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Service Manual HP DesignJet 430 HP DesignJet 450C HP

1. 13 Perform the accuracy calibration refer to Chapter 5 TI 4 28 Service Configuration Plot The service configuration plot contains the following information DesignJet 4XX Service Configuration Plot Firmware Release X XX XX SPROC release X X Servo Processor Code revision number EEROM Contents EEROM CONTENTS This is for the Printer design engineers to interpret NOTE All EEPROM Parameters are since last EEROM Reset Number of Power Cycles 19 Number of Color Plots 13 Number of Black Plots 15 Number of Pens 7666 Factory Spittoon 0 used Number of Bail Errors 0 Number of System Errors 2 Last System Error 0x00000550 errno 0x3c0001 Last System Error at file media_load c line 2810 Bench Run Bench Run Maximum Y Axis Carriage Axis PWM Bench Run Maximum X Axis Media Axis PWM 87 Encoder Tests Maximum Y Axis Carriage Axis PWM 62 Encoder Tests Maximum X Axis Media Axis PWM 62 X axis Calibration Amp1 7 467 Phase1 0 450 Amp2 8 956 Phase2 2 325 Factor 0 000500 Service Tests HP DesignJet 430 450C and 455CA Printers 4 29 Printing the Service Configuration Plot To print the service configuration plot 1 In service mode 2 load a sheet in portrait orientation In normal mode load a sheet in portrait orientation The service configuration plot can be plotted without the need to enter the service mode This is because the customer will be requested to plot
2. page 4 23 This tests the operation of the bail system Service Station and the Y axis by engaging and disengaging the bail lift mechanism and capping uncapping the cartridges 11 Electrical Test b page 4 24 This tests the operation of some of the electrical components of the electronics module 12 Servo Encoder Test page 4 25 The servo encoder test performs the following e Media axis encoder test Verifies the operation of the servo loop media axis feedback e Carriage axis encoder test Verifies the operation of the servo loop carriage axis feedback e Records the maximum friction detected in the EEROM You can view this information on the service configuration plot 13 Service Monitor p page 4 26 The service monitor is useful to find out why the Printer is not plotting what you expect it to plot It enables you to read the graphics language instructions that the Printer is receiving from the computer Instead of plotting the drawing that you send the Printer prints the beginning and end of the code that would otherwise have been used to plot the drawing 14 EEROM Model ID Configuration Procedure p page 4 27 This procedure is necessary if the Printer needs to be reconfigured as a DesignJet 480 450C or 455CA 15 Service Configuration Plot page 4 29 Gives a service report of the Printer 16 Clearing the EEROM p page 4 32 Instructions on how to clear the EEROM Service Tests HP DesignJet 430 450C
3. Service Manual HP DesignJet 430 HP DesignJet 450C HP DesignJet 455CA Printers Using this Manual Purpose This manual contains information necessary to test calibrate and service e HP DesignJet 430 printers models C4718A and 4714A e HP DesignJet 450C printers models C4715A and 4716A e HP DesignJet 455CA printers models C6080A and C6081A For information about using these printers refer to the corresponding user and quick reference guides Readership The procedures described in this manual are to be performed by HP certified service personnel only Part Numbers Part numbers for plotter options accessories and service parts are located in chapter 7 Conventions This manual contains information for the color HP DesignJet 430 450C and 455CA printers A small arrow p is used to indicate other parts of the Service Manual or User s Guide where you can find information related to the topic you are consulting ii Using this Manual HP DesignJet 430 450C and 455CA Printers Contents Using this Mamita 43sni0s215 taeeknecanedes anaE a a E E eE a ii Safety Symbols sosro terseret ni haha edhe cake aie e a a dade hanes x 1 Troubleshooting Is the Printer Using the Latest Firmware Revision 0 0005 1 2 Important Information 1 04 hs 0k 4505 oecnkakd Babee R Ree KERR KEES ERR eee 1 2 What Can I do when a System Error Code Appears on the Front Pamel Display gc vid 2dns ade d
4. cece eee eens 5 5 To check the carriage to media distance 00 c cece eee eee ees 5 5 To adjust the carriage to media distance 0 cece ee eee ees 5 7 iv Contents HP DesignJet 430 450C and 455CA Printers 6 Image Quality Print Quality Troubleshooting Checklist 2 s 5 de oc0e dws deen Sesed ands 6 2 Print Quality Pl t s2 uy 245saes Rove eine verdes anneau e een E ESEESE 6 3 Tntrod cton sgeime rer det MERETE seh eecats Mikel E E T EARE 6 3 Using the Print Quality Plot s ci0s20 04s ececveacteoeeressiedaaekeuss 6 3 Printing the Print Quality Plot iec sscecsercrecreecsrcsrestrecs rrura 6 3 Analyzing the Print Quality Plot 12 2c sciank sawed neaeaenreeemnw dans 6 5 Test Pattern 1 Cartridge Warm up 45 015 de0s4 oda dee vieaSetecatbeess 6 5 Test Pattern 2 Nozzle Print Test io s lt cseueieks sex cebaedesdtexne seeds 6 5 Test Pattern 3 Vertical Line Straightness Test 0 0 c eee eee 6 7 Test Pattern 4 Color Alignment Quality Test 00 cee eens 6 9 Test Pattern 5 Color Variation Test lt 0dscesscesedduatenetancescess 6 11 Test Pattern 6 Banding Test 22 0 25462cc0csescecensaandnatacenaa ana 6 12 No Printing Defects Found in the Print Quality Plot 6 15 Media secere eine ary Ean tek hoes heehee eee E EE ss 6 15 Print Quality Defects Troubleshooting 0 c cee cee eee eens 6 16 Starwheel Marks oss01 52 20 ceeassesesevetetvasectorthvavanndeeewes
5. 450C and 455CA Printers Parts and Diagrams Figure 11 Entry Platen Drive Roller Bail and Overdrive Assembly Parts and Diagrams HP DesignJet 430 450C and 455CA Printers 7 23 Printer Labels Reference HP Part Number Quantity Description peas 1 5961 3524 1 Serial Label Right End Cover 2 C3178 00030 1 Carriage Label DesignJets 450C and 450CA C4701 00009 1 Carriage Label DesignJets 430 3 C3190 40052 1 Quick Reference Guide Holder 4 C4713 00013 1 Nameplate DesignJets 430 C4715 00013 1 Nameplate DesignJets 450C C6080 00001 1 Nameplate DesignJets 455CA 5 C4705 00017 1 Cartridge Insertion Label Left End Cover 7 24 HP DesignJet 430 450C and 455CA Printers Parts and Diagrams Users Puide and Quick Reference Puide Bundle HP Part Number C4713 60041 C4713 60042 C4713 60043 C4713 60044 C4713 60045 C4713 60046 C4713 60047 C4713 60048 C4713 60049 C4713 60050 HP Part Number C4715 60041 C4715 60042 C4715 60043 C4715 60044 C4715 60045 C4715 60046 C4715 60047 C4715 60048 C4715 60049 C4715 60050 Description English Manual Bundle Korean Manual Bundle Taiwanese Manual Bundle German Manual Bundle French Manual Bundle Spanish Manual Bundle Italian Manual Bundle Japanese Manual Bundle Portuguese Manual Bundle Chinese Manual Bundle Nront Panel Overlays Description English Front Panel Overlay Korean Front Panel Overlay Taiwanese Front Panel Overlay German Front Panel Overlay French Fro
6. 92 pwm Test Mode X Axis Cycle 65 pwm Test Mode X Axis Cycle 66 pwm 4 If there is a shutdown the Glossy LED LED J will start to flash after the first cycle If you are viewing information via the serial port you will see output similar to the following 3 X AXIS TEST Test Mode X Axis Cycle 79 pwm Test Mode X Axis Cycle 115 pwm Test Mode X Axis Cycle 127 pwm Test Mode Error 1 on X axis test 5 The test continuously repeats itself until you press the Cancel and Media Source keys The test is continued on the next page 4 16 HP DesignJet 430 450C and 455CA Printers Service Tests If the test fails to resolve the problem try one of the following 1 Switch OFF the Printer and manually moving the carriage along the slider rod check for obstacle or friction in the X axis 2 Check for a faulty or badly connected X axis Encoder Cable 3 Replace media motor page 8 23 4 Replace electronics module page 8 13 Only replace one component at a time and perform the test again before replacing another component Using this procedure you will be able to determine exactly which component failed Service Tests HP DesignJet 430 450C and 455CA Printers 4 17 Bench Run The bench run is a routine that each Printer performs before it leaves the manufacturing site It attempts to filter out Printers that could have an early breakdown due to a fault in manufacturing The bench run tests the o
