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1. Josues juasaid e1 p1eoq E JOSUaS uomnisod paeoq peeuiuud onia re IE Jeob sso2o0Jd O I 1414 ovr f z 10sues e1nje1eduie Wing Plougjos SABA AY d I dund l unnoeA CEU UR e npoui duind unnoeA Jepooue uonisod 10 0W SSa20Jd ue unag 40 0W eAup odim deg f p99 1edeg zu INOHd33 Jejunoo eoueuojuieul wnq pieog j041u09 19MOd yun nd ad m deg juasaid Aes Aydwea Aes aded nd C no Jedeg lod Jojeou PaSa lp una women queuua mvaas L Oma paeog ule Jopeo xul iagram Figure 1 14 Printer Functional Block D General Information 1 45 1 46 Drum Transfix Assembly The drum transfix assembly Figure 1 15 forms the key portion of the printer where imaging takes place The main features of the drum transfix assembly Figure 1 16 are the drum and transfix roller In operation the image to be printed on paper is first printed on the rapidly rotating drum A sheet of paper heated by the paper preheater is then passed between the drum now rotating much more slowly and the transfix roller Under the pressure between the drum and the transfix roller the image is transferred to the sheet of paper heater 840 4 45 Figure 1 15 The Drum And Its Systems ii LINX Solid Inkjet 100 Service Manual A WARNING Encoder Home disk sensor Temperature sensor 55 C Home flag Ev os IZ
2. Install From Disk m 7 The Sterling iiLINX SIJ 100 Printer selection will appear Click Next Printer Networking 7 23 Add Printer Wizard Te ee Sterling iLINX SIJ 100 8 Click on the port you want to use with the printer For local parallel port printing use LPT 1 Click Next Add Printer Wizard _ m x COM4 Infrared Serial COM Connections Port 4 COMS 3Com 3C562D 3C563D EL III LAN 3 FAX MODEM Unknown local port p FAX Unkneagn local port j 2s FILE Creates a file on disk zt Py Printer Port pm LPT3 Infrared Printing LPT Port pcaw pm Unknown local port 9 You can type a name for the printer or use the default name You can also select the printer as a default printer if desired Click Finish 7 24 ii LINX Solid Inkjet 100 Printer Service Manual Windows NT 4 0 Procedure 1 Before you begin make all physical connections from the PC to the Solid Inkjet 100 to allow the printer to be recognized as a new hardware device Reboot your PC The New Hardware Found screen will appear briefly Click Next NOTE If the New Hardware Found screen does not appear use the procedures in Add Printer Procedures Optional M amp hod following this section 3 Insert the CD ROM containing the Solid Inkjet 100 Printer driver software 4 Select Driver from disk provided by hardware manufacturer option Click OK 5 Thelnstall from disk screen wil
3. Oil Streaks On Print Oil stains the edge of the print 1 2 Inspect the drum maintenance drawer Is the wiper blade damaged If necessary replace the drum maintenance drawer Arethe drum maintenance cam roller and electric clutch operating correctly Test them using PC based diagnostics Ensure the left and right drum maintenance actuators operate correctly when lifted by the cams of the drum maintenance cam roller Troubleshooting 3 27 Poor Ink Adhesion Poor Image Durability 1 Verify the paper preheater temperature using PC based diagnostics 2 Thedrum is too cold Verify the drum temperature using PC based diagnostics Ensure the drum temperature sensor is properly positioned and has no contamination between it and the drum surface 3 Try a different ream of paper 4 Thetransfix spring pressureis incorrect Perform the procedure Transfix roller pressure spring adjustment Incomplete Image Transfer To Paper All of the image does not transfer to the paper Part of the image remains on the drum to be picked up by a chase page or the next print This is usually caused by insufficient or nonuniform drum oiling 1 Inspect the drum maintenance drawer Is the wi per blade damaged If necessary replace the drum maintenance drawer 2 Inspect the drum maintenance system Does the drum maintenance roller contain sufficient oil Replace the drum maintenance roller if necessary 3 Arethe drum maintenance c
4. 1 Hmge Frotcoverpvot U U UU 4 0650 403 00 ee Front cover control panel E s ett cover B E XIt cover 7T DU03436700 ee TepooverwihinKFoaddoo E E ear cover A 4 ii LINX Solid Inkjet 100 Service Manual Figure A 1 Cabinet parts Material Number Listings A 5 Table A 2 Imaging Parts Item Part Number Serial Number Qty Name and Description Number Effective Discontinued T 6050402700 1 Y axispulleyassembly 2 2146101 9 Drum maintenance actuators leffandright S 3S35r105101 A 1 Maintenance drawer guide lef aintenance drawer aintenance drawer guide rig 6 650 3617 00 1 Spring transfix actuation Part of 650 3617 00 Drum Transfix Assy z 5 rum transfix assembly 8 441 2137 03 1 Cap wipe purge assembly E E rinthea I 10 174380700 1 Cable print Gata m B nk loader 12 1660714200 1 4 Vacuumhoserbber T 1700900 1 Vacuumpumpassemby tm 166 0713900 T1 Wacuumhose ngid U UUU l ead maintenance drive belt Part of 650 3615 00 Belt Kit T6 650 3619 00 T Pulley head maintenance drive Part of 650 3619 00 Gear Kit T7 650 3615 00 T Head maintenance timing belt and ratchet clips Part of 650 3615 00 Belt Kit T8 T34 0265 00 T Plug Maintenance drawer Tite counter z z urge Filter Oo own E over neat piate printnea ermal duc A 6 ii LINX Solid Inkjet 100 Service Manual Fig
5. A 14 ii LINX Solid Inkjet 100 Service Manual Q 0388 23 Figure A 6 Solenoid and Clutch Parts Material Number Listings A 15 Table A 7 Gear and Belt Parts Item Part Number Serial Number Qty Name and Description Number Effective Discontinued T 650 3619 00 T Pulley lower paper transport Part of 650 3619 00 Gear Kit 2 650 3615 00 T Paper feed roller drive belt Part of 650 3615 00 Belt Kit 39 650 3615 00 1 9 Tensioner process bel Part of 650 3615 00 Belt Kit q 650 3619 00 T Lower process gear pulley Part of 650 3619 00 Gear Kit E g rocess drive belt Part of 650 3615 00 Belt Kit 6 650 3619 00 T Roller flat head maintenance Part of 650 3619 00 Gear Kit ead tilt cam gear Part of 650 3619 00 Gear Kit 8 351 T015 00 Guide head tilt g 650 3615 00 T Head maintenance timing belt and ratchet clip Part of 650 3615 00 Belt Kit TO 650 3619 00 T Pulley drive head maintenance Part of 650 3619 00 Gear Kit xit roller drive belt Part of 650 3615 00 Belt Kit TZ 650 3619 00 T Pulley exit drive DE Part of 650 3619 00 Gear Kit T3 650 3615 00 T ensioner exit drive belt Part of 650 3615 00 Belt Kit T4 650 3619 00 T ranstix gear eccentric Part of 650 3619 00 Gear Kit T5 650 3619 00 T Gear compound eccentric flagged Part of 650 3619 00 Gear Kit uplex roller gear pulley Part of 650 3619 00 Gear Kit T7 650 3619 00 1 Paper path idler 1 Part of 650 3619 00 Gear kit T8
6. Verifying the Printer and Host Connections 3 3 3 2 ii LINX Solid Inkjet 100 Service Manual System Power up Sequence The following lists the chain of events that occur when you turn on reset or initialize the printer You can follow this list as one means of determining if the printer is operating correctly The exact chain of events depends upon where the printer believes the printhead is positioned The printer records in NVRAM the last known position of the printhead and the cap wipe purge assembly Power switch turned on 1 Low level power on self test POST diagnostics are performed The two status LEDs at the rear panel should be blinking and the front panel LEDs areturned on 2 If POST diagnostics pass the front panel Error LED is turned off and the LCD display is cleared 3 Depending upon the printhead position Printhead in Standby or Print position a b If the printer is in its Standby mode the cap wi pe purge motor is run to ensure that the cap wipe purge assembly activates its home position sensor If the printer is in Print mode the printhead is moved to its x axis home position and then centered The process motor is rotated totilt the printhead forward if not already forward rotate all the rollers to their ready positions disengage the transfix roller and lower the maintenance drawer blade and wiper Printhead in Cap wipe purge position a The heaters in the
7. Waste Tray The maintenance drawer contains a waste tray that collects the ink that has been purged from the printer s ink jets The waste tray should be emptied each time the maintenance drawer is removed from the printer Refer to Emptying the Waste Tray in the iiLINX Solid Inkjet 100 User Manual for instructions on removing and emptying the waste tray Be sure to insert the waste tray into the maintenance drawer before reinstalling the maintenance drawer in the printer Never reuse waste ink in the printer fiLINX Solid Inkjet 100 Service Manual Lubrication Tools and supplies required Light oil e Grease Nye Rheolube 368B In general all of the printer s bearings and motors are lifetime factory lubricated However over time and under certain extreme operating conditions oil and grease may dry out causing squeaks and rumbling noises in the printer Look for fine metal particles a clear sign of an old or worn bearing Under these circumstances replace the bearing or the assembly A drop of grease on a noisy bushing will quiet a noisy printer Too much lubrication can get into the paper path and attract dust so apply lubrication sparingly Lubricate the following only when needed e Bushings Apply a drop of light oil to a bushing if it is noisy or running dry e Plastic gear train The gear train from the process motor to the paper feed module requires only a small amount of white grease for noise reducti
8. 0388 31 Figure 4 7 Installing the Gap ToolCap Wipe Purge Assembly Belt Adjustments The tension of the cap wipe purge assembly belts is factory set Do not adjust them unless you remove or replace one or both belts The belts are K evlar reinforced they will not stretch over their lifetime The belts are also factory adjusted for parallel tracking alignment ii LINX Solid Inkjet 100 Service Manual As long as the belts cap wipe purge assembly motor and the belt clips which hold the cap wipe purge assembly are not disturbed no adjustment is needed However if you replace one or both of the belts or the cap wi pe purge drive motor you must ensure that the belts are in alignment timing with each other this ensures that the cap wi pe purge assembly is perfectly aligned to the faceplate of the printhead If the belts are not aligned the printhead purging is ineffective due to poor sealing between the printhead faceplate and the cap wipe purge assembly 1 Ensure that the cap wipe purge assembly is properly installed Also ensure that the cap wipe purge drive motor is installed in place and that both the left and right side drive belt locks are assembled correctly Rotate the large drive gear to pull the cap wipe purge assembly to about the middle of its travel in the chassis frame slot Ensure each drive belt lock is tightened to its fourth tooth as illustrated in Figure 4 7 Position the left side drive belt lock
9. 11 12 13 Remove the right cover Remove the left cover Disconnect the head tilt spring Tilt back the printhead and center it Remove the top cover Remove the ink loader Disconnect the wiring harness leading from the cap wipe purge assembly to the power supply wiring harness Clip the tie wraps and disconnect the vacuum hose leading to the vacuum pump module Rotate the cap wipe drive gear to position the cap wipe purge assembly 25 mm 1 in from the top of its travel Place a few sheets of paper between the drum and the cap wipe purge assembly to prevent scratching the drum Removethe right timing belt s lower pulley to create slack in theright timing belt Remove the metal vacuum line from the assembl y Remove the wiring from the right cap wi pe purge assembly bracket Push the wiring through the print engine s frame so that you can unloop it from the cap wipe purge assembly While holding onto the cap wipe purge assembly remove the three pin screws that hold the cap wipe purge assembly in the grooves on each side of the print engine Reverse these steps to reinstall the cap wipe purge assembly Refer to the wiring diagrams in Appendix C for details on dressing the cap wipe purge wiring 6 42 iiLINX Solid Inkjet 100 Printer Service Manual Cap Wipe Purge assembly Long pin screw 840 4 43 Figure 6 27 Removing the Cap Wipe Purge Assembly Removing Cap Wipe Purge Belts Remov
10. Drum Motor and Process Motor Remove the right cover Remove the left cover 1 2 3 Removethe front panel 4 Remove the drum maintenance drawer 5 If you are removing the Y axis motor remove the Y axis belt drive assembly o Remove the upper feed roller assembly 7 Removethe paper drum heater 8 Removethe four screws securing either motor to the drum transfix assembly Remove the motor Undip the cableties retaining the motor s wiring harness Reverse these steps to install the Y axis or process motor Removal and Replacement 6 39 ve Ayah W 2N Process motor Kos N Drum transfix assembly 840 4 21 Figure 6 25 Y axis Drum Motor and Process Motor Removing the Paper Path Motor 1 Remove the right cover 2 Disconnect the paper path motor wiring harness from the power control board Free its wiring harness from the cable restraints 3 Remove the three screws securing the paper path motor in place Remove the motor Reverse these steps to reinstall the paper path motor 6 40 ii LINX Solid Inkjet 100 Printer Service Manual A 7 MIY Bs K Q N O Ko VA TO BK Q O XS SES Figure 6 26 Removing the Paper Path Motor Removal and Replacement 6 41 Cap Wipe Purge Assembly present at the printer heaters while the printer is plugged into AC Even when the printer is turned off AC line voltages may be power WARNING 10
11. Ifa list of zones appears in the lower left portion of the Chooser select the proper zone 4 A list of printers appears in the right portion of the Chooser find your printer s name The printer s default name is listed on the Configuration Page see Printing a Configuration Page earlier in this chapter If the name does not appear check the cable connection between your printer and the network NOTE It is possiblefor the Printer Name fidd on the Configuration Page to be blank When the printer is powered up it uses a default name and then checks to see that no other printer on the network has the same name If enough printers with the same default nameare present it can take several minutes for the printer to establish a uniquename If the Printer Namefidd on the Configuration Pageis blank wait a short ti me and reprint the Configuration Page 7 10 ii LINX Solid Inkjet 100 Printer Service Manual Novell NetWare Configuration Using the Quick Configuration Wizard Log On to the File Server NOTE Many of theoperations performed using the PhaserShare Administrator require SUPERVISOR privileges for example creating queues e NetWare 3 x Log on to the default NetWare file server as SUPERVISOR or SUPERVISOR equivalent NetWare 4 x Bindery mode Log on to the default NetWare file server as SUPERVISOR SUPERVISOR equivalent or ADMIN B NetWare 4 x NDS NetWare Directory Services mode Log on to the default NetW
12. PE LED pattern is two quick flashes on then off for a count of two for a total cycle time of just over two seconds The front panel Power light is turned on the Error light is flashed and the LCD is cleared Verifying Print Engine Operation By Printing Its Startup Page 1 2 If it is not already on turn on the printer If the printer does not begin initializing go to the topic Verifying power supply operation below Once the Power light is on not blinking and the front panel displays Ready to Print scroll toMenu and press the Select button Then scroll tothe Demo and Test Pages menu item press the Select button and then scroll and select the Print Startup Page menu item The printer should print out a Startup Page If the printer prints a Startup Page then the print engine is working correctly If the printer does not print a Startup Page then a problem exists with the print engine Troubleshooting 3 5 Verifying Power Supply Operation A WARNING Required tools e TORX T 20 screwdriver e Digital multimeter DMM The power supply is divided into two sections the AC section used for heaters and the DC section for control logic printhead drivers and motors Verifying the power supply involves three steps e Checking for proper AC voltage e Inspecting the power supply fuses e Testing for a shorted motor or solenoid driver which shuts down the power supply Measuring Power Supply Voltages
13. Preheater L entry right ii edge sensor oy 4 fj b X Maintenance EAT blade position E sensor Hand feed Paper empty sensor Paper pick Tray type sensor sensor sensors 0388 07 Figure 1 7 Sensors and Switches on the Right Side of the Print Engine General Information 1 11 Transfix exit sensor Drum temperature sensor Duplex paper sensor gt A or Drum home position sensor bos Ki Drum encoder 5 k Ee Preheater B exit sensor Process gear position sensor Transfix roller Preheater exit sensor Preheater located on inside wall of drum transfix frame O 0388 34 Figure 1 8 Sensors and Switches on the Left Side of the Printer 1 12 ji LINX Solid Inkjet 100 Service Manual The actual position of some printer assemblies such as the printhead or the cap wipe purge assembly cannot be ascertained at all times The printer records in NVRAM where it last positioned such assemblies each time it moves them If after power down or a CAUTION power interruption the assemblies are manually repositioned the printer erroneously assumes that the assemblies are in the position it last left them This assumption can result in damage to the printer when it tries to position the assemblies For example the printhead could be tilted forward and crash into the raised cap wipe purge assembly Before turning on the printer ensure the printhead is tilted forward centered in fron
14. Press the Select button 8 Press Reset Printer All the information changes will take effect after the printer resets Printer Networking 7 5 Setting IP Parameters DHCP Dynamic Host Configuration Protocol DHCP is a system in which Windows NT servers can allocate P addresses dynamically Under DHCP the server gives the printer called a DHCP dient an IP address when the printer is reset 1 When the front panel displays READY TO PRINT press the down arrow button until Menu is highlighted Press the Select button 2 Press the down arrow button until Network Settings is highlighted Press the Select button 3 Press the down arrow button until TCP IP is highlighted Press the Select button 4 Press the down arrow button until DHCP BOOTP is highlighted Press the Select button to toggle the function on or off 5 Press the down arrow button until Exit is highlighted Press the Select button 6 In order toturn on the DHCP BOOTP interface highlight Reset Printer Now Press the Select button You must reset the printer to turn on the DHCP BOOTP interface Thereset will take approximately 2 minutes to complete The printer will automatically print a Startup Pageto confirm that the function is on DHCP Transactions On power up or reset the printer sends a DHCP discover packet indicating its Ethernet address and requesting an IP address e TheDHCP server responds to the discover packet with a DHCP offe
15. trailing edge of the paper is detected by the exit sensor ending the print cycle General Information 1 69 1 70 Exit Transfix roller v sensor 7 e on eccentric shaft v Transfix exit sensor N Paper Lf preheater p Transfix cam Trans Transfix solenoid roller gear roller i Transfix DN qo roller shaft p N X X x s SE EN co ee e NS T Transfix OU UNIT Ne A cam K WY y NSF Process motor Process drive compound gear Compound gear position sensor 840 4 52 Figure 1 31 Image Transfixing Stripping and Paper Exiting ii LINX Solid Inkjet 100 Service Manual Printer Self Maintenance To maintain peak operation reliability and print quality the printer has several automatic or semiautomatic maintenance functions Refer to Figure 1 32 These functions may be started automatically after a certain number of prints or during printer startup or they may be started by the customer if a print quality defect is noted e Printhead maintenance cycle e Paper preheater cleaning e Transfix roller oiling Drum cleaning chase page Printhead Maintenance Cycle This topic describes the cleaning cycles used to remove bubbles or foreign matter that cause a printhead jet to malfunction Three basic actions take place during a cleaning cycle e purging e wiping e flushing These actions are used in different combinations for three different types of clea
16. 1 2 3 4 Remove the right left and front covers Remove the upper feed roller assembly Remove the paper drum heater Disconnect the preheater exit sensor wiring harness from the J 170 of the left 1 O board A Be careful in the next step not to scratch or mar the drum CAUTION 5 Remove the screw securing the preheater exit sensor to the inside of the left drum transfix assembly frame Remove the sensor and its wiring harness Reverse these steps to install the preheater exit sensor 6 50 ii LINX Solid Inkjet 100 Printer Service Manual Disconnect wiring harne SS Left I O board Transfix roller Preheater exit sensor in its bracket Drum Remove screw 840 4 65 Figure 6 32 Removing the Preheater Exit Sensor Removal and Replacement 6 51 6 52 Removing the Drum Temperature Sensor Remove the right cover Remove the left cover Remove the top cover Remove the ink loader Unplug the drum temperature sensor from the left I O board oO wu B WN FP Remove the screw securing the drum temperature sensor to the printer frame Carefully remove the sensor Reverse these steps to install the drum temperature sensor Drum temperature sensor P d Ss Wiring harness Sensor retaining screw Figure 6 33 Removing Drum Temperature Sensor ii LINX Solid Inkjet 100 Printer Service Manual Installing RAM DIMMs The printer accepts two SDRAM DIMMs which
17. 11 Removing the Power Supply Removal and Replacement 6 17 Power Control Board 6 18 HM e po oN DU F WN Ht Turn off the printer and remove the power cord Remove the right cover Remove the left cover Remove the top cover Remove the rear cover Remove the ink loader Remove the main board Remove the power supply Remove the network card or its cover plate whichever is in place Remove the internal hard drive or cover plate whichever is in place ii LINX Solid Inkjet 100 Printer Service Manual Power control board 840 4 35 Figure 6 12 Removing the Power Control Board 11 Disconnect the wiring harnesses leading to the power control board 12 Remove the four screws securing the power control board cover plate Remove the plate 13 Remove the four screws securing the power control board in place Lift and remove the board Reverse these steps to install the power control board Removal and Replacement 6 19 Paper Drum Heater Disconnect the power cord AC voltages may be present at the heaters even with the printer turned off WARNING 1 Removetheright cover 2 Removethe left cover Paper Drum heater Figure 6 13 Removing the Paper Drum Heater 3 Removethe upper feed roller as described in the topic U pper feed roller assembly 4 Disconnect the locking wiring harness from the right side of the paper drum heater 6 20 iiLINX Soli
18. 2 Ifthe problem persists replace the printhead Wrinkling 1 Try different media from a sealed package In high humidity environments paper left exposed unpacked absorbs moisture and begins to warp 2 Ensure the deskew fingers inside the front cover are not damaged or missing 3 Inspect the maintenance drawer wiper blade Replace the maintenance drawer if necessary 4 Thetransfix spring pressure is incorrect Perform the procedure Transfix Roller Pressure Spring Adjustment 5 Replace the drum transfix assembly Image Is Offset Or Cut Off 1 Check the application for the correct image sizing and orientation 2 Ensure that Letter or A4 is the selected paper size Troubleshooting 3 29 3 30 Oil Streaks On Top Of Print 1 Clean the stripper fingers 2 Run chase pages through the printer to clean the drum Use the front panel menu item Remove I nk Smears under Troubleshooting 3 Clean the maintenance drawer blade or replace the maintenance kit Image Is Rotated 90 Degrees 1 Inthe application s Page Setup make sure that the image is selected to print in Portrait or Landscape orientation as you expect Printer isn t in the Chooser 1 Ensure that the printer is turned on and the rear panel health light is flashing at a regular rate 2 Check the Network or AppleTalk control panel to ensurethe proper network or zone is selected 3 Check to see if the printer has not been renam
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20. 3 Scroll tothe Service Support menu and press the Select button 4 Press and hold the Left arrow button 5 While holding the Left arrow button press the Select button to enter the hidden Service menu 6 Scroll tothe menu item Test Prints and press the Select button 7 Select a test print by scrolling to a print and pressing the Select button Refer to Appendix B Test Prints It discusses each test print and what printing defect it reveals 4 6 ii LINX Solid Inkjet 100 Service Manual Adjustments Process Belt Tension Adjustment 1 Turn off the printer and remove the left side cabinet panel 2 Toadjust the belt tension loosen the process belt tensioner With a spring scale press inward on the tension idler of the process belt with a pressure of 0 7 kg 14 g 24 oz 0 5 oz and then tighten the tensioner in place Do not over tension the belt Adjustments 4 7 Press here to set belt deflection Process belt tensioner 0388 28 Figure 4 2 Setting Process Belt Tension 3 Reinstall the left side panel 4 8 ii LINX Solid Inkjet 100 Service Manual Exit Roller Drive Belt Tension Adjustment 1 Turn off the printer and remove the left side cabinet panel 2 Toadjust the belt tension loosen the exit roller drive belt tensioner With a spring scale press downward on the idler tensioner of the exit roller drive belt with a pressure of 0 34 kg 14 g 12 oz 0 5 oz then tighten th
21. 650 3619 00 T Paper path idler 2 Part of 650 3619 00 Gear Kit T9 650 3619 00 T Gear pulley upper teed roller preheat entry Part of 650 3619 00 Gear Kit E z ea l ssembly A 16 ii LINX Solid Inkjet 100 Service Manual 0388 22a Figure A 7 Gear and Belt Parts Material Number Listings A 17 Table A 8 Sensor and Flag Parts Item Part Number Serial Number Qty Name and Description Number Effective Discontinued 1 650 3618 00 1 Cap wipe purge home flag Part of 650 3618 00 Flag Kit 2 650 3618 00 T Drum maintenance cam home flag Part of 650 3618 00 Flag Kit 3 386 6902 00 Media tray sense flag assembly 7 650 3618 00 1 Paper out sensor flag Part of 650 3618 00 Flag Kit 5 650 3618 00 1 Paper pick flag Part of 650 3618 00 Flag Kit 5 650 3618 00 T Handfeed sensor tlag inside front access cover Part of 650 3618 00 Flag Kit 7 351 1047 00 T Preheat entry right edge sensor A size sensor handfeed sensor Part of 351 1047 00 upper feeder roller assembly 8 9 5803 00 Preheater exit sensor assemb y 9 9 4968 00 Process gear sensor E g axis encoaer kit see E elow 650 3618 00 ranstix exit sensor ag Part of 650 3618 00 F ag Kit and 351 1016 00 Pivoting Low Exit Guide T2 TT9 5800 00 T Front cover open sensor Part of 650 4039 00 Front Cover Control Panel T3 650 4039 00 T Duplex paper sensor tlag Part of 650 4039 00 Front Cover Control Panel T4 650 4039 00 T Duplex paper sensor Part of 650 4039 00 Fr
22. AC line voltages are present on the power supply and possibly in the printer via the heaters while the printer is plugged into an AC outlet even if the power switch is off 1 Turn off the printer and unplug it from its power outlet 2 AC Input With the DMM set to measure AC voltages measure the power being supplied to the printer It should measure between 87 to 128 VAC 115 VAC nominal or 174 to 250 VAC 220 VAC nominal 3 Proceed to the topic Inspecting the power supply fuses below NOTE If a heater shorts F2 or F3 opens The power supply does not shut down however a Service Required error codeis displayed on the front pand Inspecting The Power Supply Fuses Three fuses F 1 F2 and F3 are mounted on the power supply 1 Turn off the printer and remove the power cord 2 Removethe screws securing the power supply Disconnect the wiring harnesses plugged into the power supply and remove power supply 3 6 ji LINX Solid Inkjet 100 Service Manual A CAUTION 3 With a DMM determine that the fuses on the power supply are functional Fuse F1 is the AC input fuse for the DC section of the power supply If F 1 opens the power supply does not function and should be replaced Fuse F2 and Fuse F3 are used for the AC heaters within the printer they protect the power supply from most often a shorted triac If F2 or F3 blows it is best to replace the power supply rather than the fuse Otherwise with the f
23. Any string 32 characters or less administrator for the zone the printer is assigned to Network Node 1 32 ij LINX Solid Inkjet 100 Service Manual Table 1 4 Configuration Page Settings continued Parameter Description Saved in Default Limits or alternate choices NVRAM IPX Indicates which IPX frame types the printer accepts IPX Networks Ethernet 802 2 yes Enabled Disabled Ethernet 802 3 yes Enabled Disabled Ethernet II yes Enabled Disabled Ethernet SNAP yes Enabled Disabled NetWare port interpreter Language Indicates the type of yes PostScript Disabled lt interpreter gt interpreters in use at the port Filtering Interpretation of special yes None Interpreter based characters Job pipelining Indicates if multiple printfile yes On Off processing is allowed Operating Mode Print server Print Server Name Name of printer server yes TEK01B009 user defined hardware dependant Connection Mode 1 Directory Services yes 2 Bindery 1 Directory Services 3 Directory 2 Bindery and Bindery Services 3 Directory and Bindery Services Preferred DS Tree Directory Services Tree where yes Max length 48 bytes printer initially connects General Information 1 33 Table 1 4 Configuration Page Settings continued Parameter Login Password Enable Banners Config Retry Interval Queue Scan Interval Status Message TCP IP port interpreter Host Name IP Address Network Mask Router Gateway Frame
24. LINX Solid Inkjet 100 Printer Service Manual Installing the Internal Hard Drive 1 Power down the printer Leave the power cord plugged in to provide a ground path for static discharges 2 Remove the network card or the network card slot cover plate whichever is in place 3 Loosen the two securing screws holding the internal hard drive or cover plate and remove it 4 Slidein the replacement internal hard drive and tighten the two screws 5 Reinstall the network card or the network card slot cover plate whichever was removed earlier 6 Turn on the printer and print the configuration page it lists information regarding the internal hard drive Internal hard drive 840 4 40 Figure 6 38 Installing Internal Hard Drive Removal and Replacement 6 57 Upgrading Software The operating system of the Solid Inkjet 100 printer is capable of reprogramming the embedded software using flash memory technology When instructed to flash the OS overlays a special boot program the flash monitor onto RAM and reboots the processor The flash monitor then boots and downloads a formatted data stream containing executable object code into the flash ROM After completing the flash the monitor reinstalls the nominal boot program The main value of this functionality is found during printer development when software changes are applied daily To support daily flashing the OS spawns a daemon that listens for a remote flash requ
25. Panel 1 When the front panel displays READY TO PRINT press the down arrow button until Menu is highlighted Press the Select button 2 Press the down arrow button until Network Settings is highlighted Press the Select button 3 Press the down arrow button until TCPAP is highlighted Press the Select button 4 SetthelP address a Pressthe down arrow button until IP Address is highlighted Press the Select button b Press the left or right arrow buttons to highlight the 3 digit part of the address that you want to set Press the up or down arrow keys to change the numbers c When the address is set press the Select button 5 Setthe network mask a Pressthe down arrow button until Network Mask is highlighted Press the Select button b Press the left or right arrow buttons to highlight the 3 digit part of the address that you want to set Press the up or down arrow keys to change the numbers c When the address is set press the Select button 6 Setthe default router gateway address a Pressthe down arrow button until Default Router Gateway Address is highlighted Press the Select button b Press the left or right arrow buttons to highlight the 3 digit part of the address that you want to set Press the up or down arrow keys to change the numbers c When the address is set press the Select button 7 Toreturn the printer to normal operation press the down arrow button until Exit is highlighted
26. Peak vacuum should be greater than 46 cm Hg 18 in Hg 9 psi If the vacuum is less than 46 cm Hg then the cap wipe purge gasket is leaking or the vacuum pump is defective To isolate the problem go to Action Step 8 Troubleshooting 3 11 3 12 NOTE The Decay time should take about 6 seconds for the Peak vacuum to bleed off to 0 cm Hg If thereis no Decay time sudden drop to zero the cap wi pe purge gasket is bad If the Decay time is longer than 6 seconds then something is restricting the tubing ink in tubing tothe air valve or the air valveis bad Disconnect the tubing between the metal vacuum tube and vacuum module Blow through the metal vacuum tube to assure the cap wi pe purge assembly or tubing is not blocked with ink Replace any part cap wipe purge assembly tubing vacuum module etc that is contaminated with ink If the vacuum does not bleed off at all then the air valve is not opening properly or the orifice in the air valve solenoid is blocked Replace the vacuum module NOTE Checking the cap wi pe purge assembly performance by looking for the KISS effect when the printhead separates from the cap wipe purge gasket at the end of a purge cycleis not an accurate method of checking purge performance and it does not work on all solid ink printers U se your vacuum gauges 7 Check theink distribution in waste tray The last check is to look at the ink in the waste tray after a single CLEAN cycle If
27. PostScript Firmware Versions Flash Installed Installed RAM Memory Slot 1 Memory Slot 2 ROM Fonts Available Sys Start Job Job Timeout Wait Timeout Energy Star Timeout Media Source Upper Tray Lower Tray Print Quality Custom LUTs Parallel Port Language Encoding Job Pipelining Output Device Handshake USB Language Encoding Job Pipelining IDE Disk Network Information Version Time Time Source Last Config Time SysAdmin Contact iiLINX SIJ 100 810 675 135 Yes BOPPO30 BLINX solid inkjet 100 08 00 11 0A 50 3B 3010 106 7 OS 1 4 PS 11 28 Eng 11 28 Net 10 92 06 14 1999 Yes 64 MBytes SDRAM Non Parity 32 MBytes KMM3 665 403CTL GO SDRAM Non Parity 32 MBytes 16LSDT464AG 662C1 136 Fonts Run Unlimited 40 seconds 30 hours Lower Tray Paper Letter Paper Letter High Resolution Medical None Enabled PostScript Binary Off Parallel Port Bi directional Enabled PostScript Binary Off Not Connected 10 92x Fri Jul 02 11 58 08 1999 Clock not set Tue Apr 27 08 08 08 1999 Printed On Jul 2 1999 11 58 07 STERLING Diagnostic Imaging Printer Location Network Address EtherTalk amp Language Filtering Job Pipelining Name Printer Type Zone Network Node IPX IPX Networks Ethemet 802 2 Ethernet 802 3 Ethemet Il Ethemet SNAP NetWare amp Language Filtering Job Pipe
28. Printer Service Manual 3 Torque the mounting screws to 20 in Ibs 4 Performa Cold Printhead To Drum Spacing Adjustment followed by a Hot Printhead To Drum Spacing Adjustment X axis Motor And Drive Assembly Reveiw these general operation requirements before servicing the X axis motor and drive assembly Home Position The printer is completely dumb about where the head is other than based on motor count tracking in RAM after homing Accurate homing is dependent on a free moving head shaft assembly When the X axis is free to move homing can be verified by audibly listening to the tick sound as the motor continues to drive after the head travel limit is attained Moving the X axis by manually turning the gear will require power cycling the printer to reestablish the correct home location Friction Print quality could suffer if the X axis drive system friction becomes too high Lack of lubricant at the interface between the nose cone and yoke can increase friction and wear considerably Excess friction at the leadscrew gear interface would also occur if not properly lubricated Parking Bind Under unusual circumstances the X axis could become bound up when parked This would most likely occur if the interface between the gear and stop collar was not lubricated Drive parameters have been optimized to prevent binding However if such a bind does occur it can result in either no X axis movement or a delay
