NJ1000i-1200i Printer Service Manual_05122006

Revised 05-12-2006

Printer Service Manual

Chapter 1 Features Chapter 2 Setup Chapter 3 Networking Chapter 4 Software Suite Chapter 5 Calibrations Chapter 6 Operations Chapter 7 Routine Maintenance Chapter 8 Cartridge Replacement Chapter 9 Firmware Download Chapter 10 Troubleshooting Chapter 11 Disassembly Chapter 12 Mechanical Alignments Chapter 13 Illustrated Parts List

NOTE: All button and video links shown in this manual are not active – please proceed to the Service Guide Presentation for interactive functions.

Printer Information: Features

Service Guide

Printer Components

Printer Technology

Ink System

Dryer System

Print Speeds

Media Support System

Software Interface

Cartridge Warranty


Service Guide

Features Video

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

Printer Components


Service Guide

1. Intelligent Mask Technology (IMT)

A simple screen that is applied to image files by the printer to determine which dots are layed down during each swath or print pass when printing in a particular print mode. A different print mask is applied for each color plane. 3-pass printing with conventional masking tends to result in hue-shift banding, especially with pigment inks. The main reason is that 3-pass printing builds the printed image with two right-to-left swaths and one left-to-right swath. Consider a carriage layout that has magenta and yellow sharing the same swath: This results in yellow ink drops landing on the media first with magenta on top when printing right-to-left. When the carriage moves left-to-right magenta goes down first with yellow on top. This tends to result in two distinct alternating color bands a third of a swath high that are highly visible from a distance with pigment inks on certain media types.

IMT makes it possible to achieve better image quality during high speed printing. High speed printing is more difficult because of the higher densities printed per swath and the short time interval between the printing of some ink drops before other drops are printed on top or nearby. Print masking controls and limits coalescence to even out the resultant density and color, and reduce banding and graininess.

AnimationPrinter Technology


Service Guide

Printer Technology


Service Guide

2. Rapid Evaporation Drying System

The advanced dual-component drying system uses the principle of conducted heat to dry printed images with much greater efficiency than can be achieved with hot air dryers. The media web is fed over a heated aluminum nose that is curved to maintain intimate contact with the back of the web for effective heat transfer. The nose is an isolated extrusion that incorporates three longitudinal fins with an electrical heating strip mounted to each fin inside the curve. This design evens out heat flow to minimize cold spots under high density printed areas across the web without the long warm-up time of a much thicker section. Ambient air flow is used to pull away moisture and improve drying efficiency by another 30% over that achieved with the heated nose alone.

A fan driven air plenum is used to distribute air flow evenly across the print width. Air flow is downward, carrying heat away from the print zone to improve nozzle reliability and to reduce the risk of edge curl. An intelligent control system regulates electrical power to achieve and maintain temperature set points between 35 and 55 degrees C.

AnimationPrinter Technology


Service Guide

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

Ink Refill Bottles

- 6 ink bottles (ML, CL, Y, K, M, C)- Refill bottles are easy to replace - Encrypted for ink monitoring (740 ml shutoff)- One set of ink lines; switch over capability (Dye or Pigment)- Plug and Play ink refill bottle (700 ml) with septum/needle interface - Clean-hands installation- Mechanical color keying of bottle

Ink System


Service Guide

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

Animation

Carriage Assembly

- Robust carriage bushing design; thick bushings with spring loaded bias for better dimensional stability - Bushings are grooved to minimize the effect of dirt and debris- Cartridge doors secure printheads in place- Ink is regulated to printhead via ink line dampers - One-step cartridge installation process

Ink System


Service Guide

Auto Clean Unit

1) Door Magnet2) Suction motor (for priming ink lines)3) Bottle full sensor4) Ink Receptacle (bottle)5) Bottle present sensor

Active Service Station

- Clean hands ink line filling through service station- Motor controlled multi-port color control selection valve- Eliminates ink prime devices- Clean hands cartridge maintenance through service station- Ink is deposited into a waste bottle

Ink System

1) Color selection valve

2) Station Motor


Service Guide

1) Air Plenum2) Input air flow3) Output air flow4) Heated Nose (insulated)5) Electrical heating strips (35-55 degrees C)6) Platen (print zone)

- 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.

Rapid Drying System


Service Guide

Print Mode

High Speed mode (2 pass)Productivity mode (3 pass)Fine mode (4 pass)Enhanced mode (6 pass)High Quality (16 pass)

Note: Printer ships with 64 MB SDRAM and is not up gradable; HP-GL/2 is not supported. An additional 32 MB RAM resides on the main board.

60 inch model

220 sfph (20.4 smph)150 sfph (14.0 smph)115 sfph (10.7 smph)75 sfph (7.0 smph)26 sfph (2.8 smph)

42 inch model

195 sfph (18.1 smph)140 sfph (13.0 smph)104 sfph (9.6 smph)70 sfph (6.5 smph)23 sfph (2.5 smph)

VideoPrint Speeds


Service Guide

1) Primary Feed Roll2) Feed Sensor (bracket extended 2 inches)3) Feed Roll 2 (or TakeUp Roll)4) TakeUp Sensor5) AutoLoad Paper Sensor6) Media Pinch Roller7) Lower Roller

- 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.

Media Support System


Service Guide

Setup Requirements:1) Server workstation with RIP loaded; Windows 2000/XP/XP PRO/Windows 2003 Server, Network Card, 3.0 GHz Processor, 1 GB RAM, 160 GB hard drive2) Printer Installation Software3) Client workstation (not required)4) Network Switch/HUB; 100FD Capability5) Printer (built-in 100baseT Network card)6) Web Access (for Software Updates)

Software Interface


Service Guide

Setup Tasks:

Software Installation:

- Server/Client Control Setup (follow Typical Setup)

- Database Server (automatic)

- Drivers, EFPU, and Custom Colors Utility (automatic)

- Network Connectivity (automatic)

Software Interface


Service Guide

Cartridge Warranty VolumeCartridge Average LifeCartridge End of LifeWarranty Coverage

700 ml1400 to 2100 ml2800 mlVerify ink throughput by selecting UTILITY MENU - INK STATUS MENU - CART INFONote: Nozzle failures are 100% filled blocks as observed in Prime pattern

Ink Kit Configurations

- Ink Refill Bottle (700 ml)- Ink and Cartridge Kit (700 ml)

Cartridge Warranty

Installation/Operations: Printer Setup

Service Guide

Printer Unpacking

Install Takeup/Feed System

Install Auto clean Unit/Raise Printer

Initialization

Load Media

Install Ink

Install Ink Cartridges

Print Test Patterns

Open Jet Compensation


Service Guide

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.

Video

Open printer head box flaps. Using two (2) people minimum, rotate box/pallet over 90 degrees onto one side. Note: ensure the air plenum is facing up.

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.

Step 1.

Printer Unpacking


Service Guide

Step 2.

Using two (2) people minimum, pull printer free from packaging by grabbing shipping brackets (through plastic) and sliding printer away from box.

Printer Unpacking


Service Guide

Step 3.

Remove power cord box and accessory box (contains screwdriver, ink line priming tools and software CD).

Using the 6 (long and short) pieces of packing foam (white foam strips); place in triangular formations (3 per pile) on the floor directly in front of each printer cover.

Note: ensure triangular foam piles are centered directly in front of each printer cover.

Printer Unpacking


Service Guide

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).

Step 4.

Printer Unpacking


Service Guide

Step 5.

Remove the plastic packaging from printer.

Caution: verify printer is stable prior to stand installation.

Printer Unpacking


Service Guide

Step 1.

Remove the cross-support bracket by removing two bolts and wing nuts.

At right side of printer (control panel end), remove the 2 shipping bracket bolts and wing nuts. One person will need to hold printer while the other person removes the bracket to prevent from rolling.

Remove right lower shipping bracket (4 screws) and upper shipping bracket.

VideoInstall Takeup/Feed System


Service Guide

Step 2.

1) Install and secure the right stand foot (4 screws) onto stand leg. Position the right stand leg and attach electrical plug connection (located inside leg) to printer base jack – ensure the plug and jack are squarely aligned when connecting. Ensure restraining clips are secure.

2) Attach right stand leg with 4 screws - do not tighten screws down at this time.

3) Caution: do not pinch harness wiring when attaching to avoid damage.



Service Guide

Step 3.

At left side of printer, remove the 2 shipping bracket bolts and wing nuts.

Remove left lower shipping bracket (4 screws) and upper shipping bracket. Set brackets to one side.



Service Guide

Step 4.

a) Secure stand foot to left stand leg (4 screws). Attach the left stand leg (4 screws) - do not tighten screws down at this time.

b) Attach and secure crossbar to stand legs (4 screws). Tighten 8 (eight) stand leg screws at this time.



Service Guide

5 Step Process:

Video

Note: 4 short securing screws are pre-installed. 1) Connect 2 electrical connections; ensure plugs are securely seated into jacks. 2) Remove nipple cover from pump. 3) Connect ink tubing connection to motor/pump nipple.

Note: ink tubing connection should be located inside printer base. Caution: Do not loosen quick connect valve.

4) Remove tape from securing screws. 5) Pitch unit to the right and secure over the 4 screws; tighten securing screws.

Install Auto Clean Unit/Raise Printer


Service Guide

Step 1.

Lock two of the stand feet casters.

WARNING: Installed printer can weigh up to 270 lbs (122 kilograms); only perform this heavy lift with four (4) people.

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.

Initialization


Service Guide

Step 2.

Remove remaining packaging materials including the center shipping bracket. To remove the center shipping bracket lower the dryer (air plenum) to the maintenance position by removing the restraining pins at either side of dryer.

Initialization


Service Guide

Step 3.

Video

Ensure voltage selector switch is set to input line voltage (115 or 230 volts). Note: printer ships in the 230V position. Plug in printer and turn on printer power switch.

Caution: For regions which experience intermittent voltage fluctuations a line conditioner and surge protector are suggested to help protect the printers power supply.

Initialization


Service Guide

Step 4.

After a 9 to 10 second power up delay, ensure the carriage traverses across entire printing area and back without error during initialization process.

The main menu should be displayed when initialization is complete.

Initialization


Service Guide

Step 1. Install Feed Media/Roller

Video

1) Unlock roll guide2) Slide guide away from spindle3) Install spindle into new roll of media

4) Install roll guide5) Tighten roll guide against media edge6) Install feed roller into printer; ensure gears mesh properly

Load Media


Service Guide

Step 2. Install Takeup Core/Roller

1) Install media core onto spindle2) Install roll guide3) Lock roll guide against media core4) Install takeup roller into printer; ensure gears mesh properly

Load Media


Service Guide

Step 3.

Pull media from feed roller; fully insert media edge into media path channel. Align to white mark on left rear side of platen. After a 9 second delay media will be automatically pulled into the printer path. Media will be sensed and sized automatically.

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.

Load Media


Service Guide

Step 4.

Use the takeup roller when multiple or long print jobs are going to be processed and printed. Three inch core adapters are available if takeup roll is being loaded onto a laminator. For takeup operations, tape media edge to the media core; ensure media edges line up evenly with media core edges.

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.

Load Media


Service Guide

Step 1.

Video

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.

Note: Wait 5 minutes prior to performing line fill (must allow enough time for the intermediate reservoirs to fill properly)

Install Ink


Service Guide

Step 2.

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).

Install Ink


Service Guide

Step 3.

Activate line pump. Select and hold Utility Menu - Prime Menu – Service Station Menu – Pump On. Release Pump On when ink is observed in cartridge tubing line. The line fill process takes approximately 20 seconds per color. Repeat procedure for remaining stall positions.

