Current
Circuit
Breaker
(RCCB)
The ECabinet located on the right side of the printer and is the enclosure where the main electronics
(Electronic Control System, E-box) and all the power electrical components of the printer are located. The
system if fed via two power lines, one single phase line and another tri-phase line see the Installation Guide
and Site Preparation guide for specifications.
The E-Cabinet responsible for distributing all the power lines to the functional areas, it includes the active
power elements of the heating and curing subsystem. It also performs safety cut-outs when any of the four
emergency stops are pushed
Some of the components inside the e-cabinet are independent units isolated from the electronics therefore
diagnosing any issues via Firmware is not possible.
To diagnose most electrical issues, voltage and continuity checks are required from the Service Engineer
by using multi-meter tools (Voltmeter, Amp meter, resistor meter, continuity checks)
Components
The Ecabinet contains the following
components:
• The Ebox
• Secondary 24v Power supply
• Secondary 42v Power supply
• Circuit breakers & Residual Current Circuit
• Contactor (Heating and Curing)
• Fuses (Heating and Curing)
• E-Box system (which includes a main
• Safety relay
• Fan
• Scan Axis break resistor
• Vacuum system transformer (110v)
• Main switch
• Power Enable button
• Light indication for Phases
• 3 Phase Line filter
• 1 Phase Line filter
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breaker (RCCB)
power supply delivering ATX tensions and
also 24V and 42V)
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Inside the ECabinet (1 of 2)
Ebox
Secondary 24v supply
Secondary 42v supply
Heating
and
Curing
Power
Modules
(power
lines are
thicker in
the LX800)
Safety Relay
Contactor
RM 3 Phase
Terminal
Blocks
ECabinet
fan
1 Phase
Line filter
Line filter 42v
line +resistors
Roll to Free
Floor
control
system
LX800
Power fuses heating/
Curing
Fuse block (1A, 2A, 4A
3 Phase line filter
Power enable
button
Vacuum power
On
Vacuum
transformer 110v
Main switch
Light indicator
for phases
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Inside the ECabinet (2 of 2)
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Ecabinet Fuse blocks
Fuse Application
• Fuses: 1,2,3 (1A) Indicator Lamps
• Fuses 6, 7 (1A): PID controllers
• Fuse 8 (2A): Phase 110 from Trafo to Pump
• Fuse 9 (2A): Neutral 0V from Trafo to Pump
• Fuse 10 (4A): protects 110V transformer
• Fuse 11 (2A): 24V from Main interconnect to e-cabinet
Functionality
1. The E-Cabinet is the power distribution centre for the whole printer
It is the central point where both input power lines (Single and tri-phase) are connected and then distributed
to the different power components.
Single Phase components powered through ACB1
• Heating Controller Module
• Curing Controller Module
• Secondary 42V power supply (SAX motor, Media Path Motors)
• Secondary 24V power supply (Curing Fans)
• Vacuum Fan
• E-Box
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Single Phase components powered through ACB2
• Printer PC (Windows, IPS)
• Printer Monitor
• Printer Switch
Tri-Phase components powered through ACB3 and RCCB
• Heating and Curing Power modules – Heating and curing lamps
- Contains the Ebox
- Emergency stop mechanism for the machine.
- Heating and curing control and power distribution.
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ECabinet electrical overview
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42v Secondary Power Supply, Power distribution diagram
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Functionality interlinked between diagrams
Power
Fuses
Heating
Line
Filter
Main
Switch
Circuit
Breaker
Contactor
KM SW-1
Power
Module
Heating
Heating
Configuration Block
(star/triangle)
Lamps
Heating
Power
Fuses
Curing
Power
Module
Curing
Curing
Configuration Block
(star/triangle)
Lamps
Curing
A. 3 phase power supplied to the Heating and curing Modules through the power fuse blocks (FH4,
FH5):
B. Single phase power distribution.
C. 42v secondary power supply actuation (by safety relay)
D. Power modules control signals from PID controllers.
E. Safety line connections (cuts connector of the 3 phase line).
F. PWM signal and fault from curing fan array to Main Interconnect (24v power is directly supplied
from 24 volt secondary PSU).