29. RARP 1 34 ii LINX Solid Inkjet 100 Service Manual Description Indicates whether or not a network password has been set Print banner Time in seconds to wait before retrying to configure Rate at which printer will scan queue for print jobs Indicates the type of interpreter in use at the port The Internet Protocol address If null the address will be set at run time via RARP or BOOTP Indicates which fields of the IP Address designate the network portion and which designate the node portion If null the mask will be determined from the printer s IP address or the BOOTP or ICMP Netmask Reply A list of addresses of the gateways to other networks Data packet encapsulation type for ARP RARP requests and IP datagrams Reverse Address Resolution Protocol Boot Parameter Protocol Used for setting the printer s IP address from a boot server Saved in NVRAM yes yes yes yes yes yes yes yes yes yes Default Not set No 60 seconds 15 seconds Not Set Default None DIX False Limits or alternate choices Set Not set An integer 1 through 300 in seconds Not authorized Disabled String of 15 or fewer characters of the format N N N N followed by the word Dynamic if IP Address Dynamic parameter is set to true String of 15 or fewer characters of the format N N N N String of 15 or fewer characters of the format N N N N Adaptive 802 2
30. SNAP May be followed by the word Dynamic True Table 1 4 Configuration Page Settings continued Parameter BOOTP DHCP IP Address Source SMTP Server SMTP Reverse Path DNS Primary Server Secondary Server Search Domain Names s LPR Filtering Job pipelining Host Access List AppSocket port interpreter Saved in NVRAM Description Used for setting the printer s IP address from a boot server yes Indicates from what source the IP address was obtained yes Host that email notification will deal with yes Destination of email error messages yes Provides the IP address of the primary Domain Name Services server Addition source of IP address for a Domain Name Services server Local domain name of DNS resolver Interpretation of special characters yes Indicates if multiple printfile processing is allowed yes List of TCP IP network addresses for host access to printer yes Default False Empty field Empty field None None None None yes Limits or alternate choices True 16 characters 80 characters This is overridden by BOOTP DHCP 256 characters Interpreter based no Unrestricted General Information 1 35 Table 1 4 Configuration Page Settings continued Parameter Language Filtering Job pipelining Host Access List Syslog Log Hosis Log Priority SNMP Trap Hosts Authentication Fail
31. Solution Caution Hot Surfaces Insert Maintenance Drawer A The printer is stopped Do not touch hot surfaces Reinsert Maintenance Drawer A Maintenance Drawer A is missing Open fron cover and insert Maintenance Drawer A The printer is stopped Open the front cover Do not touch hot surfaces Reinsert Maintenance Drawer A Power Switch is Off Melting Ink Please Wait The power switch has been turned to the off position But the printer is currently melting ink Power turned off Wait 30 minutes before moving printer The printer is shutting down it will shut off momentarily Waste Tray B full Open front cover to empty The printer is stopped Open the front cover Empty and reinsert Waste Tray B Close the front cover Caution Hot surfaces Empty Waste Tray B The printer is stopped Do not touch hot surfaces Empty and reinsert Waste Tray B Close the front cover Fast cool down mode XX Complete Do not move printer until cool Remove Maintenance Drawer A for shipping See manual for details The printer is cooling the ink Do not move the printer until the printer turns itself off Standard shutdown 2 Minutes or less The printer is shutting down VxWorks Shell Manufacturing Mode For Service use only 2 22 jiLINX Solid Inkjet 100 Service Manual Chapter 3 Troubleshooting This chapter provides troubleshooting assistance as follows
32. The power switch does not interrupt AC power to the power supply it only signals the supply and the printer logic to begin a shutdown sequence Even with the power switch in the OFF position AC line voltages are present on the power supply heaters and heater wiring There are no field adjustments necessary on the power supply General Information 1 59 Fe Drum heater 1 oN F Reservoir heater 1 AAA High density ink melter Intermediate density ink melter Power on o Low density ink melter C ear ink melter wi Do e purge ter o c 59 O Reservoir heater 3 c o E stack left P e heater D per p c o E x stack right Reservoir heater 2 Drum heater 2 oN o Triac control lines from Reservoir heater 4 the power control board L 4 pic 840 4 66 Figure 1 26 Power Supply Block Diagram 1 60 ji LINX Solid Inkjet 100 Service Manual A WARNING Print Process in Operation Once an image has been processed and a printing bitmap created a print cycle begins The printhead and drum are brought up to their
33. Yes 64 Mbytes 136 yes 0 seconds Limits or alternate choices Any name defined by the customer up to 32 characters in length No Legal values have the form XX XX XX XX XX XX a aa b bb c cc d dd where a aa is the Sterling version of VxWorks b bb is the PostScript version number c cc is the engine code version and d dd is the network code firmware version 64 96 128 no Any value denoted in seconds 0 means unlimited amount of time General Information 1 29 Table 1 4 Configuration Page Settings continued Parameter Wait Timeout Energy Star time out Intelligent Ready Media Source Upper Tray Lower Tray Print Quality Parallel Port Enabled Language Encoding Job pipelining Output Device 1 30 Description Amount of time the image processor waits for additional data from a host Amount of idle time allowed before the printer switches to a low energy power down mode Indicates if the automatic standby wake up feature is enabled Indicates the default tray the printer uses for self prints Indicates the size and type of tray installed Indicates the size and type of tray installed Indicates the combined setting of the HW Resolution Indicates if the parallel port is enabled Indicates the language interpreter in use at the port Indicates the type of data encoding at the parallel port Indicates if multiple printfile processing is allowed Devic
34. and pick the sheet of paper With the paper pick sensed the paper feed motor drives the upper and lower paper feed rollers and carries the sheet of paper to the paper preheater On its way the sheet of paper passes the deskew fingers which are flexible plastic fingers mounted on the front cover The deskew fingers guide the paper and create a buckle in the paper which aligns the paper tothe paper path The paper stops at the entry to the paper preheater tripping the paper preheater entry sensor on the left end of the paper preheater The paper alsotrips the paper width A A4 size sensors on the right end of the paper preheater to verify that the width of the paper is within the printer s specifications At this point the paper feed motor is stopped to wait for more ink deposition on the drum When ink deposition is about 9596 complete the paper feed motor is activated to bring the sheet of paper through the paper preheater and tothetransfix position The paper preheater heats the paper to improve ink transfer The leading edge of the sheet of paper trips the paper preheater exit sensor as it passes out of the paper preheater General Information 1 67 Exit Paper y p sensor 4 size sensors Transfix Y exit sensor Preheater exit sensor va Deskew o ee fingers Paper pick sensor er feed roller Paper preheater entry sensor Upper feed roller clutch Pick feed roller roller 840 4
35. appear on the front or back of prints e Oily spots appear along the top of prints e Mispicks or multiple picks occur at the media tray e Persistent paper jams inside the printer or at the media tray e Wiggly vertical stripes caused by too much oil created by a dirty maintenance drawer blade Most print quality and media transport problems can be cured by initiating cleaning procedures available through the printer s front panel menu Cleaning Supplies Required The following cleaning supplies are required e 90 or higher pure isopropyl alcohol e Lint free wipes e Lint free swabs Do not use rubbing alcohol because it can contain water and oils that leave undesirable residue on the printer parts Never use water to clean the printer s internal components Appropriate cleaning procedures for specific print quality or paper transport problems are listed in Table 5 1 Cleaning and Maintenance 5 3 Table 5 1 Problems and Cleaning Procedures Problem Type Light stripes or missing colors Missing or light stripes on prints Ink smears oil spots or random ink streaks Ink smears on the front back or edges of a page Oil drum fluid on top edge of print Media jams Paper pick or jamming problems at the tray Paper jamming problems at the front door Paper jamming problems at the exit Paper pick or jamming problems at the lower tray feed roller Double picks Solution Select the automated procedure Clean Jets
36. are 64 Mbyte in size The printer recognizes any acceptable size SDRAM DIMM in any RAM DIMM slot Use the following steps to installing new RAM DIMMs 1 Power down the printer Leave the power cord plugged in to provide a ground path for static discharges 2 Loosen the two rear panel screws securing the main board Slide out the main board 3 Torelease an installed RAM DIMM spread the latches securing each end of the DIMM in the connector SDRAM DIMM 840 4 37s Figure 6 34 Locating RAM DIMMs 4 Toinstall a RAM DIMM in the keyed DIMM connector insert the DIMM until it locks in place When properly inserted a tab on each end of the connector slips into a notch on each end of the RAM DIMM 5 Reinstall the main board intothe printer 6 Reconnect the host interface cables Turn on the printer and print the start page to verify the memory installation Removal and Replacement 6 53 RAM Real time DIMMS PA clock NVRAM Code ROM Nc DIMM p Printer ID 840 4 36 Figure 6 35 Installing RAM DIMMs Installing the Code ROM DIMM The code ROM DIMM contains both print engine and PostScript firmware Use the following steps to resinstall the Code ROM DIMM 1 Power down the printer Leave the power cord plugged in to provide a ground path for static discharges 2 Loosen the two rear panel screws securing the main board Slide out the main board 3 Torelease an installed code ROM DIMM spr
37. are made Although printhead failures will occur they will occur at significantly lower rates than in the past It is important that other parts of the printer related to printhead operation and maintenance cap wi pe purge assembly vacuum module or tubing be inspected and if necessary replaced to avoid unnecessary printhead replacements and service callbacks Table 3 1 provides the process for troubleshooting the printhead As you proceed through the Action steps listed in thetable please check the appropriate boxes under Look for and What next to document the troubleshooting process If you must replace the printhead keep a filled out copy of this table with the defective printhead and the Weak and Missing et stest print The following steps provide the details to accompany the table 1 Check the 8 digit serial number of the printhead in the Service Support menu or on the label on top of the printhead before replacing it Record the number on Line 2 of the checklist There are two numbers on the printhead look at the 8 digit number 2 Check printhead drive voltage H ead Adjust It is critical that new printheads only be run at the factory default of 128 Often the Head Adjust has been raised on the old head to extend its life Adjusting it above 128 will cause the jets to fail on multi page jobs and increases customer ink usage 3 Print ServiceTest Print 2 Weak and Missing ets Use this test print to evaluate the
38. are not already loose loosen the printhead s four locking screws two at each end of the printhead until they are just 4 14 iiLINX Solid Inkjet 100 Service Manual 11 snug in place Install the digital gap indicator and bracket to the left side of the printer frame and tilt arm as described in the Procedure Mounting the Digital Indicator Gauge Ensure the digital indicator is set to inches in NOTE Always movethe printhead by moving thetilt arm 12 At theright side of the printhead insert the right printhead spacer between the printhead and the drum Check the indicator it should read 0 0070 0 0010 inches Adjust the printhead s spacing adjustment by twisting a flat blade screwdriver in the adjustment slot to move the printhead s position until the indicator reads the correct value NOTE Do not insert both spacers at thesametime as this will only measure the larger of the two gaps 13 14 15 16 17 18 Remove the right printhead spacer and install the left spacer between the printhead and drum Repeat the adjustment Confirm the right side is still in adjustment If not alternate between the two sides until both sides read 0 0070 0 0010 inches Remove the spacer Snug the four locking screws using an X pattern Then tighten the four screws using the same X pattern to 20 in Ibs If not connected plug the printhead s data ribbon cable and power wiring harness into the power control board
39. bolt 8 32 x 687 212 0206 00 5 8 32 x 1 00 T 20 Taptite 212 0207 00 5 8 18 x 75 T 20 Torx 212 0209 00 5 8 32 x 375 Torx 212 0219 00 5 8 32 x 75 screw 212 0221 00 3 10 32 x 5 8 x 060 captive washer 213 0906 01 5 8 32 x 375 screw 213 1075 00 5 10 32 x 5 T 25 screw 213 1096 00 5 8 32 x 5 torx screw 213 1109 00 5 6 32 x 375 T 15 torx screw 213 1111 00 5 6 32 x 1 25 T 15 screw 213 1115 00 5 8 16 x 5 torx screw 213 1118 00 5 4 40 x 5 16 slotted combo torx 213 1119 00 5 6 32 x 5 16 slotted combo torx 354 0737 00 5 125 e ring 354 0738 00 5 5mm e ring 354 0756 00 5 M6 5mm bent e ring 358 0791 00 5 bushing 358 0823 00 5 exit roller bushing 358 0824 00 5 preheat entry roller bushing A 22 ii LINX Solid Inkjet 100 Service Manual Supplies and Accessories Table A 11 Supplies and Accessories Part Number Serial Number Qty Name and Description Effective Discontinued FSDT0695 T Solid Inkjet TOO Cleaning Kit a FSD10393 T Solid Inkjet Swabs Pads 10 348 1572 00 1 Separator pad paper FS016 1752 00 T Maintenance cartridge kit roller and counter aste ink tray 0 U01920200 0D 1 FParalercabr adapter 1284C t0 1285B8 E rivers and Utilities CD Englis rivers and Utilities CD European Languages rivers and Utilities CD Japanese z rivers and Utilities CD Simplifie inese rivers and Utilities CD Traditional Chinese z rivers and Utilities Diskettes Korean 61 0305 00 T Power cord
40. cap wipe purge assembly and printhead performance If you see ink mixing from one row to the next e g Medium 46 to Clear 46 this indicates the cap wipe purge blade may be damaged If it is install a new cap wipe purge assembly If you see weak or missing jets the probl em could be caused by the cap wipe purge assembly the vacuum system tubing air valve or pump the printhead or the printhead data cable To isolate the problem begin by checking the ii LINX Solid Inkjet 100 Service Manual performance of the cap wipe purge assembly and vacuum system Action Steps 4 8 If you see white pinstripes spaced 0 25 cm 0 1 inches apart across the page but not present on the test page the problem is not with the cap wipe purge assembly or printhead Check for something binding the x axis e g a cable rubbing the printhead The x axis shaft may need to be lubricated To lubricate apply three dabs 1 10 in diameter of Nye Rheolube 368F grease on the threads of the x axis shaft Visually check the printhead s faceplate Through close examination of the printhead s faceplate you can determine if the wiper blade and gasket are damaged If you see any tiny wax droplets inside the ring where the cap wipe purge gasket seals against the printhead faceplate Figure 3 2 the cap wipe purge gasket is leaking during purge This can be caused by a misaligned printhead or a defective gasket To verify printhead alignment mo
41. check the paper preheater s temperature Replace if necessary Missing Ink Or Low Density Ink Band Running Length of Print Possible missing or weak jet 1 Print the Service Test Print 2 Weak Missing J ets to determine if a jet is not performing Perform up to three printhead cleaning cycles to try to clean a clogged jet If necessary turn off the printer and allow the printhead to cool for a minimum of 4 hours Ensure the printhead maintenance vacuum system operates correctly If weak or missing jet cannot be recovered replace the printhead Scratches parallel to the long axis of printing Usually caused by foreign debris in the paper path 1 2 Run a sheet of paper through the manual feed to see if the scratch appears on the print If it does not the scratch occurred in the paper pick and early transport of the paper A scratch or smear caused by the paper preheater can be caused by debris built up on the heating surfaces Run the front panel deaning procedure Remove I nk Smears Additionally you can manually force a sheet of thick 65 to 80 Ib paper through the paper preheater to buff the paper preheater heating surfaces With the leading and trailing ends of the sheet of paper extending from the entry and exit of paper preheater gentl y pull the sheet of paper back and forth several times and then remove the sheet of paper Be careful of the paper sensor flags 3 24 ii LINX Solid Inkjet 100 Service Ma
42. complete Print quality is OK If PQ not OK go to ACTION 11 Install a new printhead only after completing previous steps 11 left and right HTD adjustments are 11 If HTD adjustment is uneven from equal at HOT adjustment side to side CWP will not purge Note f you have not replaced the CWP and f properly Adjust HTD and go to ACTION 12 you re not confident the printhead is Note Hot printhead adjustment must defective change the CWP be performed for good purge f performance and good print quality Check printhead drive voltage 12 Head Adjust setting of 128 12 If Head Adjust is not 128 set it to Check for Service Required Errors 128 and go to ACTION 13 13A 13 004 43 or 13 020 41 errors 13A Readjust HTD left or right side of etstack not heating as quickly as it printhead is too close to drum If error should reoccurs replace printhead 13B 13 001 40 13 002 41 13 003 42 13B Reseat printhead ribbon cable 13 017 46 13 018 48 and 13 035 47 before replacing printhead 14 Check CWP purge performance 13C 4 002 41 and 4 006 45 errors 13C Check printhead ribbon cable rinthead NVRAM all zeroes before replacing power control board ACTION 6 followed by printhead 14 good purge performance with NEW 14 If purge performance is good go to printhead ACTION 10 to verify 3 16 ij LINX Solid Inkjet 100 Service Manual Figure 3 1 shows what a printhead faceplate will look like after a good cap w
43. default will be equal to the Ink 0 setting It is not accessible from the front panel menu Adjusting Dmax will set the upper limit for optical density that the printer will produce It is accessible through the Default Printer Settings menu under OD Defaults Table 4 2 Ink Settings Name Number on Default Expected of Ink Color Ink Stick Range Clear 11 0 09 0 03 to 0 10 Low 12 0 89 0 60 to 0 90 Intermediate 13 1 89 1 50 to 2 00 High 14 3 54 3 00 to 3 70 NOTE OD measurements are based on theuse of a reflective densitometer with polarization filter Approved models are Gre amp ag D19C filter type 47B P and X Rite 400B Optical Density Calibration Setting Ink Densities Optical Density should be performed or at least checked on a yearly basis Performing optical density calibration involves measuring the density values for the primary inks and inputting them in the front panel Then a test print is printed and measured to verify calibration To calibrate Optical Density 1 Print ServiceTest Print 10 2 Using an approved densitometer measure all the squares in columns A C E H K and L and calculate the averages for Inks 0 3 3 Input these values into the front panel through the Hidden Service menu under Set Ink Density Return to Ready Adjustments 4 29 4 Print Service Test Print 9 5 Measure points P1 through P20 and calculate the averages for the boxes having the four different densities Lo
44. discolored inks flush out discolored inks Check print engine and PostScript firmware versions install current firmware version supplied by Service Review proper operation of printer using a customer file if possible Qj Review with the customer all work that was performed and how to properly care for printer Cleaning and Maintenance 5 9 5 10 iLINXTM Solid Inkjet 100 Service Manual Chapter 6 2 Chapter 6 A WARNING Removal and Replacement This chapter provides steps to remove and replace key printer Field Replaceable Units F RUs After a brief discussion about the importance of locking the printhead hardware and then software repair and replace procedures are provided Sharp burrs and or edges are present inside the printer Use caution when servicing equipment Locking the Printhead llli 6 3 Removing the Covers 000 cece eee eee 6 4 Front DOO uus ie quei evite Gat dow a TRIN DCN UR te 6 8 Exit Door and Exit Roller llle 6 8 Ink Loader siet SEG EDAD ME Lie 6 12 Eas ccs he Wi dPado Super Beka gid ts 6 13 Vacuum Pump Assembly 00000 eee eee ee 6 20 Main Board 0 ccc tte tee 6 3 SDRAM DIMM 0 0000 cece eh 6 20 Code ROM SIMM 0000 e cece eee eee 6 25 Power Control Board 1 2 0 60 cece eee 6 6 Left and Right I O Boards 00 000 e eee eee 6 10 Network Card 0 0 0 0 6 30 Internal Hard Drive 0 0 ee 6 3
45. field enter a name for the port this can be the printer name model location or any other descriptive name of your choice such as SIJ 100 b Usethe Tab key to move to the DNS Name Address field c Inthe DNS Name Address field enter the printer s P address for example 192 1 1 2 Click OK NOTE The printer must be on thenetwork and powered on for PhaserPort software to detect it and compl ee installation NOTE If you do not know the printer s IP address contact your system administrator 2 Atthe Finish Installation screen click Next The installer will automatically run the Add Printer Wizard which allows you to install the driver for the Solid Inkjet 100 The drivers are located on your printer s CD ROM e f you have not already installed the printer driver go to Install the Driver following this section e If you have already installed the printer driver click Cancel at the Finish Installation screen Then goto Adding a port to an existing printer Printer Networking 7 15 Install the Driver 1 In the Add Printer Wizard click Next Choose Local printer the dick Next TheManufacturers and Printers dialog box is displayed Click Have Disk From the Install From Disk dialog box type d N where d is the CD ROM drive Click OK Select the Sterling iiLINX Solid Inkjet 100 Click Next If prompted that a driver is already installed for this printer select Keep existing driver recommende
46. from the front panel Troubleshooting menu Select the automated procedure Remove Ink Smears from the front panel Troubleshooting menu Check the drum maintenance tray for ink Select the automated procedure Remove Ink Smears from the front panel Troubleshooting menu Clean the pick roller Clean the transport rollers Use the blue thumbwheel on the duplex roller to manually rotate the rollers Clean the exit rollers and the stripper fingers Use the blue thumbwheel on the duplex roller to manually rotate the rollers Clean the Auxiliary Feeder Unit assembly Clean pick pad with 90 alcohol NOTE Media jams areusually caused by bad media or a hardware fault i e a defective sensor Most jams will not be resolved by cleaning rollers so carefully observe the media and theresults of the service diagnostics when troubleshooting media jams Cleaning Page Under certain conditions the printer purges its ink jet nozzles to dear any jets plugged with ink When the purge is completed the printer outputs a cleaning page to clear the purge pattern from the print drum Ink jets are purged under the following conditions e During warm up from a power off condition e When the printer exits the Energy Star mode e When customers initiate the Print J et Test Page automatic cleaning procedure from the front pane Troubleshooting menu 5 4 iiLINXTM Solid Inkjet 100 Service Manual Vacuum Vacuum dust from the top cover the
47. functions are available Esc or Enter Return make it go away e F1 Brings up a more complete description about the currently highlighted test e Esc and Enter Return Either key replaces the selection screen with the current tty window Any currently selected test remains selected Running Tests Tests are downloaded from the PC tothe printer When a downloadable test is selected it takes a few moments to download the test Whilethetest is downloading the message bar indicates this fact and the completion indicator shows how much of the file has been loaded Troubleshooting 3 35 Test Suite List MS DOS Prompt DIAGS_UI T 6x12 j Hele e al fey fl Al ile Tests un ext o Suite Sel Individual Test System Verification 0 1 Press the Return key to enter the test group selection window 2 Usethe arrow keys to scroll through the list of tests suites Press the Tab key or the right arrow to select a test suite 3 36 ii LINX Solid Inkjet 100 Service Manual Once you select a test suite the individual tests of that suite are displayed Cyrole Solenoids clutch Pump boas lan 3 Usethe arrow keys to highlight a particular test 4 Pressthe space bar to select or deselect a test You can select as many tests as you like Torun a highlighted test once press the Return key Troubleshooting 3 37 3 38 5 After selecting the test s press Ctrl R to start the test s specifying the n
48. in coming off the collar which would cause a positional imaging offset Power Interruption The X axis shaft head assembly can gradually movetothe right when power to the printer or motor is interrupted prior to doing a parking move This occurs because the thread pitch slope is steep enough to allow the gear to rotate if unchecked by motor resistance Home position is lost when this happens but the printer re homes when the power is cycled Removal 1 Removetheright cover 2 Removethe left cover Disconnect the head tilt spring 3 Disconnec the X axis motor wiring harness at the X axis motor Removal and Replacement 6 33 4 Remove the two screws securing the X axis motor and bracket in place 5 Rotate the black plastic retainer counter clockwise 6 Lift up on the bottom portion of the X axis drive yoke Lift up on the yoke and remove the upper portion of the yoke 7 Removethe nose cone from the gear 8 Rotate the X axis gear counter d ockwise to remove it from the X axis shaft X axis drive yoke 27 Gear remove bottom first Nose Retainer cone 840 4 22 Figure 6 22 Removing the X axis Motor and Drive Assembly 6 34 ii LINX Solid Inkjet 100 Printer Service Manual Reassembly of the X axis Motor and Drive Assembly For reassembly apply a small amount of grease on the tip of the nose cone Apply a small amount 3 dabs on the threads of the X axis shaft Be sure to rotate the black plastic re
49. of the paper between the transfix roller and the beginning of the image on the drum The drum s rotation rotates the transfix roller and begins to pull the sheet of paper between them The transfix roller shaft rotates slightly more so a protrusion on the transfix roller cam causes the stripper fingers to momentarily drop down onto the deadband of the drum and catch the leading edge of the sheet of paper and direct the paper to the rotating exit rollers which are belt driven by the paper path motor The transfix roller shaft rotates slightly more to clear the protrusion on the transfix roller cam and raise the stripper fingers so they no longer contact the drum The process motor stops leaving the transfix roller cam in its half rotated position Friction from the rotating drum continues to turn the transfix roller which freely rotates on the transfix roller shaft Theink on the drum transfers to the sheet of paper pulled by the friction between the drum and the transfix roller After about 1 8 seconds the complete image has been transferred to the paper The process motor drives the transfix gear until the transfix gear is completely unloaded At this point the transfix gear is disengaged from the process motor gear the transfix cam solenoid is latched again and the transfix roller is lifted off of the drum The paper path motor driving the exit rollers through a drive belt pushes the remainder of the sheet of paper intothe exit tray The
50. only when necessary ii LINX Solid Inkjet 100 Service Manual Memory Considerations The printer dual frame buffer allows for printing one image while processing a second image which gives greater printing throughput With additional RAM memory the printer s capabilities increase as detailed in Table 1 1 Table 1 1 Installed RAM and Printer Capabilities Feature Base Additional RAM Upgrade 64 Mbytes 128 Mbytes Fast draft printing yes yes High Resolution Medical Printing yes yes Pipelining yes yes DICOM Support no yes To verify what type of RAM is installed print the 2 page Configuration Page from the Front Panel menu and refer to Installed RAM For example Installed RAM 64 Mbytes Memory Slot 1 SDRAM Non parity 32 Mbytes KMMe 665 403 CTL GO Memory Slot 2 SDRAM Non parity 32 Mbytes 16LSDT 464AG 662C1 General Information 1 5 Print Engine Assemblies Internal features of the print engine are illustrated in Figure 1 2 Cap Wipe Purge Printhead Ink load assembly assembly Drum Transfix De roller WN joes Process d motor Paper Drum heater X axis drive Y axis and motor motor Paper feed motor 0388 02 Figure 1 2 Internal Features of the Print Engine 1 6 ji LINX Solid Inkjet 100 Service Manual Seven circuit boards support the printer s electronics Refer to Figures 1 3 and 1 4 Two boards called I O boards left and right support the front panel solenoids
51. operating temperatures and the ink levels in the ink reservoirs are checked and ink is added from the ink loader if necessary Next the printhead is driven horizontally to its home position and the drum is rotated to its home position Keep your fingers away from the process gear drive system it uses a closed loop drive system A closed loop servo drive system is inherently dangerous Since the motor speeds up if it senses the process gears drive system slowing down fingers caught in the process belts and gears can be severely injured Printhead Tilt The printhead is tilted forward into its print position Refer to Figure 1 27 The process motor is activated which drives the process drive belt The belt in turn drives a compound gear Through a follower gear the compound gear drives the head tilt cam gear clockwise A cam follower mounted on the lower end of the head tilt arm follows the rotating cam gear which tilts the printhead The head tilt cam gear rotates until a set of missing teeth in the cam gear disengage it from the cam drive gear The cap wipe purge assembly in its standby position draws a leaf spring away from a cam lobe located at the back side of the tilt arm gear When the leaf spring pushes against the cam lobe of the tilt arm gear it forces the gear to mesh with the cam drive gear Pulling the leaf spring away effectively latches the head tilt cam gear in the printhead forward position At this point the pri
52. printer selection click Next Add Printer Wizard E hy Sterling nLINX SIJ 100 Printer Networking 7 27 8 Typein the name of the printer then click Next Add Printer Wizard a ng Sterling LINX SIJ 100 9 Select Not Shared then click Next Add Printer Wizard 7 28 ii LINX Solid Inkjet 100 Printer Service Manual 10 Click Finish The Printer should now be installed You can print a test page for verification Add Printer Wizard Printer Networking 7 29 Macintosh Software Install 1 2 Insert the printer s CD ROM Double click on the installer and follow the online instructions Set Up the Driver 1 2 From the Apple menu select Chooser Click the icon of the printer driver LaserWriter 8 on the left side of the window Click the Zone for your printer if applicable From the list of printers on the right side of the window select your printer If it is not in the list check the hardware connections and verify that you have selected the correct zone in the Chooser on the left side of the window Click Setup Create to select the correct PostScript Printer Description PPD file After the automatic setup has completed dick Setup and dick Configure Select the options that are installed in your printer for example memory configuration Auxiliary Feeder or internal hard drive this information can be found on the Sta
53. retain the lowest black plastic pand Breakage or separation can interfere with head tilt resulting in a poor seal with the cap wipe purge during the purge process Replace theink loader if broken or defective ii LINX Solid Inkjet 100 Service Manual Table 3 1 Printhead Troubleshooting C 1 Enter serial LY Goto ACTION 2 Check printhead drive voltage 2 Head Adjust setting of 128 O 2 If Head Adjust is not 128 set it to 128 Go to ACTION 3 rint Service Test Print 2 Weak and Missing Jets L 3A If so replace CWP ACTION 9 3A color mixing from one row to the next row for same jet 3B If so go to ACTION 4 3B weak or missing jet s Visually check printhead faceplate 4A streaks or smudges of wax in the 4A If so wiper is damaged Replace et area of the printhead CWP ACTION 9 4B tiny wax droplets V shape inside If so CWP is leaking Adjust HTD the ring where the CWP gasket seals or if gasket is damaged a to against the printhead faceplate ION 9 Otherwise go to ACTION 5 i heck CWP wi ket visal arae Wiper and gasket 5A any separation on the wiper blade If so replace CWP ACTION 9 or pitting of the CWP gasket 5B good visual inspection 4A 5A so go to ACTION 6 Troubleshooting 3 15 Table 3 1 Printhead Troubleshooting cont Check vacuum and decay time at_metal pipe using vacuum T TE Ac T during front panel L GA a peak vacuum reading during C 6A
54. sheet high capacity paper tray assembly give the printer a two tray capability The high capacity paper tray assembly is usually referred to as an auxiliary feeder unit A 133 MHz PowerPC processor oversees print engine operations and PostScript image processing The printer features an integral bidirectional parallel port IEEE 1284C with ECP mode and a 10baseT Ethernet port with support for EtherTalk TCP IP DHCP and Windows Peer to Peer A USB high speed serial port is also provided An optional Ethernet interface board offers a 10BaseT 100BaseT 10Base2 Ethernet connection providing standard protocol support for EtherTalk TCP IP and DHCP When installed this card disables the standard 10baseT port A second rear panel slot accommodates an internal IDE hard drive for DICOM support Solid inks Solid inks sometimes called phase change inks are solid at room temperature and are liquid at the higher temperature used during printing The inks solidify almost instantly after being jetted onto the printer s drum Each of the Solid Inkjet 100 printer inks is especially formulated for this printer the inks are not interchangeable with other models of solid ink printers NOTE Turning the printer off and allowing it to cool causes it to perform a printhead cleaning and purge cycle upon power up The printer s purge cycle consumes a significant amount of ink During normal use and servicing turn the printer off and allow it to cool
55. speed dependent upon print resolution As the drum reaches the correct speed the ink jets begin to fire to deposit the image on the oiled portion of the drum As the jets fire the printhead slews in the X axis to complete the image on the drum General Information 1 63 1 64 A QN Camshaft 2 home V position L Drum flag maintenance drawer camshaft Process motor S CAS Process drive belt Maintenance drawer camshaft electric clutch Maintenance drawer ie m Cam pushes oil roller and blade against drum Oil on Blade drum Cam lowers oil roller and blade assembly 840 4 54 Figure 1 28 Drum Preparation For Printing ii LINX Solid Inkjet 100 Service Manual Printing When printing the printer performs a four jet interlace in which each jet lays down a particular number of pixel columns depending on the print resolution Each jet lays down one pixel column for each drum rotation this varies from 30 to 44 rotations 30 409 dpi and 44 600 dpi Each jet travels horizontally the distance of 125 to 181 pixels 125 9409 dpi and 183 9600 dpi to lay down its 30 to 44 pixel columns within that pixel field The 125 to 181 pixel wide field of each jet overlaps the pixel field of six other jets this is where interlacing occurs During the horizontal movement of the printhead extra 1 or 2 step movements are made to properly align the pixel columns and prevent a column from overlapping an
56. the front and rear cushions on the Auxiliary Feeder unit Place the entire assembly into the cardboard box 1239 01 General Information 1 25 Configuration Page The configuration page shown on pages 1 27 and 1 28 lists the values the printer stores in its NVRAM These values can be informative when troubleshooting the printer particularly networked operations The configuration page gives information such as e General information about the printer such as page count the programmed name Ethernet address time outs number of fonts and total memory e Printhead information such as serial number calibration and adjust values e Parallel port settings USB setting e Harddrive e Network information e EtherTalk settings e Novell NetWare settings e TCP IP settings Configuration page settings are provided in Table 1 4 Printing the Configuration Page 1 Turn on the printer 2 Allow the printer to complete its power up self tests The front panel displays READY TO PRINT 3 Scroll to Menu and press the Select button 4 Scroll tothe menu item Demo and Test Pages and press the Select button 5 Scroll tothe menu item Print Configuration Page and press the Select button 1 26 ji LINX Solid Inkjet 100 Service Manual Configuration General Information Printer Name Total Page Count Upper Tray Paper Pages Lower Tray Paper Pages Start Page Enabled Serial Number Product Printer ID Adobe