Following ink line filling, disconnect the line fill cartridge from the last stall position but leave needle connected to septum fitting. Select Pump On to clean assembly of ink; disconnect priming assembly when complete.

Install Ink


Service Guide

Step 1.

Video

Open cartridge door.

Step 2.

Remove accumulator; remove blue tape from cartridge.

Step 3.

Slide cartridge into cartridge stall and close cartridge door. Door must be closed to properly bias cartridge position.

Install Ink Cartridges


Service Guide

Step 1. Print Color Test

Video

Select Utility Menu - Service Menu - Diagnostics Menu - Color Test. Choose All Colors, select Ok

Verify solid rectangular print swaths are printed for each color with no visible ink starvation.

Print Test Patterns


Service Guide

Step 2. Print Prime Pattern

Select Utility Menu - Prime Menu - Prime All

Verify printhead nozzle performance - ensure diagonal lines are smooth and clogged jets are not present.

Print Test Patterns


Service Guide

Step 3. Print the Test Print

Select Utility Menu - Service Menu - Test Print

Use this print to evaluate printer calibrations and general color output.

Print Test Patterns


Service Guide

Step 1. Print Prime Pattern to verify nozzle performance.

Video

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.

xxx

Open Jet Compensation

Installation/Operations: Networking

Service Guide

Automatic Configuration

Manual IP Address Configuration


Service Guide

System Setup:1) MAC design station2) PC workstation3) PC server with RIP loaded4) Switch/hub5) Printer; DHCP Disabled is the default setting

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.

Automatic Configuration


Service Guide

Step 1. Set IP and network information. At printer select SETUP MENU - NETWORK MENU - IP CONFIG MENU. Ensure host computer has the IP address, Subnet, and Gateway addresses assigned. Computer and Printer should be within the similar IP ranges (typically the first 3 numbers of IP address should be the same; both should have the same Subnet and Gateway addresses).

Step 2. Check Network Info to ensure network information is correctly setup.

Note: Disable DHCP at Printers DHCP Client screen for peer-to-peer configurations; enable DHCP for larger network configurations (IP address will be automatically assigned - use this IP address).

Step 3. Set this IP address within RIP or add Standard TCP printer port (generic) using this address.



Service Guide

To download IP address directly to printer:

Step 1. At the Command/DOS prompt enter: arp -s IPaddress MACaddress (MAC address can be found under Printers Network Menu). For Example: arp -s 192.168.100.104 00-C0-EB-04-76-07 and then press Enter.

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.


Printer Information: Software Suite

Service Guide

Software Installation

Printer Installation

Server Setup

Datbase Server

Client Control

Job Accounting

Technical Support Reporting

Software Activation


Service Guide

Note: Individual utilities may be installed if configuring onto a remote Client system only.

Software Suite Install

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.

Software Installation


Service Guide

Printer Drivers Install

Printer Installation will automatically detect printer on the subnet, install drivers and designate IP addresses.

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.

Follow the screen prompts to complete the installation.

Printer Installation


Service Guide

Procedure:

Stop server. Select settings to make changes to server configuration

Walk through of connection to the server and printer information screens

Software / Utilities

Setup of the Client User Interface and 5 other packages.

Requires only one server for all printers/computers

Server Setup


Service Guide

Runs in the background

- Stores information on media type, ink cost and productions times.

- Assist in cost reporting and print cost reporting.

Database Server


Service Guide

Platform Support:

For use on Windows 2000, Server or Win XP/XP Pro

- Remote Printer Control Center

- Job Accounting

- Ink Usage/Waste

- Technical Support and Service Interface

Client Control Panel


Service Guide

Displayed Results:

Output tracking features

- User selectable fields for tracking all aspects of job costs.

- Accurate reporting of media and ink used per job.

- Accurate reporting of time required to print jobs.

Job Accounting


Service Guide

- Used to export Database information

- Information can be exported to a text file (csv) and sent to an email address

- Can be customized to export specific information

- Can be customized with user/contact information

- Supports additional comments

Technical Support Reporting


Service Guide

The printer software suite will expire the Job Accounting feature after 90 plot hours unless the printer software is registered. There are three ways to register:

1. Direct from the Registration page during software installation (web connection required from software installation location) or at Client Control Panel, choose Help – Product Registration.

2. Through website (www.encad.com), printer serial number will be required.

3. Call directly into US Technical support with printer serial number.

Encad San Diego will have a utility which will automatically generate a code (xxxx xxxx xxxx xxxx xxxx xxxx xxxx) upon registration and an e-mail with the activation code will be forwarded back to the customer. From the Client Control Panel select: Help - Product Activation - Add Key. Enter the code and select Ok.

Software Activation

Installation/Operations: Calibrations

Service Guide

Calibration Path Summary

Printer Calibrations

Prime Pattern

Manual Jet Compensation


Service Guide

Line Accuracy Calibration:

1. Perform Line Length Test; measure distance

2. Adjust Line Length Value (i.e. enter 33.06)

3. Perform Deadband Calibration

4. Perform Color Calibration Vertical

5. Perform Color Calibration Horizontal

For graphics printing (minimized microbanding) perform Graphics Calibration. For accurate line length accuracy perform the Line Accuracy Calibration. Either way, the 4 primary calibrations must be performed prior to conducting any printer operations. Refer to Service Bulletin 1 or Technical Bulletin 1 for complete instructions.

Graphics Calibration:

1. Perform Line Length Test; measure distance

2. Measure Line Length Value (i.e. 33.06)

2. Modify Img Quality Value (i.e. 33.06) and press Ok. Save Calibration to User setting.

3. Perform Deadband Calibration

4. Perform Color Calibration Vertical

5. Perform Color Calibration Horizontal

6. Evaluate print performance (Demo image/6-pass mode)

7. If necessary perform micro-alignment, print the Printer Calibration Test Target.rtl (from Service CD). Adjust Paper Calib Value to reduce microbanding. Perform Color Calibration Vertical



Service Guide

Calibration Menu

Paper Calib Menu

Note 1: the media feed/stepping rate is determined by either the Paper Calib Value or the Line Length/Img Quality Value last entered, but not both.

Note 2: DO NOT use the PAPER CALIB TEST as results may vary.

All printer calibrations are located in one menu.



Service Guide

Step 1. Graphics Calibration

a. Perform Line Length Test, select UTILITY MENU - CALIBRATION MENU - PAPER CALIB MENU - LINE LENGTH TEST. A line pattern will be printed in the center of the media; the pattern extends approximately 33 inches or 838.2 mm. Measure and enter true distance between lines (a 35 inch ruler may be printed from Service CD).

b. Modify Img Quality Value (i.e. 33.06) and press OK. Save Calibration to User setting.

c. Perform Deadband Calibration, Color Calibration Vertical and Horizontal (see following pages).

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.



Service Guide

e. Evaluate print performance using a demo image in 6-pass mode.

f. If banding is unacceptable, then print the Printer Calibration Test Target.rtl (send file through EFPU) located on Service CD.

g. Adjust Paper Calib Value to reduce microbanding. Analyze the calibration test target print for media overfeed or underfeed. If overfeed is observed as in example A below (white lines/gaps occurring), then reduce the Paper Calib Value by one or two values and retest (i.e. change from 4806 to 4805). If underfeed is observed as in example B below (dark lines/overlap occurring), then increase the Paper Calib Value by one or two values and retest (i.e. change from 4806 to 4807).

Example A (need to decrease values). Example B (need to increase values).

h. Perform Color Calibration Vertical (see following pages).

Step 1. Graphics Calibration



Service Guide

a. Perform Line Length Test, select UTILITY MENU - CALIBRATION MENU - PAPER CALIB MENU - LINE LENGTH TEST. Measure and enter true distance between lines (a 35 inch ruler may be printed from Service CD).

b. Adjust LINE LENGTH VALUE and select OK. Save Calibration to User setting.

c. Evaluate the test pattern, cut media and remove from printer. Measure the distance between the horizontal lines and enter the measured value under Line Length Value. Press OK, this will lock the media feed value.

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).

Step 1. Line Accuracy Calibration



Service Guide

Step 2. Deadband Calibrations

Select UTILITY MENU - CALIBRATION MENU - COLOR DB MENU - COLOR DB TEST. For each color choose the best group of aligned vertical lines.

Note the compensation number below each group of vertical lines.



Service Guide

Step 3. Color Calibration Vertical

Perform whenever a cartridge is removed or replaced. Select UTILITY MENU - CALIBRATION MENU - COLOR CALIB MENU - VERT. CALIB. TEST

Step 4. Color Calibration Horizontal.

Choose number which best represents alignment between both colors for each field.

Perform Horiz Calib Test; repeat procedure as above.



Service Guide

Check printhead nozzle performance by activating the Prime pattern. Select UTILITY MENU - PRIME MENU - PRIME ALL. Verify diagonal lines are smooth and clogged jets are not present. 1) Solid blocks represent failed jets; compensation engaged no user interaction is necessary. The cartridge warranty is provided from a designated number of these blocks observed in pattern and less than 700 ml ink throughput. Refer to regional cartridge warranty claim documentation from technical support. 2) Perform Manual Jet Compensation as necessary for: 3) Clogged Jets4) Mis-directed Jets5) Degraded Jets

VideoPrime Pattern


Service Guide

A series of patterns will print:1) Color Test; ink system pressure test, also used to help unclog print head nozzles2) Prime pattern; test to check all 640 print head nozzles3) 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.

If a cartridge problem is suspected, check cartridge performance by selecting UTILITY MENU - SERVICE MENU - DIAGNOSTICS MENU - PRIME SCRIPT. Select appropriate cartridge stall to check.

Prime Script


Service Guide

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.

To bypass a clogged or misfiring jet select UTILITY MENU - CALIBRATION MENU - OPEN JET MENU - EDIT LIST MENU. Select appropriate color.

Manual Jet Compensation

Installation/Operations: Printer Operations

Service Guide

Media Load and Verification

Dryer Modes

Humidity Control

Printer Readiness

Reservoir Replacement

Ink Cartridge Replacement

Ink Waste Disposal

Printer Safety

Ink Line Filling

Cutter Replacement

Printer Flushing


Service Guide

Video -Complete Media Load

Video -Quick Media LoadInstall media onto spindle and attach the media guide and tighten the blue locking nut. Verify spindle gears mesh properly. Ensure left media guide is locked next to the white alignment mark. Adjust right media guide to within 2 mm of media edge (guides should not touch media edges). Load media into the printer, align with white alignment mark.

Note: when media reaches end of roll do not forward media through printer rollers. Sometimes the end of roll contains excess glue which may cause frictional problems with the printer media transport system.

Note: paper will be automatically advanced following a 6 second delay and then measured.

Media Loading


Service Guide

Perfect Media Load

1. Load media at rear of printer. NOTE: Avoid damaging electrostatic strip at rear.

2. Move the rear edge media guides aside so that the media can move freely, left to right.

3. At front of printer reach down and hold the feed roller guide (do not allow roller to move), at main menu press and hold Feed Media - Forward.

4. The feed gear will start to move in an attempt to drive the media forward, but do not allow media to feed.

5. The media will begin to align itself, observe media right edge until no side-to-side motion is observed.

6. Release the Forward button after media stops moving sideways. Media should be aligned with feed roll edge.

7. At Main Menu select Load Media.

8. Move the left and right rear edge media guides to within 1-2 mm of media edges, but not touching. Install Paper Edge Guides (2) and Media Edge Holders (2).

Video -Perfect Media LoadMedia Loading


Service Guide

Video

To activate the drying system select Setup Menu - Dryer Menu - Dryer Setting. Scroll through available selections.