G. 24v fault signal to the Main Interconnect (this line is used to detect if the 24v secondary power
supply is providing 24v or not).
H. E-cabinet internal fan fault signal to Main Interconnect (fault reported when fans do not rotate when
powered).
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I. 24v fused line arrival to the e-cabinet from the Main Interconnect.
J. E-stop 24v power line (these 24v activate the safety relay).
K. Feedback to the Main Interconnect safety relay is active (with negative logic). This indicates the
printer is armed from the circuit breakers.
L. KM Contact active (closed). Feedback to the Main Interconnect.
In the following pages are the printers circuit diagrams. Refer to the circled numbers and letters to jump
from one circuit diagram to another.
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ECabinet Circuit Diagrams
Circuit Diagram 1: Power in distributing
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Circuit Diagram 2: Power modules, power control lines
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Circuit Diagram 3: Temperature Controllers
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Circuit Diagram 4: Vacuum Transformer
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Circuit Diagram 5: Secondary Power Supplies and Internal Ecabinet Fan
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Circuit Diagram 6: Safety Control system
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Circuit Diagram 7: Ebox Connections
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Circuit Diagram 8: PC Monitor Switch power connections
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Related tests, utilities, and calibrations
• Electrical cabinet diagnostic test Page 306.
Service parts
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• Electrical Cabinet Page 451.
- Circuit Breaker
- Internal Fan
- Secondary Power Supplies
- Power Fuse Holder Block
- Safety Relay
- Scan Axis Brake Motor
- Vacuum Fan Power Transformer
- Main Power Switch
- Heating and Curing Temperature Sensor
- Power Fuses
- 3 Phase line filter
- Main Power Breaker
- Heating and Curing Power Module
-
Removal and installation
• Electrical Cabinet Page 522.
18 Printer systems
E-Box
Formatter PCA
Upper and Lower PCI PCA
Main Power Supply
ATX +24/42 PSU)
ECabinet
PrintMech PCA
ATX
On/Off switch
Hard Disk
1
Yellow led: Power
on>Stand by ON
Blue led: ATX On > Formatter
powered
Main Power Supply
Green led: 24/42
Printer On
The Ebox contains the main electrical control system in the printer. The e-box is the main processing and
control element of the machine where all main electronic units are comprised.
Components
The Ebox is inside the Ecabinet and contains the following components:
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• Orange ON: System is powered (ACB 1 ON), System with Stand by power in the formatter waiting
• Blue ON: Formatter Power system (ATX) Active.Internal computer system running
• Green ON: 24/42V of the second part of the main power supply activated. These 24 Volts are the
for the Front Panel power ON button to be pressed to start up the system.
Check this led when the printer is not powering on by pressing the front panel button to ensure the
failure is not in the main power supply. If the led is Off AC power is not arriving to the main power
supply or Main power supply switch in the main power supply is off or the Main power supply is
faulty.
main source for the complete system to work. Without these 24 Volts the e-cabinet electrical system
will not work and the system will be impossible to be armed.
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Functionality
The E-box contains the primary electrical systems of the printer in one area.
Circuit Diagram: PCAs in the Ebox
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PCA Boards and connections
Components
Formatter PCA
The formatter is the motherboard of the printer, with an Intel microprocessor of 256 MB RAM memory
runs the operating system of the printer.
Hard disc drive
The HDD contains the main Firmware of the printer.
• The operating system is based on Montevista, an HP developed system.
• All calibration values, product number, serial number etc, are stored on the Hard Disc Drive. In
order to make sure that this information is not lost in the case of a failure of the HDD, a backup
is made:
- In the Main Interconnect Board for all the other information (other calibrations, total ink con-
sumption etc).