7. Producing an Image Print Mode Characteristics Note that the firmware can recognize from the plot data whether a plot is color or monochrome You do not set this parameter on the front panel Functional Overview HP DesignJet 430 450C and 455CA Printers 10 5 Servicing the Cartridges Service Station e The service station is easy to access and remove and is replaceable as one unit e The absence of a drop detector implies a different cartridge maintenance algorithm to guarantee correct nozzle conditions The Printer warms the nozzles and spits ink e Before each plot e After each cartridge change e While printing depending on cartridge humidity temperature and plot ink density e The ventilation holes which were located on the service station sled on the DesignJet 650C are now located on the ink separator to prevent them from becoming clogged Spittoon A single redesigned spittoon is located on the right side of the Printer Primer The Printers feature a manual primer based on that of the DeskJet 1200 instead of the automatic one of the DesignJet 650C e A bellows assembly provides a vacuum to suck ink from the nozzles The suction tubes have a wider diameter than those of the DesignJet 650C to help prevent clogging e An ink separator isolates the bellows from the cartridges preventing ink contamination of the bellows Although the primers for the DesignJets 430 450C and 455CA and DesignJets 230 a
8. the service configuration plot and he will be given the following instructions to plot it without entering the service mode 2 When the Ready LED lights up press the Print Quality and Media Type keys 3 The Ready light begins to flash and then remains on steady The Printer plots the service configuration plot and ejects the media 4 Unload the media Interpreting the Service Configuration Plot The parameters on the Service Configuration Plot can help you to troubleshoot the Printer more effectively Here is a short description of the all the parameters Number of Power Cycles How many times the Printer has been powered ON Number of Color Plots How many color plots have been produced since the EEROM was last erased Number of Black Plots How many mono plots have been produced since the EEROM was last erased 4 30 HP DesignJet 430 450C and 455CA Printers Service Tests Number of Pens The number of times each cartridge has been replaced The numbers refer to from left to right Cyan Magenta Yellow Black Factory Spittoon The estimated level of ink in the spittoon This level will be incorrect if the EEROM has been cleared Number of Bail Errors How many shutdowns there have been because of the Bail life mechanism Number of System Errors How many System Errors have occurred Last System Error The last System error that occurred This information might be requested in the event of an escalation
9. 4 21 Service Mod 2 esrssrrrusezips streer E TOP ESPE UNEREN EEE EEEE TEN cease ces 4 22 Stopping Aa Testeo else eegneeeeenhwGeeht ASEA AE a E a EREE 4 22 Entering Service Mode 2 0 ccc ccc ent nett e een enes 4 22 Bail Test 222 cideiwenaccheancnbimkgh dd pees onde canee eeauenediawdaares 4 23 Electrical Test ecri ncnds whe danr aces tekehen be E nw eet ane E 4 24 D rv Encoder Test eck serreiersdegr sepana dead eds tides Chad ENSE 4 25 Service Monitor Data Display 5 cave cae sx ds civduewscee cede vems deeenes 4 26 EEROM Model ID Configuration Procedure ccc eee eens 4 27 Service Configuration Plates s 1 020ev01et kone studerer reat irtee arki deae s 4 29 Printing the Service Configuration Plot 0 ccc cee cee eens 4 30 Interpreting the Service Configuration Plot 2 00 eee eee 4 30 Clearing the HE ROM 6 04430 eseeachaa a oe does ees dan eae eee TE ed woe E 4 32 5 Service Calibrations Accuracy Colbranon ecssse seene pone sen cee deen pend hares de ceeadendd 5 2 PUPPOSE cacce dake derne iipei tianara Ra dese ORRE een L vee Rede Re 5 2 What is the End Point Accuracy Specification 0 0 c eee eee 5 2 What can Affect the End Point Accuracy 00 cece cece eens 5 2 Before Performing the Accuracy Calibration 0c cece eee 5 3 Performing the Accuracy Calibration 0 c cece cee eens 5 3 Adjusting the Carriage to Media Distance 0
10. HP media and after the Print Quality Plot test the same quality problems appear advise the customer to use genuine HP media Repeat the Print Quality Plot test using genuine HP Media Printing the Print Quality Plot 1 Before printing the plot in Normal mode set the Media Type and Print Quality on the front panel to the settings that you want to test 2 Load a sheet of media in portrait orientation 3 When the Ready LED lights up press the Form Feed and Media Source keys together The Ready light begins to flash and the media moves slightly forward The carriage moves to the right side of the Printer and the fan turns on The Printer plots the print quality plot and ejects the media 4 Unload the media Print Quality HP DesignJet 430 450C and 455CA Printers 6 3 Print Quality Plot The print quality plot for the HP DesignJet 430 450C 455CA is represented below Use a 10X magnifier to help identify plot quality problems Tew 1 iG Print dS Rev La Ten 2 Test 6 6 4 HP DesignJet 430 450C and 455CA Printers Print Quality Analyzing the Print Quality Plot The Print Quality Plot will contain six patterns as follows 1 Cartridge Warm Up See below 2 Nozzle Print Test See below 3 Vertical Line Straightness Test page 6 7 4 Color Alignment Quality Test page 6 9 5 Color Variation Test page 6 11 6 Banding Test page 6 12 Test Pattern 1 Cartridge Warm up This pattern warms up
11. In order to understand the meaning of each combination of lights you should check the table in this chapter to help you to understand the meaning You will therefore find this table useful in troubleshooting Key to table starting below The fifteen lights on the printer s front J e e o panel The sequence of explanations in o e the table is e e E 2 e amp e Statuse Error e e Group group e quali Q Do e aS group group group J This light is ON and STEADY 3 This light is ON and FLASHING This light is OFF or this is the relevant light The state of this light is not relevant Lights Explanation and Action No lights All lights off If no lights are on you may have a power problem or the printer may be switched g S off e o 3 2 HP DesignJet 430 450C and 455CA Printers User Messages Lights Explanation and Action Status group READY light off The printer is not ready to print J e Check the state of the other lights and e e look them up in this table e e e e READY e The printer is ready to print J J e Send your print from your computer or e e for a special internal print press the o o appropriate key combination e e e aaa The printer is busy with a task or is m receiving a file e e Wait A PAPER o lf combined with one of the four media e o type group ligh