57. the cap wipe purge assembly and vacuum system are working properly there should be ink evenly distributed across the waste tray 3 4 in wide Refer to Figure 3 7 If not check the head to drum gap The cap wipe purge gasket is leaking 8 If vacuumis less than 46 cm Hg at metal pipe check If the Peak purge vacuum is less than 46 cm Hg 18 in Hg 9 psi check the vacuum at the pump side of the vacuum module without the vacuum T If vacuum is less than 51 cm Hg 20 in Hg 9 9 psi replace the vacuum module NOTE In diagnostics go to the NVRAM PE ROM test and sdect the sub test Access NVRAM Read Write Data The default is set to 20 V This will causethe pump to run somewhat louder during the dean cycles ii LINX Solid Inkjet 100 Service Manual If vacuum is greater than 51 cm Hg the cap wipe purge gasket is leaking Replace the cap wipe purge assembly 9 Install a new cap wipe purge assembly After installing a new cap wipe purge assembly it may take from 4 6 front panel Clean cycles before the cap wipe purge gasket seals properly Besureto verify the new cap wipe purge assembly performs properly Action Steps 4 to 8 10 Install a new printhead only after directed by Action Steps 1 8 If you arenot surethe printhead is the problem change the cap wi pe purge assembly first NOTE The factory has set the printhead adjustable mounts at the maximum distance from the drum to avoid accidental grinding or crashi
58. the printer resets the changes take effect when the reset is complete After the reset you are prompted to print a Test Page It is recommended that you print a Test Pageto verify a successful installation Setting IPX Frame Types from the Front Panel When the front panel displays READY TO PRINT press the down arrow button until Menu is highlighted Press the Select button Press the down arrow button until Network Settings is highlighted Press the Select button Press the down arrow button until NetWare is highlighted Press the Select button Press the down arrow button until IPX Frame Type is highlighted Press the Select button Press the down arrow button until the desired frametypeis highlighted Press the Select button until On is displayed If desired you can set more than one frame type Toreturn the printer to normal operation press the down arrow button until Exit is highlighted Press the Select button Printer Networking 7 13 Windows 95 and Windows 98 PhaserPort Software TCP IP Configuration for a PC If you do not already have a TCP IP address configured for your PC contact your system administrator to ensure that the configuration is made according to your company guidelines If there is no TCP IP network already in place configure your PC with a unique address such as 192 1 1 1 To check the IP address for your PC follow these steps 1 Fromthe Start menu cick Run 2 Enter wini
59. 002 41 TCH JS LEFT SHORT The thermistor in the left jetstack appears to be 0x6c02 tech fault left jetstack shorted shorted 13 003 42 TCH JS LEFT HOT The left jetstack heater is running away Unplug 0x6c03 tch fault left jetstack run away the printer NOW 13 004 54 TCH JS LEFT SLOW The left jetstack heater is not heating at all or is 0x6d04 tch fault left jetstack not heating not heating as quickly as it should 13 017 46 TCH JS RIGHT OPEN The thermistor in the right jetstack appears to be 0x6c11 tch fault right jetstack open open 13 018 48 TCH JS RIGHT SHORT The thermistor in the right jetstack appears to be 0x6c12 tch fault right jetstack shorted shorted 13 019 40 TCH JS RIGHT HOT The right jetstack heater is running away Unplug 0x6c13 tch fault right jetstack run away the printer NOW Error Codes and Messages 2 11 13 000 Head Thermals Error Codes continued por Codes Front Panel Software Error Code Display 13 020 52 TCH_JS_RIGHT_SLOW The right jetstack heater is not heating at all or 0x6d14 tch timer right jetstack not heating is not heating as quickly as it should 13 033 45 TCH RESERVOIR OPEN The thermistor in the reservoir appears to be 0x6c21 tch fault reservoir open open 13 034 46 TCH RESERVOIR SHORT The thermistor in the reservoir appears to be 0x6c22 tch fault reservoir shorted shorted 13 035 47 TCH RESERVOIR HOT The reservoir heater is running away Unplug the 0x6c23 tch fault r
60. 20TORX tip e Torque Limiting Screwdriver e Computer running PC based service diagnostics To prevent damage to the printer remove the printhead tilt arm spring before moving the X axis to tilt the printhead If the spring is attached when moving the X axis the printhead may tilt rapidly and impact the drum To avoid damage to the printhead never touch the faceplate with your hands or any foreign object including tools and media Even if the printhead is cold use the printhead removal tool and printhead reservoir removal procedure Place the removed printhead on a clean level surface During this section of the worksheet you will perform a mechanical adjustment of the printhead to establish the spacing between the printhead faceplate and print drum For best print quality the spacing should be equal on the left and right sides of the printhead The adjustment is made when the printhead is cold After the printer warms up the spacing is then checked to ensure it is within tolerance 1 Remove the right cover and the left cover 2 Removethe top cover ii LINX Solid Inkjet 100 Service Manual Remove the ink loader and the metal heat cover Tilt the printhead to its print position and if removed attach the head tilt spring Torque the mounting screws to 20 in Ibs Install the digital gap indicator and bracket to the left side of the printer frame and tilt arm as described in the Procedure Mounting the Digital Indicat
61. 30 ii LINX Solid Inkjet 100 Service Manual Vacuum Check Tools required e Magnetic screwdriver e Vacuum gauge e T20TORX tip T 15TORX tip T connector for vacuum gauge e PC diagnostics Usethis check to verify the actions of the vacuum pump and the solenoid valve In addition you can determine if the cap wipe purge assembly is sealing properly against the printhead faceplate 1 Turn off the printer 2 Remove the top and right side covers 3 With aT connector connect the vacuum gauge to the between the vacuum pump module and the cap wipe purge unit Adjustments 4 31 T connector Vacuum assembly Cap Wipe Purge vacuum hose 0388 35 Figure 4 12 Connecting the Vacuum Gauge To The Printer 4 Turn on the printer and enable the PC diagnostics as explained in the topic PC based Diagnostics 5 Runthe Purge Printhead test from the H ead Maintenance test suite When the solenoid valve is energized you should see the vacuum gauge jump to about the value 51 cm Hg 20 in Hg 10 psi and within 4 to 6 seconds bleed off to 0 If the vacuum does not reach the expected value e Thereisa leak in the vacuum system from the pump e Theaccumulator and their plumbing or the vacuum pump is defective If the vacuum drops to zero immediately the cap wipe purge unit is not sealed to the printhead This test allows you to check the action of the vacuum as it is applied tothe printhead the cap wipe purge assem
62. 4 000 PC Processor Control Supervisor mor codes Front Panel Software Error Code Display 001 PC_DEV_FAULT_HEAD_READ Failure reading Head NVRAM data check wiring 63240 pc fault printhead NVRAM error to head 12C bus and other hardware PC_DEV_FAULT_HEAD_ZEROS Head NVRAM data was all zeroes has this head pc fault printhead NVRAM zeroes been through normalization If so check wiring to head etc PC_DEV_FAULT_HEAD_ONES Head NVRAM data was all ones has this head pc fault printhead NVRAM ones been through normalization If so check wiring to head etc PC_DEV_FAULT_HEAD_CHECKSUM Head NVRAM checksum failure the data within pc fault printhead NVRAM checksum the head NVRAM has been corrupted Check the hardware The head may need to be renormalized 4 005 4 PC_DEV_FAULT_DM_CAM_ERR Failure positioning the drum maintenance cam 0x2405 pc fault DM cam position during a PM cycle Check the DM cam solenoid clutch home sensor and related hardware 2 6 iiINXTM Solid Inkjet 100 Service Manual 4 000 PC Processor Conirol Supervisor continued Error Codes LS Front Panel Software Error Code Display PC DEV FAULT 300DPI CAL Calibration Failure Target Volt Sec Area of 300 pc fault 300 dpi calib DPI could not be achieved Check the hardware The head may need to be renormalized PC DEV FAULT 600DPI CAL Calibration Failure Target Volt Sec Area of 600 pc fault 600 dpi calib DPI could not be achie
63. 4 5 Printing the Configuration Page 200ee eee eeee 4 6 Adjustments e a E a E a eae 4 x Process Belt Tension Adjustment 04 4 x Exit Roller Drive Belt Tension Adjustment 4 x Y axis Belts Tension Adjustment 000 4 x Printhead to Drum Spacing Adjustment 4 x Cap Wipe Purge Assembly Belt Adjustments 4 x Drum Position Encoder Gap iliis 4 x Transfix Roller Pressure Spring Adjustment 4 x X axis Scale Adjustment 2 00 cee eee eee 4 x Adjusting Look Up Tables 0 0000 e eee eae 4 x Setting Interpolation Defaults 0 00 eae 4 x Measuring Dmax and Dmin 000 ee 4 x Vacuum Check 0 000 cece eens 4 x Resetting NVRAM 000 c eee eae 4 x Enabling Ethertalk llle 4 x Adding Windows NT Drivers 000 eee eee 4 x Configuring Solaris Workstation 0 00000 cea eee 4 x Configiure FTP Settings 000 cece eee eee 4 x View and Configure Syslog Settings 000 5 4 x Calibration vx reene im ERE EL eger xde quede ale ee 4 x ii LINX Solid Inkjet 100 Service Manual Front Panel Menu The print engine features an interactive menu that allows you to review or change the printer s stored parameters as well as initiate test prints and printer service routines A map of the front panel menu is shown in Figure 4 1 Adjustments 4
64. 5 Power Supply 00 cece eee eee 6 16 Upper Feed Roller Assembly 02000 e eee eae 6 19 Lower Feed Roller Assembly 2 aana 6 20 Preheat Drum Heater Assembly 20002 cee eae 6 28 Preheater Exit Sensor illii eee 6 30 Drum Temperature Sensor 000 e eee aeeaee 6 100 Drum Transfix Assembly 00 00 c eee eee 6 42 Drum Position Sensor Assembly 0002000 ee eeee 6 46 P nthead eoe aita i Oe eI an eet sates 6 50 X axis Motor and Drive Assembly 00000 0 eae 6 51 Y axis Belt Drive Assembly nauau ananuna aaa 6 52 Cap Wipe Purge Assembly 0 20 000 eee eee eee 6 83 Stripper Finger Assemblies 0000 cece eee eee 6 90 Pick Roller and Pick Roller Electric Clutch 6 93 Maintenance Can Roller and Electric Clutch 6 95 Maintenance Drawer Counter Connector Assembly 6 100 Upgrading Software 0 cee eee 6 120 Upgrading Firmware Flash Copy from P S File 6 125 ii LINX Solid Inkjet 100 Printer Service Manual Locking the Printhead A CAUTION A CAUTION During normal power down the printer tilts the printhead back and energizes the X axis drive to move the printhead to the far right This allows the printhead s tilt arm which moves as the printhead moves to engage a pin protruding from the left side printer frame This effectively automatically lock
65. 53 Figure 1 30 Paper picking and positioning for transfixing 1 68 ji LINX Solid Inkjet 100 Service Manual Transfixing Stripping And Exiting As the leading edge of the sheet of paper trips the paper preheater exit sensor it starts the transfix roller being lowered to its transfix position The process motor rotates dockwise rotating the process drive compound gear counterclockwise Fourteen flags on the circumference of the gear represent the fourteen teeth on the small gear on the back of the compound gear When the teeth of the small gear arein the proper position as detected by the compound gear position sensor the transfix cam solenoid energizes to release the spring loaded transfix cam on the right end of the transfix roller shaft This allows the transfix roller gear which up to this point in time had missing teeth disengaged to the 14 tooth gear of the process drive compound gear to rotate slightly and engage the small gear of the compound gear During this time the drum rotating at about 24 rpm positions the deadband to coincide with the arrival of the leading edge of the sheet of paper which is moving at the same rate as the drum The rotating transfix gear rotates the transfix roller shaft about one half revolution The transfix roller which is eccentrically mounted on the transfix roller shaft rotates into contact with the paper 5 mm behind the leading edge and then stops This sandwiches the leading edge
66. ALANS 49 9 CuSrH c JUI 9 eos sixy x PS UOISI9A MA ourdug uoneurojur uloged Wy eo ueuojurepq etos UnWN d ulened ISQ HIdlNS t CWU Z JUI 1S2 L eAnoefqQ 1uuq UOISIOA peoH N uped qunog 1edeq 0L SSoIppV dI eiqer dN J007T sa8ed p spo T GO ZE MOT T JUI jsa eAnooefqns jug e epeos sixy x 1snfpy aed TO PLH A A A A POW I juno Jodeg 19407 JoAloS Ud uonegodaojup Slog Surssr A XeoM c 1 9 O 0 AUT yrsuoq JU 19 NS peoH A A A A A A qunog 1edeq 19ddN 9ureN UNA apo rrenQ wg a8ed 1 spo T CIO C 7T SJL SAL KIOISTH INLA IN A N S5999 01 j29 os JN JN So qeumnsuo uoneognuopg Joy sSurjog IAUNA MOLE 3Jo sso1d 31oddng oorA1os popuoixq yioddng oora1jog Lon Je Adjustments 4 5 Hidden Service Menu To access the hidden service menu 1 Scroll tothe Service Support menu and press the Select button 2 Press and hold the Left arrow button 3 While holding the Left arrow button press the Select button Service Support Menu Previous Menu Test Prints Set Ink Density Adjust X Axis Scale H ead to Drum Adjust Drift Compensation On Off Reset Printer Reset NVRAM Restore Factory Defaults Head Adjust Select Custom Look Up Tables J am Count Panic Count Engine Copy Count Seal Drum Exit Printing Service Test Prints 1 Turn on the printer 2 Allow the printer to complete its power up self tests The front panel displays READY TO PRINT
67. CD THERMISTOR SLOW The drum heater is not heating at all or is not 0x7804 tcd timer drum not heating heating as quickly as it should 15 005 4x TCD FAN BLOCKED The drum fan heater is blocked not operational 0x7c05 tcd fault drum fan blocked or the heater is running away Unplug the printer NOW 16 000 Preheat Thermals Error Codes peor codes Front Panel Software Error Code Display 16 001 43 TCP_THERMISTOR_OPEN The preheater thermistor appears to be open 0x8401 tcp fault preheat open 16 002 44 TCP_THERMISTOR_SHORT The preheater thermistor appears to be shorted 0x8402 tcp fault preheat shorted 16 003 45 TCP_THERMISTOR_HOT The preheater heater is running away Unplug the 0x8403 tcp fault preheat run away printer NOW 16 004 46 TCP_THERMISTOR_SLOW The preheater heater is not heating at all or is 0x8404 tcp timer preheat not heating not heating as quickly as it should Error Codes and Messages 2 13 22 LSS TC Media Jams Error Codes NCIUUUR ese aeree 01 ot hon rayses mesas oe atom chp soser aum um usmeimhtem rernm ei ich omy esens woe 0 memes O 7 ase gr Ber opene jans tee 1otomng erer caaea 07 rerereea sensos o inner Front cover 0 0 0 W m k ak a ai a fu N IOD o A X ES Ea eal Doc Ee n be e fa 3 m T indicates whether a timeout or an event occurred Event 1 Timeout C indicates checksum 2 14 jiLIN
68. Chapter Chapter 1 General Information This chapter provides information and a general overview of the iiLINX Solid Inkjet 100 Printer Theory of operation printer specifications and components are presented in the following sections 1 2 iiLINX Solid Inkjet 100 Service Manual General Information TheiiLINX Solid Inkjet 100 printer shown in Figure 1 1 is a user installable low maintenance environmentally friendly High Quality Referral Image PostScript printer 0388 01 Figure 1 1 The iLINX Solid Inkjet 100 Printer shown with optional Auxiliary Feeder Unit Assembly To ensure complete understanding of the Solid Inkjet 100 printer we recommend participation in Solid Inkjet 100 printer service training General Information 1 3 Solid Inkjet 100 Printer Overview 1 4 The Solid Inkjet 100 Printer is an Adobe PostScript Level 3 Version 3010 grayscale solid inkjet printer It supports 409 x 409 dots per inch dpi resolution at draft mode and 600 x 600 dpi at High Resolution M edical mode The speed of producing images is 4 8 pages per minute ppm in draft mode and 2 5 ppm in High Resolution Medical mode Base Solid Inkjet 100 printer The base Solid Inkjet 100 printer features 136 built in fonts and is equipped with 64 Mbytes of RAM It can be upgraded to 128 M bytes of RAM by adding an optional 64 Mbyte RAM DIMM All printers support two available paper trays A and A4 trays and an optional 500
69. DEV FAULT LATE CLEAN REQUEST PC DEV FAULT INK OUT DURING FLUSH 0x2416 TIMEOUT 2 8 pc fault ink out timeout iiLINXTV Solid Inkjet 100 Service Manual Timeout during head adjust A 20 minute timer elapsed before the exit head adjust command was executed The only recovery possible is to cycle the power switch This head s NVRAM contains a format of data not supported by this version of firmware The head or firmware must be replaced Ambient temperature is less than 10 degrees Centigrade The printer cannot be warmed up under these circumstances Printhead temperature has dropped below the head clean needed threshold This condition occurred after the warmup sequencer had determined a head clean operation was not needed Declared when the printer is booted in FTTR mode and the head cap contact flag is set in NVRAM The printer cannot run in FTTR mode with head cap contact because it would be unwise to separate the two when cold Service requested that this be a device fault in order to bluntly alert the service person to the condition Declared when the printer is booted in FTTR mode and the drum is dirty Reasoning that cleaning the drum when very cold could increase the chance of gluing media to the drum surface and creating an ugly mess around the stripper fingers Service requested that this be a device fault in order to bluntly alert the service person to the condition Timeout during head flush for ink yel
70. E 1284C Twisted Pair 10BaseT Ethernet connector Universal Serial Bus port A special 5 pin connector accommodates a service RS 232 cable from aPC running PC based diagnostics The rear panel also includes two option slots With the addition of an optional Ethernet I nterface network card in the lower slot the printer can support 10Base2 or 100BaseT Ethernet connectors NOTE When an optional Ethernet Interface card is installed the printer s built in 10BaseT Ethernet port is disabled The second slot accommodates an internal IDE hard drive for print DICOM support Health LEDs Two health LEDs indicatethe status of the printer s CPU functions PostScript PS processing and Print Engine PE control Blinking The printer is operating normally Both LEDs blink irregularly during diagnostics To indicate the printer passes the POST tests and is operating normally the left PS LED flashes in a heartbeat rhythm on 0 5 seconds off 0 5 seconds The right PE LED pattern is two quick flashes on then off for a count of two for a total cyde time of just over two seconds If a soft error occurs image processing occurs but in a reduced capacity Soft errors include failure of expansion memory DIMMs or of any of the interface ports When a soft error occurs the printer automatically prints a startup page listing the error On or Off or blinking a coded error indication A hard error condition has occurred that would keep the i
71. Encoder N Paper drum SS heater Entry 72 assembly Servo motor Warning Closed loop servo drive 840 4 47 Figure 1 16 Drum Transfix Assembly An encoder disk and sensor on the left end of the drum monitors the drum s speed as well as its home position The drum heater heats the surface of the drum to about 55 C 131 F for imaging A temperature sensor in contact with the drum surface monitors the drum temperature The main board interprets the sensor s signal and turns on the drum heater and drum fan to heat the drum or turns on the drum fan alone to cool the drum The drum is driven by a closed loop servo motor which through a double reduction belt drive rotates the drum at a high speed for imaging and a constant low speed for image transfer to paper Keep your fingers away from the drum drive system it uses a closed loop drive system A closed loop servo drive system is inherently dangerous Since the motor speeds up if it senses the drum drive system slowing down fingers caught in the drum belts and gears can be severely injured General Information 1 47 Maintenance Drawer The maintenance drawer performs two functions Its primary function is to create a thin intermediate liquid transfer surface a layer of silicone oil on the surface of the drum prior to printing The oil keeps the ink from sticking to the drum s surface and facilitates its transfer tothe sheet of paper The oil is contained in an oil
72. If less than 46 cm Hg 18 in Hg 9 eye purge psi go to ACTION 7 Peak vacuum at metal pipe If greater than 46 cm Hg go to LOOK FOR step 6B L 6B the time it takes for the vacuum to L 6B If decay time is about 6 seconds go to decay to 0 cm Hg ACTION 10 Decay time If there is no decay time sudden drop to zero CWP gasket is bad Go to ACTION 9 If decay time is less than 6 seconds check metal and rubber tubing for ink If decay time is much longer than 6 seconds replace vacuum module saunas ta pi i i mE bu ree nM 7 peak vacuum at pump side of vacuum PI less than ote Hg 6010 9 9 9 during front panel CLEAN cycle module without T during front panel CLEAN psi replace vacuum module cycle If greater than 51 cm Hg go to ACTION 8 Measured vacuum at pump Locate source of CWP vacuum leak 1 8A Replace rubber or metal tubing and go to 8A plugged tubing between CWP and air ACTION 6 solenoid or vacuum module 8B Align belts and go to ACTION 6 8B misaligned CWP belts LJ ec misaligned printhead to drum 8C Align HTD and go to ACTION 6 8D interference with printhead tilt 8D Repair mechanical interference and go to mechanism ACTION 6 9 Install new CWP Do up to 6 purge cycles to test performance 9 good CWP purge performance 9 New CWP may take 4 6 purges before optimal performance Go to ACTION 6 10 weak or missing jet s 10 If no weak or missing jets repair is
73. If no power is evident no lit LEDs replace the power supply 5 Turn off the printer Reconnect the 40 volt loopback connector to the power control board then disconnect all load connectors from the power control board Turn the printer on If the rear panel LEDs still do not illuminate the power control board has a shorted driver and must be replaced If the LEDs do illuminate isolate which motor or fan is overloading the power control board and power supply by turning off the printer and sequentially plugging each cablein oneat a time and turning on the printer until the power supply is disabled Replacethe defective component Also refer to the next topic Testing for a shorted motor 6 Turn off the printer Disconnect the two 2C bus cables from the power control board This isolates the I O boards and their solenoid drivers If the rear panel LEDs illuminate isolate which I O board is shorting or which I 2C cable is defective 7 Ifthe power supply still does not work replace the power supply 3 8 ji LINX Solid Inkjet 100 Service Manual Testing For A Shorted Motor 1 Reinstall the power supply if removed in the previous procedure 2 Disconnect the process motor the Y axis motor X axis motor and the cap wipe purge assembly motor wiring harnesses from the power control board 3 Turn on the printer again to see if it does not overload now that the motors are disconnected from the power supply If the power s
74. Inspect both ends of the data ribbon cable to ensure they are properly seated Recheck the gap at both ends of the printhead Remove the digital indicator gauge and bracket from the frame Reinstall the ink loader and metal heat cover Adjustments 4 15 19 Terminate the PC based diagnostics and disconnect the laptop 20 Reinstall the top cover 21 Print Service Test Print 12 Comb Pattern to check alignment Insert flatblade screwdriver in adjusting slot Use a twisting motion to move the printhead Va e apnd t Tighten locking screws when both left and right adjustments are complete Position gap tool between the printhead and drum hook in side frame and over shaft t O Repeat adjustment at this end of printhead with 0388 31 LEFT gap tool Figure 4 5 Setting the Head to Drum Gap Adjustment When powering up after installing a new printhead reset the Head Adjust in the hidden Service menu to 128 If this step is forgotten the jets may eject too much ink on the page causing one or more of the following CAUTION shifting or displacement of ink during transfix wrinkling jet drop out causing random weak vertical streaks in solid fills It may take multiple solid fills for this effect to 4 16 ii LINX V Solid Inkjet 100 Service Manual occur NOTE Some service actions could leave the tilt arm in the wrong location to
75. MIN 9IEMION poxi oos IPON RIG slog WLAD uone yuo Wig vipo A SunuoAo1q A A A A A p PIPIN Ayyendy 918301 x e 10g wq uonnjsow ys Po Amend Wud adv ISIL 1of WUA de nuo uug Wig Sunorduy N AN A A A Sums x10 sBumog muud jnejoq K Sunooyso gnogy soSeq iso pue ouraq uoyng au SUSAN soido diay Figure 4 1 Front Panel Menu Map ii LINX Solid Inkjet 100 Service Manual 4 4 seSed p SIKA Pros Lewung 9 uni eos 7X qyunog do oursuq JIWS unq Surpueg t IL qunog orueq woy JULIg Surpueg ip E AQL qunog wef aseu sods NIA TAL le Se quL uae quio z T QLL dN J007 urojsn VAS AN IN J094 TONTO sIXv x T 1snfpy peoH a IN uoneJqi e up ysuoqpxuperojw K synejeq K1012e o10 sooT MON IAUNA IPS J949 uoneIqme qo 6 pue WVUYAN PSA JAV3IAN PSA IXIL ISIA g MON Ud PSY K lojulq VS MON PLH ysnja JO UO fei mepa spaao y AeID OGZ L qsnfpyuonesusduiog jq peoH ysnyy 7X A IN oj uone pe1sugp sased QT 9jo duio WY eoueuojurepq WojeuisrjA IZIS IPIN GO PIPIA WIA 9 jueunsnfpy K jsnfpy um q 0 peoH uonezruiojsn LAT Jedeq AN AN AN AN Surureuro1 sund xeW d woped
76. PgDn Move the display of tests one screen full at a time The highlight block generally stays in place on the screen so this also changes the highlighted test In the Individual Test column Up and Down arrows Movethe Individual Test selection highlight block up or down on the screen When the highlight block reaches the top or bottom of the screen it causes the list to scroll if there are more tests in that direction on the list Space bar Toggles the Status of the currently highlighted test to Selected if the test is not selected and to not selected if itis already selected Left arrow Moves back tothe Test Suite column Alt S Toggles the Status of all tests in the Suite which contains the currently highlighted test all to Selected if the currently highlighted test is not selected and all to not selected if it is anything else The status of the other tests in the suite is immaterial AIt A Toggles the Status of ALL tests LikeAlt S the new setting for all tests is based on the currently highlighted test regardless of the individual settings of the other tests Alt R Selects the currently highlighted test and opens the Run window to prepare to execute the currently selected test ii LINX Solid Inkjet 100 Service Manual Diagnostics Global Help Screen MS DOS Prompt DIAGS UI fr s w 3 Cale ef sfs al top ile ic ptions Individual Test Status AIt H Opens a small Help window to remind which
77. Please wait You have selected Cancel wait while the job is removed from the queue Canceling Cleaning Pleas wait The current cleaning operation has been canceled 2 18 iLINX TM Solid Inkjet 100 Service Manual Table 2 2 Front Panel Status Messages continued Status Message Solution Standby mode Press any button to return to Ready The printer is in an automatic power saving mode Press any button to return the printer to Ready NOTE Pressing Help removes Standby so you do not actually see this Help message Energy Star Mode active Press any button to return to Ready Reduces power consumption Head To Drum Adjust For Service use only Upper media tray empty Load paper The printer is stopped Load paper into the upper media tray insert in the printer Lower paper tray empty Load paper only The printer is stopped Load paper into the lower paper tray insert in the printer Media tray empty Load paper The printer is stopped Load the paper into the tray insert in the printer Replace lower paper tray The lower paper tray is missing Printing can continue from the upper tray Replace upper media tray The upper media tray is missing Replace the tray to continue printing Replace media tray The media tray is missing Replace the tray to continue printing Cleaning sheet needed Load paper The printer was interrupt
78. Standard U S TT5V a z ipping carton ki Material Number Listings A 23 A 24 ii LINX Solid Inkjet 100 Service Manual
79. X Solid Inkjet 100 Service Manual 22 000 Jam Error Codes Front Panel Software Error Code Display 22 721 0 DECLARED JAM Media not staged at preheater entry in time for transfix 22 722 0C DECLARED JAM Media jam at stripper fingers 22 901 0C DOOR EVENT The front access door is opened 22 902 0C DOOR EVENT The top stripper access door is opened 31 000 Media Preheater Error Codes Front Panel Software Error Code Display 31 003 4x MP FAULT PREHEAT EXIT SENSOR BAD Declared at boot time when a check is made to determine the condition of the preheat exit sensor Declared when the sensors around the preheat exit sensor indicate the presence or absence of media contrary to that indicated by the preheat exit sensor Error Codes and Messages 2 15 PostScript detected Error Codes NOTE Codes from 24 000 through 24 999 are engine failures reported by PostScript They are NOT stored in the fault history table in NVRAM These are reported when the engine has been stuck in a state for 25 minutes Error Code Meaning S 000 1 unused unused unused Engine is stuck while oiling the drum 2 16 iLINXTM Solid Inkjet 100 Service Manual PostScript amp detected Error Codes continued Error Code Meaning o Engine is stuck while cooling down Engine is stuck while in the cool state Should never happen Engine is stuck while in head adjust state Engine is stuck while flushing the head Win
80. al Indicator Gauge Kit Small 3 16 in flat blade screwdriver 9 64 in hex tip Magnetic screwdriver e T20TORX tip e Torque Limiting Screwdriver e Computer running PC based service diagnostics This procedure assures that the printhead is the proper distance from the drum Make this adjustment after removing or replacing the printhead and performing a cold adjustment or when the head has not been installed but requires a minor adjustment 1 Remove the right cover and the left cover 2 Removethetop cover 3 Removethe ink loader and the metal heat cover 4 Tilt the printhead toits print position and if removed attach the head tilt spring drive gear If not the printhead to drum gap may be too small The head tilt cam gear must be completely disengaged from the allowing the printhead faceplate to come in contact with the drum CAUTION 5 Placethe printer in diagnostic mode by setting dip switch 1 in the down position 6 Prepare your laptop computer for running diagnostics and connect the diagnostics cableto the printer 7 Turn on the printer 8 In your PC based diagnostics scroll to the Printhead Adjust test suite and run the Do Printhead to Drum Gap Adjustment Hot routine The routine automatically centers the printhead and brings the printhead and drum totheir operating temperatures 9 If they are not already tightened tighten the printhead mounting screws to 20 in Ibs 10 Ifthey
81. allow a normal power up This is especially truein replacing the Printhead When this happens unusual noise and a loud slam may occur after which thetilt system will recover properly This happens as thetilt arm struggles past theship restrain tab A quick power down and power up will verify normal operation has been resumed To prevent the slam condition position the head near the center of the X axis travel beforeturning on the printer Mounting the Digital Indicator Gauge Mount the Digital Indicator Gauge The digital indicator gauge must be mounted properly to obtain stable printhead to drum spacing readings U se the mounting holes post and screw provided on the chassis when mounting the gauge Refer to Figure 4 6 to mount the gauge When installing the digital indicator gauge push forward on the gauge s mounting bracket so it is tight against the hex screw and the upper screw in the chassis and then tighten the upper chassis screw The gauge brack must betight against the mounting post While installing the tilt arm bracket push forward on the bracket so Adjustments 4 17 it is flush with the head tilt arm and then tighten the two screws The bracket must be flush with the tilt arm LA IAS Upper chassis screw War Push forward here so bracket is tight against chassis O Push forward here so bracket mounts flush with head tilt arm Figure 4 6 Mounting the Digital Indicator Gauge Zero the Digital I
82. along the left side of the print engine to the power control board and left O board Remove the drum position sensor assembly Remove the upper feed roller assembly Remove the paper drum heater Remove the drum temperature sensor po 09 v Remove the C dip securing the compound gear and remove the gear 10 Loosen the exit roller drive belt tensioner Remove the exit roller drive belt 11 Removethetilt arm spring ii LINX Solid Inkjet 100 Printer Service Manual Exit roller drive belt tensioner Wiring harness Exit roller drive belt gear Remove drum transfix assembly screws C clip 840 4 19 Figure 6 16 Removing the Drum Transfix Assembly Left Side 12 Right side Removethe Y axis belt drive assembly 13 Disconnect the wiring harnesses leading tothe transfix solenoid bracket Remove the three screws securing the bracket in place and remove the bracket 14 Removetheleft and right frame bridges Each is held in place with two screws 15 Removethe two screws securing the front of the drum transfix frameto the inside printer frame 16 Removethefive screws securing the left side of the drum transfix assembly to the print engine Notethat one screw is removed with a 3 32 hex key Removal and Replacement 6 25 17 Remove the five screws securing the right side of the drum transfix assembly to the print engine Note that one screw is removed with a hex key 18 Carefully lift a
83. am roller and electric dutch operating correctly Test them using PC based diagnostics 4 Ensurethe left and right drum maintenance actuators operate correctly when lifted by the cams of the drum maintenance cam roller 5 Thedrum may betoo warm Verify the drum temperature using PC based diagnostics Ensure the drum temperature sensor is properly positioned and has no contamination between it and the drum surface 6 Verify the paper preheater temperature using PC based diagnostics 7 Try a different ream of paper Repeating Print Defects On Print The distance between each artifact of a repeating image defect reveals which imaging component is causing the defect 1 Repeating defect 13 6 cm 5 34 in in the vertical direction are caused by thetransfix roller 3 28 ii LINX Solid Inkjet 100 Service Manual 2 White or dark lines parallel to the long edge of the print spaced 1 4 mm 0 054 in in solid fills using High Resolution Medical printing mode indicate the x axis step accuracy is incorrect Ensure the long spring mounted underneath the printhead is intact and not contaminated with ink remove the maintenance drawer to access the underside of the printhead Inspect the x axis drive system replace it if necessary Banding Parallel To Long Edge Of Print Fills are inconsistent with wide bands of varying density 1 The head to drum gap is too great Perform the procedure Printhead To Drum Spacing Adjustment
84. and sensors The main board contains the printer s CPU processor RAM and ROM The power supply accepts the AC input voltage and distributes it or converts it to various other levels of required DC voltages and distributes them The power control board distributes power supply voltages to the other printer boards and drives many printer motors The front panel provides a user interface to the printer The printhead drive board a part of the printhead manages the signals and voltages of the printhead s printing elements and sensors The optional Ethernet interface card and internal hard drive could be considered the eighth and ninth circuit boards Front panel IP sA I O board right 0388 03 Figure 1 3 Circuit Boards of the Print Engine Right Front View General Information 1 7 Printhead drive board Optional Internal hard drive S Ethernet Interface card F Power i control board Power ial I O board Main board left 0388 04 Figure 1 4 Circuit Boards of the Print Engine Left Rear View 1 8 iiLINX Solid Inkjet 100 Service Manual An internal data bus called the I C bus connects all 1 O boards to the main board Refer to Figure 1 5 Through this single bus the main board can poll the O boards for the state of the printer s sensors as well as actuate the printer s solenoids This data bus greatly simplifies the wiring that would otherwise be required for monitoring numerous sensors a