- In the ISM board for information related with the ISM area (calibrations of the ink sensors,
level of ink in the intermediate tanks, etc).
NOTE: In order to prevent the loss of calibration values, never replace the Hard disc system
and the ISS Main Board or the Hard disc system and the Main Interconnect Board at
the same time.
Upper and Lower Engine PCI Board
These two boards are the main controllers of the printer. They are responsible for all real-time
processing and are the ultimate controllers of all electromechanical systems.
The Lower Engine PCI Board controls all substrate path components (Drive Roller, Spindle Motors,
OMAS, etc.), and the link to the following controllers: Controllers of the PH cleaning roller (situated
on the main interconnect board). The one connected to the remote controller board controlling the
capping station movement motor. Both controllers are connected through the same bus (MICC).
20 Printer systems
The Upper Engine PCI Board controls all non-substrate path components (carriage, scan axis motor,
scan beam height/PPS, PH cleaning assembly, service station, etc).
Printmech Board
The Printmech Board is mainly used to drive the four substrate advance motors.
• 2 Front Spindle motors (connected in series)
• 1 Rear Spindle motor.
• 1 Media advance motor (the drive roller motor)
NOTE: The motors are driven by 42V obtained from the secondary power supply which is
located inside the electrical cabinet.
NOTE: To check that the 42V power supply arrives from the secondary power supply, see the
V Power 2 LED located on the Printmech Board.
Printmech leds
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Main Interconnect Board connections
J306
J307
J3
J308
J4
J1
J27
J6
J8
J7
J5
J10
J12
J13
J26
J19
J22
J23
J15
J16
J17
J11
J310
J305
J301
J21
J20
J300
J18
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Most of the signals to or from the electronics box pass through the interconnect board. All of the
cables connected to the Main Interconnect Board have labels indicating to which connection it
should be connected.
J Plug Description J Plug Description
J1 Scan Axis Motor data J16
J3 Drop Detector J17
J4 Front Panel J18 Roll to Free Floor Control/power
J5 Remote Control Board (Service Station) J19 Power 24v (E-Cabinet, PPS, ISS)
J6 Remote Control Board (PPS) J22, J23 From secondary power supply 42v
J10 Media Input (Rear Spindle System) J300
J7 ISM 1 (Ink system Module: data 1) J301
J8 ISM 2 (Ink system Module: data 2) J306 To upper engine PCI Board
J12 PH Cleaning System data (Encoders) J307 To lower engine PCI Board
J13 Front Right PPS (data) Encoder+switch J308 Front Panel Intermediate cable
J26 Rear Right PPS (data) Encoder+switch J305/J310 To Printmech 42v
J15 Ecabinet Faulty Signals J20 Power supply to Carriage 24v
J11 Media Output (Front spindle system Encoder) J21 Power supply to Carriage 42v
J27 OMAS/Vacuum control data
Power& Control for PPS rear right motor PH
Cleaning Roller motors & Capping Station 24v
power to remote controller
Power & Motor control for PPS front right motor &
vacuum controller (24v & 5v)
Encoder readers from the Printhead cleaning
Rollers to the Upper Engine PCI board
42v from secondary 42 v power supply to
PrintMech
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Main Interconnect Board LEDs
2
1
3
4
5
6
8
7
9
10
11
12
Number Description Number Description
1 24 LEDs (DS6 to DS29) 7 From PPS encoder (rear, right)(DS36)
2
3Not used 9
4 Power temperature sensor 10 24v to Scan Axis motor (DS40)
5 5v for the PPS encoder (rear, right)(DS41) 11 Scan Axis motor comms signal (DS32-33)
6 5v for the PPS encoder (front, right)(DS37) 12 From Scan Axis Motor (DS34)
ATX from Main Power Supply+12v, +5 (including
5v stand-by)
8 From PPS encoder (front, right) (DS35)
12v from main power supply going to Front
Panel (DS39)
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Photo detail of Main Interconnect
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Pin outs of the Main Interconnect
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Pin outs of the Main Interconnect
The’ J17’ on the label
identifies the J17 connector
on the Main Interconnect
Board.
