Professional Documents
Culture Documents
NOTE: All button and video links shown in this manual are not active please proceed to the Service Guide Presentation for interactive functions.
1) Ink Refill Bottles 2) Intermediate Reservoir 3) Carriage Assembly 4) Cartridge/Printhead 5) Active Service Station 6) Rapid Drying System 7) Auto Clean Unit 8) Media Support System 9) Operator Control Panel 10) Pinch Roller Drive
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Intermediate Reservoir
- Intermediate reservoir at reservoir base - provides consistent ink supply pressure - Replace ink on-the-fly - Prevents job interruptions (52 ml capacity) - Ink level LOW warning sensor (30 minutes) - Ink level OUT stop, protects cartridge
Cartridge/Printhead
- Increased productivity with 640 nozzle printheads - Improved quality with 30% smaller drop size - Clean hands shipping and installation - Foam filled, eliminate tubing and needles - 2100 ml average life; 2800 ml shutoff
1) Door Magnet 2) Suction motor (for priming ink lines) 3) Bottle full sensor 4) Ink Receptacle (bottle)
1) Color selection valve 2) Station Motor
- The heated nose quickly warms the media up with 3 electrical heating strips that provide even heat flow - The forced air plenum is used to remove moisture and heat from media surface to allow faster drying - 12 dryer modes are available for a wide range of media types; air plenum can operate on or off. Ink dries 30% faster than hot air drying systems. May be rotated down for maintenance purposes; may be removed for certain Bond media. System uses 25% less energy over other drying systems.
- Four media supply modes are available: Sheet, Roll, Roll 2 and TakeUp - Media rolls can be easily exchanged with the removable media spindles. The Autoload paper sensor has a 6 second delay when media is manually loaded at rear of printer. The lower roller and pinch rollers control paper travel. The Roll 2 mode allows for a second roll of media to be loaded onto the lower roller (no takeup available). Note: 20,000 volt minimum protection is provided by 2 permanent rear electrostatic discharge strips located in platen.
Ink Kit Configurations - Ink Refill Bottle (700 ml) - Ink and Cartridge Kit (700 ml)
Load Media
Install Ink Install Ink Cartridges Print Test Patterns Open Jet Compensation
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WARNING: Printer head and packaging weigh up to 374 lbs (170 kilograms); only perform heavy lifts with two (2) or four (4) people as referenced by respective step. Also see video procedures. Approximately 3 x 4 square meters of space will be required for setup.
Note: A total of three boxes should be at installation site: printer head (on pallet), stand box (contains Takeup System and Auto Clean Unit), and Ink Accessory Box. NOTE: If printer was in cold storage (below freezing) then allow 24 hours for printer to acclimate to new environment prior to assembling.
Using two (2) people minimum, lift each printer end onto the foam supports. NOTE: the protective metal shipping brackets must not be touching floor surface. Verify the printers air plenum is facing up (rear side of printer facing down).
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Remove right lower shipping bracket (4 screws) and upper shipping bracket.
Remove left lower shipping bracket (4 screws) and upper shipping bracket. Set brackets to one side.
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4) Remove tape from securing screws. 5) Pitch unit to the right and secure over the 4 screws; tighten securing screws.
Using a four (4) person lift, grasp base of left and right bottom covers, rear side/edge of top cover; lift printer to standing position.
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Caution: For regions which experience intermittent voltage fluctuations a line conditioner and surge protector are suggested to help protect the printers power supply.
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Verify media is sized correctly by selecting Utility Menu - Display Settings. Verify correct paper width is displayed. Adjust media guides to within two millimeters of media edges. Note: do not allow media guides to touch media or paper feed drag/banding may be encountered.
Note: media may also be manually loaded by selecting Feed Media Menu - Forward. Advance media until media is observed across the printing surface. Select Load Media at control panel to load.
Install Media Edge Holders (magnetic) onto Y-Arm side - the holders prevent media edges from lifting during low humidity conditions. Install left and right paper guides over media edges - the guides will help media move through the air plenum.
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Note: Wait 5 minutes prior to performing line fill (must allow enough time for the intermediate reservoirs to fill properly)
Obtain the 6 new ink bottles remove the shipping caps from bottles. Open the left cover and install all 6 bottles. Ensure bottle fittings mate properly with each intermediate reservoir fitting.
Lower air plenum and access cartridges (select Utility Menu - Access Cartridge). Obtain the Cartridge with Tube Assembly (and plug bar) from printer Accessory Box. Connect Cartridge with Tube Assembly needle to septum fitting located on right side plate (lift front access door). Install plug bar into service station if a yellow label is present at right front corner. Attach line fill cartridge into the light Magenta stall.
The Cartridge with Tube Assembly (and plug bar) is a setup tool for filling ink lines and may be used to help eliminate air bubbles from an ink line. Caution: do not use for a complete flushing of ink lines unless a red star is present on auto clean door or possible damage may result to auto clean motor/pump; a Flush Kit will be required (P/N 222351-00 or 221984-01).
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Step 3. Slide cartridge into cartridge stall and close cartridge door. Door must be closed to properly bias cartridge position.
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Verify solid rectangular print swaths are printed for each color with no visible ink starvation.
Verify printhead nozzle performance - ensure diagonal lines are smooth and clogged jets are not present.
Use this print to evaluate printer calibrations and general color output.
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To perform manual jet bypass select Utility Menu - Calibration Menu - Open Jet Menu - Edit List Menu. After inspecting the Prime pattern, select appropriate color and toggle respective jet (s) off.
Obtain User CD from Printer packaging and install CD onto Server/RIP workstation. After CD executes, load SOFTWARE UTILITIES (follow typical installation) and PRINTER SETUP (driver/networking portion). For more information refer to Software Control on this CD.
