Xerox Solid Inkjet 100 Solid Inkjet Printer Service Manual

Chapter

General Information

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Chapter 1

General Information

This chapter provides information and a general overview of the iiLINX

Solid Inkjet 100 Printer. Theory of operation, printer specifications and components are presented in the following sections:

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ii LINX™ Solid Inkjet 100 Service Manual

General Information

The iiLINX Solid Inkjet 100 printer, shown in Figure 1-1, is a userinstallable, low maintenance, environmentally friendly, High Quality

Referral Image PostScript printer.

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Figure 1-1. The iiLINX Solid Inkjet 100 Printer (shown with optional

Auxiliary Feeder Unit Assembly)

To ensure complete understanding of the Solid Inkjet 100 printer, we recommend participation in Solid Inkjet 100 printer service training.

General Information

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Solid Inkjet 100 Printer Overview

The Solid Inkjet 100 Printer is an Adobe PostScript Level 3 (Version

3010) grayscale, solid inkjet printer. It supports 409 x 409 dots-perinch (dpi) resolution at draft mode, and 600 x 600 dpi at High

Resolution Medical mode. The speed of producing images is 4.8 pagesper-minute (ppm) in draft mode, and 2.5 ppm in High Resolution

Medical mode.

Base Solid Inkjet 100 printer

The base Solid Inkjet 100 printer features 136 built-in fonts, and is equipped with 64 Mbytes of RAM. It can be upgraded to 128 Mbytes of RAM by adding an optional 64 Mbyte RAM DIMM.

All printers support two available paper trays: A and A4 trays and an optional 500-sheet high-capacity paper tray assembly give the printer a two-tray capability. The high-capacity paper tray assembly is usually referred to as an auxiliary feeder unit.

A 133-MHz PowerPC processor oversees print engine operations and

PostScript image processing. The printer features an integral bidirectional parallel port (IEEE 1284C with ECP mode) and a

10baseT Ethernet port (with support for EtherTalk, TCP/IP, DHCP and Windows Peer-to-Peer). A USB high-speed serial port is also provided.

An optional Ethernet interface board offers a 10BaseT/100BaseT/

10Base2 Ethernet connection providing standard protocol support for

EtherTalk, TCP/IP and DHCP. When installed, this card disables the standard 10baseT port.

A second rear panel slot accommodates an internal IDE hard drive for

DICOM support.

Solid inks

Solid inks, sometimes called phase-change inks, are solid at room temperature and are liquid at the higher temperature used during printing. The inks solidify almost instantly after being jetted onto the printer’s drum. Each of the Solid Inkjet 100 printer inks is especially formulated for this printer; the inks are not interchangeable with other models of solid ink printers.

NOTE: Turning the printer off and allowing it to cool causes it to perform a printhead cleaning and purge cycle upon power-up. The printer’s purge cycle consumes a significant amount of ink. During normal use and servicing, turn the printer off and allow it to cool only when necessary.

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Memory Considerations

The printer dual frame buffer allows for printing one image while processing a second image (which gives greater printing throughput).

With additional RAM memory, the printer’s capabilities increase as detailed in Table 1-1:

Table 1-1. Installed RAM and Printer Capabilities

Feature

Fast (draft) printing

Base

(64 Mbytes)

yes

Additional RAM Upgrade

(128 Mbytes)

yes

High-Resolution

Medical Printing yes yes

Pipelining

DICOM Support yes no yes yes

To verify what type of RAM is installed, print the 2-page

Configuration Page from the Front Panel menu and refer to “Installed

RAM.”

For example:

Installed RAM:

Memory Slot 1:

Memory Slot 2:

64 Mbytes

SDRAM/Non-parity/32 Mbytes/

KMMe 665 403 CTL-GO

SDRAM/Non-parity/32 Mbytes/

16LSDT 464AG-662C1

General Information

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Print Engine Assemblies

Internal features of the print engine are illustrated in Figure 1-2.

Cap/Wipe/Purge assembly

Drum

Transfix roller

Process motor

Printhead Ink load assembly

Paper/

Drum heater

Y-axis motor

X-axis drive and motor

Paper feed motor

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Figure 1-2. Internal Features of the Print Engine

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Seven circuit boards support the printer’s electronics. (Refer to

Figures 1-3 and 1-4). Two boards, called I/O boards, left and right, support the front panel, solenoids and sensors. The main board contains the printer’s CPU processor, RAM and ROM. The power supply accepts the AC input voltage and distributes it or converts it to various other levels of required DC voltages and distributes them.

The power control board distributes power supply voltages to the other printer boards and drives many printer motors. The front panel provides a user interface to the printer. The printhead drive board, a part of the printhead, manages the signals and voltages of the printhead’s printing elements and sensors. The optional Ethernet interface card and internal hard drive could be considered the eighth and ninth circuit boards.

Front panel

I/O board right

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Figure 1-3. Circuit Boards of the Print Engine (Right Front View)

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Printhead drive board

Optional

Internal hard drive

Optional

Ethernet

Interface card

Power supply

Main board

I/O board left

Figure 1-4. Circuit Boards of the Print Engine (Left Rear View)

Power control board

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An internal data bus, called the I 2 C bus, connects all I/O boards to the main board. (Refer to Figure 1-5.) Through this single bus, the main board can “poll” the I/O boards for the state of the printer’s sensors as well as actuate the printer’s solenoids. This data bus greatly simplifies the wiring that would otherwise be required for monitoring numerous sensors and solenoids. The I 2 C bus also extends down to the

Auxiliary Feeder Unit.

Auxiliary feeder unit connection

Figure 1-5. The Printer’s I 2 C Bus

I

2

C bus

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General Information

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Cap/Wipe/Purge carriage drive

The printer features a printhead maintenance system used to clean the printhead faceplate and clear clogs from the printhead nozzles.

(Refer to Figure 1-6.) The system consists of a vacuum pump assembly, the cap/wipe/purge assembly, the cap/wipe/purge carriage drive, the purge hose and tubing, and the purge filter.

Purge

Filter

Figure 1-6. Printhead Maintenance System

Vacuum pump assembly

Purge hose and tubing


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Sensors in the printer provide information to the main board to determine the state of the printer. The printer monitors the positions of some of the movable assemblies, such as the drum, as well as the temperature of many other assemblies, such as the printhead, paper preheater and the drum. Figure 1-7 shows the sensors and switches on the right side of the print engine. Figure 1-8 illustrates the sensors and switches on the left side of the printer.

Ink load cover sensor

Top cover switch

Ink-stick- low sensor

Ink-stick- out sensor

Front cover switch

Exit/tray-full sensor

Preheater entry/right edge sensor

Hand-feed sensor

Paper-pick sensor

A4-size media sensor

A-size media sensor

Cap/Wipe/Purge home sensor

Tray type sensors

Maintenance blade position sensor

Paper-empty sensor

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Figure 1-7. Sensors and Switches on the Right Side of the Print Engine

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Transfix exit sensor

Drum temperature sensor

Duplex paper sensor

Drum-homeposition sensor

Drum encoder sensor

Process gear position sensor

Preheater exit sensor located on inside wall of drum/transfix frame

Preheater exit sensor

Transfix roller

Preheater

Drum

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Figure 1-8. Sensors and Switches on the Left Side of the Printer

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Upper feed roller clutch

CAUTION

The actual position of some printer assemblies, such as the printhead or the cap/wipe/purge assembly, cannot be ascertained at all times. The printer records, in NVRAM, where it last positioned such assemblies each time it moves them. If, after power-down or a power interruption, the assemblies are manually repositioned, the printer erroneously assumes that the assemblies are in the position it last left them. This assumption can result in damage to the printer when it tries to position the assemblies. For example, the printhead could be tilted forward and crash into the raised cap/wipe/purge assembly.

Before turning on the printer, ensure the printhead is tilted forward, centered in front of the drum and the cap/wipe/purge assembly is in the retracted, home position. The tilt cam gear should be disengaged from the gear drive train.

Electric clutches and solenoids are used by the printer to engage rollers as needed to move paper through the printer as well as start some print processes. Refer to Figure 1-9.

Drum maintenance cam clutch

Cap/Wipe/Purge clutch

Pick clutch

Transfix solenoid

Air valve solenoid

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Figure 1-9. Solenoids and Clutches on the Print Engine

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The Main Board

The main board features the printer’s PowerPC processor that controls the engine and the PostScript processing. Refer to Figure 1-

10. Prominent on the main board is the code ROM DIMM and the

RAM DIMM plug-in modules. The code ROM DIMM also contains the printer’s on-board fonts. Variations of the code ROM DIMM contain alternate language fonts such as Kanji or Hangul.

Network connection is provided through a built-in 10baseT port.

The printer stores unique printer status and PostScript values in its

NVRAM module. The printer’s Ethernet address, unique to each printer, is stored in Boot ROM/Printer ID chip, an 8-pin socketed IC in location U390. All these socketed components should be transferred to a replacement main board to maintain customer-unique settings.

Boot ROM/

Printer ID

RAM DIMMs

NV RAM/

Real Time Clock

Code ROM

DIMM

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Figure 1-10. Features of the Main Board

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Media Tray Type Sensing

The combinations of the three tray sensors inform the print engine what type of media tray (A or A4) is installed. These combinations are shown in Table 1-2. The print engine does not detect the type of media installed in the tray; it only detects the particular tray being used by the presence of sensor flags on the side of the tray. The tray sensors are located on the right-side interior of the paper tray slot, mounted on I/O board right. There are two tray types:

• Letter (A-size). This tray is sized for 8.5 x 11-inch (U.S.) paper.

• Metric Letter (A4-size). This tray is used for 210 x 297 mm

(Metric) paper.

Table 1-2.

Tray Switch Sensor Combinations

Top switch

Middle switch

Bottom switch

Tray type

A Paper

Closed

Open

Open

A4 Paper

Open

Closed

Open

Front Panel

These front panel features (shown in Figure 1-11) are found on the printer:

• 128 x 64 pixel backlit LCD graphic display

• Two push buttons and four navigation arrow buttons

• Two LEDs (Power and Error)

LCD. The backlit LCD serves two purposes: displaying current image processor and print engine status information and displaying an interactive menu. Status information includes image processor status such as Ready to Print, Receiving Data and Printing. Print engine status includes messages such as Out of Paper, Paper Jam and Add

Ink as well as error messages.

Customers can review and modify certain NVRAM, I/O ports and peripheral parameters. Using the front panel to review and change parameters is discussed in the topic, “Adjustments”.

Buttons. Four of the six buttons are arranged as a diamond-shaped keypad. The other two buttons are used as Select and Help.

In the Service Support menu, pressing and holding the Left arrow button , and then pressing the Select button enters the hidden service support menu.

Pressing and holding the Right arrow button and then pressing the

Select button proceeds immediately to the language selection menu.

General Information

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Pressing and holding the Left arrow while turning off the printer will confirm the printhead is correctly parked by flashing both front panel LEDs.

Turning the printer on with the rear panel DIP switch 2 in the

“down” position, allows access to the front panel during the warm-up cycle.

The topic “Resetting NVRAM” explains how to use the front panel buttons to reset the NVRAM to its factory-default values.

Navigation buttons

Power

READY TO PRINT

Error

LCD

Display

Help button

Figure 1-11. Printer Front Panel

Select button

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Rear Panel

Connectors

The rear panel (Figure 1-12) of the printer features the host interface connectors to the printer; it includes the following connectors:

• Standard parallel (high-density connector), IEEE 1284C

• Twisted Pair (10BaseT) Ethernet connector

• Universal Serial Bus port

• A special 5-pin connector accommodates a service RS-232 cable from a PC running PC-based diagnostics.

The rear panel also includes two option slots. With the addition of an optional Ethernet Interface network card in the lower slot, the printer can support 10Base2 or 100BaseT Ethernet connectors.

NOTE: When an optional Ethernet Interface card is installed, the printer’s built-in 10BaseT Ethernet port is disabled.

The second slot accommodates an internal IDE hard drive for print

DICOM support.

Health LEDs

Two health LEDs indicate the status of the printer’s CPU functions:

PostScript (PS) processing and Print Engine (PE) control.

• Blinking: The printer is operating normally. Both LEDs blink irregularly during diagnostics. To indicate the printer passes the POST tests and is operating normally, the left (PS) LED flashes in a “heartbeat” rhythm (on 0.5 seconds, off 0.5

seconds). The right (PE) LED pattern is two quick flashes on, then off for a count of two for a total cycle time of just over two seconds.

If a soft error occurs, image processing occurs, but in a reduced capacity. Soft errors include failure of expansion memory

DIMMs or of any of the interface ports. When a soft error occurs, the printer automatically prints a startup page listing the error.

• On or Off, or blinking a coded error indication: A hard error condition has occurred that would keep the image processor board from operating. Refer to the topic “Error Codes and

Messages” for the meaning of a coded indication.

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Ethernet Card

TX

RX

100

Mbs

TP

LINK

10/100Base-TX 10Base2

Switches

Four DIP switches allow you to reset the printer or place the printer in different operating modes. Figure 1-12 illustrates the rear panel of the printer and location of the DIP switches.

Table 1-3.

Rear Panel DIP Switch Settings

Function

Normal operating mode

Service mode

Reset printer

Manufacturing mode

(Bypass mode)

Development mode

(engineering use only)

Recovery mode

(engineering use only)

Switch 1

UP

DOWN

UP

UP

DOWN

DOWN

Switch 2 Switch 3

UP UP

UP

UP

DOWN

UP

UP

UP

DOWN

UP

DOWN

DOWN

Switch 4

UP

UP

DOWN

UP

UP

UP

IDE hard drive

Optional Ethernet

Interface card

PostScript health light

Print

Engine health light

Service

RS-232

Ethernet

10BaseT

Parallel USB DIP switches

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Figure 1-12. Rear Panel

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Bypass Mode (Manufacturing Mode)

Bypass mode allows you to access the front panel menus (bypassing the engine and PostScript initializing processes) without having to wait for the printhead to warm up. This way, you can observe or change some of the printer settings without waiting for the printer to complete the normal warm up sequence. Meanwhile, the printer continues to warm-up and initialize “in the background.”

1. At the rear of the printer, set DIP Switch 2 in the down position. Ensure Switches 1, 3 and 4 are up. (Normal operation is all switches up.)

2. Turn on the printer.

The printer will not print a Cleaning Page or a Startup Page when placed in Bypass Mode.

Cool Down Mode

The printer features a menu item that accelerates the cooling down of the printhead. When the printer is turned off, it automatically gives the option of performing a quick cool down.

1. Turn off the printer.

2. Scroll to the menu item Quick Cool to Move and press the

Select button.

3. Open printer doors to help speed the cooling process.

The printer turns off all the engine heaters and runs the fans on high until the ink in the printhead has solidified. Then the printer shuts itself off.

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Preparation for Moving the Solid Inkjet 100 Printer and

Accessories

It is very important that you follow the correct repacking procedure before shipping the Solid Inkjet 100 printer. Complete repacking is required. Failure to properly repack the printer can damage the printer’s internal components. You are responsible for any shipping damage to the printer that results from improper or inadequate packing.

Repacking for shipment consists of four basic tasks. Each of these tasks is explained in detail. If you have questions regarding any of the repacking procedures, call Sterling for assistance:

Sterling Diagnostic Imaging, Customer Care Center at (800) 252-

9099. Outside the U.S. and Canada, contact your local Sterling

Diagnostic Imaging service organization.

Overview

After reviewing this section, follow the more detailed processes which follow to complete this task.

1.

Turn off the printer using the On/Off switch and then selecting

Shut Down For Moving Printer at the front panel.

2.

Remove the maintenance drawer, seal it in a plastic bag, and store the tray on a flat surface.

NOTE: A used maintenance drawer leaks drum fluid if tipped.

3.

Make sure that the printer has completed its shut down before moving the printer (after approximately 15 minutes, the front panel goes blank). This allows the ink to solidify.

4.

Repack the printer and its accessories using the original packing materials.

Turning off the Printer

CAUTION

To avoid damaging the printer’s internal components, always turn the printer power off using the On/Off switch (this places the printhead in the proper position for safe shipment). Failure to do so

may result in damage to the printer.

Never turn off the printer by pulling the power cord.

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1.

Use the rear-panel On/Off switch to turn off the printer.

2. At the front panel, immediately select Quick Cool to Move

Printer (you have 4 seconds before the display goes blank).

The printer reports the shut down status and takes approximately 15 minutes to cool down. While it is cooling, it is recommended that you remove the maintenance drawer (see the next topic).

CAUTION

If you do not select Quick Cool to Move Printer, you must wait 30 minutes for the ink to solidify. Before moving the printer, always wait for the ink to solidify or you may damage the printer.

Removing the Maintenance Drawer

CAUTION

To avoid damaging the printer, always remove the maintenance drawer before moving or shipping the printer. Never ship a partially used maintenance drawer.

1. Open the printer’s front cover.

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General Information

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2.

Remove the maintenance drawer from the printer. Once you’ve removed the maintenance drawer, keep it level.

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WARNING

A used maintenance drawer leaks drum fluid if tipped. Keep the maintenance drawer level to prevent spills. Contact with maintenance drawer fluid poses no health risk, however, do not leave the used maintenance tray where it could spill and create a slipping hazard.

3.

Place the used maintenance drawer in a plastic bag and seal the bag. Store the used maintenance drawer for future use. Do

not ship a partially used maintenance drawer.

Disconnecting the Cables

Once the printer completes its shut down process, the front panel goes blank. Once this happens, disconnect the power cord and all other cables from the printer.

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Repacking the Printer and its Accessories

WARNING

The printer weighs about 36 kg (79 lb.). Do not attempt to lift it without the assistance of another person.

1. Repack the media tray. Remove the media trays and remove all media from the trays. Position the cardboard tray insert into the media tray to prepare it for shipping. Reinsert the media tray into the printer.

1239-38b

2.

Repack the printer. Position the lower cushion insert in the shipping tray as shown in the illustration. Lower the printer onto the cushion inserts. Place the plastic bag provided over the printer. Place the cushion inserts on each side of the printer.

3.

Repack the printer’s accessories. Place the power cord, cleaning kit, and all printer documentation in the area provided in the accessories box. Do not ship a partially used maintenance drawer.

General Information

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Figure 1-13. Repacking the Printer

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WARNING

The printer is not permanently attached to the Auxiliary Feeder unit.

When moving the printer or auxiliary feeder unit, move each unit separately to avoid damage or personal injury. The printer weighs about 36 kg (79 lb.). Do not attempt to lift it without the assistance of another person.

Repacking the Auxiliary Feeder Unit

If you have an Auxiliary Feeder unit, repack for shipment using the original packaging.

Remove the media tray from the Auxiliary Feeder unit and remove all media from the tray. Slide the media tray into the Auxiliary Feeder unit and place the assembly inside the plastic shipping bag. Place the front and rear cushions on the Auxiliary Feeder unit. Place the entire assembly into the cardboard box.

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Configuration Page

The configuration page, shown on pages 1-27 and 1-28, lists the values the printer stores in its NVRAM. These values can be informative when troubleshooting the printer, particularly networked operations. The configuration page gives information such as:

• General information about the printer, such as page count, the programmed name, Ethernet address, time-outs, number of fonts and total memory

• Printhead information such as serial number, calibration and adjust values

• Parallel port settings

• USB setting

• Hard drive

• Network information

• EtherTalk settings

• Novell NetWare settings

• TCP/IP settings

Configuration page settings are provided in Table 1-4.

Printing the Configuration Page


2. Allow the printer to complete its power-up self-tests. The front panel displays:

READY TO PRINT

3. Scroll to Menu and press the Select button.

4. Scroll to the menu item Demo and Test Pages and press the

Select button.

5. Scroll to the menu item Print Configuration Page and press the Select button.

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General Information

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Table 1-4. Configuration Page Settings

P a r a m e t e r

Printer name

Description

The current name of the printer as seen on a network

Saved in

NVRAM

yes

D e f a u l t

Ii LINX

SIJ100

Limits or alternate choices

Any name defined by the customer up to 32 characters in length.

Page count; upper and lower tray counts

Total number of print jobs processed through the image processor.

yes 0

Startup page enabled

Indicates if the printer prints a startup page upon power-up.

yes Yes No

Serial number Unique number representing the printer serial number yes

Product

Printer ID A unique number for each

Ethernet-capable printer.

yes

Ii LINX Solid

Inkjet 100

Hardwaredependent.

3016.106

Legal values have the form xx:xx:xx:xx:xx:xx

PostScript version Firmware level of the

PostScript interpreter code.

N/A

Firmware version Firmware levels of the main board operating system code version, printer engine’s operating system code,

PostScript code, engine code, and networking code.

Flash Installed

Installed RAM Total amount, type, and size of

RAM on the main board in each

DIMM slot.

N/A

ROM fonts available

Number of fonts stored in the printers ROM memory.

yes Sys/Job Start Indicates if the printer is to execute a Sys/Start job file found on an attached hard drive at power-up

Job Timeout Amount of time a job can take to process.

yes

Yes

64 Mbytes

136 yes

0 seconds a.aa/b.bb/c.cc/d.dd, where a.aa is the Sterling version of VxWorks, b.bb is the PostScript version number, c.cc is the engine code version, and d.dd is the network code firmware version

64, 96,128 no

Any value denoted in seconds. 0 means unlimited amount of time

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Table 1-4. Configuration Page Settings (continued)


Wait Timeout

Description

Amount of time the image processor waits for additional data from a host.

Saved in

NVRAM

yes

D e f a u l t Limits or alternate choices

40 seconds Any value greater than 14 denoted in seconds; 0 means unlimited amount of time

67 hours Any integer from 1 to 999 denoting hours.

Energy Star timeout

Amount of idle time allowed before the printer switches to a low energy power down mode.

yes

Intelligent Ready Indicates if the automatic standby/wake up feature is enabled.

yes on off yes Upper Tray Upper Tray, Lower Tray Media Source Indicates the default tray the printer uses for self-prints

Upper Tray Indicates the size and type of tray installed no Letter, A4 no Letter, A4 Lower Tray Indicates the size and type of tray installed

Print Quality Indicates the combined setting of the HW Resolution.

yes yes

High

Resolution

Medical

High Resolution Medical, Draft

Enabled Disabled

Parallel Port

E n a b l e d

Indicates if the parallel port is enabled

Language

Encoding

Indicates the language interpreter in use at the port

Indicates the type of data encoding at the parallel port

Job pipelining Indicates if multiple printfile processing is allowed

Output Device Device used for standard output and standard error yes yes yes yes

PostScript

Binary

Off

Parallel

ACSII (normal), Raw, TBCP

0n any communication device

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Handshake

Description

Setting whether unidirectional or bidirectional communication is used.

Saved in

NVRAM

yes


Bi-directional Uni-directional

U S B

Language

Encoding

Indicates the language interpreter in use at the parallel port

Indicates the type of data encoding at the port yes yes

Job Pipelining Indicates if multiple printfile processing is allowed

IDE Disk

Size

Indicates if the internal hard drive is installed

Indicates the physical size of the installed IDE drive

Boot Delay Number of seconds the printer waits before booting up the hard drive.

Polling

Network

Information

Version

Time

Time Source

<day><date><time><year>

Source of the time set in printer, such as a remote computer dialog box yes no no yes

PostScript

Binary

Off

0

Set at factory

ACSII (normal), TBCP

On

Disk size in Gbytes

Any positive integer

Integer 1 to 255

Clock not set

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P a r a m e t e r Description

Last Config Time Last date the printer’s configurations were altered

Saved in

NVRAM

yes

SysAdmin contact Name of system administrator yes


Empty string

Empty string Printer Location Physical location of printer as set by system administrator yes no

P h a s e r S h a r e

Indicates the type of Phaser

Share network card installed

Network Address A unique number for each

Ethernet-capable printer.

yes

Built-in Ethernet

EtherTalk Indicates the type of interpreter in use at the port.

yes

Hardwaredependent.

Legal values have the form xx:xx:xx:xx: xx: xx

PostScript

Level 2

Not installed, Disabled,

<interpreter> enabled

PostScript

None

Language

Filtering

Job Pipelining Indicates if multiple printfile processing is allowed

Name

Interpretation of special characters

Printer type yes yes

The current name of the printer as seen on a network yes

Indicates the type of printer installed at the port.

Zone Name assigned by network administrator for the zone the printer is assigned to.

yes

Network Node

Off

Ii LINX SIJ

100

On

Any name defined by the customer up to 32 characters in length.

LaserWriter Any string, 32 character or less

Any string, 32 characters or less

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I P X

Description

Indicates which IPX frame types the printer accepts

Saved in

NVRAM


IPX Networks

Ethernet 802.2

Ethernet 802.3

Ethernet II

Ethernet SNAP

NetWare port interpreter

Language Indicates the type of interpreters in use at the port.

Filtering Interpretation of special characters yes yes yes yes Job pipelining Indicates if multiple printfile processing is allowed

Operating Mode

Print Server Name Name of printer server.

yes yes yes yes

Enabled

Enabled

Enabled

Enabled

PostScript

None

On

Disabled

Disabled

Disabled

Disabled

Disabled, <interpreter>

Interpreter-based

Off

Print server

TEK01B009, hardware dependant user-defined

2 - Bindery 1 - Directory Services, 3 - Directory and Bindery Services

Connection Mode 1 - Directory Services,

2 - Bindery

3 - Directory and Bindery Services yes

Preferred DS Tree Directory Services Tree where printer initially connects yes Max length 48 bytes

General Information

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Login Password Indicates whether or not a network password has been set.

Saved in

NVRAM

yes

D e f a u l t

Not set


Set, Not set

Enable Banners Print banner yes No

60 seconds Config Retry

Interval

Queue Scan

Interval

Time in seconds to wait before retrying to configure yes

Rate at which printer will scan queue for print jobs.

yes 15 seconds An integer 1 through 300 in seconds

Status Message

TCP/IP port interpreter

Indicates the type of interpreter in use at the port.

yes

Host Name

IP Address The Internet Protocol address.

If null, the address will be set at run time via RARP or BOOTP.

yes Not Set

Default

Not authorized, Disabled

String of 15 or fewer characters of the format N.N.N.N followed by the word “Dynamic” if IP Address

Dynamic parameter is set to true.

String of 15 or fewer characters of the format N.N.N.N

Network Mask Indicates which fields of the

IP Address designate the network portion and which designate the node portion.

If null, the mask will be determined from the printer’s

IP address or the BOOTP or

ICMP Netmask Reply.

yes

Router/ Gateway A list of addresses of the gateways to other networks.

Frame

RARP yes

Data packet encapsulation type for ARP/ RARP requests and IP datagrams.

yes

Reverse Address Resolution

Protocol/ Boot Parameter

Protocol. Used for setting the printer’s IP address from a boot server.

yes

None

DIX

False

String of 15 or fewer characters of the format N.N.N.N

Adaptive, 802.2-SNAP. May be followed by the word “Dynamic”

True

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BOOTP/ DHCP Used for setting the printer’s

IP address from a boot server

Saved in

NVRAM

yes

D e f a u l t

False


True

IP Address Source Indicates from what source the

IP address was obtained yes

SMTP Server Host that email notification will deal with yes yes SMTP Reverse

Path

Destination of email error messages

D N S

Empty field

Empty field

16 characters

80 characters

None This is overridden by BOOTP/

DHCP

Primary Server Provides the IP address of the primary Domain Name Services server

Secondary Server Addition source of IP address for a Domain Name Services server

Search Domain

Names(s)

Local domain name of DNS resolver

L P R

Filtering Interpretation of special characters

Job pipelining Indicates if multiple printfile processing is allowed

Host Access List List of TCP/IP network addresses for host access to printer

AppSocket port interpreter

yes yes yes

None

None

None yes

256 characters

Interpreter-based no

Unrestricted

General Information

1-35



Language

Filtering

Description

Indicates the type of interpreter in use at the System V configured port.

Saved in

NVRAM

yes

D e f a u l t

PostScript


Interpretation of special characters yes None Interpreter-based

On Off Job pipelining Indicates if multiple printfile processing is allowed yes

Host Access List List of TCP/IP network addresses for host access to printer

Syslog Protocol that acts as a remote front panel to the printer.

yes yes

Log Hosts

Log Priority

List of address of host that want to receive syslog messages.

yes

The threshold indicating the priority level of messages from the printer that will be sent to the list of log host(s).

yes

Send no messages

5

Unrestricted

Not Authorized, <null string>

List of IP addresses in the format

N.N.N.N

0 – unit is no longer usable,

1 – messages indicating action is needed on part of system administrator,

2 – critical error messages,

3 – error message,

4 – warning messages,

5 – normal but significant message,

6 – informational messages,

7 – debugging messages

Not Authorized, <null string>

S N M P

Trap Hosts

Allow the printer to respond to status queries from host-resident

SNMP utilities.

yes

A list of hosts, one for each protocol, which are able to receive traps.

yes

Authentication

Failure Traps

If enabled, the printer sends a trap for SNMP authentication failure.

yes

None None, N.N.N.N/Public,

N.N.N.N/Proxy, N.N.N.N/ Private,

N.N.N.N/Regional, N.N.N.N/Core

Enabled Disabled

1-36




H T T P

Local URL Address

Description

Indicates if HTTP support has been enabled

Saved in

NVRAM

yes

D e f a u l t

Enabled


Disabled yes yes yes

Not set Set HTTP Password

Refresh Delay

FTP

Language

Filtering

Indicates if FTP support has been enabled

Interpretation of special characters yes yes

Auto Select Not Authorized, Disabled,

None

<interpreter>

Interpreter-based

Job pipelining Indicates if multiple printfile processing is allowed yes

Login Password

Remote

Internet

Printing

Language

Indicates of remote printing,

PhaserLink printing, is enabled

Indicates the language interpreter in use at the parallel port yes yes yes Filtering Interpretation of special characters

Job Pipelining

POP3 Server IP

Address

Backup SMTP server IP address

POP3 User Name POP3 login user name

Yes yes

POP3 Password POP3 login password yes yes yes

Not set no

Not Enabled Enabled

PostScript

None

On

Empty field

Empty field

Empty field

Set

Off

40 byte field

40 byte field

General Information

1-37



POP3 Polling

Interval

Description

Interval printer waits before checking for new mail

Printing Password Password required for using internet printing feature

Saved in

NVRAM

yes yes

Authorized Hosts List of host connections allowed to use internet printing feature yes

Authorized Users List of email names allowed to use internet printing feature yes

D e f a u l t

3 minutes 1 to 32767

Not Set

Empty field

Empty field


Set

256 byte field

256 byte field

1-38


Specifications

Physical Dimensions

Table 1-5 provides the printer dimensions. Table 1-6 provides the printer clearance requirements.

NOTE: The printer must be mounted on a surface that is flat within 2 degrees of horizontal. All four of the printer’s feet must be in contact with the mounting surface.

Table 1-5. Printer Dimensions

P r i n t e r

Height

38.8 cm (15.3 in.)

Auxiliary

Feeder Unit

12.7 cm (5.0 in.)

C a r t

47.6 cm (18.75 in.)

Width

D e p t h

43.2 cm (17.0 in.) 43.2 cm (17.0 in.) 45.7 cm (18.0 in.)

59.7 cm (23.5 in.) 59.7 cm (23.5 in.) 55.2 cm (21.75 in.)

Weight

36.0 Kg (79 lbs.) 11.8 Kg (26 lbs.) 23.4 Kg (51.5 lbs.)

Table 1-6. Printer Installation Clearances

Top

45.7 cm (18 in.)

Left

Right

Front

10.2 cm (4 in.)

10.2 cm (4 in.)

Clearance must be sufficient to replace trays and clear paper jams.

10.2 cm (4 in.)

Rear

Bottom

No obstruction under printer that could block its cooling vents.

General Information

1-39

Functional Specifications

Printing process

Grayscale ink sticks

Print Quality

Solid inkjet onto plain paper

Clear, low-, medium- and highdensity ink sticks, each shapecoded

Selectable 409 x 409, or 600 x 600 dpi (horizontal and vertical)

Engine printing speed

NOTE: Engine printing speed measures the elapsed time from loading to ejecting the paper. Print times do not include image processing time, which varies according to image complexity.

Draft mode

(409 x 409 dpi)

Approximately 12.8 sec. for A or

A4 size

High Resolution Medical mode

(600 x 600 dpi)

Approximately 25 sec. for A or A4 size

Minimum printing margins

Maximum print area

Top and bottom

5 mm (0.2 in.)

Left and right sides

6.5 mm (0.26 in.)

A size: 8.1 x 10.5 in.

A4 size: 200 x 284 mm

1-40


Electrical specifications

Do not use extension cords of any length or gauge.

WARNING

Primary line voltages

Primary voltage

Power consumption

Current rating

87–132 VAC (115 VAC nominal)

174–264 VAC (220 VAC nominal)

Input voltage range is auto-sensed.

47–63 Hz frequency range

200 watts standby

300 watts at idle

600 watts during printing

Maximum power consumption is

1000 watts during warmup.

115 VAC configuration:

8 amp max./1 amp min.

220 VAC configuration:

4 amp max./1 amp min.

Fusing

NOTE: Fuses are not user-accessible.

Secondary voltages

F1: (DC switcher) 6.3-amp slo blo

F2: (Drum heater 1, reservoir heater 1, ink melt chambers, cap/ wipe/purge unit) 10-amp slo blo

F3: (Jet stack left and right, paper pre-heaters, reservoir heaters 2, 3 and 4) 10-amp slo blo

+5V

±

2.5%

+12 V

±

5%

-12 V

±

5%

+40 V -5%, +12%

-52 V

±

10%

+54 V

±

10%

General Information

1-41

CAUTION

Operate printer only within specified environmental ranges.

Environmental specifications

If combustible fluids are brought into contact with hot elements of the printer, evacuate the area and call for service personnel.