85. are file server as ADMIN or ADMIN equivalent NOTE Whilenot required it is recommended that you log in only to the fileservers to be configured with this printer Start the PhaserShare Administrator Double click the PhaserShare Administrator icon Refer to your Windows documentation for complete information on how to start applications When you start the PhaserShare Administrator the Main window is displayed Select a Print Server In the Main window Printer List click the print server name printer name NOTE If the printer is notin thelist of available printers there could bea network hardware problem an incorrect frametype or incorrect search options settings Contact your Sterling Service Representative Printer Networking 7 11 Launch the Quick Configuration Wizard Click Quick Configuration to launch the Quick Configuration Wizard Configure the Printer and Set Up Queues 1 2 If desired change the Print Server Name or Printer Name Select connection mode s by checking the box es for Bindery Services NDS Services or both Click Next the dialogs that follow allow you to configure Bindery connections NDS connections or both You need to supply the following information for these connections Information Needed for Bindery Connections Select either the configuration file server or the preferred file server from the drop down list click Next If the file server you want is not on the list pro
86. are four LEDs mounted in a square pattern The upper two LEDs are yellow the bottom two are green The left hand pair of LEDs indicate activity the green LED will flash when the card is receiving data from the network and the yellow LED will flash when the card transmits data to the network The right hand pair of LEDs indicate the operating mode The top right yellow LED will be on when the speed is 100M bits It is off for IOM bits The bottom right green LED will be on when the twisted pair 11145 connector is in use and there is a good link to a hub It will be off if the link fails or when the coax BNC connector is selected General Information 1 77 Optional Internal Disk Drive The internal disk drive board contains a 3 2 Gigabyte IDE disk drive interfaced to the 32 bit PCI bus using a CMD Technology PCI 646 PCI to IDE data conversion chip Disk drive data transfer rates are 3 5 Mbytes sec minimum and 5 M bytes sec maximum and are 16 bits wide 1 78 ii LINX Solid Inkjet 100 Service Manual Chapter Chapter 2 Error Codes and Messages This chapter provides a description of the error codes and messages Rear panel LEDs error codes 200 0c eeeee 2 X 2 2 iiLINXTM Solid Inkjet 100 Service Manual Rear Panel LEDs Error Codes The rear panel LEDs are located on each side of the rear panel DIP switches NOTE All references to right and left areas viewed from the reat of the printer The left LED repr
87. are sourced from the image processing controller and are routed to the option slots on the power control board Two optional PCI based boards optional Ethernet Interface and Internal Disk Drive are available and plug into the power control board back plane Only one Ethernet interface is supported at a time If an optional Ethernet Interface card is plugged into the printer the printer s on board 10 BaseT Ethernet is disabled Main Board The power control board contains all of the motor power drivers with actual control for the drivers located on the main controller Switching for all heaters is contained in the power supply The main controller or processing controller uses a Motorola PowerPC 603e running at a nominal bus frequency of 32 MHz The 603e PLL is configured for 4 1 operation resulting in a CPU frequency of 128 Mhz DRAM is interfaced with a 64 bit bus and the PCI bus is 32 bits wide running at 33 MHz Other interfaces in addition to PCI bus are parallel port serial port and USB device side port There are two dram SDRAM DIMM sockets on the board These will accommodate industry standard 64 MB SDRAM modules up to a total of 128 MB There is one 168 pin DIMM socket for ROM FLASH on the main controller The interface to the controller is 64 bits Four DIP switches are located on the rear panel and from left to right are Service M ode 3 Service Mode 2 Service Mode 1 and System Reset The Three service Mode switches a
88. as a remote computer dialog box Default Limits or alternate choices Bi directional Uni directional PostScript Binary ACSII normal TBCP Off On Disk size in Gbytes 0 Any positive integer Integer 1 to 255 Set at Clock not set factory General Information 1 31 Table 1 4 Configuration Page Settings continued Parameter Description Saved in Default Limits or alternate choices NVRAM Last Config Time Last date the printer s yes configurations were altered SysAdmin contact Name of system administrator yes Empty string Printer Location Physical location of printer yes Empty string as set by system administrator PhaserShare Indicates the type of Phaser no Built in Ethernet Share network card installed Network Address A unique number for each yes Hardware Ethernet capable printer dependent Legal values have the form XX XX XX XX XX XX EtherTalk Indicates the type of interpreter yes PostScript Not installed Disabled in use at the port Level 2 interpreter enabled Language PostScript Filtering Interpretation of special yes None characters Job Pipelining Indicates if multiple printfile yes Off On processing is allowed Name The current name of the printer yes li LINX SIJ Any name defined by the customer as seen on a network 100 up to 32 characters in length Printer type Indicates the type of printer LaserWriter Any string 32 character or less installed at the port Zone Name assigned by network yes
89. assistance of another person 1 Repack the media tray Remove the media trays and remove all media from the trays Position the cardboard tray insert into the media tray to prepare it for shipping Reinsert the media tray into the printer 1239 38b 2 Repack the printer Position the lower cushion insert in the shipping tray as shown in the illustration Lower the printer onto the cushion inserts Place the plastic bag provided over the printer Place the cushion inserts on each side of the printer Repack the printer s accessories Place the power cord cleaning kit and all printer documentation in the area provided in the accessories box Do not ship a partially used maintenance drawer General Information 1 23 Figure 1 13 Repacking the Printer 1 24 jiLINX Solid Inkjet 100 Service Manual A WARNING The printer is not permanently attached to the Auxiliary Feeder unit When moving the printer or auxiliary feeder unit move each unit separately to avoid damage or personal injury The printer weighs about 36 kg 79 Ib Do not attempt to lift it without the assistance of another person Repacking the Auxiliary Feeder Unit If you have an Auxiliary Feeder unit repack for shipment using the original packaging Remove the media tray from the Auxiliary Feeder unit and remove all media from the tray Slide the media tray into the Auxiliary Feeder unit and place the assembly inside the plastic shipping bag Place
90. b after communication is established with the printer The baud rate can be se faster for quicker test downloading If the printer s power is cycled the PC s baud rate must be rese to 19 2 Kb to reestablish communication with theprinter PC based Diagnostics Screen Display Once communication with the printer is made the diagnostics display the startup screen on the computer gt MS DOS Prompt DIAGS UI Poles fr s 3 uae e ef Al Tests un ext top ile 29K tty window 3 32 iiLINX V Solid Inkjet 100 Service Manual The startup screen features the following elements A conventional looking Menu Bar across the top of the screen all diagnostic functions are accessible via this menu The middle of the screen is a blank gray area this is a 23 x 80 tty in which all interaction takes place with the tests when they arerunning The bottom line of the screen gives feedback about the state of the system It is divided into four fields ee Theleft most and largest field is the message field It contains descriptive text summarizing the operation of tests in progress and of the diagnostics program itself ee Next is the completion indicator When downloading test files tothe printer this field indicates the progress of the operation with a percentage compl ete display n wheren is O to 100 When running a lengthy series of tests a display n of N indicates the test progress ee Third is the view field This i
91. ble 174 3810 00 1 Vacuum Module Cable 174 3811 00 1 Y Axis Pos Encoder Cable Part Number Sub Part Number Qty Flag Kit Not available individually 650 3618 00 004 4386 00 1 Shipping Box 105 1066 02 1 Latch Flag C W P Home Flag 386 6681 00 1 Paper Out Flag 386 7020 00 1 Paper Pick Flag 386 7028 00 1 Sensor Strip Flag 386 7037 00 1 Handfeed Entrance Flag 386 7081 00 1 DM Home Flag Material Number Listings A 21 Table A 10 Parts Kits continued Part Number Sub Part Number Qty Flag Kit Not available individually 650 36 19 00004 3879 00 T Shipping Box 334 7987 01 1 White Tektronix Label 401 0715 00 1 Eccentric Shaft Compound Gear 401 0727 00 2 Idler Pulley 401 0728 00 1 Drive Shaft Pulley 401 0795 00 1 Preheat Entry Gear Pulley 401 0796 00 1 Idler 1 Paper Path Gear 401 0797 00 1 Idler 2 Paper Path Gear 401 0798 01 1 Duplex Roller Gear 401 0799 00 1 Duplex Roller Gear Pulley 401 0800 00 1 Exit Drive Pulley 401 0801 00 1 Lower Transport Pulley 401 0803 00 1 Preheat Entry Roller Gear 401 0805 00 1 HM Drive Pulley 401 0806 00 1 DM Cam 401 0810 00 1 Cap Drive Pulley 401 0812 00 1 Flat Roller 401 0818 00 1 Lower Process Gear Pulley 401 0819 00 1 Head Tilt Cam 401 0839 00 1 Eccentric Shaft Gear Part Number Sub Part Number Qty Hardware Kit Not available individually E Ipping Ox 210 1509 00 5 Washer 0 5 x 0 204 211 0409 01 5 Screw with washer 4 40 x 312 212 0195 00 5 M4 7 x 12mm screw 212 0199 01 5 Shoulder
92. bly should be sharply sucked against the printhead faceplate If it is not there may bean 4 32 ji LINX Solid Inkjet 100 Service Manual ink dogin the vacuum tube leading to the cap wipe purge assembly If the vacuum does not bleed off then the air valve is not opening properly the 7 mil orifice a part of the vacuum pump assembly is blocked or the vacuum tubing may be clogged If the printhead is hot such a condition can allow ink to be sucked into the vacuum system tubing If the vacuum takes longer than 4 to 6 seconds to bleed off the air valve solenoid or the cap wipe purge assembly may be defective If the vacuum bleeds off too quickly the tubing will be blocked or the cap wipe purge assembly may be defective check to see if the cap wipe purge assembly is not sealing properly to the faceplate Check that the cap wipe purge assembly is properly positioned by performing the Cap Wipe Purge Assembly Belt Adjustments Resetting NVRAM Resetting NVRAM returns most the printers s PostScript NVRAM stored parameters including those of the network card to their factory defaults except the copy count for images processed through the image processor the Adobe firmware serial number the usage profile and the authorization codes Print engine NVRAM values are not changed by the following procedure Select NVRAM parameters are not reset by the standard resets found in the front panel or PC based diagnostics These inclu
93. cedure selected through the front panel troubleshooting menu Remove I nk Smears The purpose of this cleaning item is to dean ink out of the paper preheater that may have been deposited there Ink can be deposited if a jammed print with ink on it was pulled backwards through the paper preheater Heavier weight high grade quality bond paper works best for this procedure In the paper preheater clean cycle these events take place The user starts the Remove nk Smears menu item 1 Theprinter overheats the paper preheater to 100 C softening ink trapped inside the paper preheater Ordinarily the paper preheater runs at temperatures of between 60 and 65 C for paper printing 2 Theprinter picks and passes up to 25 sheets of paper through the print path Each sheet absorbs and removes ink from the paper preheater but only the first five sheets are chased at the elevated temperature Then up to 20 additional sheets are chased while the preheater cools down The sheets are cleaning but their main function is to bring the preheater temperature back down The total number of chase sheets will vary from situation to situation The printer can resume printing when the preheat temperature drops to 75 C or below 3 Theprinter returns to the Troubleshooting menu Because of the higher paper temperatures involved this function can also be used to clean the drum surface of ink deposits caused by a contaminated blade on the drum maintenance draw
94. ceed with these steps 1 Click File Servers to display the File Servers Browse dialog box Select the server you want Click OK You are returned to the File Server Selection dialog box Select either the configuration file server or the preferred file server from the drop down list Click Next Create and select a new queue or select an existing queue Click Finish Information Needed for NDS Connections Specify the current Directory Services Tree the tree where the print server will reside Specify the current Directory Services Context the location in the directory services tree where the print server will reside Create and select a new queue or select an existing queue Click Finish 7 12 ii LINX Solid Inkjet 100 Printer Service Manual Verify Information and Finish the Configuration After you have entered the configuration information the Quick Configuration Wizard displays the Configured Printer Information dialog box which reports the information you have entered 1 2 3 1 Verify that the information is correct e ftheinformation is correct click Apply Changes e ftheinformation is not correct dick Back to return to previous dialog boxes and correct the information Click Next to return to the Configured Printer Information dialog box Click Apply Changes e Toexit the wizard and return to the Main window without making any changes click Cancel After you dick Apply Changes
95. ch related Error Codes Winch motor or sensors are not responding Error Codes and Messages 2 17 Front Panel Status Messages The Front Panel status messages and solutions are shown in Table 2 2 The messages are listed in descending priority order Table 2 2 Front Panel Status Messages Status Message Solution Warming up Please wait The printer is heating the ink wait until Ready to Print is displayed Ready to Print The printer is ready to accept print jobs Ink low Add ink Check ink levels add appropriate ink sticks to the correct ink loading bins Maintenance Kit is low Only XX Pages remaining before empty Reorder a Maintenance Kit now Replace Kit soon Processing Data Please wait The printer is processing data wait until Ready to Print or Printing is displayed Receiving data Please wait The printer is receiving data wait until Ready to Print or Printing Is displayed Printing Please wait A print job is printing wait until Ready to Print is displayed Warming up Please wait The printer is heating the ink wait until Ready to Print is displayed Warming up Please wait XX complete The printer is heating the ink warm up may take as long as 17 minutes wait until Ready to Print is displayed Initializing Initializing printer mechanisms Please wait Cleaning The printhead is being cleaned Please wait Canceling print job
96. clear Remove jammed media and reinsert lower media tray edia jam Remove Media to clear Remove jammed media to resume printing Media jam Open front cover to clear Remove jammed media and close the front cover to resume printing Media jam Open exit cover to clear Remove jammed media Verify that the correct media is loaded and close the exit cover to resume printing Incorrect media size Load letter size paper Printer needs letter size paper to remove ink left from a failed print Incorrect media size Load A4 size paper Printer needs A4 size paper to remove ink left from a failed print Drawer A locked Close front cover to continue The printer is stopped close the front cover to resume printing Printer error Contact service report fault For the latest information contact your local service provider Lower paper tray empty Load paper The printer is stopped Load paper into lower paper tray insert in printer Caution Hot surfaces Remove Maintenance Drawer A Caution Waste Tray B may be hot The printer is stopped Do not touch hot surfaces Remove and reinsert Maintenance Drawer A Caution Hot surfaces Replace the Maintenance Kit Cl and C2 The printer is stopped Do not touch hot surfaces Remove Maintenance Kit C1 and C2 Error Codes and Messages 2 21 Table 2 2 Front Panel Status Messages continued Status Message
97. cs SSS 003 d707 00 1 4Ovofserviceplgandjumper ti lt i C 73CCt t ead to drum Calibration toot ki 003 1733 000 1 Headdo drumspacerreplacemens 003 32200 D h T Service diagnostics diskete SWv 824 rinthead removal too _ O03 1504 0000 C i i i i lt i lt i lt i lt 1 Hmneadresevorpugset CSsi_ _CS S lt lt 3 C7272727 7 orx Bi orx Bi orx Bi 5 25 Tork Bi 003377 00 T 3 VacumCGauge acuum tting A 20 ii LINX Solid Inkjet 100 Service Manual Parts Kits Table A 10 Parts Kits Part Number Serial Number Qty Name and Description Effective Discontinued olid Inkje elt Ki olid Inkje able Ki olid Inkje ag Ki olid Inkje ear Pulleyt Ki olid Inkje ardware Ki Part Number Sub Part Number Qty Belt Kit Not available individually ipping Box 214 4811 00 1 Exit Drive Belt 214 4812 00 1 Simplex Transport Belt 214 4815 00 1 Lower Process Belt 214 4826 00 1 Drive Belt 344 0540 00 1 Base Belt Clip 344 0541 00 1 Ratchet Belt Clip 401 0727 00 2 Idler Pulley 407 4501 00 1 Exit Belt Tensioner 407 4547 01 1 Process Belt Tensioner Part Number Sub Part Number Qty Cable Kit Not available individually 650 3616 00 004 4386 00 T Shipping Box EE 174 3803 01 1 Heater Cable 174 3804 00 1 I O Left Cable 174 3805 00 1 I O Right Cable 174 3808 01 1 Left Umbilical Cable 174 3809 00 1 Right Umbilical Ca
98. d Click Next In the Available ports list select the port you created during the first part of the installation PhaserPortv2 1 0 0 Click Next In the Printer name dialog box givethe printer a unique name if another Sterling iiLINX Solid Inkjet 100 is installed for example SIJ 100 N etwork At the Setup Complete screen select Yes want to restart my computer now Your computer will now dose all applications and perform a restart Your driver will now be ready for use Adding a Port to an Existing Printer Usethis procedure to add change a port for a printer when you have already installed the driver 1 2 3 Select your printer driver a From the Start menu select Settings b From the Settings menu select Printers c In the Printers window right mouse dick your printer driver iiLINX Solid Inkjet 100 From the pop up menu choose Properties When the properties dialog for the printer is displayed dick Details 7 16 iiLINX Solid Inkjet 100 Printer Service Manual Windows NT 4 Highlight PhaserPort and click OK this displays the Add PhaserPort dialog a Inthe Description field enter a name for the port this can be the printer name model location or any other descriptive name of your choice such as SIJ 100 Network b Inthe Name Address field enter the IP address of the printer for example 192 1 1 2 and click OK NOTE If you do not know the printer s IP address contact you
99. d nozzles Following the vacuum cycle the cap wipe purge assembly performs a wipe operation on the faceplate using its squeegee like wiper blade The cap wipe purge assembly also receives the ink ejected from the printhead during the flush portion of the printhead maintenance cycle The flushed ink is routed to the waste tray of the drum maintenance drawer The cap wipe purge assembly is heated to keep the waste ink fluid during the wipe and purge operations Cap Wipe Purge assembly transport Cap Wipe Purge assembly a Cap Wipe Purge N assembly home sensor on I O board right g T O E assembly belt ge Vacuum system Solenoid valve di unenergized Air Pump Vacuum accumulator Air JE 7 mil orifice Filter Cap Wipe Purge assembly Solenoid valve energized 840 4 56 Figure 1 24 Cap Wipe Purge Assembly 1 56 ji LINX Solid Inkjet 100 Service Manual A WARNING The cap wipe purge assembly is attached to a pair of parallel belts on a rotating shaft To perform a printhead maintenance cycle the printhead is first tilted away from the drum Then the cap wipe purge assembly motor drives the cap wipe purge assembly belts which pull the attached cap wipe purge assembly up to the faceplate of the printhead The printhead is then tilted forward to seal against the cap wi pe purge assembly When the cap wipe purge assembly is in its lowered home position it unlocks the mainte
100. d Inkjet 100 Printer Service Manual 5 At the front of the paper drum heater remove the two screws securing the heater to the inside of the printer frame Do not confuse the mounting screws with the nearby smaller brass colored assembly screws Reverse these steps to install the paper drum heater Upper Feed Roller Assembly A WN PF Remove the right cover Remove the left cover Disconnect the head tilt spring Left side Remove the upper feed roller electric dutch from the end of the upper feed roller shaft by moving the locking tab on the clutch away from the shaft Remove the feed roller drive belt and compound gear from the left end of the upper feed roller Note the small slot in the compound gear to ease removal Removal and Replacement 6 21 Disconnect head tilt a OO eS oe feed roller shaft 2 P eit drive D MN bet Compound gear Upper feed roller electric clutch 840 4 13 Figure 6 14 Remove the Upper Feed Roller Assembly left side 6 Front Open the front door and remove the drum maintenance drawer Also remove the bright metal duplex paper guide from the front of the printer It is held in place with two screws 7 Removetheleft and right maintenance drawer guides Each is held in place by a single screw at the front and two frame latches at the rear NOTE If you havetrouble removing the right maintenance drawer guide manually rotatethe X axis driveto movethe printhead in its forwa
101. d Inkjet 100 Service Manual 0388 1 Figure A 4 Motor and Fan Parts Material Number Listings A 11 Table A 5 Circuit Board Parts Item Part Number Serial Number Qty Name and Description Number Effective Discontinued oard rig z oard le E ank cover plate hara arive 7 671 3994 0 Optional Ethernet interface card 386 6998 01 1 Blank cover plate interface card 5 671 4892 00 T Flash ROM DIMM English 671 4893 00 1 Flash ROM DIMM Japanese Morisawa 671 4894 00 1 Flash ROM DIMM Chinese Traditional 671 4895 00 1 Flash ROM DIMM Chinese Simplified 671 4896 00 1 Flash ROM DIMM Korean Hangul 671 4902 00 1 Flash ROM DIMM Japanese Heisei s 05038600 1 S MbyeRHAMDIMM T 05040700 90 1 Man board Power PCwomemoy 4691 allas Real Time CIOCI odule 9 0650402 4 g0 1 Powersupply 7074 ank cover plate riser boar T2TT 00 rinter TZ T1q3rTt04100 1 Jumpen44Ovoltisolaion i x ower control boar A 12 ii LINX Solid Inkjet 100 Service Manual Figure A 5 Circuit Board Parts Material Number Listings A 13 Table A 6 Solenoid and Clutch Parts Item Part Number Serial Number Qty Name and Description Number Effective Discontinued 401 0792 00 Electric clutch upper eed roller exit roller printhead maintenance 2 401 0808 00 1 HPcmrccouth pikroler S 401080700 1 Electric clutch drum maintenance SSS 7 40r0792 00 1 Electric clutch cap wipe purge drive z olenold transtlx assembly
102. de copy counts panic counts ink density calibrations and boot parameters among others If particular parameters become corrupt the printer may not operate correctly or may not recover If NVRAM corruption of this type occurs the most effective method of correcting the problem is to replace the offending NVRAM part with a new part Toreset the printer to its factory default values follow this procedure 1 If possible print the Configuration Page for a record of all the printer s port settings and other customer unique settings 2 Enter the Service Support menu 3 Press and hold the Left arrow button 4 While holding the Left arrow button press the Select button to enter the hidden service menu 5 Scroll tothe menu item Reset NVRAM and press the Select button 6 Scroll tothe menu item Reset NVRAM and Reset Printer Now and press the Select button again to reset NVRAM Alternately you can also usethe PC diagnostics to selectively return either the print engine NVRAM contents or the PostScript NVRAM contents to their factory default values as shown in the following illustrations Adjustments 4 33 Running Reset PE NVRAM to Default or Clear PS NVRAM downloads a file to the printer that performs the indicated reset function there is no confirmation or cancel function Calibration 4 34 X axis Calibration The calibration specification is 1 count 0 01 at t 0 and 3 count 0 03 over time Usethe following steps t
103. e procedurein Add Printer Procedures Windows 95 98 Optional Method following this section 3 Insert the CD ROM containing the Solid Inkjet 100 Printer driver software 7 20 iiLINX Solid Inkjet 100 Printer Service Manual 4 Click on Have Disk 5 Thelnstall from Disk screen will appear Type d or the appropriate drive for your CD ROM in the copy manufacturer s files box Click OK 6 The Sterling iiLINX SIJ 100 will appear Click Next 7 Click Next again 8 Click Finish Add Printer Procedure Windows 95 98 Optional Method 1 Fromthe Windows Start Menu select Settings Printers Jes Office Document L7 P open Office Document Programs Favorites E Printers Taskbar amp Start Menu 3 Folders amp Icons amp Hep active Desktop Time reo Bun a Log Off Barorke Windows9b5 2 Double dick on Add Printer Printer Networking 7 21 3 TheAdd Printer Wizard screen should appear Click Next 5 Insert the device drivers CD ROM into the CD ROM drive and select Have Disk 7 22 ii LINX Solid Inkjet 100 Printer Service Manual Apple Laserwriter Apple LaserWriter II NT Apple Laserwriter Personal NT Apple Laserwriter Il NTX Apple Laserwriter Ilf Apple Laserwriter Ilg asenwiriter Pl 6 Thelnstall from Disk screen will appear Type d or the appropriate drive for your CD ROM in the copy manufacturer s files box Click OK
104. e dialog box give the printer a unique name if another Sterling iiLINX Solid Inkjet 100 is installed for example SIJ 100 AppleTalk Select Not shared and dick Next If you want to print a Test page select Yes and dick Finish Printer Networking 7 19 Installing Printer Software NOTE For network installation configuration seetheiiLINX Solid Inkjet 100 User Manual Windows 95 Procedure 1 Before you begin make all physical connections from the PC to the Solid Inkjet 100 to allow the printer to be recognized as a new hardware device 2 Reboot your PC The New Hardware Found screen will appear briefly Click Next NOTE If the New Hardware Found screen does not appear use the Add Printer Procedures Windows 95 98 Optional M amp hod procedurelater in this chapter 3 Insert the CD ROM containing the Solid Inkjet 100 Printer driver software 4 Select Driver from disk provided by hardware manufacturer option Click OK 5 Thelnstall from Disk screen will appear Type d or the appropriate drive for your CD ROM in the copy manufacturers files box Click OK The printer is now installed Windows 98 Procedure 1 Before you begin make all physical connections from the PC to the Solid Inkjet 100 to allow the printer to be recognized as a new hardware device 2 Reboot your PC The New Hardware Found screen will appear briefly Click Next NOTE If theNew Hardware Found screen does not appear useth
105. e mark on the both the left and right spring set Screws ii LINX Solid Inkjet 100 Service Manual 6 On the side of the printer corresponding to the wrinkling tighten the set screw clockwise 1 8 of a revolution using a 4 mm hex driver On the side that does not wrinkle loosen its set screw 1 8 of a revolution NOTE Whatever adjustment is added to one side must be taken away from the other sideto maintain roller balance 7 Reassemble the printer and again print the Service Test Print 16 Primary Solid Fills 8 If wrinkling still occurs on the same side repeat Step 6 and 7 Do not adjust the set screws more than 3 8 of a revolution from their original position Any adjustment beyond this point results in CAUTION ink adhesion problems 9 If wrinkling continues to occur replace the drum transfix assembly Original registration mark 3 8 turn 3 8 turn maximum maximum Tension spring set screws Figure 4 10 Adjusting The Transfix Roller Pressure Springs Adjustments 4 25 Increase scale Correct Decrease scale X axis Scale Adjustment This adjustment sets the gain or rate of travel of the printhead s X axiS movement 1 2 adjust to raise center bars Allow the printer to warm up toits idle Ready to Print state Enter the hidden service menu by scrolling to the Service Support menu and pressing the Select button Then press and hold the Left arrow button and while holding the Left a
106. e tensioner in place Do not over tension the belt Press here to set belt deflection Exit roller drive belt tensioner lt lt gt a Figure 4 3 Setting Exit Roller Drive Belt Tension 3 Reinstall the left side panel Adjustments 4 9 4 10 Y axis Belts Tension Adjustment Perform this procedure after loosening or removing the Y axis belt drive assembly Refer to Figure 4 4 1 Ensure that the three mounting screws that secure the Y axis drive assembly to the chassis are one turn loose and that the Y axis idler bracket slides freely with respect to the chassis NOTE If thereis a situation in which diagnostics are not available when installing a new Y axis drive assembly or drum transfix assembly then locate any previously placed index marks on the pulleys and proceed as if reusing existing parts Allow the system to cool as long as feasible before mounting the Y axis drive assembly onto the chassis Tensioning of the Y axis drive assembly without diagnostics increases the risk of failures associated with low bet tension for example a growling sound heard upon cold power ups 2 Attach the Y axis belt tension tool in its unloaded or folded out position to the keyholes in the side frame of the printer just below and in front of the Y axis drive assembly The tool s fishhook should engage the eyelet of the Y axis drive assembly 3 Pull forward and down on the lever arm of the tension tool to apply ten
107. e the right left and top covers Disconnect the head tilt spring Tilt back the printhead Remove the ink loader F WN PF Manually rotate the cap wipe purge drive enough to raise the cap wipe purge assembly so the two belt locks are accessible on left and right side of the printer frame Removal and Replacement 6 43 5 At the right side of the printer slide the metal vacuum hose out of the cap wipe purge unit 6 Unlatch the timing belt lock of each belt to free each belt When installing new belts reverse these steps and attach each belt so that the pointer on each belt lock points at the index mark on the printer side frames Tighten each lock to its fourth tooth as illustrated Perform the belt alignment adjustment using procedure in Chapter 4 to ensure the belts are aligned and that the cap wipe purge assembly will correctly seal against the printhead faceplate Belt lock Index mark on right frame bs Latch Left belt lock align pointer between two index marks For new belt break off actuator on left side belt lock Right cap wipe purge assembly belt Leave gap between latch and belt tensioner 840 4 29 Figure 6 28 Removing Cap Wipe Purge Timing Belts 6 44 ii LINX Solid Inkjet 100 Printer Service Manual Removing Stripper Finger Assemblies 1 Remove the right left and top covers 2 Upper stripper finger assembly At the right side of the printer remove the transfix sole
108. e used for standard output and standard error ii LINX Solid Inkjet 100 Service Manual Saved in NVRAM yes yes yes yes no no yes yes yes yes yes yes Default 40 seconds 67 hours on Upper Tray High Resolution Medical Enabled PostScript Binary Off Parallel Limits or alternate choices Any value greater than 14 denoted in seconds 0 means unlimited amount of time Any integer from 1 to 999 denoting hours off Upper Tray Lower Tray Letter A4 Letter A4 High Resolution Medical Draft Disabled ACSII normal Raw TBCP On any communication device Table 1 4 Configuration Page Settings continued Parameter Handshake USB Language Encoding Job Pipelining IDE Disk Size Boot Delay Polling Network Information Version Time Time Source Description Saved in NVRAM Setting whether unidirectional yes or bidirectional communication is used Indicates the language yes interpreter in use at the parallel port Indicates the type of data yes encoding at the port Indicates if multiple printfile yes processing is allowed Indicates if the internal no hard drive is installed Indicates the physical size no of the installed IDE drive Number of seconds the yes printer waits before booting up the hard drive lt day gt lt date gt lt time gt lt year gt Source of the time set in printer such
109. ead the latches securing each end of the DIMM in the connector 6 54 ii LINX Solid Inkjet 100 Printer Service Manual 4 Toinstall the code ROM in the keyed DIMM connector insert the DIMM until it locks in place When properly inserted a tab on each end of the connector slips into a notch on each end of the ROM DIMM 5 Reinstall the main board intothe printer 6 Reconnect the host interface cables Turn on the printer and make a test print Code ROM SIMM d 840 4 38s Figure 6 36 Installing Code ROM DIMM Removal and Replacement 6 55 Installing the Optional Ethernet Network Card 1 Power down the printer Leave the power cord plugged in to provide a ground path for static discharges Remove the interface cable 2 Loosen the two securing screws holding the network card or the cover plate and remove it 3 Slidein the replacement network card and tighten the two screws 4 Reconnect the interface cables Turn on the printer and print the configuration page it lists information regarding the Ethernet interface 5 For installations of a new Ethernet card affix the Ethernet address label to the underside of the top cover where it can easily be accessed Also apply a Do not use sticker over the 10baseT Ethernet port on the main board The built in Ethernet port is disabled by the presence of an Ethernet network card Network card 840 4 41 Figure 6 37 Installing Network Card 6 56 ii
110. ead tilt cam gear disengaged from drive gear 840 4 55 Figure 1 22 Printhead Tilting Mechanism 1 54 ii LINX Solid Inkjet 100 Service Manual Ink Loader Theink loader consists of four parallel channels with an ink melting element at the end of each of the four channels Refer to Figure 1 23 Ink sticks one color loaded in each channel are pressed by coil spring pressure into the melting elements As ink is required by the printhead the appropriate color s melting element is activated and the end of the ink stick is melted The melted ink drips intothe ink reservoirs of the printhead underneath Sensors in the ink loader alert the customer to install more ink sticks before the current sticks are completely consumed If theink level sensors inside the printhead detect that the printhead has run out of ink but the ink low out sensors are not activated the front panel reports an Ink J am error Ink loader door Ink stick m OO Ink met 11 units Ai sansar Coil spring Ink out sensor Printhead Q 840 4 46 Figure 1 23 Ink Loader General Information 1 55 Cap Wipe Purge Assembly The cap wipe purge assembly is along shallow cup with an elastomeric gasket Refer to Figure 1 24 When raised and pressed against the face of the printhead it forms an airtight seal After forming the seal a partial vacuum is applied to the faceplate to suck out air bubbles and any debris that may be obstructing the printhea
111. ecognizes is saved in a configuration file called DIAGS INI and persists from session to session Presently there is a short list of configurable items but any program setting you make need only be done once Diagnostic Pull down Menus Summary All of the functionality in the user interface is accessible from the menu bar Some of the functions are additionally available via accelerator key Alt key synonyms The following discusses the pull down menu left to right Tests Command AIt T Opens the Tests selection window ii LINX Solid Inkjet 100 Service Manual View Menu Provides for changing various screens and major modes of operation for the program Tests Switches to the 68K window to show results of test running on the print engine Erase Screen Erases all the characters from the currently selected window it has no affect on the test running Debug Check List Item Enables or disables a trace of all 1 O between the user interface and the printer it is off by default Test Stats Lists the status of the last test sequence to run Run Command E xecutes a test sequence Next Command Stops the currently running test and immediately starts the next test Stop Command Stops the currently running test and stops the sequence in progress File Menu Alt F This menu controls the saving and loading of test selection sequences described above New Creates a new test selection sequence desel
112. ects all tests and erases their previous completion codes Open Opens an existing previously saved file Save Saves the current test selections in the current file If the selection sequences is new never been saved the user is prompted to specify a file name save As Saves the current test selections in a particular file eXit Alt X Exits the diagnostic program Troubleshooting 3 43 Options Menu Provides for customizing of program operation Submenus include e CommPort Provides for changing the baud rate of the link and for changing the communication port used The default baud rate is 19 2K Some diagnostic hosts support rates up to 57K Whenever the printer is reset or power cycled it resets its serial port to 19 2K Help Menu The system includes limited on line help The most useful help pertains to the tests themselves and is available via the Tests menu e About Gives the program version and other statistics about its operation Usage overview Gives the user an overview of the system and explains running the first test e F1 Describes an individually highlighted test 3 44 ii LINX Solid Inkjet 100 Service Manual Chapter 4 2 Chapter 4 Adjustments and Calibrations Bypass Mode manufacturing mode illus 4 3 Cool Down Mode 0 00 cece eee eee 4 3 Hidden Service Menu 0 000 eee eee eee 4 4 Bypassing a short Menu liliis ee