12 dryer modes are available; refer to dryer matrix label affixed to printer top cover.

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.

Dryer Modes


Service Guide

Ideal humidity for printing is between 45 and 55 percent, at a temperature of 68-72 degree F. (20-22.2 degrees C.). Refer to Service Bulletin 8.

Low Humidity problems: 1) Media warping and edge curl problems leads to visible carriage head strike on media surface. Ensure paper guides/edge holders are properly affixed to printer. Caution: keep magnetic assemblies away from the control panel display or damage will result.2) Inconsistent print quality is normally observed in severe low humidity environments. To compensate more ink must be used to balance the color loss.

High humidity problems:1) Dry time drastically increases with high humidity levels.2) Lamination issues often result; increasing time required to finish jobs.3) Color Shift from one day to the next may occur.

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.

Environmental FactorsHumidity Control


Service Guide

Video

To ensure the printer is ready prior to printing first activate the prime pattern by selecting Utility Menu - Prime Menu - Prime All. Refer to Technical Bulletin 1 for complete Printer Calibrations.

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.

Printer Readiness


Service Guide

End of Plot

Ensure the End of Plot mode is correctly setup. Select Setup Menu - Dryer Menu - End of Plot. Three modes are available:

On With Rewind (dries image and then rewinds print to save media)

On Without Rewind (dries image, does not rewind the print)

Off (no media advancement following printing, does not dry the remainder of print)

Edge Band Mode

Edge Band is a special mode used to help eliminate instances of First Drop (inconsistent small horizontal lines .2 mm to 10 mm appearing at left or right edges of print) - refer to Troubleshooting.

Select Setup Menu - Paper Option Menu - Margins - Edge Band.

The Edge Band mode employs the same spacing as Normal Margins but prints a 6 color line within each normal margin area.

Note: This mode does not encroach/crop the printed image. Enhanced margins with the edge band mode is not available.

Video - Edge BandPrinter Readiness


Service Guide

Video

Firmly grasp the used reservoir bottle and pull straight up. Install new reservoir by pushing reservoir firmly down into the intermediate reservoir at base of stall.

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.

Reservoir Replacement


Service Guide

Video

To replace an ink cartridge:

- Access cartridges by selecting Utility Menu – Access Cartridges.

- Lift the cartridge door by pulling on door lip up at a 45 degree angle.

- Remove defective cartridge from carriage.

- Remove tape from new cartridge and install cartridge.

- Close cartridge door by pressing down firmly until door locks.

- Return carriage to service station.

Caution: do not install/remove cartridges through the service station access door or damage to print heads or service station may result.

Ink Cartridge Replacement


Service Guide

Video

To remove the ink disposal bottle open the auto clean unit door and remove ink disposal bottle. Install empty waste disposal bottle and close auto clean unit door.

Ink Waste Disposal


Service Guide

Video

General operating tips to keep in mind:

- Never touch the slide shaft while printer is operating or damage may occur to printer.

- Never remove the service station while printer is in operation or bodily harm may result.

- Always keep top cover down to prolong carriage bushing life.

- Never install or remove cartridges through the access door or damage to print heads or service station may occur.

- Keep magnetic assemblies (Paper Guides/Media Edge Holders) away from the control panel display or damage will result.

Printer Safety


Service Guide

Video

Use this procedure to restore ink line pressure when a pressure loss occurs. Also refer to Technical Bulletin 4.

- Access Cartridges and remove cartridge for ink line to be primed.

- Install the Plug Bar (for new service stations only - yellow label) into the service station and attach tubing needle to septum fitting.

- Attach line fill cartridge into the cartridge stall position.

- Select and hold Utility Menu - Prime Menu – Service Station Menu – Pump On. Release ‘Pump On’ when ink is observed in cartridge tubing line. The line fill process takes approximately 4-15 seconds.

- When ink line is primed disconnect the line fill cartridge from stall position but leave tubing needle connected to septum fitting. Select Pump On to clean assembly of ink. Disconnect assembly when complete and remove plug bar from service station.

Ink Line Filling


Service Guide

Video

Select ‘Access Cartridges’ to move carriage assembly to maintenance position.

At left side of carriage assembly, press down on cutter tab to remove cutter. Pull cutter free.

Install the new cutter by pushing cutter assembly into carriage’s left side until a click is heard.

Return carriage to home position.

Cutter Replacement


Service Guide

Video

Refer to Technical Bulletin 3 for complete printer flushing/repacking instructions.

- If an ‘early model’ auto clean motor/pump assembly is installed, no red star is present on auto clean unit door, then only use the EasyPrime equipped Printer Flush Kit P/N 222351-00 for flushing the ink lines or permanent damage to auto clean motor/pump may result.

- If the auto clean unit has a red star visible on inside of auto clean unit door or the printer is equipped with the newer version of the auto clean unit pump (blue in color) then either the cartridge with tube assembly and/or plug bar assembly may be used in conjunction with Printer Flush Kit P/N 221984-01 for flushing the ink lines.

Printer Flushing

Maintenance: Routine Maintenance

Service Guide

Checking Plot Hours

Cartridge

Service Station

Platen Surface

Encoder Strip/Encoder Sensor

Flex Driver Cables

Slide Shaft

Carriage Paper Sensor

Carriage Bushing Replacement

Note: strict adherence to plot hours listed is strongly recommended to reduce time between failures.


Service Guide

Routine Maintenance is based on plot hours. Obtain the Inkjet Printer Cleaning Kit prior to performing routine maintenance, P/N 216883-XX USA and Canada; P/N 218439-XX International. Additionally, for preventive maintenance cleaning (i.e. encoder sensor) then obtain Domestic Cleaning Kit P/N 220970; International customers may order Cleaning Kit P/N 221191.

NOTE: Use the printers control panel to check the plot hours. Select UTILITY MENU-DISPLAY SETTINGS. The plot time will be displayed at the bottom of the screen.

Checking Plot Hours


Service Guide

Video

Step 1. Activate the Clean Function. Select UTILITY MENU-PRIME MENU-CLEAN. Select cartridge stall to clean. Step 2. Activate the Prime Pattern to verify jet performance. Select UTILITY MENU-PRIME MENU-PRIME SINGLE. Select appropriate cartridge stall to check.

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.

Video

Cartridge


Service Guide

xxx xxx

NOTE: DO NOT REMOVE SERVICE STATION WHEN CLEANING

Manual Cleaning Procedure

Frequency: Every 40 plot hours.

Move carriage out to maintenance position by selecting UTILITY MENU-ACCESS CARTRIDGES. Open service station access door. Dampen a lint-free cloth with NovaKlean solution, apply to wipers and seals. Clean all wipers and seals thoroughly. Ensure no lint fibers remain on surfaces.

Video

Service Station


Service Guide

Frequency: Every 75 plot hours

After removing power from the printer and lowering air plenum to maintenance position apply NovaKlean solution or De-Ionized water to a lint-free towel and wipe the entire surface area platen surface.

Ensure no ink residue or cloth fibers remain on the platen.

Allow platen to dry completely before reinstalling media.

Platen Surface


Service Guide

Video

Frequency: Clean strip every 20 plot hours; clean sensor every 200 plot hours. Symptoms of dirty encoder strip/sensor include image shift as pictured below.

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.

Encoder Strip/Encoder Sensor


Service Guide

Video


After removing power from the printer and lowering air plenum to maintenance position remove the cartridges from the carriage assembly.

Apply NovaKlean to a lint-free towel and wipe the entire surface area of each cable.

Ensure no ink residue or cloth fibers remain on the cables.

Allow cables to dry completely before reinstalling cartridges.

Flex Driver Cables


Service Guide


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.

Caution: never use lubricants or silicates on the slide shaft.

VideoSlide Shaft


Service Guide

Frequency: During Preventive Maintenance or when a problem is encountered (i.e. Internal Shutdown - Carriage Axis Error).

After removing power from printer pull carriage assembly away from service station area. Remove the black and magenta cartridges.Remove service station by removing shim at left side using needle nose pliers (new station design) and gently pulling on two tabs and lifting station out. Caution: do not force station tabs or damage may occur; control tab movement with two fingers.Slide carriage assembly over service station access hole. Apply NovaKlean solution to a lint-free cloth, gently blot the paper sensor located directly behind the Magenta stall at base of carriage.Note: sensor is out of view (see picture below), but can be felt with finger tips. Both the LED and receiver portions of the sensor need to be thoroughly cleaned.

VideoCarriage Paper Sensor


Service Guide

Step 1. Remove power from printer.

Video

Step 2. Remove the Ink Delivery System Carriage Cover support brackets by removing 4 securing screws.



Service Guide

Step 3. Remove the left and right Bushing Retainers.

Step 4. Remove the two screws securing the cutter actuator.

Step 5. Remove both Carriage Bushings by prying away from carriage and sliding off of slide shaft.

Video


Maintenance: Cartridge Replacement

Service Guide

Checking Cartridge/Bottle Status

Cartridge Replacement Procedure

Checking Prime Pattern

Open Jet Bypass Procedure

Printing Tips

Ink Switch Over Procedure


Service Guide

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).

Verify warranty terms with technical support - see claim form.

To check cartridge/bottle status select Utility Menu - Service Menu - Ink Status Menu - Disp: Cart Info. (or Bottle Info.)

Checking Cartridge/Bottle Status


Service Guide

Video

Step 1. Access cartridges via control panel (Utility Menu - Access Cartridge)

Step 2. Open respective cartridge door by pulling out, and then up. Remove cartridge by pulling straight out.



Service Guide

Step 3. Remove accumulator/septum assembly from cartridge by pulling assembly straight out.

Step 4. Remove tape from cartridge bottom and install into cartridge stall. Close cartridge door. Note: cartridge door must be closed and locked to properly bias cartridge position.

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.



Service Guide

VideoTo print the prime pattern select Utility Menu - Prime Menu - Prime All

The Prime pattern checks the electrical firing capability of all 640 jets. Verify all cartridge nozzles are firing properly.

Checking Prime Pattern


Service Guide

Video -Cartridge Cleaning

Verify all cartridge jets (nozzles) are firing properly. For random jet clogs or misfires perform open jet bypass manually. Select Utility Menu-Calibration Menu-Open Jet Menu-Edit List Menu. Select color and specific jet to bypass, Toggle the jet off by depressing Toggle.

The Auto Pass Correction feature will automatically step the printer into the next available print mode. In the example below 3, 4, and 6 pass modes are not available in magenta - the printer will automatically switch to the 8 pass print mode regardless what mode was sent from the RIP. NOTE: This feature may be disabled by the customer.

If multiple jets (observed in groups) appear clogged, or excessive misfires are observed, cleaning of the cartridge and flex driver cables contacts may be necessary. Refer to Maintenance.

Open Jet Bypass Procedure


Service Guide

Video -Printer CautionsCaution: Do not replace a cartridge through service station access door or this may cause damage to both cartridge and/or service station seals.

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.

Printing Tips


Service Guide

Video - Printer Flushing

Step 1. Obtain Flush/Ink Switch Over Kit (P/N 222351-00 or 221984-01 - verify with technical support as to Flush Kit required). Remove all ink reservoirs and cartridges.

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.

Ink Switch Over Procedure

Maintenance: Firmware Download

Service Guide

Checking Firmware Version

Hardware/Software Requirements

Software Control Download Procedure

Stand Alone Download Procedure


Service Guide

Step 1. Select Utility Menu - Service Menu - About

Step 2. Determine firmware level prior to downloading new firmware. Firmware level is indicated by the Vers. (version) line.