WARNING

Temperature

Humidity

Altitude

Vibration/shock

Operating

15-32 C

°

(59 to 90

°

F)

Storage and shipping

-30 to 60

°

C (-22 to 140

°

F)

Operating

15 to 80% relative humidity,

non-condensing

Nonoperating

15 to 95% relative humidity, non-condensing

Operating

0 to 2400 m (8,000 ft.) at 25

°

C

Nonoperating

0 to 15000 m (50,000 ft.)

Nonoperating (vibration)

Will withstand 0.5 G excitation, 5 to 500

Hz, 3 axes for up to 7 minutes with no impairment or subsequent damage.

Nonoperating (shock)

0.5 g, 25 minute sweep, 5-200-5 Hz,

100–200 sec./sweep cycles

Operating (shock)

The printer may have any corner raised and dropped 1.5 cm (0.6 in.) while printing is in progress, without impairment of operation that cannot be recovered by a printhead purge cycle. The printer may

1-42


have any corner raised and dropped 6 cm

(2.4 in.) while idle without subsequent impairment of operation.

Operating (drop)

Printer only with the main tray installed; maintenance drawer installed; printhead unlocked; no internal packaging: 0.5 in for one drop on all four bottom edges

Printer in “Ready” mode and at operating temperature: 1.0 in. drop on all four bottom edges

General Information

1-43

Theory of Operation

This topic covers the following subassemblies and diagram within the printer:

• Functional block diagram

• Drum/transfix assembly

• Maintenance drawer

• Printhead

• X-axis movement

• Printhead tilt mechanism

• Ink loader

• Cap/wipe/purge assembly

• Power supply

• Power control board

• Main board

• Optional Ethernet interface card (100 BaseT)

• Optional internal disk drive

• Print process in operation

• Printhead maintenance cycle

Functional Block Diagram

Figure 1-14 presents a functional block diagram of the printer.

1-44


Figure 1-14. Printer Functional Block Diagram

General Information

1-45

Drum/Transfix Assembly

The drum/transfix assembly (Figure 1-15) forms the key portion of the printer where imaging takes place. The main features of the drum/transfix assembly (Figure 1-16) are the drum and transfix roller. In operation, the image to be printed on paper is first “printed” on the rapidly rotating drum. A sheet of paper heated by the paper preheater is then passed between the drum (now rotating much more slowly) and the transfix roller. Under the pressure between the drum and the transfix roller, the image is transferred to the sheet of paper.

Transfix roller

Paper preheater

Paper path

Drum heater

Drum

Figure 1-15. The Drum And Its Systems

840-4-45

1-46


Encoder disk

Home flag

Encoder

Paper/drum heater

Entry assembly

Servo motor

Warning: Closed-loop servo drive

Home sensor

Temperature sensor (~55

°

C)

Drum

Transfix roller

Fan

Belt drive

840-4-47

Figure 1-16. Drum/Transfix Assembly

An encoder disk and sensor on the left end of the drum monitors the drum’s speed as well as its “home” position. The drum heater heats the surface of the drum to about 55 o

C (131 o

F) for imaging. A temperature sensor in contact with the drum surface monitors the drum temperature. The main board interprets the sensor’s signal and turns on the drum heater and drum fan to heat the drum, or turns on the drum fan alone to cool the drum.

The drum is driven by a closed-loop servo motor which, through a double reduction belt drive, rotates the drum at a high speed for imaging and a constant low speed for image transfer to paper.

WARNING

Keep your fingers away from the drum drive system; it uses a closed-loop drive system. A closed-loop servo drive system is inherently dangerous. Since the motor speeds up if it senses the drum drive system slowing down, fingers caught in the drum belts and gears can be severely injured.

General Information

1-47

Maintenance Drawer

The maintenance drawer performs two functions. Its primary function is to create a thin intermediate liquid transfer surface, a layer of silicone oil, on the surface of the drum prior to printing. The oil keeps the ink from sticking to the drum’s surface and facilitates its transfer to the sheet of paper. The oil is contained in an oil saturated roller.

The drum maintenance drawer’s second function is to collect waste ink from printhead purges in a waste tray. Refer to Figure 1-17.

Maintenance drawer

Actuator

Cam pushes oil roller and blade against drum

Oil roller

Camshaft home position flag

Drum maintenance drawer camshaft

Process motor

Process drive belt

Maintenance drawer camshaft electric clutch

Drum

Blade

Oil on drum

Drum

Cam lowers oil roller and blade assembly

840-4-54

Figure 1-17. Drum Maintenance Drawer

Prior to each print, a cam, driven by the process motor, raises the oil roller against the slowly rotating drum. A compliant blade, also raised by the same cam, assures that the oil film is smooth and even across the drum’s surface. The blade also directs excess oil back through a

1-48


felt filter to the oil roller for reuse. As the drum completes one rotation, the rotating cam lowers the oil roller and then a moment later, lowers the blade.

A removable NVRAM chip, mounted on the drawer, stores the number of oiling cycles performed by the maintenance drawer.

Printhead

The printhead (Figure 1-18) is the heart of the printer. Refer to Figure

1-17. The printhead spans nearly the length of the drum. Using its

448 ink-jet nozzles (112 jets for each density), with a horizontal motion of slightly more than 5 mm (0.2 inches), the printhead can print the entire image on the rotating drum.

Reservoir

Drum

Head drive board

Figure 1-18. Printhead

Jet stack

Printhead

840-4-48

General Information

1-49

Figure 1-19 shows a cross-section of the inkjet array and the jet nozzle arrangement.

The printhead’s jet stack is fabricated from a stack of chemically etched steel plates which are brazed together to form the ink-jet array. Channels formed by the stacked plates route ink past the 448 individual, piezoelectric crystal-driven diaphragms, which force the ink in droplets out the 448 corresponding nozzles. Looking at the printhead face, the nozzles are arranged in four rows with the intermediate density nozzles forming the top row, the low density nozzles forming the next row 22 /300” below, and the clear nozzles forming the third row 11/300” below and the high density nozzles forming the fourth row 22/33” below. During the printing process, the printhead would only have to travel 22 pixels horizontally to provide complete coverage. (In actuality, the printhead travels much further to interlace with the output of neighboring jets.)

The Drift Compensation setting in the hidden Service Support menu enables automatic drift compensation. When it is turned on, it slowly increases the printhead drive voltage over time to maintain optimal printhead performance.

1-50


Intermediate

Low

Clear

High

22 pixels*

11 pixels*

22 pixels*

Ink inlet

Manifolds

Piezoelectric crystals

22 pixels

* 300 dpi pixels

840-4-49

Figure 1-19. Printhead Detail

The ink-jet array is bonded to a cast aluminum ink reservoir. The reservoir supplies the molten ink to the ink-jet array. Heaters in the reservoir and the ink-jet array maintain the ink at a temperature of about 140 o C for printing. The level of the ink in the reservoir is kept at a constant level.

General Information

1-51

X-axis Movement

X-axis or lateral movement of the printhead is accomplished using a stepper motor driving a fine-thread leadscrew. The printhead, mounted to the X-axis shaft, moves right and left across the surface of the drum.

To find the printhead home position, the X-axis system drives the printhead in an open loop. The printhead is driven against the left printer frame for a few seconds, and then reversed a set number of steps.

A spring attached to the printhead and right printer frame, provides a preloaded tension so the printhead moves smoothly.

X-Axis shaft

Tension spring

Printhead

X-Axis Motor

X-Axis shaft

Drum

Drive gear

Frame

Frame

Nose cone gear

840-4-50

Figure 1-20. X-axis Printhead Movement During Printing

1-52


Printhead Tilting Mechanism

To accommodate printhead maintenance, the printhead can be tilted back away from the drum. (Refer to Figures 1-21 and 1-22.) This creates room for the cap/wipe/purge assembly to be moved into position in front of the printhead faceplate. The printhead tilts back on its X-axis shaft that it travels on. The X-axis shaft is connected to the head tilt arm. At the lower end of the arm is a cam-follower. The cam follower (and tilt arm) respond to the movement of the head tilt cam gear. As the gear rotates, the arm follows the motion and tilts back the printhead.

Printhead print position

Printhead

Head tilt arm

X-axis shaft

Cam follower rim

Printhead maintenance position

Leaf spring tension engages drive gear

Return spring

Drum

Drive gear not engaged

Tilt cam gear

Cam

Leaf spring

840-4-57

Figure 1-21. Printhead Tilting Operation

General Information

1-53

A return spring at the top of the tilt arm pulls the printhead toward the drum.

In the print position, the tilt arm gear’s missing teeth are positioned at the tilt arm gear’s drive gear. When actuated, a leaf spring pushes against a cam lobe on the backside of the tilt cam gear to give the tilt cam gear a slight rotation and engage its teeth to the drive gear. The leaf spring is held away from the cam lobe of the tilt cam gear by the cap/wipe/purge assembly in its standby position. Slightly raising the cap/ wipe/purge assembly releases the leaf spring and allows it to push the cam lobe and rotate the tilt arm gear slightly.

Head tilt arm

Cam follower

Head tilt cam gear

Head tilt cam gear disengaged from drive gear

Figure 1-22. Printhead Tilting Mechanism

Process motor

Process drive compound gear

840-4-55

1-54


Ink Loader

The ink loader consists of four parallel channels with an ink melting element at the end of each of the four channels. (Refer to Figure 1-23.)

Ink sticks, one color loaded in each channel, are pressed by coil-spring pressure into the melting elements. As ink is required by the printhead, the appropriate color’s melting element is activated and the end of the ink stick is melted. The melted ink drips into the ink reservoirs of the printhead underneath. Sensors in the ink loader alert the customer to install more ink sticks before the current sticks are completely consumed.

If the ink level sensors inside the printhead detect that the printhead has run out of ink, but the ink low/out sensors are not activated, the front panel reports an “Ink Jam” error.

Ink stick

Ink loader door

Ink melt units

Ink out sensor

Ink low sensor

Printhead

Coil spring

840-4-46

Figure 1-23. Ink Loader

General Information

1-55

Cap/Wipe/Purge Assembly

The cap/wipe/purge assembly is a long, shallow cup with an elastomeric gasket. (Refer to Figure 1-24.) When raised and pressed against the face of the printhead, it forms an airtight seal. After forming the seal, a partial vacuum is applied to the faceplate to suck out air bubbles and any debris that may be obstructing the printhead nozzles. Following the vacuum cycle, the cap/wipe/ purge assembly performs a wipe operation on the faceplate using its squeegee-like wiper blade. The cap/wipe/purge assembly also receives the ink ejected from the printhead during the flush portion of the printhead maintenance cycle. The flushed ink is routed to the waste tray of the drum maintenance drawer. The cap/wipe/purge assembly is heated to keep the waste ink fluid during the wipe and purge operations.

Cap/Wipe/Purge assembly transport


Cap/Wipe/Purge assembly home sensor

(on I/O board right)

Drum

Printhead

Cap/Wipe/Purge assembly belt

Solenoid valve

"unenergized"

Vacuum system

Air

Pump

Vacuum accumulator

Air

7 mil orifice

Filter


Solenoid valve

"energized"

840-4-56

Figure 1-24. Cap/Wipe/Purge Assembly

1-56


The cap/wipe/purge assembly is attached to a pair of parallel belts on a rotating shaft. To perform a printhead maintenance cycle, the printhead is first tilted away from the drum. Then the cap/wipe/purge assembly motor drives the cap/wipe/purge assembly belts, which pull the attached cap/wipe/ purge assembly up to the faceplate of the printhead. The printhead is then tilted forward to seal against the cap/wipe/purge assembly.

When the cap/wipe/purge assembly is in its lowered home position, it unlocks the maintenance drawer so it can be removed. If the cap/ wipe/purge assembly is away from its home position the drum maintenance drawer is locked in place.

WARNING

When servicing the printer be careful of the cap/wipe/purge assembly as it passes the printhead. If a damaged wiper blade of the cap/wipe/purge assembly catches on the printhead it could propel hot liquid ink upward into your face.

Vacuum for the purge cycle is obtained from the vacuum/pump module which contains a vacuum pump and an air valve solenoid

(Figure 1-25). The body of the vacuum/pump module forms a vacuum accumulator. A small vacuum pump, running for 75 to 90 seconds, creates a strong vacuum in the vacuum accumulator. Then an air valve is energized for a fraction of a second, exposing the printhead faceplate to the strong, accumulated vacuum to suck debris and bubbles out of the printhead nozzles. With the air valve once again deenergized, air is metered through the 7-mil orifice to gradually release the vacuum at the faceplate.

General Information

1-57

Purge


Printhead faceplate

Vacuum/Pump module


Vacuum accumulator space

Vacuum pump

Wipe

Flush

Wiper blade

Dab

Figure 1-245 Cap/Wipe/Purge Assembly and Vacuum System

840-4-51

1-58


Power Supply

The power supply has two main, yet interrelated sections: the AC section and the DC section. In the AC section, power is routed to 14 opto-isolated triacs which, under main board logic control, supply AC power to the 14 heaters in the printer.

Two fuses provide current protection to the triacs. Fuse F2 and F3 protect the power supply from, most often, a shorted triac caused by a defective heater. If F2 or F3 fuse blows, it is best to replace the power supply (and, of course, the defective heater), rather than the fuse.

Otherwise, with the fuse replaced, but the triac shorted, AC power may be applied to the heater without the printer even being turned on. Each time the main board turns on a triac to activate a heater, it is turned on for only a fraction of a second. The main board must constantly readdress each heater it wants to remain on. By this means, if the print engine firmware should fail, the heaters automatically shut off. The printer is also protected by thermal fuses located inside: two fuses for the drum heater, and one each for the paper preheater and the cap/wipe/purge assembly. A thermal fuse opens in the unlikely event of a “runaway” heater following a firmware failure.

The DC power supply generates +5 volts for the printer’s logic, + 40 volts for the motors, +54 volts and -52 volts for the printhead drivers, and

±

12 volts for fans. Fuse F1 provides protection for the switching power supply in the DC section. The block diagram for the power supply is illustrated in Figure 1-26.

WARNING

Do not touch the power supply; AC line voltages are present. The power-switch does not interrupt AC power to the power supply, it only signals the supply and the printer logic to begin a shutdown sequence. Even with the power switch in the OFF position, AC line voltages are present on the power supply, heaters and heater wiring.

There are no field adjustments necessary on the power supply.

General Information

1-59

Power on

AC in

F1

F2

+5 V

+40 V

+54 V

-52 V

+12 V

-12 V

Triac control lines from the power control board

F3

F

°

Drum heater 1

F

°

Reservoir heater 1

High density ink melter

Intermediate density ink melter

Low density ink melter

Clear ink melter

Cap/wipe/purge unit heater


Jet stack left

Paper pre-heater

Jet stack right


Drum heater 2


840-4-66

Figure 1-26. Power Supply Block Diagram

1-60


Print Process in Operation

Once an image has been processed and a printing bitmap created, a print cycle begins. The printhead and drum are brought up to their operating temperatures and the ink levels in the ink reservoirs are checked and ink is added from the ink loader, if necessary. Next, the printhead is driven horizontally to its home position and the drum is rotated to its home position.

WARNING

Keep your fingers away from the process gear drive system; it uses a closed-loop drive system. A closed-loop servo drive system is inherently dangerous. Since the motor speeds up if it senses the process gears drive system slowing down, fingers caught in the process belts and gears can be severely injured.

Printhead Tilt

The printhead is tilted forward into its print position. (Refer to Figure

1-27.) The process motor is activated, which drives the process drive belt. The belt, in turn, drives a compound gear. Through a follower gear, the compound gear drives the head tilt cam gear clockwise. A cam follower, mounted on the lower end of the head tilt arm, follows the rotating cam gear, which tilts the printhead. The head tilt cam gear rotates until a set of missing teeth in the cam gear “disengage” it from the cam drive gear. The cap/wipe/purge assembly, in its standby position, draws a leaf spring away from a cam lobe located at the back side of the tilt arm gear. (When the leaf spring pushes against the cam lobe of the tilt arm gear it forces the gear to mesh with the cam drive gear.) Pulling the leaf spring away effectively latches the head tilt cam gear in the printhead forward position. At this point, the printhead is in its upright print position (home position). (The head tilt cam gear is principally rotated in a counterclockwise direction to tilt the printhead forward and back. It only rotates clockwise during some printhead cleaning operations.)

Tilted forward, the missing teeth of the head tilt cam gear allow the process motor and gear train to perform other print functions without affecting the printhead’s tilt position. The cap/wipe/purge assembly is raised slightly to allow the head tilt cam gear (with a slight spring assist from the leaf spring pushing against the cam lobe on the back of the tilt cam gear) to advance forward enough to engage its drive gear and tilt the printhead back.

General Information

1-61

Head tilt arm

Cam follower

Head tilt cam gear

Head tilt cam gear disengaged from drive gear

Figure 1-27. Tilting The Printhead

Process motor


840-4-55

1-62


Drum Preparation

To prepare the drum, a thin, intermediate liquid transfer surface is applied to the surface of the drum. (Refer to Figure 1-28.) First the drum is rotated to a speed of 51 cm per second (20 inches per second).

Next, the oil roller and blade of the maintenance drawer are raised into contact with the drum. To accomplish this, the process motor rotates clockwise, driving the process drive belt and the compound gear. Rotating clockwise, the compound gear drives a gear train that drives the maintenance camshaft’s 3-position electric clutch which, in turn, engages the maintenance drawer camshaft. The maintenance drawer camshaft clutch energizes to release the 3-position clutch, allowing it and the camshaft to rotate about one-half revolution to the next stop. The cams on the ends of the camshaft push against followers on each side of the maintenance drawer, forcing the oil roller and blade against the drum. The de-energized clutch holds the camshaft in this position.

As the drum nears the end of its rotation, the clutch energizes for a moment, allowing the camshaft to rotate further; this lowers the oil roller but leaves the blade in contact with the drum to smooth out the last of the oil on the drum.

The clutch energizes for a third time to allow the camshaft to rotate to its home position, and lower the blade. The point at which the blade ends contact with the drum leaves a bead of oil, called an oil bar. The oil bar defines the edge of a 40 mm (1.5 in.) swath of the drum which is not oiled; this swath is called the deadband. No ink will be deposited on the deadband during the print cycle. Instead, the paper stripper fingers, which lift the paper off of the drum during printing, are lowered into contact with the drum in the deadband. This keeps them from accumulating any oil on their fingertips which would stain the edge of the print as it is stripped off of the drum.

At this point, the drum starts rotating again at a speed dependent upon print resolution. As the drum reaches the correct speed, the inkjets begin to fire to deposit the image on the oiled portion of the drum.

As the jets fire, the printhead slews in the X-axis to complete the image on the drum.

General Information

1-63

Maintenance drawer

Actuator

Cam pushes oil roller and blade against drum

Oil roller

Camshaft home position flag

Drum maintenance drawer camshaft

Process motor

Process drive belt

Maintenance drawer camshaft electric clutch

Drum

Blade

Oil on drum

Drum

Cam lowers oil roller and blade assembly

840-4-54

Figure 1-28. Drum Preparation For Printing

1-64


Printing

When printing, the printer performs a “four-jet interlace” in which each jet lays down a particular number of pixel columns depending on the print resolution. Each jet lays down one pixel column for each drum rotation; this varies from 30 to 44 rotations (30 @ 409 dpi and

44 @ 600 dpi). Each jet travels horizontally the distance of 125 to

181 pixels (125 @ 409 dpi and 183 @ 600 dpi) to lay down its 30 to

44 pixel columns within that pixel field. The 125 to 181 pixel-wide field of each jet overlaps the pixel field of six other jets; this is where interlacing occurs.

During the horizontal movement of the printhead, extra 1 or 2-step movements are made to properly align the pixel columns and prevent a column from overlapping another column. The actual number of steps depends on the print resolution.

Physically, each jet is horizontally located 22/300 of an inch from its neighbor.

Interlacing “averages out” the variability between jets by interlacing each jet with three other jets. As shown in the Figure 1-28, of the pixel columns printed by any single jet, only two of its pixel columns are actually ever adjacent. Usually they are separated by three other pixel columns produced by other jets, hence the name four-jet

interlace. Because of the physical spacing between jets and the pixel field that each jet travels, the pixel columns of any one jet actually interlaces with the pixel columns of six other jets, although no more than four at any one time.

During some diagnostic printing, such as the Cleaning Test Print, the printhead slews to the right and lays down 112 parallel bands of ink.

Each band is about 1.86 mm (0.073 inch) wide and is composed of 30 pixel columns of dots from an individual jet. As the printhead slews to the right, the drum rotates 30 times; the number of pixel columns each set of jets deposits on the drum. (A set of jets is one of the 112 vertical arrangements of low density, medium density, clear and high density jets.) With no interlacing, the test print reveals the deficiencies of a single jet compared to the rest. Only in the Test Print

2: Weak/Missing Jets (I-mode) and the Print Jets Test Page test print, does the printhead simply slew sideways with no jet interlacing.

General Information

1-65

22/300" separation between jets

125 to 181 pixel-wide field traveled by a jet

(depending on print resolution)

Output of four side-by-side jets

1 of 4

2 of 4

3 of 4

4 of 4

Step

4 of 4

3 of 4

2 of 4

1 of 4

Step

Step

Columns of pixel dots produced by previous set of four adjacent jets. Note how the ending columns of this set interlace with beginning columns of the next set of four jets.

Column of pixel dots produced by four adjacent jets are interlaced together for printing. Each jet produces between 30 and

44 pixel columns.

840-4-62

Figure 1-29. Printing Latent (Pre-transferred) Image On The Drum

1-66


Paper Pick

To pick a sheet of paper, the process motor rotates clockwise, driving the process drive belt and the compound gear counterclockwise. (Refer to Figure 1-30.) Rotating counterclockwise, the compound gear turns and, in turn, engages a gear train that rotates the pick roller clutch gear counterclockwise. The paper pick electric clutch energizes for a moment, engaging the paper pick clutch and allowing it to rotate one revolution. The pick roller rotates and pulls a sheet of paper from the paper tray. The sheet of paper trips the paper pick sensor to assure that the paper was picked from the tray. If the paper is not sensed, the pick solenoid is energized, up to six times, to rotate the pick roller again to attempt to recover from the mis-pick and pick the sheet of paper.

With the paper-pick sensed, the paper-feed motor drives the upper and lower paper-feed rollers and carries the sheet of paper to the paper preheater. On its way, the sheet of paper passes the deskew fingers which are flexible, plastic fingers mounted on the front cover.

The deskew fingers guide the paper and create a buckle in the paper which aligns the paper to the paper path.

The paper stops at the entry to the paper preheater, tripping the paper preheater entry sensor on the left end of the paper preheater.

The paper also trips the paper width (A/A4-size) sensors on the right end of the paper preheater to verify that the width of the paper is within the printer’s specifications. At this point, the paper feed motor is stopped to wait for more ink deposition on the drum.

When ink deposition is about 95% complete, the paper feed motor is activated to bring the sheet of paper through the paper preheater and to the transfix position. The paper preheater heats the paper to improve ink transfer. The leading edge of the sheet of paper trips the paper preheater exit sensor as it passes out of the paper preheater.

General Information

1-67

Exit sensor


Preheater exit sensor

Paper preheater entry sensor

Paper size sensors

Upper feed roller

Deskew fingers

Paper pick sensor

Upper feed roller clutch

Pick clutch

Pick roller

Lower feed roller

840-4-53

Figure 1-30. Paper picking and positioning for transfixing

1-68


Transfixing, Stripping And Exiting

As the leading edge of the sheet of paper trips the paper preheater exit sensor, it starts the transfix roller being lowered to its transfix position. The process motor rotates clockwise, rotating the process drive compound gear counterclockwise. Fourteen flags on the circumference of the gear represent the fourteen teeth on the small gear on the back of the compound gear. When the teeth of the small gear are in the proper position, as detected by the compound gear position sensor, the transfix cam solenoid energizes to release the spring-loaded transfix cam on the right end of the transfix roller shaft. This allows the transfix roller gear (which up to this point in time had missing teeth “disengaged” to the 14-tooth gear of the process drive compound gear), to rotate slightly and engage the small gear of the compound gear. During this time, the drum, rotating at about 24 rpm, positions the deadband to coincide with the arrival of the leading edge of the sheet of paper (which is moving at the same rate as the drum).

The rotating transfix gear rotates the transfix roller shaft about onehalf revolution. The transfix roller, which is eccentrically mounted on the transfix roller shaft, rotates into contact with the paper (5 mm behind the leading edge) and then stops. This sandwiches the leading edge of the paper between the transfix roller and the beginning of the image on the drum. The drum’s rotation rotates the transfix roller and begins to pull the sheet of paper between them. The transfix roller shaft rotates slightly more so a protrusion on the transfix roller cam causes the stripper fingers to momentarily drop down onto the deadband of the drum and catch the leading edge of the sheet of paper and direct the paper to the rotating exit rollers, which are belt driven by the paper path motor. The transfix roller shaft rotates slightly more to clear the protrusion on the transfix roller cam and raise the stripper fingers so they no longer contact the drum.

The process motor stops, leaving the transfix roller cam in its halfrotated position. Friction from the rotating drum continues to turn the transfix roller, which freely rotates on the transfix roller shaft.

The ink on the drum transfers to the sheet of paper pulled by the friction between the drum and the transfix roller. After about 1.8

seconds, the complete image has been transferred to the paper. The process motor drives the transfix gear until the transfix gear is completely unloaded. At this point, the transfix gear is disengaged from the process motor gear, the transfix cam solenoid is latched again and the transfix roller is lifted off of the drum.

The paper path motor, driving the exit rollers through a drive belt, pushes the remainder of the sheet of paper into the exit tray. The trailing edge of the paper is detected by the exit sensor, ending the print cycle.

General Information

1-69

Exit sensor


Transfix roller on eccentric shaft

Paper preheater

Transfix roller gear

Transfix roller shaft

Transfix roller

Transfix cam solenoid

Process motor


Compound gear position sensor

Transfix cam

840-4-52

Figure 1-31. Image Transfixing, Stripping and Paper Exiting

1-70


Printer Self-Maintenance

To maintain peak operation, reliability and print quality, the printer has several automatic or semiautomatic maintenance functions.

(Refer to Figure 1-32.) These functions may be started automatically after a certain number of prints or during printer startup, or they may be started by the customer if a print quality defect is noted.

• Printhead maintenance cycle

• Paper preheater cleaning

• Transfix roller oiling

• Drum cleaning (chase page)

Printhead Maintenance Cycle

This topic describes the cleaning cycles used to remove bubbles or foreign matter that cause a printhead jet to malfunction. Three basic actions take place during a cleaning cycle:

• purging

• wiping

• flushing

These actions are used in different combinations for three different types of cleaning cycles:

• quick wipe

• short cleaning

• long cleaning

The long cleaning cycle is performed automatically when the Clean

Jets menu item is run a second time.

The long cleaning is described here. The short cleaning and the quick wipe are basically subsets of the long cleaning cycle.

General Information

1-71

Wipe

Flush

Dab

Purge


Printhead faceplate

Vacuum/Pump module


Vacuum accumulator space

Vacuum pump

Wiper blade

840-4-51

Figure 1-32. Printhead Maintenance Cycle

1-72


Preparation. Following printer power-up from a cold start or in response to a front panel menu selection, the print engine begins a printhead long cleaning cycle. The first step is to stop any ink melting operation. The printhead is tilted into the standby position. In this case, the cam follower follows the rotating cam gear, tilting the printhead backward. Following the head tilt, the cap/pipe/purge clutch energizes to engage the cap/wipe/purge timing belts to the paper path drive system. Then the paper path motor rotates counterclockwise to pull the cap/wipe/purge assembly into its cleaning position. Next, the printhead is tilted forward slightly to seal against the cap/wipe/purge assembly.The vacuum pump turns on for .5

seconds, just before sealing to build a slight vacuum in the accumulator. The solenoid valve opens as the cap seals on the printhead to prevent air from being pushed into the printhead. The cap then moves down a little bit to improve the seal. Then the main board starts the vacuum pump, which begins to create a vacuum in the vacuum accumulator. The pressure in the accumulator is lowered to about 10 psi. It takes the vacuum pump about 75 to 90 seconds to achieve this vacuum and then the pump is shut off.

Purge. Actual cleaning begins with the air valve solenoid energizing for 0.300 seconds; this momentarily routes the vacuum accumulator to the cap/wipe/purge assembly and exposes the printhead faceplate to the vacuum. The vacuum bleeds off after about 6 seconds through the 7 mil orifice. This is repeated 3 to 4 times, depending on the purge type, with 15 seconds between events. Then the printhead is tilted backward to break the seal and the printer waits 10 seconds for the waste ink to drain from the cap/wipe/purge assembly into the waste tray.

Long wipe. The paper path motor slowly rotates clockwise to pull the cap/wipe/purge assembly’s wiper blade down the face of the printhead, wiping away ink and debris.

Long flush. The printhead is tilted back slightly and the cap/wipe/ purge assembly is raised to bring the wiper blade even with the jet nozzles. All jets are fired for 6 seconds to flush mixed ink and foreign matter out of the jets. The waste ink drips into the waste tray of the drum maintenance drawer.

Dab. The cap/wipe/purge assembly is lowered slightly and the printhead is tilted forward to dab the wiper blade against the lower faceplate, to clean ink off the wiper. The dab is actually a short wipe and it is done on the part of the faceplate below the nozzles

Short wipe. Following the dab, the cap/wipe/purge assembly is raised and the printhead is tilted forward against the wiper blade.

The cap/wipe/purge assembly is slowly lowered again to clean the faceplate but stops sooner, before it can run into the debris from the first wipe.

Short flush. The printhead is tilted back slightly and the cap/wipe/ purge assembly is raised to bring the wiper blade even with the jet nozzles. All jets are fired again for 0.6 seconds.

General Information

1-73

Following the second flush, the printhead is tilted back and the cap/ wipe/purge assembly is lowered into its standby position. A cap/wipe/ purge home sensor on I/O board right detects when the cap/wipe/ purge assembly is stored in its standby position. Then the printhead is tilted forward into its print position and a cleaning or “mud” page is printed. The cleaning page allows each jet to eject ink that may be slightly contaminated with another ink.

7 day flush. If no printhead clean cycle has been run for 7 days, the printer automatically performs a printhead flush to expel old ink from the printhead orifices. This gets rid of any old, “cooked” ink and improves printhead reliability.

Paper Preheater Cleaning

This is a customer-initiated cleaning procedure, selected through the front panel troubleshooting menu Remove Ink Smears. The purpose of this cleaning item is to clean ink out of the paper preheater that may have been deposited there. Ink can be deposited if a jammed print, with ink on it, was pulled backwards through the paper preheater.

Heavier-weight, high-grade quality bond paper works best for this procedure.

In the paper preheater clean cycle, these events take place:

The user starts the Remove Ink Smears menu item.

1. The printer overheats the paper preheater to 100 o

C, softening ink trapped inside the paper preheater. Ordinarily the paper preheater runs at temperatures of between 60 and 65 o

C for paper printing.

2. The printer picks and passes up to 25 sheets of paper through the print path. Each sheet absorbs and removes ink from the paper preheater, but only the first five sheets are chased at the elevated temperature. Then up to 20 additional sheets are chased while the preheater cools down. The sheets are cleaning, but their main function is to bring the preheater temperature back down. The total number of chase sheets will vary from situation to situation. The printer can resume printing when the preheat temperature drops to 75˚C or below.

3. The printer returns to the Troubleshooting menu.

Because of the higher paper temperatures involved, this function can also be used to clean the drum surface of ink deposits caused by a contaminated blade on the drum maintenance drawer.

1-74


Transfix Roller Oiling

At the first opportunity after making 50 prints when no prints are queued and the printer is idle, the printer performs a transfix roller oiling cycle. During this cycle, oil is applied to the drum as it would be during a print cycle. Then the transfix roller is lowered against the drum and the drum rotates; this transfers some of the oil to the transfix roller, then the transfix roller is raised to its standby position. Oiling the transfix roller prevents ink and media from sticking to the transfix roller.

Drum Cleaning (Chase Page)

The printer performs a drum cleaning with a chase page automatically anytime a paper jam occurs after an image has been

“printed” on the drum. The chase page transfers the image, which may not be complete, off the drum and is usually discarded. The printer then attempts to reprint the print that jammed. The chase page is processed the same as a regular print except the drum is not oiled and no image is printed on the drum (since an image is already printed on the drum).

General Information

1-75

Power Control Board

The power control board functions as a back plane. This circuit board is the point of electrical interface to the print head, main controller, optional Ethernet Interface card, internal hard disk drive, I/O boards.

and power supply. The PCI bus signals supporting the optional

Ethernet Interface card and internal disk drive are sourced from the image processing controller and are routed to the option slots on the power control board. Two optional PCI based boards: optional

Ethernet Interface and Internal Disk Drive are available and plug into the power control board (back plane). Only one Ethernet interface is supported at a time. If an optional Ethernet Interface card is plugged into the printer, the printer’s on-board 10 Base T Ethernet is disabled.

Main Board

The power control board contains all of the motor power drivers with actual control for the drivers located on the main controller. Switching for all heaters is contained in the power supply.

The main controller, or processing controller, uses a Motorola

PowerPC 603e running at a nominal bus frequency of 32 MHz. The

603e PLL is configured for 4:1 operation resulting in a CPU frequency of 128 Mhz. DRAM is interfaced with a 64 bit bus and the PCI bus is

32 bits wide running at 33 MHz. Other interfaces in addition to PCI bus are parallel port, serial port, and USB device side port.

There are two dram (SDRAM) DIMM sockets on the board. These will accommodate industry standard 64 MB SDRAM modules up to a total of 128 MB.

There is one 168 pin DIMM socket for ROM/FLASH on the main controller. The interface to the controller is 64 bits.