12. LEDs KLM should light up as you short circuit the two pins 6 Once you have short circuited the two pins the Fast Normal and Best LEDs LEDs ABC should light up again 7 Press the Cancel and Media Source keys together to exit the deconfiguration mode The instructions are continued on the next page Service Tests HP DesignJet 430 450C and 455CA Printers 4 97 8 Configure the Printer with the correct model ID as follows Only one opportunity is given to perform this procedure and there is no indication that it was successful If the Printer is to be configured as a DesignJet 450C Color Printer hold the Media Source key down and press the two Color Configuration Print Quality Media Type keys at the same time If the Printer is to be configured as a DesignJet 430 Monochrome Printer hold the Media Source key down and press the two Mono Configuration Print Quality Setup keys at the same time If the Printer is to be configured as a DesignJet 455CA LFP Printer hold the Media Source key down and press the two LFP Configuration Print Quality Reprint keys at the same time lc ZIF PEM MIT HEFAHT CANOE OSTAS BEAD O eo CARE Loan NEDA Gp Hr designer asoc FAST MEMS TIPE HAL PAPE ROLL pees ar Ha gt HF DesignJet 430 Ley L a Le gt HP DesignJet 4550A O NEMATE Maret SOURCE ar 9 Turn the Printer OFE 10 Reconnect the media motor encoder cable to the main PCA connector ENC X 11 Turn the Printe
13. Loading 1 Check that the Media Sensor is installed correctly 2 Check if the cable for the Media Sensor is connected correctly 3 Check if the Pincharms are down the Pincharm lever should be up 4 If the media is continuously rejected during the media edge check then make sure that the Line Sensor is installed correctly If necessary perform the Carriage Test page 4 12 5 Make sure the line sensor is calibrated Perform the Accuracy Calibration page 5 2 6 Replace the Media Sensor part of the overdrive assembly page 8 50 7 Replace the Carriage Assembly page 8 37 Only replace one component at a time and check if the problem has been solved before replacing another component Using this procedure you will be able to determine exactly which component failed What can I do if the Printer has problems with the Cutter 1 Ifthe Carriage Assembly has problems picking up the Cutter e Check that the cable for the Front Panel Assembly is is not loose and is routed correctly in the cover clips A loose cable can be trapped by the Cutter preventing the Cutter from moving e Make sure that the Spittoon Assembly is correctly installed and is aligned with the Overdrive Assembly If the Spittoon is loose or mispositioned the cutter will have problems parking in the right cover 2 Ifthe media crashes when moving the Cutter e Make sure that there is no media trapped inside the Cutter mechanism Remove the Cutter to inspect
14. Z SLIS A N Nigune 2 pPmntemSuppont Parts and Diagrams HP DesignJet 430 450C and 455CA Printers T 5 Figure 3 Rollfeed Assembly Reference HP Part Number Quantity Description on Drawing 1 C4717 60004 1 Rollfeed Hardware Kit 2 C4717A 1 Rollfeed Assembly D A1 size Includes Spindle Hardware kit and Hubs C4719A 1 Rollfeed Assembly E A0 size Includes Spindle Hardware kit and Hubs 3 C4717 60003 1 Spindle D A1 size C4719 60003 1 Spindle E A0 size 4 C4717 40017 2 Spindle Hub C4713 60120 1 Spindle Hub Kit for Chinese Spindles only 5 C4713 60038 1 Extensions Kit Assembly 7 6 HP DesignJet 430 450C and 455CA Printers Parts and Diagrams Figure 3 Rollfeed Assembly Parts and Diagrams HP DesignJet 430 450C and 455CA Printers Figure 4 Covers Reference HP Part Number Quantity Description ji ee 1 C4713 60014 1 Top Cover D A1 size C4714 60014 1 Top Cover E A0 size 2 C4713 40029 1 Left End Cover 3 C4713 40046 1 Switch Button 4 C4713 60030 1 Right End Cover 5 C4713 60097 1 Back Cover D A1 size C4714 60097 1 Back Cover E A0 size 6 0515 2246 2 Screw Torx M3 T C4699 60072 1 Cable Cip Assembly 8 C4713 00011 1 SIMM Cover Plate 9 See Page 7 26 1 RAM SIMM 10 C4713 60125 1 ROM SIMM Version A 01 03 7 8 HP DesignJet 430 450C and 455CA Printers Parts and Diagrams Figure 4 Covers Parts and Diagrams HP DesignJet 430 450C and 455CA Printers 7 9 Figure 5 Front Panel Sp
15. een een errre 8 44 Reinstalling the Drive Roller 0 0 ccc cece ccc ete teen nee 8 45 Removing the Pinch Arm Lift Mechanism 0 c cece eee eee 8 47 Removing the Overdrive Assembly including the Overdrive Roller Media Separator Media Deflectors and Media Sensor 0005 8 50 Removing the Entry Platen lt 00654 60006044 s004 cee sndas bed nedeactaceuaan 8 52 9 Preventive Maintenance Moisture on Printer 0 cece NEEE EERE enn RERE EIA 9 2 Level of Printer Usage o 5c406600 bene eee bed dba Pada bee weds ee Rere es 9 2 Friction on Slider Rod seis thie cee anaes den dey Sako e hse ken dnwac canteens 9 2 Noisy Carriage Wheel sconces duns Peden deed nds cadneee apae onian tiei tastaia 9 2 Ink Spline nosh doc eceuenes beeen nechiasearewrhwagnee beet e daa 9 3 Belt Swelling eserse esimus te bee o ie de gna mea blac dene E ES 9 3 Cleaning the Printer ocsscreisisccrerinesiesiset aian a Leen eee aes 9 4 General Cleaning sre is capeee ee da wie ses ERENER EEEE ERE nee neues bh 9 4 Cleaning the Drive Roller 0 cc ccc cc ccc ce ete ence etn ens 9 4 vi Contents HP DesignJet 430 450C and 455CA Printers 10 Functional Overview Introduction 275 c2os eas 2 s ca diene bbe oe gk oes ban ada TE EO EOE NANNE 10 2 Roll Me did cite ern eVeuncaee nnen hen eeet eee eek ea ere sn ESEESE ewes 10 2 Removing Static Charge from the Media 00 ccc ccc e eee 10 2 Gripping
16. into the Printer in the direction indicated by the arrows on the calibration plot see Figure 2 The Ready LED begins to flash The Printer takes less than 10 minutes to read the calibration sheet calculate the calibration data save the data in the EEROM and eject the sheet 9 Unload the sheet Service Calibrations HP DesignJet 430 450C and 455CA Printers 5 3 Figure 1 Figure 2 u utbet tt bo dod 5 4 HP DesignJet 430 450C and 455CA Printers Service Calibrations Adjusting the Carriage to Media Distance It is very important that the distance between the carriage and the media is within certain limits If the distance between the cartridge nozzles and the media is too small ink smears on the media If the distance is too big unwanted spray appears around the ink dots and vertical lines are not straight A big distance may also prevent the carriage from actuating the bail lever Whenever you remove the Drive Roller or the Cartridge Carriage take care to reinstall them correctly Incorrect installation may result in the carriage being too close or too far from the media For the correct installation procedure Chapter 8 To check the carriage to media distance A Gauge included with the carriage assembly has been produced to check the carriage to media distance to make sure it is within the tolerances allowed Use this gauge to check the carriage to media distance as follows 1 Open the to
17. it correctly e Remove the Cutter and make sure that both rotary blades are touching each other by the flat sides and not the sloping sides If the rotary blades are touching each other by the sloping sides you must reseat them e Ifthe Printer is placed on a table it must be placed as close to the edge as possible to make sure that the media that is coming out falls correctly If the Printer is in the middle of the table the media that is coming out will be lifted up causing the cutter to crash into it Troubleshooting HP DesignJet 430 450C and 455CA Printers 1 7 What can I do if the Bail Mechanism Fails 1 2 EEROM Errors Obstructions Check that there are no obstructions in the way of the Bail Assembly Wearing of parts The cam gear and engaging gear may not make correct contact with the left drive roller gear even though the carriage is actuating the engaging lever This can happen due to excessive wearing of parts Another problem may be that the bail cable has broken Carriage motor control The carriage may not properly locate the engagement lever preventing the gears from engaging Any problems with the carriage motor control system for example the encoder strip or associated mechanics could cause this problem Also if the carriage cannot find the true left stop during initialization caused by interference the engaging lever cannot be located Bail cam The bail may fall from the up position This can ha