Checking Firmware Version


Service Guide

Operating Systems:

Windows 2000/XP/XP Pro

- Ethernet cable from server workstation

- Crossover ethernet cable from peer to peer workstation

Software Required:

-Software Control Panel provided on CD with printer

- EFPU (Encad File Print Utility)

1) Host Workstation

2) Software Control Panel Software (EFPU software)

3) Ethernet Cable (crossover cable required for peer-to-peer connection)

4) Printer

Hardware/Software Requirements


Service Guide

Step 1. Open Printer Software Control panel, select Auto-Update.

Step 2. Via web browser, latest firmware revision will be downloaded. If a web connection is not available, obtain firmware from technical support and perform the Stand Alone Download Procedure.

Step 3. Open EFPU (File Print Utility) software.- Create a new folder (i.e. printer download)- Add firmware .rom file (choose all files to view) to EFPU window

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

Software Control Download Procedure


Service Guide

Step 1. System setup

- Establish ethernet peer-to-peer connection to printer via crossover cable (set IP address at printers control panel)

- Load EFPU (Encad File Print Utility) software

- Create a new folder (i.e. printer download)

- Select TCP printer port (Note: an LPT port must be available for the EFPU to work properly. Load a Windows driver; setup for local port and LPT1 if necessary.)

- Add firmware .rom file to EFPU window



Service Guide

Step 2. Download Firmware

- Within EFPU program, highlight firmware file and select Print.

- Printer should emit a single audible beep after approximatly 60 seconds.

Step 3. Verify Download was successful. Cycle power to printer.

- Check the About screen for current firmware version


Troubleshooting: Advanced Analysis

Service Guide

Prime Pattern Problems Connectivity Failure

Error Messages xxx

Horizontal Banding Problems xxx

Vertical Banding Problems 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).

Ink System/Pressure Failures

Improper Print Output

Printer Initialization Failure

Carriage Movement Problems

Media Feed/TakeUp Failure

Media Drive/Image Skew Problems

Dryer System Failure


Service Guide

1. Checking Prime Pattern

Video - Printer Readiness

Inspect and verify all cartridge nozzles are firing properly. To print the prime pattern select Utility Menu - Prime Menu - Prime All. If cartridge misfires or clogged jets are observed in the prime pattern activate the clean routine by selecting Prime Menu - Clean. Choose the appropriate cartridge stall to clean. If necessary activate printhead suction. Select Prime Menu - Service Station Menu - Vacuum Prime. Note: activating vacuum prime will remove approximately 1 ml of ink from cartridge.

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.

Prime Pattern Problems


Service Guide

2. Manual Jet Bypass/Cartridge Cleaning

Video - Cartridge Cleaning

To perform Manual jet bypass (open jet compensation) select Utility Menu - Calibration Menu - Open Jet Menu - Edit List Menu. Choose the appropriate color to edit. Scroll to clogged/degraded jet, toggle jet to off position.

Note: if jets appear clogged cleaning of the cartridge and flex driver cables contacts may be necessary. If 80 or 160 jets appear to be damaged, first try reseating cartridge and/or clean rear electrical contacts and flex cable surfaces.



Service Guide

3. Prime Script Test Pattern

If an electrical failure in the cartridge is suspected verify performance by selecting Utility Menu - Service Menu - Diagnostics Menu - Prime Script. Select appropriate cartridge stall to check.

A series of patterns will print:1) Color Test; ink system pressure test, also used to help unclog print head nozzles2) Prime pattern; test to check all 640 print head nozzles3) 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.



Service Guide

Possible Recoverable Error Condition: 1. Internal Error: Shutdown Carriage Axis Failure.2. [Cl] Bottle Error!3. Y:Max Ink Temp.! Abort Job? or Y:Overcurrent Cartridge Shutdown! 4. K: Warning - Ink Reservoir Low! message appears but ink level is correct.5. M: Ink Reservoir Low! message appears and ink level is below normal.6. [Y] Pen Error!/Pen Error - Job Paused!/APC unavailable. Abort Job?7. Warning: Empty Waste Bottle Now! (door is closed and bottle is empty)8. Pen Error 10.

Video - Carriage Axis Error

Probable Cause:1. Dirty slide shaft, bushings, or encoder strip; Unseated or damaged bushings/trailing cable.2. Improper bottle contact with ID sensor. Damaged bottle IC and/or OEM bottle installed.3. Improper Y cartridge ink level/pressure; air bubbles in ink line. Cartridge deprime.4. Damaged K intermediate reservoir or sensor/connection.5. Damaged M intermediate reservoir or air leak in line exists. Check tubing and damper.6. Improper contact between cartridge and flex cable. Damaged cartridge/ID chip.7. Damaged sensor/wiring connection. Motor/pump is installed incorrectly.8. Invalid ink type - change respective cartridge or bottle.

Expanded Error Message List

Error Messages


Service Guide

Error Messages


Service Guide

Note: Printer Operations/User Guide documentation should be consulted for any other operational problems encountered.

Common Operational Error Condition:1. Paper Not Loaded!/Job Pause - Out of Paper!2. C: Warning - Ink Reservoir Low!/Job Pause - E.O.M. Detected!3. Warning: Empty Waste Bottle Now!4. Reminder: Adjust Rear Paper Guides!5. Warning: Reinstall Service Station!6. Cartridge End of Life.7. Dryer Warming Up, Print Anyway?8. Ethernet: 100HD (6.7E-01, etc.) seen under Network Menu

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.

Error Messages


Service Guide

Note: these conditions normally require parts replacement by a certified technician.

Service Required Error Condition:1. Paper Sensor Failure.2. Auto-Paper Sensor Failure.3. Encoder Sensor Failure.4. MBID Error - Code x (x = error code).5. Carriage Paper Sensor is Unstable/TX Caller Error6. Dryer Sensor Fault!/Dryer System Fault - Dryer Off7. No Display at control panel. Printer repeatedly reboots.8. Carriage FPGA error. 9. Fatal PPC40X 11C.C128 error message10. TSR error (all cartridges)11. Ethernet Down

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.

Error Messages


Service Guide

1. For general banding problems first ensure print head nozzles are firing correctly by checking the Prime pattern. Activate Clean or Vacuum Prime (3x maximum) to help clear nozzles. Perform color test.

Videos

Clogged nozzles or misfiring nozzles (check open jet detection) may produce single-band (line) misfires in the printed image.

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.

Horizontal Banding Problems


Service Guide

2. Microbanding is defined as consistent bands spaced horizontally (spaced 0.5 mm to 14 mm) down the entire print or through a particular color space.

Ensure lower rollers are free of residue and verify vacuum fan suction is present below platen during printing. Check calibrations by activating the Paper Calib Test, Color Deadband, and Color Calibrations (vertical and horizontal). Refer to Calibrations and/or Service Bulletin 1.

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.



Service Guide

3. Scraping Bands appearing at media edges are likely caused by incompatible media type or media edge curl caused by low humidity in operating environment.

Enable the Edge Band Mode (or turn on Gutters at RIP) to help reduce Edge Spikes or First Drop from occurring. See video.

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).



Service Guide

4. Severe Data shift combined with gradual image shift (at vertical border/edge of print) is either a dirty carriage encoder sensor or encoder strip. Clean all surfaces thoroughly using an ammonia based glass cleaner - refer to Maintenance. Refer to Technical Bulletin 5.

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.



Service Guide

7. For color specific in-swath banding increase print pass mode (i.e. from 6-pass to 16-pass; printer should not band in 16-pass). Check prime pattern; replace respective cartridge.

Contact technical support for assistance. Download and install the latest firmware - refer to Firmware Download.

Video

Note: right or left side banding may be caused by the rear paper guides being too close to media edges; this will also affect paper feed values.

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.



Service Guide

1. Vertical banding across an image (printed on backlit/duratrans media) can be caused by excessive dryer temperature. Lower dryer temperature or turn dryer off and re-print image to verify. Follow media reference guidelines - refer to Technical Bulletin 6.

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.

Vertical Banding Problems


Service Guide

3. The absence of one color, producing printed image gaps in the vertical plane, normally indicates the trailing cable is damaged. Refer to step 5. For data shift problems verify proper printer grounding; refer to Service Bulletin 8.

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.



Service Guide

5.If vertical swaths or gaps appears in image, the trailing cable/connector is probably damaged. Inspect T-cable. Reseat trailing cable connections at carriage/main board. Replace trailing cable assembly.

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.

Video



Service Guide

1. Ink delivery failures are typically signified by a cartridge MAX INK TEMP error. If one color fails to print verify ink system pressure is normal. Re-prime ink line (s) using the Cartridge with Tube Assembly and the Pump On feature (or pull ink directly into special service tool: pressure test cartridge/VacLok Syringe). No large air bubbles (gaps) should be present in main ink line. Verify all ink tubing connections are good.

Video - Testing Ink Pressure

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.



Service Guide

4. Under DIAGNOSTICS MENU, select the INK RESERVOIR TEST. All values should indicate a level 1 if ink is installed; the normal full level (the observer may note the level is slighly more than 50%; approximately 50 ml. If a sensor failure occurs replace Intermediate Reservoir PwA.

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.



Service Guide

7. For an auto clean unit sensor failure (i.e. EMPTY WASTE BOTTLE NOW or MISSING WASTE BOTTLE error message) reseat both wiring harness connections between auto clean unit and platen.

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.



Service Guide

8. For an auto clean unit pump failure (i.e. ink is spitting out of service station or complete pump failure occurs) replace pump assembly. Pump failures include improper operation during routine cap evacuation (normally occurs every 2.5 minutes during print operations) or during line filling (PUMP ON) operations. Pump should be heard when activated.

To test pump select UTILITY MENU - PRIME MENU - SERVICE STATION MENU - PUMP ON.

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.

Pump Assembly with screws



Service Guide

1. Ensure all cartridges are firing properly.

2. Verify relative humidity levels are between 40 and 60 percent. Install humidifier or de-humidifier as appropriate to prevent color shifting between tiles. Always bag media when not in use. Refer to Technical Bulletin 6.

3. Check RIP (Raster Image Processor) ink/media output profile settings; also check input ICC settings. Install new/updated profiles from RIP vendor (NOTE: this is the primary solution to correct color problems).

4. Re-linearize ink/media profiles to maintain proper gray balance using RIP ink/media color calibration software (i.e. Media Manager/Media Profiler) or 3rd party color calibration software. Contact RIP vendor or color specialist for assistance.

5. Refer to Service Bulletin 7 for error code related problems.

Video - Environmental Factors

Incorrect color output

Proper color output



Service Guide

5. Activate Prime Pattern test. If cartridge jets are misfiring or are clogged/missing (as observed in the prime pattern) reseat the cartridge. In the example image (at right) the Magenta cartridge was incorrectly seated into the carriage assembly.

6. Assuming printer calibrations have been performed properly, replace the cartridge if unacceptable image quality is observed from a ripped/external test print.

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.



Service Guide

9. For sudden color shifts (i.e. observed during a tiling job), the TSR value may be reading incorrectly (TSR Found -; TSR error). Verify Cartridges TSR status. Power off printer and clean cartridge/flex driver cable connections - refer to maintenance. Replace cartridge if necessary.

When a print head is installed it may appear to work fine (all jets firing, etc.) but the color output may be incorrect due to a mis-read of the temperature sensing resistor (TSR). This will cause the cartridge to switch from an internal TEMP CONTROL mode to a PREHEAT MODE; there is no warning built-in to notify the operator of this situation. Verify the cartridge status by selecting the adjacent F keys at Cartridge Status menu; verify signal level is detected (TSR Found +); TSR value is normally between 455 and 525.