Four DIP switches are located on the rear panel and from left to right are: Service Mode 3. Service Mode 2, Service Mode 1 and System

Reset. The Three service Mode switches are defined by software and the System Reset is hardwired. After initialization both the

PostScript and Engine LEDs blink to indicate normal operation. The

Postscript and Engine LEDs are located to the left and right of the

DIP switch respectively.

The Ethernet connector contains two integral LEDs. The yellow indicates transmit and green indicates receive.

The image processing controller contains an on-board Digital

Semiconductor 21041-AB 10 Base T Ethernet port located at JR160.

The controller’s built-in Ethernet interface will support 10Mbit halfduplex Ethernet connections over category 3 (or higher) twisted pair cable and is automatically disabled when the optional 100 base T interface is installed.

Both the IEEE 1284 parallel port and the serial ports are

1-76


4

5

6

7

0

1

2

3 implemented using a Cirrus Logic CL-CD1284. The parallel port uses a 36 pin IEEE 1284 connector on the rear panel. The serial port provides RX and TX only with no handshaking. It is connected via a 5 pin square post 0.1" centers connector recessed into the rear panel.

The CL-CD1284 general purpose 8-bit parallel 55º port is used for the following functions:

BIT # FUNCTION DESCRIPTION

Input

Input

Input

Output

Input

Input

Input

Output

Service mode switch 1



Reset control tor NETCHIP 2890

Bit 1 of the 2 bit board version number

Bit 2 of the 2 bit board version number

Parallel Port master ready (host logic high)

Parallel slave ready (peripheral logic high)

Optional Ethernet Interface Card (100 Base T)

The optional Ethernet Interface card has an RJ-45 connector, a 50ohm BNC (coax) connector and four LEDs on the rear panel. The card includes a DEC 21143 Ethernet MAC, an ICS 1890 MII PHY and an

82C92 coax transceiver. There are no jumper or switch settings on the card. It supports 100Mbit connections over the RJ-45 connector using two pairs of category 5 cable at up to 100 meters (l00 Base-TX), or

10Mbit connections over the same connector using two pairs of category 3 (or greater) cable at up to 300 meters (10 Base-T). The card fully supports 802.3u clause 28 autonegotiation with parallel detection at 10 and 100 Mbits/sec on the RJ45 port. When connected to a hub switch port, the printer will determine the best possible speed and duplex setting, either 100Base-TX full-duplex, 100Base IX half-duplex, 10Base-T full-duplex or l0Base T half-duplex. If the RJ-

45 port is not connected or the link to the hub/switch fails (e.g. due to a cable fault), the card will switch to 10Mbit/sec half-duplex operation over the coax (BNC) interface. Users should not connect cables to both ports; doing so will not disrupt the customer’s network but may prevent the printer from communicating properly.

The operating mode of the interface may be determined from the

Network Type parameter or by observation of the back-panel LEDs.

There are four LEDs mounted in a square pattern. The upper two

LEDs are yellow; the bottom two are green. The left-hand pair of

LEDs indicate activity: the green LED will flash when the card is receiving data from the network and the yellow LED will flash when the card transmits data to the network. The right-hand pair of LEDs indicate the operating mode. The top right yellow LED will be on when the speed is 100Mbits. It is off for l0Mbits. The bottom right green LED will be on when the twisted-pair (11145) connector is in use and there is a good link to a hub. It will be off if the link fails or when the coax (BNC) connector is selected.

General Information

1-77

Optional Internal Disk Drive

The internal disk drive board contains a 3.2 Gigabyte IDE disk drive interfaced to the 32 bit PCI bus using a CMD Technology PCI646 PCI to IDE data conversion chip. Disk drive data transfer rates are 3.5

Mbytes/sec minimum and 5 Mbytes/sec maximum and are 16 bits wide.

1-78


Chapter

Error Codes and Messages

2-1

Chapter 2

Error Codes and Messages

This chapter provides a description of the error codes and messages.

Rear panel LEDs error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-x

2-2

iiLINX™ Solid Inkjet 100 Service Manual

Rear Panel LEDs Error Codes

The rear panel LEDs are located on each side of the rear panel DIP switches.

NOTE: All references to right and left are as viewed from the reat of the printer.

The left LED represents the operation of the PostScript firmware.

The right LED represents operation of the main board’s print engine firmware. During the Power On Self Tests (POST), the two LEDs toggle back and forth for each successful pass through each SDRAM test. A failure in the power on self tests is indicated by the left LED

(the PS LED) flashing in a specific pattern of long and/or short flashes and repeated indefinitely. A long flash represents a 5, while a short flash is a 1. For example, a long flash followed by 4 short flashes is 5 + 4 = 9. If the left LED repeatedly flashes in the same sequence, then the PostScript processor has encountered an error and is looping. The possible LED-encoded error codes are listed in Table

2-1. Other failures are indicated by the failure being printed on the

Startup Page.

Table 2-1. Main Board Power-up Self-test Error Codes

D e t a i l s

1

2

Left LED

F l a s h e s

Long flash=5

Short flash=1

2L+ 1S=11

Meaning

not used

SDRAM SIMM Presence

3

4

5

6

SDRAM Bank 0

SDRAM Bank 1

SDRAM Bank 2

SDRAM Bank 3

This test verifies for the presence of both

SDRAM SIMMs. If both SDRAM SIMMs are missing, the resultant error indication is 2 short flashes from the left LED.

This test verifies DRAM Bank 0 in the DRAM

DIMM located in position 0 (closest to the rear panel.)


DIMM located in position 0 (closest to the rear panel.)


DIMM located in position 1 (farthest from the rear panel.)


DIMM located in Position 1 (farthest from the rear panel.)

7

8 not used not used


2-3

Table 2-1. Main Board Power-up Self-test Error Codes (continued)

D e t a i l s

13

14

11

12 none

Left LED

F l a s h e s

Long flash=5

Short flash=1

2L+ 1S=11

9

Meaning

NVRAM

10

EPROM

Mariner ASIC

Medusa ASIC

Super Glue ASIC

CL1284 IC

SCSI

This test does a walking 1's and a walking 0's test for the last 4 bytes in the VXWorks section of the NVRAM.

This test verifies in the first 24 bytes from the

EPROM that verifies that the Tektronix Ethernet address 0x08, 0x00, and 0x11 has been copied into three locations.

This test reads and verifies the version level of the Mariner ASIC.

This test reads and verifies the version level of the Medusa ASIC.

This test reads and verifies the version level of the Super Glue ASIC.

This test reads and verifies the version level of the parallel port controller CL1284 chip.

This test verifies the functionality of the SCSI

I/O processor. Any test failures with this component are treated as non-fatal errors with the error information written to the Start Page. If a failure is detected, the message

SCSI Option

Card with one of the following messages will be sent to the Start Page:

• Wrong values in script-set registers.

• Script operation timed-out.

• Script operation returns wrong error code.

• DMA transfer spills outside buffer.

• DMA transfer data mismatch.

2-4


Table 2-1. Main Board Power-up Self-test Error Codes (continued)

D e t a i l s Left LED

F l a s h e s

Long flash=5

Short flash=1

2L+ 1S=11 none

Meaning

10BaseT none

Ethernet 100 BaseT Option card

This test verifies the functionality of the Ethernet

LAN Controller chip. Any test failures with this component are treated as non-fatal errors with the error information written to the Start Page. If a failure is detected, the message

Ethernet with one of the following messages will be sent to the Start Page:

• General Failure

• MAC internal loopback failure

• MII internal loopback failure

(currently disabled)

This test verifies the functionality of the Ethernet

LAN Controller chip. Any test failures with this component are treated as non-fatal errors with the error information written to the Start Page. If a failure is detected, the message

Ethernet

Option Card with one of the following messages will be sent to the Start Page:

• General Failure

• MAC internal loopback failure

• MII internal loopback failure


2-5

Service Required Error Codes

Following are the Service required error codes that are displayed on the front panel.

2,000: SY I/O Board

Front Panel

Display

2,001.40

Error Codes

Software Error Code

SY_DEV_FAULT_IO_RIGHT

2,002.40

SY_DEV_FAULT_IO_LEFT

Meaning

The engine could not detect the presence of the

I/O Right circuit board. Make sure all connections are made.

The engine could not detect the presence of the

I/O Left circuit board. Make sure all connections are made.

4,000: PC Processor Control Supervisor

Front Panel

Display

4,001.40

(0x2401)

4,002.41

(0x2402)

Error Codes


PC_DEV_FAULT_HEAD_READ pc fault: printhead NVRAM error

PC_DEV_FAULT_HEAD_ZEROS pc fault: printhead NVRAM zeroes

4,003.42

(0x2403)

4,004.43

(0x2404)

PC_DEV_FAULT_HEAD_ONES pc fault: printhead NVRAM ones

PC_DEV_FAULT_HEAD_CHECKSUM pc fault: printhead NVRAM checksum

4,005.44

(0x2405)

PC_DEV_FAULT_DM_CAM_ERR pc fault: DM cam position

Meaning

Failure reading Head NVRAM data: check wiring to head, I2C bus and other hardware.

Head NVRAM data was all zeroes: has this head been through normalization? If so, check wiring to head, etc.

Head NVRAM data was all ones: has this head been through normalization? If so, check wiring to head, etc.

Head NVRAM checksum failure: the data within the head NVRAM has been corrupted. Check the hardware. The head may need to be renormalized.

Failure positioning the drum maintenance cam during a PM cycle: Check the DM cam, solenoid, clutch, home sensor, and related hardware.

2-6


4,000: PC Processor Control Supervisor (continued)

Front Panel

Display

4,006.45

(0x2406)

Error Codes


PC-DEV_FAULT_300DPI_CAL pc fault: 300 dpi calib

4,007.46

(0x2407)

4,008.47

(0x2408)

4,009.48

(0x2409)

PC_DEV_FAULT_600DPI_CAL pc fault: 600 dpi calib

PC_DEV_FAULT_STUCK_DMC pc fault: DM oil sense

PC_DEV_FAULT_DM_CAM_BEGIN pc fault: DM cam start position

4,010.40

(0x240a)

4,011.41

(0x240b)

PC_DEV_FAULT_DM_CAM_BU_WD pc fault: DM cam blade up/web down

4,012.42

(0x240c)

PC_DEV_FAULT_DM_CAM_END pc fault: DM cam end position

4,013.43

(0x240d)

4,014.44

(0x240e)

PC_DEV_FAULT_DM_CAM_BU_WU pc fault: DM cam blade up/web down

PC_DEV_FAULT_GEAR_GRIND pc fault: PM disengage

PC_DEV_FAULT_6x6DPI_CAL pc fault: 6x6 dpi calib

Meaning

Calibration Failure: Target Volt-Sec Area of 300

DPI could not be achieved. Check the hardware.

The head may need to be renormalized.

Calibration Failure: Target Volt-Sec Area of 600

DPI could not be achieved. Check the hardware.

The head may need to be renormalized.

Failure to advance the drum maintenance oiling mechanism. It has been in the new state for too long. Check the hardware.

At the start of a drum maintenance cycle, when the DM cam position should have been at blade down/web down, the DM cam home sensor should have been TRUE and was instead FALSE.

Check DM cam solenoid, clutch, home sensor, and related hardware.

During the drum maintenance cycle, when the

DM cam position should have been at blade up/web up, the DM cam home sensor should have been FALSE and was instead TRUE. Check

DM cam solenoid, clutch, home sensor, and related hardware.

During the drum maintenance cycle, when the

DM cam position should have been at blade up/web down, the DM cam home sensor should have been FALSE and was instead TRUE. Check

DM cam solenoid, clutch, home sensor, and related hardware

At the end of a drum maintenance cycle, when the DM cam position should have been at blade down/web down, the DM cam home sensor should have been TRUE and was instead FALSE.

Check DM cam solenoid, clutch, home sensor, and related hardware.

During power-on initialization, the engine is unable to disengage the process motor. Prior to declaring this fault, the engine has attempted to move the process motor through enough revolutions to disengage the head tilt mechanism, but the motor stalled somewhere along the way. The X-axis was then displaced to the right 0.15 inches and the disengage was repeated, but the motor stalled again. This leads to this device fault. The head is unable to move on the tilt axis, perhaps because it is colliding with something (head restraint pin, cap, poorly installed ink loader, screwdriver, etc.).

Calibration Failure: 600x600 DPI waveform could not be generated. Check the hardware. The head may need to be renormalized


2-7

4,000: PC Processor Control Supervisor (continued)

Front Panel

Display

4,015.45

(0x240f)

Error Codes


PC_DEV_FAULT_HEAD_ADJUST_TIMEOUT pc fault: head adjust timeout

4,016.46

(0x2410)

4,017.47

(0x2411)

4,018.48

(0x2412)

PC_DEV_FAULT_HEAD_NV_FORMAT pc fault: printhead NVRAM format

PC_DEV_FAULT_AMBIENT_TOOCOLD pc fault: tempt too cold

PC_DEV_FAULT_LATE_CLEAN_REQUEST pc fault: late clean request

4,020.41

(0x2414)

4,021.42

(0x2415)

4,022.43

(0x2416)

PC_DEV_FAULT_FTTR_HEADCAP pc fault: FTTR head cap contact

PC_DEV_FAULT_FTTR_DIRTYDRUM pc fault: FTTR dirty drum

PC_DEV_FAULT_INK_OUT_DURING_FLUSH

_TIMEOUT pc fault: ink out timeout

Meaning

Timeout during head adjust. A 20 minute timer elapsed before the exit head adjust command was executed. The only recovery possible is to cycle the power switch.

This head’s NVRAM contains a format of data not supported by this version of firmware. The head or firmware must be replaced.

Ambient temperature is less than 10 degrees

Centigrade. The printer cannot be warmed up under these circumstances.

Printhead temperature has dropped below the head-clean-needed threshold. This condition occurred after the warmup sequencer had determined a head clean operation was not needed.

Declared when the printer is booted in FTTR mode and the head/cap contact flag is set in

NVRAM. The printer cannot run in FTTR mode with head/cap contact because it would be unwise to separate the two when cold. Service requested that this be a device fault in order to bluntly alert the service person to the condition.

Declared when the printer is booted in FTTR mode and the drum is dirty. Reasoning that cleaning the drum when very cold could increase the chance of gluing media to the drum surface and creating an ugly mess around the stripper fingers. Service requested that this be a device fault in order to bluntly alert the service person to the condition.

Timeout during head flush for ink yellowing. The printer ran out of ink and a ten minute timer elapsed before more ink was added. The only recovery possible is to cycle the power switch.

2-8


5,000: VA Drum Error Codes

Front Panel

Display

5,001.41

(0x2c01)

Error Codes


YA_HOME_FAIL ya fault: drum home sensor

5,002.42

(0x2c02)

YA_ENCODER_FAIL ya fault: drum encoder

Meaning

Drum home sensor failure: the drum turned one full revolution without seeing the drum home sensor activate.

Drum motion failure: the drum stalled, possibly because the drum position sensor electronics have failed, or because the motor drive or drive belts have failed, or because something is physically blocking the motion of the drum.

6,000: XA X-axis Error Codes

Front Panel

Display

6,000.41

(0x3400)

Error Codes


XA_FAULT_MCURRENT xa fault: over/under current

6,001.42

(0x3401)

XA_FAULT_NOHOME xa fault: home sensor

6,002.43

(0x3402)

6,003.44

(0x3403)

XA_FAULT_NGHOME xa fault: unexpected home sensor

XA_FAULT_LOST xa fault: home calibration

Meaning

X-axis motor over/under current. Indicates that motor coil(s) are open, or shorted, or the XA motor fuse has opened.

X-axis home position not found. Indicates that the XA home sensor has failed, or something has prevented the printhead motion during a home operation.

Unexpected X-axis home sensor activation. The sensor has failed, the motor control is moving the head in the wrong direction, or the user has engaged the head restraint mechanism.

A verify of the home calibration failed. After locating the home sensor transition, the DMC computed X-axis position varied from the home value by more than the acceptable tolerance.


2-9

7,000: Process Motor Error Codes

Front Panel

Display

7,002.4x

(0x3c01)

Error Codes


PM_FAULT_PROCESS_MOTOR_STALL

7,003.4x

(0x3c02)

7,004.4x

(0x3c09)

Meaning

PM_FAULT_COMPOUND_GEAR_SENSOR_BAD

PM_FAULT_DM_CAM_SENSOR_BAD

The process motor stalled during operation. This has several possible causes, depending on what the PM was connected to at the time of operation.

No transitions are observed of the compound gear sensor when the compound gear should be turning. Perhaps the sensor is bad (it falls off easily), or the PM to compound gear linkage is broken.

No transitions are observed of the drum maintenance cam sensor. The sensor may be bad or the DM cam may be jammed.

8,000: Cap Drive and Web Sensors Error Codes

Front Panel

Display

8,001.44

(0x4401)

Error Codes


CAP_FAULT_HOME_SENSOR cap fault: home sensor

8,002.45

(0x4403)

CAP_FAULT_OVERCURRENT cap fault: overcurrent

Meaning

An expected transition of the cap home sensor did not occur. The home sensor may be faulty, or the cap motor may not be operating, or the cap may be jammed and unable to move.

An overcurrent fault has been detected. Either the cap motor is shorted, the purge pump motor is shorted, a solenoid is shorted, or the cap stalled. (This fault does not actually occur because the mechanism is loose. When the cap jams, the motor skips over teeth.) Check the hardware.

2-10


9,000: Ink Loader: Ink Melters and Printhead Ink Level Sensors Error Codes

Front Panel

Display

9,005.40

(0x4c05)

Error Codes


IL_FAULT_LOW_JAM il fault: low density ink-stick jam

9,006.41

(0x4c06)

IL_FAULT_INTER_JAM il fault: intermediate density ink stick jam

9,007.42

(0x4c07)

9,008.43

(0x4c08)

IL_FAULT_CLEAR_JAM il fault: clear ink stick jam

IL_FAULT_HIGH_JAM il fault: high density ink stick jam

Meaning

The low density ink melt heater is on, but Ink 12 does not seem to be dripping. Check that the stick of Ink 12 is able to advance in the chute.

The intermediate density ink melt heater is on, but Ink 13 does not seem to be dripping. Check that the stick of Ink 13 is able to advance in the chute.

The clear ink melt heater is on, but Ink 11 does not seem to be dripping. Check that the stick of

Ink 11 is able to advance in the chute.

The high density ink melt heater is on, but Ink 14 does not seem to be dripping. Check that the stick of Ink 14 is able to advance in the chute.

13,000: Head Thermals Error Codes

Front Panel

Display

13,001.40

(0x6c01)

13,002.41

(0x6c02)

13,003.42

(0x6c03)

13,004.54

(0x6d04)

13,017.46

(0x6c11)

13,018.48

(0x6c12)

13,019.40

(0x6c13)

Error Codes


TCH_JS_LEFT_OPEN tch fault: left jetstack open

TCH_JS_LEFT_SHORT tech fault: left jetstack shorted

TCH_JS_LEFT_HOT tch fault: left jetstack run-away

TCH_JS_LEFT_SLOW tch fault: left jetstack not heating

TCH_JS_RIGHT_OPEN tch fault: right jetstack open

TCH_JS_RIGHT_SHORT tch fault: right jetstack shorted

TCH_JS_RIGHT_HOT tch fault: right jetstack run-away

Meaning

The thermistor in the left jetstack appears to be open.

The thermistor in the left jetstack appears to be shorted.

The left jetstack heater is running away. Unplug the printer NOW!

The left jetstack heater is not heating at all, or is not heating as quickly as it should.

The thermistor in the right jetstack appears to be open.

The thermistor in the right jetstack appears to be shorted.

The right jetstack heater is running away. Unplug the printer NOW!


2-11

13,000: Head Thermals Error Codes (continued)

Front Panel

Display

13,020.52

(0x6d14)

13,033.45

(0x6c21)

13,034.46

(0x6c22)

13,035.47

(0x6c23)

13,036.50

(0x6d24)

Error Codes


TCH_JS_RIGHT_SLOW tch timer: right jetstack not heating

TCH_RESERVOIR_OPEN tch fault: reservoir open

TCH_RESERVOIR_SHORT tch fault: reservoir shorted

TCH_RESERVOIR_HOT tch fault: reservoir run-away

TCH_RESERVOIR_SLOW tch timer: reservoir not heating

Meaning

The right jetstack heater is not heating at all, or is not heating as quickly as it should.

The thermistor in the reservoir appears to be open.

The thermistor in the reservoir appears to be shorted.

The reservoir heater is running away. Unplug the printer NOW!

The reservoir heater is not heating at all, or is not heating as quickly as it should.

14,000: Cap Thermals Error Codes

Front Panel

Display

14,001.41

(0x7401)

14,002.42

(0x7402)

14.003.43

(0x7403)

14,004.44

(0x7404)

14,005.45

(0x7405)

Error Codes


TCC_THERMISTOR_OPEN tcc fault: cap open

TCC_THERMISTOR_SHORT tcc fault: cap shorted

TCC_THERMISTOR_HOT tcc fault: cap run-away

TCC_THERMISTOR_SLOW tcc timer: cap heater not heating

TCC_WRONG_TYPE_CAP tcc fault: cap incorrect

Meaning

The cap thermistor appears to be open.

The cap thermistor appears to be shorted.

The cap heater is running away. Unplug the printer NOW!

The cap heater is not heating at all, or is not heating as quickly as it should.

The installed cap heater is incorrect for this printer. Verify the correct cap heater is installed and/or the correct firmware is installed for this printer.

2-12


15,000: Drum Thermals Error Codes

Front Panel

Display

15,001.42

(0x7c01)

15,002.43

(0x7c02)

15,003.44

(0x7c03)

15,004.56

(0x7d04)

15,005.4x

(0x7c05)

Error Codes


TCD_THERMISTOR_OPEN tcd fault: drum open

TCD_THERMISTOR_SHORT tcd fault: drum shorted

TCD_THERMISTOR_HOT tcd fault: drum run-away

TCD_THERMISTOR_SLOW tcd timer: drum not heating

TCD_FAN_BLOCKED tcd fault: drum fan blocked

1

6,000: Preheat Thermals Error Codes

Front Panel

Display

16,001.43

(0x8401)

16,002.44

(0x8402)

16,003.45

(0x8403)

16,004.46

(0x8404)

Error Codes


TCP_THERMISTOR_OPEN tcp fault: preheat open

TCP_THERMISTOR_SHORT tcp fault: preheat shorted

TCP_THERMISTOR_HOT tcp fault: preheat run-away

TCP_THERMISTOR_SLOW tcp timer: preheat not heating

Meaning

The drum thermistor appears to be open.

The drum thermistor appears to be shorted.

The drum heater is running away. Unplug the printer NOW!

The drum heater is not heating at all, or is not heating as quickly as it should.

The drum fan heater is blocked, not operational or the heater is running away. Unplug the printer

NOW!

Meaning

The preheater thermistor appears to be open.

The preheater thermistor appears to be shorted.

The preheater heater is running away. Unplug the printer NOW!

The preheater heater is not heating at all, or is not heating as quickly as it should.


2-13

22,LSS,TC: Media Jams Error Codes

6

7

4

5

9

L indicates the location of the jam.

1 Bottom Hi-capacity Paper Feeder

2

3

Middle Hi-capacity Paper Feeder

Top standard tray

Handfeed

Front cover

Top cover

Y-axis jams (see following error codes)

SS indicates sensor location.

00

01

02

03

04

05

06

Usually because of an opened door

Bottom High-Capacity tray sensors

Bottom High-Capacity pick sensors

Middle High-Capacity tray sensors

Middle High-Capacity pick sensors

Standard tray sensors

Standard tray pick sensors

Door opened jams (see following error codes) 07 Handfeed sensors

08 Preheat entry sensor

09 Width sensors

10 Width A sensor

11 Width A4 sensor

12 Preheat exit sensor

13 Stripper exit sensor

14 Media Exit sensor

15 <undefined>

16 VE_DM CYCLE_DONE out of order

17 VR_TF_ROLLER_LIFTED out of order

18 Unknown reason

T indicates whether a timeout or an event occurred

0 Event

1 Timeout

C indicates checksum

2-14


22,000 Jam Error Codes

Front Panel

Display

22,703,0C

22,704,0C

22,705,0C

22,707,0C

22,708,0C

22,721,0C

Error Codes


DECLARED JAM

DECLARED JAM

DECLARED JAM

DECLARED JAM

DECLARED JAM

DECLARED JAM

22,722,0C

22,901,0C

22,902,0C

DECLARED JAM

DOOR EVENT

DOOR EVENT

Meaning

Stall event

Sensor failure

Media jam at exit tray

Media too long at exit tray

Media too short at exit tray

Media not staged at preheater entry in time for transfix

Media jam at stripper fingers

The front access door is opened

The top, stripper, access door is opened

31,000 Media Preheater Error Codes

Front Panel

Display

31,003.4x

Error Codes


MP_FAULT_PREHEAT_EXIT_SENSOR_BAD

Meaning

Declared at boot time when a check is made to determine the condition of the preheat exit sensor. Declared when the sensors around the preheat exit sensor indicate the presence or absence of media contrary to that indicated by the preheat exit sensor.


2-15

PostScript®-detected Error Codes

NOTE: Codes from 24,000 through 24,999 are engine failures reported by PostScript. They are NOT stored in the fault history table in NVRAM. These are reported when the engine has been stuck in a state for 25 minutes.

Error Code

24,000.17

24,000.18

24,002.10

24,003.11

24,000.12

24,005.13

24,006.14

24,007.15

24,007.16

24,009.17

24,010.18

24,011.10

24,012.11

24,013.12

24,014.13

24,015.14

24,016.15

Meaning

Engine reports power is off—impossible.

Engine reports it is running diagnostics—impossible.

Engine is stuck in the VxWorks shell.

Engine is stuck in mechanism init.

(unused)

Engine is in state ready but is not permitting commands.

Engine is stuck, in standby.

Engine is stuck, while printing.

Engine is stuck, while cleaning the drum.

Engine is stuck, while purging the head.

Engine is stuck, while wiping the head.

Engine is stuck, while oiling the roller.

(unused)

Engine has a fault but will not say why.

Engine is stuck while powering down.

(unused)

Engine is stuck while oiling the drum.

2-16


Error Code

24,017.16

24,018.17

24,019.18

24,020.10

24,021.11

24,022.12

24,023.13

24,024.14

PostScript®-detected Error Codes (continued)

Meaning

Engine is stuck while turning the pick rollers.

Engine is stuck while warming up—thermals will not stabilize.

Engine is stuck while warming up—thermals are stable.

Engine is stuck while warming up—it is too cold to warm up.

Engine is stuck while cooling down.

Engine is stuck while in the cool state. (Should never happen.)

Engine is stuck while in head adjust state.

Engine is stuck while flushing the head.

Winch-related Error Codes

Error Code

26,001.44

Meaning

Winch motor or sensors are not responding.


2-17

Front Panel Status Messages

The Front Panel status messages and solutions are shown in

Table 2-2. The messages are listed in descending priority order.

Table 2-2. Front Panel Status Messages

Status Message Solution

Warming up—Please wait

Ready to Print

The printer is heating the ink; wait until

Ready to Print

is displayed.

The printer is ready to accept print jobs.

Ink low—Add ink

Check ink levels; add appropriate ink sticks to the correct ink-loading bins.

Maintenance Kit is low. Only

XX Pages remaining before empty.

Reorder a Maintenance Kit now. Replace Kit soon.

Processing Data—Please wait

Receiving data—Please wait

Printing—Please wait

Warming up—Please wait

Warming up, Please wait.

XX% complete

Initializing

Cleaning

Canceling print job—Please wait.

Canceling Cleaning—Please wait.

The printer is processing data; wait until

Ready to Print or Printing is displayed.

The printer is receiving data; wait until

Ready to Print

or

Printing

is displayed.

A print job is printing; wait until

Ready to Print

is displayed.

The printer is heating the ink; wait until

Ready to Print

is displayed.

The printer is heating the ink; warm up may take as long as

17 minutes; wait until

Ready to Print

is displayed.

Initializing printer mechanisms—Please wait.

The printhead is being cleaned—Please wait.

You have selected Cancel; wait while the job is removed from the queue.

The current cleaning operation has been canceled.

2-18


Table 2-2. Front Panel Status Messages (continued)

Status Message

Standby mode—Press any button to return to Ready

Solution

The printer is in an automatic power-saving mode. Press any button to return the printer to

Ready

.

NOTE: Pressing Help removes Standby—so you do not actually see this Help message.

Reduces power consumption.

Energy Star Mode active—

Press any button to return to Ready

Head-To-Drum Adjust

Upper media tray empty—

Load paper

Lower paper tray empty—

Load paper only

Media tray empty—Load paper

Replace lower paper tray

Replace upper media tray

Replace media tray

Cleaning sheet needed—Load paper

Cleaning sheet needed—Load letter-size paper

Cleaning sheet needed—Load

A4-size paper

For Service use only.

The printer is stopped. Load paper into the upper media tray; insert in the printer.

The printer is stopped. Load paper into the lower paper tray; insert in the printer.

The printer is stopped. Load the paper into the tray; insert in the printer

The lower paper tray is missing. Printing can continue from the upper tray.

The upper media tray is missing. Replace the tray to continue printing.

The media tray is missing. Replace the tray to continue printing.

The printer was interrupted while printing a page. The printer requires a sheet of blank paper to remove the ink of the partially printed page before it can continue printing. Load paper in the paper tray.

The printer was interrupted while printing a page. The printer requires a sheet of blank letter-size paper to remove the ink of the partially printed page before it can continue printing.

Load paper in the letter-size paper tray.

The printer was interrupted while printing a page. The printer requires a sheet of blank A4-size paper to remov ethe ink of the partially printed page before it can continue printing. Load paper inthe A4-size paper tray.


2-19


Status Message

Close front cover to continue

Close exit cover to continue

Close top cover to continue

Ink sticks jammed—Open and close top cover to clear jam

Output tray full—Remove printed pages to continue

Out of ink—Open top cover.

Add ink.

Add ink. Close top cover.

Drawer A locked—Close front cover to continue

Paused

Printing—Pause Pending this page completes.

Media jam—Retry manual feed

Media jam—incorrect media size—Open exit cover to clear

Media jam—Open front cover to clear

Media jam—Remove media tray to clear

Solution

The printer is stopped; close the front cover to resume printing.

The printer is stopped; close the exit cover to resume printing.

The printer is stopped; close the top cover to resume printing.

Ink sticks under the top cover are not sliding properly. Open and close the top cover to resolve the problem. If the problem persists, jostle the ink sticks until there are no spaces between the sticks.

The media in the output tray is either jammed or the tray is filled to capacity. Remove hte printed pages to continue.

The printer is stopped. Open the top cover. Add ink. Close the top cover.

The printer is stopped. Add ink. Close the top cover.

Waste Tray B is cooling; Close the front cover and wait two minutes for Drawer A to be unlocked.

The printer is in pause mode. You may add media or ink safely. Press Resume to continue.

The printer is finishing the current page. It will pause when

Remove media. Verify that media used is within specifications. Use both hands to reinsert sheet until it feeds and stops.

Remove jammed media and close the exit cover to resume printing.

Open the front cover and remove media to resume printing.

Remove jammed media and reinsert media tray.

2-20




Media jam—Remove upper media tray to clear

Media jam—Remove lower tray to clear

Caution! Hot surfaces—

Replace the Maintenance Kit

C1 and C2.

Remove jammed media and reinsert upper media tray.

Remove jammed media and reinsert lower media tray.

Media jam—Remove Media to clear

Lower paper tray empty—

Load paper

Caution! Hot surfaces—Remove

Maintenance Drawer A.

Caution!—Waste Tray B may be hot.

Remove jammed media to resume printing.

Media jam—Open front cover to clear

Media jam—Open exit cover to clear

Incorrect media size—Load letter-size paper

Incorrect media size—Load

A4-size paper

Remove jammed media and close the front cover to resume printing.

Remove jammed media. Verify that the correct media is loaded and close the exit cover to resume printing.

Printer needs letter-size paper to remove ink left from a failed print.

Printer needs A4-size paper to remove ink left from a failed print.

Drawer A locked—Close front cover to continue

The printer is stopped; close the front cover to resume printing.

Printer error—Contact service;

For the latest information, contact your local service provider.

report fault

The printer is stopped. Load paper into lower paper tray; insert in printer.

The printer is stopped. Do not touch hot surfaces! Remove and reinsert Maintenance Drawer A.

The printer is stopped. Do not touch hot surfaces! Remove

Maintenance Kit C1 and C2.


2-21



Caution! Hot Surfaces—Insert

Maintenance Drawer A

Maintenance Drawer A is missing. Open fron cover and insert Maintenance Drawer A.

The printer is stopped. Do not touch hot surfaces! Reinsert

Maintenance Drawer A.

The printer is stopped. Open the front cover. Do not touch hot surfaces! Reinsert Maintenance Drawer A.

Power Switch is Off

Melting Ink Please Wait

The power switch has been turned to the off position. But, the printer is currently melting ink.

Power turned off—Wait 30 minutes before moving printer.

The printer is shutting down; it will shut off momentarily.

Waste Tray B full—Open front cover to empty

Caution! Hot surfaces—Empty

Waste Tray B.

Fast cool down mode—XX%

Complete. Do not move printer until cool. Remove

Maintenance Drawer A for shipping—See manual for details

The printer is stopped. Open the front cover. Empty and reinsert Waste Tray B. Close the front cover.

The printer is stopped. Do not touch hot surfaces! Empty and reinsert Waste Tray B. Close the front cover.

The printer is cooling the ink. Do not move the printer until the printer turns itself off.

Standard shutdown

(2 Minutes or less)

The printer is shutting down.

VxWorks Shell

Manufacturing Mode

For Service use only.