Note: For NT systems enter MAC address with colons: i.e. 00:C0:EB:04:76:07 Step 2. Verify IP address download was successful by verifying IP address at Printers Network menu. Step 3. Ping IP address to ensure connection is valid. At the Command/DOS prompt enter: ping IPaddress (i.e. ping 192.168.100.104). Verify 4 REPLY returns are displayed. Step 4. Set this IP address within RIP/Driver.
Select the Typical installation for a first or single computer installation. For a second computer, select Advanced and install only the client portion of the software.
Note: Individual utilities may be installed if configuring onto a remote Client system only.
There are two types of installations. Complete the Server installation for a single computer or server. Complete the Client printer installation for a second and all sub-computer installations.
Software / Utilities Setup of the Client User Interface and 5 other packages.
Calibration Menu
Note 2: DO NOT use the PAPER CALIB TEST as results may vary.
d. Activate the Deadband Test to verify printer calibrations, select Utility Menu - Service Menu - Calibration Menu - Deadband Test. This will check the electrical and mechanical calibrations. All 6 colors should line up vertically across the entire print. At both ends, check the next to last line.
A line pattern will be printed in the center of the media; the pattern extends approximately 33 inches or 838.2 mm. Accuracy tolerance is +/- 0.2% over image length.
d. Perform Deadband Calibration, Color Calibration Vertical and Horizontal (see following pages).
Choose number which best represents alignment between both colors for each field.
A series of patterns will print: 1) Color Test; ink system pressure test, also used to help unclog print head nozzles 2) Prime pattern; test to check all 640 print head nozzles 3) PData patterns; Image data ports. Pdata 1 governs nozzles 1-320. Pdata 2 governs nozzles 321640. 4) Fire patterns; Fire 1 and Fire 2 provide pulses. They are sampled to fire nozzles. 5) PWR1 through 8 patterns; indicates power lines. Each power line governs 2 primitives of nozzles. 6) A1 through A5 patterns; indicates address lines.
Scroll to appropriate jet and toggle the jet off. Compensated jets will appear as 80 percent filled blocks the next time the Prime pattern is printed.
Note: paper will be automatically advanced following a 6 second delay and then measured.
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Note: air plenum may be lowered to maintenance position by removing 2 locking pins and gently lowering plenum. Place in up postion for all printer operations.
12 dryer modes are available; refer to dryer matrix label affixed to printer top cover.
Environmental Factors
These problems can be avoided by maintaining proper temperature and humidity levels (RH). The use of humidifiers will add more water to the air, resulting in a humidity level increase. This will help prevent heating season problems caused by dry air.
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The Prime pattern checks the electrical firing capability of all 640 jets for all six colors. Verify all cartridge nozzles are firing properly. If necessary perform open jet bypass, select Utility Menu - Calibration Menu - Open Jet Menu - Edit Jet List. Toggle misfiring or clogged jets off; select Ok to save changes. Refer to Technical Bulletin 6 for print and lamination guidelines.
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Note: if replacing a reservoir bottle during print operations, a print shutdown error will occur if bottle is not replaced within 30 seconds. The identification chip on reservoir must firmly make contact with intermediate reservoir sensor contacts. Check reservoir information: Utility Menu - Service Menu Bottle Status.
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Caution: do not install/remove cartridges through the service station access door or damage to print heads or service station may result.
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NOTE: Use the printers control panel to check the plot hours. Select UTILITY MENUDISPLAY SETTINGS. The plot time will be displayed at the bottom of the screen.
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Step 3. Activate the Vacuum Prime Function one time only. Select UTILITY MENU-PRIME MENU-SERVICE STATION MENU-VACUUM PRIME. Select cartridge stall to prime. Step 4. Activate the Prime Pattern to verify jet performance. Select UTILITY MENU-PRIME MENU-PRIME SINGLE. Select appropriate cartridge stall to check.
Step 5. To perform manual cleaning, remove cartridge from the carriage assembly. Dampen a lint-free cloth with NovaKlean solution or isopropyl alcohol; clean all ink residues away by wiping cartridge bottom edges. Blot the jet plate surface thoroughly and wipe the cartridges rear electrical contacts. Clean flex driver cable to prevent ink residue transfer. Note: Verify surfaces are dry prior to reinstalling cartridge.
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To clean the encoder strip first remove power from printer. Dampen an industrial cotton swab with NovaKlean solution, clean the top and bottom surfaces of the entire length of the encoder strip. Several cotton swabs may be necessary to completely clean the encoder strip. Perform a second cleaning using isopropyl alcohol. To clean the encoder sensor use Windex solution (obtain Domestic Cleaning Kit P/N P/N 220970; International customers order Cleaning Kit P/N 221191) and spray directly onto sensor (behind Magenta stall). Clean area with canned air and lint-free towels.
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Apply NovaKlean solution to a lint-free towel and wipe the entire surface area of the slide shaft including the service station area. Perform a second cleaning using isopropyl alcohol.
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Step 2. Remove the Ink Delivery System Carriage Cover support brackets by removing 4 securing screws.
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Step 5. Remove both Carriage Bushings by prying away from carriage and sliding off of slide shaft.
Ink Type, Color and Ink Volume/Throughput will be displayed. Warranted ink throughput varies from region to region (i.e. Typically less than 700 ml ink throughput and 3-pass print mode is no longer supported).
Step 2. Open respective cartridge door by pulling out, and then up. Remove cartridge by pulling straight out.
Step 5. Select Access Cartridge to return carriage to home position. Refer to Service Bulletin 7 if cartridge/bottle errors occur. Refer to Troubleshooting for all other problems.
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The Prime pattern checks the electrical firing capability of all 640 jets. Verify all cartridge nozzles are firing properly.
If cartridges are striking the media cease printer operations immediately. Only operate printer with suggested dryer setting, media types and at suggested humidity ranges. Refer to Technical Bulletin 6 for detailed print and lamination guidelines. Verify Media Edge Holders, Paper Guides, and Media Edge Guides are positioned properly. Refer to Troubleshooting or contact technical support.