NOTE: If TSR ERROR is displayed for all cartridges then the carriage board is probably damaged. Check trailing cable connections; Replace Carriage PWA.

Cartridge Status - Advanced Menu Screen

NOTE: ID should equal 6 after .10 ml of ink throughput; firmware dependent



Service Guide

10. If printed data appears to be out of synchronization (in the horizontal/carriage movement direction) or resembles ink overspray, combined with an abnormal cartridge failure rate (as low as 50 ml througput) then earth grounding to the printer will need to be verified. Refer to Service Bulletin 8.

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.



Service Guide

1. Check power connection and power source to printer. Check circuit breaker position - if breaker is protruding out then the power supply is probably damaged. With power off, cycle 115V/230V voltage selector switch to ensure contact positioning is good. Reboot printer to retest.

Video

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).



Service Guide

3. To help locate the problem, isolate loads by disconnecting connections to Dryer, takeup and feed system and Auto Clean Unit. If necessary, isolate motor loads: J13, J7, and J9.

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.

5. If main board has intermittent or no LED activity, replace Power Supply.



Service Guide

6. For partial initializations (i.e. carriage stops at left side during power up), replace memory module (SDRAM: 64MB) at Main PWA.

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.



Service Guide

8. If printer reboots repeatedly with the control panel message...CLEARING MACHINE TYPE...then either the keypad connection (via green cable) is unseated or the keypad assy. is damaged. Replace keypad assy. (sheet switch).

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.

Video - Keypad/Display RemovalPrinter Initialization Failure


Service Guide

1. Check printed image for skewing/data shift - clean encoder sensor/strip. Refer to maintenance and Technical Bulletin 5.

NOTE 1: No lubricants should be present on the slide shaft, carriage belt or carriage bushings. Clean printer thoroughly - refer to Maintenance.

NOTE 2: For OEM4 printers verify the plastic guide (42 or 60 inch guide controlling media height) is not deformed and causing interference. Modify or replace guide as necessary.

Video - Carriage Axis Error

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.

Video - Encoder Sensor/Strip Cleaning



Service Guide

3. Remove carriage bushing retainers and carriage bushings. Inspect carriage bushings and clean lint/excessive residue buildup from bushing as necessary. Replace bushings if excessive wear is observed (see step 7) or at 1000 plot hours.

Inspect bushing shims (4 total) for wear and tear - replace shims if either the bushing shims are missing or if the shim edges are lifting.

Video - Carriage Bushing Removal

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.



Service Guide

7. Temporarily remove cutter and service station from the printer; retest to verify fault condition. Check UTILITY MENU - DISPLAY SETTINGS menu for logged plot hours. Replace service station if REINSTALL SERVICE STATION error message is observed; upgrade to non-geared station type if necessary. Refer to Service Bulletin 10.

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.

8. Clean the carriage paper sensor - refer to Routine Maintenance. This will help eliminate any overlapping problems from occurring.



Service Guide

10. Replace the Trailing Cable. Refer to Disassembly.

Video - Trailing Cable Removal

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.



Service Guide

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).

Video - Legs Testing

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.

Media Feed/TakeUp Failures


Service Guide

4. Check wiring harness connection between the platen and main PWA (check for loose or disconnected wires). Verify wiring resistances; if damaged replace wiring harness assembly. Inspect for ink contamination at plug (from service station); clean/flush connections thoroughly if ink is present in connector.

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).



Service Guide

6. If sensors are functioning correctly but gear/shaft (s) fails to turn (no motor drive), verify electrical resistance of feed/take-up motor. Check resistance levels between motor gear and ground, values should be between 0 and several hundred Kohms (5 to 70 ohms is typical). Values in the Mohms indicate the motor bearings are probably damaged or printer is not grounded properly. Swap motor positions to isolate problem; replace motor if out of range.

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.



Service Guide

9. While running LEGS TEST verify drive signals to motor (i.e. pulsing 24.0 volts dc, 0.0 volts dc when not active). Swap or replace respective motor if determined damaged.

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.



Service Guide

1. Ensure media is loaded properly following Technical Bulletin 1 guidelines; check rear paper guides.

NOTE: maximum compatible media thickness is 0.024 inches or 0.6 mm. Clean lower rollers of vinyl adhesive residues if present.

Video -Perfect Media Load

2. Perform diagnostic tests as outlined in Service Bulletin 17 to verify the lower roller and center support shaft/bearing assembly are functioning properly. This includes a lower roller gear/drive test, mechanical alignment test, lower roller skew test, and a lower drive inspection. NOTE: Both the lower roller and new support shaft/bearing assembly (pictured at right) should be replaced at the same time if a damaged lower roller is discovered.

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).



Service Guide

3. If tile lengths are drastically inconsistent throughout entire job (i.e. tile to tile) and/or severe banding/inconsistent banding then the lower drive roller may have insufficient/improper drive compression (applied from the center support shaft/bearing assy).

Remove center support shaft/bearing assy and inspect lower roller for damage. If damage is observed then the lower drive system and center support shaft/bearing assy. will need replacement. CAUTION: refer to SB17 for evaluating lower drive performance and for complete lower drive system replacement instructions.

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.

- Inconsistent banding

- tile length differences



Service Guide

4. If the media does not advance or banding is spaced every 1.33 (or every 8) inches consistently down print this typically indicates a stepper motor failure. Verify motor winding resistance across Main PWA J7 (pins 1 - 2 is normally 2.3 ohm, pins 1 - 3 is normally 4.2 ohm.). Replace the lower drive system for either failure - refer to Service Bulletin 17. (NOTE: stepper motor cannot be replaced independently)

5. Check Main PWA signal drives during FEED MEDIA - FOWARD/BACKWARD tests. Verify +24 volts dc at Main PWA R13/R18 (refer to Main PWA schematic, sheet 6 of 14). Replace Main PWA if drive signals are not present.

6. If the lower roller is not visibly damaged but image to image lengths continue to fluctuate drastically (combined with severe banding), then the large press-fitted gear (at right end of lower roller) may be defective. Run four (4) line length tests to verify media slip is occurring. Replace the lower drive system - refer to Service Bulletin 17. There is no reliable way to test this gear independent of the rest of the system.

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.



Service Guide

7. Check roller heights and platen compression levels. Refer to Service Bulletin 17. The carriage and Y-Arm will need to be removed. Verify L/R/C lower roller heights and C1/C2 compression values (do not rely on the platen profile label below service station - values should be measured for field installation accuracy!). If values are incorrect then shim or adjust the lower drive system as necessary.

Typical In-Field Alignment Example: Roller Height (in) above Platen Left 7 6 5 4 3 2 Right 0.011 0.008 0.006 0.010 0.009 0.010 0.011 0.018

NOTE: LOW is 0.006, HIGH is 0.018, RANGE is 0.012; this example used a smile profile of 0.003



Service Guide

1. Power off printer. Cycle voltage selector switch (i.e. 230v to 115v to 230v; set to region). Power on Printer; activate the dryer and check dryer status: Select SETUP MENU - DRYER MODE MENU - DRYER SETTING (select 4), press Ok. Select UTILITY MENU - SERVICE MENU - DIAGNOSTICS MENU - ACCESSORY MENU - DRYER STATUS. Normally the T1 and T2 values (temperature sensors) should drive up to 40C after approximately 5 minutes. If not, refer to Service Bulletin 6 and the following steps.

Video - Printer Initialization

2. Remove power from printer and remove right-rear cover. Check dryer connection at Main PWA (J12). Remove bottom right cover. Reseat all dryer board connections, including dryer connection at Dryer PWA (J12); verify dryer SSR connection at Dryer PWA (J4).

3. NOTE: If the circuit breaker is blown (protruding outwards) there is usually a reason why it is blown, such as an electrical short. Verify circuit breaker continuity between TB1-1 and SSR-1 - refer to AC wiring schematic. If open, then the circuit breaker is open/blown and will need replacement. Following CB replacement, first verify electrical continuity across all wiring harnesses/heater strips/sensors prior to power up.



Service Guide

4. For a dryer system only failure (heat portion only; air plenum is operational) check SSR (solid state relay located below the power supply) activation signal (from Main PWA) for 4.5 to 15 volts dc at SSR-3. Refer to AC wiring schematic. When the SSR is enabled it allows AC to pass to the 6 (six) heater strips (at approximately 3/4 of input AC source voltage). Activation signal, HTR ON signal (also at Dryer PWA J4-2) only occurs at the time of dryer activation (best to activate this by placing DRYER SETTING TO 0, press Ok; set DRYER SETTING TO 6, press Ok. Simultaneously look for dc signal when pressing Ok). If activation does not occur, then an error condition has occurred (DRYER SENSOR FAULT). Replace SSR if damaged.

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).



Service Guide

7. Conduct electrical resistance checks. Power off printer. Verify electrical resistance across both thermocouple sensors (J8 and J9) for approximately 10K ohms. Verify electrical resistance across dryer fuse (J6), for approximately 0.3 to 0.9 ohms (possibly up to 2 ohms), but not open. If discovered open, place fuse in freezer (below 0C for 25 minutes to reset). Retest fuse assembly.

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.



Service Guide

10. Replace any wiring harness with faulty resistance values (greater than 0.6 ohms across wiring/jacks).

11. Replace Main PWA if failure persists.

NOTE: Ensure the air plenum is properly grounded in accordance with Service Bulletin 8.



Service Guide

3. Check cable type for respective configuration. Use regular RJ-45 patch Ethernet cable when connecting to HUB or Switch; use crossover cable if going direct from computer to printer. Verify HUB/Switch operation; swap ports to verify function.

1. Ensure network is within IP range of printer (i.e. first three sets of numbers are the same) and port is assigned/configured (For Windows systems ensure the Windows driver is loaded with active IP address). Verify SUBNET and GATEWAY addresses; typically the same as the computer/server. Check IP CONFIG MENU - refer to NETWORKING section.

2. Verify DHCP (Dynamic Host Control Protocol) configuration; normally disabled for most installations Check printers network LED status at rear of printer.

4. Attempt to ping the printer - refer to the NETWORKING section.

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.)

Connectivity Failure

Service: Disassembly

Service Guide

Right Covers Carriage Assembly

Left Covers Ink Delivery/Trailing Cable Assembly

Keypad and Display Intermediate Reservoir Assembly

Main PWA and Clone Procedure Service Station/Station Upgrade

Power Supply/Cooling Fan Auto Clean Unit

Power Components Encoder Strip Assembly

Dryer PWA and Voltage Switch Pinch Roller Assembly

Servo Motor Media Drive System

Ink Dampers/Septums Nose Heater Assembly

Carriage Bushings Air Plenum Assembly

Carriage PWA Media Takeup/Feed System

Trailing Cable


Service Guide


Video

Step 2. Remove the Right Rear Cover by removing 2 securing screws.

Note: The Printer Service Tool Kit prior is required for performing most major service actions.

Right Covers


Service Guide

Right CoversStep 3. Disconnect the Air Plenum.

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.

Right Covers


Service Guide

Step 1. Remove 2 screws securing top-left cover.

Video

Step 2. Remove 6 screws securing left cover.

Note: gently twist left cover to aid in removal; 4 clips secure cover to reservoir bay.

Left Covers


Service Guide


Video


Caution: keep magnetic assemblies (i.e. Paper Guides/Media Edge Holders) away from the control panel display or damage

will result.

Keypad and Display


Service Guide

Step 3. Disconnect the Air Plenum.

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Step 4. Remove the Right Lower Cover. Ensure inner clips securing right lower cover are disengaged.

Keypad and Display


Service Guide

Step 5. Disconnect the keypad from J5 on the MPWA.