2-22


Chapter

Troubleshooting

3-1

Chapter 3

Troubleshooting

This chapter provides troubleshooting assistance as follows:

Verifying the Printer and Host Connections . . . . . . . . . . . . . . . . . 3-3

3-2


System Power-up Sequence

The following lists the chain of events that occur when you turn on, reset or initialize the printer. You can follow this list as one means of determining if the printer is operating correctly. The exact chain of events depends upon where the printer “believes” the printhead is positioned. The printer records in NVRAM the last known position of the printhead and the cap/wipe/purge assembly.

Power switch turned on:

1. Low-level, power-on self-test (POST) diagnostics are performed.

The two status LEDs at the rear panel should be blinking and the front panel LEDs are turned on.

2. If POST diagnostics pass, the front panel Error LED is turned off and the LCD display is cleared.

3. Depending upon the printhead position:

Printhead in Standby or Print position

a. If the printer is in its Standby mode, the cap/wipe/purge motor is run to ensure that the cap/wipe/purge assembly activates its home position sensor. If the printer is in

Print mode, the printhead is moved to its x-axis home position and then centered.

b.

The process motor is rotated to tilt the printhead forward (if not already forward), rotate all the rollers to their ready positions, disengage the transfix roller, and lower the maintenance drawer blade and wiper.

Printhead in Cap/wipe/purge position

a. The heaters in the printhead and cap/wipe/purge assembly are activated to melt the ink “gluing” them together.

b.

The printhead is tilted back.

c.

The ink is allowed to drain from the cap/wipe/purge assembly.

d. The cap/wipe/purge assembly is lowered to its home position.

e.

A short wipe is performed and the cap/wipe/purge assembly is returned to its home position.

f.

The process motor is rotated to tilt the printhead forward (if not already forward), rotate all the rollers to their ready positions, disengage the transfix roller and lower the maintenance drawer blade and wiper.

g.

The printhead is moved to its x-axis home position and then centered.

Troubleshooting

3-3

Printhead is in the print position but the cap/wipe/ purge assembly is in some unknown intermediate position:

a. If the cap/wipe/purge assembly is not detected in its home position, then the heaters in the printhead and cap/wipe/purge assembly are activated in case the printhead and cap/wipe/purge may be “glued” together by cooled ink.

b.

After waiting for the ink to melt, the cap/wipe/purge assembly is lowered to its home position.

c.

The process motor is rotated to tilt the printhead forward (if not already forward), rotate all the rollers to their ready positions, disengage the transfix roller and lower the maintenance drawer blade and wiper.

d. The printhead is moved to its X-axis home position and then centered.

e.

A short wipe is performed and the cap/wipe/purge assembly is returned to its home position.

4. The printhead is tilted back to the locked position.

5. The front panel displays a warm up message.

6. The heaters are enabled and the drum begins to rotate.

7. When the ink in the printhead is molten, the cap/wipe/purge assembly is positioned to the purge position.

8. The printhead tilts forward and a purge cycle begins.

9. A cleaning page is printed.

10. The front panel displays a message that the printer is initializing and then ready.

The print engine is initialized.

3-4


Verifying Main Board CPU Operation

1. If the printer does not power up (rear fan is off and power-up diagnostics LEDs are off), go to the topic, “Verifying power supply operation” below.

2. Observe the rear panel LEDs located on each side of the rear panel DIP switches. The left LED represents the operation of the PostScript firmware. The right LED represents operation of the main board’s print engine firmware. During the POST tests the two LEDs toggle back and forth for each successful pass through each DRAM test. A failure in the power on self tests is indicated by the left LED (the PS led) flashing in a specific pattern of long and/or short flashes and repeated indefinitely.

Other failures are indicated by the failure being printed on the

Startup page.

After successful power-up, the left (PS) LED flashes in a “heartbeat” rhythm (on 0.5 seconds, off 0.5 seconds). The right (PE) LED pattern is two quick flashes on, then off for a count of two for a total cycle time of just over two seconds. The front panel Power light is turned on, the Error light is flashed, and the LCD is cleared.

Verifying Print Engine Operation By Printing

Its Startup Page

1. If it is not already on, turn on the printer. If the printer does not begin initializing, go to the topic, “Verifying power supply operation” below.

2. Once the Power light is on (not blinking) and the front panel displays

Ready to Print

, scroll to Menu and press the

Select button. Then scroll to the Demo and Test Pages menu item, press the Select button, and then scroll and select the

Print Startup Page menu item. The printer should print out a Startup Page.

If the printer prints a Startup Page, then the print engine is working correctly. If the printer does not print a Startup Page, then a problem exists with the print engine.

Troubleshooting

3-5

Verifying Power Supply Operation

Required tools:

• TORX T-20 screwdriver

• Digital multimeter (DMM)

The power supply is divided into two sections: the AC section used for heaters and the DC section for control logic, printhead drivers and motors. Verifying the power supply involves three steps:

• Checking for proper AC voltage.

• Inspecting the power supply fuses.

• Testing for a shorted motor or solenoid driver, which shuts down the power supply.

Measuring Power Supply Voltages

WARNING

AC line voltages are present on the power supply and possibly in the printer, via the heaters, while the printer is plugged into an AC outlet, even if the power switch is off.

1. Turn off the printer and unplug it from its power outlet.

2. AC Input: With the DMM set to measure AC voltages, measure the power being supplied to the printer. It should measure between 87 to 128 VAC (115 VAC nominal) or 174 to 250 VAC

(220 VAC nominal).

3. Proceed to the topic, “Inspecting the power supply fuses” below.

NOTE: If a heater shorts, F2 or F3 opens. The power supply does not shut down, however, a Service Required error code is displayed on the front panel.

Inspecting The Power Supply Fuses

Three fuses (F1, F2 and F3) are mounted on the power supply.

1. Turn off the printer and remove the power cord.

2. Remove the screws securing the power supply. Disconnect the wiring harnesses plugged into the power supply and remove power supply.

3-6


3. With a DMM, determine that the fuses on the power supply are functional. Fuse F1 is the AC input fuse for the DC section of the power supply. If F1 opens, the power supply does not function and should be replaced.

CAUTION

Fuse F2 and Fuse F3 are used for the AC heaters within the printer; they protect the power supply from, most often, a shorted triac. If

F2 or F3 blows, it is best to replace the power supply rather than the fuse. Otherwise, with the fuse replaced, but the triac shorted, AC power may be applied to the heater without the printer being turned on, resulting in a thermal runaway condition.

If the fuses are functional, but the printer’s power supply does not output DC voltages, proceed to the topic, “Testing for shorted drivers.”

Testing for Shorted Drivers


2. Disconnect the +40 DC loopback connector (the 4-pin connector with the two loopback wires) from J250 at the top of the power control board. (This isolates the Y-axis motor, process motor, Xaxis motor, paper feed motor, vacuum pump, solenoids and clutches).

3. Attach the service load connector to J250 on the top of the power control board, behind the printhead, to simulate a load on the power supply. When viewed from the front of the printer, the lead with the ground clip should be to the right. See Figure

3-10 for correct orientation. Attach the service load connector’s ground clip to the printer frame. Do not leave the service load connector in place and powered-up for longer than 5 minutes; it gets hot from the current load.

Troubleshooting

3-7

Warning: AC voltage hazard. Never attempt to plug service load connector here.

Service load connector

0388-66

J 250

Figure 3-10. Attaching Service Load Connector To J250

4. Turn on the printer. If the rear panel LEDs illuminate

(indicating power), the power control board or its loads are current-limiting the power supply. Go to Step 5. If no power is evident (no lit LEDs), replace the power supply.

5. Turn off the printer. Reconnect the +40 volt loopback connector to the power control board; then disconnect all load connectors from the power control board. Turn the printer on. If the rear panel LEDs still do not illuminate, the power control board has a shorted driver and must be replaced. If the LEDs do illuminate, isolate which motor or fan is overloading the power control board and power supply by turning off the printer and sequentially plugging each cable in one at a time and turning on the printer until the power supply is disabled. Replace the defective component. Also refer to the next topic “Testing for a shorted motor.”

6. Turn off the printer. Disconnect the two I2C bus cables from the power control board. (This isolates the I/O boards and their solenoid drivers.) If the rear panel LEDs illuminate, isolate which I/O board is shorting or which I2C cable is defective.

7. If the power supply still does not work, replace the power supply.

3-8


Testing For A Shorted Motor

1. Reinstall the power supply if removed in the previous procedure.

2. Disconnect the process motor, the Y-axis motor, X-axis motor and the cap/wipe/purge assembly motor wiring harnesses from the power control board.

3. Turn on the printer again to see if it does not overload now that the motors are disconnected from the power supply.

If the power supply is functional, proceed to the procedure, “Testing motor and solenoid resistances,” below.

If the motors and solenoids are not shorted, but the power supply still does not function, replace the power control board.

Testing Motor And Solenoid Resistances

1. Turn off the printer and disconnect the power cord.

2. With a DMM set for measuring resistance, test each motor’s windings for correct resistance (disconnected from the printer).

Refer to Table 3-2. Rotate the motor’s drive shaft slightly while taking the measurement.

Table 3-2. Motor And Solenoid Resistances

Motor or solenoid

Process motor

Y-axis motor

X-axis motor

Paper feed motor

Maintenance Drawer Camshaft electric clutch

Paper-pick electric clutch

Transfix cam solenoid

Resistance (approx.)

3 ohms

2 ohms

60 ohms/phase

<1 ohms/phase

10 ohms

10 ohms

45 ohms

Troubleshooting

3-9

Printhead Troubleshooting

NOTE: The Jet Test Page, which may be printed using the

Troubleshooting front panel menu and is automatically printed after the Cleaning Page, contains a localized warning when printed on A4size paper. The warning message suggests that the page be re-printed on wider (A-size) paper. This is because the outer-most jets are not exercised when the print is made on A4-size media. However, the warning should be ignored if the printer is not going to be used with

A-size paper. The outer-most jets are never used for A4 images, so there is no penalty unless wider images are made.

Although printhead failures will occur, they will occur at significantly lower rates than in the past. It is important that other parts of the printer related to printhead operation and maintenance (cap/wipe/ purge assembly, vacuum module or tubing) be inspected and, if necessary, replaced to avoid unnecessary printhead replacements and service callbacks.

Table 3-1 provides the process for troubleshooting the printhead. As you proceed through the “Action” steps listed in the table, please check the appropriate boxes under “Look for” and “What next” to document the troubleshooting process. If you must replace the printhead, keep a filled-out copy of this table, with the defective printhead and the Weak and Missing Jet stest print. The following steps provide the details to accompany the table.

1. Check the 8-digit serial number of the printhead in the Service

Support menu or on the label on top of the printhead before replacing it. Record the number on Line 2 of the checklist.

There are two numbers on the printhead; look at the 8-digit number.

2. Check printhead drive voltage (Head Adjust). It is critical that new printheads only be run at the factory default of 128. Often, the Head Adjust has been raised on the old head to extend its life. Adjusting it above 128 will cause the jets to fail on multipage jobs and increases customer ink usage.

3. Print Service Test Print 2: Weak and Missing Jets. Use this test print to evaluate the cap/wipe/purge assembly and printhead performance.

If you see ink mixing from one row to the next, (e.g.

Medium 46 to Clear 46) this indicates the cap/wipe/purge blade may be damaged. If it is, install a new cap/wipe/purge assembly.

If you see weak or missing jets, the problem could be caused by the cap/wipe/purge assembly, the vacuum system

(tubing, air valve or pump), the printhead, or the printhead data cable. To isolate the problem, begin by checking the

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performance of the cap/wipe/purge assembly and vacuum system. (Action Steps 4–8.)

If you see white “pinstripes” spaced 0.25 cm (0.1 inches) apart across the page (but not present on the test page), the problem is not with the cap/wipe/purge assembly or printhead.

Check for something binding the x-axis (e.g. a cable rubbing the printhead). The x-axis shaft may need to be lubricated.

To lubricate, apply three dabs (1/10-in. diameter) of Nye

Rheolube 368F grease on the threads of the x-axis shaft.

4. Visually check the printhead’s faceplate. Through close examination of the printhead’s faceplate, you can determine if the wiper blade and gasket are damaged.

If you see any tiny wax droplets inside the ring where the cap/wipe/purge gasket seals against the printhead faceplate

(Figure 3-2), the cap/wipe/purge gasket is leaking during purge.

This can be caused by a misaligned printhead or a defective gasket. To verify printhead alignment, move the cap/wipe/purge to the purge position and tilt the printhead forward until the upper edge of the gasket touches the faceplate. If the left and right sides touch the faceplate at the same time, the printhead side-to-side alignment is OK and the problem is with the gasket. If not, you’ll need to readjust the printhead gap.

If you see streaks or smudges of wax in the jet area of the printhead’s faceplate after a clean cycle (Figure 3-3), the cap/ wipe/purge wiper blade is damaged and the cap/wipe/purge assembly needs to be replaced.

5. Visually check the cap/wipe/purge wiper and gasket. Move the printhead all the way back and raise the cap/wipe/purge assembly. Inspect the rubber wiper (Figure 3-4), especially at the ends, for signs of separation or damage to the blade. (See figure 3-5 for damage to printhead.) Gently probe the cap/wipe/ purge gasket with fingers or blunt tool for signs of separation from the cap assembly. Replace if defective.

6. Empty maintenance tray and check vacuum and decay time. To check the cap/wipe/purge assembly purge performance, first empty the waste tray. Attach the vacuum gauge (003-1377-00) using a vacuum “T” (131-6819-00) at the metal pipe used to connect to the cap/wipe/purge assembly. Perform the Clean Jets cycle from the Troubleshooting menu on the front panel. Check the Peak vacuum and Decay time to determine if there is a problem with the vacuum system (pump, air valve or tubing) or cap/wipe/purge gasket. The Peak vacuum should be greater than 46 cm Hg (18 in. Hg, 9 psi). If the vacuum is less than 46 cm Hg, then the cap/wipe/purge gasket is leaking or the vacuum pump is defective. To isolate the problem, go to Action

Step 8.

Troubleshooting

3-11

NOTE: The Decay time should take about 6 seconds for the Peak vacuum to bleed off to 0 cm Hg.

If there is no Decay time (sudden drop to zero), the cap/wipe/ purge gasket is bad.

If the Decay time is longer than 6 seconds, then something is restricting the tubing (ink in tubing) to the air valve or the air valve is bad. Disconnect the tubing between the metal vacuum tube and vacuum module. Blow through the metal vacuum tube to assure the cap/wipe/purge assembly or tubing is not blocked with ink. Replace any part (cap/wipe/purge assembly, tubing, vacuum module, etc.) that is contaminated with ink.

If the vacuum does not bleed off at all, then the air valve is not opening properly or the orifice in the air valve solenoid is blocked. Replace the vacuum module.

NOTE: Checking the cap/wipe/purge assembly performance by looking for the “KISS” effect when the printhead separates from the cap/wipe/purge gasket at the end of a purge cycle is not an accurate method of checking purge performance and it does not work on all solid-ink printers. Use your vacuum gauges!

7. Check the ink distribution in waste tray. The last check is to look at the ink in the waste tray after a single CLEAN cycle. If the cap/wipe/purge assembly and vacuum system are working properly, there should be ink evenly distributed across the waste tray (~3/4 in. wide). (Refer to Figure 3-7.) If not, check the head-to-drum gap. The cap/wipe/purge gasket is leaking.

8. If vacuum is less than 46 cm Hg at metal pipe, check. If the

Peak purge vacuum is less than 46 cm Hg (18 in. Hg, 9 psi), check the vacuum at the pump side of the vacuum module

without the vacuum “T”.

If vacuum is less than 51 cm Hg (20 in. Hg, 9.9 psi), replace the vacuum module.

NOTE: In diagnostics, go to the NVRAM/PE ROM test and select the sub-test “Access NVRAM Read/Write Data.” The default is set to 20 V.

This will cause the pump to run somewhat louder during the clean cycles.

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If vacuum is greater than 51 cm Hg, the cap/wipe/purge gasket is leaking. Replace the cap/wipe/purge assembly.

9. Install a new cap/wipe/purge assembly. After installing a new cap/wipe/purge assembly, it may take from 4–6 front panel

Clean cycles before the cap/wipe/purge gasket seals properly.

Be sure to verify the new cap/wipe/purge assembly performs properly. (Action Steps 4 to 8.)

10. Install a new printhead only after directed by Action Steps 1–8.

If you are not sure the printhead is the problem, change the cap/wipe/purge assembly first.

NOTE: The factory has set the printhead adjustable mounts at the maximum distance from the drum to avoid accidental grinding or crashing with the drum upon installation. Therefore, it is critical that they be properly adjusted so that a good seal will be obtained with the cap/wipe/purge assembly. This should be adjusted while COLD. Once the printer is warmed up and the printhead is HOT, the printhead-todrum gap MUST be adjusted again.

NOTE: The front panel Head-to-Drum Adjust will time-out after 20 minutes which will result in a 4,015.45 error. To clear the error, cycle power on the printer.

11. Check for Service Required Errors. After installing the printhead, you may get one of the following service errors due to mis-adjustment or cabling problems:

4,002.41 and 4,006.45

Printhead NVRAM all zeroes. If the data cable between the power control board and the printhead is not plugged in properly or damaged (Figure 3-8), this error will occur.

Reseat or replace the data cable.

13,003.35, 13,019.40 and 13,035.47

Heater running away. If the data cable is not making a good connection, the incorrect data will be sent to the main board. Reseat or replace the printhead data cable before replacing printhead.

13,004.43 or 13,020.41

Jetstack not heating as quickly as it should. Readjust the left or right head-to-drum adjustment; the jetstack is too close to the drum which prevents it from warming up. If the error reoccurs after the adjustment, replace the printhead.

Troubleshooting

3-13

Additional Printhead Error Codes:

13,001.40 and 13,0017.47

Open left and right jet stack thermistor. Reseat or replace the data cable. If the error reoccurs, replace printhead. If the new printhead gives the same error, replace the power control board.

13,002.41 and 13,018.48

Jet stack thermistor appears to be shorted. Reseat or replace the data cable. If the error reoccurs, replace the printhead. If the new printhead gives same error, replace the power control board.

13,033.45

The thermistor in the reservoir appears to be open. If the

4-pin connector on the top of the driver board (Figure 3-

9) is disconnected, this error will occur. Turn off the printer and reseat the cable.

13,034.46

Thermistor appears to be shorted. Look to see if the 4 prong plug on the top of the driver board is plugged in correctly. If it is, check the data cable. If the data cable is good, replace printhead. If the error happens on the new printhead, replace the power control board.

13,035.47 and 13,036.48

Reservoir heater is running away, or reservoir is not heating. With these errors it is most likely a problem with the printhead.

12. Check cap/wipe/purge assembly purge performance. After installing a new printhead, you must recheck the cap/wipe/ purge assembly (Action Steps 4–7). If the printhead is not installed correctly, the cap/wipe/purge gasket may leak.

NOTE: A broken ink loader can cause the cap/wipe/purge gasket to not seal. Look for signs of breakage of the black plastic parts on the underside, especially the bosses that retain the lowest black plastic panel. Breakage or separation can interfere with head tilt, resulting in a poor seal with the cap/wipe/purge during the purge process. Replace the ink loader if broken or defective.

3-14


Table 3-1. Printhead Troubleshooting

ACTION:

Identify Printhead:

1.

Get printhead serial number.

LOOK FOR:

❑

1. Enter serial #:

_______________

Determine Problem:

2. Check printhead drive voltage.

3.

rint Service Test Print 2: Weak and

Missing Jets.

❑

2. Head Adjust setting of 128.

❑

3A. color mixing from one row to the next row for same jet.

❑

3B. weak or missing jet(s).

Inspect Printhead and CWP:

4.

Visually check printhead faceplate.

5.

Visually check CWP wiper and gasket.

❑

4A. streaks or smudges of wax in the et area of the printhead

❑

4B. tiny wax droplets (V-shape) inside the ring where the CWP gasket seals against the printhead faceplate.

❑

5A. any separation on the wiper blade, or pitting of the CWP gasket.

❑

5B. good visual inspection (4A-5A).

WHAT NEXT:

❑

Go to ACTION 2.

❑

2. If Head Adjust is not 128, set it to 128.

Go to ACTION 3.

❑

3A. If so, replace CWP: ACTION 9.

❑

3B. If so, go to ACTION 4.

❑

4A. If so, wiper is damaged. Replace

CWP: ACTION 9.

❑

4B. If so, CWP is leaking. Adjust HTD gap, or if gasket is damaged, go to

ACTION 9. Otherwise, go to ACTION 5.

❑

5A. If so, replace CWP: ACTION 9.

❑

5B. If so, go to ACTION 6.

Troubleshooting

3-15

Table 3-1. Printhead Troubleshooting (cont.)

ACTION:

Check CWP Purge Performance:

6.

Check vacuum and decay time at metal pipe using vacuum "T" during front panel

CLEAN cycle.

7.

f vacuum is less than 46 cm Hg at metal pipe (LOOK FOR 6A), check vacuum at pump side of vacuum module without “T” during front panel CLEAN cycle.

8. Locate source of CWP vacuum leak.

LOOK FOR: WHAT NEXT:

❑

6A. a peak vacuum reading during purge:

Peak vacuum at metal pipe:

__________

❑

6B. the time it takes for the vacuum to decay to 0 cm Hg:

Decay time:

__________

❑

6A. If less than 46 cm Hg (18 in Hg, 9 psi), go to ACTION 7.

If greater than 46 cm Hg, go to LOOK

FOR step 6B.

❑

6B. If decay time is about 6 seconds, go to

ACTION 10.

If there is no decay time (sudden drop to zero), CWP gasket is bad. Go to ACTION 9.

If decay time is less than

6 seconds, check metal and rubber tubing for ink.

If decay time is much longer than

6 seconds, replace vacuum module.

❑

7. peak vacuum at pump side of vacuum module without "T" during front panel CLEAN cycle.

Measured vacuum at pump:

__________

❑

7. If less than 51 cm Hg (20 in Hg, 9.9

psi), replace vacuum module.

If greater than 51 cm Hg, go to ACTION 8.

❑

8A. plugged tubing between CWP and air

❑ solenoid or vacuum module.

❑

8B. misaligned CWP belts.

❑

8C. misaligned printhead-to-drum.

8D. interference with printhead tilt mechanism.

❑

8A. Replace rubber or metal tubing and go to

ACTION 6.

❑

8B. Align belts and go to ACTION 6.

❑

8C. Align HTD and go to ACTION 6.

❑

8D. Repair mechanical interference and go to

ACTION 6.

Install NEW CWP:

9. Install new CWP. Do up to 6 purge cycles to test performance.

Retest print quality:

10. Print Service Test Print 2: Weak and Missing

Jets.

❑

9. good CWP purge performance.

❑

10. weak or missing jet(s).

❑

❑

9. New CWP may take 4-6 purges before optimal performance. Go to ACTION

6.

10.

If no weak or missing jets, repair is complete. Print quality is OK.

If PQ not OK, go to ACTION 11.

Install NEW Printhead

11. Install a new printhead only after completing previous steps.

Note:

If you have not replaced the CWP and you're not confident the printhead is defective, change the CWP.

12. Check printhead drive voltage.

❑

11. left and right HTD adjustments are equal at HOT adjustment.

Note:

Hot printhead adjustment must be performed for good purge performance and good print quality.

❑

12. Head Adjust setting of 128.

13. Check for Service Required Errors.

14. Check CWP purge performance:

ACTION 6.

❑

13A. 13,004.43 or 13,020.41 errors: etstack not heating as quickly as it should.

❑

13B. 13,001.40, 13,002.41, 13,003.42,

13,017.46, 13,018.48 and 13,035.47.

❑

13C. 4,002.41 and 4,006.45 errors: rinthead NVRAM all zeroes.

❑

14. good purge performance with NEW printhead.

❑

❑

11. If HTD adjustment is uneven from side-to-side, CWP will not purge properly. Adjust HTD and go to ACTION 12.

12. If Head Adjust is not 128, set it to

128 and go to ACTION 13.

❑

13A. Readjust HTD: left or right side of printhead is too close to drum. If error reoccurs, replace printhead.

❑

13B. Reseat printhead ribbon cable before replacing printhead.

❑

13C. Check printhead ribbon cable before replacing power control board

(followed by printhead).

❑

14. If purge performance is good, go to

ACTION 10 to verify.

3-16


Figure 3-1 shows what a printhead faceplate will look like after a good cap/wipe/purge blade wipe. Notice that there are no smudges or streaks of ink in the nozzle area.

Figure 3-1. Good Cap/Wipe/Purge Blade Wipe

Figure 3-2 shows a close-up of the printhead faceplate identifying the tiny drops of ink that indicate a cap/wipe/purge gasket leak. Notice the “V” or funnel shape the droplets form just under the area where the cap/wipe/purge gasket seals against the faceplate (ink stain).

Random drops can be ignored.

Figure 3-2. Cap/Wipe/Purge Gasket Leaking

Figure 3-3 shows the affect on the printhead when the cap/wipe/purge blade is not working . In this example, the blade has several (6) defects. In most cases, you will probably only see one smudge or streak.

Figure 3-3. Bad Cap/Wipe/Purge Blade Wipe

Troubleshooting

3-17

Figure 3-4 shows a close-up of one of the damaged areas of the cap/ wipe/purge blade used on the printhead shown in Figure 3-3. The edge of the blade is pushed inward and flattened which prevents a good wiping action. In most cases you will not be able to see the damage to the blade, however, you will see its affect on the printhead faceplate as streaks or smudges of ink in the nozzle area.

Figure 3-4. Cap/Wipe/Purge Blade Damaged

Figure 3-5 shows a close-up of the left side of a printhead. Here the cap/wipe/purge blade has separated allowing the metal spring to rub the faceplate and damage the printhead.

Figure 3-5. Cap/Wipe/Purge Blade Separated

Figure 3-6 shows a bad purge due to a lack of vacuum.

Figure 3-6. Bad Purge

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Figure 3-7 shows a good purge.

Figure 3-7. Good Purge

Figure 3-8 shows a bad printhead data cable. Part of the cable is separated from the connector.

Figure 3-8. Bad Printhead Data Cable

Troubleshooting

3-19

Figure 3-9 shows the thermistor cable which connects to the driver board disconnected. This can happen while installing the ink loader.

Figure 3-9. Thermistor Cable Unplugged

Media Jams And The Paper Path

Required tools:

• TORX screwdriver and tips

• Digital multimeter

Jams fall into the following four categories:

• Media-based problems

• Paper-pick errors

• Paper-feeding errors

• Paper-ejecting errors

Media-Based Problems

1. Fanning the media eliminates its tendency to double-pick.

2. Inspect the paper for bent, torn or folded corners.

3. Check to ensure no small pieces of paper are in the paper path.

4. Ensure that the correct media is in the correct media tray. The tray switch actuators indicates the size and the type of media loaded in the tray; the printer does not directly sense the size or type of media.

5. Ensure that only Sterling-specified paper is being used.

3-20


Paper-Pick Errors

Paper-pick errors occur when the media in the media tray mispicks or the printer double-picks two or more sheets of paper.

1. Fan the media before inserting it in the media tray.

2. In humid environments, keep media sealed in packaging until it is needed for printing.

3. Ensure that the media fits properly in the tray. With the left edge of the stack of paper flush against the tray rail, there should be a small gap between the right edge of the stack of paper and the opposite side rail.

4. Clean the interior of the media tray. When installing paper, push the stack of paper down until the tray’s lift-plate locks to the bottom of the tray. This prevents the top sheet of paper from being mispositioned as the tray is inserted in the printer.

5. Check that the pick roller is being rotated. In its starting position, the pick roller’s flat side should face down; the flat, keyed end on the left end of the pick roller shaft faces up. If it is not, proceed to the topic “Checking the process motor and drive train.”

6. Clean the pick roller with alcohol and a lint-free cloth. Paper dust can coat the pick roller and affect its ability to grip the paper and pull it out of the tray. Also clean the transport rollers.

7. Use the PC-based diagnostic’s “Verify Drive Current

Requirements” test to check the operation of the paper-pick system.

8. Inspect the wiring harness leading to the paper transport clutch for nicks, cuts or crimped wiring. Ensure the connector is seated.

9. Inspect the paper-feed path for obstructions.

Print Transfer Jams

1. Using PC diagnostics, test the paper preheater. If the test fails, replace the paper/drum heater assembly.

2. Check to see if the upper feed roller drive belt is broken or slipped off of its pulleys. In such a case, the upper feed roller does not rotate when the lower feed roller rotates.

3. Check that the feed rollers rotate smoothly and that the front cover is fully closed and seated.

Troubleshooting

3-21

4. Check the paper-eject path for obstructions. Ensure no small pieces of paper are trapped around the stripper fingers.

If a piece of paper is trapped in the paper preheater, try pushing it out by inserting a stiff piece of cardstock into the paper preheater.

5. Ensure that the transfix roller rotates during the transfix process.

6. Test the sensors in the paper path. Look for damaged or nonoperating sensor flags.

7. Check the transfix solenoid and its cam. Ensure they operate correctly and are properly lubricated.

Checking The Process Motor And Drive Train

1. Determine if the process motor runs. If it does not rotate, go to

Step 2. If it does rotate, go to Step 5.

2. Measure to determine if +40 VDC is being supplied to the motor. If it is, go to Step 3. If it is not, inspect the process motor’s wiring harness. If the harness is functional, then troubleshoot the power control board and power supply. Refer back to the topic, “Verifying Power Supply Operation.”

3. Disconnect the motor’s wiring harness. Measure the resistance of the motor’s windings. The expected resistances are listed in

Table 3-2. If the windings are opened, shorted or far out of tolerance, replace the motor.

4. If the motor’s winding resistances are within specification, inspect the wiring harness for nicks, crimps, opens or other problems. If the harness is functional, then replace the power control board.

5. Inspect the gear train on the inside of the printer frame; look for stripped gears or broken teeth. Be sure to inspect the inner teeth on the process motor gear.

Media Skews Passing Through The Paper Path

1. Check to see if the media is excessively curled. Curled media can get mistracked in the paper path.

2. Examine the paper path; ensure it is clear of obstructions.

3. Ensure that the pick roller is clean so that it picks up a sheet of media smoothly and evenly.

4. Check the upper and lower feed rollers. Also make sure that the front door is properly closed.

3-22


5. Check the flexible, white paper deskew springs on the inside of the front cover. Ensure none are bent, damaged, or missing.

6. The printer should be installed on a flat, level surface.

Printing And Print Quality Problems

Generally, print problems fall into the following six categories:

• Streaks or lines in the prints

• No printing

• Printing too light or too dark

• Poor quality printing

• Image is offset or cut off

• Wrinkling

Streaks Or Lines Across The Print

1. Check the Y-axis belt tension. If the Y-axis drive is not smoothly and consistently rotating the drum, horizontal bands or lines appear in the print.

2. Replace the Y-axis motor.

3. Replace the power control board.

Streaks Or Lines Down The Print

1. Clean the blade of the drum maintenance drawer.

2. Possible missing or weak jet. Print the Service Test Print 2,

Weak/Missing Jets, to determine if a jet is not performing.

Perform up to three printhead cleaning cycles to try to clean a clogged jet.

3. If necessary, turn off the printer and allow the printhead to cool for 4 hours.

4. Test the vacuum system for proper vacuum levels and operation.

5. Ensure that no wiring harnesses are interfering with the horizontal slewing of the printhead. In such a case, the streaks or lines should be parallel and evenly spaced.

6. Check for media in the exit path.

Troubleshooting

3-23

7. The x-axis drive is not functioning correctly. If the x-axis drive does not slew the printhead smoothly and evenly during printing, vertical lines appear in the print. Print Service Test

Print 11, X-axis Calibration, to reveal an x-axis problem.

Replace the X-axis drive, if indicated.

8. Replace the x-axis drive assembly.


10. If streaks are on the front side of a print, the paper preheater may be scraping ink off the print. Clean the preheater using the front panel-initiated cleaning process, Remove Ink Smears.

11. Smears on a print may also be caused by the paper preheater operating at a too-high temperature. Use the PC diagnostics to check the paper preheater’s temperature. Replace if necessary.

Missing Ink Or Low Density Ink Band Running

Length of Print

Possible missing or weak jet.

1. Print the Service Test Print 2, Weak/Missing Jets, to determine if a jet is not performing. Perform up to three printhead cleaning cycles to try to clean a clogged jet.

2. If necessary, turn off the printer and allow the printhead to cool for a minimum of 4 hours.

3. Ensure the printhead maintenance vacuum system operates correctly.

4. If weak or missing jet cannot be recovered, replace the printhead.

Scratches parallel to the long axis of printing

Usually caused by foreign debris in the paper path.

1. Run a sheet of paper through the manual feed to see if the scratch appears on the print. If it does not, the scratch occurred in the paper pick and early transport of the paper.

2. A scratch or smear caused by the paper preheater can be caused by debris built up on the heating surfaces. Run the front panel cleaning procedure Remove Ink Smears. Additionally, you can manually force a sheet of thick 65 to 80 lb. paper through the paper preheater to “buff” the paper preheater heating surfaces. With the leading and trailing ends of the sheet of paper extending from the entry and exit of paper preheater, gently pull the sheet of paper back and forth several times and then remove the sheet of paper. Be careful of the paper sensor flags.

3-24


White Portion Of Image Is Dark

Ink on a print where no ink should be printed is often called a latent image. A latent image remains on the drum when it should have been transferred to its sheet of paper. An insufficient amount of oil on the drum, provided by a dirty, defective or old maintenance roller may be the problem.

1. Clean the wiper blade of the drum maintenance drawer. If necessary, replace the maintenance kit.

2. Run diagnostics to ensure that printer temperatures are in tolerance. Ensure that the drum heater is properly positioned.

Ensure that the customer is using Sterling-specified paper.