The ‘INT’ on the label
signifies Main INTerconnect
Board, which this cable is
connected to
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Labels on the cables
Labels are attached to the cables to identify where the cables go to, and in some cases identify the
functionality of the cable.
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Label abbreviations
Related part Abbreviation on label
Switch SW
Encoder ENC
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Power PWR
Lan LAN
Cover CV
Main Interconnect Board INT
Engine upper PCI board ENG 0
Engine lower PCI board ENG 1
PrintMech board PM
Hard Disk Drive HDD
Main Power Supply PWR
Powe r Cabinet PWR CAB
Secondary 24V Power supply PWR CAB SEC 24V
Secondary 42V Power supply PWR CAB SEC 42V
E-cabinet 24V intermediate connection PWR CAB 24V Out
IR temperature Sensor - Left (Curing) SAX TS - LEFT
CUR IR temperature Sensor - Right SAX TS - RIGHT PZ - H
Print zone lamps power SAX PZ - H PWR
Curing lamps power SAX CURING PWR
Curing fans CURING FANS
Front Spindle Motor FSM - T/B ( Top/Botto m)
Rear Spindle Motor RSM
Drive Roller Motor MA (media advance)
Carriage Lid Switch C Lid SW
Printhead Board C PH1/2/3
Note: SAX=Scan Axis
L65500/LX600 Power lines specifications: 3 phase line
High Voltage system Low voltage systems
Input voltage 3 x 380-415V~ (-10%+6%) 3 x 200-220V~ (-10%)
Circuit Breaker 20A 32A
Input frequency 50Hz 60Hz
Power consumption 12kW 12kW
maximum load current (per phase) 32A 32A
L65500/LX600 Power lines specifications: Single phase line
High Voltage system Low voltage systems
Input voltage (phase to neutral) 3 x 220-240V~ (-10%+6%) 115-127 V~ (-10%) (Japan 200 V~)
Input frequency 50Hz 60Hz
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High Voltage system Low voltage systems
Power consumption 1kW 1kW
maximum load current (per phase) 10A 10A
LX800 Power lines specifications: 3 phase line
High Voltage system Low voltage systems
Input voltage (line to line) 3 x 380-415V~ (-10%+6%) 3 x 200-220V~ (-10%)
Input frequency 50Hz 60Hz
Power consumption 15kW 15kW
maximum load current (per phase) 30A 50A
LX800 Power lines specifications: Single phase line
High Voltage system Low voltage systems
Input voltage (line to line) 200-240V~ (-10%+6%) 115-127 V~ (-10%) (Japan 200 V~)
Input frequency 50Hz 60Hz
Power Consumption 1kW 1kW
Maximum load current (per phases) 10A 10A
Related tests, utilities, and calibrations
• From diagnostic mode: Electronics Page 291.
• Service Utilities: Electrical system Page 291.
Service parts
• Electrical Cabinet Page 451.
Printer systems
Removal and installation
Electronics Page 509.
Printer systems 27
Substrate path
Drive Roller Encoder disc
Drive Roller Motor Assembly
Pinch mechanism
Drive Roller
Rear Spindle
Drive
Roller
Encoder
sensor
The media roll is mounted on the rear spindle and is collected on the front spindle. Media goes from the rear
spindle over the drive roller, over the print platen, over the diverter and onto the front spindle.
Each of the spindles has its own motor system. Vacuum is applied at the level of the print platen to keep the
substrate flat.
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Components
The advance of the media is applied by the motor of the drive roller. There is a pinch mechanism to prevent
the substrate slipping against the drive roller.
The accuracy of the substrate advance is controlled with two components:
• The Driver Roller Encoder disc.
• The OMAS: This is an optical sensor which works like a camera taking pictures of the media’s fibre,
the pictures are then compared, measuring actual distances during movements in order to apply
small corrections in the advancement of the substrate.
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