Step 6. Disconnect the display from J4 on the MPWA.

Keypad and Display


Service Guide

Step 7. Remove the Display Mount Cover Assembly.

Note: during assembly ensure grounds are properly attached.

Keypad and Display


Service Guide

Step 8. Remove the EMI shield.

Step 9. Remove the Display Assembly and/or Keypad Assembly.

Keypad and Display


Service Guide


Video


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Main PWA and Clone Procedure


Service Guide

Step 3. Remove all connections to the Main PWA.

Caution: ensure that the locking clip is released before removing the Trailing Cable connection (J1).

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Service Guide

Step 4. Remove the Memory Module.

Step 5. Remove the Main PWA.

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Service Guide

Step 6. Main PWA Clone Procedure

A) Replacement of a main board in the field will require either the customer to be running Server/Client Control software or the technician to have the printer software available on a laptop computer. There is no dongle or password for this operation. The software has a hidden service page (Note: will only be displayed when connected to a non-serialized main board). The only way to activate the page is to connect to the PC running the software with a main board that has no serial number. A serial number present will disable the control channel functions required to clone a board.

B) When this condition exists, the service page can be activated by launching Client Control Panel; select TOOLS - SHOW SERVICE PAGE. In the current version, this activation method is always present. When the software releases, the Show Service Page menu item will be hidden until the main board with no serial number is detected.



Service Guide

C) The SHOW SERVICE PAGE has two simple choices:

1. If the customer is running Client software with the database, a list of potential clones will be displayed. The service tech will select the appropriate one and press a button to send the settings and serial number to the new main board.

2. If the customer is not running our software, the service tech can connect a laptop computer to the printer via cross-over, select the service page as described above and type in the serial number manually then send it to the printer.

Caution: Ensure the printers alphanumeric serial number (exact letter/number combination) is downloaded or the Main PWA will need to be returned to an Encad service center for re-initialization.

D) If it is determined the new main board does not fix the problem, do not clone the main board or reset the serial number. Clear Machine Type by holding bottom-left key and powering up printer; Clearing Machine Type should be displayed after approximately 20 seconds. Remove Main PWA and replace with original Main PWA.



Service Guide


Video


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Power Supply/Cooling Fan


Service Guide

Step 3. Disconnect the Air Plenum. Remove the Right Lower Cover. Ensure inner clips securing right lower cover are disengaged.

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Service Guide


Note: during assembly, ensure grounds are properly attached.

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Service Guide


Caution: ensure the locking clip is released before removing the Trailing Cable connection (J1).



Service Guide

Step 6. Remove all connections to the Dryer PWA.



Service Guide

Step 7. Remove the PWA Mounting Bracket Assembly.

Step 8. Rotate the PWA Mounting Bracket Assembly 90° towards the back of the printer.

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Service Guide

Step 9. Remove connections to the Power Supply and/or Cooling Fan.

Step 10. Remove the Power Supply and/or Cooling Fan.

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



Service Guide


Video


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Power Components


Service Guide

Step 3. Disconnect the Air Plenum. Remove the Right Lower Cover. Ensure inner clips securing right lower cover are disengaged.

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Power Components


Service Guide


Note: during assembly, ensure grounds are properly attached.

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Power Components


Service Guide


Caution: Ensure that the locking clip is released before removing the Trailing Cable connection (J1).

Power Components


Service Guide


Note: during assembly, thermal sensor connections (J8-J9) air plenum fan connections (J10-J11) and nose heater connections (J1-J3) plug order is not critical since sensors, fans and heaters energize together respectively.

Power Components


Service Guide

Step 7. Remove the PWA Mounting Bracket Assembly.


Power Components


Service Guide

Step 9. Disconnect and remove the Power Entry Module.

Note: during assembly, ensure that the ground is properly connected.

During assembly, ensure that the Circuit Breaker is depressed.

Step 10. Disconnect and remove the Circuit Breaker.

Power Components


Service Guide

Step 11. Disconnect and remove the Nose Heater Switching Relay (10 amp Solid State).

Note: during assembly, ensure the wiring harnesses are properly oriented.

Power Components


Service Guide


Video


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Dryer PWA


Service Guide


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Dryer PWA


Service Guide


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Dryer PWA


Service Guide


Caution: ensure the locking clip is released before removing the Trailing Cable connection (J1).

Dryer PWA


Service Guide


Note: during assembly, thermal sensor connections (J8-J9) air plenum fan connections (J10-J11) and nose heater connections (J1-J3) plug order is not critical since sensors, fans and heaters energize together respectively.

Dryer PWA


Service Guide

Step 8. Remove the PWA Mounting Bracket Assembly by removing 4 screws and removing two nuts which secure the two ground wires.


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Dryer PWA


Service Guide

Step 10. Disconnect and remove the Voltage Selector Switch.

Caution: during assembly ensure the voltage selector switch is properly configured to the local power source, 115V or 230V.


Step 11. Remove the Dryer PWA.

Dryer PWA


Service Guide


Video


Note: It is strongly recommended to obtain the Printer Service Tool Kit prior to performing major service actions.

Servo Motor


Service Guide

Step 3. Remove the Auto Clean Unit.

CAUTION: Ensure the waste disposal bottle has been previously removed from the auto clean unit or ink may spill.

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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Servo Motor


Service Guide

Step 4. Remove Servo Motor Connector from J9 on the MPWA.

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Servo Motor


Service Guide

Step 5. Slide the Carriage Assembly towards the center of the printer.

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.

Belt Removal Tool

Servo Motor


Service Guide

Step 7. Remove the Belt from the Servo Motor Pulley.

Step 8. Remove the Servo Motor by removing 2 securing screws; lower through platen access hole.

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Servo Motor


Service Guide


Video

Step 2. Lower the Air Plenum to the service position.

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.

Ink Dampers/Septums


Service Guide

Step 3. For Septum assembly removal, remove the Cartridge, Cartridge Door and Spring.

Note: when cartridge is removed place on a flat surface so the needle points upwards to avoid possible leaking.

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.

Door Spring position

Ink Dampers/Septums


Service Guide

Step 4. Remove the septum pressure restraint and E-Clip securing the Septum Assembly.

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.

Hose Clamp Tool

Ink Dampers/Septums


Service Guide

Step 6. For Damper Assembly removal, remove the Ink Delivery System Carriage Cover by removing 4 screws and the 2 Supporting Brackets.

Note: the Ink System Test Kit is required for this procedure.

Caution: verify the connection locking clip is released before removing the Trailing Cable connector.

Step 7. Disconnect the Trailing Cable connection from J1 on the Carriage PWA.

Ink Dampers/Septums


Service Guide

Step 8. Clamp the tube supplying ink to the Damper and cut both tubing lines to the Damper Assembly.

Note: do not use flared tube ends or air leaks into line tubing may occur.

Step 9. Remove damper by removing 2 securing screws.

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

Ink Dampers/Septums


Service Guide


Video

Step 2. Remove the Ink Delivery System Carriage Cover support brackets by removing 4 securing screws.

Carriage Bushings


Service Guide

Step 3. Remove the left and right Bushing Retainers.

Step 4. Remove 2 screws securing cutter actuator.

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).

Carriage Bushings


Service Guide


Video

Step 2. Remove the Ink Delivery System Carriage Cover and 2 Support Brackets by removing 4 securing screws.

Caution: verify that the locking clip is released before removing the Trailing Cable connection (J1).

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.

Carriage Board


Service Guide

Step 4. Remove Electronics Cover by pulling plastic cover clips outward.

Carriage Assembly

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Carriage Board


Service Guide

Step 5. Disconnect remaining connections on the Carriage PWA.

J4-J9 Flex Driver Cables

J2 Paper Sensor; J3 Encoder Sensor

Carriage Board


Service Guide

Step 6. Remove one screw securing Carriage PWA.

Caution: always wear electrostatic discharge (ESD) protection when working with ESD sensitive electronic assemblies or components.

Carriage Board


Service Guide

Step 1. Remove power from printer and lower air plenum to maintenance postion.

Step 2. Remove the Ink Delivery System Carriage Cover and 2 Support Brackets by removing 4 securing screws.

Video

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.

Carriage Assembly


Service Guide

Step 4. Open 6 cartridge doors and remove cartridges from carriage.

Step 5. Remove 6 door assemblies by first removing the 6 pressure restraints. Remove each door support by depressing clips on both sides of door support.

Step 6. Place cartridges on a flat surface so the needle points upwards to avoid leaking.

Note: do not disconnect ink line from septum assembly or repriming of ink lines will be necessary following this procedure.

Carriage Assembly


Service Guide

Step 7. Place cartridge door assemblies onto a drop cloth

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 8. Remove cutter from left side of carriage assembly.

Carriage Assembly


Service Guide

Step 9. Install belt removal tool by twisting between left side plate and frame tensioner to release carriage belt tension.

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.

Carriage Assembly


Service Guide

Step 12. Remove 1 screw securing each bushing retainer; remove carriage bushings from carriage.

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: Ensure that the Idler Assembly is oriented correctly on installation.

Carriage Assembly


Service Guide

Step 15. Remove Carriage Belt and Carriage Assembly from slide shaft - gently move reservoir chassis as needed to aid in removal.

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).

Carriage Assembly


Service Guide

Step 17. If replacing the Encoder Sensor disconnect J3 at Carriage PWA; for paper sensor replacement disconnect J2 at Carriage PWA.To clean the encoder sensor, lightly dampen a lint-free towel with distilled water or an isopropyl alcohol cleaning pad. Apply to sensor surfaces by gently rubbing towel back and forth until residue is gone. To clean the paper sensor, lightly dampen a lint-free towel with distilled water or an isopropyl alcohol cleaning pad. Apply to transmitter and receiver surfaces and flex cable surface. Gently dab until residue is gone. Repeat procedures as necessary.

Carriage Assembly


Service Guide

Step 18. Remove the Paper Sensor; needle nose pliers may be necessary to help remove paper sensor board from guide channel.

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.

Carriage Assembly


Service Guide

Step 1. Remove power from printer and lower air plenum to maintenance postion (if attached). The ink lines may be flushed using the ink system kit; evacuate and flush ink lines with distilled water.

Video - Ink Delivery Removal

Step 2. Remove the Ink Delivery System Carriage Cover and 4 screws securing 2 Support Brackets. Remove support brackets.

Caution: ensure locking clip is depressed prior to removing; do not twist plug from connector or damage will result.

Step 3. Lift cover and disconnect the Trailing Cable connection from J1 on the Carriage PWA.

Ink Delivery/Trailing Cable Assembly


Service Guide

Step 4. Remove the Right Rear Cover by removing 2 securing screws. Remove 2 screws securing trailing cable grounding plate.

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.

Video - Trailing Cable Removal

Go to Trailing Cable Removal procedure



Service Guide

Step 6. Open cartridge doors and remove cartridges.

Step 7. Remove 6 door assemblies by first removing door blocker, then removing door support by depressing 2 clips on either side of door support.

Step 8. Place ink delivery carriage cover onto a drop cloth.

Step 9. Disconnect the Chain Shelf by removing 2 screws at rear of printer.



Service Guide

Step 10. Disconnect tubing lines from 6 septum assemblies using small needle nose pliers. Lift ink delivery cover up for 2 minutes to allow ink lines to completely drain back to intermediate reservoirs.

Step 11. After removing the left bottom cover, loosen ink tube restraining clamps at reservoir chassis.

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 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.



Service Guide

Step 1. Remove power from printer; evacuate ink from defective intermediate reservoir using special service tool only (VacLok syringe and Pressure Test Cartridge).

Videos

Step 2. Gently disconnect the Intermediate Reservoir Sensor Board connector.