Some recycled paper brands may be too rough.


4. Replace the printhead data cable.

5. Replace the main board.

6. Replace the printhead.

Grayscale Density Is Uneven

This may be due to poor thermal regulation in the printer, resulting in uneven heating of the printhead, which in turn results in uneven ink drop jetting.

1. Clean the wiper blade and the wick of the drum maintenance drawer. Inspect the operation of the drum maintenance cam roller and the left and right cam actuators it pushes against.

2. Perform the procedure, “Printhead-To-Drum Spacing

Adjustment” and “Transfix Roller Pressure Spring

Adjustment”.


Not Printing

The printer processes a sheet of paper, but no image is printed on it.

If you do not get ink on the print, but you get ink in the waste liner during a cleaning cycle, replace the printhead data cable.

If you do not get ink on the print or during a cleaning cycle:

1. Check the cap/wipe/purge performance.

2. Check for a loose connector on the power cable leading to the printhead. Replace the printhead power cable.

Troubleshooting

3-25



Printing Too Light Or Too Dark

Perform the procedure, “Printhead-To-Drum Spacing Adjustment.”

Fuzzy text

Text appears indistinct and difficult to read.

1. Head-to-drum gap is too great. Verify the gap with the adjustment as explained in the topic “Printhead-To-Drum

Spacing Adjustment.”

2. Verify the drum temperature using PC-based diagnostics.

Ensure the drum temperature sensor is clean and properly positioned.

3. If the problem persists, replace the printhead.

Poor Ink Fills

Primary fills appear banded and inconsistent.

1. Head-to-drum gap is too small. Verify the gap with the adjustment explained in the topic “Printhead-To-Drum Spacing

Adjustment.”


Ensure the drum temperature sensor is clean and properly positioned.

3. Verify the paper preheater temperature using PC-based diagnostics.


Poor Small Text Resolution

Small characters appear heavy and “plug up.”


Ensure the drum temperature sensor is properly positioned.

2. Inspect and clean the drum temperature sensor.

3. Ensure that the X-axis drive system is correctly assembled and lubricated.


3-26


Ghosting

Drum is too warm.

Verify the drum temperature using PC-based diagnostics. Ensure the drum temperature sensor is clean and properly positioned.

Ghost Of First Print On The Next Print

Incomplete image transfer is taking place on the first print.

1. Inspect the drum maintenance system. Does the drum maintenance roller contain sufficient oil? Replace the drum maintenance roller (and counter chip), if necessary.

2. Is the drum maintenance cam roller and electric clutch operating correctly? Test them using PC-based diagnostics.

3. Ensure the left and right drum maintenance actuators operate correctly when lifted by the cams of the drum maintenance cam roller.

Vertical Lines Appear Wavy

Straight vertical lines appear to be wavy and ill-formed.

1. Too much oil on the drum. Inspect the drum maintenance drawer. Is the wiper blade damaged? If necessary, replace the drum maintenance drawer.

2. Are the drum maintenance cam roller and electric clutch operating correctly? Test them using PC-based diagnostics.


Oil Streaks On Print

Oil stains the edge of the print.

1. Inspect the drum maintenance drawer. Is the wiper blade damaged? If necessary, replace the drum maintenance drawer.



Troubleshooting

3-27

Poor Ink Adhesion, Poor Image Durability


2. The drum is too cold. Verify the drum temperature using PCbased diagnostics. Ensure the drum temperature sensor is properly positioned and has no contamination between it and the drum surface.

3. Try a different ream of paper.

4. The transfix spring pressure is incorrect. Perform the procedure “Transfix roller pressure spring adjustment”.

Incomplete Image Transfer To Paper

All of the image does not transfer to the paper. Part of the image remains on the drum to be picked up by a chase page or the next print. This is usually caused by insufficient or nonuniform drum oiling.

1. Inspect the drum maintenance drawer. Is the wiper blade damaged? If necessary, replace the drum maintenance drawer.

2. Inspect the drum maintenance system. Does the drum maintenance roller contain sufficient oil? Replace the drum maintenance roller, if necessary.



5. The drum may be too warm. Verify the drum temperature using PC-based diagnostics. Ensure the drum temperature sensor is properly positioned and has no contamination between it and the drum surface.


7. Try a different ream of paper.

Repeating Print Defects On Print

The distance between each artifact of a repeating image defect reveals which imaging component is causing the defect.

1. Repeating defect 13.6 cm (5.34 in.) in the vertical direction are caused by the transfix roller.

3-28


2. White or dark lines parallel to the long edge of the print, spaced 1.4 mm (0.054 in) in solid fills, using High Resolution

Medical printing mode indicate the x-axis step accuracy is incorrect. Ensure the long spring mounted underneath the printhead is intact and not contaminated with ink; remove the maintenance drawer to access the underside of the printhead.

Inspect the x-axis drive system; replace it if necessary.

Banding Parallel To Long Edge Of Print

Fills are inconsistent with wide bands of varying density.

1. The head-to-drum gap is too great. Perform the procedure,

“Printhead-To-Drum Spacing Adjustment.”


Wrinkling

1. Try different media from a sealed package. In high-humidity environments, paper left exposed (unpacked) absorbs moisture and begins to warp.

2. Ensure the deskew fingers inside the front cover are not damaged or missing.

3. Inspect the maintenance drawer wiper blade. Replace the maintenance drawer, if necessary.

4. The transfix spring pressure is incorrect. Perform the procedure “Transfix Roller Pressure Spring Adjustment”.

5. Replace the drum/transfix assembly.

Image Is Offset Or Cut Off

1. Check the application for the correct image sizing and orientation.

2. Ensure that Letter or A4 is the selected paper size.

Troubleshooting

3-29

Oil Streaks On Top Of Print

1. Clean the stripper fingers.

2. Run chase pages through the printer to clean the drum. Use the front panel menu item “Remove Ink Smears” under

“Troubleshooting.”

3. Clean the maintenance drawer blade or replace the maintenance kit.

Image Is Rotated 90 Degrees

1. In the application’s Page Setup, make sure that the image is selected to print in Portrait or Landscape orientation, as you expect.

Printer isn’t in the Chooser

1. Ensure that the printer is turned on and the rear panel health light is flashing at a regular rate.

2. Check the Network or AppleTalk control panel to ensure the proper network or zone is selected.

3. Check to see if the printer has not been renamed or placed in another zone. You can print a Configuration Page, which lists this EtherTalk information as well as other information about the printer.

3-30


PC-based Diagnostics

The PC-based diagnostics is provided for interactively testing the operations and functionality of the printer. The diagnostics are provided on a 3-1/2 inch floppy diskette. All of the diagnostic tests are started from the PC and are downloaded to the printer.

The PC-based diagnostics were developed to run on a PC as this is the portable computer in use by the field service organization.

Requirements

• Printer serial cable adapter (level shifter), P/N 012-1543-00.

• Serial null modem cable, P/N 012-1535-00.

• IBM PC or PC-clone or compatible, preferably a Pentium® or

486; 286-based PCs are intolerably slow.

• At least 640K of RAM. About 2 Mbytes of disk space to store the diagnostic program and its test suite.

• A mouse is optional, but is not supported by the user interface.

• MS-DOS environment. This may be Windows® DOS or MS-

DOS on a PC.

By convention, each set of diagnostic files is installed into a single directory (for ease of removal and updating);

C:\100DIAGS\< version number>\

is the default

(i.e.:

C:\100DIAGS\1128

)

Starting The Diagnostics

1. Turn off the printer and the Service Laptop computer. Connect the serial port of the computer to the special diagnostic, 5-pin serial port of the printer; using the special serial cable adapter.

(Pin 1 is the left-most pin of the five pin connector, looking at the back of the printer).

2. Push down Switch 1, the service mode DIP switch. (The switch is the left-most of the four DIP switches on the rear panel of the printer, looking at the back of the printer) The other switches should be up.

3. Using the serial null modem cable, connect the serial port adapter to the COM1: serial port on the PC.

4. Turn on the PC in DOS mode. Older versions of Windows 95 will only run the PC-based diagnostics if the computer is booted in DOS mode; they will not run the diagnostics from the

MS-DOS Prompt application.

Troubleshooting

3-31

5. Set the PC’s comm port to COMM1. Set the baud rate to 19.2

kbaud, 8 data bits, 1 stop bit and no parity.

6. In your DOS window, go to the

C:\

prompt.

7. To install the diagnostics from a diskette onto your computer, type:

A:INSTALL /all <return>

.

8. Connect to the directory containing the diagnostic software

(

C:\100DIAGS)

. Launch the diagnostics program by typing diags xxx, where xxx is the name of the print engine firmware level. (Typing diags lists the available diagnostic versions.) Once launched, the program repeatedly attempts to communicate with the printer. The link status indicator, in the bottom-right corner of the screen, reads “NO” until this link is established; once communication is established, it reads “OK.”

NOTE: The Comm Port should be set to 57.6 kb after communication is established with the printer. The baud rate can be set faster for quicker test downloading. If the printer’s power is cycled, the PC’s baud rate must be reset to 19.2 Kb to reestablish communication with the printer.

PC-based Diagnostics Screen Display

Once communication with the printer is made, the diagnostics display the startup screen on the computer.

3-32


The startup screen features the following elements:

• A conventional-looking Menu Bar across the top of the screen; all diagnostic functions are accessible via this menu.

• The middle of the screen is a blank gray area; this is a 23 x 80

“tty” in which all interaction takes place with the tests when they are running.

• The bottom line of the screen gives feedback about the state of the system. It is divided into four fields:

•• The left-most, and largest field is the “message” field. It contains descriptive text summarizing the operation of tests in progress and of the diagnostics program itself.

•• Next is the completion indicator. When downloading test files to the printer, this field indicates the progress of the operation with a percentage-complete display “n%”

(where n is 0 to 100). When running a lengthy series of tests, a display “n of N” indicates the test progress.

•• Third is the “view” field. This indicates which “channel” is being viewed in the tty screen. The 29K channel displays information related to the communication line.

The 68K channel displays information related to the printer and the diagnostic tests.

•• In the bottom-right corner is a tiny field which indicates the status of the communication link between the PC and the printer’s processor. It says “OK” when the link is working and “NO” when communication is lost.

Selecting Tests

Press Alt-T or move the highlight block to the Tests pull-down menu and press Return to activate the test selection window.

Use the following keys to navigate the lists of tests. The left column,

Test Suites, lists the groups of test. The center column shows the individual tests within a selected test suite. The right column,

“Status,” indicates if a test is selected. You can select a single test, a series of tests, or all the tests is a test suite.

In the Test Suites column:

• Up and Down arrows – Move the Test Suite selection highlight block up or down on the screen. When the highlight block reaches the top or bottom of the screen, it causes the list to scroll if there are more tests in that direction on the list.

• Tab or Right arrow– Activates a suite of tests. The individual tests of the selected test suite are displayed in the Individual

Test column.

Troubleshooting

3-33

Alternately, select a test by typing its corresponding letter instead of using arrow keys.

• PgUp and PgDn – Move the display of tests one screen-full at a time. The highlight block generally stays in place on the screen, so this also changes the highlighted test.

In the Individual Test column:

• Up and Down arrows – Move the Individual Test selection highlight block up or down on the screen. When the highlight block reaches the top or bottom of the screen, it causes the list to scroll if there are more tests in that direction on the list..

• Space bar – Toggles the Status of the currently highlighted test: to “Selected” if the test is not selected and to not selected if it is already selected.

• Left arrow - Moves back to the Test Suite column.

• Alt-S – Toggles the Status of all tests in the Suite which contains the currently highlighted test: all to Selected if the currently highlighted test is not selected and all to not selected if it is anything else. The status of the other tests in the suite is immaterial.

• Alt-A – Toggles the Status of ALL tests. Like Alt-S, the new setting for all tests is based on the currently highlighted test, regardless of the individual settings of the other tests.

• Alt-R – Selects the currently highlighted test and opens the

Run window to prepare to execute the currently selected test.

3-34


Diagnostics Global Help Screen

• Alt-H – Opens a small Help window to remind which functions are available. Esc or Enter (Return) make it go away.

• F1 – Brings up a more complete description about the currently highlighted test.

• Esc and Enter (Return) – Either key replaces the selection screen with the current tty window. Any currently selected test remains selected.

Running Tests

Tests are downloaded from the PC to the printer. When a downloadable test is selected, it takes a few moments to download the test. While the test is downloading, the message bar indicates this fact and the completion indicator shows how much of the file has been loaded.

Troubleshooting

3-35

Test Suite List

1. Press the Return key to enter the test group selection window.

2. Use the arrow keys to scroll through the list of tests suites.

Press the Tab key or the right arrow to select a test suite.

3-36


Once you select a test suite, the individual tests of that suite are displayed.

3. Use the arrow keys to highlight a particular test.

4. Press the space bar to select or deselect a test. You can select as many tests as you like.

To run a highlighted test once, press the Return key.

Troubleshooting

3-37

5. After selecting the test(s), press Ctrl-R to start the test(s) specifying the number of test cycles to run. The tests run in the order they appear in the menu. Depending on the test, a screen may be displayed to modify how the tests run.

The solenoid and clutch test, shown above, allows you to selectively actuate a printer solenoid or clutch as well as the drum fan.

NOTE: Some test groups have a Choices option which allows for specification or selection of parameters which may influence the operation of successive test in the current test group. The selections are lost when another test group is loaded.

If necessary, you can highlight an individual test and press the F1 key to display a help message that describes the test.

There are a few tests (Sensor Test, Thermal Test and Fault History) that are very infomative when trying to determine the status of individual parts of the printer. They are described below in more detail.

3-38


Sensor Test

The Sensor Test shows you the real-time state of the printer’s sensors.

You can manually test the sensors to determine if they operate correctly.

Troubleshooting

3-39

Thermal Test

The Thermal Tests let you select, start and observe the operation of the printer’s heaters and determine if they are operational. The test displays the real-time temperature of active heaters. A graphic display illustrates if the heater temperatures are within tolerance.

NOTE: For accurate thermal regulation and measurement, the printer covers should be in place.

3-40


Fault History

The Fault History displays faults as error codes, stored in the printer’s NVRAM, and the copy count when the fault occurred. Type y to clear the history log.

Troubleshooting

3-41

Saving And Restoring Test Selections

The current test selection may be saved to a file and later restored, including the completion status of tests which were run earlier. The result of loading a saved test selection file is exactly the same as if the settings were re-specified manually. It provides a way to pre-select tests for particular audiences.

Tests are executed in the order they appear in the menu, not in the order they are selected.

The default file name extensions for saved test selections is .TSV.

The diags.ini file keeps the settings for the port number, baud rate, whether the debug messages are on or off, and the saved file name.

Definitions: port: 0 port: 1 baud: 0 baud: 1 baud: 2 baud: 3 comm port 1 comm port 2

9,600 bps

19,200 bps

38,400 bps

57,600 bps debug: 0 debug: 1

Debug Messages off

Debug Messages on save: {blank} save: {filename.extension} no file available name of file

Saving And Restoring Other Settings

Any user-configurable setting that the program recognizes is saved in a configuration file called DIAGS.INI and persists from session to session. Presently there is a short list of configurable items, but any program setting you make need only be done once.

Diagnostic Pull-down Menus Summary

All of the functionality in the user interface is accessible from the menu bar. Some of the functions are additionally available via

“accelerator” key (Alt- key) synonyms. The following discusses the pull-down menu left to right.

Tests Command (Alt-T)

Opens the “Tests” selection window.

3-42


View Menu

Provides for changing various screens and major modes of operation for the program.

• Tests – Switches to the 68K window to show results of test running on the print engine.

• Erase Screen – Erases all the characters from the currently selected window; it has no affect on the test running.

• Debug Check List Item – Enables or disables a trace of all

I/O between the user interface and the printer; it is off by default.

• Test Stats – Lists the status of the last test sequence to run

Run Command

Executes a test sequence.

Next Command

Stops the currently running test and immediately starts the next test.

Stop Command

Stops the currently running test and stops the sequence in progress.

File Menu (Alt-F)

This menu controls the saving and loading of test selection sequences, described above.

• New – Creates a new test selection sequence (deselects all tests and erases their previous completion codes).

• Open – Opens an existing, previously saved file.

• Save – Saves the current test selections in the “current” file. If the selection sequences is new (never been saved) the user is prompted to specify a file name.

• save As – Saves the current test selections in a particular file.

• eXit (Alt-X) – Exits the diagnostic program.

Troubleshooting

3-43

Options Menu

Provides for customizing of program operation. Submenus include:

•

CommPort – Provides for changing the baud rate of the link and for changing the communication port used. The default baud rate is 19.2K. Some diagnostic hosts support rates up to

57K. Whenever the printer is reset or power-cycled, it resets its serial port to 19.2K.

Help Menu

The system includes limited on-line help. The most useful help pertains to the tests themselves and is available via the Tests menu.

• About – Gives the program version and other statistics about its operation.

• Usage overview – Gives the user an overview of the system and explains running the first test.

• F1 – Describes an individually highlighted test.

3-44


Chapter

Adjustments

4-1

Chapter 4

Adjustments and Calibrations

Bypass Mode (manufacturing mode) . . . . . . . . . . . . . . . . . . . . . . 4-3

Cool Down Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Hidden Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Bypassing a “short menu” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Printing the Configuration Page . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-x

Process Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . 4-x

Exit Roller Drive Belt Tension Adjustment . . . . . . . . . . . . . . . . 4-x

Y-axis Belts Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-x

Printhead-to-Drum Spacing Adjustment . . . . . . . . . . . . . . . . . 4-x

Cap/Wipe/Purge Assembly Belt Adjustments . . . . . . . . . . . . . 4-x

Drum Position Encoder Gap . . . . . . . . . . . . . . . . . . . . . . . . . . 4-x

Transfix Roller Pressure Spring Adjustment . . . . . . . . . . . . . . 4-x

X-axis Scale Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-x

Adjusting Look-Up Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-x

Setting Interpolation Defaults . . . . . . . . . . . . . . . . . . . . . . . . . 4-x

Measuring Dmax and Dmin . . . . . . . . . . . . . . . . . . . . . . . . . . 4-x

Vacuum Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-x

Resetting NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-x

Enabling Ethertalk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-x

Adding Windows NT Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-x

Configuring Solaris Workstation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-x

Configiure FTP Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-x

View and Configure Syslog Settings . . . . . . . . . . . . . . . . . . . . . . . 4-x

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-x

4-2


Front Panel Menu

The print engine features an interactive menu that allows you to review or change the printer’s stored parameters, as well as initiate test prints and printer service routines. A map of the front panel menu is shown in Figure 4-1.

Adjustments

4-3

Figure 4-1. Front Panel Menu Map

4-4


Figure 4-1. Front Panel Menu Map (continured)

Adjustments

4-5

Hidden Service Menu

To access the hidden service menu:

1. Scroll to the Service Support menu and press the Select button.

2. Press and hold the Left arrow button.

3. While holding the Left arrow button; press the Select button.

Service Support Menu

Previous Menu

Test Prints

Set Ink Density

Adjust X-Axis Scale

Head-to-Drum Adjust

Drift Compensation (On/Off)

Reset Printer

Reset NVRAM

Restore Factory Defaults

Head Adjust

Select Custom Look-Up Tables

Jam Count: #

Panic Count: #

Engine Copy Count: #

Seal/Drum

Exit

Printing Service Test Prints


2. Allow the printer to complete its power-up self-tests. The front panel displays:

READY TO PRINT

3. Scroll to the Service Support menu and press the Select button.


5. While holding the Left arrow button, press the Select button to enter the hidden Service menu.

6. Scroll to the menu item Test Prints and press the Select button.

7. Select a test print by scrolling to a print and pressing the

Select button.

Refer to Appendix B, “Test Prints.” It discusses each test print and what printing defect it reveals.

4-6


Adjustments

Process Belt Tension Adjustment

1. Turn off the printer and remove the left-side cabinet panel.

2. To adjust the belt tension, loosen the process belt tensioner.

With a spring scale, press inward on the tension idler of the process belt with a pressure of 0.7 kg,

±

14 g (24 oz.,

±

0.5 oz.) and then tighten the tensioner in place. Do not over-tension the belt.

Adjustments

4-7

Press here to set belt deflection

Figure 4-2. Setting Process Belt Tension

3. Reinstall the left side panel.

Process belt tensioner

0388-28

4-8


Exit Roller Drive Belt Tension Adjustment

1. Turn off the printer and remove the left-side cabinet panel.

2. To adjust the belt tension, loosen the exit roller drive belt tensioner. With a spring scale, press downward on the idler tensioner of the exit roller drive belt with a pressure of 0.34 kg,

±

14 g (12 oz.,

±

0.5 oz.) then tighten the tensioner in place. Do not over-tension the belt.

Press here to set belt deflection

Exit roller drive belt tensioner

Figure 4-3. Setting Exit Roller Drive Belt Tension

3. Reinstall the left side panel.

0388-29

Adjustments

4-9

Y-axis Belts Tension Adjustment

Perform this procedure after loosening or removing the Y-axis belt drive assembly. (Refer to Figure 4-4.)

1. Ensure that the three mounting screws that secure the Y-axis drive assembly to the chassis are one turn loose and that the Yaxis idler bracket slides freely with respect to the chassis.

NOTE: If there is a situation in which diagnostics are not available when installing a new Y-axis drive assembly or drum/transfix assembly, then locate any previously placed index marks on the pulleys and proceed as if re-using existing parts. Allow the system to cool as long as feasible before mounting the Y-axis drive assembly onto the chassis. Tensioning of the Y-axis drive assembly without diagnostics increases the risk of failures associated with low belt tension (for example, a “growling” sound heard upon cold power-ups).

2. Attach the Y-axis belt tension tool (in its unloaded or folded out position) to the keyholes in the side frame of the printer just below and in front of the Y-axis drive assembly. The tool’s fishhook should engage the eyelet of the Y-axis drive assembly.

3. Pull forward and down on the lever arm of the tension tool to apply tension to the Y-axis belts.

4. While the belts are under tension, rotate the drum pulley five times to rotate the belts and seat them in place.

5. Beginning with the upper-right screw, tighten the three mounting screws to 30 in.-lbs. to secure the Y-axis drive assembly in place.

6. Using PC-based diagnostics, run the test: “Position for Belt

Tightening” in the “Y-Axis Group” test suite. This positions the belts in the proper orientation for retensioning. Do not move the pulleys.

7. Place an index mark on the edge of each pulley: Mark the Yaxis drive pulley and the drum pulley where the edges are closest to one another, disregarding previous marks. Use a distinct color if the pulleys have been previously marked.

8. Loosen the 3 mounting screws until the bracket slides freely on the chassis and then re-tighten the screws to 30 in.-lb.

9. Release the tension tool’s lever arm and remove the tool.

10. Reassemble the printer and make a test print.

4-10


Tighten screws after setting tension

Mark the pulleys

Attach tension tool to keyholes

Figure 4-4. Setting the Y-axis Belt Tension

Y-axis belt assembly

Pull lever arm to set tension

0388-30

Adjustments

4-11

Cold Printhead-to-Drum Spacing Adjustment

Tools required:

• Printhead-to-Drum Digital Indicator Gauge Kit

• Small (3/16 in.) flat-blade screwdriver

• 9/64 in. hex tip

• Magnetic screwdriver

• T-20 TORX tip

• Torque Limiting Screwdriver

• Computer running PC-based service diagnostics

CAUTION

To prevent damage to the printer, remove the printhead tilt arm spring before moving the X-axis to tilt the printhead. If the spring is attached when moving the X-axis, the printhead may tilt rapidly and impact the drum

To avoid damage to the printhead, never touch the faceplate with your hands or any foreign object including tools and media.

CAUTION

Even if the printhead is cold, use the printhead removal tool and printhead reservoir removal procedure.

Place the removed printhead on a clean, level surface.

During this section of the worksheet, you will perform a mechanical adjustment of the printhead to establish the spacing between the printhead faceplate and print drum. For best print quality, the spacing should be equal on the left and right sides of the printhead.

The adjustment is made when the printhead is cold. After the printer warms up the spacing is then checked to ensure it is within tolerance.

1.

Remove the right cover and the left cover.

2.

Remove the top cover.

4-12


3.

Remove the ink loader and the metal heat cover.

4.

Tilt the printhead to its print position and, if removed, attach the head tilt spring.

5.

Torque the mounting screws to 20 in/lbs.

6.

Install the digital gap indicator and bracket to the left side of the printer frame and tilt arm as described in the Procedure

“Mounting the Digital Indicator Gauge”. Ensure the digital indicator is set to inches, “in.”

NOTE: Always move the printhead by moving the tilt arm.

7.

At the left side of the printhead, insert the left printhead spacer between the printhead and the drum. Check the indicator, it should read 0.0030 + / - 0.0010 inches. Adjust the printhead’s spacing adjustment by twisting a flat-blade screwdriver in the adjustment slot to move the printhead’s position until the indicator reads the correct value.

NOTE: Do not insert both spacers at the same time as this will only measure the larger of the two gaps.

8.

Remove the left printhead spacer and install the right spacer between the printhead and the drum. Repeat the adjustment.

Confirm the left side is still in adjustment. If not, alternate between the two sides until both sides read 0.0030

±

0.0010

inches.

9.

Remove the spacers. Snug the four locking screws using an X pattern.Then tighten the four screws, using the same X pattern, to 20 in.-lbs.

10.

Plug the printhead’s data ribbon cable and power wiring harness into the power control board and the printhead.

Inspect both ends of the data ribbon cable to ensure they are properly seated. Reconnect the two printhead ground wires to the printer frame.

11.

Perform the “Hot Printhead-to-Drum Spacing Adjustment” to set the correct gap between the “hot” printhead and the drum.

Adjustments

4-13

Hot Printhead-To-Drum Spacing Adjustment

Tools required:

• Printhead-to-Drum Digital Indicator Gauge Kit

• Small (3/16 in.) flat-blade screwdriver

• 9/64 in. hex tip


• T-20 TORX tip

• Torque Limiting Screwdriver

• Computer running PC-based service diagnostics

This procedure assures that the printhead is the proper distance from the drum. Make this adjustment after removing or replacing the printhead and performing a cold adjustment or when the head has not been installed, but requires a minor adjustment.

1.

Remove the right cover and the left cover.

2.

Remove the top cover.

3.

Remove the ink loader and the metal heat cover.

4.

Tilt the printhead to its print position and, if removed, attach the head tilt spring.

CAUTION

The head tilt cam gear must be completely disengaged from the drive gear. If not, the printhead-to-drum gap may be too small, allowing the printhead faceplate to come in contact with the drum.

5.

Place the printer in diagnostic mode by setting dip switch 1 in the down position.

6.

Prepare your laptop computer for running diagnostics and connect the diagnostics cable to the printer.

7.

Turn on the printer.

8.

In your PC- based diagnostics, scroll to the “Printhead Adjust” test suite and run the “Do Printhead-to-Drum Gap Adjustment

(Hot)” routine. The routine automatically centers the printhead, and brings the printhead and drum to their operating temperatures.

9.

If they are not already tightened, tighten the printhead mounting screws to 20 in- lbs.

10.

If they are not already loose, loosen the printhead’s four locking screws (two at each end of the printhead) until they are just

4-14


snug in place.

11.

Install the digital gap indicator and bracket to the left side of the printer frame and tilt arm as described in the Procedure

“Mounting the Digital Indicator Gauge”. Ensure the digital indicator is set to inches, “in.”

NOTE: Always move the printhead by moving the tilt arm.

12.

At the right side of the printhead, insert the right printhead spacer between the printhead and the drum. Check the indicator it should read 0.0070

±

0.0010 inches. Adjust the printhead’s spacing adjustment by twisting a flat-blade screwdriver in the adjustment slot to move the printhead’s position until the indicator reads the correct value.

NOTE: Do not insert both spacers at the same time as this will only measure the larger of the two gaps.

13.

Remove the right printhead spacer and install the left spacer between the printhead and drum. Repeat the adjustment.

Confirm the right side is still in adjustment. If not, alternate between the two sides until both sides read 0.0070

±

0.0010

inches.

14.

Remove the spacer. Snug the four locking screws using an X pattern. Then tighten the four screws, using the same X pattern, to 20 in.-lbs.

15.

If not connected, plug the printhead’s data ribbon cable and power wiring harness into the power control board. Inspect both ends of the data ribbon cable to ensure they are properly seated.

16.

Recheck the gap at both ends of the printhead.

17.

Remove the digital indicator gauge and bracket from the frame.

18.

Reinstall the ink loader and metal heat cover.

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4-15

Insert flatblade screwdriver in adjusting slot.

Use a twisting motion to move the printhead.

Gap tool

Tighten locking screws when both left and right adjustments are complete

19.

Terminate the PC-based diagnostics and disconnect the laptop.

20.

Reinstall the top cover.

21.

Print Service Test Print 12: Comb Pattern to check alignment.

Position gap tool between the printhead and drum, hook in side frame and over shaft

RIGHT

Printhead in print position

Repeat adjustment at this end of printhead with

LEFT gap tool

0388-31

Figure 4-5. Setting the Head to Drum Gap Adjustment

CAUTION

When powering up after installing a new printhead, reset the “Head

Adjust in the hidden Service menu to “128”. If this step is forgotten, the jets may eject too much ink on the page, causing one or more of the following:

• shifting or displacement of ink during transfix

• wrinkling

• jet “drop out”causing random weak vertical streaks in

solid fills. It may take multiple solid fills for this effect to

4-16


occur.

NOTE: Some service actions could leave the tilt arm in the wrong location to allow a normal power up. This is especially true in replacing the Printhead. When this happens, unusual noise and a loud slam may occur after which the tilt system will recover properly. This happens as the tilt arm struggles past the ship restrain tab. A quick power down and power up will verify normal operation has been resumed. To prevent the slam condition, position the head near the center of the X-axis travel before turning on the printer.

Mounting the Digital Indicator Gauge

Mount the Digital Indicator Gauge

The digital indicator gauge must be mounted properly to obtain stable printhead-to drum spacing readings. Use the mounting holes, post and screw provided on the chassis when mounting the gauge.

Refer to Figure 4-6 to mount the gauge.

When installing the digital indicator gauge, push forward on the gauge’s mounting bracket so it is tight against the hex screw and the upper screw in the chassis, and then tighten the upper chassis screw.

The gauge brack must be tight against the mounting post.

While installing the tilt arm bracket, push forward on the bracket so

Adjustments

4-17

it is flush with the head tilt arm, and then tighten the two screws.

The bracket must be flush with the tilt arm.

Upper chassis screw

Push forward here so bracket is tight against chassis screw and hex screw

Push forward here so bracket mounts flush with head tilt arm

Cutout for hex screw

0388-31

0388-36

Figure 4-6. Mounting the Digital Indicator Gauge.

Zero the Digital Indicator Gauge

If the digital indicator gauge is not zeroed properly, it will produce unstable readings. To zero the gauge:

1. Place your thumb on the gray Origin button.

2. Place your index finger underneath the gauge.

3. Press and hold the Origin button until the gauge zeroes, being careful to support the gauge with your index finger.

4. To test the stability, move the head tilt arm back and then forward several times. The gauge should return to zero each time the head tilt arm is moved forward. Do not move the tilt arm by the bracket mounted on it. This will cause the arm to flex and your readings will vary.

4-18


Install the Gap Tools

The left and right gap tools must be installed properly to correctly adjust the printhead-to-drum spacing. To install the tools (refer to

Figure 4-7):

1. Postition the tip of the gap tool between the printhead and the drum.

2. Hook one side of the tool through the hole in the chassis.

3. Hook the other side of the tool over the chrome shaft above the printhead.

NOTE: The left and right gap tools should never be interchanged because they are different thicknesses.

To properly adjust the printhead-to-drum gap, use only one gap tool at a time.

To prevent the printhead adjustment from changing, remove the gap tool when torquing the printhead screws.

Adjustments

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Hook tool through hold in chassis and over shaft

RIGHT

0388-31

Figure 4-7. Installing the Gap ToolCap/Wipe/Purge Assembly Belt

Adjustments

The tension of the cap/wipe/purge assembly belts is factory-set. Do not adjust them unless you remove or replace one or both belts. The belts are Kevlar-reinforced; they will not stretch over their lifetime.

The belts are also factory-adjusted for parallel tracking (alignment).

4-20


As long as the belts, cap/wipe/purge assembly motor, and the belt clips

(which hold the cap/wipe/purge assembly) are not disturbed, no adjustment is needed.

However, if you replace one or both of the belts or the cap/wipe/purge drive motor, you must ensure that the belts are in alignment (timing) with each other; this ensures that the cap/wipe/purge assembly is perfectly aligned to the faceplate of the printhead. If the belts are not aligned, the printhead purging is ineffective, due to poor sealing between the printhead faceplate and the cap/wipe/purge assembly.

1. Ensure that the cap/wipe/purge assembly is properly installed.

Also ensure that the cap/wipe/purge drive motor is installed in place and that both the left- and right-side drive belt locks are assembled correctly.

2. Rotate the large drive gear to pull the cap/wipe/purge assembly to about the middle of its travel in the chassis frame slot.

3. Ensure each drive belt lock is tightened to its fourth tooth, as illustrated in Figure 4-7.

4. Position the left-side drive belt lock so its pointer points between the index mark on the printer frame.

5. Holding the left belt so it does not move, inspect the right-side drive belt lock’s pointer. It should point at the index marks on the right-side printer frame.

If the right-side pointer does not point to the index mark while the left-side belt lock is between its marks, loosen the right drive belt by removing the lower idler pulley and adjusting the belt so that it aligns with the timing mark.

6. Repeat until the right-side belt lock’s pointer points at the index mark on the right-side frame as the left-side belt lock’s pointer points between its index marks on the left-side frame.