Step 2. Attach Flush system components according to instructions (either use the EasyPrime with Cartridge with Tube Assembly or Cartridge with Tube Assembly/Plug Bar). Attach needle end to the right side plate septum fitting. Activate the Pump On (Utility Menu - Prime Menu - Service Station Menu - Pump On) on the keypad display until all ink is evacuated from ink line. Repeat for each stall position. Step 3. Place distilled water into Flush Reservoirs. Install into each reservoir position for 5 minutes (each intermediate reservoir should fill with water). Remove Flush Reservoir. Activate the Pump On button on the keypad display until all ink is evacuated from ink line. Step 4. Remove disposal bottle and dispose of ink/water waste in accordance with regional regulations. Flush water from all ink lines using above procedure.
Step 5. Install the New Ink Reservoirs and Cartridges. Activate the Line Fill procedure for each color until ink line is full. Remove Line Fill Cartridges. Install new cartridges and perform necessary printer readiness checks and calibrations prior to print operations.
Step 2. Determine firmware level prior to downloading new firmware. Firmware level is indicated by the Vers. (version) line.
Software Required: -Software Control Panel provided on CD with printer - EFPU (Encad File Print Utility)
Step 4. Download Firmware - Within EFPU program, highlight firmware file (.ROM file) and select Print. - Printer should emit a single audible beep after approximatly 60 seconds.
Step 5. Verify Download was successful. Cycle power to printer. - Check the About screen for current firmware revision
Step 3. Verify Download was successful. Cycle power to printer. - Check the About screen for current firmware version
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ATTENTION: sample test prints (or digital photographs) mailed to technical support should contain arrows/marks indicating the problem area, media travel direction, print pass mode used, and printer firmware level. Include the Prime pattern and Color Test (6 pass mode).
Note: typically up to 30 jets can be electrically damaged and/or compensated before the Productivity mode (3-pass) support is no longer supported (indicated by a hyphen). Clean cartridges manually if necessary; ensure the bottom surfaces, jet plate, rear electrical contacts, and flex driver cable surfaces are thoroughly cleaned. For severe jet failures (i.e. more than 160), with a new cartridge, replace respective flex driver cable.
A series of patterns will print: 1) Color Test; ink system pressure test, also used to help unclog print head nozzles 2) Prime pattern; test to check all 640 print head nozzles 3) PData patterns; Image data ports. Pdata 1 governs nozzles 1-320. Pdata 2 governs nozzles 321-640. 4) Fire patterns; Fire 1 and Fire 2 provide pulses. They are sampled to fire nozzles. 5) PWR1 through 8 patterns; indicates power lines. Each power line governs 2 primitives of nozzles. 6) A1 through A5 patterns; indicates address lines.
Probable Cause: 1. Out of paper/Misfeed; Feed sensor alignment is incorrect. 2. Cyan ink reservoir is low or out of ink (Refer to Service Bulletin 7) 3. Auto Clean Unit ink bottle is full (or missing). 4. No error, just a friendly reminder to operator. 5. Service station failure - service station upgrade required. 6. Cartridge/Printhead life has been terminated. A new printhead must be installed. 7. Nose heater is not completely heated, pressing Ok will bypass wait period. 8. Incompatible ethernet switch being used. Ethernet: 100FD is the normal indication.
Note: Printer Operations/User Guide documentation should be consulted for any other operational problems encountered.
Probable Cause: 1. Damaged carriage paper sensor (refer to Service Bulletin 7). 2. Damaged auto-load paper sensor (refer to SB7). 3. Damaged encoder sensor (refer to SB7). 4. Damaged main PWA (refer to SB7/contact technical support). 5. Damaged carriage paper sensor (refer to SB7). 6. Incorrect voltage switch position (115 vs. 230). Dryer circuitry damaged (refer to SB7 and SB6) 7. Improper connections. Damaged control panel display or power supply. 8. Loose or damaged trailing cable connection (refer to SB7). 9. Damaged memory module. 10. Damaged carriage PWA. 11. Damaged main PWA.
Note: dirty print heads or dirty cable surfaces can also cause cartridge misfires. Thoroughly clean the printer, refer to Maintenance. Replace cartridge if severe banding persists.
Note: low pass print modes such as 2, 3, 4, or 6 may exhibit microbanding with high ink saturation levels or with light/solid color spaces. Increasing print pass mode to 6 or 8-pass gradually eliminates the banding. Verify proper dryer settings and media compatibility.
Verify humidity levels are within specification (20 to 70 percent RH; 45 to 55 percent RH is optimum) and check the media compatibility list (i.e. some 3rd party vinyl media has been known to leave glue on supply roller/lower rollers causing banding). Proper operating temperature levels should also be adhered to for best results (59 - 85 degrees F; 15 30 degrees C). Verify paper edge guides/magnetic media holders are installed.
If low absorption media (i.e. bond) is primarily used by customer verify paper guides are in place (OEM4 customers should verify plastic guide is not interfering with carriage). NOTE: the carriage head height may need to be raised (i.e. from 65/1000 to 85/1000 inches) for some bond/textile applications. Refer to Mechanical Alignments. NOTE: The service station may need to be shimmed to correspond with any significant head height changes (i.e. over 85/1000).
5. If severe horizontal bands appear every 1.25 or every 8.0 inches down the print then the lower drive system is the likely cause. Check center support bracket alignment and orientation. Refer to Service Bulletin 4 and 17. Verify ESD protection. Replace the lower drive system, center support bracket and shaft/bearing assembly.
6. If micro banding cannot be corrected, check the Color Calibration Vertical Test Pattern. Verify the horizontal lines are equally spaced apart - if lines appear inconsistent the stepper motor feed is severely out of tolerance. Check the Paper Calib Test/Line Length Test, enter only one value to reset stepper feed. Refer to Service Bulletin 1.