113. ed or placed in another zone You can print a Configuration Page which lists this EtherTalk information as well as other information about the printer ii LINX Solid Inkjet 100 Service Manual PC based Diagnostics The PC based diagnostics is provided for interactively testing the operations and functionality of the printer The diagnostics are provided on a 3 1 2 inch floppy diskette All of the diagnostic tests are started from the PC and are downloaded to the printer The PC based diagnostics were developed to run on a PC as thisis the portable computer in use by the field service organization Requirements e Printer serial cable adapter level shifter P N 012 1543 00 Serial null modem cable P N 012 1535 00 e IBM PC or PC done or compatible preferably a Pentium or 486 286 based PCs are intolerably slow e Atleast 640K of RAM About 2 Mbytes of disk space to store the diagnostic program and its test suite A mouseis optional but is not supported by the user interface e MS DOS environment This may be Windows DOS or MS DOS on a PC By convention each set of diagnostic files is installed into a single directory for ease of removal and updating C 100DIAGS lt version number gt is the default i e C LOODIAGS 1128 Starting The Diagnostics 1 Turn off the printer and the Service Laptop computer Connect the serial port of the computer to the special diagnostic 5 pin serial port of the printer u
114. ed while printing a page The printer requires a sheet of blank paper to remove the ink of the partially printed page before it can continue printing Load paper in the paper tray Cleaning sheet needed Load letter size paper The printer was interrupted while printing a page The printer requires a sheet of blank letter size paper to remove the ink of the partially printed page before it can continue printing Load paper in the letter size paper tray Cleaning sheet needed Load A4 size paper The printer was interrupted while printing a page The printer requires a sheet of blank A4 size paper to remov ethe ink of the partially printed page before it can continue printing Load paper inthe A4 size paper tray Error Codes and Messages 2 19 Table 2 2 Front Panel Status Messages continued Status Message Solution Close front cover to continue The printer is stopped close the front cover to resume printing Close exit cover to continue The printer is stopped close the exit cover to resume printing Close top cover to continue The printer is stopped close the top cover to resume printing Ink sticks jammed Open and close top cover to clear jam Ink sticks under the top cover are not sliding properly Open and close the top cover to resolve the problem If the problem persists jostle the ink sticks until there are no spaces between the sticks Output tray full Remove printed
115. ense 5 Lift and remove the ink loader Removal and Replacement 6 11 Ink loader Wiring harnesses Vacuum pump 840 4 09 Figure 6 7 Removing the Ink Loader Reverse these steps to install the ink loader Refer to Wiring Diagrams in Appendix C for illustrations showing how to route the ink loader s wiring harness 6 12 ii LINX Solid Inkjet 100 Printer Service Manual Fans Removing the Left Fan 1 Remove the left cover 2 Disconnect the wiring harnesses leading to the left fan 3 Remove the two screws securing the left fan to the side frame Remove the fan Left fan 840 4 25 Figure 6 8 Removing the Left Fan Reverse these steps to install theleft fan Orient the fan soit blows inward Removal and Replacement 6 13 Removing the Drum Fan 1 Removethe right cover 2 Disconnect the drum fan s wiring harnesses 3 Remove the three screws securing the drum fan in place Remove the fan Drum fan wiring harness Drum fan p Bulkhead bracket 840 4 10 Figure 6 9 Removing the Drum Fan Reverse these steps to install the fan Orient the fan so it blows inward Besure to mount the cap wipe purge wiring harness bulkhead bracket to the lower left of the fan Refer to Wiring Diagrams in Appendix C for an illustration showing how to dress the drum fan wiring 6 14 ii LINX Solid Inkjet 100 Printer Service Manual Main Board 2 3 Power down the printe
116. ension on the exit roller drive belt Slip the belt off the exit roller drive pulley 5 Usea small flatblade screwdriver to releasethe drive pulley from the exit roller shaft Also remove the left side keyed white plastic bushing 6 Remove the exit roller lower exit guide and exit door from the printer 7 Undip the lower exit guide from the exit roller 8 Slide the exit roller out of the exit door Reverse these steps to install the exit door Removal and Replacement 6 9 Exit roller Cap Wipe Purge electric clutch Right keyed bushing release with sma 840 4 08 Figure 6 6 Removing the Exit Door and Exit Roller 6 10 ji LINX Solid Inkjet 100 Printer Service Manual A WARNING A WARNING A WARNING Removing the Ink Loader Even when the printer is turned off AC line voltages may be present at the printer heaters while the printer is plugged into AC power 1 Turn off the printer and remove the power cord Allow the ink loader to cool Hot waste ink from a cleaning operation drains to the waste ink tray where it cools Avoid a burn hazard by allowing the printer time to cool before continuing 2 Removethe right left and top covers 3 Remove the vacuum pump module 4 Disconnect the two wiring harnesses leading to the ink loader Do not dangle the ink loader by its connector over the side of the printer as it may result in an intermittent connection and faulty ink s
117. er ii LINX Solid Inkjet 100 Service Manual Transfix Roller Oiling At the first opportunity after making 50 prints when no prints are queued and the printer is idle the printer performs a transfix roller oiling cycle During this cyde oil is applied to the drum as it would be during a print cycle Then the transfix roller is lowered against the drum and the drum rotates this transfers some of the oil to the transfix roller then the transfix roller is raised to its standby position Oiling the transfix roller prevents ink and media from sticking to the transfix roller Drum Cleaning Chase Page The printer performs a drum cleaning with a chase page automatically anytime a paper jam occurs after an image has been printed on the drum The chase page transfers the image which may not be complete off the drum and is usually discarded The printer then attempts to reprint the print that jammed The chase page is processed the same as a regular print except the drum is not oiled and noimageis printed on the drum since an imageis already printed on the drum General Information 1 75 1 76 Power Control Board The power control board functions as a back plane This circuit board is the point of electrical interface to the print head main controller optional Ethernet Interface card internal hard disk drive 1 O boards and power supply The PCI bus signals supporting the optional Ethernet Interface card and internal disk drive
118. esents the operation of the PostScript firmware The right LED represents operation of the main board s print engine firmware During the Power On Self Tests POST the two LEDs toggle back and forth for each successful pass through each SDRAM test A failure in the power on self tests is indicated by the left LED the PS LED flashing in a specific pattern of long and or short flashes and repeated indefinitely A long flash represents a 5 while a short flash is a 1 For example a long flash followed by 4 short flashes is 5 4 29 Ifthe left LED repeatedly flashes in the same sequence then the PostScript processor has encountered an error and is looping The possible LE D encoded error codes are listed in Table 2 1 Other failures are indicated by the failure being printed on the Startup Page Table 2 1 Main Board Power up Self test Error Codes Left LED Flashes Long flash 5 Short flashz1 2L4 18 211 SDRAM SIMM Presence This test verifies for the presence of both SDRAM SIMMs If both SDRAM SIMMs are missing the resultant error indication is 2 short flashes from the left LED SDRAM Bank 0 This test verifies DRAM Bank 0 in the DRAM DIMM located in position 0 closest to the rear panel SDRAM Bank 1 This test verifies DRAM Bank 1 in the DRAM DIMM located in position 0 closest to the rear panel SDRAM Bank 2 This test verifies DRAM Bank 0 in the DRAM DIMM located in position 1 farthest from the rear SDRAM Bank 3 This test verif
119. eservoir run away printer NOW 13 036 50 TCH RESERVOIR SLOW The reservoir heater is not heating at all or is not 0x6d24 tch timer reservoir not heating heating as quickly as it should 14 000 Cap Thermals Error Codes Error Codes SSS Front Panel Software Error Code Display 14 001 41 TCC_THERMISTOR_OPEN The cap thermistor appears to be open 0x7401 tcc fault cap open 14 002 42 TCC_THERMISTOR_SHORT The cap thermistor appears to be shorted 0x7402 tcc fault cap shorted 14 003 43 TCC THERMISTOR HOT The cap heater is running away Unplug the 0x7403 tcc fault cap run away printer NOW 14 004 44 TCC THERMISTOR SLOW The cap heater is not heating at all or is not 0x7404 tcc timer cap heater not heating heating as quickly as it should TCC WRONG TYPE CAP The installed cap heater is incorrect for this tcc fault cap incorrect printer Verify the correct cap heater is installed and or the correct firmware is installed for this printer 2 12 jiLINX Solid Inkjet 100 Service Manual 15 000 Drum Thermals Error Codes peor codes Front Panel Software Error Code Display 15 001 42 TCD_THERMISTOR_OPEN The drum thermistor appears to be open 0x7c01 tcd fault drum open 15 002 43 TCD THERMISTOR SHORT The drum thermistor appears to be shorted 0x7c02 tcd fault drum shorted 15 003 44 TCD THERMISTOR HOT The drum heater is running away Unplug the 0x7c03 tcd fault drum run away printer NOW 15 004 56 T
120. est A flash instruction can also be initiated from the OS command shell using flash Either of these mechanisms load the flash monitor described above The formatted data stream is received remotely via the network or parallel port However when the printer is booted in Customer Mode the flash daemon is not active because the Ethernet connection that services the OS is disabled The only available Ethernet pathway into the printer is attached to the PostScript Interpreter It is useful to retain the ability to download the embedded software remotely in part because it simplifies upgrades in the field Thus the PostScript language has been extended to permit remote flashing during any boot mode The custom operator updateflash is used to download the formatted data stream used by the flash monitor into the frame buffer RAM The flash monitor is then booted and programs the flash ROM using the data stream supplied not remotely but locally from RAM If the attempt to flash from RAM subsequently fails the monitor reboots itself and expects data to be supplied remotely 6 58 ii LINX Solid Inkjet 100 Printer Service Manual Chapter Chapter 7 Printer Networking This guide provides information to help you quickly install the ii LINX Solid Inkjet 100 Printer in the following environments Mac OS EtherTalk Windows 95 and Windows 98 Windows NT amp Novell NetWare The accompanying CD ROM also co
121. et stack left and right paper pre heaters reservoir heaters 2 3 and 4 10 amp slo blo Secondary voltages 45V 2 596 12 V t 596 12 V 5 40 V 5 12 52 V 1096 54 V 10 General Information 1 41 Operate printer only within specified environmental ranges CAUTION Environmental specifications If combustible fluids are brought into contact with hot elements of the printer evacuate the area and call for service personnel WARNING Temperature Operating 15 32 C 59 to 90 F Storage and shipping 30 to 60 C 22 to 140 F Humidity Operating 15 to 8096 relative humidity non condensing Nonoperating 15 to 95 relative humidity non condensing Altitude Operating 0 to 2400 m 8 000 ft at 25 C Nonoperating 0 to 15000 m 50 000 ft Vibration shock Nonoperating vibration Will withstand 0 5 G excitation 5 to 500 Hz 3 axes for up to 7 minutes with no impairment or subsequent damage Nonoperating shock 0 5 g 25 minute sweep 5 200 5 Hz 100 200 sec sweep cycles Operating shock The printer may have any corner raised and dropped 1 5 cm 0 6 in while printing is in progress without impairment of operation that cannot be recovered by a printhead purge cycle The printer may 1 42 ii LINX Solid Inkjet 100 Service Manual have any corner raised and dropped 6 cm 2 4 in while idle without subsequent impairment of operation Operating drop Printer only with the main tray
122. f shielded or screened cables may be required Shielded describes BM defined cables used with the DB 9 connector Screened describes cables that are dectrically similar to Category 4 UTP Unshieded Twisted Pair but with an added shield or screen 10Base T or 100Base Tx Twisted Pair 100Base T x requires Category 5 100 Ohm UTP cabling Do not use silver satin telephone extension cables for 10Base T networks either as drop cords or as patch cables in the wiring closet Silver satin cables are flat usually silver or gray with 28 gauge stranded or tinsel conductors Do not use shielded twisted pair cable intended for IBM Token Ring networks or voice grade level 1 or 2 unshielded twisted pair cable for wiring runs These cables do not meet the requirements for 10Base T and will lead to unreliable operation Printer Networking 7 9 Mac OS Ethertalk Configuration NOTE The printer s AppleTalk connection works with Macintosh System software 7 0 7 1 7 5 7 6 8 0 8 1 and 8 5 Finding the Printer s Name in the Chooser 1 FromtheApple menu select Chooser 2 Intheleft hand side of the Chooser find the LaserWriter 8 icon If the LaserWriter 8 icon is not in the Chooser you need toinstall the printer driver Click on the LaserWriter 8 icon NOTE Toinstall a Solid Inkje 100 Printer driver on a Macintosh network via Ethertalk refer to Installing Printer Software in Chapter 2 under Macintosh Software 3
123. f the printhead faceplate The printhead tilts back on its X axis shaft that it travels on The X axis shaft is connected to the head tilt arm At the lower end of the arm is a cam follower The cam follower and tilt arm respond to the movement of the head tilt cam gear As the gear rotates the arm follows the motion and tilts back the printhead Printhead i print position i Eorum spring Printhead J LL A Drum Head tilt arm us T xia gear X axis shaft fi o5 engaged ee i Tilt cam Cam ollower V geai rim Cam Leaf Printhead Spn P maintenance position Leaf spring tension engages drive gear Figure 1 21 Printhead Tilting Operation General Information 1 53 A return spring at the top of the tilt arm pulls the printhead toward the drum In the print position the tilt arm gear s missing teeth are positioned at the tilt arm gear s drive gear When actuated a leaf spring pushes against a cam lobe on the backside of the tilt cam gear to give the tilt cam gear a slight rotation and engage its teeth to the drive gear The leaf spring is held away from the cam lobe of the tilt cam gear by the cap wipe purge assembly in its standby position Slightly raising the cap wipe purge assembly releases the leaf spring and allows it to push the cam lobe and rotate the tilt arm gear slightly Head tilt am DO o Cam M N Head tilt cam gear Process motor Process drive compound gear H
124. ft covers removed remove the rear cover Reverse these steps to install the rear cover Rear Cover 840 4 05 Figure 6 3 Removing Rear Cover 6 6 ji LINX Solid Inkjet 100 Printer Service Manual Removing the Front Panel 1 Open the exit door 2 Remove the right and left covers 3 Remove the three screws securing the front panel One of the screws is located inside the exit door area 4 Disconnect the front panel display wiring harness from the right I O board Slide the front panel rearward slightly lift and remove the front panel Reverse these steps to install the front panel Figure 6 4 Removing Front Panel Removal and Replacement 6 7 Removing the Front Door 1 With a small flatblade screwdriver press the release lever on the front door left pivot The release is located inside a small hole on the left pivot 2 Slide the door s right pivot off the right frame post 3 Remove the front door Reverse these steps to install the front door 840 4 07 Figure 6 5 Removing Front Door 6 8 ji LINX Solid Inkjet 100 Printer Service Manual Removing the Exit Door and Exit Roller 1 Remove the right cover 2 Remove the left cover 3 Attheright side of the printer remove the cap wipe purge electric dutch Use a small flatblade screwdriver to release the clutch from the shaft Also removethe right side keyed white plastic bushing 4 Attheleft side of the printer releasethe t
125. gnostics Ensure the drum temperature sensor is properly positioned Inspect and clean the drum temperature sensor Ensure that the X axis drive system is correctly assembled and lubricated If the problem persists replace the printhead 3 26 ii LINX Solid Inkjet 100 Service Manual Ghosting Drum is too warm Verify the drum temperature using PC based diagnostics Ensure the drum temperature sensor is clean and properly positioned Ghost Of First Print On The Next Print Incomplete image transfer is taking place on the first print 1 Inspect the drum maintenance system Does the drum maintenance roller contain sufficient oil Replace the drum maintenance roller and counter chip if necessary Is the drum maintenance cam roller and electric clutch operating correctly Test them using P C based diagnostics Ensurethe left and right drum maintenance actuators operate correctly when lifted by the cams of the drum maintenance cam roller Vertical Lines Appear Wavy Straight vertical lines appear to be wavy and ill formed 1 2 Too much oil on the drum Inspect the drum maintenance drawer Is the wiper blade damaged If necessary replace the drum maintenance drawer Arethe drum maintenance cam roller and electric dutch operating correctly Test them using P C based diagnostics Ensurethe left and right drum maintenance actuators operate correctly when lifted by the cams of the drum maintenance cam roller
126. he printhead is tilted forward to dab the wiper blade against the lower faceplate to dean ink off the wiper The dab is actually a short wipe and it is done on the part of the faceplate below the nozzles Short wipe Following the dab the cap wipe purge assembly is raised and the printhead is tilted forward against the wiper blade The cap wipe purge assembly is slowly lowered again to dean the faceplate but stops sooner before it can run into the debris from the first wipe Short flush The printhead is tilted back slightly and the cap wipe purge assembly is raised to bring the wiper blade even with the jet nozzles All jets are fired again for 0 6 seconds General Information 1 73 1 74 Following the second flush the printhead is tilted back and the cap wipe purge assembly is lowered into its standby position A cap wipe purge home sensor on I O board right detects when the cap wipe purge assembly is stored in its standby position Then the printhead is tilted forward into its print position and a deaning or mud pageis printed The cleaning page allows each jet to eject ink that may be slightly contaminated with another ink 7 day flush f no printhead dean cycle has been run for 7 days the printer automatically performs a printhead flush to expel old ink from the printhead orifices This gets rid of any old cooked ink and improves printhead reliability Paper Preheater Cleaning This is a customer initiated cleaning pro
127. he U S and Canada contact your local Sterling Diagnostic maging service organization Overview After reviewing this section follow the more detailed processes which follow to complete this task 1 Turn off the printer using the On Off switch and then selecting Shut Down For Moving Printer at the front panel 2 Remove the maintenance drawer seal it in a plastic bag and store the tray on a flat surface NOTE A used maintenance drawer leaks drum fluid if tipped 3 Makesure that the printer has completed its shut down before moving the printer after approximately 15 minutes the front panel goes blank This allows the ink to solidify 4 Repack the printer and its accessories using the original packing materials Turning off the Printer To avoid damaging the printer s internal components always turn the printer power off using the On Off switch this places the printhead in the proper position for safe shipment Failure to do so may result in damage to the printer Never turn off the printer by pulling the power cord ii LINX Solid Inkjet 100 Service Manual 1 Usetherear panel On Off switch to turn off the printer 2 Atthe front panel immediately select Quick Cool to Move Printer you have 4 seconds before the display goes blank The printer reports the shut down status and takes approximately 15 minutes to cool down While it is cooling it is recommended that you remove the maintenance drawer see the nex
128. he down position Ensure Switches 1 3 and 4 areup Normal operation is all switches up 2 Turn on the printer The printer will not print a Cleaning Page or a Startup Page when placed in Bypass Mode Cool Down Mode The printer features a menu item that accelerates the cooling down of the printhead When the printer is turned off it automatically gives the option of performing a quick cool down 1 Turn off the printer 2 Scroll tothe menu item Quick Cool to Move and press the Select button 3 Open printer doors to help speed the cooling process The printer turns off all the engine heaters and runs the fans on high until the ink in the printhead has solidified Then the printer shuts itself off General Information 1 19 Preparation for Moving the Solid Inkjet 100 Printer and Accessories 1 20 A CAUTION It is very important that you follow the correct repacking procedure before shipping the Solid Inkjet 100 printer Complete repacking is required Failure to properly repack the printer can damage the printer s internal components You are responsible for any shipping damage to the printer that results from improper or inadequate packing Repacking for shipment consists of four basic tasks Each of these tasks is explained in detail If you have questions regarding any of the repacking procedures call Sterling for assistance Sterling Diagnostic maging Customer Care Center at 800 252 9099 Outside t
129. he drum horizontal bands or lines appear in the print Replace the Y axis motor Replace the power control board Streaks Or Lines Down The Print Clean the blade of the drum maintenance drawer Possible missing or weak jet Print the Service Test Print 2 Weak M issing J ets to determine if a jet is not performing Perform up to three printhead cleaning cycles totry to dean a clogged jet f necessary turn off the printer and allow the printhead to cool for 4 hours Test the vacuum system for proper vacuum levels and operation Ensure that no wiring harnesses are interfering with the horizontal slewing of the printhead In such a case the streaks or lines should be parallel and evenly spaced Check for media in the exit path Troubleshooting 3 23 10 11 The x axis drive is not functioning correctly If the x axis drive does not slew the printhead smoothly and evenly during printing vertical lines appear in the print Print Service Test Print 11 X axis Calibration to reveal an x axis problem Replace the X axis drive if indicated Replace the x axis drive assembly Replace the power control board If streaks are on the front side of a print the paper preheater may be scraping ink off the print Clean the preheater using the front panel initiated cleaning process Remove I nk Smears Smears on a print may also be caused by the paper preheater operating at a too high temperature Use the PC diagnostics to
130. he drum position assembly Precisely mark the end of the drum shaft relative to the drum home flag on the drum position sensor assembly this is not necessary if you are also replacing the drum as part of the drum transfix assembly Removal and Replacement 6 27 Mark on the drum shaft to align with the home flag Drum home flag u XS Drum position encoder wheel 840 4 17 Figure 6 18 Marking the Drum Home Flag Sensor Alignment 6 Rotatethetilt gear to orient the gear s missing teeth to the drum position sensor assembly s rear mounting screw 7 With a small flatblade screwdriver slidethe retaining spring out of the encoder wheel s groove toward the encoder disk 8 Removethethree screws securing the drum position sensor assembly housing to the print engine Insert the gap tool to hold the encoder wheel in position Slide the assembly off the drum shaft f necessary use the small flat blade screwdriver to push the encoder disk hub along the shaft as you removethe assembly 6 28 ii LINX Solid Inkjet 100 Printer Service Manual Slide the retaining spring out of the Groove groove Screws 840 4 18 Figure 6 19 Removing the Drum Position Sensor Assembly Reverse these steps to reinstall the drum position sensor assembly The drum must be in the same position relative to the drum position encoder wheel when the drum position sensor assembly was removed This ensures that the stripper fingers co
131. ies DRAM Bank 1 in the DRAM DIMM located in Position 1 farthest from the rear not used not used Error Codes and Messages 2 3 Table 2 1 Main Board Power up Self test Error Codes continued Left LED Flashes Long flash 5 Short flash 1 2L4 1S 11 This test does a walking 1 s and a walking 0 s test for the last 4 bytes in the VXWorks section of the NVRAM This test verifies in the first 24 bytes from the EPROM that verifies that the Tektronix Ethernet address 0x08 0x00 and 0x11 has been copied into three locations 11 Mariner ASIC This test reads and verifies the version level of the Mariner ASIC 12 Medusa ASIC This test reads and verifies the version level of the Medusa ASIC 13 Super Glue ASIC This test reads and verifies the version level of the Super Glue ASIC 14 CL1284 IC This test reads and verifies the version level of the parallel port controller CL1284 chip none SCSI This test verifies the functionality of the SCSI I O processor Any test failures with this component are treated as non fatal errors with the error information written to the Start Page If a failure is detected the message SCSI Option Card With one of the following messages will be sent to the Start Page Wrong values in script set registers Script operation timed out Script operation returns wrong error code DMA transfer spills outside buffer DMA transfer data mismatch 2 A iiLINX M Solid Inkjet 100 Service Manua
132. installed maintenance drawer installed printhead unlocked no internal packaging 0 5 in for one drop on all four bottom edges Printer in Ready mode and at operating temperature 1 0 in drop on all four bottom edges General Information 1 43 Theory of Operation This topic covers the following subassemblies and diagram within the printer e Functional block diagram e Drum transfix assembly e Maintenance drawer e Printhead e X axis movement e Printhead tilt mechanism e Ink loader e Cap wipe purge assembly e Power supply e Power control board e Main board e Optional Ethernet interface card 100 BaseT e Optional internal disk drive e Print process in operation e Printhead maintenance cycle Functional Block Diagram Figure 1 14 presents a functional block diagram of the printer 1 44 ijLINX Solid Inkjet 100 Service Manual 25 8860 pasn jou 10sues YyouIMs uoums Jeded xejdng J9 02 doy J9A09 1u0J4 Josues jxe E 1a yad uoinio a X9ld LETS yoynjo urea Josues auiou un Jeued 1uoJ4 Josuoas ePBung ediw de5 t C soueus ujeu uxo XISUBAL c uniq sosues ane 10sues a6pe yel z uoo 491104 iin Aenmxa s Anua yeayaid a pee 1eddf JOSU9S X9ld c JOSUes azis py Josues 1opooua Josues wng woy Qu wnq Q 1osu s dwg Josues ezis y Josues dHO 4edeg osrr yoynyo Josues paajpuey eBung ediw de5 Josues ezis pv V osi r
133. ipe purge blade wipe Notice that there are no smudges or streaks of ink in the nozzle area Figure 3 1 Good Cap Wipe Purge Blade Wipe Figure 3 2 shows a close up of the printhead faceplate identifying the tiny drops of ink that indicate a cap wipe purge gasket leak Notice the V or funnel shape the droplets form just under the area where the cap wipe purge gasket seals against the faceplate ink stain Random drops can be ignored Figure 3 2 Cap Wipe Purge Gasket Leaking Figure 3 3 shows the affect on the printhead when the cap wipe purge blade is not working In this example the blade has several 6 defects n most cases you will probably only see one smudge or streak Figure 3 3 Bad Cap Wipe Purge Blade Wipe Troubleshooting 3 17 Figure 3 4 shows a close up of one of the damaged areas of the cap wipe purge blade used on the printhead shown in Figure 3 3 The edge of the blade is pushed inward and flattened which prevents a good wiping action In most cases you will not be able to see the damage to the blade however you will see its affect on the printhead faceplate as streaks or smudges of ink in the nozzle area Figure 3 4 Cap Wipe Purge Blade Damaged Figure 3 5 shows a close up of the left side of a printhead Here the cap wipe purge blade has separated allowing the metal spring to rub the faceplate and damage the printhead Figure 3 5 Cap Wipe Purge Blade Separated Figure 3 6 shows a bad p
134. ive board 840 4 48 Figure 1 18 Printhead General Information 1 49 Figure 1 19 shows a cross section of the inkjet array and the jet nozzle arrangement The printhead s jet stack is fabricated from a stack of chemically etched steel plates which are brazed together to form the ink jet array Channels formed by the stacked plates route ink past the 448 individual piezoelectric crystal driven diaphragms which force the ink in droplets out the 448 corresponding nozzles Looking at the printhead face the nozzles are arranged in four rows with the intermediate density nozzles forming the top row the low density nozzles forming the next row 22 300 below and the clear nozzles forming the third row 11 300 below and the high density nozzles forming the fourth row 22 33 below During the printing process the printhead would only have to travel 22 pixels horizontally to provide complete coverage In actuality the printhead travels much further to interlace with the output of neighboring jets The Drift Compensation setting in the hidden Service Support menu enables automatic drift compensation When it is turned on it slowly increases the printhead drive voltage over time to maintain optimal printhead performance 1 50 ji LINX Solid Inkjet 100 Service Manual Ink inlet i Manifolds Piezoelectric crystals Inter mediate Sd 22 pixels Low 1 22 pixels Clear m E 11pixe
135. jet stack thermistor Reseat or replace the data cable If the error reoccurs replace printhead If the new printhead gives the same error replace the power control board 13 002 41 and 13 018 48 J et stack thermistor appears to be shorted Reseat or replace the data cable If the error reoccurs replace the printhead If the new printhead gives same error replace the power control board 13 033 45 The thermistor in the reservoir appears to be open If the 4 pin connector on the top of the driver board Figure 3 9 is disconnected this error will occur Turn off the printer and reseat the cable 13 034 46 Thermistor appears to be shorted Look to see if the 4 prong plug on the top of the driver board is plugged in correctly If it is check the data cable If the data cableis good replace printhead If the error happens on the new printhead replace the power control board 13 035 47 and 13 036 48 Reservoir heater is running away or reservoir is not heating With these errors it is most likely a problem with the printhead 12 Check cap wipe purge assembly purge performance After installing a new printhead you must recheck the cap wipe purge assembly Action Steps 4 7 If the printhead is not installed correctly the cap wipe purge gasket may leak NOTE A broken ink loader can cause the cap wipe purge gasket to not seal Look for signs of breakage of the black plastic parts on the underside especially the bosses that
136. k Next If you want to print a Test page select Yes and click Finish Creating an AppleTalk Port Adding an AppleTalk Port 1 2 3 4 5 Click on Start Settings and Printers In the Printers dialog box double click Add Printer Select My Computer and click Next If the printer is connected to the network dick Add Port Double dick AppleTalk Printing Devices in the Printer Ports dialog box if the AppleTalk Printing Devices is not available contact your Windows NT Administrator Windows will now search for AppleTalk Printers this may take a few minutes When your printer appears in the Available AppleTalk Printing Devices click on the printer name and dick OK At the prompt Do you want to capture this AppleTalk printing device click No When returned to the Printer Ports box click Close At the Add Printer Wizard dialog box click the box next to this new port which will add a check mark Click Next Installing the printer driver 10 In the Add Printer Wizard dialog box click Have Disk to add a new Solid Inkjet 100 Type the path name to the driver files This can be d or the current location of your CD ROM drive Click OK Select the Sterling iiLINX Solid Inkjet 100 Click Next If prompted that a driver is already installed for this printer select Keep existing driver recommended Click Next If the printer driver does not exist goto Step 15 14 15 16 In thePrinter nam
137. l Table 2 1 Main Board Power up Self test Error Codes continued Left LED Flashes Long flash 5 Short flash 1 2L4 1S 11 10BaseT Ethernet 100 BaseT Option card This test verifies the functionality of the Ethernet LAN Controller chip Any test failures with this component are treated as non fatal errors with the error information written to the Start Page If a failure is detected the message Ethernet with one of the following messages will be sent to the Start Page General Failure MAC internal loopback failure MII internal loopback failure currently disabled This test verifies the functionality of the Ethernet LAN Controller chip Any test failures with this component are treated as non fatal errors with the error information written to the Start Page If a failure is detected the message Ethernet Option Card with one ofthe following messages will be sent to the Start Page General Failure MAC internal loopback failure e MII internal loopback failure Error Codes and Messages 2 5 Service Required Error Codes Following are the Service required error codes that are displayed on the front panel 2 000 SY I O Board SY DEV FAULT IO RIGHT The engine could not detect the presence of the I O Right circuit board Make sure all connections are made 2 002 40 SY DEV FAULT IO LEFT The engine could not detect the presence of the I O Left circuit board Make sure all connections are made
138. l l s 63 rioja Ex oe A NOTE For accuratethermal regulation and measurement the printer covers should bein place ii LINXTM Solid Inkjet 100 Service Manual Fault History The Fault History displays faults as error codes stored in the printer s NVRAM and the copy count when the fault occurred Type y to clear the history log BSUS Froni PR aa i lt History Recorda B NWEAM FE FIN Troubleshooting 3 41 3 42 Saving And Restoring Test Selections The current test selection may be saved to a file and later restored including the completion status of tests which wererun earlier The result of loading a saved test selection file is exactly the same as if the settings were re specified manually It provides a way to pre select tests for particular audiences Tests are executed in the order they appear in the menu not in the order they are selected The default file name extensions for saved test selections is TSV The diags ini file keeps the settings for the port number baud rate whether the debug messages are on or off and the saved file name Definitions port 0 comm port 1 port 1 comm port 2 baud 0 9 600 bps baud 1 19 200 bps baud 2 38 400 bps baud 3 57 600 bps debug 0 Debug M essages off debug 1 Debug M essages on save blank no file available save filename extension name of file Saving And Restoring Other Settings Any user configurable setting that the program r
139. l N N N N Core Disabled Table 1 4 Configuration Page Settings continued Parameter Description HTTP Indicates if HTTP support has been enabled Local URL Address HTTP Password Refresh Delay FTP Language Indicates if FTP support has been enabled Filtering Interpretation of special characters Job pipelining Indicates if multiple printfile processing is allowed Login Password Remote Indicates of remote printing Internet PhaserLink printing is enabled Printing Language Indicates the language interpreter in use at the parallel port Filtering Interpretation of special characters Job Pipelining POP3 Server IP Backup SMTP server IP Address address POP3 User Name POP3 login user name POP3 Password POP login password Saved in NVRAM yes yes yes yes yes yes yes yes yes yes Yes yes yes yes Default Limits or alternate choices Enabled Disabled Not set Set Auto Select Not Authorized Disabled lt interpreter gt None Interpreter based yes no Not set Set Not Enabled Enabled PostScript None On Off Empty field Empty field 40 byte field Empty field 40 byte field General Information 1 37 Table 1 4 Configuration Page Settings continued Parameter Description POP3 Polling Interval printer waits before Interval checking for new mail Printing Password Password required for using internet printing feature Authorized Hosts List of h