18. operation of the FIBIS Column address and the shuffler THIS TEST HAS BEEN FOUND TO BE VERY UNSTABLE DUE TO SOME INTERACTIONS BETWEEN SOME OF THE COMPONENTS OF THE ELECTRONICS MODULE IT IS SOMETIMES IMPOSSIBLE TO EXIT THIS TEST WITHOUT SWITCHING OFF THE PRINTER Perform the Electronics test as follows 1 In service mode 1 press Electronics Test Media Source and Reprint Keys 2 The test will start and all the LEDs will turn OFF There will be no movement in the Printer and you must wait for the Front Panel to indicate if the test has passed or failed 3 Ifthe test passes the Sheet LED LED O will light up 4 If the test fails the Sheet LED LED O will start to flash 5 The test continuously repeats itself until you press the Cancel and Media Source keys If the test fails try replacing the following component 1 Electronics Module page 8 13 Service Tests HP DesignJet 430 450C and 455CA Printers 4 21 Service Mode 2 Service Mode 2 contains tests that do need a complete initialization of the Printer This means if there is a system error in normal mode it is NOT possible to enter into Service Mode 2 If possible try entering into Service Mode 1 and performing the tests there The tests in service mode 2 DO NOT send test information to the printer s serial port For some of the tests you will need to print the Service Configuration Plot Details page 4 29 in order to check the results Stopping a T
19. printer should be used Use of non HP media or HP media not certified for the the printer may significantly reduce the color and print quality of the required images For details of HP media refer to the User s Guide or the Media Guide To have accurate colors the media settings must match the type of media loaded in the printer If the customer is using non HP media with HP drivers the colors in the required print may not be accurate Advise the customer to use HP media if they want to improve the accuracy of the colors Print Quality HP DesignJet 430 450C and 455CA Printers 6 15 Print Quality Defects Troubleshooting STARWHEEL MARKS On some drawings for example CAD drawings having a thick lined frame around them on some types of media you may notice some small marks made by the starwheels These cannot be avoided UNEVEN FILL DENSITY Symptoms Blotchy area fills Product Fault e An incorrect media type setting has been selected on the front panel and does not correspond to the media being used Media Fault The ink is incompatible with the media and does not spread uniformly through the area fill Solutions One or both of the following actions may be appropriate to solve an uneven fill density problem Change the media type setting on the front panel Use a more suitable media type Replace the faulty cartridge s If the problem is occurring in black area fills on color plots printed in Normal
20. the cartridges leaving them in a perfect operating condition You can ignore this pattern and continue with Test Pattern 2 Test Pattern 2 Nozzle Print Test In this test all the 96 nozzles of each cartridge are tested For each of the 4 colors you will see the numbers 1 to 90 over the diagonally stepped lines in increments of 5 These numbers correspond to the nozzle number that prints each step There are two cartridge nozzle errors see Figure 1 e Nozzles not printing e Nozzles misdirected CORRECT ee 35 Nozzle 20 Nozzle 70 Misdirected Weak INCORRECT Figure 1 Print Quality HP DesignJet 430 450C and 455CA Printers 6 5 Nozzles not printing Nozzles Out 1 Ifthe diagonally stepped lines are broken in one or more steps it indicates that this specific nozzle s may be blocked and are not printing Nozzles misdirected If all the stepped lines are visible in the pattern then all the cartridge nozzles are printing However the nozzles could still be misdirected possibly due to some dried ink around the nozzles 1 In the top pattern marked with numbers if the diagonally stepped lines are not equally positioned in every step it indicates that this specific nozzle s may be misdirected Nozzles Problem 1 Nozzles Problem 2 Corrective Action Some cartridge nozzles in any one color are not printing Cartridge nozzles are misdirected in any one color Try the following steps 1 Prim
21. 0C and 455CA Printers 2 1 System Error Codes If you have an error code which is not documented in this Service Manual or you have an error which you cannot resolve then report the error to the HP Response Center or the nearest HP Support Office When reporting the error have the following information ready Model and Serial Number of the printer Which firmware revision the printer is using The complete error number The Service Print Utilities Service Tests The Current configuration sheet Which software application the customer is using name version etc Is the problem reproducible by you Additional comments about the usage the setting etc Important Information on Troubleshooting Error Codes Before spending time troubleshooting the problem by doing the various tests or replacing parts which may not need replacing check which firmware revision the printer is using or check if a service note deals with this particular problem Some problems which occurred in earlier firmware releases may have been solved in later revisions So if there is a new firmware revision then update the ROM SIMM before replacing any parts Refer to Chapter 7 for the part number of the ROM SIMM 2 2 HP DesignJet 430 450C and 455CA Printers System Error Codes SETUP FORM FEED REPRINT CANCEL STATUS DO READY ERROR KO CARTRIDGES GROUP GROUP ALIGN MEDIA LO DATA FO LOAD MEDIA MO MEDIA AO FAST GO PAPER BO NORMAL HO F
22. E NE EA ede ERE ASR 10 6 SPIOON serret TE EEEE E r E E E R E Rs O a T 10 6 Primer 664 sored twee beh pe ar eE ee ghee aie E 10 6 Ele ctroni s M du le seriissesrredteciniisr ree eirean e rare RSN EEE EEE 10 7 DENSOS eaaa a eaa a e aa a ae e a a a a E A E 10 7 ROM wevcseeceivebechevarawtetenweseeicetheneds E E E EE 10 7 BAM gcic0cagaivnseidiweiehndas EEE ERF edeeohne EAP ESI ORRE REEE E EE 10 7 EEROM eenen e hdc Somes Hea a a a a Admease aA 10 7 Inp t Output Interfaces 12 jcens ohetdusndeteexeiaee EE ENEN 10 8 Bi TONICS se rcrerre cirein ange dard sirake dd be EREE EEr hed a es 10 8 RS 232 0 ostos irae E E AREENA ENEO AREARE ES DNES TERATE AKER ERNES 10 8 Power QUOD sdrenrenisentin td ern A a a aE 10 8 Water Condensation cca00 nies dditedecabadean dowel eekendadaacmeaae 10 8 Memory USage occas tanl Eraro sale tie ntwe te oedan Ree eae daa E RA 10 9 Plot OrienGariOt 2 4 44 co cte verses wend bese deed E e eae neds 10 9 Raster Image Processor 0 cece cece tenet nent nent nenens 10 9 HP DesignJet 430 450C and 455CA Printers Contents vii General Definition of Safety Symbols 2 WARNING X CAUTION International caution symbol refer to manual the product is marked with this symbol when it is necessary for the user to refer to the instruction manual in order to protect against damage to the instrument Indicates dangerous voltage terminals fed from the interior by voltage exceeding 1000 volts