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8. If one or two bands (apparent data shift) appear in the image the feed roller may be restricted. Check feed system sensor operation; clean lower rollers. Refer to Media Drive/Image Skew Problems. Other causes include rear media guide interference (should not press hard against media), ethernet data starvation, failing servo motor, improper printer grounding (ESD interference typically with 3rd party low cost PP or Self Adh PP), dirty encoder sensor, or dirty/damaged carriage bushings. Replace bushings every 1000 print hours - refer to Maintenance.
2. If a single vertical band results (from 0.3 cm to 2 cm wide) from the trailing cable striking the chain shelf surface (cable has been recently replaced). Ensure cable extends 6-7 inches maximum beyond clamp/restraint. Other causes of single vertical bands/swath patterns include abnormal carriage obstructions (i.e. damaged pinch roller); damaged encoder strip or teflon strip.
4. Carriage head scrapes may be inadvertently described by customers as vertical banding, particularly when the cartridges lightly scrape the media surface. Often the scraping resembles scratches across the media surface. Check carriage head height and media type (some media types will cockle with ink oversaturation, i.e. bond).
Note: verify carriage head height is correct (65/1000 of an inch clearance) using service Head Height Kit - refer to Mechanical Alignments.
6.If two adjacent lines appear down the print then the lower roller may have a defect causing the upper roller to deform the image. Verify carriage head height is correct. Check rollers for contamination or damage, replace as necessary.
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2. Replace printhead or cartridge. The internal cartridge ink level may not be proper (chimney to foam separation has occurred). Replace ink bottle if discovered leaking. Refer to Service Bulletin 7 for advanced troubleshooting.
3. Obtain the Ink System Test kit. Check damper pressure using the VacLok syringe connected to the pressure test cartridge. If ink cannot be pulled into syringe then an ink line is pinched; check for pinched ink line (behind intermediate reservoir). Check damper; replace damper if seal is broken.
5. Replace septum assembly (at carriage). A small leak may exist internal to assembly.
6. Replace entire ink delivery system if ink tubing is suspected damaged. For OEM5 systems replace the ink delivery system tubing (cheaper option) if cracking of ink lines is observed; it is suggested to also replace all 6 dampers.
Reseat wiring harness connections inside platen and at MPWA (J18 is connected to pump). Remove and clean any observed ink debris from plugs/connectors.
Replace the auto clean unit sensor wiring harness assembly. NOTE: sensors cannot be replaced independently.
NOTE: If right-side spitting is observed onto the printed image and symptom only occurs during cap evacuation (every 2.5 minutes) this is NOT an auto clean unit pump failure. Refer to ESD control and print grounding guidelines as outlined in Service Bulletin 8 to correct this problem.
7. Clean all flex driver cable contacts and rear cartridge surfaces of ink residue. Refer to Routine Maintenance. Reseat all flex driver cable connections at carriage board and retest. If severe jet failures persist replace respective flex driver cable.
8. Replace carriage board if excessive cartridge failures occcur (i.e. OVERCURRENT errors) and related color problems persist.
Using a polarity tester verify electrical outlet has the proper polarity and grounding of the power source. Conduct standard grounding checks at printer, using an AC scale reading verify there is no voltage present on the printers rear metal plate (plate on which the power switch is mounted against). If AC voltage (anything higher than 2 volts is improper) is present at plate, platen surface or slide shaft then a faulty ground is present.
11. CAUTION: ground faults can cause up to half of the input/line voltage to appear on the equipment. Exercise basic hardware electrical safety practices if a ground fault is suspected. Refer to Service Bulletin 8.
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2. Reseat SDRAM module (64 MB) connection to Main PWA; reseat both trailing cable connections. If memory module is unseated, damaged, or missing the printer will not initialize completely (carriage will partially move to left side and will error with a carriage axis error). Note: Memory should not be substituted; memory cannot be upgraded. Damaged memory may be indicated by error message FATAL PPC40X 11C.C128
3. Check right base assembly internal power/wiring, and dryer board connections. If dryer board is not switching properly or air plenum fans fail to energize then replace dryer board assy. (damaged transistor chip).
4. If partial initialization occurs, check carriage board LED D1 (should illuminate for 9-10 seconds then turn off). If LED does illuminate the the power supply is good but programming is faulty. Replace trailing cable, Memory module or Main PWA to correct.
7. Replace main board. NOTE: If dryer fails to energize verify 115/230 volt selector switch is in the correct position. Reseat all dryer board connections and main board SSR connection (J12). Check Dryer heater fuse resistance - refer to Service Bulletin 6 for dryer system troubleshooting. Refer to Dryer System Failure.
NOTE: If printer does initialize but will not process/print jobs the problem is normally the carriage paper sensor is not detecting the media. Check UTILITY MENU - DISPLAY SETTINGS for NO PAPER LOADED indication. Thoroughly clean platen, cutter groove, and carriage paper sensor - refer to Routine Maintenance. Verify there are no scratches in the cutter groove since the paper sensor seeks this zone when detecting paper. Repaint groove as necessary. Replace carriage paper sensor if failure persists.
NOTE: If, at anytime, navigation of the control panel display is not possible or navigation problems persist then the keypad connection is either unseated or the keypad assy. is damaged. Replace keypad assy. (sheet switch) as appropriate.
2. Check SDRAM module at Main PWA; printer may partially initialize if memory module is unseated. Perform soft NVRAM (Non-Volatile RAM) clear by holding bottom left control panel key and powering on printer until message...Clearing Machine Type..is displayed.
4. Check trailing cable connections at carriage and main board - reseat connections at carriage board and main board. Inspect cable for surface breaks or burnt wire runs, refer to Vertical Banding symptoms. 5. If carriage stops in the same place everytime then check the autoload sensor wiring to plug - ensure all wires are connected. 6. Check encoder strip and teflon strip for visible damage. Replace if damaged.