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4-21

Belt lock

Index mark on right frame

Fan

Idler pulley

Right cap/wipe/purge assembly belt

Unlock

Latch

For new belt, break off actuator on left-side belt lock

Left belt lock: align pointer between two index marks

Lock

Leave gap between latch and belt tensioner

0388-32

Figure 4-8. Aligning (Timing) The Cap/Wipe/Purge Assembly

Drive Belts

Drum Position Encoder Gap

This procedure ensures that the drum-position sensor assembly’s encoder wheel rotates freely inside the gap of the drum-position sensor without the encoder wheel’s disk touching the sensor. If the disk touches the sensor, it can abrade the disk and result in erroneous drum position readings.

1. Ensure that the retaining spring is not in the drum-position

4-22


sensor assembly’s encoder wheel groove. This ensures that the encoder wheel is not tensioned and slides easily onto the drum shaft.

2. If not already mounted in place, secure the drum-position sensor assembly onto the drum shaft and secure it to the printer frame.

3. Through the access hole in the drum-position sensor assembly, position the encoder gap tool on the drum shaft, maintaining a position perpendicular to the shaft.

4. Reposition the drum-position sensor assembly’s encoder wheel on the drum shaft until it butts firmly against the encoder gap tool.

5. Holding the gap tool in place, with a small, flatblade screwdriver, slide the encoder wheel’s retaining spring into the encoder wheel’s groove.

6. Remove the gap tool. Reassemble the printer and make a test print.

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Gap tool

Groove

Retaining spring

Drum position sensor assembly

0388-33

Figure 4-9. Setting The Drum Position Encoder Gap

Transfix Roller Pressure Spring Adjustment

1. Print the Service Test Print 16: Primary Solid Fills (4 pages).

2. If any of the prints are wrinkled on both the left and right sides of the print, the drum/transfix assembly must be replaced. No adjustment will solve the problem.

3. If wrinkling is only present on the left or right side of any print, note which side.

4. Remove the front cover to access the drum/transfix assembly.

5. Draw a reference mark on the both the left and right spring set screws.

4-24


6. On the side of the printer corresponding to the wrinkling, tighten the set screw clockwise 1/8 of a revolution, using a 4 mm hex driver. On the side that does not wrinkle, loosen its set screw 1/8 of a revolution.

NOTE: Whatever adjustment is added to one side must be taken away from the other side to maintain roller balance.)

7. Reassemble the printer and again print the Service Test Print

16: Primary Solid Fills.

8. If wrinkling still occurs on the same side, repeat Step 6 and 7.

CAUTION

Do not adjust the set screws more than 3/8 of a revolution from their original position. Any adjustment beyond this point results in ink adhesion problems.

9. If wrinkling continues to occur, replace the drum/transfix assembly.

Original registration mark

3/8 turn maximum

3/8 turn maximum

Tension spring set screws

0388-38

Figure 4-10. Adjusting The Transfix Roller Pressure Springs

Adjustments

4-25

X-axis Scale Adjustment

This adjustment sets the gain or rate-of travel of the printhead’s Xaxis movement.

1. Allow the printer to warm up to its idle, “Ready to Print,” state.

2. Enter the “hidden” service menu by scrolling to the Service

Support menu and pressing the Select button. Then press and hold the Left arrow button and, while holding the Left

arrow button, press the Select button.

3. Scroll to the menu item Adjust X-Axis Scale and press the

Select button. Scroll to the menu item Print Subjective Test

Pattern and press the Select button.

4. The print features four gray columns, each containing a jagged black band. The black bands should all align vertically with each other.

5. If an adjustment is needed, scroll to the menu item Set X-Axis

Scale. Change the displayed value to a new value, if necessary.

Increasing the scale value raises the two center black bars.

Decreasing the scale value lowers the two center black bars.

6. Select the menu item Print Subjective Test pattern to verify the adjustment. Repeat the adjustment, if necessary.

Try to align the two center black bands and the two outer black bands within one tick mark on the vertical scale.

Increase scale adjust to raise center bars

Correct Decrease scale adjust to lower center bars

0388-67

Figure 4-11. Adjusting the X-axis Scale Adjustment

NOTE: The X-Axis Scale Adjustment menu also includes the item for printing the Objective Test pattern. This pattern is only useful at the factory. The Subjective Test pattern should be used instead.

4-26


Adjusting Look-Up Tables

The Look-Up Table (LUT) menu displays all of the LUT resources currently available in the printer. The default LUT is indicated with a check mark. The list of available LUTS is in alphabetic order. If there are Contrast values within a family, the menu button is labeled contrast. If there is not a contrast, the menu selection is limited to

OK. The standard family/contrast values is displayed in Table 4-1.

There may be up to 4 Custom LUT also stored in the Hidden Service

Menu.

Table 4-1. Look-Up Tables

Family

Linear soc-fixed soc-variable midtones shoulder toe oem_1 oem_2

Contrasts Available

5

10

12

2

1

12

15

10

Custom Look-Up Tables

1. Cycle through up to 4 of the downloaded LUT. The tables appear as a choice to save if the name is 16 characters or less, the Transfer Table type is 3 or 4 and there are 6 coefficients or less. Selecting the user tables and selecting OK saves it in

NVRAM.

NOTE: The message that the table has been saved is displayed for 2 seconds.

name of custom table

Saved as Table 1

2. If this table had been previously saved, you must confirm to replace the table selection.

Replace Current Table 1 name of custom table? OK

If there have not been any custom tables downloaded to the printer, when the menu button is pressed the front panel displays

No Custom Look-Up Table Are Available.

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Paper LUT

The menu item Paper LUT Customization is found under the menu

Service Support. The Paper LUT Customization setting is a number ranging from 0.5 to 1.0. It affects how built-in look-up tables appear on paper. (User-defined LUT families and the Linear LUT are not affected.) Lower values whiten images, while higher values darken images.

NOTE: The default setting is 0.8. Adjusting this value is not recommended.

Setting Interpolation Defaults

This option lets you change the default image interpolation mode.

Since image resolution is usually 150 to 300 dpi, and the printer produces images at 600 dpi, most images are automatically expanded or scaled when printed. Use this option to specify the way your images are smoothed or blended when they are scaled.

Bilinear

This selection blends adjacent pixels in an image in a manner that is linear in both the horizontal and vertical axes of the image. Bilinear is the most common, and the fastest, image smoothing method.

Cubic

These selections are slower methods of image smoothing that produce sharper image detail. The values represent degrees of sharpness, with the smaller values producing the sharpest image detail.

Replication

This selection uses a technique that expands with each pixel. Use

Replication for an accurate representation of image data, with no smoothing modifications.

4-28


Service Test Print 10/

Front Panel Designation

Ink 0

Ink 1

Ink 2

Ink 3

Setting Dmin and Dmax

Adjustments can be made to the Dmin and Dmax settings in the driver software of the workstation you are sending the data from. Any settings sent by the drivers will overwrite the default settings on the printer for that job.

Adjusting Dmin will set the lower limit for optical density that the printer will produce. The Dmin default will be equal to the Ink 0 setting. It is not accessible from the front panel menu.

Adjusting Dmax will set the upper limit for optical density that the printer will produce. It is accessible through the Default Printer

Settings menu under OD Defaults.

Table 4-2. Ink Settings

Name of Ink Color

Number on

Ink Stick

Default Expected

Range

Clear

Low

Intermediate

High

11

12

13

14

0.09

0.89

1.89

3.54

0.03 to 0.10

0.60 to 0.90

1.50 to 2.00

3.00 to 3.70

NOTE: OD measurements are based on the use of a reflective densitometer with polarization filter. Approved models are Gretag

D19C (filter type 47B/P) and X-Rite 400B.

Optical Density Calibration (Setting Ink

Densities)

Optical Density should be performed (or at least checked) on a yearly basis. Performing optical density calibration involves measuring the density values for the primary inks and inputting them in the front panel. Then, a test print is printed and measured to verify calibration.

To calibrate Optical Density:

1. Print Service Test Print 10.

2. Using an approved densitometer, measure all the squares in columns A, C, E, H, K, and L, and calculate the averages for

Inks 0–3.

3. Input these values into the front panel through the Hidden

Service menu under “Set Ink Density.” Return to “Ready.”

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4-29

4. Print Service Test Print 9.

5. Measure points P1 through P20, and calculate the averages for the boxes having the four different densities: Low, Medium,

High and Super High. The values for these densities must be within the following ranges:

Low

Medium

High

Super High

0.13 to 0.17

0.93 to 1.07

1.65 to 1.85

2.61 to 2.89

If calibration is not achieved, do the following:

• Check that averages were calculated correctly.

• Check that the densitometer is calibrated and is the correct type. It must be a Gretag D19C or X-Rite 400B and must contain a “polarizing” filter.

• Perform the following iteration:

If Super High failed,

a. First, check to make sure that the front panel setting for

Dmax is greater than 2.75. If so, proceed to the next step. If not, set Dmax to 3.2, reprint Service Test Print 9 and remeasure.

b. Subtact 2.75 from the actual value measured.

c. Add this value to “Ink 3” and adjust in the Hidden

Service Menu.

d. Go to “Ready.” Reprint Service Test Print 9 and remeasure.

If Low Failed,

a. Check that Dmin (Info➔Printer Settings➔Dmin) is equal to Ink 0. If it is, proceed to Step b. If it is not, adjust Dmin equal to Ink 0. Since Dmin has no direct knob, the way to do this is to adjust Ink 0 down 0.01, return to “Ready,” then adjust Ink 0 back up 0.01. This will cause Dmin to default to whatever Ink 0 is. Proceed to Step c.

b. If Low fails on the high side, add 0.01 to Ink 0. If Low fails on the low side, subtract 0.01 from Ink 0. Adjust Ink 0 in the Hidden Service Menu.

c . Go to “Ready.” Reprint Service Test Print 9 and remeasure.

4-30


Vacuum Check

Tools required:


• Vacuum gauge

• T-20 TORX tip

• T-15 TORX tip

• T-connector for vacuum gauge

• PC diagnostics

Use this check to verify the actions of the vacuum pump and the solenoid valve. In addition, you can determine if the cap/wipe/purge assembly is sealing properly against the printhead faceplate.


2. Remove the top and right-side covers.

3. With a T-connector, connect the vacuum gauge to the between the vacuum/pump module and the cap/wipe/purge unit.

Adjustments

4-31

60

-76

40

20

0

Vacuum guage

T-connector

Vacuum assembly

Cap/Wipe/Purge vacuum hose

0388-35

Figure 4-12. Connecting the Vacuum Gauge To The Printer

4. Turn on the printer and enable the PC diagnostics as explained in the topic, “PC-based Diagnostics.”

5. Run the “Purge Printhead test” from the “Head Maintenance” test suite. When the solenoid valve is energized, you should see the vacuum gauge jump to about the value 51 cm Hg (20 in.

Hg, 10 psi) and within 4 to 6 seconds bleed off to 0.

If the vacuum does not reach the expected value:

• There is a leak in the vacuum system from the pump

• The accumulator and their plumbing or the vacuum pump is defective

If the vacuum drops to zero immediately, the cap/wipe/purge unit is not sealed to the printhead.

This test allows you to check the action of the vacuum as it is applied to the printhead; the cap/wipe/purge assembly should be sharply sucked against the printhead faceplate. If it is not, there may be an

4-32


ink clog in the vacuum tube leading to the cap/wipe/purge assembly.

If the vacuum does not bleed off, then the air valve is not opening properly, the 7-mil orifice (a part of the vacuum/pump assembly) is blocked or the vacuum tubing may be clogged. If the printhead is hot, such a condition can allow ink to be sucked into the vacuum system tubing. If the vacuum takes longer than 4 to 6 seconds to bleed off, the air valve solenoid or the cap/wipe/purge assembly may be defective.

If the vacuum bleeds off too quickly, the tubing will be blocked or the cap/wipe/purge assembly may be defective; check to see if the cap/ wipe/purge assembly is not sealing properly to the faceplate. Check that the cap/wipe/purge assembly is properly positioned by performing the “ “Cap/Wipe/Purge Assembly Belt Adjustments.”

Resetting NVRAM

Resetting NVRAM returns most the printers’s PostScript NVRAMstored parameters, including those of the network card, to their factory defaults, except the copy count (for images processed through the image processor), the Adobe firmware serial number, the usage profile and the authorization codes. Print engine NVRAM values are not changed by the following procedure.

Select NVRAM parameters are not reset by the standard resets found in the front panel or PC-based diagnostics. These include copy counts, panic counts, ink density calibrations, and boot parameters among others. If particular parameters become corrupt, the printer may not operate correctly or may not recover. If NVRAM corruption of this type occurs, the most effective method of correcting the problem is to replace the offending NVRAM part with a new part.

To reset the printer to its factory-default values, follow this procedure:

1. If possible, print the Configuration Page for a record of all the printer’s port settings and other customer-unique settings.

2. Enter the Service Support menu.


4. While holding the Left arrow button, press the Select button to enter the hidden service menu.

5. Scroll to the menu item Reset NVRAM and press the Select button.

6. Scroll to the menu item Reset NVRAM and Reset Printer

Now and press the Select button again, to reset NVRAM.

Alternately, you can also use the PC diagnostics to selectively return either the print engine NVRAM contents or the PostScript NVRAM contents to their factory default values as shown in the following illustrations.

Adjustments

4-33

Running Reset PE NVRAM to Default or Clear PS NVRAM downloads a file to the printer that performs the indicated reset function; there is no confirmation or cancel function.

Calibration

CAUTION

X-axis Calibration

The calibration specification is

±

1 count (0.01) at t=0 and

±

3 count

(0.03) over time. Use the following steps to calibrate the X-axis to within these specifications.

Do not lean on or interrupt the printer while printing the Subjective

Test Print.

1. Print the Subjective Test Print.

2. In the hidden Service menu, scroll to the menu item Adjust X-

Axis Scale and press the Select button.

3. Scroll to the menu item Print Subjective Test Pattern and press the Select button.

4. View the pattern and determine if there is evidence of underscan or overscan. Count the hash marks. Read from the table at the top of the print to determine the next adjusted scale factor.

5. Enter the new scale factor using the Up- and Down-arrow buttons to adjust to the proper value.

6. Print the Subjective Test Print again.

7. Repeat the process, as needed.

4-34


Engine Copy Count

The engine copy count maintains the number of pages printed successfully. The total does not include blank cleaning pages nor pages that jam. (The other copy counts, available from the Startup

Page, Configuration Page, and front panel menu Info, do include pages that jam.) The engine copy count is not zeroed by a standard

NVRAM reset and is left intact by the factory. The engine copy count is displayed following the colon.

The engine copy count is not normally shown as part of the service menu Fault History. However, a special “hidden” fault history menu does display the engine copy count above the fault history list. The special fault history menu can be displayed while the printer is awaiting clearance of a jam. This is the quickest way to access the current jam code. To display the special fault history menu before clearing a jam, do the following:

1.

Remove the standard media tray from its secure insertion point. The tray does not need to be completely removed from its slot.

2.

Enter the “hidden” fault history menu by holding the Left arrow button down and pressing the Help button.

Adjustments

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4-36


Chapter

Cleaning and Maintenance

5-1

Chapter 5

Cleaning and Maintenance

This chapter describes the cleaning procedures to keep the printer in peak operating condition. Some cleaning procedures, such as purging the ink-jets are done automatically when necessary. Other procedures, such as scrubbing the paper-feed rollers with an alcoholsoaked cloth, must be done by customers. The chapter is presented in the following sections:

Cleaning Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Cleaning Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Cleaning Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Drum Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-2


Cleaning Overview

The printer should be cleaned when any of the following symptoms occur:

• Light stripes appear in prints.

• Ink smears or random streaks appear on the front or back of prints.

• Oily spots appear along the top of prints.

• Mispicks or multiple picks occur at the media tray.

• Persistent paper jams inside the printer or at the media tray.

• Wiggly vertical stripes caused by too much oil created by a dirty maintenance drawer blade.

Most print-quality and media-transport problems can be cured by initiating cleaning procedures available through the printer’s front panel menu.

Cleaning Supplies Required

The following cleaning supplies are required:

• 90% or higher, pure isopropyl alcohol

• Lint-free wipes

• Lint-free swabs

CAUTION

Do not use rubbing alcohol because it can contain water and oils that leave undesirable residue on the printer parts. Never use water to clean the printer’s internal components.

Appropriate cleaning procedures for specific print-quality or paper transport problems are listed in Table 5-1.


5-3

Table 5-1. Problems and Cleaning Procedures

Problem Type

Light stripes or missing colors

Missing or light stripes on prints

Ink smears, oil spots or random ink streaks

Ink smears on the front, back or edges of a page

Solution

Oil (drum fluid) on top edge of print

Media jams

Paper-pick or jamming problems at the tray

Paper jamming problems at the front door

Paper jamming problems at the exit

Paper-pick or jamming problems at the lower tray feed roller

Double picks

Select the automated procedure Clean Jets from the front panel Troubleshooting menu.

Select the automated procedure Remove Ink

Smears from the front panel Troubleshooting menu.

Check the drum maintenance tray for ink.

Select the automated procedure Remove Ink

Smears from the front panel Troubleshooting menu.

Clean the pick roller.

Clean the transport rollers. Use the blue thumbwheel on the duplex roller to manually rotate the rollers.

Clean the exit rollers and the stripper fingers.

Use the blue thumbwheel on the duplex roller to manually rotate the rollers.

Clean the Auxiliary Feeder Unit assembly.

Clean pick pad with 90% alcohol.

NOTE: Media jams are usually caused by bad media or a hardware fault (i.e., a defective sensor). Most jams will not be resolved by cleaning rollers, so carefully observe the media and the results of the service diagnostics when troubleshooting media jams.

Cleaning Page

Under certain conditions, the printer purges its ink-jet nozzles to clear any jets plugged with ink. When the purge is completed, the printer outputs a cleaning page to clear the purge pattern from the print drum. Ink jets are purged under the following conditions:

• During warm-up from a power-off condition.

• When the printer exits the Energy Star mode.

• When customers initiate the Print Jet Test Page automatic cleaning procedure from the front panel Troubleshooting menu.

5-4


Vacuum

Drum Temperature Sensor

With a dry swab, clean any buildup around the drum temperature sensor. You can access the sensor through the opened stripper finger cover. Also make sure the sensor rides evenly on the drum surface.

You can remove the sensor, if necessary, to clean under it.

Maintenance

Vacuum dust from the top cover, the metal heat shield over the printhead and plastic dust cover under the stripper fingers. Dust should also be vacuumed from the vents, near the fans and anywhere else where it is observed.

Maintenance roller

The printer uses the maintenance roller as part of its selfmaintenance routine to coat the print drum with oil before each print.

The maintenance roller (and its counter) must be replaced after

15,000 prints (the starter maintenance roller must be replaced after

7,500 prints). A front panel message indicates when the maintenance roller is low. Printing is still possible when the maintenance roller fluid is low. When a front panel message indicates the maintenance roller is “empty,” the maintenance roller and its counter must be replaced before continued printing is possible. Refer to the instructions included with the kit to replace the maintenance roller kit.

NOTE: The Drum Maintenance Unit Replacement Kit has a one year shelf life.

NOTE: The drum fluid, an oil, poses no known adverse health effects.

Refer to the Material Safety Data Sheet for more information.


5-5

The number of remaining cycles can be obtained from the front panel as follows.

1.

Allow the printer to warm up to its idle, “Ready to Print,” state.

2.

Scroll to the Info selection and press the Select button.

3.

Repeat for the menus Consumables and Maintenance Kit

Information.

4.

Scroll to the item Prints remaining. The number of remaining oiling cycles is displayed following the colon.

When the number of remaining oiling cycles reaches 1000, the front panel automatically displays the count as part of status message indicating that the maintenance kit is low. A replacement kit should be ordered at this time. The kit-low message remains, counting down the number of remaining oiling cycles, until the count reaches 0. At that point, the message is updated, stating that the kit is empty and requires replacement. The printer will no longer print until the maintenance drawer is replaced.

The front panel messages are accompanied by similar messages emitted over the back-channel. These are “maintenance kit low” and

“maintenance kit exhausted.” While the drawer is in the process of being replaced (that is, whenever it is removed), the back-channel emits “maintenance kit missing.”

In addition, one other back-channel message is associated with the maintenance drawer. The message is “waste liner full: please empty.”

This indicates the waste-ink tray must be emptied before normal operation will resume. For quick reference, the front panel displays additional instruction.

Waste Tray

The maintenance drawer contains a waste tray that collects the ink that has been purged from the printer’s ink jets. The waste tray should be emptied each time the maintenance drawer is removed from the printer. Refer to “Emptying the Waste Tray,” in the

iiLINX™ Solid Inkjet 100 User Manual for instructions on removing and emptying the waste tray. Be sure to insert the waste tray into the maintenance drawer before reinstalling the maintenance drawer in the printer. Never reuse waste ink in the printer.

5-6


Lubrication

Tools and supplies required

• Light oil

• Grease (Nye Rheolube 368B)

In general, all of the printer’s bearings and motors are lifetime factory-lubricated. However, over time and under certain extreme operating conditions, oil and grease may dry out, causing squeaks and rumbling noises in the printer. Look for fine metal particles — a clear sign of an old or worn bearing. Under these circumstances, replace the bearing or the assembly.

A drop of grease on a noisy bushing will quiet a noisy printer. Too much lubrication can get into the paper path and attract dust, so apply lubrication sparingly.

Lubricate the following only when needed:

• Bushings: Apply a drop of light oil to a bushing if it is noisy or running dry.

• Plastic gear train: The gear train from the process motor to the paper-feed module requires only a small amount of white grease for noise reduction purposes. Apply grease sparingly so that it does not fling off of the gears when they turn. You need only to apply a dab of grease to a single gear and the grease will migrate throughout the entire gear train. Do not apply oil to gears; only use approved grease.

NOTE: Do not apply lubricant to the head tilt gear or the head tilt gear guide.

• X-axis drive. Apply a small amount of grease on the tip of the nose cone. Apply a small amount, 3 dabs, on the threads of the

X-axis shaft.

• White (nylon) plastic bearings and cams: No lubrication required.

Inspection

Rollers: Replace the rollers when you see any of the following defects:

• Flat spots.

• Out of roundness.

• Cracked rubber.


5-7

• Loss of traction (tackiness) causing pick or feed failures.

Gears: Replace gears that show any signs of wear or breakage. Look for these problems:

• Thinned gear teeth.

• Bent or missing gear teeth; check especially where a metal gear drives a plastic gear.

• Fractured or cracked gears. (Oil or incorrect grease on a plastic gear can cause the gear to crack.)

Belts: Inspect the belts for wear. There are eight rubber belts in the printer:

• A belt from the process motor to the compound gear

• Two belts from the y-axis motor drive

• A belt from the lower paper feed roller to the upper paper feed roller

• Two belts on the cap/wipe/purge drive

• An exit roller drive belt

• A small belt for driving the cap/wipe purge assembly from the cap/wipe/purge clutch

Look for these problems:

• Loose rubber particles below the belts indicate a worn belt.

• Missing teeth in the belts.

• Cracking or moderate fraying; a small amount of fraying is inevitable, so look for other signs of wear before replacing the belt.

Clutches: There are four clutches: the paper-pick roller clutch, the upper feed roller clutch, the maintenance drawer cam clutch and the cap/wipe/purge clutch. Symptoms of a malfunctioning clutch are the printer not picking paper from the tray or other paper jams. Also the cap/wipe/purge system could fail. In such cases, replace the clutch.

5-8


Preventative Maintenance Checklist

❏

Clean feed rollers, exit rollers and guides and stripper fingers only when ink or debris is visible.

❏

Clean upper and lower tray pick rollers only when ink or debris is visible.

❏

Clean maintenance drawer wiper blade.

❏

Clean (dust or vacuum) interior and exterior of printer, including fans and air inlets/outlets on cart.

❏

Inspect cap/wipe/purge gasket, wiper blade, and printhead faceplate; if gasket or wiper is damaged, or printhead faceplate has streaks, replace cap/wipe/purge assembly.

❏

Check optical density; if necessary calibrate optical density or replace printhead.

❏

Check print quality using Quality Test; clean printhead or adjust printhead-to-drum gap and X-axis scale factor.

❏

Check for “cooked” or discolored inks; flush out discolored inks.

❏

Check print engine and PostScript firmware versions; install current firmware version (supplied by Service.)

❏

Review proper operation of printer using a customer file, if possible.

❏

Review with the customer all work that was performed and how to properly care for printer.


5-9

5-10


Chapter

Removal and Replacement

6-1

Chapter 6

Removal and Replacement

This chapter provides steps to remove and replace key printer Field

Replaceable Units (FRUs). After a brief discussion about the importance of locking the printhead, hardware and then software repair and replace procedures are provided.

WARNING

Sharp burrs and/or edges are present inside the printer. Use caution when servicing equipment.

Locking the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Removing the Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Exit Door and Exit Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Ink Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Vacuum Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Main Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

SDRAM DIMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Code ROM SIMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

Power Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Left and Right I/O Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Network Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

Internal Hard Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Upper Feed Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

Lower Feed Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Preheat/Drum Heater Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

Preheater Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

Drum Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-100

Drum/Transfix Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

Drum Position Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

X-axis Motor and Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 6-51

Y-axis Belt Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52

Cap/Wipe/Purge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83

Stripper Finger Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90

Pick Roller and Pick Roller Electric Clutch . . . . . . . . . . . . . . . . . . 6-93

Maintenance Can Roller and Electric Clutch . . . . . . . . . . . . . . . . . 6-95

Maintenance Drawer Counter Connector Assembly . . . . . . . . . . . 6-100

Upgrading Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120

Upgrading Firmware “Flash Copy” from P.S. File . . . . . . . . . . . . . 6-125

6-2

ii LINX™ Solid Inkjet 100 Printer Service Manual

Locking the Printhead

During normal power-down, the printer tilts the printhead back and energizes the X-axis drive to move the printhead to the far right.

This allows the printhead’s tilt arm, which moves as the printhead moves, to engage a pin protruding from the left-side printer frame.

This effectively automatically locks the printhead in place for moving and shipping. The printer will not lock the printhead if any printer door is open.

CAUTION

After servicing the printer with power off, never leave the printhead in the tilted-forward, far-right position. Upon power-up, the printhead will be tilted backward and the head tilt arm will crash into the head lock pin. This can damage process gears and belts driving the tilt arm.

After servicing the printer. When you service the printhead, Xaxis drive, cap/wipe/purge assembly or other relevant printer components, leave the printhead in its print position, centered in front of the drum. Upon power-up the printer can safely move the printhead.

Manually locking the printhead. If you must manually lock the printhead:

1. Disconnect the head tilt spring.

2. With the printer powered off, carefully tilt the printhead back about two-thirds of the way by rotating the compound gear.

CAUTION

Do not allow the spring-loaded printhead to fall forward or it may damage the drum.

3. Manually rotate the X-axis drive gear to move the printhead to the right extreme of its travel. Ensure the lock pin on the left side of the printer frame properly engages the slot in the head tilt arm.

4. Rotate the X-axis gear in the opposite direction about one rotation. This prevents the X-axis drive from binding so tightly that the motor cannot free it upon power-up.

5. Reinstall the head tilt spring.


6-3

Removing the Covers

Removing the Right and Left Covers

1. Open the front door.

2. Remove the two screws securing the left (or right) cover in place. A sheet-metal screw secures the cover inside the front door. A machine screw secures the cover at the rear cover.

3. Remove the left (or right) cover.

NOTE: For reassembly, note how the cover interlocks with the bottom of the printer frame. Pushing in on the bottom-center of the cover helps to lock it in place.

Reverse these steps to install the right or left cover.

Screw

Screw

Figure 6-1. Removing Right Cover

Right cover

840-4-02

6-4


Removing the Top Cover

NOTE: Vacuum dust out of the top cover before you remove it.

1. Remove the right cover.

2. Remove the left cover.

3. Open the ink load door and tilt it back. Unclip the ink load door arms from the ink loader’s spring crossarm.

4. Slide the ink loader’s spring crossarm to the rear of the ink loader. Note how pins on the ends of the ink-loader crossarm align with notches in the top cover for removal.

5. Remove the four screws securing the top cover in place.

6. Tilt up the rear-end of the top cover and lift and remove the top cover.

Reverse these steps to install the top cover.

Top cover

Figure 6-2. Removing Top Cover

840-4-04


6-5

Removing the Rear Cover



3. Remove the top cover.

4. With the top, right and left covers removed, remove the rear cover.

Reverse these steps to install the rear cover.

Rear Cover

Figure 6-3. Removing Rear Cover

6-6


840-4-05

Removing the Front Panel

1. Open the exit door.

2. Remove the right and left covers.

3. Remove the three screws securing the front panel. One of the screws is located inside the exit door area.

4. Disconnect the front panel display wiring harness from the right I/O board. Slide the front panel rearward slightly, lift and remove the front panel.

Reverse these steps to install the front panel.

Front panel

Right I/O board

840-4-06

Figure 6-4. Removing Front Panel


6-7

Removing the Front Door

1. With a small, flatblade screwdriver, press the release lever on the front door left pivot. The release is located inside a small hole on the left pivot.

2. Slide the door’s right pivot off the right frame post.

3. Remove the front door.

Reverse these steps to install the front door.

Left pivot

Release

Figure 6-5. Removing Front Door

6-8


Right frame post

840-4-07

Removing the Exit Door and Exit Roller



3. At the right side of the printer, remove the cap/wipe/purge electric clutch. Use a small, flatblade screwdriver to release the clutch from the shaft. Also remove the right-side keyed, white plastic bushing.

4. At the left side of the printer, release the tension on the exit roller drive belt. Slip the belt off the exit roller drive pulley.

5. Use a small, flatblade screwdriver to release the drive pulley from the exit roller shaft. Also remove the left-side keyed, white plastic bushing.

6. Remove the exit roller, lower exit guide and exit door from the printer.

7. Unclip the lower exit guide from the exit roller.

8. Slide the exit roller out of the exit door.

Reverse these steps to install the exit door.


6-9

Exit door

Lower exit guide

Exit roller drive pulley

Left keyed bushing

Lift release with small screwdriver

Exit roller

Cap/Wipe/Purge electric clutch

Right keyed bushing

Figure 6-6. Removing the Exit Door and Exit Roller

840-4-08

6-10


Removing the Ink Loader

WARNING

Even when the printer is turned off, AC line voltages may be present at the printer heaters while the printer is plugged into AC power.

1. Turn off the printer and remove the power cord. Allow the ink loader to cool.

WARNING

Hot waste ink from a cleaning operation drains to the waste ink tray where it cools. Avoid a burn hazard by allowing the printer time to cool before continuing.

2. Remove the right, left and top covers.

3. Remove the vacuum/pump module.

4. Disconnect the two wiring harnesses leading to the ink loader.

WARNING

Do not dangle the ink loader by its connector over the side of the printer as it may result in an intermittent connection and faulty ink sense.

5. Lift and remove the ink loader.


6-11

Ink loader

Wiring harnesses

Vacuum/ pump module

840-4-09

Figure 6-7. Removing the Ink Loader

Reverse these steps to install the ink loader. Refer to “Wiring

Diagrams” in Appendix C for illustrations showing how to route the ink loader’s wiring harness.

6-12


Fans

Removing the Left Fan


2. Disconnect the wiring harnesses leading to the left fan.

3. Remove the two screws securing the left fan to the side frame.

Remove the fan.

AIR FLOW

Left fan

840-4-25

Figure 6-8. Removing the Left Fan

Reverse these steps to install the left fan. Orient the fan so it blows inward.


6-13

Removing the Drum Fan


2. Disconnect the drum fan’s wiring harnesses.

3. Remove the three screws securing the drum fan in place.

Remove the fan.

Drum fan wiring harness

Drum fan

AIR FLOW

Bulkhead bracket

840-4-10

Figure 6-9. Removing the Drum Fan

Reverse these steps to install the fan. Orient the fan so it blows inward. Be sure to mount the cap/wipe/purge wiring harness bulkhead bracket to the lower left of the fan. Refer to “Wiring

Diagrams” in Appendix C for an illustration showing how to dress the drum fan wiring.

6-14


Main Board

1. Power down the printer. Leave the power cord plugged in to provide a ground path for static discharges. Remove the interface cables.

2. Loosen the two rear panel securing screws.

3. Slide out the main board. Refer to Figure 6-9.

If you are replacing the main board, transfer the socketed realtime clock/NVRAM chip and the printer ID chip (location U390) to the new board so the printer’s settings and Ethernet address are retained.

Also swap the code ROM DIMM and the SDRAM DIMMs.

Reverse these steps to install the main board.

RAM

DIMMS

Real time clock/NVRAM

Code ROM

DIMM

Printer ID

Main board

840-4-36

Figure 6-10. Removing the Main Board


6-15

Power supply

WARNING

Even when the printer is off, AC line voltage may be present at the printer heaters while the printer is plugged into AC power.




4. Remove the rear cover.


6. At the right side of the printer, disconnect the two wiring harnesses leading to the power supply. Refer to Figure 6-10.

7. Remove the four screws securing the power supply in place.

Remove the power supply.

Reverse these steps to install the power supply.

6-16



Power supply

Figure 6-11. Removing the Power Supply

840-4-32


6-17

Power Control Board





5. Remove the rear cover.

6. Remove the ink loader.

7. Remove the main board.

8. Remove the power supply.

9. Remove the network card or its cover plate, whichever is in place.

10. Remove the internal hard drive or cover plate whichever is in place.

6-18


Cover plate

Power control board

840-4-35

Figure 6-12. Removing the Power Control Board

11. Disconnect the wiring harnesses leading to the power control board.

12. Remove the four screws securing the power control board cover plate. Remove the plate.

13. Remove the four screws securing the power control board in place. Lift and remove the board.

Reverse these steps to install the power control board.


6-19

Paper/Drum Heater

WARNING

Disconnect the power cord. AC voltages may be present at the heaters, even with the printer turned off.