23. EEROM unless you press the Cancel and Media Source keys 4 If the test passes the Best LED LED C will light up after the first cycle 5 If there is a shutdown in the Y axis the Best LED LED C will start to flash 6 Ifthe Printer does not raise the Bail Assembly then the test has failed If the bail fails the test try replacing the following component 1 Bail lift mechanism page 8 28 4 8 HP DesignJet 430 450C and 455CA Printers Service Tests Front Panel Test The purpose of this test is to verify the operation of the front panel keys and LEDs Perform the Front Panel test as follows 1 In service mode 1 press Front Panel Test Form Feed Key If you are viewing information via the serial port you will see output similar to the following 1 Front Panel Test This message only informs you that the test has started and a message will not appear if the test passes or fails 2 The test will start and all the LEDs will flash for 2 seconds after which they will all be turned OFF Check that all LEDs are functioning correctly when they flash 3 To check that the front panel keys function correctly press them one by one Each time a key is pressed the Coated LED LED PD will be lit 4 Ifa key is not functioning the Coated LED LED I will remain OFF 5 The test continuously repeats itself until you press the Cancel and Media Source keys If the test fails to resolve the problem try one of th
24. HP DesignJet 430 450C and 455CA Printers 7 17 Figure 9 Bail and Overdrive Mechanisms Reference HP Part Number Quantity Description jeene 1 C3190 60132 1 Pulley Assembly 2 C3190 40022 1 Engaging Lever 3 0515 1743 2 Screw M4 x 10 Tap T20 4 2 Washer Included with Item 3 5 0515 2200 1 Screw M3 x 8 Tap T10 6 1 Washer Included with Item 5 T 07575 80012 1 Gear Support Spring 8 C4713 40016 1 Engaging Lever Support 9 0624 0617 1 Screw 6 9 937 Plast T15 10 C3190 40019 1 Cam Gear 11 0624 0745 1 Screw 12 3050 0026 1 Washer 13 C1633 40027 1 Engaging Gear 14 C3190 40020 1 Bail Lift Cam 15 C3190 60007 1 Bail Cable 16 C3190 80013 1 Cable Spring 17 C3190 40021 1 Gear Support 18 C2847 20017 1 Shoulder Screw 19 C1633 40019 1 Overdrive Gear 20 0515 0083 1 Ring Net 250 OD 21 C3190 60131 1 Clutch Assembly 22 C4713 40030 1 Sideplate Bushing 7 18 HP DesignJet 430 450C and 455CA Printers Parts and Diagrams Figure 9 Bail and Overdrive Mechanisms Parts and Diagrams HP DesignJet 430 450C and 455CA Printers 7 19 Figure 10 Pincharm Assembly Reference HP Part Number Quantity Description Deas 1 0624 0771 1 Screw M8 x 30 Mach T10 2 C47138 40025 1 Pincharm Lever 3 0515 2282 1 Screw 4 1 Washer Included with Item 3 5 C4713 60034 1 Pincharm Sensor Assembly 6 C4713 80003 1 Pincharm Mechanical Spring T C4713 60116 1 Right Cam Journal Assembly 8 C3190 60149 1 Left Cam Journal Assembly 9 C2847 20005 1 Pincharm Ba
25. ILM CO BEST IO coatep J O cossy PRINT QUALITY MEDIA TYPE MEDIA SOURCE LED Symbols LED Letters LED Code Examples o Off Flashing KLM LEDs K L and M are flashing On Steady Steady DEL LEDs D E and L are on System Error codes The following pages contain the possible error codes and the instructions necessary to solve the problem System Error Codes HP DesignJet 430 450C and 455CA Printers 2 3 Error Codes for the HP DesignJet 430 450C and 455CA Printers Steady DK Steady DL Cartridges Data Media An error which the customer could probably solve like a paper jam minor cartridge problem etc In order to get more information on the error the CANCEL key must be pressed which will display a Subcode Use the error codes below to find information on the subcode Cartridges Data Media This error code indicates a severe problem which will require a Service Engineer to troubleshoot In order to get more information on the error the CANCEL key must be pressed which will display a Subcode Use the error codes below to find information on the subcode Ready Cartridges The RAM SIMM test failed Possible causes e RAM SIMM installed is not an original HP supported part e RAM SIMM badly connected e Faulty RAM SIMM e Faulty electronics module Ready Data Cartridge Continuity Test Failure Possible causes e Cartridges faulty or badly seated Faulty or b
26. Jet 430 450C and 455CA Printers 6 9 ooo HORIZONTAL FRR 43me CORRECT i z IHCORREET Figure 5 _______ HORIZONTAL FRra sS 357M CORRECT INCORRECT Figure 6 Alignment Problem Third color present misalignment in either the boxes or circles of the test image see Figures 5 amp 6 Corrective Action Try the following steps 1 Perform the Cartridge Alignment Calibration Details Users Guide using genuine HP media then print the Print Quality Plot again to see if there has been any improvement 2 Ifthe error is still present replace the failing cartridge and print the Print Quality Plot again 6 10 HP DesignJet 430 450C and 455CA Printers Print Quality 3 Ifthe problem continues perform the Accuracy Calibration Details page 5 2 and print the Print Quality Plot again to see if there has been any improvement 4 If the error continues try the following e Replace the Trailing Cable page 8 8 e Replace the Carriage Assembly p page 8 37 e Replace the X axis Assembly page 8 23 Only replace one component at a time and check if the problem has gone before replacing another component Using this procedure you will be able to determine exactly which component failed Test Pattern 5 Color Variation Test This test produces four boxes black blue cyan and yellow In each box there are two horizontal bands the lower band is 100 shade the
27. Movement Error Possible causes Something is causing excessive friction in the Y axis carriage axis The carriage touches the bail as it moves System Error Codes HP DesignJet 430 450C and 455CA Printers 2 9 Ready Load Media Media Error in X axis encoder quadrature Possible causes e Incorrect routing of the motor cables Electrical noise in motors o e Faulty motor encoder Motor received an electrostatic discharge while operating Align Media Load Media Media Error in Y axis encoder quadrature Possible causes Damaged or broken encoder strip Faulty or badly connected trailing cable Steady EFM Incorrect routing of the motor cables Electrical noise in motors Faulty motor encoder Trailing Cable received an electrostatic discharge while the Printer was operating Replace the Trailing Cable page 8 8 Align Media Data Cartridge Alignment Error Possible causes e Faulty Cartridges Dirty or incorrect media Faulty Line Sensor Faulty Carriage Assembly Faulty Electronics Module Steady EL 2 10 HP DesignJet 430 450C and 455CA Printers System Error Codes User Messages HP DesignJet 430 450C and 455CA Printers 3 1 User Messages The lights on the front panel provide the means for your day to day communication with the printer They tell you the printer s current status and if there is an error the nature of the error
28. PWM of both axis will be saved in the EEROM 3 To view the results of the test you must print the Service Configuration Plot Print Quality and Media Type keys 4 Ifthe test fails an error code will appear on the front panel Refer to Chapter 2 in order to correctly troubleshoot the failure Service Tests HP DesignJet 430 450C and 455CA Printers 4 25 Service Monitor Data Display The service monitor is useful to find out why the Printer is not plotting what you expect it to plot It enables you to read the graphics language instructions that the Printer is receiving from the computer Instead of plotting the drawing that you send the Printer prints the beginning and end of the code that would otherwise have been used to plot the drawing You need a basic knowledge of the graphics language instructions to be able to pick out the important information from the printed code Perform the Service Monitor as follows 1 In service mode 2 load a sheet of media A8 size or B size minimum in portrait orientation 2 Press Service Monitor Media Type and Media Source Keys 3 Send the file from the computer through the serial or parallel ports The Ready LED begins to flash 4 Wait until the computer has indicated that it has sent the file The Ready LED continues to flash 5 While the Ready LED is flashing press Service Monitor Media Type and Media Source Keys again The Ready LED continues to flash After a minute