8. Clean the carriage paper sensor - refer to Routine Maintenance. This will help eliminate any overlapping problems from occurring. 9. Activate Servo PWM test under diagnostics, select UTILITY MENU - SERVICE MENU DIAGNOSTICS - SERVO CYCLE TEST. Perform for 10 cycles and press OK. The PWM Avg levels should typically be between 130 and 215; maximum levels are normally between 200 and 255. Carriage Axis Errors will occur above 242 on early model printers (prior to 07/2005) or above 312 on later model printers (post 07/2005). Replace the servo motor if intermittent failures are experienced (NOTE: assumes printer is clean of residues/lubricants and carriage bushings have already been replaced); replace if more than 2000 plot hours have elapsed since last motor replacement. Verify motor winding resistance (At Main PWA J9) of approximately 2.9 ohms (+ 1 or 2 ohms); replace motor if zero (0) or greater than 80 ohms.
11. Activate SERVO CYCLE TEST and verify drive voltage of +24 volts dc (Main PWA R27 or U20-3). Refer to Main PWA schematics, sheet 6 of 14. Replace Main PWA if motor drive signal is absent. NOTE: the main board is rarely the cause for this type of error condition. Verify Steps 1 through 8 again. Contact technical support to assist in making a final determination.
1. Perform LEGS TEST. Tape media onto feed roller so both sensors are NOT blocked by media (both sensors should be illuminated red). Select UTILITY MENU SERVICE MENU - DIAGNOSTICS MENU - ACCESSORY MENU - LEGS TEST. Both rollers should slowly pulse in one direction only. Block one sensor at a time and verify the respective roller reverses direction. If both or either sensor test fails proceed to step 2, otherwise check SETUP MENU - PAPER SUPPLY OPTION. Verify the supply mode is not set to SHEET (disables both sensors).
2. Check bracket alignment to ensure optic sensor is aligned with reflective tape. Bend bracket as necessary until LED illuminates red in color. Replace if severely bent (NOTE: optic diaphram tape must also be transferred to new assembly). NOTE: During legs test control panel display values should change from a 0 to 1 when sensor is blocked. 3. If problem occurs during a new printer installation, then check wiring harness connection between the right stand leg and platen. Verify plug is properly seated and retest.
5. Verify sensor connections to right stand leg; reseat both connections. Check sensor electrical resistance (BLU and BLK is 2.3 M ohm., BRN and BLK is O.L or infinite). For single sensor failure (no red LED indication) replace respective sensor. Refer to leg drive schematics.
NOTE: If smoke/alarm comes from the printer then inspect Main PWA U26 (located behind trailing cables) and U2 I/Cs for damage (visible melting of I/Cs). If damage is observed at Main PWA replace Main PWA and both feed and takeup sensors (and possibly carriage board if U26 damage was severe enough). One of the sensors likely fused bringing +24V up to U26 main pwa sensor input, then over to the U2 FPGA).
7. Check electrical resistance across motor windings (remove motor housing via 4 screws, disconnect wires to motor and check across motor input leads). Range is typically 29 to 36 ohms. Replace motor if greater than 120 ohms. Swap motor assembly positions to isolate failure.
8. Check strike plate condition to help avoid future imaging problems. Carbon fibers should be present and standing upright on strikeplate. Replace as necessary.
10. For problems which cannot be resolved replace entire right stand leg assembly or replace leg drive harness (lower cable within right stand leg). 11. Perform resistance checks across dryer/winder harness (upper cable) wiring. Refer to leg drive schematics. Replace harness if damaged.
12. At MPWA verify motor drive DC outputs (+24 vdc) while running the legs test. Feed Motor (J11 7 or U19-4); TakeUp Motor (J11 9 or U19-7). Refer to leg drive schematic. Replace main PWA if motor drive signal is absent.
NOTE: Refer to Technical Bulletin 5 for image skew related problems (this is different from media skew; the printed border skews/shifts while the media is aligned properly).
NOTE: It is common to experience length problems with the first tile (Tile #1) on many media types; problems may be experienced with all tiles on certain vinyl media due to humidity exposure vs. inherent media properties (expansion control). Refer to Technical Bulletin 7 for proper tiling guidelines.
NOTE: In either case, first inspect the center support bracket and inspect for metal debris inside bracket or below lower roller position. Ensure shims are present on the center support bracket, these are normally required to prevent excessive pressure onto the lower roller shaft. Thoroughly clean inside of bracket of metal shavings/residues and reinstall into printer and re-test.
NOTE: LOW is 0.006, HIGH is 0.018, RANGE is 0.012; this example used a smile profile of 0.003
5. Check for AC power coming into Dryer PWA J7 (measure across pins 1 and 3). Verify proper wiring orientation if a new installation or previously repaired.
6. For an air plenum only failure (heating system is functional) first check dryer board air plenum fan connections. Replace the dryer board assembly (damaged transistor).
8. Disconnect J1, J2, and J3 from Dryer board; verify electrical resistance between pins 1-2 and 2-3 for 89 ohms (80.1 mininum/97.9 maximum). If any of the resistances are faulty then replace dryer heater (nose) assembly.
9. Check electrical resistance at soldered connections between dryer board/voltage selector switch harness assembly. If any of the resistances are faulty then replace dryer board assy.
NOTE: Ensure the air plenum is properly grounded in accordance with Service Bulletin 8.
5. Replace Main PWA if no network activity is observed (LEDs do not illuminate), but other printer functions are active (i.e. power is present, internal test prints function, etc.)
Note: The Printer Service Tool Kit prior is required for performing most major service actions.
Step 4. Remove the Right Lower Cover. Ensure inner clips securing Right Lower Cover are disengaged.
Note: to aid in lower cover removal gentle twisting of cover may be necessary.