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.

Intermediate Reservoir Assembly


Service Guide

Step 4. Clamp off the ink tubing line on both sides of the service butt-splice with hose clamp tool.

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).



Service Guide

Step 6. Remove intermediate reservoir from chassis by removing 4 securing screws.

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.

* = Reservoir restraining clips



Service Guide

Step 8. Remove Identification Sensor PWA by removing 4 screws (two T7 star-head and two cross head screws).

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.

Video - Repriming Ink Line

Video - Cleaning Primer Tool



Service Guide


Video - Service Station Replacement


NOTE: Refer to Service Bulletin 10 or the video below to replace an early model station (geared) with the new station model (non-geared).

Video - Service Station Upgrade

Service Station


Service Guide

Step 3. If replacing an early model station (geared) with a new service station (non-geared) then remove the disposal bottle from Auto Clean Unit and remove the Auto Clean Unit Assembly. Disconnect two wiring connections.

Caution: only loosen the securing screws, removal of the securing screws is not required. Damage to electronic cables may occur if assembly is dropped.

Service Station


Service Guide

Step 4. Lift out the Service Station by releasing both locking clips.

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.

Service Station


Service Guide

Step 6. If replacing a geared service station with a new service station version then disconnect the station motor/sensor connection from J13 on the Main PWA. Install jumper into J13 to bypass sensor operations. Refer to Service Bulletin 10 for complete instructions. Perform steps 7 and 8.

Service Station


Service Guide

Step 7. Disconnect plug adjacent to sensor connection.

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.

xxx

Step 8. Remove the 2 securing screws and remove the station motor/sensor assembly (including bracket).

Service Station


Service Guide


Video

Step 2. Remove disposal bottle from auto clean unit.

Note: Loosen the securing screws and lower unit approximately 15 cm. Removal of the securing screws are not required.

Caution: do not drop unit or damage to plug connections/wiring may occur.

Auto Clean Unit


Service Guide

Step 3. Clamp the tubing going to the Suction Motor. If necessary cut the tubing off of the Suction Motor is tubing end is severly flared or leaking ink.

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

Auto Clean Unit


Service Guide


Video


xxx

Encoder Strip Assembly


Service Guide

Step 3. Remove the Ink Delivery System Carriage Cover and 2 Support Brackets.

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).



Service Guide

Step 5. Remove Carriage Assembly - refer to carriage assembly removal procedures.

Step 6. Disconnect 6 cartridge door assemblies from carriage by removing door restraints and pushing on door support clips to release each assembly.



Service Guide

Step 7. Move the Carriage Cover to one side.

xxx

Step 8. Remove carriage bushings from carriage by removing the bushing retainers at each side (1 screw secures each retainer).



Service Guide

Step 9. Install the Belt Removal Tool (P/N 216688-00) between frame tensioner and left side plate. Twist to release carriage belt tension.

Step 10. Slide the Belt off of the Servo Motor Pulley. Remove the Belt Removal Tool.

xxxEncoder Strip Assembly


Service Guide

Step 11. Remove the Frame Tensioner, Idler Assembly and the Compression Spring.

Caution: Ensure that the Idler Assembly is oriented correctly before installation.

xxx

Step 12. Remove the Cutter Actuator by removing 2 securing screws.



Service Guide

Step 13. Disconnect Ink Reservoir Chassis by removing 6 screws. Note: left covers do not need to be removed to remove carriage assembly.

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.



Service Guide

Step 15. Using a pen, draw position marks above the old encoder stablizer bracket assembly. Remove Stabilizer Bracket/Encoder Strip Assembly.

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.



Service Guide

Step 1. Remove the Rear/Back Cover by removing 12 securing screws.

Step 2. Pitch the back cover toward the rear slightly. Pinch roller e-clips 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.

Video - Pinch Roller ReplacementPinch Roller Replacement


Service Guide

Step 3. While holding the Pinch Roller, remove the E-Clip and pull the Pinch Roller back through the Y-Arm Bracket. Remove the Compression Spring using spring pliers or spring hook tool at the rear end of Pinch Roller.

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.

Pinch Roller Replacement


Service Guide

NOTE: Refer to Service Bulletin 17 for complete replacement instructions.Step 1. Remove power from printer.

Video


Step 3. Remove the Left Top Cover by removing 4 screws.

Media Drive System


Service Guide

Step 4. Disconnect Ink Reservoir Chassis by removing 6 screws; move assembly clear.

xxx

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.

Media Drive System


Service Guide

Step 5. Disconnect the Stepper Motor connector from J7 on the MPWA.

Step 6. Disconnect the Vacuum Fan connectors from J15 and J16 on the MPWA.

xxx

Media Drive System


Service Guide

Step 7. Remove Service Station by first removing station shim at left side (new stations only). Reinstall shim once station has been removed from printer.

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.

Stepper Motor Ground

Media Drive System


Service Guide

Step 9. Disconnect Vacuum Fans (3 screws each) and Exhaust Grills (4 screws each). Remove the Exhaust Grills.

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.

Media Drive System


Service Guide

Step 11. Disconnect the Lower Roller Assembly from the Platen by removing 6 securing screws.

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.

Media Drive System


Service Guide

Step 13. Remove the Left Base Plate by removing 9 securing screws.

Step 14. Remove the top cover by removing 4 securing screws.

xxx

Step 15. Remove the Left Side Plate by removing 5 securing screws.

Media Drive System


Service Guide

Step 16. Remove Left Foam Block. Do not tear Foam Block or proper vacuum may not be obtained.

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.

Media Drive System


Service Guide

Step 18. Remove the Lower Roller Assembly and Vacuum Fans.

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.

Media Drive System


Service Guide


Video


xxx

Nose Heater Assembly


Service Guide



xxx



Service Guide

Caution: Ensure that the Air Plenum is locked in the operational position.

Step 5. Remove both pivoting screws.

Step 6. While firmly holding the Air Plenum, release both position locking pins. Remove the Air Plenum.



Service Guide

Step 7. Disconnect the Heater Element connectors from J1, J2 and J3 on the Dryer PWA.

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.



Service Guide

Step 10. Remove the (rear) screws securing the Nose Spacers to the Platen.

xxx

Note: once the nose heater has been removed the thermocouple sensors and thermocouple fuse may be removed.

Step 11. Remove Nose Heater Assembly.



Service Guide


Video


xxx

Air Plenum Assembly


Service Guide



xxx

Air Plenum Assembly


Service Guide

Caution: Ensure that the Air Plenum is locked in the operational position.

Step 5. Remove both pivoting screws.

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.

Air Plenum Assembly


Service Guide


Video

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.

Media Takeup/Feed System


Service Guide

Note: Inspect the Carbon Fiber Brushes on the ESD Strike Plate for wear. Carbon fiber brushes should not be worn or bent. Replace strike plate (s) if defective.

Step 3. Cut the Motor tie-strap and disconnect the Motor.

Note: An additional 3 screws and an E-Clip will need to be removed to seperate the Motor from the Motor Mount.



Service Guide

Step 4. Disconnect Sensor. Cut tie-straps and unscrew the Sensor from the bracket to remove.



Service Guide

Step 1. After removing printer power, right rear cover and lowering air plenum, remove 4 screws securing ink delivery carriage cover support brackets. Remove 2 support brackets.

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.

Video

Trailing Cable


Service Guide

Step 5. Pry 2 restraining tabs securing ink chain to carriage cover.

Step 6. Separate ink chain links by prying or pulling ink chain links apart every 10-15 cm along entire chain length.

Step 3. Remove ink chain restraint by removing two #8 star-head screws. Use a Torque #8 driver.

Step 4. Remove 2 chain shelf screws.

Trailing Cable


Service Guide

Step 7. Tape trailing cable lock to protect connector lock.

Step 8. Remove trailing cable from chain by removing cable slack and pulling free.

Gently pry up on each chain link with a small flathead screwdriver to allow cable connector to move past each link.

Caution: do not overstress cable (s) during installation or damage to cable (s) will result.

Trailing Cable


Service Guide

Step 10. Disconnect trailing cable from main board.

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.

Step 9. Remove 2 screws securing trailing cable grounding plate.

Trailing Cable

Service: Mechanical Alignments

Service Guide

Alignment Theory

Tools Required

Special Notes

Slide Shaft Adjustment

Carriage Head Height Adjustment


Service Guide

XXX

Head to Platen Height Relationship

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.

Alignment Theory


Service Guide

Head Height Adjustment Kit (221955-00):- Modified test cartridge with dual tension bands- Micrometer dial gauge- Shaft mounting block- Extension tip (for dial gauge stem)- Service station plate (221816-01)- 1/16 and 7/64 inch hex-key wrench tools

- 1/4 inch open-ended wrench

Cross-head screwdriver, no. 2

Tools Required


Service Guide

Note 1: A special tool kit is required to perform the mechanical adjustments. Refer to Service Bulletin 3 for complete procedures/updates.

Note 2: Only perform mechanical adjustments if carriage head scraping is observed on media surface, if the color deadband adjustment cannot be calibrated, or if the encoder strip/stabilizer bracket is moved or replaced.

Note 3: Remove power and media from printer before beginning adjustments. Lower the air plenum by removing the two locking pins.

Special Notes


Service Guide

Video

Step 1. Obtain the Head Height Alignment Kit.

Step 2. Assemble the shaft mounting block to the micrometer dial gauge using 1/16 inch hex-key wrench; ensure the elbow is flush to the front. Tighten the set-screw at the rear of the shaft mounting block.

Step 3. After moving air plenum to maintenance position, place shaft mounting block and gauge over the slide shaft on the left most printable surface (above slide shaft supports), zero the gauge at this first location.

Step 4. Move the shaft mounting block and dial gauge to the right end (above slide shaft supports) and take a measurement.

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 ¼” open ended wrench adjust the turn buckle (or turn buckles - 60 inch unit) for the average computed value.

Slide Shaft Adjustment


Service Guide

Video

Step 1. Obtain tools: head height test cartridge, dial gauge, extension tip, 1/16 and 7/64 inch hex-key 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 ¼” 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.



Service Guide

Step 6. Remove media from the printer. Remove all 6 cartridges. Remove the foam pad from K cartridge stall position.

Step 7. Install the test cartridge into the K cartridge stall position; gauge should be facing toward left side of printer.

Step 8. Measure in front of each adjustment screw for 65 +/- 3; only observe the gauge’s inner set of numbers. Firmly force encoder stabilizer bracket up or down with tool and tighten 7/64 screws at rear of printer.

Step 9. To adjust at the service station area, remove the service station. Place service station plate into the access hole (towards right side) and move gauge/cartridge onto plate surface. Adjust for 65 +/- 3.