29. Service Manual part number C3187 90000 Information on the DesignJet 650C HP C2858B C2859B DesignJet 650C Service Manual part number C2858 90000 Rev B Roll Media When a roll feed assembly is installed on the Printer roll media can be used The roll feed assembly consists of e Two roll feed components e A spindle e Two media stops The roll feed assembly is installed below the sheet media entry path to allow the ease of loading for sheet media When roll media is loaded into the Printer it is passed around a diverter roll which optimizes the infeed path to the Printer Once a plot print is completed a built in cutter automatically slides across the paper to cut the plot print from the roll Removing Static Charge from the Media An anti static brush located under the entry platen prevents static charge from building up on the media A charge can cause the media to stick to itself and jam the Printer 10 2 HP DesignJet 430 450C and 455CA Printers Functional Overview Gripping the Media When you load the media it is gripped by the pinch arms Pinch Arm Sensor The pinch arm sensor is a switch sensor that is attached to the Printer Chassis It detects the position of the pinch arm lever Linkage attaching the lever to a cam causes the cam to release the switch as the pinch arms are raised The pinch arm sensor is electrically connected to the main PCA Providing a Force on Top of the Med
30. The test continuously repeats itself until you press the Cancel and Media Source keys Cartridge Continuity Test Failure If any cartridge Continuity test fails to resolve the problem try one of the following 1 Remove the failing Cartridge and clean the flex contacts on the Carriage and the Cartridge Reseat the Cartridge and try the test again 2 Replace the Cartridge of the relevant failing color and perform this test again 3 Check and if necessary replace the Trailing Cable page 8 8 4 Replace the Carriage Assembly page 8 37 5 Replace the Electronics Module page 8 13 Only replace one component at a time and perform the test again before replacing another component Using this procedure you will be able to determine exactly which component failed The test is continued on the next page Service Tests HP DesignJet 430 450C and 455CA Printers 4 13 Line Sensor Test Failure If the Line Sensor test fails to resolve the problem try one of the following 1 Line sensor incorrectly calibrated The accuracy calibration includes calibration of the line sensor on the carriage You must use HP Matte film when performing the accuracy calibration Details Chapter 5 Otherwise the line sensor will have problems loading some types of media 2 Check and if necessary replace the Trailing Cable page 8 8 3 Replace the Carriage Assembly page 8 37 4 Replace the Electronics Module page 8 18 Only replace on
31. accuracy calibration whenever the EEROM is erased Electronics module is replaced Drive roller is removed or replaced Media X axis motor is removed or replaced Drive roller gear is removed or replaced Cartridge carriage is replaced Mark encoder is removed or replaced Optical sensor is removed or replaced What is the End Point Accuracy Specification The end point accuracy specifies how accurately a Printer can draw a given length of line The end point accuracy specification for the Printers is 0 38 mm 0 015 in or 0 2 of the specified vector length whichever is greater at 23 C 73 F at 50 60 relative humidity on HP matte film Use the following formula to calculate the Printer s accuracy Measured length Desired length Desired length What can Affect the End Point Accuracy Various part tolerances inside the Printer affect the accuracy in particular the drive roller Other outside influences include x 100 Error e Media thickness Thicker media creates longer lines e Media expansion As the media grows so do the lines e The application software may be instructing the Printer to draw an incorrect line length e The EEROM has been cleared The accuracy constants are stored in this non volatile memory component 5 2 HP DesignJet 430 450C and 455CA Printers Service Calibrations Before Performing the Accuracy Calibration 1 Under normal environmental conditions and on HP Matte Fil
32. adly connected trailing cable Dirty carriage flex circuit Faulty carriage Faulty electronics module 2 4 HP DesignJet 430 450C and 455CA Printers System Error Codes Steady DEFK Steady DFK Ready Media X axis Shutdown Possible causes e Obstacle or friction in X axis e Faulty or badly connected X axis Encoder Cable e Faulty media motor or motor cable pinched e Faulty electronics module Ready Align Media Load Media Cartridges Memory or Accuracy Calibration Problems Possible causes e Not enough memory for the current plot Add extra memory by installing a bigger RAM SIMM Refer to Chapter 7 for the correct part numbers of the RAM SIMMs If this error code appeared while performing the Accuracy Calibration e Check that the quality of the Accuracy Calibration print is good If the quality is bad try to clean the black cartridge or replace it e Make sure that you load the Accuracy Calibration print in the correct position and orientation and make sure that you select the correct media type e Make sure that the line sensor on the carriage is clean If the Line sensor is dirty or not functioning correctly it will have problems reading the accuracy calibration print e Faulty Trailing Cable Faulty Carriage Assembly e Faulty Electronics Module Ready Load Media Cartridges Mechanical Problem Possible causes e Check the Bail Assembly e Check the Capping Positi
33. ail lift mechanism page 8 28 Service Tests HP DesignJet 430 450C and 455CA Printers 4 23 Electrical Test This tests the operation of some of the electrical components of the electronics module THIS TEST HAS BEEN FOUND TO BE VERY UNSTABLE DUE TO SOME INTERACTIONS BETWEEN SOME OF THE COMPONENTS OF THE ELECTRONICS MODULE IT IS SOMETIMES IMPOSSIBLE TO EXIT THIS TEST WITHOUT SWITCHING OFF THE PRINTER Perform the Electrical test as follows 1 In service mode 2 press Electrical Test Form Feed Key 2 The test will start and the Printer will check some of the electrical parts 3 Ifthe test fails an error code will appear on the front panel Refer to Chapter 2 in order to correctly troubleshoot the failure 4 24 HP DesignJet 430 450C and 455CA Printers Service Tests Servo Encoder Test The servo encoder test performs the following e Media axis encoder test Verifies the operation of the servo loop media axis feedback e Carriage axis encoder test Verifies the operation of the servo loop carriage axis feedback e Records the maximum friction detected in the EEROM You can view this information on the service configuration plot Perform the Servo Encoder test as follows 1 In service mode 2 press Servo Encoder Test Media Type Key 2 The test will start and there will be slight movements in the X and Y axis After every 5 movements the direction of the movement will change in both axis The maximum