Note: gently twist left cover to aid in removal; 4 clips secure cover to reservoir bay.
Caution: keep magnetic assemblies (i.e. Paper Guides/Media Edge Holders) away from the control panel display or damage will result.
Step 4. Remove the Right Lower Cover. Ensure inner clips securing right lower cover are disengaged.
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Caution: ensure that the locking clip is released before removing the Trailing Cable connection (J1).
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Caution: ensure the locking clip is released before removing the Trailing Cable connection (J1).
Step 8. Rotate the PWA Mounting Bracket Assembly 90 towards the back of the printer.
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NOTE: During reassembly ensure the power supply connections to the power supply are correct, wiring should be connected from, as observed from left to right, white, black, and green
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Caution: Ensure that the locking clip is released before removing the Trailing Cable connection (J1).
Note: during assembly, thermal sensor connections (J8-J9) air plenum fan connections (J10J11) and nose heater connections (J1-J3) plug order is not critical since sensors, fans and heaters energize together respectively.
Step 8. Rotate the PWA Mounting Bracket Assembly 90 towards the back of the printer.
Note: during assembly, ensure the wiring harnesses are properly oriented.
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Step 4. Remove the Right Lower Cover. Ensure inner clips securing right lower cover are disengaged.
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Caution: ensure the locking clip is released before removing the Trailing Cable connection (J1).
Step 9. Rotate the PWA Mounting Bracket Assembly 90 towards the back of the printer.
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Caution: during assembly ensure the voltage selector switch is properly configured to the local power source, 115V or 230V.
Note: It is strongly recommended to obtain the Printer Service Tool Kit prior to performing major service actions.
Note: Loosen the 4 securing screws to remove unit; removal of the securing screws are not required. Caution: hold assembly while disconnecting 2 electrical connections or damage may occur to wiring harnesses/plugs.
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Step 6. Release carriage belt tension using the Belt Removal Tool (P/N 216688-00); insert and twist tool between the frame tensioner and left-side plate.
Step 8. Remove the Servo Motor by removing 2 securing screws; lower through platen access hole.
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Caution: damper and septum fittings can be easily damaged. Carefully remove ink tubing from connection points using pliers/flathead screwdriver to gently pry tubing free.
Tip: to re-install the cartridge door spring first place spring into the position shown (with door installed). With a flat-head screwdriver gently force the rear spring tab all the way down until it snaps into place. This will need to be repeated until sucessful. Test spring installation by unlocking the door, the cartridge door should pop up to the fully open position.
Step 5. Clamp ink tubing above septum assembly; gently pry ink tubing free using needle nose pliers. Cut ink tubing if tube end is flared too large. Remove the Septum Assembly.
Caution: verify the connection locking clip is released before removing the Trailing Cable connector.
Caution: new Damper assemblies are extremely fragile - do not drop ink delivery cover or compress damper assembly or damage may occur (leaking).
Step 10. Following septum/damper replacement, use the Primer tool (VacLok syringe/cartridge) to restablish ink line pressure. Ensure no air bubbles are present in ink line or head failures/error messages will be encountered during printing.
Videos
Step 2. Remove the Ink Delivery System Carriage Cover support brackets by removing 4 securing screws.
Step 5. Using a small flat-head screwdriver, remove bushings by gently prying away from carriage and sliding off of slide shaft. Step 6. If bushing shims are damaged then replace all 4 shims (0.004 inches thick; self-adhesive vinyl).
Step 2. Remove the Ink Delivery System Carriage Cover and 2 Support Brackets by removing 4 securing screws.
Step 3. Lift cover and disconnect the Trailing Cable connection from J1 on the Carriage PWA using a small flathead screwdriver. Move the Carriage Cover aside.
Caution: verify that the locking clip is released before removing the Trailing Cable connection (J1).
Carriage Assembly
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Caution: always wear electrostatic discharge (ESD) protection when working with ESD sensitive electronic assemblies or components.
Note: It is not necessary to break ink line integrity (disconnect tubing connections) or remove the reservoir chassis for this procedure. Caution: to avoid damaging lock do not twist plug from connector J1.
Step 3. Disconnect trailing cable from carriage board by pressing on lock with a small blunt tool.
Note: do not disconnect ink line from septum assembly or repriming of ink lines will be necessary following this procedure.
Caution: Do not drop ink delivery system or damage to dampers may occur; ink may leak out of the ink tubes if accidently disconnected from the septum assemblies.
Step 10. Slide the Belt off of the Servo Motor Pulley. Remove the Belt Removal Tool.
Step 11. Remove 2 screws securing cutter actuator and remove actuator.
Step 13. Remove the Frame Tensioner, Idler Assembly and the Compression Spring.
Step 14. Disconnect Ink Reservoir Chassis by removing 6 screws and moving 3 to 4 millimeters toward rear (left covers do not need to be removed).
Caution: During re-installation verify the Encoder Strip is between the Encoder Sensor edges. Damage to the Encoder Strip is possible if care is not observed when sliding carriage back onto the slide shaft.
Step 16. If ink line becomes separated during carriage removal/replacement the ink line (s) will need to be reprimed using the Primer tool (VacLok syringe/cartridge).
Caution: paper sensor flex cable is extremely fragile, only make gentle bends when re-installing. Step 19. Remove the Encoder Sensor by gently working sensor free from carriage restraining clip. NOTE: If removing the carriage flex driver cables please note that two small clear plastic shims (adhesive) are to be reinstalled at the base of each cable - see picture at right for proper positioning. Failure to do so will result in cartridge recognition type errors.
Caution: encoder sensor carriage housing clip is extremely fragile, do not push too hard on housing clip when removing sensor.
Step 3. Lift cover and disconnect the Trailing Cable connection from J1 on the Carriage PWA.
Caution: ensure locking clip is depressed prior to removing; do not twist plug from connector or damage will result.