140. l appear Type d or the appropriate drive for your CD ROM in the copy manufacturers files box Click OK The printer is now installed Add Printer Procedure Optional Method 1 2 3 From the Windows Start M enu Select Settings Printers Double click on Add Printer The Add Printer Wizard screen will appear Select My Computer and dick Next Add Printer Wizard This wizard helps you install your printer or make printer connections This printer will be managed by All settings will be managed and configured on this computer Network printer server Connect to a printer on another machine All settings for this printer are managed by a print server that has been set up by an administrator lt Back Cancel Printer Networking 7 25 4 Select the box labeled LPT1 local port and click Next Add Printer Wizard f Local Port Local Port Local Port Local Port Local Port Local Port 5 Insert the device drivers CD ROM into the CD ROM drive and select Have Disk Add Printer Wizard AGFA AccuSetSF v52 3 AGFA AccuSet 800 AGFAAccuSet 8005F v52 3 AGFA AccuSet 8005F v2013 108 j 58 000 7 26 ii LINX Solid Inkjet 100 Printer Service Manual 6 ThelInstall from Disk screen will appear Type d or the appropriate drive for your CD ROM in the copy manufacturer s files box Click OK Install From Disk 7 Highlight the Sterling iiLINX SIJ 100
141. lace the paper drum heater assembly Check to see if the upper feed roller drive belt is broken or slipped off of its pulleys In such a case the upper feed roller does not rotate when the lower feed roller rotates Check that the feed rollers rotate smoothly and that the front cover is fully dosed and seated Troubleshooting 3 21 3 22 Check the paper eject path for obstructions Ensure no small pieces of paper are trapped around the stripper fingers If a piece of paper is trapped in the paper preheater try pushing it out by inserting a stiff piece of cardstock into the paper preheater Ensure that the transfix roller rotates during the transfix process Test the sensors in the paper path Look for damaged or nonoperating sensor flags Check the transfix solenoid and its cam Ensure they operate correctly and are properly lubricated Checking The Process Motor And Drive Train 1 Determine if the process motor runs If it does not rotate go to Step 2 If it does rotate goto Step 5 Measure to determine if 40 VDC is being supplied to the motor If it is goto Step 3 If it is not inspect the process motor s wiring harness If the harness is functional then troubleshoot the power control board and power supply Refer back to the topic Verifying Power Supply Operation Disconnect the motor s wiring harness Measure the resistance of the motor s windings The expected resistances are listed in Table 3 2 If the
142. lining Operating Mode Print Server Name Connection Mode Preferred DS tree Login Password Enable Banners Config Retry Interval Queue Scan Interval Status Message TCPAP Host Name IP Address Network Mask Router Gateway Frame RARP BOOTP DHCP IP Address Source SMTP Server SMTP Reverse Path DNS j PhaserShare Series B Built In Ethernet Interface 08 00 11 0a 50 3b Enabled PostScript None On HLINX SIJ 100 LaserWriter GG ENET 8248 11 Enabled 00000000 00000000 00000000 00000000 Enabled PostScript None On Print Server TEKOA503B Directory Services Not Set False 60 seconds 15 seconds Can t find NDS tree will retry in 60 sec Enabled phaser 192 168 14 20 255 255 255 0 192 168 1 11 Ethemet Il Disabled Disabled Front Panel Disabled Configuration LPR Filtering Job Pipelining Host Access List AppSocket Language Filtering Job Pipelining Host Access List Syslog SNMP Trap Host Authentication Traps HTTP Local URL Address HTTP Password Refresh Delay FTP Language Filtering Job Pipelining Login Password Remote Internet Printing Language Filtering Job Pipelining POPS Server POP3 User Name POP3 Password POP3 Polling Interval Printing Password Authorized Hosts Authorized Users Enabled None On Enabled PostScript None On Disabled False Enabled Not Set 60 seconds Enabled PostSc
143. lowing The printer ran out of ink and a ten minute timer elapsed before more ink was added The only recovery possible is to cycle the power switch 5 000 VA Drum Error Codes Error Codes re Front Panel Software Error Code Display 5 001 41 YA_HOME_FAIL Drum home sensor failure the drum turned one 0x2c01 ya fault drum home sensor full revolution without seeing the drum home sensor activate 5 002 42 YA ENCODER FAIL Drum motion failure the drum stalled possibly 0x2c02 ya fault drum encoder because the drum position sensor electronics have failed or because the motor drive or drive belts have failed or because something is physically blocking the motion of the drum 6 000 XA X axis Error Codes peor codes Front Panel Software Error Code Display 6 000 41 XA FAULT MCURRENT X axis motor over under current Indicates that 0x3400 xa fault over under current motor coil s are open or shorted or the XA motor fuse has opened 6 001 42 XA FAULT NOHOME X axis home position not found Indicates that 0x3401 xa fault home sensor the XA home sensor has failed or something has prevented the printhead motion during a home operation 6 002 43 XA FAULT NGHOME Unexpected X axis home sensor activation The 0x3402 xa fault unexpected home sensor sensor has failed the motor control is moving the head in the wrong direction or the user has engaged the head restraint mechanism 6 003 44 XA FAULT LOST A verify
144. ls High ye 22 pixels O N gt 9O 300 dpi pixels 840 4 49 Figure 1 19 Printhead Detail The ink jet array is bonded to a cast aluminum ink reservoir The reservoir supplies the molten ink to the ink jet array Heaters in the reservoir and the ink jet array maintain the ink at a temperature of about 140 C for printing The level of the ink in the reservoir is kept at a constant level General Information 1 51 1 52 X axis Movement X axis or lateral movement of the printhead is accomplished using a stepper motor driving a fine thread eadscrew The printhead mounted to the X axis shaft moves right and left across the surface of the drum To find the printhead home position the X axis system drives the printhead in an open loop The printhead is driven against the left printer frame for a few seconds and then reversed a set number of steps A spring attached to the printhead and right printer frame provides a preloaded tension so the printhead moves smoothly X Axis shaft nae Tension foes ey m Nose cone gear 840 4 50 Figure 1 20 X axis Printhead Movement During Printing ii LINX Solid Inkjet 100 Service Manual Printhead Tilting Mechanism To accommodate printhead maintenance the printhead can be tilted back away from the drum Refer to Figures 1 21 and 1 22 This creates room for the cap wipe purge assembly to be moved into position in front o
145. mage processor board from operating Refer to the topic Error Codes and Messages for the meaning of a coded indication General Information 1 17 Switches Four DIP switches allow you to reset the printer or place the printer in different operating modes Figure 1 12 illustrates the rear pane of the printer and location of the DIP switches Table 1 3 Rear Panel DIP Switch Settings Function Switch 1 Switch 2 Switch 3 Switch 4 Normal operating mode UP UP UP UP Service mode DOWN UP UP UP Reset printer UP UP UP DOWN Manufacturing mode UP DOWN UP UP Bypass mode Development mode DOWN DOWN DOWN UP engineering use only Recovery mode DOWN UP DOWN UP engineering use only IDE hard drive Optional Ethernet Interface card PostScript health Print light Engine health light es 7 O Service Ethernet Parallel USB DIP RS 232 10BaseT switches 0388 11 Figure 1 12 Rear Panel 1 18 ii LINX Solid Inkjet 100 Service Manual Bypass Mode Manufacturing Mode Bypass mode allows you to access the front panel menus bypassing the engine and PostScript initializing processes without having to wait for the printhead to warm up This way you can observe or change some of the printer settings without waiting for the printer to complete the normal warm up sequence Meanwhile the printer continues to warm up and initialize in the background 1 Attherear of the printer set DIP Switch 2 in t
146. metal heat shield over the printhead and plastic dust cover under the stripper fingers Dust should also be vacuumed from the vents near the fans and anywhere else where it is observed Drum Temperature Sensor With a dry swab clean any buildup around the drum temperature sensor You can access the sensor through the opened stripper finger cover Also make sure the sensor rides evenly on the drum surface You can remove the sensor if necessary to clean under it Maintenance Maintenance roller The printer uses the maintenance roller as part of its self maintenance routine to coat the print drum with oil before each print The maintenance roller and its counter must be replaced after 15 000 prints the starter maintenance roller must be replaced after 7 500 prints A front panel message indicates when the maintenance roller is low Printing is still possible when the maintenance roller fluid is low When a front panel message indicates the maintenance roller is empty the maintenance roller and its counter must be replaced before continued printing is possible Refer tothe instructions included with the kit to replace the maintenance roller kit NOTE The Drum Maintenance Unit Replacement Kit has a one year shaf life NOTE Thedrum fluid an oil poses no known adverse health effects Refer to the Material Safety Data Sheet for moreinformation Cleaning and Maintenance 5 5 5 6 The number of remaining cycles can be ob
147. n power is routed to 14 opto isolated triacs which under main board logic control supply AC power tothe 14 heaters in the printer Two fuses provide current protection to the triacs Fuse F2 and F3 protect the power supply from most often a shorted triac caused by a defective heater If F2 or F3 fuse blows it is best to replace the power supply and of course the defective heater rather than the fuse Otherwise with the fuse replaced but the triac shorted AC power may be applied to the heater without the printer even being turned on Each time the main board turns on a triac to activate a heater it is turned on for only a fraction of a second The main board must constantly readdress each heater it wants to remain on By this means if the print engine firmware should fail the heaters automatically shut off The printer is also protected by thermal fuses located inside two fuses for the drum heater and one each for the paper preheater and the cap wipe purge assembly A thermal fuse opens in the unlikely event of a runaway heater following a firmware failure The DC power supply generates 5 volts for the printer s logic 40 volts for the motors 54 volts and 52 volts for the printhead drivers and 12 volts for fans Fuse F1 provides protection for the switching power supply in the DC section The block diagram for the power supply is illustrated in Figure 1 26 Do not touch the power supply AC line voltages are present
148. n end of this assembly into the upper leg opening and orient to couple them Take case not to wipe lubricant out of the span The pocket should only come into contact with the end of the nose cone Rotate the yoke assembly downward over the nose cone and latch the lower leg to the stiffener tab Rotate the stop collar as required to permit attachment of the leg during this installation Install the X axis motor Take care to fully seat the motor positioning boss into the stiffener panel Install the motor bracket Connect the X axis motor wiring harness Perform the X axis Scale Adjustment procedure Y axis Belt Drive Assembly Remove the right cover Disconnect the wiring harness leading from the front panel to the right I O board passing beside the Y axis belt drive assembly Remove the drum fan AN Never loosen or remove the three screws securing the assembly parts together CAUTION Removal and Replacement 6 37 Y axis belt assembly Never remove these screws Tension screws 840 4 12 Figure 6 24 Removing the Y axis Belt Drive Assembly 4 Remove the three tension set screws securing the Y axis belt drive assembly to the engine frame Remove the assembly with its two belts NOTE Tension the drive bdts using the procedure Y axis belts tension adjustment Reverse these steps to install the Y axis belt drive assembly 6 38 ii LINX Solid Inkjet 100 Printer Service Manual Y axis
149. nance drawer so it can be removed If the cap wipe purge assembly is away from its home position the drum maintenance drawer is locked in place When servicing the printer be careful of the cap wipe purge assembly as it passes the printhead If a damaged wiper blade of the cap wipe purge assembly catches on the printhead it could propel hot liquid ink upward into your face Vacuum for the purge cyde is obtained from the vacuum pump module which contains a vacuum pump and an air valve solenoid Figure 1 25 The body of the vacuum pump module forms a vacuum accumulator A small vacuum pump running for 75 to 90 seconds creates a strong vacuum in the vacuum accumulator Then an air valveis energized for a fraction of a second exposing the printhead faceplate to the strong accumulated vacuum to suck debris and bubbles out of the printhead nozzles With the air valve once again de energized air is metered through the 7 mil orifice to gradually release the vacuum at the faceplate General Information 1 57 Cap Wipe Purge assembly Vacuum Pump module Printhead faceplate Purge Air valve solenoid Vacuum accumulator space Wipe Wiper blade Flush Dab 840 4 51 Figure 1 245 Cap Wipe Purge Assembly and Vacuum System 1 58 ji LINX Solid Inkjet 100 Service Manual A WARNING Power Supply The power supply has two main yet interrelated sections the AC section and the DC section In the AC sectio
150. nd remove the drum transfix assembly Protect the drum surface Left frame Ed bridge arnesses Transfix Right frame solenoid bracket Drum transfix V assembly Remove 2 inside screws A Remove 4 Screws Remove hex screw X 840 4 20 Figure 6 17 Removing the Drum Transfix Assembly right side f 6 26 ii LINX Solid Inkjet 100 Printer Service Manual Reverse these steps to install the drum transfix assembly NOTE Upon reassembly install the hex keyed screws first they align the drun transfix assembly to the engine frame Make these adjustments after installing a new drum 1 2 1 2 Ensure the drum position encoder sensor gap Set the Y belt tension refer to the topic Y axis Belts Tension Adjustment Power up the printer in Bypass Mode to skip the startup and mud pages Enter the hidden Service menu and select Seal Drum to seal the new drum Perform the printhead to drum adjustment described in the topic Printhead To Drum Spacing Adjustment Drum Position Sensor Assembly Remove the left cover Remove the top cover Unhook the head tilt spring to avoid possible damage to the printhead and drum 3 Disconnect the drum home position sensor wiring harness from J 180 of the left 1 O board leading to the drum position assembly Disconnect the drum position encoder sensor at the drum position assembly Remove the clear plastic dust cover from t
151. nd solenoids The I C bus also extends down to the Auxiliary Feeder Unit Auxiliary feeder unit connection AS 0388 05 x Figure 1 5 The Printer s PC Bus General Information 1 9 The printer features a printhead maintenance system used to clean the printhead faceplate and clear clogs from the printhead nozzles Refer to Figure 1 6 The system consists of a vacuum pump assembly the cap wipe purge assembly the cap wipe purge carriage drive the purge hose and tubing and the purge filter Cap Wipe Purge carriage drive Purge Filter Vacuum pump assembly Purge hose and tubing Cap Wipe Purge assembly 0388 06 Figure 1 6 Printhead Maintenance System 1 10 ji LINX Solid Inkjet 100 Service Manual Sensors in the printer provide information to the main board to determine the state of the printer The printer monitors the positions of some of the movable assemblies such as the drum as well as the temperature of many other assemblies such as the printhead paper preheater and the drum Figure 1 7 shows the sensors and switches on the right side of the print engine Figure 1 8 illustrates the sensors and switches on the left side of the printer Ink load Ink stick cover sensor out sensor Exit tray full sensor Ink stick low sensor Top cover switch Front cover switch BS SS oM E A4 size media sensor So A size media sensor 4 d N Rm Cap Wipe Purge Qf home sensor
152. ndicates which channel is being viewed in the tty screen The 29K channel displays information related to the communication line The 68K channel displays information related to the printer and the diagnostic tests ee nthe bottom right corner is a tiny field which indicates the status of the communication link between the PC and the printer s processor It says OK when the link is working and NO when communication is lost Selecting Tests Press Alt T or movethe highlight block to the Tests pull down menu and press Return to activate the test selection window Use the following keys to navigate the lists of tests The left column Test Suites lists the groups of test The center column shows the individual tests within a selected test suite The right column Status indicates if a test is selected You can select a single test a series of tests or all the tests is a test suite In the Test Suites column Up and Down arrows Move the Test Suite selection highlight block up or down on the screen When the highlight block reaches the top or bottom of the screen it causes the list to scroll if there are more tests in that direction on the list Tab or Right arrow Activates a suite of tests The individual tests of the selected test suite are displayed in the Individual Test column Troubleshooting 3 33 3 34 Alternately select a test by typing its corresponding letter instead of using arrow keys PgUp and
153. ndicator Gauge If the digital indicator gauge is not zeroed properly it will produce unstable readings To zero the gauge 1 Place your thumb on the gray Origin button 2 Place your index finger underneath the gauge 3 Press and hold the Origin button until the gauge zeroes being careful to support the gauge with your index finger 4 Totest the stability move the head tilt arm back and then forward several times The gauge should return to zero each time the head tilt arm is moved forward Do not move the tilt arm by the bracket mounted on it This will cause the arm to flex and your readings will vary 4 18 ii LINX Solid Inkjet 100 Service Manual Install the Gap Tools The left and right gap tools must be installed properly to correctly adjust the printhead to drum spacing To install the tools refer to Figure 4 7 1 Postition the tip of the gap tool between the printhead and the drum 2 Hook one side of the tool through the hole in the chassis 3 Hook the other side of the tool over the chrome shaft above the printhead NOTE Theleft and right gap tools should never beinterchanged because they are different thicknesses To properly adjust the printhead to drum gap use only one gap tool at atime To prevent the printhead adjustment from changing renove the gap tool when torquing the printhead screws Adjustments 4 19 4 20 and over shaft I cna UE A A lus QO old in chassis K ES 3
154. ner during a deaning cyde replace the printhead data cable If you do not get ink on the print or during a deaning cycle 1 Check the cap wipe purge performance 2 Check for a loose connector on the power cable leading to the printhead Replace the printhead power cable Troubleshooting 3 25 3i Replace the power control board 4 Replacethe printhead Printing Too Light Or Too Dark Perform the procedure Printhead To Drum Spacing Adjustment Fuzzy text Text appears indistinct and difficult to read 1 2 3 H ead to drum gap is too great Verify the gap with the adjustment as explained in the topic Printhead To Drum Spacing Adjustment Verify the drum temperature using PC based diagnostics Ensure the drum temperature sensor is dean and properly positioned If the problem persists replace the printhead Poor Ink Fills Primary fills appear banded and inconsistent 1 2 3 4 Head to drum gap is too small Verify the gap with the adjustment explained in the topic Printhead To Drum Spacing Adjustment Verify the drum temperature using PC based diagnostics Ensure the drum temperature sensor is clean and properly positioned Verify the paper preheater temperature using PC based diagnostics If the problem persists replace the printhead Poor Small Text Resolution Small characters appear heavy and plug up 1 Verify the drum temperature using PC based dia
155. ng it in the media tray In humid environments keep media sealed in packaging until it is needed for printing Ensure that the media fits properly in the tray With the left edge of the stack of paper flush against the tray rail there should be a small gap between the right edge of the stack of paper and the opposite side rail Clean the interior of the media tray When installing paper push the stack of paper down until the tray s lift plate locks to the bottom of the tray This prevents the top sheet of paper from being mispositioned as the tray is inserted in the printer Check that the pick roller is being rotated In its starting position the pick roller s flat side should face down the flat keyed end on the left end of the pick roller shaft faces up If it is not proceed tothe topic Checking the process motor and drivetrain Clean the pick roller with alcohol and a lint free cloth Paper dust can coat the pick roller and affect its ability to grip the paper and pull it out of thetray Also dean thetransport rollers Usethe PC based diagnostic s Verify Drive Current Requirements test to check the operation of the paper pick system Inspect the wiring harness leading to the paper transport dutch for nicks cuts or crimped wiring Ensure the connector is seated Inspect the paper feed path for obstructions Print Transfer Jams 1 2 3 Using PC diagnostics test the paper preheater If the test fails rep
156. ng with the drum upon installation Therefore it is critical that they be properly adjusted so that a good seal will be obtained with the cap wipe purge assembly This should be adjusted while COLD Once theprinter is warmed up and the printhead is HOT the printhead to drum gap MUST be adjusted again NOTE Thefront pand Head to Drum Adjust will time out after 20 minutes which will result in a 4 015 45 error To clear theerror cycle power on the printer 11 Check for Service Required Errors After installing the printhead you may get one of the following service errors due to mis adjustment or cabling problems 4 002 41 and 4 006 45 Printhead NVRAM all zeroes If the data cable between the power control board and the printhead is not plugged in properly or damaged Figure 3 8 this error will occur Reseat or replace the data cable 13 003 35 13 019 40 and 13 035 47 Heater running away If the data cable is not making a good connection the incorrect data will be sent tothe main board Reseat or replacethe printhead data cable before replacing printhead 13 004 43 or 13 020 41 J etstack not heating as quickly as it should Readjust the left or right head to drum adjustment the jetstack is too dose to the drum which prevents it from warming up If the error reoccurs after the adjustment replace the printhead Troubleshooting 3 13 3 14 Additional Printhead Error Codes 13 001 40 and 13 0017 47 Open left and right
157. ning cycles e quick wipe e short cleaning e long cleaning The long cleaning cycle is performed automatically when the Clean J ets menu item is run a second time The long cleaning is described here The short cleaning and the quick wipe are basically subsets of the long cleaning cycle General Information 1 71 Cap Wipe Purge assembly Vacuum Pump module Printhead faceplate Purge Air valve solenoid Vacuum accumulator space Wipe Wiper blade Flush Dab 840 4 51 Figure 1 32 Printhead Maintenance Cycle 1 72 ii LINX Solid Inkjet 100 Service Manual Preparation Following printer power up from a cold start or in response to a front panel menu selection the print engine begins a printhead long cleaning cycle The first step is to stop any ink melting operation The printhead is tilted into the standby position In this case the cam follower follows the rotating cam gear tilting the printhead backward Following the head tilt the cap pipe purge clutch energizes to engage the cap wipe purge timing belts to the paper path drive system Then the paper path motor rotates counterclockwise to pull the cap wipe purge assembly into its cleaning position Next the printhead is tilted forward slightly to seal against the cap wipe purge assembly The vacuum pump turns on for 5 seconds just before sealing to build a slight vacuum in the accumulator The solenoid valve opens as the cap seals
158. noid bracket 3 Remove the cutting screw securing the right end of the upper stripper finger assembly to the printer frame Remove the upper stripper finger assembl y 4 Lower stripper finger At the right side of the printer remove the C dips securing the spring unit in place Remove the spring unit spring and bushing 5 At the left side of the printer remove the C dip securing the left end of the lower stripper finger assembly Carefully remove the bushing and lower stripper finger without damaging the dust cover underneath Reverse these steps to install the stripper finger assemblies Removal and Replacement 6 45 Upper stripper finger assembly Lower stripper finger assembly Cam rider Transfix Extruded pin Spring Y C clip pee Xa y eC A Spring unit S SOS 6 Ceelip ld So Cutting screw 840 4 27 Figure 6 29 Removing Stripper Finger Assemblies Removing the Maintenance Cam Roller and Electric Clutch 1 Removetheright cover 2 Removethe left cover 3 Disconnect the maintenance cam roller electric dutches wiring harness from the left I O board 4 Attheleft side of the printer remove the C clip securing the maintenance cam roller electric dutch Remove the clutch 6 46 ii LINX Solid Inkjet 100 Printer Service Manual 5 Remove the right I O board 6 Attheright side of the printer use a small flatblade screwdriver to unlock the main
159. ntact the drum in the same location as before otherwise print artifacts will result e Install the encoder wheel on the drum shaft precisey aligning the home flag to the alignment mark drawn on the shaft e Use the encoder wheel gap tool to space the encoder wheel to the drum position sensor Removal and Replacement 6 29 Printhead 6 30 present at the printer heaters while the printer is plugged into AC A Even when the printer is turned off AC line voltages may be power The printhead is hot WARNING Au FW NY a Remove the right cover and the left cover Disconnect the head tilt spring Remove the top cover Remove the ink loader Remove the metal heat shield from over the printhead Disconnect the power wiring and data harnesses leading from the printhead to the power control board Also disconnect the two ground wires from the printer frame Carefully plug the printhead s reservoir chamber holes with the silicone plugs The plugs keep liquid ink from spilling if you should inadvertently tip the printhead ii LINX Solid Inkjet 100 Printer Service Manual TEN Sk Disconnect ica Silicone LO reservoir Figure 6 20 Plugging the Reservoir Holes 8 Rotate the removal tool s plastic leg into its up position Slide 10 11 12 13 14 the removal tool s standoff locks inward Place a few sheets of paper between the printhead and the drum to protect the drum surface Ca
160. ntains NWSET for printer configuration on NetWare networks The README file for NWSET is in the net_util folder under Netware The Solid Inkjet 100 printer can also be interfaced to an iiLINX Network running version 2 8 1 software or higher or a DICOM Print Server DPS running version 1 3 software or higher Reference the appropriate installation documentation for these interfaces Before You Begin Network Configuration e Set up your printer and physcially connect it to the network See the iiLINX Solid Inkjet 100 User Manual for information about setting up the printer e Install the Solid Inkjet 100 driver for your printer on every Macintosh and PC that will send print jobs to the printer For details on driver installation see Installing Printer Software in theiiLINX Solid Inkje amp 100 User Manual For NetWare environments To speed the setup process and avoid conflicts familiarize yourself with the components of your network You should know which version s of NetWare are installed which versions of client software are used and the network topology e g frame types routers hubs and cabling Printing a Configuration Page Your printer s Configuration Page supplies useful information for installing and configuring the printer on a network Printing a Configuration Page 1 When the front panel displays READY TO PRINT press the down arrow button until Menu is highlighted Press the Select button 2 Press
161. nthead is in its upright print position home position The head tilt cam gear is principally rotated in a counterclockwise direction to tilt the printhead forward and back It only rotates clockwise during some printhead cleaning operations Tilted forward the missing teeth of the head tilt cam gear allow the process motor and gear train to perform other print functions without affecting the printhead s tilt position The cap wipe purge assembly is raised slightly to allow the head tilt cam gear with a slight spring assist from the leaf spring pushing against the cam lobe on the back of the tilt cam gear to advance forward enough to engage its drive gear and tilt the printhead back General Information 1 61 Head tilt arm Cam follower Head tilt cam gear Process motor Process drive compound gear Head tilt cam gear disengaged from drive gear 840 4 55 Figure 1 27 Tilting The Printhead 1 62 ji LINX Solid Inkjet 100 Service Manual Drum Preparation To prepare the drum a thin intermediate liquid transfer surface is applied to the surface of the drum Refer to Figure 1 28 First the drum is rotated to a speed of 51 cm per second 20 inches per second Next the oil roller and blade of the maintenance drawer are raised into contact with the drum To accomplish this the process motor rotates clockwise driving the process drive belt and the compound gear Rotating clockwise the compound gear drives a gear train
162. nual White Portion Of Image Is Dark Ink on a print where noink should be printed is often called a latent image A latent image remains on the drum when it should have been transferred to its sheet of paper An insufficient amount of oil on the drum provided by a dirty defective or old maintenance roller may be the problem 1 Clean the wiper blade of the drum maintenance drawer If necessary replace the maintenance kit 2 Run diagnostics to ensure that printer temperatures are in tolerance Ensurethat the drum heater is properly positioned Ensurethat the customer is using Sterling specified paper Some recycled paper brands may be too rough Replace the power control board Replacethe printhead data cable Replace the main board o wu PR W Replacethe printhead Grayscale Density Is Uneven This may be due to poor thermal regulation in the printer resulting in uneven heating of the printhead which in turn results in uneven ink drop jetting l Clean the wiper blade and the wick of the drum maintenance drawer Inspect the operation of the drum maintenance cam roller and the left and right cam actuators it pushes against 2 Perform the procedure Printhead To Drum Spacing Adjustment and Transfix Roller Pressure Spring Adjustment 3 Replacethe printhead Not Printing The printer processes a sheet of paper but no image is printed on it If you do not get ink on the print but you get ink in the waste li
163. o calibrate the X axis to within these specifications Do not lean on or interrupt the printer while printing the Subjective Test Print CAUTION 1 Print the Subjective Test Print 2 Inthehidden Service menu scroll tothe menu item Adjust X Axis Scale and press the Select button 3 Scroll tothe menu item Print Subjective Test Pattern and press the Select button 4 View the pattern and determine if there is evidence of underscan or overscan Count the hash marks Read from the table at the top of the print to determine the next adjusted scale factor 5 Enter the new scale factor using the Up and Down arrow buttons to adjust to the proper value 6 Print the Subjective Test Print again 7 Repeat the process as needed ii LINX Solid Inkjet 100 Service Manual Engine Copy Count The engine copy count maintains the number of pages printed successfully The total does not include blank cleaning pages nor pages that jam The other copy counts available from the Startup Page Configuration Page and front panel menu Info do include pages that jam The engine copy count is not zeroed by a standard NVRAM reset and is left intact by the factory The engine copy count is displayed following the colon The engine copy count is not normally shown as part of the service menu Fault History However a special hidden fault history menu does display the engine copy count above the fault history list The special fault his
164. of the home calibration failed After 0x3403 xa fault home calibration locating the home sensor transition the DMC computed X axis position varied from the home value by more than the acceptable tolerance Error Codes and Messages 2 9 7 000 Process Motor Error Codes mor codes Front Panel Software Error Code Display 7 002 4x PM FAULT PROCESS MOTOR STALL The process motor stalled during operation This 0x3c01 has several possible causes depending on what the PM was connected to at the time of operation 7 003 4x PM FAULT COMPOUND GEAR SENSOR BAD No transitions are observed of the compound 0x3c02 gear sensor when the compound gear should be turning Perhaps the sensor is bad it falls off easily or the PM to compound gear linkage is broken 7 004 4x PM FAULT DM CAM SENSOR BAD No transitions are observed of the drum 0x3c09 maintenance cam sensor The sensor may be bad or the DM cam may be jammed 8 000 Cap Drive and Web Sensors Error Codes peor codes Front Panel Software Error Code Display 8 001 44 CAP FAULT HOME SENSOR An expected transition of the cap home sensor 0x4401 cap fault home sensor did not occur The home sensor may be faulty or the cap motor may not be operating or the cap may be jammed and unable to move 8 002 45 CAP FAULT OVERCURRENT An overcurrent fault has been detected Either 0x4403 cap fault overcurrent the cap motor is shorted the purge pump motor is shorted a s
165. olenoid is shorted or the cap stalled This fault does not actually occur because the mechanism is loose When the cap jams the motor skips over teeth Check the hardware 2 10 iLINX Solid Inkjet 100 Service Manual 9 000 Ink Loader Ink Melters and Printhead Ink Level Sensors Error Codes peor codes Front Panel Software Error Code Display 9 005 40 IL FAULT LOW JAM The low density ink melt heater is on but Ink 12 0x4c05 il fault low density ink stick jam does not seem to be dripping Check that the stick of Ink 12 is able to advance in the chute 9 006 41 IL FAULT INTER JAM The intermediate density ink melt heater is on 0x4c06 il fault intermediate density ink stick jam but Ink 13 does not seem to be dripping Check that the stick of Ink 13 is able to advance in the chute 9 007 42 IL FAULT CLEAR JAM The clear ink melt heater is on but Ink 11 does 0x4c07 il fault clear ink stick jam not seem to be dripping Check that the stick of Ink 11 is able to advance in the chute 9 008 43 IL FAULT HIGH JAM The high density ink melt heater is on but Ink 14 0x4c08 il fault high density ink stick jam does not seem to be dripping Check that the stick of Ink 14 is able to advance in the chute 13 000 Head Thermals Error Codes Error Codes pM Front Panel Software Error Code Display 13 001 40 TCH JS LEFT OPEN The thermistor in the left jetstack appears to be 0x6c01 tch fault left jetstack open open 13
166. olid Inkjet 100 Service Manual sensor assembly s encoder wheel groove This ensures that the encoder wheel is not tensioned and slides easily onto the drum shaft If not already mounted in place secure the drum positi on sensor assembly onto the drum shaft and secure it to the printer frame Through the access hole in the drum position sensor assembly position the encoder gap tool on the drum shaft maintaining a position perpendicular to the shaft Reposition the drum position sensor assembly s encoder wheel on the drum shaft until it butts firmly against the encoder gap tool Holding the gap tool in place with a small flatblade screwdriver slide the encoder wheel s retaining spring intothe encoder wheel s groove Remove the gap tool Reassemble the printer and make a test print Adjustments 4 23 4 24 Gap tool Groove ph Drum position sensor assembly amp Figure 4 9 Setting The Drum Position Encoder Gap I aZ p7 Jl x m 0388 33 Transfix Roller Pressure Spring Adjustment 1 Print the Service Test Print 16 Primary Solid Fills 4 pages 2 If any of the prints are wrinkled on both the left and right sides of the print the drum transfix assembly must be replaced No adjustment will solve the problem 3 If wrinkling is only present on the left or right side of any print note which side 4 Remove the front cover to access the drum transfix assembly 5 Draw areferenc