Paper / Drum heater

Wiring harness

840-4-16

Figure 6-13. Removing the Paper/Drum Heater

3. Remove the upper feed roller as described in the topic “Upper feed roller assembly.”

4. Disconnect the locking wiring harness from the right side of the paper/drum heater.

6-20


5. At the front of the paper/drum heater remove the two screws securing the heater to the inside of the printer frame. Do not confuse the mounting screws with the nearby smaller, brasscolored assembly screws.

Reverse these steps to install the paper/drum heater.

Upper Feed Roller Assembly



3. Disconnect the head tilt spring.

4. Left side: Remove the upper feed roller electric clutch from the end of the upper feed roller shaft by moving the locking tab on the clutch away from the shaft.

5. Remove the feed roller drive belt and compound gear from the left end of the upper feed roller. Note the small slot in the compound gear to ease removal.


6-21

Disconnect head tilt spring

Upper feed roller shaft

Slot

Compound gear

Upper feed roller electric clutch

Feed drive belt

840-4-13

Figure 6-14. Remove the Upper Feed Roller Assembly (left side)

6. Front: Open the front door and remove the drum maintenance drawer. Also, remove the bright, metal duplex paper guide from the front of the printer. It is held in place with two screws.

7. Remove the left and right maintenance drawer guides. Each is held in place by a single screw at the front and two frame latches at the rear.

NOTE: If you have trouble removing the right maintenance drawer guide, manually rotate the X-axis drive to move the printhead (in its forward position) to the center of its travel.

8. Remove the screw securing the right side of the upper feed roller assembly to the inside of the printer frame.

6-22


9. Disconnect the wiring harness leading from the upper feed roller assembly to the inside the left side of the printer frame.

10. Remove the C-clip located on the left-inside printer frame securing the upper feed roller assembly in place.

11. Remove the upper feed roller assembly. Separate the assembly into its two halves.

Reverse these steps to install the upper feed roller assembly.

Keyed bushing

C-clip

Wiring harness

Upper feed roller assembly

Keyed bushing

Left maintenance drawer guide

Right maintenance drawer guide

Key pin on right frame aligns upper feed roller assembly

Remove screw from right side

840-4-14

Figure 6-15. Removing the Upper Feed Roller Assembly (Front)


6-23

Drum/Transfix Assembly

NOTE: When the drum (see Drum/Transfix Assembly) is replaced, the new drum should be conditioned using the Seal Drum print suite before the printer is returned to normal service. The Seal Drum suite is comprised of five clear solid-fill prints.



3. Remove the front panel.

4. Left side: Free the wiring harness leading from the drum/ transfix assembly along the left side of the print engine to the power control board and left I/O board.

5. Remove the drum position sensor assembly.

6. Remove the upper feed roller assembly.

7. Remove the paper/drum heater.

8. Remove the drum temperature sensor.

9. Remove the C-clip securing the compound gear and remove the gear.

10. Loosen the exit roller drive belt tensioner. Remove the exit roller drive belt.

11. Remove the tilt arm spring.

6-24


Wiring harness

Exit roller drive belt tensioner

Exit roller drive belt

Tilt arm spring

C-clip

Compound gear

Hex screw

Remove drum/transfix assembly screws

840-4-19

Figure 6-16. Removing the Drum Transfix Assembly (Left Side)

12. Right side. Remove the Y-axis belt drive assembly.

13. Disconnect the wiring harnesses leading to the transfix solenoid bracket. Remove the three screws securing the bracket in place and remove the bracket.

14. Remove the left and right frame bridges. Each is held in place with two screws.

15. Remove the two screws securing the front of the drum/transfix frame to the inside printer frame.

16. Remove the five screws securing the left side of the drum/ transfix assembly to the print engine. Note that one screw is removed with a 3/32” hex key.


6-25

17. Remove the five screws securing the right side of the drum/ transfix assembly to the print engine. Note that one screw is removed with a hex key.

18. Carefully, lift and remove the drum/transfix assembly. Protect the drum surface.

Left frame bridge

Drum transfix assembly

Right frame bridge


Transfix solenoid bracket

Remove

2 inside screws

Remove 4 screws

Remove hex screw

840-4-20

Figure 6-17. Removing the Drum/Transfix Assembly (right side)

6-26


Reverse these steps to install the drum/transfix assembly.

NOTE: Upon reassembly, install the hex-keyed screws first; they align the drum/transfix assembly to the engine frame.

Make these adjustments after installing a new drum.

1. Ensure the drum position encoder sensor gap.

2. Set the Y-belt tension; refer to the topic “Y-axis Belts Tension

Adjustment”

3. Power up the printer in Bypass Mode to skip the startup and mud pages.

4. Enter the hidden Service menu and select Seal Drum to seal the new drum.

5. Perform the printhead to drum adjustment described in the topic “Printhead-To-Drum Spacing Adjustment.”

Drum Position Sensor Assembly



CAUTION

Unhook the head tilt spring to avoid possible damage to the printhead and drum.

3. Disconnect the drum home-position sensor wiring harness from

J180 of the left I/O board leading to the drum position assembly. Disconnect the drum position encoder sensor at the drum position assembly.

4. Remove the clear plastic dust cover from the drum position assembly.

5. Precisely mark the end of the drum shaft relative to the drum home flag on the drum position sensor assembly; this is not necessary if you are also replacing the drum (as part of the drum/transfix assembly).


6-27

Mark on the drum shaft to align with the home flag

Drum home flag

Drum position encoder wheel

840-4-17

Figure 6-18. Marking the Drum Home Flag Sensor Alignment

6. Rotate the tilt gear to orient the gear’s missing teeth to the drum position sensor assembly’s rear mounting screw.

7. With a small, flatblade screwdriver, slide the retaining spring out of the encoder wheel’s groove toward the encoder disk.

8. Remove the three screws securing the drum position sensor assembly housing to the print engine. Insert the gap tool to hold the encoder wheel in position. Slide the assembly off the drum shaft. If necessary, use the small flat-blade screwdriver to push the encoder disk hub along the shaft as you remove the assembly.

6-28


Slide the retaining spring out of the groove

Drum position sensor assembly

Groove

Screws

840-4-18

Figure 6-19. Removing the Drum Position Sensor Assembly

Reverse these steps to reinstall the drum position sensor assembly.

The drum must be in the same position relative to the drum position encoder wheel when the drum position sensor assembly was removed.

This ensures that the stripper fingers contact the drum in the same location as before; otherwise, print artifacts will result.

• Install the encoder wheel on the drum shaft, precisely aligning the home flag to the alignment mark drawn on the shaft.

• Use the encoder wheel gap tool to space the encoder wheel to the drum position sensor.


6-29

Printhead

WARNING

Even when the printer is turned off, AC line voltages may be present at the printer heaters while the printer is plugged into AC power. The printhead is hot.

1. Remove the right cover and the left cover.

2. Disconnect the head-tilt spring.



5. Remove the metal heat shield from over the printhead.

6. Disconnect the power wiring and data harnesses leading from the printhead to the power control board. Also disconnect the two ground wires from the printer frame.

7. Carefully plug the printhead’s reservoir chamber holes with the silicone plugs. The plugs keep liquid ink from spilling if you should inadvertently tip the printhead.

6-30


Disconnect

Silicone reservoir plugs

840-4-23

Figure 6-20. Plugging the Reservoir Holes

8.

Rotate the removal tool’s plastic leg into its up position. Slide the removal tool’s standoff locks inward.

9.

Place a few sheets of paper between the printhead and the drum to protect the drum surface.

10.

Carefully, lower the printhead removal tool onto the printhead.

Rotate the process motor to tilt the printhead forward about

2.5 cm (1 inch).

11.

Slide the standoff locks outward to secure the tool to the printhead. Loosen the two mounting screws securing the printhead in place.

12.

Lift and remove the printhead. Lower the removal tool leg to safely restthe printhead on a flat surface.

13.

Using the printhead removal tool, reverse the removal steps to reinstall the printhead.

14.

Perform the Cold Printhead-to-Drum Spacing Adjustment and then the Hot Printhead-to-Drum Spacing Adjustment.


6-31

Install removal tool

Loosen mounting screws

Slide lock to secure to printhead

Removal tool leg

(in up position)

840-4-24

Figure 6-21. Removing the Printhead

Installation. If not already in place, install the printhead’s data ribbon cable to the printhead.

1. Install the printhead with the tile mount about half-way back.

Work the head up/down on each side to be certain the head is all the way down and seated. Then tighten the two mounting screws so they are snug.

2. Loosen the printhead’s four (Head-to-Drum HTD) gap adjustment screws and push the printhead away from the drum; then tilt the printhead to its print position by turning the process gear on the left side of the printer and attach the head tilt spring. The head tilt arm will be seated at the end of the slot of the steel band.

6-32


3. Torque the mounting screws to 20 in./lbs.

4. Perform a “Cold” Printhead-To-Drum Spacing Adjustment, followed by a “Hot” Printhead-To-Drum Spacing Adjustment.

X-axis Motor And Drive Assembly

Reveiw these general operation requirements before servicing the Xaxis motor and drive assembly.

• Home Position. The printer is completely “dumb” about where the head is other than based on motor count tracking in RAM after homing. Accurate homing is dependent on a free moving head/shaft assembly. When the X-axis is free to move, homing can be verified by audibly listening to the “tick” sound as the motor continues to drive after the head travel limit is attained.

Moving the X-axis by manually turning the gear will require power cycling the printer to reestablish the correct home location.

• Friction. Print quality could suffer if the X-axis drive system friction becomes too high. Lack of lubricant at the interface between the nose cone and yoke can increase friction and wear considerably. Excess friction at the leadscrew/gear interface would also occur if not properly lubricated.

• Parking Bind. Under unusual circumstances the X-axis could become bound up when parked. This would most likely occur if the interface between the gear and stop collar was not lubricated. Drive parameters have been optimized to prevent binding. However, if such a bind does occur, it can result in either no X-axis movement or a delay in coming off the collar, which would cause a positional imaging offset.

• Power Interruption. The X-axis shaft/head assembly can gradually move to the right when power to the printer or motor is interrupted prior to doing a parking move. This occurs because the thread pitch slope is steep enough to allow the gear to rotate if unchecked by motor resistance. Home position is lost when this happens but the printer re-homes when the power is cycled.

Removal


2. Remove the left cover. Disconnect the head-tilt spring.

3. Disconnect the X-axis motor wiring harness at the X-axis motor.


6-33

4. Remove the two screws securing the X-axis motor and bracket in place.

5. Rotate the black, plastic retainer counter-clockwise.

6. Lift up on the bottom portion of the X-axis drive yoke. Lift up on the yoke and remove the upper portion of the yoke.

7. Remove the nose cone from the gear.

8. Rotate the X-axis gear counter-clockwise to remove it from the

X-axis shaft.

X-axis motor

Gear

Retainer

Nose cone

X-axis drive yoke

(remove bottom first)

840-4-22

Figure 6-22. Removing the X-axis Motor and Drive Assembly

6-34


Reassembly of the X-axis Motor and Drive

Assembly

For reassembly, apply a small amount of grease on the tip of the nose cone. Apply a small amount, 3 dabs, on the threads of the X-axis shaft. Be sure to rotate the black, plastic retainer so it ends locks the yoke in position. Perform the procedure “ X-axis scale adjustment.”

CAUTION

When reinstalling the motor, take care to fully seat the motor positioning boss into the stiffener panel for proper operation.

1. Place the retainer over the leadscrew. Orient it so that the flat side faces generally toward the motor.

2. Put lubrication on the leadscrew and screw the threaded gear—longer hub facing out. Turn it all the way on (clamped against the stop collar) then back off 1/4 turn.

NOTE: The X-axis shaft/head assembly will be spring loaded but should otherwise be free to travel.


6-35

X-axis motor

Gear

Retainer

Nose cone

X-axis drive yoke

(install top first)

E790-42-S

Figure 6-23. Installing the X-axis Motor and Drive Assembly

3. Install the upper yoke leg by hooking it into the stiffener tab: pivot toward the side frame until it hooks then pivot back out.

Installing the yoke legs requires orienting the stop collar to allow access to the tabs.

4. Clean the mating surfaces of the gear hub and nose cone

(diameter and base) then slip the nose cone over the gear hub.

5. Lubricate the yoke pocket.

6-36


6. Engage the yoke span and the un-mounted yoke leg by rotating the end tabs of the span to fit through the large rectangular hole of the leg. Orient so the parts are coupled perpendicular to one another.

7. Insert the free span end of this assembly into the upper leg opening and orient to couple them. Take case not to wipe lubricant out of the span. The pocket should only come into contact with the end of the nose cone.

8. Rotate the yoke assembly downward over the nose cone and latch the lower leg to the stiffener tab. Rotate the stop collar as required to permit attachment of the leg during this installation.

9. Install the X-axis motor. Take care to fully seat the motor positioning boss into the stiffener panel.

10. Install the motor bracket

11. Connect the X-axis motor wiring harness.

12. Perform the X-axis Scale Adjustment procedure.

Y-axis Belt Drive Assembly


2. Disconnect the wiring harness leading from the front panel to the right I/O board passing beside the Y-axis belt drive assembly.

3. Remove the drum fan.

CAUTION

Never loosen or remove the three screws securing the assembly parts together.


6-37

Y-axis belt assembly

Never remove these screws

Tension screws

840-4-12

Figure 6-24. Removing the Y-axis Belt Drive Assembly

4. Remove the three tension set screws securing the Y-axis belt drive assembly to the engine frame. Remove the assembly with its two belts.

NOTE: Tension the drive belts using the procedure, “Y-axis belts tension adjustment.”

Reverse these steps to install the Y-axis belt drive assembly.

6-38


Y-axis (Drum) Motor and Process Motor



3. Remove the front panel.

4. Remove the drum maintenance drawer.

5. If you are removing the Y-axis motor, remove the Y-axis belt drive assembly.



8. Remove the four screws securing either motor to the drum/ transfix assembly. Remove the motor. Unclip the cable ties retaining the motor’s wiring harness.

Reverse these steps to install the Y-axis or process motor.


6-39

Process motor

Drum transfix assembly

Y-axis motor

840-4-21

Figure 6-25. Y-axis (Drum) Motor and Process Motor

Removing the Paper Path Motor


2. Disconnect the paper path motor wiring harness from the power control board. Free its wiring harness from the cable restraints.

3. Remove the three screws securing the paper path motor in place. Remove the motor.

Reverse these steps to reinstall the paper path motor.

6-40


Remove three screws

Paper path motor

840-4-28

Figure 6-26. Removing the Paper Path Motor


6-41

Cap/Wipe/Purge Assembly

WARNING

Even when the printer is turned off, AC line voltages may be present at the printer heaters while the printer is plugged into AC power.



3. Disconnect the head-tilt spring. Tilt back the printhead and center it.



6. Disconnect the wiring harness leading from the cap/wipe/purge assembly to the power supply wiring harness. Clip the tie wraps and disconnect the vacuum hose leading to the vacuum/ pump module.

7. Rotate the cap wipe drive gear to position the cap/wipe/purge assembly 25 mm (1 in.) from the top of its travel.

8. Place a few sheets of paper between the drum and the cap/ wipe/purge assembly to prevent scratching the drum.

9. Remove the right timing belt’s lower pulley to create slack in the right timing belt.

10. Remove the metal vacuum line from the assembly.

11. Remove the wiring from the right cap/wipe/purge assembly bracket.

12. Push the wiring through the print engine’s frame so that you can unloop it from the cap/wipe/purge assembly.

13. While holding onto the cap/wipe/purge assembly, remove the three pin screws that hold the cap/wipe/purge assembly in the grooves on each side of the print engine.

Reverse these steps to reinstall the cap/wipe/purge assembly. Refer to the wiring diagrams in Appendix C for details on dressing the cap/ wipe/purge wiring.

6-42


Vacuum inlet

Short pin screw

Cap Wipe/ Purge assembly

Short pin screw

Long pin screw

840-4-43

Figure 6-27. Removing the Cap/Wipe/Purge Assembly

Removing Cap/Wipe/Purge Belts


2. Disconnect the head-tilt spring. Tilt back the printhead.


4. Manually rotate the cap/wipe/purge drive enough to raise the cap/wipe/purge assembly so the two belt locks are accessible on left and right side of the printer frame.


6-43

5. At the right side of the printer, slide the metal vacuum hose out of the cap/wipe/ purge unit.

6. Unlatch the timing belt lock of each belt to free each belt.

When installing new belts, reverse these steps and attach each belt so that the pointer on each belt lock points at the index mark on the printer side frames. Tighten each lock to its fourth tooth as illustrated. Perform the belt alignment adjustment using procedure in

Chapter 4 to ensure the belts are aligned and that the cap/wipe/purge assembly will correctly seal against the printhead faceplate.

Belt lock

Index mark on right frame

Fan

Right cap/wipe/purge assembly belt

Unlock

Latch

Left belt lock: align pointer between two index marks

For new belt, break off actuator on left-side belt lock

Lock

Leave gap between latch and belt tensioner

840-4-29

Figure 6-28. Removing Cap/Wipe/Purge Timing Belts

6-44


Removing Stripper Finger Assemblies


2. Upper stripper finger assembly. At the right side of the printer, remove the transfix solenoid bracket.

3. Remove the cutting screw securing the right end of the upper stripper finger assembly to the printer frame. Remove the upper stripper finger assembly.

4. Lower stripper finger. At the right side of the printer, remove the C-clips securing the spring unit in place. Remove the spring unit, spring and bushing.

5. At the left side of the printer, remove the C-clip securing the left end of the lower stripper finger assembly. Carefully remove the bushing and lower stripper finger without damaging the dust cover underneath.

Reverse these steps to install the stripper finger assemblies.


6-45

Upper stripper finger assembly

Lower stripper finger assembly

Transfix roller cam

Cam rider

Extruded pin

Spring

C-clip

Bushing

Bushing

Spring

Spring unit

C-clip

Cutting screw

840-4-27

Figure 6-29. Removing Stripper Finger Assemblies

Removing the Maintenance Cam Roller and Electric

Clutch



3. Disconnect the maintenance cam roller electric clutches wiring harness from the left I/O board.

4. At the left side of the printer, remove the C-clip securing the maintenance cam roller electric clutch. Remove the clutch.

6-46


5. Remove the right I/O board.

6. At the right side of the printer, use a small, flatblade screwdriver to unlock the maintenance cam roller flag from the end of the maintenance cam roller.

7. Inside the left-side printer frame, remove the C-clip securing the maintenance cam roller in place. Remove the maintenance cam roller.

Reverse these steps to install the maintenance cam roller and electric clutch.

Maintenance roller electric clutch

Bearing

C-clip

Maintenance cam roller flag

Lock

840-4-31

Figure 6-30. Removing Maintenance Cam Roller and Electric Clutch


6-47

Removing Maintenance Drawer Counter Connector

Assembly

WARNING

Allow the printer to cool for 30 minutes.



3. Remove the maintenance drawer.

4. Disconnect the maintenance drawer counter connector assembly’s wiring harness from the power control board.

5. Reach in through the maintenance drawer cavity and squeeze the snap-fit maintenance drawer counter connector assembly to free it from the printer frame. Carefully remove it and its wiring harness.

Reverse these steps to install the maintenance drawer counter connector assembly.

6-48


Disconnect wiring harness

Maintenance drawer counter connector assembly

840-4-64

Figure 6-31. Removing Maintenance Drawer Counter Connector

Assembly


6-49

Removing Preheater Exit Sensor

WARNING

Allow the printer to cool for 30 minutes.

1. Remove the right, left and front covers.



4. Disconnect the preheater exit sensor wiring harness from the

J170 of the left I/O board.

CAUTION

Be careful in the next step not to scratch or mar the drum.

5. Remove the screw securing the preheater exit sensor to the inside of the left drum/ transfix assembly frame. Remove the sensor and its wiring harness.

Reverse these steps to install the preheater exit sensor.

6-50


Disconnect wiring harness

Left I/O board

Transfix roller

Preheater exit sensor in its bracket

Drum

Remove screw

840-4-65

Figure 6-32. Removing the Preheater Exit Sensor


6-51

Removing the Drum Temperature Sensor

1. Remove the right cover,




5. Unplug the drum temperature sensor from the left I/O board.

6. Remove the screw securing the drum temperature sensor to the printer frame. Carefully remove the sensor.

Reverse these steps to install the drum temperature sensor.

Drum temperature sensor

Wiring harness

Sensor retaining screw

Figure 6-33. Removing Drum Temperature Sensor

6-52


840-4-26

Installing RAM DIMMs

The printer accepts two SDRAM DIMMs which are 64 Mbyte in size.

The printer recognizes any acceptable size SDRAM DIMM in any

RAM DIMM slot. Use the following steps to installing new RAM

DIMMs.

1. Power down the printer. Leave the power cord plugged in to provide a ground path for static discharges.

2. Loosen the two rear panel screws securing the main board.

Slide out the main board.

3. To release an installed RAM DIMM, spread the latches securing each end of the DIMM in the connector.

SDRAM DIMM

DIMM 2

DIMM 1

840-4-37s

Figure 6-34. Locating RAM DIMMs

4. To install a RAM DIMM in the keyed DIMM connector, insert the DIMM until it locks in place. When properly inserted, a tab on each end of the connector slips into a notch on each end of the RAM DIMM.

5. Reinstall the main board into the printer.

6. Reconnect the host interface cables. Turn on the printer and print the start page to verify the memory installation.


6-53

RAM

DIMMS

Real time clock/NVRAM

Code ROM

DIMM

Printer ID

Main board

840-4-36

Figure 6-35. Installing RAM DIMMs

Installing the Code ROM DIMM

The code ROM DIMM contains both print engine and PostScript firmware. Use the following steps to resinstall the Code ROM DIMM


2. Loosen the two rear panel screws securing the main board.

Slide out the main board.

3. To release an installed code ROM DIMM, spread the latches securing each end of the DIMM in the connector.

6-54


4. To install the code ROM in the keyed DIMM connector, insert the DIMM until it locks in place. When properly inserted, a tab on each end of the connector slips into a notch on each end of the ROM DIMM.

5. Reinstall the main board into the printer.

6. Reconnect the host interface cables. Turn on the printer and make a test print.

Code ROM SIMM

Figure 6-36. Installing Code ROM DIMM

840-4-38s


6-55

Installing the Optional Ethernet Network Card

1. Power down the printer. Leave the power cord plugged in to provide a ground path for static discharges. Remove the interface cable.

2. Loosen the two securing screws holding the network card or the cover plate and remove it.

3. Slide in the replacement network card and tighten the two screws.

4. Reconnect the interface cables. Turn on the printer and print the configuration page; it lists information regarding the

Ethernet interface.

5. For installations of a new Ethernet card, affix the Ethernet address label to the underside of the top cover where it can easily be accessed. Also apply a “Do not use” sticker over the

10baseT Ethernet port on the main board. The built-in

Ethernet port is disabled by the presence of an Ethernet network card.

Network card

Figure 6-37. Installing Network Card

6-56


840-4-41

Installing the Internal Hard Drive


2. Remove the network card or the network card slot cover plate, whichever is in place.

3. Loosen the two securing screws holding the internal hard drive or cover plate and remove it.

4. Slide in the replacement internal hard drive and tighten the two screws.

5. Reinstall the network card or the network card slot cover plate, whichever was removed earlier.

6. Turn on the printer and print the configuration page; it lists information regarding the internal hard drive.

Internal hard drive

840-4-40

Figure 6-38. Installing Internal Hard Drive


6-57

Upgrading Software

The operating system of the Solid Inkjet 100 printer is capable of reprogramming the embedded software using flash memory technology. When instructed to flash, the OS overlays a special boot program, the flash monitor, onto RAM and reboots the processor. The flash monitor then boots and downloads a formatted data stream containing executable object code into the flash ROM. After completing the flash, the monitor reinstalls the nominal boot program.

The main value of this functionality is found during printer development, when software changes are applied daily. To support daily flashing, the OS spawns a daemon that listens for a remote flash request. A flash instruction can also be initiated from the OS command shell using flash ()

. Either of these mechanisms load the flash monitor described above. The formatted data stream is received remotely, via the network or parallel port.

However, when the printer is booted in Customer Mode, the flash daemon is not active because the Ethernet connection that services the OS is disabled. The only available Ethernet pathway into the printer is attached to the PostScript Interpreter. It is useful to retain the ability to download the embedded software remotely, in part because it simplifies upgrades in the field. Thus the PostScript language has been extended to permit remote flashing during any boot mode.

The custom operator updateflash is used to download the formatted data stream used by the flash monitor into the frame buffer RAM.

The flash monitor is then booted and programs the flash ROM using the data stream supplied not remotely, but locally from RAM. If the attempt to flash from RAM subsequently fails, the monitor reboots itself and expects data to be supplied remotely.

6-58


Chapter

7

Printer Networking

7-1

t of c

Printer Networking

This guide provides information to help you quickly install the ii

LINX™ Solid Inkjet 100 Printer in the following environments:

•

•

Mac® OS (EtherTalk)

Windows® 95 and Windows® 98

•

•

Windows NT®

Novell® NetWare®

The accompanying CD-ROM also contains NWSET for printer configuration on NetWare networks. The README file for NWSET is in the net_util folder under Netware.

The Solid Inkjet 100 printer can also be interfaced to an iiLINX

Network running version 2.8.1 software or higher; or a DICOM Print

Server (DPS) running version 1.3 software or higher. Reference the appropriate installation documentation for these interfaces.

7-2


Before You Begin Network Configuration

• Set up your printer and physcially connect it to the network.

See the iiLINX Solid Inkjet 100 User Manual for information about setting up the printer.

• Install the Solid Inkjet 100 driver for your printer on every

Macintosh and PC that will send print jobs to the printer. For details on driver installation, see “Installing Printer Software” in the iiLINX Solid Inkjet 100 User Manual.

• For NetWare environments. To speed the setup process and avoid conflicts, familiarize yourself with the components of your network. You should know which version(s) of NetWare are installed, which versions of client software are used, and the network topology (e.g., frame types, routers, hubs, and cabling).

Printing a Configuration Page

Your printer’s Configuration Page supplies useful information for installing and configuring the printer on a network.

Printing a Configuration Page

1. When the front panel displays

READY TO PRINT

, press the down-arrow button until Menu is highlighted. Press the

Select button.

2. Press the down-arrow button until Demo and Test Pages is highlighted. Press the Select button.

3. Press the down-arrow button until Print Configuration

Page is highlighted. Press the Select button.

Printer Networking

7-3

Setting the Printer’s IP Addressing Parameters

In order to install the printer in a network environment, obtain the information listed in Table 3-1. It might be helpful to write down this information so you can refer to it during the configuration procedure.

CAUTION

To avoid any network conflicts, contact your system administrator for the appropriate IP address settings.

Table 7-1. Information for TCP/IP Configuration

Information

Internet (IP) address for the printer

Network mask

Broadcast address

Gateway IP address

Comments

Format is x.x.x.x, where x represents a decimal number from 0–255.

If you are unsure, leave this blank; the printer will choose an appropriate mask.

If you are unsure, leave this blank; the printer computes an appropriate broadcast address.

The address the printer uses to send broadcast packets. Regardless of how this parameter is set, the printer accepts broadcast packets from any of the commonly used broadcast address conventions.

Router address. You need this address if you want to communicate with the printer from anywhere other than the local network segment.

7-4


Setting IP Parameters from the Front Panel


READY TO PRINT


Select button.

2. Press the down-arrow button until Network Settings is highlighted. Press the Select button.

3. Press the down-arrow button until TCP/IP is highlighted.

Press the Select button.

4. Set the IP address: a. Press the down-arrow button until IP Address is highlighted. Press the Select button.

b.

Press the left- or right-arrow buttons to highlight the

3-digit part of the address that you want to set. Press the up- or down-arrow keys to change the numbers.

c.

When the address is set, press the Select button.

5. Set the network mask: a. Press the down-arrow button until Network Mask is highlighted. Press the Select button.

b.



c.


6. Set the default router/gateway address: a. Press the down-arrow button until Default

Router/Gateway Address is highlighted. Press the

Select button.

b.



c.


7. To return the printer to normal operation, press the downarrow button until Exit is highlighted. Press the Select button.

8. Press Reset Printer. All the information changes will take effect after the printer resets.

Printer Networking

7-5

Setting IP Parameters—DHCP

Dynamic Host Configuration Protocol (DHCP) is a system in which

Windows NT servers can allocate IP addresses dynamically. Under

DHCP, the server gives the printer (called a DHCP client) an IP address when the printer is reset.


READY TO PRINT


Select button.

2. Press the down-arrow button until Network Settings is highlighted. Press the Select button.

3. Press the down-arrow button until TCP/IP is highlighted.


4. Press the down-arrow button until DHCP/BOOTP is highlighted. Press the Select button to toggle the function on

(or off).

5. Press the down-arrow button until Exit is highlighted. Press the Select button.

6. In order to turn on the DHCP/BOOTP interface, highlight

Reset Printer Now. Press the Select button.

You must reset the printer to turn on the DHCP/BOOTP interface.

The reset will take approximately 2 minutes to complete. The printer will automatically print a Startup Page to confirm that the function is on.

DHCP Transactions

• On power up or reset, the printer sends a DHCP discover

packet, indicating its Ethernet address and requesting an IP address.

• The DHCP server responds to the discover packet with a

DHCP offer packet, which contains an IP address from within the assigned scope and the assigned lease.

• The printer examines the DHCP offer packet and decides whether to accept the lease. The printer sends a request packet, accepting the IP address and the lease.

NOTE: There can be multiple DHCP servers on the same network, each defining its own scopes and leases. The printer selects the first lease offered.

• The DHCP server sends an acknowledgment packet to the printer, which completes the transaction.

7-6


Ethernet

®

Interface

Built-in Ethernet

®

Connector

The printer’s built-in Ethernet® connector has the following connections and indicators:

1. LINK indicator—on indicates a working connection to a hub;

off indicates no connection to a hub.

2. RCV indicator (green)—blinks while the network interface is receiving.

3. XMT indicator (yellow)—blinks while the network interface is transmitting.

4. Twisted pair (10Base-T) connector.

PhaserShare

®

Series B Ethernet

®

Interface

The PhaserShare® Series B Ethernet interface conforms to the

IEEE 802.3 and Ethernet II standards. With the printer’s built-in

Ethernet interface, you can connect the printer directly to an

Ethernet network using twisted pair (10Base-T) cables. With the optional Ethernet interface card, you can connect the printer directly to an Ethernet network using twisted pair cables (10Base-T or

100Base-Tx or 10Base-2).

When an optional Ethernet interface card is installed, the printer’s built-in Ethernet connector is disabled; use the connectors on the card.

When an optional Ethernet interface card is purchased as an upgrade kit, follow the instructions that are shipped with the card.

CAUTION

To avoid damaging the network interface, turn off the printer before making any Ethernet connections.

Printer Networking

7-7

Optional Ethernet

®

Interface Card

The optional Ethernet interface card (Figure 7-1) has the following connections and indicators:

1. TX indicator (yellow)—blinks while the network interface is transmitting.

2. RX Link indicator (green)—blinks while the network interface is receiving.

3. Speed indicator (yellow)—on indicates 100 Mbps; off indicates

10 Mbps.

4. Twisted pair connection indicator—on indicates a working connection to a hub; off indicates no connection to a hub. If the

10Base-2 connector is used, this indicator is off.

5. Twisted pair (10Base-T or 100Base-Tx) connector.

6. Thin coax (10Base-2) connector.

1 3 5 6

PhaserShare

TM

Series B

Ethernet Card

TX

RX

100

Mbs

TP

LINK

10/100Base-TX

10Base2

2 4

Figure 7-1. Optional Ethernet® Interface Card

9789-05

7-8


Ethernet

®

Cables and Termination

NOTE: To fully comply with EMI (electro-magnetic interference) specifications, the use of shielded or screened cables may be required.

“Shielded” describes IBM-defined cables used with the DB-9 connector.

“Screened” describes cables that are electrically similar to Category 4

UTP (Unshielded Twisted Pair), but with an added shield or screen.

10Base-T or 100Base-Tx (Twisted Pair)

100Base-Tx requires Category 5 (100-Ohm UTP) cabling.

CAUTION

Do not use “silver satin” telephone extension cables for 10Base-T networks, either as drop cords or as patch cables in the wiring closet. (Silver satin cables are flat, usually silver or gray, with

28-gauge stranded or tinsel conductors.) Do not use shielded twisted pair cable intended for IBM Token Ring networks or voicegrade (level 1 or 2) unshielded twisted pair cable for wiring runs.

These cables do not meet the requirements for 10Base-T and will lead to unreliable operation.

Printer Networking

7-9

Mac

®

OS: Ethertalk Configuration

NOTE: The printer’s AppleTalk connection works with Macintosh

System software 7.0, 7.1, 7.5, 7.6, 8.0, 8.1, and 8.5.

Finding the Printer’s Name in the Chooser

1. From the Apple menu, select Chooser.

2. In the left-hand side of the Chooser, find the LaserWriter 8 icon. (If the LaserWriter 8 icon is not in the Chooser, you need to install the printer driver.) Click on the LaserWriter 8 icon.

NOTE: To install a Solid Inkjet 100 Printer driver on a Macintosh network (via Ethertalk), refer to “Installing Printer Software” in

Chapter 2 under “Macintosh Software”.

3. If a list of zones appears in the lower-left portion of the

Chooser, select the proper zone.

4. A list of printers appears in the right portion of the Chooser; find your printer’s name. The printer’s default name is listed on the Configuration Page (see “Printing a Configuration Page” earlier in this chapter). If the name does not appear, check the cable connection between your printer and the network.