Step 5. Disconnect the Trailing Cable connection from J1 on the Main PWA. Remove double-sided stick tape from cable and pull trailing cable free.
Caution: verify the locking clip is released before removing the Trailing Cable connection (J1). Note: trailing cable cannot be easily replaced and overstress to new cable will result in permanent damage.
Step 11. After removing the left bottom cover, loosen ink tube restraining clamps at reservoir chassis.
Step 12. Clamp 6 ink tubing lines with 12 hose clamp tools on both sides of tubing butt-splice. Disconnect tubing lines at butt splices. Remove the Ink Delivery Assembly.
Step 13. Following ink delivery system replacement re-establish ink line pressure using cartridge with tube assembly and plug bar or service primer tool (VacLok syringe/cartridge; part of Ink System Test Kit). Clean the primer tool between each ink color usage.
Step 3. Clamp vent tube - it is attached to the underside of the reservoir chassis. Caution: carefully disconnect the vent tube or damage may occur to cover.
Caution: Ink may leak out of the tubes when disconnected or cut. Always Use of a drop cloth or other material is recommended to control ink leaks.
Step 5. Separate tube from the tube butt splice by pulling apart or cut the ink tube between the service splice and the Intermediate Reservoir (cut/separate line between hose clamps only).
Step 7. Remove 1 screw securing reservoir identification contactor (T7 star-head driver) and 4 screws securing restraining clips. Note: part of identification sensor PWA.
Note: ink may leak from assembly; use drop cloth to control ink discharge. Basic replacement assembly does not contain the ID housing, restraining clips or sensor PWA. These items will need to be transferred to the new intermediate reservoir.
Step 9. Following assembly replacement use the Primer tool (VacLok syringe/cartridge) to restablish ink line pressure. Ensure no air bubbles are present in ink line or head failures/error messages will be encountered during printing.
Step 2. Remove the Right Rear Cover by removing 2 securing screws. NOTE: Refer to Service Bulletin 10 or the video below to replace an early model station (geared) with the new station model (non-geared).
Caution: only loosen the securing screws, removal of the securing screws is not required. Damage to electronic cables may occur if assembly is dropped.
Step 5. If replacing the Service Station, disconnect the tubing disposal line by twising luer fittings in opposite directions. This tube is connected to the Auto Clean Unit disposal bottle. Note 1: For new service stations - When re-installing the service station verify shim is properly located and station tabs are seated flush against platen. Note 2: The valve vent line should not be pinched or obstructed check positioning.
Note: The new service station design no longer uses the motor or sensor functions. Firmware version 1.4.2 must be loaded and a jumper (J13) must be installed to allow operation of the new service station.
Step 8. Remove the 2 securing screws and remove the station motor/sensor assembly (including bracket).
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Note: Loosen the securing screws and lower unit approximately 15 cm. Removal of the securing screws are not required.
Step 4. Disconnect both electrical connections. Station may be disassembled further to gain access to motor and sensors. - Suction Pump/Motor Assembly; see video. - Bottle Full Sensor - Bottle Load (present) Sensor Assembly
Video
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Step 4. Lift cover and disconnect the Trailing Cable connection from J1 on the Carriage PWA. Move the Carriage Cover out of the way.
Caution: Ensure that the locking clip is released before removing the Trailing Cable connection (J1).
Step 6. Disconnect 6 cartridge door assemblies from carriage by removing door restraints and pushing on door support clips to release each assembly.
Step 8. Remove carriage bushings from carriage by removing the bushing retainers at each side (1 screw secures each retainer).
Step 10. Slide the Belt off of the Servo Motor Pulley. Remove the Belt Removal Tool.
Caution: Ensure that the Idler Assembly is oriented correctly before installation.
Step 14. Remove Belt and Carriage Assembly - the ink reservoir chassis may need to be moved slightly toward the rear to aid in removal.
Caution: Ensure that the Encoder Strip is between the Encoder Sensor as the Carriage Assembly is positioned back onto the Slide Shaft. Damage to the Encoder Strip is possible if care is not observed.
Note: following the repair action, a carriage head height adjustment may be required. Refer to Service Bulletin 3 or Mechanical Alignments. The printer service tool kit contains the carriage head height adjustment tools required.
Step 2. Pitch the back cover toward the rear slightly. Pinch roller eclips can be removed and replaced once the back cover is positioned to provide assembly removal (clearance provided is approximately 0.5 inch/2.5 cm)
Caution: Do not remove Y-Arm for this procedure. Only remove on OEM4 printers when the long media guide requires replacement. The 8 crescent springs at left side allow the Y-Arm to float when dryer is on for proper operation.
Step 4. Carefully tilt the back of the Pinch Roller upwards; this lowers the front of the Pinch Roller, away from the Slide Shaft. Carefully remove the spring that is going into the Slide Shaft.
Step 5. Remove the Pinch Roller. NOTE: To reinstall pinch roller, place spring into base of pinch roller, maneuver pinch roller at an angle under the slide shaft and compress spring using fingers - orient spring into spring hole at base of slide shaft.
Caution: do not over extend reservoir chassis or damage to ink tubing may occur. It is suggested to place chassis onto a small table beside printer. Do not disassemble intermediate reservoirs from ink reservoir chassis.
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Step 6. Disconnect the Vacuum Fan connectors from J15 and J16 on the MPWA.
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Step 8. Disconnect the Stepper Motor wire clamp and ground located in service Station access opening (auto clean unit may need to be removed for reinstallation). Remove Right Foam Block. CAUTION: Do not tear Foam Block or proper vacuum/suction may not exist for normal operations.
Step 10. Remove Platen Plug by prying out with one hand and screwdriver assistance from the other.
Note: Four inner tabs secure Platen Plug to the Platen. Plug may have to be broken for removal if technicians hands are too large for removal.