167. ome sensor and related hardware 4 013 43 PC_DEV_FAULT_GEAR_GRIND During power on initialization the engine is 0x240d pc fault PM disengage unable to disengage the process motor Prior to declaring this fault the engine has attempted to move the process motor through enough revolutions to disengage the head tilt mechanism but the motor stalled somewhere along the way The X axis was then displaced to the right 0 15 inches and the disengage was repeated but the motor stalled again This leads to this device fault The head is unable to move on the tilt axis perhaps because it is colliding with something head restraint pin cap poorly installed ink loader screwdriver etc 4 014 44 PC_DEV_FAULT_6x6DPI_CAL Calibration Failure 600x600 DPI waveform could 0x240e pc fault 6x6 dpi calib not be generated Check the hardware The head may need to be renormalized Error Codes and Messages 2 7 4 000 PC Processor Conirol Supervisor continued Software Error Code PC_DEV_FAULT_HEAD_ADJUST_TIMEOUT Front Panel Display 4 015 45 0x240f pc fault head adjust timeout pc fault printhead NVRAM format pc fault tempt too cold pc fault late clean request 4 020 41 PC_DEV_FAULT_FTTR_HEADCAP 0x2414 pc fault FTTR head cap contact 4 021 42 PC_DEV_FAULT_FTTR_DIRTYDRUM 0x2415 pc fault FTTR dirty drum 4 022 43 PC DEV FAULT HEAD NV FORMAT PC DEV FAULT AMBIENT TOOCOLD PC
168. on purposes Apply grease sparingly so that it does not fling off of the gears when they turn You need only to apply a dab of grease to a single gear and the grease will migrate throughout the entire gear train Do not apply oil to gears only use approved grease NOTE Do not apply lubricant to the head tilt gear or the head tilt gear guide e X axis drive Apply a small amount of grease on the tip of the nose cone Apply a small amount 3 dabs on the threads of the X axis shaft White nylon plastic bearings and cams No lubrication required Inspection Rollers Replacethe rollers when you see any of the following defects Flat spots e Out of roundness e Cracked rubber Cleaning and Maintenance 5 7 5 8 e Loss of traction tackiness causing pick or feed failures Gears Replace gears that show any signs of wear or breakage Look for these problems e Thinned gear teeth e Bent or missing gear teeth check especially where a metal gear drives a plastic gear e Fractured or cracked gears Oil or incorrect grease on a plastic gear can cause the gear to crack Belts nspect the belts for wear There are eight rubber belts in the printer A belt from the process motor to the compound gear e Two belts from the y axis motor drive A belt from the lower paper feed roller to the upper paper feed roller e Two belts on the cap wipe purge drive e Anexit roller drive belt Asmall belt for driving
169. on the printhead to prevent air from being pushed intothe printhead The cap then moves down a little bit to improve the seal Then the main board starts the vacuum pump which begins to create a vacuum in the vacuum accumulator The pressure in the accumulator is lowered to about 10 psi It takes the vacuum pump about 75 to 90 seconds to achieve this vacuum and then the pump is shut off Purge Actual deaning begins with the air valve solenoid energizing for 0 300 seconds this momentarily routes the vacuum accumulator tothe cap wipe purge assembly and exposes the printhead faceplate tothe vacuum The vacuum bleeds off after about 6 seconds through the 7 mil orifice This is repeated 3 to 4 times depending on the purge type with 15 seconds between events Then the printhead is tilted backward to break the seal and the printer waits 10 seconds for the waste ink to drain from the cap wipe purge assembly into the waste tray Long wipe The paper path motor slowly rotates dockwise to pull the cap wipe purge assembly s wiper blade down the face of the printhead wiping away ink and debris Long flush The printhead is tilted back slightly and the cap wipe purge assembly is raised to bring the wiper blade even with the jet nozzles All jets are fired for 6 seconds to flush mixed ink and foreign matter out of the jets The waste ink drips into the waste tray of the drum maintenance drawer Dab The cap wipe purge assembly is lowered slightly and t
170. ont Cover Control Panel T5 TT9 5800 00 T Exit cover open sensor Part of 650 4039 00 Front Cover Control Panel 6 9 5795 0 Drum temperature sensor assemb y E ranstix exit sensor Part o B Paper Path Sensor assembly T8 TT9 5802 00 T Paper exit tray full sensor Part of T19 5802 00 Paper Path Sensor assembly T9 200 4495 00 T Paper exit tray Tull flag Part of 200 4495 00 Exit Cover assembly Part Number Sub Part Number Qty Y Axis Encoder Kit Not available individually uck mailer 105 1078 00 1 Encoder connector retainer 119 5804 00 1 Y axis home sensor 200 4254 00 1 Y axis position cover 213 1091 00 2 2 28 x 625 screw 213 1124 00 2 4 20 x 375 T 10 screw 214 4645 00 1 Rotational encoder assembly 214 4587 00 1 Y axis encoder disk 401 0720 00 1 Y axis encoder hub 401 0736 00 1 Y axis retainer hub 311 2506 00 1 Y axis encoder 334 7987 01 i Tektronix white label 407 4315091 1 Encoder bracket A 18 ii LINX Solid Inkjet 100 Service Manual nd Flag Parts Figure A 8 Sensor a Material Number Listings A 19 Service Tools Table A 9 Service tools Part Number Serial Number Qty Name and Description Effective Discontinued 003 31488Q 1 3 Vvaxsencoderdikspacertoo n t lt C s lt lt lt i SCS axis belt tensioner 006 729970 T Grease Rheoube e SSS S 025350 T Cabe Diagnostics PC DB SF to DB2M SSS S o 012 1543 0D A 1 Cable adapter diagnosti
171. or Gauge Ensure the digital indicator is set to inches in NOTE Always movethe printhead by moving thetilt arm 7 Attheleft side of the printhead insert the left printhead spacer between the printhead and the drum Check the indicator it should read 0 0030 0 0010 inches Adjust the printhead s spacing adjustment by twisting a flat blade screwdriver in the adjustment slot to move the printhead s position until the indicator reads the correct value NOTE Do not insert both spacers at thesametime as this will only measure the larger of the two gaps 8 Remove the left printhead spacer and install the right spacer 10 11 between the printhead and the drum Repeat the adjustment Confirm the left side is still in adjustment If not alternate between the two sides until both sides read 0 0030 0 0010 inches Remove the spacers Snug the four locking screws using an X pattern Then tighten the four screws using the same X pattern to 20 in Ibs Plug the printhead s data ribbon cable and power wiring harness into the power control board and the printhead Inspect both ends of the data ribbon cable to ensure they are properly seated Reconnect the two printhead ground wires to the printer frame Perform the Hot Printhead to Drum Spacing Adjustment to set the correct gap between the hot printhead and the drum Adjustments 4 13 Hot Printhead To Drum Spacing Adjustment Tools required e Printhead to Drum Digit
172. ost connections allowed to use internet printing feature Authorized Users List of email names allowed to 1 38 use internet printing feature ii LINX Solid Inkjet 100 Service Manual Saved in NVRAM yes yes yes yes Default 3 minutes Not Set Empty field Empty field Limits or alternate choices 1 to 32767 Set 256 byte field 256 byte field Specifications Physical Dimensions Table 1 5 provides the printer dimensions Table 1 6 provides the printer clearance requirements NOTE The printer must be mounted on a surface that is flat within 2 degrees of horizontal All four of the printer s feet must bein contact with the mounting surface Table 1 5 Printer Dimensions Printer Height 38 8cm 15 3 in Width 43 2 cm 17 0 in Depth 59 7 cm 23 5 in Weight 36 0 Kg 79 Ibs Auxiliary Feeder Unit 12 7 cm 5 0 in 43 2 cm 17 0 in 59 7 cm 23 5 in 11 8 Kg 26 lbs Table 1 6 Printer Installation Clearances Cart 47 6 cm 18 75 in 45 7 cm 18 0 in 55 2 cm 21 75 in 23 4 Kg 51 5 Ibs Top 45 7 cm 18 in Left 10 2 cm 4 in Right 10 2 cm 4 in Front Clearance must be sufficient to replace trays and clear paper jams Rear 10 2 cm 4 in Bottom No obstruction under printer that could block its cooling vents General Information 1 39 1 40 Functional Specifications Printing process Grayscale ink sticks Print Quali
173. other column The actual number of steps depends on the print resolution Physically each jet is horizontally located 22 300 of an inch from its neighbor Interlacing averages out the variability between jets by interlacing each jet with three other jets As shown in the Figure 1 28 of the pixel columns printed by any single jet only two of its pixel columns are actually ever adjacent Usually they are separated by three other pixel columns produced by other jets hence the name four j amp interlace Because of the physical spacing between jets and the pixel field that each jet travels the pixel columns of any one jet actually interlaces with the pixel columns of six other jets although no more than four at any one time During some diagnostic printing such as the Cleaning Test Print the printhead slews tothe right and lays down 112 parallel bands of ink Each band is about 1 86 mm 0 073 inch wide and is composed of 30 pixel columns of dots from an individual jet As the printhead slews to theright the drum rotates 30 times the number of pixel columns each set of jets deposits on the drum A set of jets is one of the 112 vertical arrangements of low density medium density dear and high density jets With no interlacing the test print reveals the deficiencies of a single jet compared to the rest Only in the Test Print 2 Weak Missing J ets I mode and the Print J ets Test Page test print does the printhead simply slew sideway
174. pages to continue The media in the output tray is either jammed or the tray is filled to capacity Remove hte printed pages to continue Out of ink Open top cover Add ink The printer is stopped Open the top cover Add ink Close the top cover Add ink Close top cover The printer is stopped Add ink Close the top cover Drawer A locked Close front cover to continue Waste Tray B is cooling Close the front cover and wait two minutes for Drawer A to be unlocked Paused The printer is in pause mode You may add media or ink safely Press Resume to continue Printing Pause Pending this page completes The printer is finishing the current page It will pause when Media jam Retry manual feed Remove media Verify that media used is within specifica tions Use both hands to reinsert sheet until it feeds and stops Media jam incorrect media size Open exit cover to clear Remove jammed media and close the exit cover to resume printing Media jam Open front cover to clear Open the front cover and remove media to resume printing Media jam Remove media tray to clear Remove jammed media and reinsert media tray 2 20 jiLINX Solid Inkjet 100 Service Manual Table 2 2 Front Panel Status Messages continued Status Message Solution edia jam Remove upper media tray to clear Remove jammed media and reinsert upper media tray edia jam Remove lower tray to
175. pcfg 3 Click OK 4 Choose your network adapter from the pulldown list 5 ThelP address is listed in the IP Address field For more information on installing and configuring TCP IP in Windows environments see your Microsoft Windows documentation Setting the Printer s IP Address NOTE To avoid any network conflicts contact your System Administrator for the appropriate IP Address Network Mask and Router Gateway Address You can set the printer IP address by accessing the printer s front panel For more information see Setting the Printer s IP Addressing Parameters PhaserPort Software Installation l Insert the printer s software CD ROM intothe CD ROM drive 2 Double click on My Computer Double click on the CD ROM drive icon 3 Double dick on the folder phsrport 4 Double dick on the phsrport exe icon 5 Click OK tothe WinZip Self E xtractor window 7 14 ii LINX Solid Inkjet 100 Printer Service Manual 6 Click Unzip in the WinZip Self E xtractor window this will copy the program files to your hard drive 7 Click OK when the files have successfully unzipped 8 When the Tektronix PhaserPort Setup screen comes up click Next 9 When the Tektronix PhaserPort Installation screen comes up dick Next 10 When the Choose Destination Location screen comes up dick Next Create Your First Port 1 When the Add PhaserPort dialog box is displayed create your first port a Inthe Description
176. printhead and cap wipe purge assembly are activated to melt the ink gluing them together The printhead is tilted back The ink is allowed to drain from the cap wipe purge assembly The cap wipe purge assembly is lowered to its home position A short wipe is performed and the cap wipe purge assembly is returned to its home position The process motor is rotated to tilt the printhead forward if not already forward rotate all the rollers to their ready positions disengage the transfix roller and lower the maintenance drawer blade and wiper The printhead is moved to its x axis home position and then centered Troubleshooting 3 3 3 4 Printhead is in the print position but the cap wipe purge assembly is in some unknown intermediate position a If the cap wipe purge assembly is not detected in its home position then the heaters in the printhead and cap wi pe purge assembly are activated in case the printhead and cap wipe purge may be glued together by cooled ink b After waiting for the ink to melt the cap wipe purge assembly is lowered to its home position C The process motor is rotated to tilt the printhead forward if not already forward rotate all the rollers to their ready positions disengage the transfix roller and lower the maintenance drawer blade and wiper d Theprinthead is moved to its X axis home position and then centered e A short wipe is performed and the cap wipe purge assembly i
177. r Leave the power cord plugged in to provide a ground path for static discharges Remove the interface cables Loosen the two rear panel securing screws Slide out the main board Refer to Figure 6 9 If you are replacing the main board transfer the socketed realtime dock NVRAM chip and the printer ID chip location U 390 to the new board sothe printer s settings and Ethernet address are retained Also swap the code ROM DIMM and the SDRAM DIMMs Reverse these steps to install the main board RAM Real time DIMMS L clock NVRAM Code ROM DIMM LL A A Printer ID Main board NC pes A 1 a r 840 4 36 Figure 6 10 Removing the Main Board Removal and Replacement 6 15 Power supply AN Even when the printer is off AC line voltage may be present at the printer heaters while the printer is plugged into AC power WARNING Turn off the printer and remove the power cord Removethe right cover Remove the left cover Remove the rear cover Remove the top cover oO Uu FW Ww Hc Attheright side of the printer disconnect the two wiring harnesses leading to the power supply Refer to Figure 6 10 7 Removethe four screws securing the power supply in place Remove the power supply Reverse these steps to install the power supply 6 16 ii LINX Solid Inkjet 100 Printer Service Manual Wiring harnesses Power supply r 840 4 32 Figure 6
178. r system administrator 5 Click OK again to apply the changes the printer driver is now configured to use your new PhaserPort The procedures in this chapter is only valid for Windows NT version 4 0 or higher Setting the Printer s IP Address Set the printer s IP address by any of the methods described earlier in this chapter in Setting the Printer s IP Addressing Parameters TheWindows NT 4 0 PostScript driver is a PPD based driver Follow these instructions to add or update the Solid Inkjet 100 PPD file for use with Windows NT 4 x This update procedure provides printer page size information for Windows NT applications These instructions assume a basic familiarity with Windows NT operation and terminology For additional information about Windows NT refer to your Microsoft Windows NT documentation NOTE You may need the Windows NT 4 x CD ROM and your printer s software CD ROM to complete this procedure In order to successfully install the Windows NT Solid Inkje 100 driver the Windows NT Administrator MUST install the Microsoft TCP IP Printing Service and the TCP IP protocol Printer Networking 7 17 Creating Network Port Configuration The Solid Inkjet printers support two types of network ports e LPR e AppleTalk The following procedure covers LPR ports for information on AppleTalk ports refer to Creating an AppleTalk Port following this section Creating LPR Printing Adding an LPR port 1 Click on S
179. r packet which contains an IP address from within the assigned scope and the assigned lease e Theprinter examines the DHCP offer packet and decides whether to accept the lease The printer sends a request packet accepting the P address and the lease NOTE There can bemultiple DHCP servers on the same network each defining its own scopes and leases The printer sd ects thefirst lease offered e TheDHCP server sends an acknowledgment packet to the printer which completes the transaction 7 6 ii LINX Solid Inkjet 100 Printer Service Manual Ethernet Interface A CAUTION Built in Ethernet Connector The printer s built in Ethernet amp connector has the following connections and indicators 1 LINK indicator on indicates a working connection to a hub off indicates no connection to a hub 2 RCV indicator green blinks while the network interface is receiving 3 XMT indicator yellow blinks while the network interface is transmitting 4 Twisted pair 1OBase T connector PhaserShare Series B Ethernet Interface The PhaserShare Series B Ethernet interface conforms to the IEEE 802 3 and Ethernet I standards With the printer s built in Ethernet interface you can connect the printer directly to an Ethernet network using twisted pair 10Base T cables With the optional Ethernet interface card you can connect the printer directly to an Ethernet network using twisted pair cables 10Base T or 100Ba
180. rd position to the center of its travd 8 Removethe screw securing the right side of the upper feed roller assembly to the inside of the printer frame 6 22 ii LINX Solid Inkjet 100 Printer Service Manual 9 Disconnect the wiring harness leading from the upper feed roller assembly to the inside the left side of the printer frame 10 Remove the C dip located on the left inside printer frame securing the upper feed roller assembly in place 11 Remove the upper feed roller assembly Separate the assembly into its two halves Reverse these steps to install the upper feed roller assembly v Keyed T Upper feed roller bushing x assembly EZ ye SS Clip 7 e A EP N Wiring 8 harness vx Left maintenance E drawer guide ES Right maintenance Key pin drawer guide an right frame aligns upper feed roller fella assembly screw from right side 840 4 14 Figure 6 15 Removing the Upper Feed Roller Assembly Front Removal and Replacement 6 23 Drum Transfix Assembly 6 24 NOTE When thedrum see Drum Transfix Assembly is replaced the new drum should be conditioned using the Seal Drum print suite beforethe printer is returned to normal service TheSeal Drum suite is comprised of fiveclear solid fill prints Remove the right cover Remove the left cover Remove the front panel AeA W N Hp Left side Free the wiring harness leading from the drum transfix assembly
181. re defined by software and the System Reset is hardwired After initialization both the PostScript and Engine LEDs blink toindicate normal operation The Postscript and Engine LEDs are located to the left and right of the DIP switch respectively The Ethernet connector contains two integral LEDs The yellow indicates transmit and green indicates receive The image processing controller contains an on board Digital Semiconductor 21041 AB 10 BaseT Ethernet port located at J R160 The controller s built in Ethernet interface will support 10M bit half duplex Ethernet connections over category 3 or higher twisted pair cable and is automatically disabled when the optional 100 base T interface is installed Both the IEEE 1284 parallel port and the serial ports are ii LINX Solid Inkjet 100 Service Manual implemented using a Cirrus Logic CL CD1284 The parallel port uses a 36 pin IEEE 1284 connector on the rear panel The serial port provides RX and TX only with no handshaking It is connected via a 5 pin square post 0 1 centers connector recessed into the rear panel The CL CD1284 general purpose 8 bit parallel 559 port is used for the following functions BIT FUNCTION DESCRIPTION 0 Input Service mode switch 1 1 Input Service mode switch 2 2 Input Service mode switch 3 3 Output Reset control tor NETCHIP 2890 4 Input Bit 1 of the 2 bit board version number 5 Input Bit 2 of the 2 bit board version number 6 Input Parallel Port mas
182. refully lower the printhead removal tool onto the printhead Rotate the process motor to tilt the printhead forward about 2 5 cm 1 inch Slide the standoff locks outward to secure the tool to the printhead Loosen the two mounting screws securing the printhead in place Lift and remove the printhead Lower the removal tool leg to safely restthe printhead on a flat surface Using the printhead removal tool reverse the removal steps to reinstall the printhead Perform the Cold Printhead to Drum Spadng Adjustment and then the Hot Printhead to Drum Spacing Adjustment Removal and Replacement 6 31 a Install adii ui Loosen CS mounting Qu uc removal SS oS screws Removal tool leg in up position x Figure 6 21 Removing the Printhead 840 4 24 Installation f not already in place install the printhead s data ribbon cable to the printhead 1 Install the printhead with the tile mount about half way back Work the head up down on each side to be certain the head is all the way down and seated Then tighten the two mounting screws so they are snug 2 Loosen the printhead s four Head to Drum HTD gap adjustment screws and push the printhead away from the drum then tilt the printhead to its print position by turning the process gear on the left side of the printer and attach the head tilt spring The head tilt arm will be seated at the end of the slot of the steel band 6 32 iiLINX V Solid Inkjet 100
183. res of the Main Board 1 14 ii LINX Solid Inkjet 100 Service Manual Media Tray Type Sensing The combinations of the three tray sensors inform the print engine what type of media tray A or A4 is installed These combinations are shown in Table 1 2 The print engine does not detect the type of media installed in the tray it only detects the particular tray being used by the presence of sensor flags on the side of the tray The tray sensors are located on the right side interior of the paper tray slot mounted on I O board right There are two tray types e Letter A size This tray is sized for 8 5 x 11 inch U S paper Metric Letter A4 size This tray is used for 210 x 297 mm Metric paper Table 1 2 Tray Switch Sensor Combinations Tray type A Paper A4 Paper Top switch Closed Open Middle switch Open Closed Bottom switch Open Open Front Panel These front panel features shown in Figure 1 11 are found on the printer e 128 x 64 pixel backlit LCD graphic display e Two push buttons and four navigation arrow buttons e TwoLEDs Power and Error LCD The backlit LCD serves two purposes displaying current image processor and print engine status information and displaying an interactive menu Status information includes image processor status such as Ready to Print Receiving Data and Printing Print engine status includes messages such as Out of Paper Paper J am and Add Ink as well as error messages Customers can re
184. ript None On Not Set Enabled PostScript None On Not Set 3 minutes Not Set Printed On Jul 2 1999 11 58 07 STERLING Diagnostic Imaging Table 1 4 Configuration Page Settings Parameter Printer name Page count upper and lower tray counts Startup page enabled Serial number Product Printer ID PostScript version Firmware version Flash Installed Installed RAM ROM fonts available Sys Job Start Job Timeout Description The current name of the printer as seen on a network Total number of print jobs processed through the image processor Indicates if the printer prints a startup page upon power up Unique number representing the printer serial number A unique number for each Ethernet capable printer Firmware level of the PostScript interpreter code Firmware levels of the main board operating system code version printer engine s operating system code PostScript code engine code and networking code Total amount type and size of RAM on the main board in each DIMM slot Number of fonts stored in the printers ROM memory Indicates if the printer is to execute a Sys Start job file found on an attached hard drive at power up Amount of time a job can take to process Saved in NVRAM yes yes yes yes yes N A N A yes yes Default li LINX SIJ100 Yes Ii LINX Solid Inkjet 100 Hardware dependent 3016 106
185. rrow button press the Select button Scroll to the menu item Adjust X Axis Scale and press the Select button Scroll to the menu item Print Subjective Test Pattern and press the Select button The print features four gray columns each containing a jagged black band The black bands should all align vertically with each other If an adjustment is needed scroll to the menu item Set X Axis Scale Change the displayed value to a new value if necessary Increasing the scale value raises the two center black bars Decreasing the scale value lowers the two center black bars Select the menu item Print Subjective Test pattern to verify the adjustment Repeat the adjustment if necessary Try to align the two center black bands and the two outer black bands within one tick mark on the vertical scale adjust to lower center bars 0388 67 Figure 4 11 Adjusting the X axis Scale Adjustment 4 26 NOTE The X Axis Scale Adjustment menu also includes the item for printing the ObjectiveTest pattern This pattern is only useful at the factory The Subjective Test pattern should be used instead ii LINX Solid Inkjet 100 Service Manual Adjusting Look Up Tables The Look Up Table LUT menu displays all of the LUT resources currently available in the printer The default LUT is indicated with a check mark The list of available LUTS is in alphabetic order If there are Contrast values within a family the menu button is labeled contra
186. rs Removing the Right and Left Covers 1 Open the front door 2 Remove the two screws securing the left or right cover in place A sheet metal screw secures the cover inside the front door A machine screw secures the cover at the rear cover 3 Remove the left or right cover NOTE For reassembly note how the cover interlocks with the bottom of the printer frame Pushing in on the bottom center of the cover helps to lock it in place Reverse these steps to install the right or left cover Screw Vd TC Right cover 840 4 02 Figure 6 1 Removing Right Cover 6 4 ii LINX Solid Inkjet 100 Printer Service Manual Removing the Top Cover NOTE Vacuum dust out of the top cover before you remove it 1 2 Remove the right cover Remove the left cover Open the ink load door and tilt it back Undip the ink load door arms from the ink loader s spring crossarm Slide the ink loader s spring crossarm to the rear of the ink loader Note how pins on the ends of the ink loader crossarm align with notches in the top cover for removal Remove the four screws securing the top cover in place Tilt up the rear end of the top cover and lift and remove the top cover Reverse these steps to install the top cover Figure 6 2 Removing Top Cover Removal and Replacement 6 5 Removing the Rear Cover Remove the right cover Remove the left cover Remove the top cover A WN Hp With the top right and le
187. rtup page Setting up the driver allows you to select all printer options when printing Click OK Close the Chooser 7 30 iiLINX V Solid Inkjet 100 Printer Service Manual Enabling EtherTalk The EtherTalk network protocol is enabled from the front panel as follows 1 Allow the printer to warm up toits idle Ready to Print state 2 Scroll tothe selection Menu and press the Select button 3 Scroll tothe selection Network Settings and press the Select button 4 Scroll tothe toggle item Ethertalk The current setting On or Off is displayed to the right 5 Press the Select button to toggle the current setting for EtherTalk The display will reflect the new setting Printer Networking 7 31 7 32 ii LINX Solid Inkjet 100 Printer Service Manual Appendix Appendix A Material Number Listings Illustrated Parts Catalog 0 00 c eee eee A 3 DEVICE TOGIS 2 desc Lo eeu Maan as eaads bloat a aod A 22 Supplies and Accessories llli ee nes A 23 A 2 ii LINX Solid Inkjet 100 Service Manual Illustrated Parts Catalog This section provides parts listings and exploded view illustrations of field replaceable units for the Solid Inkjet 100 Printer Material Number Listings A 3 Table A 1 Cabinet parts Item Part Number Serial Number Qty Name and Description Number Effective Discontinued T ASE CO D PDUU4257T 00 1 Front cover jam access door 9 P2144801H00
188. s 0 8 Adjusting this value is not recommended Setting Interpolation Defaults This option lets you change the default image interpolation mode Since image resolution is usually 150 to 300 dpi and the printer produces images at 600 dpi most images are automatically expanded or scaled when printed Use this option to specify the way your images are smoothed or blended when they are scaled Bilinear This selection blends adjacent pixels in an image in a manner that is linear in both the horizontal and vertical axes of the image Bilinear is the most common and the fastest image smoothing method Cubic These selections are slower methods of image smoothing that produce sharper image detail The values represent degrees of sharpness with the smaller values producing the sharpest image detail Replication This selection uses a technique that expands with each pixel Use Replication for an accurate representation of image data with no smoothing modifications ii LINX Solid Inkjet 100 Service Manual Service Test Print 10 Front Panel Designation Ink O Ink 1 Ink 2 Ink 3 Setting Dmin and Dmax Adjustments can be made to the Dmin and Dmax settings in the driver software of the workstation you are sending the data from Any settings sent by the drivers will overwrite the default settings on the printer for that job Adjusting Dmin will set the lower limit for optical density that the printer will produce The Dmin
189. s returned to its home position The printhead is tilted back tothe locked position The front panel displays a warm up message The heaters are enabled and the drum begins to rotate Moo v B When the ink in the printhead is molten the cap wi pe purge assembly is positioned to the purge position eo The printhead tilts forward and a purge cycle begins 9 A cleaning page is printed 10 Thefront panel displays a message that the printer is initializing and then ready The print engine is initialized ii LINX Solid Inkjet 100 Service Manual Verifying Main Board CPU Operation 1 If the printer does not power up rear fan is off and power up diagnostics LEDs are off go to the topic Verifying power supply operation below Observe the rear panel LEDs located on each side of the rear panel DIP switches The left LED represents the operation of the PostScript firmware The right LED represents operation of the main board s print engine firmware During the POST tests the two LEDs toggle back and forth for each successful pass through each DRAM test A failure in the power on self tests is indicated by the left LED the PS led flashing in a specific pattern of long and or short flashes and repeated indefinitely Other failures are indicated by the failure being printed on the Startup page After successful power up the left PS LED flashes in a heartbeat rhythm on 0 5 seconds off 0 5 seconds The right
190. s the printhead in place for moving and shipping The printer will not lock the printhead if any printer door is open After servicing the printer with power off never leave the printhead in the tilted forward far right position Upon power up the printhead will be tilted backward and the head tilt arm will crash into the head lock pin This can damage process gears and belts driving the tilt arm After servicing the printer When you service the printhead X axis drive cap wipe purge assembly or other relevant printer components leave the printhead in its print position centered in front of the drum Upon power up the printer can safely move the printhead Manually locking the printhead f you must manually lock the printhead 1 Disconnect the head tilt spring 2 With the printer powered off carefully tilt the printhead back about two thirds of the way by rotating the compound gear Do not allow the spring loaded printhead to fall forward or it may damage the drum 3 Manually rotate the X axis drive gear to move the printhead to the right extreme of its travel Ensure the lock pin on the left side of the printer frame properly engages the slot in the head tilt arm 4 Rotate the X axis gear in the opposite direction about one rotation This prevents the X axis drive from binding so tightly that the motor cannot free it upon power up 5 Reinstall the head tilt spring Removal and Replacement 6 3 Removing the Cove
191. s with no jet interlacing General Information 1 65 125 to 181 pixel wide field traveled by a jet depending on print resolution Output of four side by side jets 1of4 22 300 2of4 separation 3 of 4 between jets Column of pixel dots produced by four adjacent jets are interlaced together for printing Each jet produces between 30 and 44 pixel columns Columns of pixel dots produced by previous set of four adjacent jets Note how the ending columns of this set interlace with beginning columns of the next set of four jets 840 4 62 Figure 1 29 Printing Latent Pre transferred Image On The Drum 1 66 ji LINX Solid Inkjet 100 Service Manual Paper Pick To pick a sheet of paper the process motor rotates dockwise driving the process drive belt and the compound gear counterclockwise Refer to Figure 1 30 Rotating counterclockwise the compound gear turns and in turn engages a gear train that rotates the pick roller clutch gear counterclockwise The paper pick electric clutch energizes for a moment engaging the paper pick clutch and allowing it to rotate one revolution The pick roller rotates and pulls a sheet of paper from the paper tray The sheet of paper trips the paper pick sensor to assure that the paper was picked from the tray If the paper is not sensed the pick solenoid is energized up to six times to rotate the pick roller again to attempt to recover from the mis pick
192. saturated roller The drum maintenance drawer s second function is to collect waste ink from printhead purges in a waste tray Refer to Figure 1 17 a SN Camshaft 2s home ioV position L Drum flag maintenance drawer camshaft Process motor AS Process drive belt Maintenance drawer camshaft electric clutch Cam pushes oil roller and blade Cam lowers oil roller and blade assembly 840 4 54 Figure 1 17 Drum Maintenance Drawer Prior to each print a cam driven by the process motor raises the oil roller against the slowly rotating drum A compliant blade also raised by the same cam assures that the oil film is smooth and even across the drum s surface The blade also directs excess oil back through a 1 48 ji LINX Solid Inkjet 100 Service Manual felt filter to the oil roller for reuse As the drum completes one rotation the rotating cam lowers the oil roller and then a moment later lowers the blade A removable NVRAM chip mounted on the drawer stores the number of oiling cycles performed by the maintenance drawer Printhead The printhead Figure 1 18 is the heart of the printer Refer to Figure 1 17 The printhead spans nearly the length of the drum Using its 448 ink jet nozzles 112 jets for each density with a horizontal motion of slightly more than 5 mm 0 2 inches the printhead can print the entire image on the rotating drum Reservoir Con Drum i N Jet stack Printhead Head dr
193. se T x or 10Base 2 When an optional Ethernet interface card is installed the printer s built in Ethernet connector is disabled use the connectors on the card When an optional Ethernet interface card is purchased as an upgrade kit follow the instructions that are shipped with the card To avoid damaging the network interface turn off the printer before making any Ethernet connections Printer Networking 7 7 Optional Ethernet Interface Card The optional Ethernet interface card Figure 7 1 has the following connections and indicators 1 TX indicator yellow blinks while the network interface is transmitting RX Link indicator green blinks while the network interface is receiving Speed indicator yellow on indicates 100 M bps off indicates 10 Mbps Twisted pair connection indicator on indicates a working connection to a hub off indicates no connection to a hub If the 10Base 2 connector is used this indicator is off Twisted pair IOBase T or 100Base T x connector Thin coax 10Base 2 connector O 5 6 PhaserShare Series B O Ethernet Card TEE MS RX D G TP 3 LINK 10 100Base TX 10Base2 O 24 9789 05 Figure 7 1 Optional Ethernet Interface Card 7 8 if LINX Solid Inkjet 100 Printer Service Manual AN CAUTION Ethernet Cables and Termination NOTE To fully comply with EMI eectro magnetic interference specifications the use o