NOTE: It is possible for the Printer Name field on the Configuration

Page to be blank. When the printer is powered up, it uses a default name and then checks to see that no other printer on the network has the same name. If enough printers with the same default name are present, it can take several minutes for the printer to establish a unique name. If the Printer Name field on the Configuration Page is blank, wait a short time and reprint the Configuration Page.

7-10


Novell

®

NetWare

®

Configuration

Using the Quick Configuration Wizard

Log On to the File Server

NOTE: Many of the operations performed using the PhaserShare

Administrator require SUPERVISOR privileges (for example, creating queues).

• NetWare 3.x. Log on to the default NetWare file server as

SUPERVISOR or SUPERVISOR equivalent.

• NetWare 4.x, Bindery mode. Log on to the default NetWare file server as SUPERVISOR, SUPERVISOR equivalent, or

ADMIN /B.

• NetWare 4.x, NDS (NetWare Directory Services) mode.

Log on to the default NetWare file server as ADMIN or ADMIN equivalent.

NOTE: While not required, it is recommended that you log in only to the file servers to be configured with this printer.

Start the PhaserShare® Administrator

Double-click the PhaserShare Administrator icon. Refer to your

Windows documentation for complete information on how to start applications.

When you start the PhaserShare Administrator, the Main window is displayed.

Select a Print Server

In the Main window Printer List, click the print server name/printer name.

NOTE: If the printer is not in the list of available printers, there could be a network hardware problem, an incorrect frame type, or incorrect search options settings. Contact your Sterling Service Representative.

Printer Networking

7-11

Launch the Quick Configuration Wizard

Click Quick Configuration to launch the Quick Configuration

Wizard.

Configure the Printer and Set Up Queues

1. If desired, change the Print Server Name or Printer Name.

2. Select connection mode(s) by checking the box(es) for Bindery

Services, NDS Services, or both.

3. Click Next; the dialogs that follow allow you to configure

Bindery connections, NDS connections, or both. You need to supply the following information for these connections:

Information Needed for Bindery Connections

Select either the configuration file server or the preferred file server from the drop-down list; click Next.

If the file server you want is not on the list, proceed with these steps:

1. Click File Servers to display the File Servers Browse dialog box.

2. Select the server you want. Click OK. You are returned to the

File Server Selection dialog box.

3. Select either the configuration file server or the preferred file server from the drop-down list. Click Next.

Create and select a new queue, or select an existing queue. Click

Finish.

Information Needed for NDS Connections

• Specify the current Directory Services Tree (the tree where the print server will reside).

• Specify the current Directory Services Context (the location in the directory services tree where the print server will reside).

• Create and select a new queue, or select an existing queue.

Click Finish.

7-12


Verify Information and Finish the Configuration

After you have entered the configuration information, the Quick

Configuration Wizard displays the Configured Printer Information dialog box, which reports the information you have entered.

1. Verify that the information is correct.

• If the information is correct, click Apply Changes.

• If the information is not correct, click Back to return to previous dialog boxes and correct the information. Click

Next to return to the Configured Printer

Information dialog box. Click Apply Changes.

• To exit the wizard and return to the Main window without making any changes, click Cancel.

2. After you click Apply Changes, the printer resets; the changes take effect when the reset is complete.

3. After the reset, you are prompted to print a Test Page. It is recommended that you print a Test Page to verify a successful installation.

Setting IPX Frame Types from the Front Panel


READY TO PRINT


Select button.

2. Press the down-arrow button until Network Settings is highlighted. Press the Select button.

3. Press the down-arrow button until NetWare is highlighted.


4. Press the down-arrow button until IPX Frame Type is highlighted. Press the Select button.

5. Press the down-arrow button until the desired frame type is highlighted. Press the Select button until On is displayed. If desired, you can set more than one frame type.

6. To return the printer to normal operation, press the downarrow button until Exit is highlighted. Press the Select button.

Printer Networking

7-13

Windows

®

95 and Windows

®

98: PhaserPort

™

Software

TCP/IP Configuration for a PC

If you do not already have a TCP/IP address configured for your PC, contact your system administrator to ensure that the configuration is made according to your company guidelines. If there is no TCP/IP network already in place, configure your PC with a unique address such as 192.1.1.1. To check the IP address for your PC, follow these steps:

1. From the Start menu, click Run.

2. Enter: winipcfg

3. Click OK.

4. Choose your network adapter from the pulldown list.

5. The IP address is listed in the IP Address field.

For more information on installing and configuring TCP/IP in

Windows environments, see your Microsoft Windows documentation.

Setting the Printer’s IP Address

NOTE: To avoid any network conflicts, contact your System

Administrator for the appropriate IP Address, Network Mask, and

Router/Gateway Address.

You can set the printer IP address by accessing the printer’s front panel. For more information, see “Setting the Printer’s IP Addressing

Parameters.”

PhaserPort

™

Software Installation

1. Insert the printer’s software CD-ROM into the CD-ROM drive.

2. Double-click on My Computer. Double-click on the CD-ROM

drive icon.

3. Double-click on the folder phsrport.

4. Double-click on the phsrport.exe icon.

5. Click OK to the WinZip Self-Extractor window.

7-14


6. Click Unzip in the WinZip Self-Extractor window (this will copy the program files to your hard drive).

7. Click OK when the files have successfully unzipped.

8. When the Tektronix PhaserPort Setup screen comes up, click Next.

9. When the Tektronix PhaserPort Installation screen comes up, click Next.

10. When the Choose Destination Location screen comes up, click Next.

Create Your First Port

1. When the Add PhaserPort dialog box is displayed, create your first port: a. In the Description field, enter a name for the port (this can be the printer name/model, location, or any other descriptive name of your choice), such as SIJ100.

b.

Use the Tab key to move to the DNS Name/Address field.

c.

In the DNS Name/Address field, enter the printer’s IP address (for example, 192.1.1.2). Click OK.

NOTE: The printer must be on the network and powered on for

PhaserPort software to detect it and complete installation.

NOTE: If you do not know the printer’s IP address, contact your system administrator.

2. At the Finish Installation screen, click Next.

The installer will automatically run the Add Printer Wizard, which allows you to install the driver for the Solid Inkjet 100.

The drivers are located on your printer’s CD-ROM.

• If you have not already installed the printer driver, go to

“Install the Driver” following this section.

• If you have already installed the printer driver, click

Cancel at the Finish Installation screen. Then go to

Adding a port to an existing printer.

Printer Networking

7-15

Install the Driver

1. In the Add Printer Wizard, click Next. Choose Local

printer, the click Next.

2. The Manufacturers and Printers dialog box is displayed.

Click Have Disk.

3. From the Install From Disk dialog box, type: d:\

(where d is the CD-ROM drive). Click OK.

4. Select the Sterling iiLINX Solid Inkjet 100. Click Next.

5. If prompted that a driver is already installed for this printer, select Keep existing driver (recommended). Click Next.

6. In the Available ports list, select the port you created during the first part of the installation (PhaserPortv2.1.0.0). Click

Next.

7. In the Printer name dialog box, give the printer a unique name if another Sterling iiLINX Solid Inkjet 100 is installed

(for example: SIJ100-Network)

8. At the Setup Complete screen, select (Yes, I want to restart

my computer now).

Your computer will now close all applications and perform a restart.

Your driver will now be ready for use.

Adding a Port to an Existing Printer

Use this procedure to add/change a port for a printer when you have already installed the driver.

1. Select your printer driver: a. From the Start menu, select Settings.

b.

From the Settings menu, select Printers.

c.

In the Printers window, right-mouse click your printer driver (iiLINX Solid Inkjet 100).

2. From the pop-up menu, choose Properties.

3. When the properties dialog for the printer is displayed, click

Details.

7-16


4. Highlight PhaserPort and click OK; this displays the Add

PhaserPort dialog.

a. In the Description field, enter a name for the port

(this can be the printer name/model, location, or any other descriptive name of your choice), such as

SIJ100-Network.

b.

In the Name/Address field, enter the IP address of the printer (for example 192.1.1.2), and click OK.

NOTE: If you do not know the printer’s IP address, contact your system administrator.

5. Click OK again to apply the changes; the printer driver is now configured to use your new PhaserPort.

Windows NT

®

The procedures in this chapter is only valid for Windows NT version

4.0 or higher.

Setting the Printer’s IP Address

Set the printer’s IP address by any of the methods described earlier in this chapter in, “Setting the Printer’s IP Addressing Parameters.”

The Windows NT 4.0 PostScript driver is a PPD-based driver. Follow these instructions to add or update the Solid Inkjet 100 PPD file for use with Windows NT 4.x. This update procedure provides printer page-size information for Windows NT applications. These instructions assume a basic familiarity with Windows NT operation and terminology. For additional information about Windows NT, refer to your Microsoft Windows NT documentation.

NOTE: You may need the Windows NT 4.x CD-ROM and your printer’s software CD-ROM to complete this procedure. In order to successfully install the Windows NT Solid Inkjet 100 driver, the Windows NT

Administrator MUST install the Microsoft TCP/IP Printing

Service and the TCP/IP protocol.

Printer Networking

7-17

Creating Network Port Configuration

The Solid Inkjet printers support two types of network ports:

• LPR

• AppleTalk

The following procedure covers LPR ports; for information on

AppleTalk ports, refer to “Creating an AppleTalk Port” following this section.

Creating LPR Printing

Adding an LPR port:

1. Click on Start, Settings, and Printers.

2. In the Printers dialog box, double-click Add Printer.

3. Select My Computer and click Next.

4. If the printer is connected to the network, click Add Port.

5. Double-click LPR Port in the Printer Ports dialog box (if the

LPR Port is not available, contact your Windows NT

Administrator).

6. In the Add LPR compatible printer dialog box, enter the printer’s IP address in the box labeled Name or address of

server providing lpd. In the box labeled Name of printer

or print queue on that server, enter

PS

(in uppercase). Click

OK.

7. When returned to the Printer Ports box, click Close.

8. At the Add Printer Wizard dialog box, click the box next to this new port; a check mark is added. Click Next.

Installing the Printer Driver:

9. In the Add Printer Wizard dialog box, click Have Disk to add a new Solid Inkjet 100.

10. Type the path name to the driver files. This can be: d:\

(or the current location of your CD-ROM drive). Click OK.



If the printer driver does not exist, go to Step 14.


(for example: SIJ100-Network).

7-18


14. Select Not shared, and click Next.

15. If you want to print a Test page, select Yes, and click Finish.

Creating an AppleTalk Port

Adding an AppleTalk Port:

1. Click on Start, Settings, and Printers.

2. In the Printers dialog box, double-click Add Printer.

3. Select My Computer and click Next.

4. If the printer is connected to the network, click Add Port.

5. Double-click AppleTalk Printing Devices in the Printer

Ports dialog box (if the AppleTalk Printing Devices is not available, contact your Windows NT Administrator).

6. Windows will now search for AppleTalk Printers (this may take a few minutes). When your printer appears in the Available

AppleTalk Printing Devices, click on the printer name and click OK.

7. At the prompt, Do you want to capture this AppleTalk

printing device?, click No.

8. When returned to the Printer Ports box, click Close.

9. At the Add Printer Wizard dialog box, click the box next to this new port which will add a check mark. Click Next.

Installing the printer driver:

10. In the Add Printer Wizard dialog box, click Have Disk to add a new Solid Inkjet 100.

11. Type the path name to the driver files. This can be: d:\

(or the current location of your CD-ROM drive). Click OK.



If the printer driver does not exist, go to Step 15.


(for example: SIJ100-AppleTalk).

15. Select Not shared, and click Next.

16. If you want to print a Test page, select Yes, and click Finish.

Printer Networking

7-19

Installing Printer Software

NOTE: For network installation/configuration, see the iiLINX Solid

Inkjet 100 User Manual.

Windows

®

95 Procedure

1. Before you begin, make all physical connections from the PC to the Solid Inkjet 100 to allow the printer to be recognized as a new hardware device.

2. Reboot your PC. The New Hardware Found screen will appear briefly. Click Next.

NOTE: If the New Hardware Found screen does not appear, use the

“Add Printer Procedures Windows 95/98 (Optional Method)” procedure later in this chapter.

3. Insert the CD-ROM containing the Solid Inkjet 100 Printer driver software.

4. Select Driver from disk provided by hardware

manufacturer option. Click OK.

5. The Install from Disk screen will appear. Type: d:\

(or the appropriate drive for your CD-ROM in the copy manufacturers files box). Click OK.

The printer is now installed.

Windows

®

98 Procedure

1. Before you begin, make all physical connections from the PC to the Solid Inkjet 100 to allow the printer to be recognized as a new hardware device


NOTE: If the New Hardware Found screen does not appear, use the procedure in “Add Printer Procedures Windows 95/98 (Optional

Method)” following this section.

3. Insert the CD-ROM containing the Solid Inkjet 100 Printer driver software

7-20


4. Click on Have Disk.


(or the appropriate drive for your CD-ROM in the copy manufacturer’s files box). Click OK.

6. The Sterling iiLINX SIJ 100 will appear. Click Next.

7. Click Next again.

8. Click Finish.

Add Printer Procedure Windows

®

95/98

(Optional Method)

1. From the Windows Start Menu, select Settings, Printers.

2. Double click on Add Printer.

Printer Networking

7-21

3. The Add Printer Wizard screen should appear. Click Next.

4. Select Local printer. Click Next.

5. Insert the device drivers CD-ROM into the CD-ROM drive and select Have Disk.

7-22


6.

The Install from Disk screen will appear. Type: d:\


7. The Sterling iiLINX SIJ 100 Printer selection will appear.

Click Next.

Printer Networking

7-23

8. Click on the port you want to use with the printer. (For local parallel port printing, use LPT1.) Click Next.

9. You can type a name for the printer or use the default name.

You can also select the printer as a default printer if desired.

Click Finish.

7-24


Windows NT

®

4.0 Procedure

1. Before you begin, make all physical connections from the PC to the Solid Inkjet 100 to allow the printer to be recognized as a new hardware device.


NOTE: If the New Hardware Found screen does not appear, use the procedures in “Add Printer Procedures (Optional Method)” following this section.

3. Insert the CD-ROM containing the Solid Inkjet 100 Printer driver software.

4. Select Driver from disk provided by hardware

manufacturer option. Click OK.

5. The Install from disk screen will appear. Type: d:\

(or the appropriate drive for your CD-ROM in the copy manufacturers files box). Click OK.

The printer is now installed.

Add Printer Procedure (Optional Method)

1. From the Windows Start Menu, Select Settings, Printers.

2. Double-click on Add Printer.

3. The Add Printer Wizard screen will appear. Select My

Computer and click Next.

Printer Networking

7-25

4. Select the box labeled LPT1 (local port) and click Next.

5. Insert the device drivers CD-ROM into the CD-ROM drive and select Have Disk.

7-26




7. Highlight the Sterling iiLINX SIJ100 printer selection, click

Next.

Printer Networking

7-27

8. Type in the name of the printer, then click Next.

9. Select Not Shared, then click Next.

7-28


10. Click Finish. The Printer should now be installed. You can print a test page for verification.

Printer Networking

7-29

Macintosh

®

Software

Install

1. Insert the printer’s CD-ROM.

2. Double-click on the installer and follow the online instructions.

Set Up the Driver

1. From the Apple menu, select Chooser.

2. Click the icon of the printer driver (LaserWriter 8) on the left side of the window.

3. Click the Zone for your printer, if applicable.

4. From the list of printers on the right side of the window, select your printer. If it is not in the list, check the hardware connections and verify that you have selected the correct zone in the Chooser on the left side of the window.

5. Click Setup/Create to select the correct PostScript Printer

Description (PPD) file.

6. After the automatic setup has completed, click Setup and click

Configure.

7. Select the options that are installed in your printer (for example, memory configuration, Auxiliary Feeder, or internal hard drive); this information can be found on the Startup page.

Setting up the driver allows you to select all printer options when printing.

8. Click OK.

9. Close the Chooser.

7-30


Enabling EtherTalk

The EtherTalk network protocol is enabled from the front panel as follows:

1. Allow the printer to warm up to its idle, “Ready to Print” state.

2. Scroll to the selection Menu and press the Select button.

3. Scroll to the selection Network Settings and press the Select button.

4. Scroll to the toggle item Ethertalk. The current setting (On or

Off) is displayed to the right.

5. Press the Select button to toggle the current setting for

EtherTalk. The display will reflect the new setting.

Printer Networking

7-31

7-32


Appendix

Material Number Listings

A-1

Appendix A

Material Number Listings

Illustrated Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-22

Supplies and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-23

A-2


Illustrated Parts Catalog

This section provides parts listings and exploded view illustrations of field-replaceable units for the Solid Inkjet 100 Printer.


A-3

Table A-1. Cabinet parts

5

6

3

4

7

8

1

2

Item

Number

Part Number Serial Number

Effective/ Discontinued

200-4366-00

200-4257-00

214-4814-00

650-4039-00

200-4365-00

200-4495-00

200-4367-00

200-4377-00

Qty

1

1

1

1

1

1

1

1

Name and Description

Right cover

Front cover, jam access door

Hinge, Front cover pivot

Front cover, control panel

Left cover

Exit cover

Top cover with inkload door

Rear cover

A-4


4

5

6

7

3

2

Figure A-1 Cabinet parts

8

1

0388-21


A-5

12

13

14

15

7

8

9

10

11

Table A-2. Imaging Parts

5

6

3

4

1

2

Item

Number



650-4027-00

214-4651-01

351-1051-01

436-0389-00

351-1053-00

650-3617-00

650-3617-00

441-2137-03

650-4049-00

174-3807-00

650-4050-00

166-0714-00

147-0079-00

166-0713-00

650-3615-00

Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

16

17

650-3619-00

650-3615-00

18 134-0265-00

19 378-0387-00

Not Shown 200-4379-01

1

1

1

1

1


Y-axis pulley assembly

Drum maintenance actuators, left and right

Maintenance drawer guide, left

Maintenance drawer

Maintenance drawer guide, right

Spring, transfix actuation.

Part of 650-3617-00 Drum/Transfix Assy

Drum/transfix assembly

Cap/wipe/purge assembly

Printhead kit

Cable, printhead data

Ink loader

Vacuum hose, rubber

Vacuum/pump assembly

Vacuum hose, rigid

Head maintenance drive belt.

Part of 650-3615-00 Belt Kit

Pulley, head maintenance drive.

Part of 650-3619-00 Gear Kit

Head maintenance timing belt and ratchet clips.


Plug, Maintenance drawer life counter

Purge Filter

Cover heat plate, printhead thermal duct

A-6


7

8

9

10

11

14

12

19

13

5

6

2

4

3

2

1

Figure A-2. Imaging Parts

17

16

15

18

0388-18


A-7

8

9

10

11

12

13

Table A-3. Paper Path Parts

5

6

3

4

7

1

2

Item

Number



351-1045-00

351-1032-00

351-1046-00

401-0778-01

401-0813-01

650-3978-00

351-1047-00

351-1048-00

351-1035-00

401-0841-00

650-4026-00

386-7018-00

401-0781-01

351-1016-00

Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1


Guide, media tray, right

Guide, pick assembly

Guide, media tray, left

Lower feed roller

Paper pick roller

Drum/preheater assembly

Upper feed assy, top half, with circuit bd

Upper feed assembly, lower half

Duplex paper guide

Duplex roller

Upper stripper finger assembly

Lower stripper finger assembly

Exit roller

Guide, lower exit, pivoting

A-8


9

10

12

11

8

7

13

6

4

5

3

2

1

Figure A-3. Paper Path Parts

0388-16


A-9

Table A-4 Motor and fan parts

4

5

2

3

6

7

Item

Number

1


Effective /Discontinued

147-0086-00

650-3621-00

119-5876-00

147-0180-01

147-0082-00

147-0108-01

119-5781-00

Qty

1

1

1

1

1

1

1


X-axis motor with gear

X-axis drive assembly (see 650-3621 below)

Drum fan

Paper path motor

Y-axis motor

Process motor, with encoder

Main fan

Part Number Sub-Part Number

(Not available individually)

Qty

650-3621 004-3879

334-7987-01

401-0828-00

401-0829-00

401-4598-00

1

1

1

1

1

X-Axis Mechanical Kit

Shipping box

Tektronix white label

Internal thread gear

Nose cone gear

Span yoke

A-10


7

6

5

Figure A-4. Motor and Fan Parts

4

3

2

1

0388-14


A-11

10

11

12

13

8

9

6

7

Table A-5. Circuit Board Parts

3

4

1

2

Item

Number

5



671-4194-50

671-4195-50

386-6997-00

671-3994-01

386-6998-01

671-4892-00

671-4893-00

671-4894-00

671-4895-00

671-4896-00

671-4902-00

650-3886-01

650-4070-80

156-4691-00

650-4024-01

386-7074-00

163-1217-00

131-1641-00

650-4029-01

Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1


I/O board, right

I/O board, left

Blank cover plate (hard drive)

Optional Ethernet interface card

Blank cover plate (interface card)

Flash ROM DIMM, English

Flash ROM DIMM, Japanese Morisawa

Flash ROM DIMM, Chinese Traditional

Flash ROM DIMM, Chinese Simplified

Flash ROM DIMM, Korean Hangul

Flash ROM DIMM, Japanese Heisei

64-Mbyte RAM DIMM

Main board, Power PC w/o memory

Dallas Real Time Clock/NVRAM Module

Power supply

Blank cover plate (SCSI riser board)

Boot ROM/Printer ID

Jumper, +40 volt isolation

Power control board

A-12


2

7

6

8

9

5

3

4

10

11

12

13

1

0388-13

Figure A-5. Circuit Board Parts


A-13

4

5

2

3

Table A-6. Solenoid and Clutch Parts

Item

Number

1



401-0792-00

401-0808-00

401-0807-00

401-0792-00

148-0301-01

1

1

1

1

Qty

1


Electric clutch, upper feed roller, exit roller, printhead maintenance

Electric clutch, pick roller

Electric clutch, drum maintenance

Electric clutch, cap/wipe/purge drive

Solenoid, transfix assembly

A-14


4

5

3

2

1

Figure A-6. Solenoid and Clutch Parts

0388-23


A-15

650-3619-00

650-3615-00

650-3619-00

650-3615-00

650-3619-00

650-3619-00

650-3619-00

650-3619-00

650-3619-00

650-3619-00

650-3627-00

650-3615-00

650-3615-00

650-3619-00

650-3615-00

650-3619-00

650-3619-00

351-1015-00

650-3615-00

17

18

19

20

14

15

16

12

13

10

11

7

8

9

5

6

2

3

4

Table A-7. Gear and Belt Parts

Item

Number

1



650-3619-00

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Qty

1

1

1

1

1

1


Pulley, lower paper transport.


Paper feed roller drive belt.


Tensioner, process belt.


Lower process, gear/pulley


Process drive belt.


Roller, flat, head maintenance


Head tilt cam gear.


Guide, head tilt

Head maintenance timing belt and ratchet clip.


Pulley, drive, head maintenance


Exit roller drive belt.


Pulley, exit drive.


Tensioner, exit drive belt.


Transfix gear, eccentric


Gear, compound eccentric, flagged


Duplex roller, gear pulley.


Paper path, idler 1

Part of 650-3619-00 Gear kit

Paper path, idler 2


Gear/pulley, upper feed roller, preheat entry


Head Tilt Assembly

A-16


20

9

7

8

10

11

12

13

14

15

6

5

4

3

16

18

17

19

2

1

0388-22a

Figure A-7. Gear and Belt Parts


A-17

13

14

15

8

9

10

11

12

16

17

18

19

2

3

4

5

6

7

Table A-8. Sensor and Flag Parts

Item

Number

1



650-3618-00

650-3618-00

386-6902-00

650-3618-00

650-3618-00

650-3618-00

351-1047-00

Qty

1

1

1

1

1

1

119-5803-00

119-4968-00

650-3622-00

650-3618-00

119-5800-00

650-4039-00

650-4039-00

119-5800-00

119-5795-01

119-5802-00

119-5802-00

200-4495-00

1

1

1

1

1

1

1

1

1

1

1

1


Cap/wipe/purge home flag.

Part of 650-3618-00 Flag Kit

Drum maintenance cam home flag.


Media tray sense flag assembly

Paper out sensor flag.


Paper pick flag.


Handfeed sensor flag, inside front access cover.


Preheat entry/right edge sensor, A-size sensor, handfeed sensor. Part of 351-1047-00 upper feeder roller assembly.

Preheater exit sensor assembly

Process gear sensor

Y-axis encoder kit (see 650-3622 below).

Transfix exit sensor flag. Part of 650-3618-00 Flag Kit and

351-1016-00 Pivoting Low Exit Guide.

Front cover open sensor.

Part of 650-4039-00 Front Cover, Control Panel.

Duplex paper sensor flag


Duplex paper sensor.


Exit cover open sensor.


Drum temperature sensor assembly

Transfix exit sensor. Part of 119-5802-00

Paper Path Sensor assembly

Paper exit/tray full sensor. Part of 119-5802-00

Paper Path Sensor assembly

Paper exit/tray full flag.

Part of 200-4495-00 Exit Cover assembly.



Qty

650-3622-00 004-4634-00

105-1078-00

119-5804-00

200-4254-00

213-1091-00

213-1124-00

214-4645-00

214-4587-00

401-0720-00

401-0736-00

311-2506-00

334-7987-01

407-4315091

2

1

1

1

1

1

1

1

1

1

1

1

2

Y-Axis Encoder Kit

Tuck mailer

Encoder connector retainer

Y-axis home sensor

Y-axis position cover

2-28 x .625 screw

4-20 x .375 T-10 screw

Rotational encoder assembly

Y-axis encoder disk

Y-axis encoder hub

Y-axis retainer hub

Y-axis encoder

Tektronix white label

Encoder bracket

A-18


14

13

10

12

11

16

15

17

18

19

9

8

1

2

7

6

5

4

3

0388-15

Figure A-8. Sensor and Flag Parts


A-19

Service Tools

Table A-9 Service tools



003-1489-00

003-1500-00

006-7997-00

012-1535-00

012-1543-00

003-1707-00

003-1749-00

003-1733-00

003-3209-00

003-1503-00

003-1504-00

003-0814-00

003-0966-00

003-0866-00

003-1462-01

003-1377-00

131-6819-00

Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1


Y-axis encoder disk spacer tool

Y-axis belt tensioner

Grease, Rheolube 768

Cable, Diagnostics,PC, DB-9F to DB25M

Cable, adapter, diagnostics

+40 volt service plug and jumper

Head-to-drum calibration tool kit

Head-to-drum spacer replacements

Service diagnostics diskette, SW v 8.24

Printhead removal tool

Printhead resevoir plug set

T10 Torx Bit

T15 Torx Bit

T20 Torx Bit

T-25 Tork Bit

Vacuum Gauge

Vacuum “T” Fitting

A-20


Parts Kits

Table A-10. Parts Kits



650-3615-00

650-3616-00

650-3618-00

650-3619-00

650-3620-00

Qty

1

1

1

1

1



Qty

650-3615-00 004-4386-00

214-4811-00

214-4812-00

214-4815-00

214-4826-00

344-0540-00

344-0541-00

401-0727-00

407-4501-00

407-4547-01

1

1

2

1

1

1

1

1

1

1



Qty

650-3616-00 004-4386-00

174-3803-01

174-3804-00

174-3805-00

174-3808-01

174-3809-00

174-3810-00

174-3811-00

1

1

1

1

1

1

1

1



Qty

650-3618-00 004-4386-00

105-1066-02

386-6681-00

386-7020-00

386-7028-00

386-7037-00

386-7081-00

1

1

1

1

1

1

1


Solid Inkjet 100 Belt Kit

Solid Inkjet 100 Cable Kit

Solid Inkjet 100 Flag Kit

Solid Inkjet 100 Gear/Pulleyt Kit

Solid Inkjet 100 Hardware Kit

Belt Kit

Shipping Box

Exit Drive Belt

Simplex Transport Belt

Lower Process Belt

Drive Belt

Base Belt Clip

Ratchet Belt Clip

Idler Pulley

Exit Belt Tensioner

Process Belt Tensioner

Cable Kit

Shipping Box

Heater Cable

I/O Left Cable

I/O Right Cable

Left Umbilical Cable

Right Umbilical Cable

Vacuum Module Cable

Y-Axis Pos. Encoder Cable

Flag Kit

Shipping Box

Latch Flag (C/W/P Home Flag)

Paper Out Flag

Paper Pick Flag

Sensor Strip Flag

Handfeed Entrance Flag

DM Home Flag


A-21

Table A-10. Parts Kits (continued)



Qty

650-3619-00004-3879-00

334-7987-01

401-0715-00

401-0727-00

401-0728-00

401-0795-00

401-0796-00

401-0797-00

401-0798-01

401-0799-00

401-0800-00

401-0801-00

401-0803-00

401-0805-00

401-0806-00

401-0810-00

401-0812-00

401-0818-00

401-0819-00

401-0839-00

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1



Qty

650-3620-00 004-4386-00

210-1509-00

211-0409-01

212-0195-00

212-0199-01

212-0206-00

212-0207-00

212-0209-00

212-0219-00

212-0221-00

213-0906-01

213-1075-00

213-1096-00

213-1109-00

213-1111-00

213-1115-00

213-1118-00

213-1119-00

354-0737-00

354-0738-00

354-0756-00

358-0791-00

358-0823-00

358-0824-00

5

5

5

5

5

5

5

5

5

5

5

5

5

5

5

5

5

5

3

5

5

1

5

5

Flag Kit

Shipping Box

White Tektronix Label

Eccentric Shaft Compound Gear

Idler Pulley

Drive Shaft Pulley

Preheat Entry Gear/Pulley

Idler #1 Paper Path Gear

Idler #2 Paper Path Gear

Duplex Roller Gear

Duplex Roller Gear/Pulley

Exit Drive Pulley

Lower Transport Pulley

Preheat Entry Roller Gear

HM Drive Pulley

DM Cam

Cap Drive Pulley

Flat Roller

Lower Process Gear/Pulley

Head Tilt Cam

Eccentric Shaft Gear

Hardware Kit

Shipping Box

Washer, 0.5 x 0.204

Screw with washer, 4-40 x .312

M4-7 x 12mm screw

Shoulder bolt, 8-32 x .687

8-32 x 1.00 T-20 Taptite

8-18 x .75 T-20 Torx

8-32 x .375 Torx

8-32 x .75 screw

10-32 x 5/8 x .060 captive washer

8-32 x .375 screw

10-32 x .5, T-25 screw

8-32 x .5 torx screw

6-32 x .375 T-15 torx screw

6-32 x 1.25 T-15 screw

8-16 x .5 torx screw

4-40 x 5/16 slotted combo torx

6-32 x 5/16 slotted combo torx

.125 e-ring

5mm e-ring

M6, 5mm bent e-ring bushing exit roller bushing preheat entry roller bushing

A-22


Supplies and Accessories

Table A-11. Supplies and Accessories



FSD10695

FSD10393

348-1572-00

FS016-1752-00

436-0370-00

013-0299-00

650-1200-01

650-1155-01

650-1170-01

650-1190-01

650-1180-01

650-1160-01

161-0305-00

065-0586-00

Qty

1

1

1

1

1

1

1

1

1

1

1

1

1

1


Solid Inkjet 100 Cleaning Kit

Solid Inkjet Swabs/Pads (10)

Separator pad, paper

Maintenance cartridge kit; roller and counter

Waste ink tray

Parallel cable adapter, 1284C to 1284B

Drivers and Utilities, CD, English

Drivers and Utilities, CD, European Languages

Drivers and Utilities, CD, Japanese

Drivers and Utilities, CD, Simplified Chinese

Drivers and Utilities, CD, Traditional Chinese

Drivers and Utilities, Diskettes, Korean

Power cord, Standard U.S., 115V

Shipping carton kit


A-23

A-24


Xerox Solid Inkjet 100 Solid Inkjet Printer Service Manual

Assistant Bot

Chapter 1

General Information

General Information

Solid Inkjet 100 Printer Overview

Base Solid Inkjet 100 printer

Solid inks

Memory Considerations

Print Engine Assemblies

The Main Board

Media Tray Type Sensing

Front Panel

Rear Panel

Connectors

Health LEDs

Switches

Bypass Mode (Manufacturing Mode)

Cool Down Mode

Preparation for Moving the Solid Inkjet 100 Printer and

Accessories

Overview

Turning off the Printer

Removing the Maintenance Drawer

Disconnecting the Cables

Repacking the Printer and its Accessories

Repacking the Auxiliary Feeder Unit

Configuration Page

Printing the Configuration Page

Specifications

Physical Dimensions

Functional Specifications

Electrical specifications

Environmental specifications

Theory of Operation

Functional Block Diagram

Drum/Transfix Assembly

Maintenance Drawer

Printhead

X-axis Movement

Printhead Tilting Mechanism

Ink Loader

Cap/Wipe/Purge Assembly

Power Supply

Print Process in Operation

Printhead Tilt

Drum Preparation

Printing

Paper Pick

Transfixing, Stripping And Exiting

Printer Self-Maintenance

Printhead Maintenance Cycle

Paper Preheater Cleaning

Transfix Roller Oiling

Drum Cleaning (Chase Page)

Power Control Board

Main Board

Optional Ethernet Interface Card (100 Base T)

Optional Internal Disk Drive

Chapter 2

Error Codes and Messages

Rear Panel LEDs Error Codes

Service Required Error Codes

Front Panel Status Messages

Chapter 3

Troubleshooting

System Power-up Sequence

Verifying Main Board CPU Operation

Verifying Print Engine Operation By Printing

Its Startup Page

Verifying Power Supply Operation

Measuring Power Supply Voltages

Inspecting The Power Supply Fuses

Testing for Shorted Drivers

Testing For A Shorted Motor

Testing Motor And Solenoid Resistances

Printhead Troubleshooting

Media Jams And The Paper Path

Media-Based Problems

Paper-Pick Errors