Step 12. Remove the Center Support through the hole on the bottom of the Platen. Note: Front side of center support bracket is labeled FRONT, ensure this sides faces toward the dryer/air plenum upon re-installation.
Note: Ensure proper orientation of the Center Support Bracket during installation or low quality output may result. The thick arm faces towards the front of printer.
Step 15. Remove the Left Side Plate by removing 5 securing screws.
Step 17. Recess the 4 screws securing the Left Leg Assembly until they are flush with the inside of the Platen.
CAUTION: do not move printer until the left stand leg screws are secure or printer may collapse.
Note: To ease in assembly removal gently shake and lift assembly while pulling out left side of platen.
Step 19. To remove the stepper motor remove two securing screws, nuts and spring. NOTE: the correct shims (differentiated by color) will need to be installed onto new lower roller support brackets and center support bracket refer to Service Bulletin 17 for instructions.
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Step 4. Remove the Right Lower Cover. Ensure inner clips securing right lower cover are disengaged.
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Step 6. While firmly holding the Air Plenum, release both position locking pins. Remove the Air Plenum.
Step 8. Disconnect the Thermocouple connectors from J8 and J9 on the Dryer PWA.
Step 9. Disconnect the Thermal Fuse connector from J6 on the Dryer PWA.
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Note: once the nose heater has been removed the thermocouple sensors and thermocouple fuse may be removed.
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Step 4. Remove the Right Lower Cover. Ensure inner clips securing right lower cover are disengaged.
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Step 6. While firmly holding the Air Plenum, release both position locking pins. Remove the Air Plenum. Disassemble air plenum completely to remove defective fan assembly. Note: 4 fans are present in the 42 inch printer, 6 fans are present in the 60 inch printer.
Step 2. Remove Drive Cradle Assembly by removing 4 securing screws. Remove ESD strike plate.
Note: motor is secured to motor mount via 2 tie-straps, 3 screws and an e-clip.
Note: An additional 3 screws and an E-Clip will need to be removed to seperate the Motor from the Motor Mount.
Step 2. Disconnect trailing cable from carriage board by pressing on lock with a small blunt tool.
Caution: to avoid damaging lock do not twist plug from connector. Connector tab will need to be depressed to release lock.
Step 6. Separate ink chain links by prying or pulling ink chain links apart every 10-15 cm along entire chain length.
Caution: do not overstress cable (s) during installation or damage to cable (s) will result.
Note: Depress lock with a small blunt tool to release trailing cable.
Step 11. Remove double-sided tape from cable and remove trailing cable from printer. Note: when reinstalling cable ensure carriage side of cable extends only 6-7 inches beyond the last link.
The distance between the bottom of the cartridge (print head) and the platen surface should be equal to 0.065 inches (65/1000 of an inch). The carriage head height normally requires adjustment following an encoder strip replacement or if print head scraping occurs on multiple media types.
Note 3: Remove power and media from printer before beginning adjustments. Lower the air plenum by removing the two locking pins.
Step 5. Move to the center position (directly over turnbuckles) and calculate the average between the left side and the right side. Step 6. Using a open ended wrench adjust the turn buckle (or turn buckles - 60 inch unit) for the average computed value.
Step 1. Obtain tools: head height test cartridge, dial gauge, extension tip, 1/16 and 7/64 inch hexkey wrenches. Step 2. Attach extension tip to dial gauge. Assemble the test cartridge and micrometer dial gauge using 1/16 hex-key wrench tool. Step 3. Ensure or 6 mm of the measuring tip extends beyond the cartridge base. Rotate gauge so it faces towards the left side, tighten the set screw securely. Step 4. Place the dial micrometer gauge on a flat surface and adjust gauges face plate so needle reads 90-10 (left of zero); Tighten gauge face screw. Step 5. Moving air plenum to maintenance position. Remove 5 printer covers (left top and bottom, right rear and bottom, and top cover). Check slotted insulator plates screws, 1/2 turn CCW. Activate dryer to heat setting of 5, select access cartridges to activate vacuum fans.
1. Loosen all screws prior to making adjustments and working towards the center of printer makes the adjustments easier. 2. When adjustment is complete ensure the carriage is parallel to the platen surface - by observing the small dial on the gauge for a consistent reading at all adjustment positions. 3. If a crossbar or stand assembly is adjusted or installed perform all mechanical adjustments again. Print Deadband (fast) to verify adjustments are correct - perform Service Bulletins 2, 3, 1, and 4 (in this order) if any problems are encountered with the Deadband print pattern.
Revised 05-12-2006
TRAILING CABLE
MAIN BOARD
+24V, GND 6 INK BOTTLES WITH DATA CHIPS LVDS DIFF. PAIRS 2 VACUUM FANS A/D CONVERTER
LVDS BCKCHL
CARRIAGE BOARD
PRINT HEADS
D
HEAD DRIVERS
LM
LC
HEATERS
FIRE
FIRE
DRYER BOARD
DRYER INTERFACE
PROGRAM
INTF.
CPROGRAM
BLOWERS
PAPER SENSOR
AC 120 / 240
3.3V @ 10A 2.5V @ 0.9A POWER SUPPLY 1.5V @ 2A 5V @ 0.1A SERVO MOTOR
24V
FPGA
MOTOR DRIVERS AUTOLOAD SENSOR INTERFACE WINDER / UNWINDER INTERFACE STEPPER MOTOR
CRYSTAL
B
AUTOLOAD SENSOR
B
WINDER / UNWINDER
ETHERNET CONNECTOR
ETHERNET PHY
2K EEPROM
POWERPC 405GP SERVICE STATION INTERFACE DISPLAY / KEYPAD INTERFACES 256K X 18 ZBT RAMS DISPLAY / KEYPAD SERVICE STATION
JTAG PORT
4M FLASH
Custom
222052-00
Sheet 1 of 1
Rev AA
Date:
5 4 3 2