194. sing the special serial cable adapter Pin 1 is the left most pin of the five pin connector looking at the back of the printer 2 Push down Switch 1 the service mode DIP switch The switch is the left most of the four DIP switches on the rear panel of the printer looking at the back of the printer The other switches should be up 3 Using the serial null modem cable connect the serial port adapter to the COM 1 serial port on the PC 4 TurnonthePC in DOS mode Older versions of Windows 95 will only run the PC based diagnostics if the computer is booted in DOS mode they will not run the diagnostics from the MS DOS Prompt application Troubleshooting 3 31 5 Set the PC s comm port to COMM 1 Set the baud rate to 19 2 kbaud 8 data bits 1 stop bit and no parity 6 In your DOS window gotothec prompt 7 Toinstall the diagnostics from a diskette onto your computer type A INSTALL all return 8 Connect tothe directory containing the diagnostic software C N100DIAGS Launch the diagnostics program by typing diags xxx Where xxx isthe name of the print engine firmware level Typing diags lists the available diagnostic versions Once launched the program repeatedly attempts to communicate with the printer The link status indicator in the bottom right corner of the screen reads NO until this link is established once communication is established it reads OK NOTE The Comm Port should be set to 57 6 k
195. sion to the Y axis belts 4 Whilethe belts are under tension rotate the drum pulley five times to rotate the belts and seat them in place 5 Beginning with the upper right screw tighten the three mounting screws to 30 in Ibs to secure the Y axis drive assembly in place 6 Using PC based diagnostics run thetest Position for Belt Tightening in the Y Axis Group test suite This positions the belts in the proper orientation for retensioning Do not move the pulleys 7 Placean index mark on the edge of each pulley Mark the Y axis drive pulley and the drum pulley where the edges are dosest to one ancther disregarding previous marks Usea distinct color if the pulleys have been previously marked 8 Loosen the 3 mounting screws until the bracket slides freely on the chassis and then re tighten the screws to 30 in Ib 9 Releasethe tension tool s lever arm and remove the tool 10 Reassemble the printer and make a test print ii LINX Solid Inkjet 100 Service Manual SW D O Tighten screws after setting Attach tension tool to keyholes di S m Bi t L Pull lever arm to set tension 0388 30 Figure 4 4 Setting the Y axis Belt Tension Adjustments 4 11 4 12 A CAUTION A CAUTION Cold Printhead to Drum Spacing Adjustment Tools required e Printhead to Drum Digital Indicator Gauge Kit Small 3 16 in flat blade screwdriver 9 64 in hex tip Magnetic screwdriver e T
196. so its pointer points between the index mark on the printer frame Holding the left belt so it does not move inspect the right side drive belt lock s pointer It should point at the index marks on the right side printer frame If the right side pointer does not point to the index mark while the left side belt lock is between its marks loosen the right drive belt by removing the lower idler pulley and adjusting the belt so that it aligns with the timing mark Repeat until the right side belt lock s pointer points at the index mark on the right side frame as the left side belt lock s pointer points between its index marks on the left side frame Adjustments 4 21 4 22 Belt lock Index mark on right frame Latch For new belt break off actuator on left side belt lock Left belt lock align pointer between two index marks Idler pulley Right Leave gap cap wipe purge i i between latch assembly belt and belt tensioner 0388 32 Figure 4 8 Aligning Timing The Cap Wipe Purge Assembly Drive Belts Drum Position Encoder Gap This procedure ensures that the drum position sensor assembly s encoder wheel rotates freely inside the gap of the drum position sensor without the encoder wheel s disk touching the sensor If the disk touches the sensor it can abrade the disk and result in erroneous drum position readings 1 Ensure that the retaining spring is not in the drum position ii LINX S
197. st If there is not a contrast the menu selection is limited to OK The standard family contrast values is displayed in Table 4 1 There may be up to 4 Custom LUT also stored in the Hidden Service Menu Table 4 1 Look Up Tables Family Contrasts Available Linear 1 soc fixed 12 soc variable 15 midtones 10 shoulder 5 toe 10 oem_1 12 oem 2 2 Custom Look Up Tables 1 Cydethrough up to 4 of the downloaded LUT The tables appear as a choice to save if the name is 16 characters or less theTransfer Table type is 3 or 4 and there are 6 coefficients or less Selecting the user tables and selecting OK saves it in NVRAM NOTE The messagethat thetable has been saved is displayed for 2 Seconds name of custom table Saved as Table 1 2 If this table had been previously saved you must confirm to replace the table selection Replace Current Table 1 name of custom table OK If there have not been any custom tables downloaded to the printer when the menu button is pressed the front panel displays No Custom Look Up Table Are Available Adjustments 4 27 4 28 Paper LUT The menu item Paper LUT Customization is found under the menu Service Support The Paper LUT Customization setting is a number ranging from 0 5 to 1 0 It affects how built in look up tables appear on paper User defined LUT families and the Linear LUT are not affected Lower values whiten images while higher values darken images NOTE The default setting i
198. t of the drum and the cap wipe purge assembly is in the retracted home position The tilt cam gear should be disengaged from the gear drive train Electric clutches and solenoids are used by the printer to engage rollers as needed to move paper through the printer as well as start some print processes Refer to Figure 1 9 Drum maintenance cam clutch Cap Wipe Purge clutch Upper feed roller clutch Air valve solenoid Transfix clutch solenoid 0388 08 Figure 1 9 Solenoids and Clutches on the Print Engine General Information 1 13 The Main Board The main board features the printer s PowerPC processor that controls the engine and the PostScript processing Refer to Figure 1 10 Prominent on the main board is the code ROM DIMM and the RAM DIMM plug in modules The code ROM DIMM also contains the printer s on board fonts Variations of the code ROM DIMM contain alternate language fonts such as Kanji or Hangul Network connection is provided through a built in 10baseT port The printer stores unique printer status and PostScript values in its NVRAM module The printer s Ethernet address unique to each printer is stored in Boot ROM Printer ID chip an 8 pin socketed IC in location U 390 All these socketed components should be transferred to a replacement main board to maintain customer unique settings Boot ROM Printer ID RAM DIMMs NV RAM Real Time Clock Code ROM 0388 09 Figure 1 10 Featu
199. t topic minutes for the ink to solidify Before moving the printer always N If you do not select Quick Cool to Move Printer you must wait 30 wait for the ink to solidify or you may damage the printer CAUTION Removing the Maintenance Drawer drawer before moving or shipping the printer Never ship a partially A To avoid damaging the printer always remove the maintenance used maintenance drawer CAUTION 1 Open the printer s front cover 1239 58 General Information 1 21 A WARNING 2 Remove the maintenance drawer from the printer Once you ve removed the maintenance drawer keep it level 1239 59 A used maintenance drawer leaks drum fluid if tipped Keep the maintenance drawer level to prevent spills Contact with maintenance drawer fluid poses no health risk however do not leave the used maintenance tray where it could spill and create a slipping hazard 3 Place the used maintenance drawer in a plastic bag and seal the bag Store the used maintenance drawer for future use Do not ship a partially used maintenance drawer Disconnecting the Cables Once the printer completes its shut down process the front panel goes blank Once this happens disconnect the power cord and all other cables from the printer 1 22 ji LINX Solid Inkjet 100 Service Manual A WARNING Repacking the Printer and its Accessories The printer weighs about 36 kg 79 Ib Do not attempt to lift it without the
200. tained from the front panel as follows 1 Allow the printer to warm up to its idle Ready to Print state 2 Scroll tothe nfo selection and press the Select button 3 Repeat for the menus Consumables and Maintenance Kit Information 4 Scroll tothe item Prints remaining The number of remaining oiling cycles is displayed following the colon When the number of remaining oiling cycles reaches 1000 the front panel automatically displays the count as part of status message indicating that the maintenance kit is low A replacement kit should be ordered at this time The kit low message remains counting down the number of remaining oiling cycles until the count reaches 0 At that point the message is updated stating that the kit is empty and requires replacement The printer will no longer print until the maintenance drawer is replaced The front panel messages are accompanied by similar messages emitted over the back channel These are maintenance kit low and maintenance kit exhausted While the drawer is in the process of being replaced that is whenever it is removed the back channel emits maintenance kit missing In addition one other back channel message is associated with the maintenance drawer The message is waste liner full please empty This indicates the waste ink tray must be emptied before normal operation will resume For quick reference the front pane displays additional instruction
201. tainer so it ends locks the yoke in position Perform the procedure X axis scale adjustment N When reinstalling the motor take care to fully seat the motor positioning boss into the stiffener panel for proper operation CAUTION 1 Placethe retainer over the leadscrew Orient it so that the flat side faces generally toward the motor 2 Put lubrication on the leadscrew and screw the threaded gear longer hub facing out Turn it all the way on clamped against the stop collar then back off 1 4 turn NOTE The X axis shaft head assembly will bespring loaded but should otherwise be free to travel Removal and Replacement 6 35 X axis motor X axis drive yoke install top first E790 42 S Figure 6 23 Installing the X axis Motor and Drive Assembly 3 Install the upper yoke leg by hooking it into the stiffener tab pivot toward the side frame until it hooks then pivot back out Installing the yoke legs requires orienting the stop collar to allow access to the tabs 4 Clean the mating surfaces of the gear hub and nose cone diameter and base then slip the nose cone over the gear hub 5 Lubricate the yoke pocket 6 36 ii LINX Solid Inkjet 100 Printer Service Manual 10 11 12 Engage the yoke span and the un mounted yoke leg by rotating the end tabs of the span to fit through the large rectangular hole of the leg Orient so the parts are coupled perpendicular to one another Insert the free spa
202. tart Settings and Printers 2 Inthe Printers dialog box double click Add Printer 3 Select My Computer and click Next 4 Ifthe printer is connected to the network click Add Port 5 Double click LPR Port in the Printer Ports dialog box if the LPR Port is not available contact your Windows NT Administrator 6 Inthe Add LPR compatible printer dialog box enter the printer s IP address in the box labeled Name or address of server providing lpd n the box labeled Name of printer or print queue on that server enter Ps in uppercase Click K 7 When returned tothe Printer Ports box click Close 8 Atthe Add Printer Wizard dialog box dick the box next to this new port a check mark is added Click Next Installing the Printer Driver 9 Inthe Add Printer Wizard dialog box click Have Disk to add a new Solid Inkjet 100 10 Typethe path name to the driver files This can be d or the current location of your CD ROM drive Click OK 11 Select the Sterling iiLINX Solid Inkjet 100 Click Next 12 If prompted that a driver is already installed for this printer select Keep existing driver recommended Click Next If the printer driver does not exist go to Step 14 13 Inthe Printer name dialog box give the printer a unique name if another Sterling iiLINX Solid Inkjet 100 is installed for example SIJ 100 N etwork 7 18 iiLINX Solid Inkjet 100 Printer Service Manual 14 15 Select Not shared and clic
203. tenance cam roller flag from the end of the maintenance cam roller 7 Inside the left side printer frame remove the C dip securing the maintenance cam roller in place Remove the maintenance cam roller Reverse these steps to install the maintenance cam roller and electric dutch Maintenance roller electric clutch Maintenance ra cam roller flag 840 4 31 Figure 6 30 Removing Maintenance Cam Roller and Electric Clutch Removal and Replacement 6 47 Removing Maintenance Drawer Counter Connector Assembly 6 48 WARNING 1 2 3 4 A Allow the printer to cool for 30 minutes Remove the right left and top covers Remove the ink loader Remove the maintenance drawer Disconnect the maintenance drawer counter connector assembly s wiring harness from the power control board Reach in through the maintenance drawer cavity and squeeze the snap fit maintenance drawer counter connector assembly to free it from the printer frame Carefully remove it and its wiring harness Reverse these steps to install the maintenance drawer counter connector assembly ii LINX Solid Inkjet 100 Printer Service Manual Disconnect wiring harness Maintenance drawer counter connector assembly 840 4 64 Figure 6 31 Removing Maintenance Drawer Counter Connector Assembly Removal and Replacement 6 49 Removing Preheater Exit Sensor A Allow the printer to cool for 30 minutes WARNING
204. ter ready host logic high 7 Output Parallel slave ready peripheral logic high Optional Ethernet Interface Card 100 Base T The optional Ethernet Interface card has an RJ 45 connector a 50 ohm BNC coax connector and four LEDs on the rear panel The card includes a DEC 21143 Ethernet MAC an ICS 1890 MII PHY andan 82C92 coax transceiver There are no jumper or switch settings on the card It supports 100M bit connections over the RJ 45 connector using two pairs of category 5 cable at up to 100 meters I00 Base TX or 10M bit connections over the same connector using two pairs of category 3 or greater cable at up to 300 meters 10 Base T The card fully supports 802 3u dause 28 autonegotiation with parallel detection at 10 and 100 Mbits sec on the RJ 45 port When connected to a hub switch port the printer will determine the best possible speed and duplex setting either 100Base T X full duplex 100Base X half duplex 10Base T full duplex or lOBase T half duplex If the RJ 45 port is not connected or the link to the hub switch fails e g due to a cable fault the card will switch to 10M bit sec half duplex operation over the coax BNC interface Users should not connect cables to both ports doing so will not disrupt the customer s network but may prevent the printer from communicating properly The operating mode of the interface may be determined from the Network Type parameter or by observation of the back panel LEDs There
205. that drives the maintenance camshaft s 3 position electric dutch which in turn engages the maintenance drawer camshaft The maintenance drawer camshaft clutch energizes to release the 3 position clutch allowing it and the camshaft to rotate about one half revolution to the next stop The cams on the ends of the camshaft push against followers on each side of the maintenance drawer forcing the oil roller and blade against the drum The de energized clutch holds the camshaft in this position As the drum nears the end of its rotation the clutch energizes for a moment allowing the camshaft to rotate further this lowers the oil roller but leaves the blade in contact with the drum to smooth out the last of the oil on the drum The clutch energizes for a third time to allow the camshaft to rotate to its home position and lower the blade The point at which the blade ends contact with the drum leaves a bead of oil called an oil bar The oil bar defines the edge of a 40 mm 1 5 in swath of the drum which is not oiled this swath is called the deadband No ink will be deposited on the deadband during the print cycle Instead the paper stripper fingers which lift the paper off of the drum during printing are lowered into contact with the drum in the deadband This keeps them from accumulating any oil on their fingertips which would stain the edge of the print as it is stripped off of the drum At this point the drum starts rotating again at a
206. the cap wipe purge assembly from the cap wipe purge clutch Look for these problems e Loose rubber particles below the belts indicate a worn belt e Missing teeth in the belts e Cracking or moderate fraying a small amount of fraying is inevitable so look for other signs of wear before replacing the belt Clutches There are four clutches the paper pick roller clutch the upper feed roller clutch the maintenance drawer cam clutch and the cap wipe purge clutch Symptoms of a malfunctioning clutch are the printer not picking paper from the tray or other paper jams Also the cap wipe purge system could fail In such cases replace the dutch iLINX Solid Inkjet 100 Service Manual Preventative Maintenance Checklist m Clean feed rollers exit rollers and guides and stripper fingers only when ink or debris is visible m Clean upper and lower tray pick rollers only when ink or debris is visible m Clean maintenance drawer wiper blade Clean dust or vacuum interior and exterior of printer including fans and air inlets outlets on cart m Inspect cap wipe purge gasket wi per blade and printhead faceplate if gasket or wiper is damaged or printhead faceplate has streaks replace cap wipe purge assembly m Check optical density if necessary calibrate optical density or replace printhead O Check print quality using Quality Test dean printhead or adjust printhead to drum gap and X axis scale factor Check for cooked or
207. the down arrow button until Demo and Test Pages is highlighted Press the Select button 3 Pressthe down arrow button until Print Configuration Page is highlighted Press the Select button Printer Networking 7 3 Setting the Printer s IP Addressing Parameters A CAUTION In order to install the printer in a network environment obtain the information listed in Table 3 1 It might be helpful to write down this information so you can refer to it during the configuration procedure To avoid any network conflicts contact your system administrator for the appropriate IP address settings Table 7 1 Information for TCP IP Configuration Information Comments Internet IP address for the printer Format is x x x x where x represents a decimal number from 0 255 Network mask If you are unsure leave this blank the printer will choose an appropriate mask Broadcast address If you are unsure leave this blank the printer computes an appropriate broadcast address The address the printer uses to send broadcast packets Regardless of how this parameter is set the printer accepts broadcast packets from any of the commonly used broadcast address conventions Gateway IP address Router address You need this address if you want to communicate with the printer from anywhere other than the local network segment 7 4 iiLINXTM Solid Inkjet 100 Printer Service Manual Setting IP Parameters from the Front
208. tory menu can be displayed while the printer is awaiting clearance of a jam This is the quickest way to access the current jam code To display the special fault history menu before dearing a jam dothe following 1 Removethe standard media tray from its secure insertion point Thetray does not need to be completely removed from its slot 2 Enter the hidden fault history menu by holding the L eft arrow button down and pressing the Help button Adjustments 4 35 4 36 ii LINX Solid Inkjet 100 Service Manual Chapter 5 2 Chapter 5 Cleaning and Maintenance This chapter describes the cleaning procedures to keep the printer in peak operating condition Some cleaning procedures such as purging the ink jets are done automatically when necessary Other procedures such as scrubbing the paper feed rollers with an alcohol soaked cloth must be done by customers The chapter is presented in the following sections Cleaning Overview 0 00 c cect eee 5 3 Cleaning Supplies Required 20000 eee 5 3 Cleaning Page 2 0c eee eet eee 5 5 VACUUM sc et deseo Se n Rb Bee ILL meses ds 5 7 Drum Temperature Sensor 00200 0c e eee eee eee 5 9 Maintenance cssc erreen ee eee 5 9 iiLINXTV Solid Inkjet 100 Service Manual Cleaning Overview A CAUTION The printer should be cleaned when any of the following symptoms occur e Light stripes appear in prints e Ink smears or random streaks
209. ty Engine printing speed Solid inkjet onto plain paper Clear low medium and high density ink sticks each shape coded Selectable 409 x 409 or 600 x 600 dpi horizontal and vertical NOTE Engine printing speed measures the elapsed time from loading to ejecting the paper Print times do not includeimage processing time which varies according to image compl exity Minimum printing margins Maximum print area ii LINX Solid Inkjet 100 Service Manual Draft mode 409 x 409 dpi Approximately 12 8 sec for A or A4 size High Resolution Medical mode 600 x 600 dpi Approximately 25 sec for A or A4 size Top and bottom 5 mm 0 2 in Left and right sides 6 5 mm 0 26 in A size 8 1 x 10 5 in A4 size 200 x 284 mm A WARNING Electrical specifications Do not use extension cords of any length or gauge Primary line voltages 87 132 VAC 115 VAC nominal 174 264 VAC 220 VAC nominal Input voltage range is auto sensed Primary voltage 47 63 Hz frequency range Power consumption 200 watts standby 300 watts at idle 600 watts during printing Maximum power consumption is 1000 watts during warmup Current rating 115 VAC configuration 8 amp max 1 amp min 220 VAC configuration 4 amp max 1 amp min Fusing NOTE Fuses arenot user accessi bl e F1 DC switcher 6 3 amp slo blo F2 Drum heater 1 reservoir heater 1 ink melt chambers cap wipe purge unit 10 amp slo blo F3 J
210. umber of test cycles to run The tests run in the order they appear in the menu Depending on the test a screen may be displayed to modify how the tests run The solenoid and clutch test shown above allows you to selectively actuate a printer solenoid or clutch as well as the drum fan NOTE Sometest groups havea Choices option which allows for specification or sd ection of parameters which may influence the operation of successive test in the current test group Thesdections are lost when another test group is loaded Dr s fim bol ele Al If necessary you can highlight an individual test and press the F 1 key to display a help message that describes the test There are a few tests Sensor Test Thermal Test and Fault History that are very infomative when trying to determine the status of individual parts of the printer They are described below in more detail ii LINX Solid Inkjet 100 Service Manual Sensor Test The Sensor Test shows you the real time state of the printer s sensors You can manually test the sensors to determine if they operate correctly LEBEN c LXX 55s Troubleshooting 3 39 3 40 Thermal Test TheThermal Tests let you select start and observe the operation of the printer s heaters and determine if they are operational The test displays the real time temperature of active heaters A graphic display illustrates if the heater temperatures are within tolerance 45 1805 Froni Ube L
211. upply is functional proceed to the procedure Testing motor and solenoid resistances below If the motors and solenoids are not shorted but the power supply still does not function replace the power control board Testing Motor And Solenoid Resistances 1 Turn off the printer and disconnect the power cord 2 With a DMM set for measuring resistance test each motor s windings for correct resistance disconnected from the printer Refer to Table 3 2 Rotate the motor s drive shaft slightly while taking the measurement Table 3 2 Motor And Solenoid Resistances Motor or solenoid Resistance approx Process motor 3 ohms Y axis motor 2 ohms X axis motor 60 ohms phase Paper feed motor 1 ohms phase Maintenance Drawer Camshaft electric clutch 10 ohms Paper pick electric clutch 10 ohms Transfix cam solenoid 45 ohms Troubleshooting 3 9 Printhead Troubleshooting 3 10 NOTE TheJ amp Test Page which may be printed using the Troubleshooting front pane menu and is automatically printed after theCleaning Page contains a localized warning when printed on A4 size paper The warning message suggests that the page be reprinted on wider A size paper Thisis becausethe outer most jets are not exercised when theprint is made on A4 size media However the warning should beignored if the printer is not going to beused with A size paper The outer most jets are never used for A4 images so there is no penalty unless wider images
212. ure A 2 Imaging Parts Material Number Listings A 7 Table A 3 Paper Path Parts Item Part Number Serial Number Number Effective Discontinued 1 351 1045 00 2 351 1032 00 3 351 1046 00 4 401 0778 01 5 401 0813 01 6 650 3978 00 7 351 1047 00 351 1048 00 8 351 1035 00 9 401 0841 00 10 650 4026 00 11 386 7018 00 12 401 0781 01 13 351 1016 00 A 8 ii LINX Solid Inkjet 100 Service Manual Qty Name and Description Guide media tray right Guide pick assembly Guide media tray left Lower feed roller Paper pick roller Drum preheater assembly Upper feed assy top half with circuit bd Upper feed assembly lower half Duplex paper guide Duplex roller Upper stripper finger assembly Lower stripper finger assembly Exit roller Guide lower exit pivoting Figure A 3 Paper Path Parts Material Number Listings A 9 Table A 4 Motor and fan parts Item Part Number Serial Number Qty Name and Description Number Effective Discontinued E axis motor with gear axis drive assembly see 650 elow z rum tan gq o MrT018001 e 1 Paperpahmoo C t a m axis motor 6 A 3147 0108 1 1 BProessmotorwthencoder z ain fan Part Number Sub Part Number Qty X Axis Mechanical Kit Not available individually 650 3621 004 3879 T Shipping box i 334 7987 01 1 Tektronix white label 401 0828 00 1 Internal thread gear 401 0829 00 1 Nose cone gear 401 4598 00 1 Span yoke A 10 ji LINX Soli
213. ure Traps 1 36 Description Saved in Default NVRAM Indicates the type of interpreter yes PostScript in use at the System V configured port Interpretation of special yes None characters Indicates if multiple printfile yes On processing is allowed List of TCP IP network yes addresses for host access to printer Protocol that acts as a remote yes front panel to the printer List of address of host that yes Send no want to receive syslog messages messages The threshold indicating the yes 5 priority level of messages from the printer that will be sent to the list of log host s Allow the printer to respond to yes status queries from host resident SNMP utilities A list of hosts one for each yes None protocol which are able to receive traps If enabled the printer sends a yes Enabled trap for SNMP authentication failure ii LINX Solid Inkjet 100 Service Manual Limits or alternate choices Interpreter based Off Unrestricted Not Authorized null string List of IP addresses in the format N N N N 0 unit is no longer usable 1 messages indicating action is needed on part of system administrator 2 critical error messages 3 error message 4 warning messages 5 normal but significant message 6 informational messages 7 debugging messages Not Authorized null string None N N N N Public N N N N Proxy N N N N Private N N N N Regiona
214. urge due toa lack of vacuum Figure 3 6 Bad Purge ii LINX Solid Inkjet 100 Service Manual Figure 3 7 shows a good purge Figure 3 7 Good Purge Figure 3 8 shows a bad printhead data cable Part of the cable is separated from the connector Figure 3 8 Bad Printhead Data Cable Troubleshooting 3 19 Figure 3 9 shows the thermistor cable which connects to the driver board disconnected This can happen while installing the ink loader Figure 3 9 Thermistor Cable Unplugged Media Jams And The Paper Path 3 20 Required tools e TORX screwdriver and tips Digital multimeter J ams fall into the following four categories e Media based problems e Paper pick errors e Paper feeding errors Paper ejecting errors Media Based Problems 1 Fanning the media eliminates its tendency to double pick 2 Inspect the paper for bent torn or folded corners 3 Check to ensure no small pieces of paper arein the paper path 4 Ensure that the correct media is in the correct media tray The tray switch actuators indicates the size and thetype of media loaded in thetray the printer does not directly sense the size or type of media 5 Ensurethat only Sterling specified paper is being used ii LINX Solid Inkjet 100 Service Manual Paper Pick Errors Paper pick errors occur when the media in the media tray mispicks or the printer double picks two or more sheets of paper 1 2 Fan the media before inserti
215. use replaced but the triac shorted AC power may be applied to the heater without the printer being turned on resulting in a thermal runaway condition If the fuses are functional but the printer s power supply does not output DC voltages proceed to the topic Testing for shorted drivers Testing for Shorted Drivers 1 2 3 Turn off the printer Disconnect the 40 DC loopback connector the 4 pin connector with the two loopback wires from J 250 at the top of the power control board This isolates the Y axis motor process motor X axis motor paper feed motor vacuum pump solenoids and clutches Attach the service load connector to J 250 on the top of the power control board behind the printhead to simulate a load on the power supply When viewed from the front of the printer the lead with the ground clip should be to the right See Figure 3 10 for correct orientation Attach the service load connector s ground dip tothe printer frame Do not leave the service load connector in place and powered up for longer than 5 minutes it gets hot from the current load Troubleshooting 3 7 Warning AC voltage hazard Never attempt to plug service load connector here Service load connector Figure 3 10 Attaching Service Load Connector To J250 4 Turn on the printer If the rear panel LEDs illuminate indicating power the power control board or its loads are current limiting the power supply Goto Step 5
216. ve the cap wipe purge to the purge position and tilt the printhead forward until the upper edge of the gasket touches the faceplate If the left and right sides touch the faceplate at the same time the printhead side to side alignment is OK and the problem is with the gasket If not you ll need to readjust the printhead gap If you see streaks or smudges of wax in the jet area of the printhead s faceplate after a clean cyde Figure 3 3 the cap wipe purge wiper blade is damaged and the cap wipe purge assembly needs to be replaced Visually check the cap wipe purge wiper and gasket Move the printhead all the way back and raisethe cap wipe purge assembly Inspect the rubber wiper Figure 3 4 especially at the ends for signs of separation or damage to the blade See figure 3 5 for damage to printhead Gently probe the cap wipe purge gasket with fingers or blunt tool for signs of separation from the cap assembly Replace if defective Empty maintenance tray and check vacuum and decay time To check the cap wipe purge assembly purge performance first empty the waste tray Attach the vacuum gauge 003 1377 00 using a vacuum T 131 6819 00 at the metal pipe used to connect to the cap wipe purge assembly Perform the Clean J ets cycle from the Troubleshooting menu on the front panel Check the Peak vacuum and Decay time to determine if there is a problem with the vacuum system pump air valve or tubing or cap wipe purge gasket The
217. ved Check the hardware The head may need to be renormalized PC DEV FAULT STUCK DMC Failure to advance the drum maintenance oiling pc fault DM oil sense mechanism It has been in the new state for too long Check the hardware PC DEV FAULT DM CAM BEGIN At the start of a drum maintenance cycle when pc fault DM cam start position the DM cam position should have been at blade down web down the DM cam home sensor should have been TRUE and was instead FALSE Check DM cam solenoid clutch home sensor and related hardware 4 010 40 PC DEV FAULT DM CAM BU WU During the drum maintenance cycle when the 0x240a pc fault DM cam blade up web down DM cam position should have been at blade up web up the DM cam home sensor should have been FALSE and was instead TRUE Check DM cam solenoid clutch home sensor and related hardware 4 011 41 PC DEV FAULT DM CAM BU WD During the drum maintenance cycle when the 0x240b pc fault DM cam blade up web down DM cam position should have been at blade up web down the DM cam home sensor should have been FALSE and was instead TRUE Check DM cam solenoid clutch home sensor and related hardware 4 012 42 PC DEV FAULT DM CAM END At the end of a drum maintenance cycle when 0x240c pc fault DM cam end position the DM cam position should have been at blade down web down the DM cam home sensor should have been TRUE and was instead FALSE Check DM cam solenoid clutch h
218. view and modify certain NVRAM I O ports and peripheral parameters Using the front panel to review and change parameters is discussed in the topic Adjustments Buttons Four of the six buttons are arranged as a diamond shaped keypad The other two buttons are used as Select and Help In the Service Support menu pressing and holding the Left arrow button and then pressing the Select button enters the hidden service support menu Pressing and holding the Right arrow button and then pressing the Select button proceeds immediately to the language selection menu General Information 1 15 Pressing and holding the Left arrow while turning off the printer will confirm the printhead is correctly parked by flashing both front panel LEDs Turning the printer on with the rear panel DIP switch 2 in the down position allows access to the front panel during the warm up gde The topic Resetting NVRAM explains how to use the front panel buttons to reset the NVRAM toits factory default values Navigation buttons Power i ie m READY TO PRINT ap Error LCD Help Select Display button button 0388 10 Figure 1 11 Printer Front Panel 1 16 ji LINX Solid Inkjet 100 Service Manual Rear Panel Connectors Therear panel Figure 1 12 of the printer features the host interface connectors to the printer it includes the following connectors Standard parallel high density connector IEE
219. w Medium High and Super High The values for these densities must be within the following ranges Low 0 13 to 0 17 Medium 0 93 to 1 07 High 1 65 to 1 85 Super High 2 61 to 2 89 If calibration is not achieved do the following Check that averages were calculated correctly Check that the densitometer is calibrated and is the correct type It must be a Gretag D19C or X Rite 400B and must contain a polarizing filter Perform the following iteration If Super High failed a First check to make sure that the front panel setting for Dmax is greater than 2 75 If so proceed to the next step If not set Dmax to 3 2 reprint Service Test Print 9 and remeasure b Subtact 2 75 from the actual value measured c Add this value to Ink 3 and adjust in the Hidden Service Menu d Goto Ready Reprint Service Test Print 9 and remeasure If Low Failed a Check that Dmin I nfo9Printer Settings gt Dmin is equal toInk O If it is proceed to Step b If it is not adjust Dmin equal to Ink 0 Since Dmin has no direct knob the way to do this is to adjust Ink O down 0 01 return to Ready then adjust Ink O back up 0 01 This will cause Dmin to default to whatever Ink 0 is Proceed to Step c b If Low fails on the high side add 0 01 to Ink 0 If Low fails on the low side subtract 0 01 from Ink 0 Adjust Ink O in the Hidden Service M enu c Goto Ready Reprint Service Test Print 9 and remeasure 4
220. windings are opened shorted or far out of tolerance replace the motor If the motor s winding resistances are within specification inspect the wiring harness for nicks crimps opens or other problems If the harness is functional then replace the power control board Inspect the gear train on the inside of the printer frame look for stripped gears or broken teeth Be sureto inspect the inner teeth on the process motor gear Media Skews Passing Through The Paper Path 1 Check to see if the media is excessively curled Curled media can get mistracked in the paper path Examine the paper path ensure it is clear of obstructions Ensure that the pick roller is clean so that it picks up a sheet of media smoothly and evenly Check the upper and lower feed rollers Also make sure that the front door is properly closed ii LINX Solid Inkjet 100 Service Manual 5 Check the flexible white paper deskew springs on the inside of the front cover Ensure none are bent damaged or missing 6 Theprinter should be installed on a flat level surface Printing And Print Quality Problems Generally print problems fall intothe following six categories Streaks or lines in the prints No printing Printing too light or too dark Poor quality printing Image is offset or cut off Wrinkling Streaks Or Lines Across The Print 1 Check the Y axis belt tension If the Y axis drive is not smoothly and consistently rotating t

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