Service Guide

Adjustment Tips

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

Service: Illustrated Parts List:

Part Number Listing– Pages 1-6

Illustrated Parts List (Reference) – Pages 7-29

Part Number Listing (by part name):IllustratedParts Cross Reference #

KODAK 1200i-NJ1000i Part Number:

Part Name/Description

B-8 222703-00 AUTOLOAD SENSOR

B-4a 220540-00 BELT, 42"

B-4b 220468-00 BELT, 60"

D-2 208987-1 BRACKET, LOWER DRIVE SUPPORT

E-7a 222038-00 BUSHING SET (2), Kodak 1200i-NJ1000i

E-14 220236-150 CARRIAGE ASSY, COMPLETE, Kodak 1200i-NJ1000i

E-12a 221584-04 CARRIAGE FLEX, 640J

E-2 220131-065 CARRIAGE PCB, 640J

K-4b 221986-00 CARTRIDGE GARAGE

K-5a 220708-00 CASE, EQUIP, WATER PROOF

D-7 223682-00 CENTER SUPPORT BRACKET ASSY

A-1 220854-02 CHASSIS, INK RESERVOIR

C-13 219127-00 CIRCUIT BREAKER, 13A

H-3 207659-01 CLAMP, PAPER GUIDE

F-1 221781-00 CONNECTOR, 1/8 ID TO 3/32 ID TUBE

1200i/1000i Illustrated Parts List

Part Number Listing (by part name):

2

K-5b 222169-00 CONTAINER, PARTS STORAGE

H-10 207673-1 CORE, PAPER, 60"

A-5 220266-02 COVER, BOTTOM, LEFT

E-1 220302-00 COVER, CARRIER ELECTRONICS

C-12 220231-03 COVER, DISPLAY MOUNT

A-4 220472-04 COVER, TOP LEFT

C-1 220850-02 COVER, TOP RIGHT, REAR

H-6 207667 CRADLE IDLER (TAKE UP)

B-6c 200507 C-RING, (PINCH ROLLER)

E-11 215644-01 CUTTER ASSY, WHITE - 5 PACK

E-11 215643-01 CUTTER BLADE, WHITE, SINGLE

F-3 221282-01 DAMPER, ASSY

C-4 210068-06 DISPLAY

E-13a 222563-150 DOOR & SEPTUM ASSY (INCLUDES COMPLETE DOOR ASSEMBLY, DOOR SUPPORT MOUNT, DOOR SPRING & BLOCKER CLIP)

E-13b 220461-01 DOOR ASSY, SINGLE

C-2 220985-03 DOOR, RIGHT COVER

C-7 220441-02 DRYER PCB (INCLUDES SLIDE SWITCH)

F-2 222016-00 ELBOW BARB 1/8 TO 3/32

E-5 209578-101 ENCODER SENSOR W/FLEX

B-3c 217236-00 ENCODER STRIP LAMINATED, 89.7" (ENCODER STRIP ONLY - NO TAPE OR STABILIZER BRACKET INCLUDED)

B-2a 220959-150 ESD BRUSH, 42"-6, ASSY (QUANTITY OF 6)

B-2b 220639-150 ESD BRUSH, 60"-6, ASSY (QUANTITY OF 6)



3

D-6 204976 EXHAUST, GRILL

I-6 220668-00 FAN, ASSY, DRYER

C-11 215566-00 FAN, COOLING (POWER SUPPLY)

D-5 214402-01 FAN, VACUUM (LEFT), 60" PRINTER ONLY

D-4 214401-01 FAN, VACUUM (RIGHT)

B-5a 203870-1 FRAME TENSIONER ONLY

I-5a 221696-01 FUSE, THERMAL CUT-OFF (84C)

H-8 207666 GEAR, MOTOR DRIVE (FEED & TAKE-UP)

B-9 215158-02 GUIDE, CENTER, COMMON (OEM4 PRINTER)

H-2 207644 GUIDE, PAPER ADJUSTABLE (FEED & TAKE-UP)

D-9 220272-01 HARNESS, DRYER/WINDER (MAIN PWA - LEG)

H-4 221427-00 HARNESS, LEG DRIVE (INNER LEG)

A-2d / F-2d 220688-02 HARNESS, RESERVOIR SENSOR

I-5b 220673-00 HARNESS, THERMAL FUSE

B-7a / I-1a 220537-150 HEATED NOSE, ASSY 42"

B-7b / I-1b 220503-150 HEATED NOSE, ASSY 60"

A-2b / F-2b 221248-00 HOUSING, SENSOR

B-5c 217269-02 IDLER ONLY

B-1b / F-3b 220535-150 INK DELIVERY ASSY 42"

B-1a / F-3a 220249-150 INK DELIVERY ASSY 60"

A-2a / F-2a 220853-04 INTERMEDIATE RESERVOIR, ASSY

C-3 209096-3 KEYPAD

H-9 211170 KIT, 2 STRIKEPLATES + 2 BRUSHES

K-4a 221984-01 KIT, FLUSH KIT ASSY



4

K-1 221955-00 KIT, HEIGHT ALIGNMENT, Kodak 1200i-NJ1000i

K-2 222185-00 KIT, INK SYSTEM TEST

B-10a 221555-00 KIT, MEDIA GUIDES ASSY

K-6b 221945-00 KIT, SERVICE SPARES PREMIUM, Kodak 1200i-NJ1000i

K-6a 221993-00 KIT, SERVICE SPARES STANDARD, Kodak 1200i-NJ1000i

A-3 221338-00 KNIFE DELATCHER

A-6a 223071-01 LINE FILLING CARTRIDGE w/PLUG BAR

A-6b 222370-00 LINE FILLING CARTRIDGE ONLY

D-3a 221855-610 LOWER DRIVE ASSY, 42" (INCLUDES STEPPER MOTOR)

D-3b 221857-610 LOWER DRIVE ASSY, 60" (INCLUDES STEPPER MOTOR)

B-10d 222007-00 MAGNET, MEDIA WEIGHT

C-6 220111-165 MAIN PWA, Kodak 1200i-NJ1000i (OEM1 PRINTER ONLY)

C-5 216391-00 MEMORY - SDRAM DIMM, 8 X 64

H-7 207767 MOTOR, FEED & TAKE-UP

J-2 220695-00 OPTICAL SW ASSY, (WASTE UNIT WIRING HARNESS & SENSOR ASSY)

K-7a 222824-00 PACKAGING, 42" PRINTER HEAD (BOX 1)

K-7b 222823-00 PACKAGING, 60" PRINTER HEAD (BOX 1)

K-7c 215631-01 PACKAGING, SPACER, BASE POSITIONER (P/O BOX 2)

K-7d 215627-01 PACKAGING, SPACER, END (P/O BOX 2)

K-7e 215628-02 PACKAGING, SPACER, HOLDER (P/O BOX 2)

B-10b 221498-01 PAPER GUIDE, LEFT

B-10b 222191-00 PAPER GUIDE, LEFT (LONG; OEM 4 PRINTER)

B-10c 221496-01 PAPER GUIDE, RIGHT



5

B-10c 222190-00 PAPER GUIDE, RIGHT (LONG; OEM 4 PRINTER)

E-10 220391-02 PAPER SENSOR W/FLEX

B-6a 221881-00 PINCH ROLLER ONLY

B-6d 222116-00 PINCH ROLLER ONLY (OEM 4 PRINTER)

D-8 215189-00 PLUG, PLATEN

C-10 220667-03 POWER ENTRY MODULE

C-8 220647-02 POWER SUPPLY (275W)

J-3 221231-150 PUMP ASSY, WASTE RESERVOIR

A-2c / F-2c 221500-01 RESERVOIR DATA BOARD, PWA

E-8 220550-01 RETAINER, BUSHING, LEFT

E-6 220374-01 RETAINER, BUSHING, RIGHT

E-9b / F-8b 220460-00 RING, RETAINING, E-TYPE, 5/16 (FOR SEPTUM)

H-5 207727-02 SENSOR ASSY, TAKE-UP & FEED

E-9a / F-8a 220420-00 SEPTUM, ASSY

G-2 220258-260 SERVICE STATION ASSY (UPGRADE KIT/REPLACEMENT)

D-1 221825-00 SERVO MOTOR, CARRIAGE

H-1a 219681-00 SHAFT, W/FIXED RT ROLLGUIDE 42 (FEED & T/U)

H-1b 219682-00 SHAFT, W/FIXED RT ROLLGUIDE 60 (FEED & T/U)

E-7b 221981-00 SHIM, BUSHING (SINGLE)

E-12b 221964-01 SHIM, CARRIAGE FLEX (144 PER SHEET)

A-3b 222182-00 SHIM, KNIFE DELATCHER

B-11 221991-00 SHIM, SHAFT SUPPORT

B-12 221992-00 SHIM, Y-ARM

D-10a 212427-00 SHIM, .005 THICK, LOWER DRIVE (AS REQUIRED)



6

D-10b 212428-00 SHIM, .010 THICK, LOWER DRIVE (AS REQUIRED)

D-10c 212429-00 SHIM, .020 THICK, LOWER DRIVE (AS REQUIRED)

I-7a 220768-04 SHROUD, PLENUM, 42-6

I-7b 220758-05 SHROUD, PLENUM, 60-6

E-4 204804 SLIDER LOWER (CARRIAGE)

E-3 204654 SLIDER UPPER (CARRIAGE)

C-9 220596-00 SOLID-STATE RELAY, 25A

E-15 220248-02 SPRING PAD (CARRIAGE)

B-5b 215348-00 SPRING, COMPRESSION (IDLER)

B-6b 212542-00 SPRING, COMPRESSION (PINCH ROLLER)

B-3b 220530-150 STABILIZER ASSY, 42" (WITH ENCODER STRIP)

B-3a 220216-150 STABILIZER ASSY, 60" (WITH ENCODER STRIP)

I-2 220510-02 THERMISTOR, COMMON

I-3 220605-00 THERMISTOR, 42"

I-4 220603-00 THERMISTOR, 60"

K-3 222088-00 TOOL, BELT REMOVAL

B-13a / F-4b 220875-02 TRAILING CABLE, SHIELDED, 42"

B-13b / F-4a 220269-02 TRAILING CABLE, SHIELDED, 60"

J-1 220558-00 WASTE CONTAINER (ONLY)

J-4 220835-05 WASTE INK RES., ASSY COMPLETE

G-1 220265-01 WIPER, SERVICE STATION

5

5

4

4

3

3

2

2

1

1

D D

C C

B B

A A

FIRE

PROGRAM

LVDS BCKCHL

FIRE

CPROGRAM

Title

Size Document Number Rev

Date: Sheet of

222052-00 AA

Block Diagram, NJ1000i

Custom

1 1Thursday, February 26, 2004

Title


Date: Sheet of

222052-00 AA


Custom


Title


Date: Sheet of

222052-00 AA


Custom


MAIN BOARD

TRAILINGCABLE

FPGA

HEADDRIVERS

+24V, GND

INTF.

LVDSINTF.

LVDS DIFF. PAIRS

PAPERSENSOR

ENCODER

CARRIAGE BOARD

LM LC M Y K C

PRINT HEADS

POWER SUPPLY

3.3V @ 10A

2.5V @ 0.9A

1.5V @ 2A

5V @ 0.1A

24V

AUTOLOAD SENSOR INTERFACE

WASTE BOTTLE INTERFACE

SERVO MOTOR

FPGA

SDRAM DIMM 64MRASTER MEMORY

MOTORDRIVERS

DRYERINTERFACE

WINDER / UNWINDER INTERFACE

FAN DRIVERS

SERVICE STATION INTERFACE

DISPLAY / KEYPAD INTERFACES

DISPLAY / KEYPAD

256K X 18 ZBT RAMS

POWERPC 405GP

SDRAM 32M MAINMEMORY

4MFLASH

A/DCONVERTER

ETHERNET PHY

2K EEPROM

JTAG PORT

CRYSTAL

CLOCK

POWER SUPPLY

1.8V

3.3V

5V24V

6 INK BOTTLESWITH DATA CHIPS

NJ1000iBlock Diagram

DRYER BOARD

ETHERNETCONNECTOR

HEATERS

BLOWERS

POWERSUPPLY

AC 120 / 240

2 VACUUM FANS

POWERSUPPLY FAN

STEPPER MOTOR

AUTOLOAD SENSOR

WASTE BOTTLE

WINDER / UNWINDER

SERVICE STATION

7V - 11VFIRING VOLTAGE

Documents

NJ1000i-1200i Printer Service Manual_05122006