34. and 455CA Printers 4 5 Service Mode 1 Service Mode 1 contains tests that do not need a complete initialization of the Printer This means if there is a system error in normal mode it is still possible to enter into Service Mode 1 Also the Sensors are disabled in Service Mode 1 which means it will not be possible to load media The only time that the sensors will be functional is during the Sensors Test THE COVER SENSOR IS DISABLED WHEN IN SERVICE MODE 1 IF THE CARRIAGE IS MOVING IT WILL NOT STOP IF THE COVER IS OPENED BE VERY CAREFUL NOT TO PUT YOUR HANDS INSIDE Some of the tests in service mode 1 send test information to the printer s serial port To view the information perform the procedure on page 4 7 The Electronics Test is continuously done in the background during Service Mode 1 If you are viewing information via the serial port you will see output similar to the following Test Mode EE test 0 Test Mode EE test 1 Stopping a Test The service tests are continuously repeated until you stop them To exit a test press the Cancel and Media Source keys some tests may take a short while before exiting To exit Service Mode 1 you must power OFF the Printer Entering Service Mode 1 1 While holding the Reprint key down switch the Printer ON 2 Once the the LEDs begin to light up one by one release the Reprint key The printer performs the electrical power on tests and then the fan turns on and remains on A
35. art Cable length Connector type at Number computer end of cable HP Vectra or HP 24541A B serial interface 24542G 3 0 m 9 8 ft 9 pin female card 9 pin connector HP 9000 workstations using 9 pin connectors IBM AT and compatible computers using 9 pin serial connectors HP Vectra PC with HP 24541A B dual serial 17255M 1 2 m 3 9 ft 25 pin male interface card using the 25 pin connector HP Apollo workstation using an SPE Serial Parallel Expansion option and supplied adapter cable DEC VAX Sun workstation IBM PC PC XT IBM PS 2 and compatible C2913A 1 2 m 3 9 ft 25 pin female computers DEC VAX using DEC BC22D BC03M or 17355M 3 0 m 9 8 ft equivalent Apple Macintosh Plus SE II Series Classic 17302A 1 5 m 4 9 ft 8 pin male mini DIN LC family Quadra family PowerBook PowerMac Apple Macintosh 128K and 512K 92219M 1 5 m 4 9 ft 9 pin male Extension cable 31391A 5 m 16 4 ft 25 pin female Parts and Diagrams HP DesignJet 430 450C and 455CA Printers Evia Preventive Maintenance HP DesignJet 430 450C and 455CA Printers 9 1 Moisture on Printer Users should use the Printer in an environment between 5 and 95 relative humidity To recover from moisture condensation turn the Printer off and using the main roller as a reference wait until the Printer is completely dry before using it again Level of Printer Usage To achieve good performance and long lifetime of the HP De
36. ctions before error occurred Include setup sheet and service configuration plot in report Steady DEFL 2 6 HP DesignJet 430 450C and 455CA Printers System Error Codes Steady DKL Steady EFL Ready Align Media Data Communication problem with RS 232 Serial Port Possible causes e Incorrect configuration in communications speed protocol e Incorrect communications cable e Error in host computer Ready Load Media Data There is a communication problem between the Main PCA and the internal microprocessors The Main PCA is faulty Replace the Electronics Module Ready Cartridges Data Mark Encoder not detected Possible causes e The line on the mark encoder is dirty or missing Faulty or badly connected trailing cable Faulty or badly connected carriage sensor Faulty or badly connected X axis Encoder Cable The drive roller has shifted slightly from the expected position mechanics Check that the carriage sensor lights just over the white mark on the drive roller when starting Faulty carriage PCA Faulty X motor Faulty Y motor Faulty electronics module Align Media Load Media Data Error reading Centronics I O Problems in the Centronics Communications Probably due to the bad contacts of the connector e If this error remains report the problem to your HP Response Center Note conditions and actions before error occurred Include setup sheet and service con
37. cuit on the cartridge See page 4 12 Carriage Test e Nozzles touch the service station thus causing puddling to occur on the print head e Some of the small slots on the encoder strip are damaged Therefore the Printer cannot position the carriage correctly during cartridge servicing e Cartridges are misaligned with respect to each other e Calibration values lost or incorrect Media Fault Some types of media have a coating that prevents them getting wet from the ink drop The ink doesn t spread out sufficiently around the point where the dot is placed Banding may not occur on some poor quality media where it is counteracted by another problem large dot gain This is where the ink spreads out excessively on the media around the desired dot position To accurately test for banding use HP polyester inkjet film Print Quality HP DesignJet 430 450C and 455CA Printers 6 13 Banding Problem If there is negative or positive banding in the test image see Figure 9 Corrective Action Try the following steps 1 Perform the Cartridge Alignment Calibration Details p Users Guide using genuine HP media then print the Print Quality Plot again to see if there has been any improvement If the problem continues perform the Accuracy Calibration Details page 5 2 and print the Print Quality Plot again to see if there has been any improvement Remove the all Cartridges and clean the flex contacts on the Car
38. e ROM Service station Trailing cable Tested by Bail cycle test Bench run Modular Test Carriage test Electrical test Modular test Carriage axis test Bail cycle test Modular test Bench run Carriage test Modular test Carriage test Modular test Service monitor Sensors test Modular test Electrical test Power on tests Bench run Electrical test Power on tests Bench run Electrical test Power on tests Servo Encoder test Sensors test Bail cycle test Front panel test Media axis test Carriage test Carriage axis test Bench run Modular test Carriage axis test Servo Encoder test Modular test Bench run Front panel test Modular test Servo Encoder test Media axis test Modular test Bench run Media axis test Modular test Bench run Sensors test Modular test Sensors test Modular test Carriage test Modular test Electrical test Power on tests Bench run Bail cycle test Electrical test Power on tests Bench run Service Tests HP DesignJet 430 450C and 455CA Printers 4 3 Service Tests Diagnostics The following is a list of all internal service tests available in the Printers Instructions for entering service mode 1 are given on page 4 6 Instructions for entering service mode 2 are given on page 4 22 1 Bail Cycle Test page 4 8 This tests the operation of the bail system Service Station and the Y axis by engaging and disengaging the bail lift mechanism and capping
39. e Raed anh weitan Powe BAG dein dR ETE aah 1 3 Have you performed a Service Test on the Failed Component Assembly 1 3 Have you Performed the Accuracy Calibration 00 eee eee 1 3 What can I do to Solve Print Quality Problems 0 0 00 cee eee 1 3 What can I do if the Line Sensor has Problems Detecting Media 1 4 What can I do if the Carriage is Noisy 2ct icsutawsaxs eee ries xbee sevens 1 4 What can I do if the Cover Sensor isn t Working 0 0 cece eee ee 1 4 What can I do if the Carriage Assembly has problems parking in the Service Station suresse oemat es rep EELER TAE EEEE EER E E 1 4 What can I do if the Printer continuously rejects Cartridges 1 5 What can I do if the Media continuously crashes 0 eee e eee 1 6 What can I do if the Printer does not Power ON 0 00 cece eee eee 1 6 What can I do if the Printer has problems with Media Loading 1 7 What can I do if the Printer has problems with the Cutter 1 7 What can I do if the Bail Mechanism Fails 00 c cece eee eee 1 8 What is an EEROM error 6 cs ccacsviadccecwenswanebanude Ghaeedetawkeden 1 8 2 System Error Codes Important Information on Troubleshooting Error Codes 2 2 System Error Codes 420i0t cadedewed aiswenddtancd sa tare dere bawsadsd iewes 2 4 3 User Messages User Messaves s5 reris deetan E hag hoe de
40. e Station Assembly Reference HP Part Number Quantity Description eee 1 0515 1748 2 Screw M4 x 17 Tap 20 2 C3190 60142 1 Service Station Assembly 3 C4713 60023 1 Primer Assembly 4 0624 0704 1 Screw 6 19 3875 Plas T15 5 3050 1267 1 Washer 6 C4713 60098 1 Encoder Strip D A1 size C4714 60098 1 Encoder Strip E A0 size 7 0515 2765 1 Screw M4 2 x 35 Pan Torx stl 8 C3190 40040 1 Left Bracket 9 C3190 00012 1 Left Strap clip C4713 40042 1 Primer Cover DesignJet 430 7 14 HP DesignJet 430 450C and 455CA Printers Parts and Diagrams Figure 7 Primer Assembly and Service Station Assembly Parts and Diagrams HP DesignJet 430 450C and 455CA Printers Reference Drawing C4713 40038 C3190 00086 C3190 60038 C3191 60038 C4713 60039 C4705 60082 C4706 60082 C4699 60052 C4700 60052 1400 1021 C4713 60040 C4701 40001 HP Part Number Quantity e A e me e ol Figure 8 Carriage Assembly and Trailing Cable Description Carriage Top Trailing Cable Metal Clip Trailing Cable Assembly D A1 size Trailing Cable Assembly EK A0 size Carriage Assembly Carriage Belt D A1 size Carriage Belt K A0 size Trailing Cable Guide D A1 size Trailing Cable Guide E A0 size Trailing Cable Plastic Clip Cutter Assembly Cartridge Cover DesignJet 430 7 16 HP DesignJet 430 450C and 455CA Printers Parts and Diagrams Figure 8 Carriage Assembly and Trailing Cable Parts and Diagrams
41. e X axis cycle 67 pwm Test Mode Y axis cycle 50 00 speed and 100 pwm Test Mode X axis cycle 66 pwm Test Mode Y axis cycle 26 67 speed and 66 pwm Test Mode X axis cycle 65 pwm Test Mode Y axis cycle 50 00 speed and 98 pwm Pen BLACK continuity WORKS Pen CYAN continuity WORKS Test Mode X axis cycle 64 pwm Pen MAGENTA continuity WORKS Pen YELLOW continuity WORKS Pen BLACK has 1cd4 identification Pen CYAN has 400 identification Pen MAGENTA has 1f00 identification Pen YELLOW has 1900 identification Optical sensor samples 255 255 255 255 255 254 254 253 253 252 252 251 251 250 250 249 Optical Sensor WORKS Encoder sensor WORKS Pen BLACK continuity WORKS Test Mode Y axis cycle 26 67 speed and 68 pwm The result of the Encoder sensor test is only reported via the serial output and not via the front panel In order to perform the encoder sensor test you must move the carriage slightly so that the encoder sensor can detect the change in status If the carriage is not moved at all the Encoder Sensor test will always fail If the carriage is moved and ONLY the Encoder Sensor test fails then you need to replace the Carriage Assembly amp page 8 37 If any of the tests fail refer to the individual test documented in this chapter for the correct troubleshooting procedure 4 20 HP DesignJet 430 450C and 455CA Printers Service Tests Electronics Test The purpose of this test is to verify the
42. e component at a time and perform the test again before replacing another component Using this procedure you will be able to determine exactly which component failed Analog Multiplexer Test Failure If the Analog Multiplexer test fails to resolve the problem try one of the following 1 Check and if necessary replace the Trailing Cable page 8 8 2 Replace the Carriage Assembly page 8 37 3 Replace the Electronics Module page 8 13 Only replace one component at a time and perform the test again before replacing another component Using this procedure you will be able to determine exactly which component failed 4 14 HP DesignJet 430 450C and 455CA Printers Service Tests Sensors Test This tests the operation of the cover sensor pincharm sensor and media sensor Perform the Sensors test as follows 1 In service mode 1 press Sensors Test Media Type Key 2 Activate the necessary sensor and check that the relevant LED status changes ON OFF Refer to the following figure to check which LED is associated with which sensor 3 The test continuously repeats itself until you press the Cancel and Media Source keys Se canon CARTAGE ai een l iman irma MEDLIA SENSOR OAIE EI AEI ER SOR tS TEST If you are viewing information via the serial port you will see output similar to the following 5 SENSORS TEST This message only informs you that the test has started and a message will not a
43. e customer is using name version etc Is the problem reproducible by you Additional comments about the usage the setting etc Have you performed a Service Test on the Failed Component Assembly If possible always perform a Service Test on the component assembly that you are about to replace just to make sure that is the component assembly that has failed If the test on that component assembly passes you should NOT replace it For information on the Service Tests and how to use them Chapter 4 Have you Performed the Accuracy Calibration Is the printer calibrated correctly after replacing a component Refer to Chapter 5 to check when the Accuracy Calibration is required What can I do to Solve Print Quality Problems Whenever an Print Quality problem appears it is advisable to print the Print Quality Plot to help diagnose the problem The Print Quality Print will help you differentiate between possible Cartridge errors and other problems such as incorrect front panel selection driver or RIP configuration or mechanical problems For information on solving Print Quality problems Chapter 6 Troubleshooting HP DesignJet 430 450C and 455CA Printers 1 3 What can I do if the Line Sensor has Problems Detecting Media 1 Excessive ink deposits on the drive roller surface can fool the sensor by reflecting the light Clean the drive roller p Chapter 9 2 Line sensor incorrectly calibrated The accuracy calibration i
44. e eee 8 12 Removing the Electronics Module 0 c cece cee cette teens 8 13 Removing the Encoder Strip 2i lt acd dessus den ees dieos eee dere odes coxa wes 8 15 Removing the Right Bracket g coved da cdedeeecadnkee eenadceddata ne Seevans 8 17 Removing the Carriage Motor 0 cc cece cece etn eee nena 8 18 Removing the SPOON 214 5282 ncsyekdeeensitends piaioueaeewansinsads 4X 8 20 Removing the Cutter Assembly 0c cee cence ene n eee ene enees 8 21 Removing the Drive Roller Gear 0 cece tenet eee 8 22 Removing the Media Motor Assembly 0 0 ccc ccc eee eee n eee neee 8 23 Removing the Pinch Arm Mechanism 00 cece ee cence neces 8 24 Removing the Primer Assembly 404 404 4 404004 40405044 e0edeuesuedsous 8 25 Removing the Service Station 0 ccc ccc cece een e een e teens 8 26 Removing the Bail Lift Mechanism 00 ccc ec eee cece eee eee 8 28 Removing the Engaging Lever Support 0 0 ccc ccc e eee eens 8 32 Removing the Trailing Cable 0s 29acs0xumdida Resdseeseeeeexaldes eoee ea 8 34 Removing the Trailing Cable Guide 0 0c cc ununa ccc e eens 8 36 Removing the Carriage Assembly 0 ccc cece cnn ene een eens 8 37 Removing the Drive Belt 0 0 ccc ccc ccc are Cernii tire Er eDis 8 41 Removing the Drive Belt Pulley 0 ccc cece cc ene ene e nee 8 42 Removing the Drive Roller 0 ccc cen
45. e following 1 Check that the cable for the Front Panel Assembly is connected to the Electronics Module Also make sure that the cable is NOT damaged or twisted 2 Replace the Front Panel Assembly page 8 12 3 Replace the Electronics Module page 8 13 Service Tests HP DesignJet 430 450C and 455CA Printers 4 9 Carriage Axis Y axis Test The purpose of this test is to verify the operation of the components of the Carriage Axis This Service Mode does not include carriage axis initialization If the carriage starts somewhere out of the Service Station it will hit the right hand side of the Printer when the test begins and the test will fail Always make sure that the carriage is parked in the service station before starting this test Perform the Carriage Axis test as follows 1 2 3 Make sure that the carriage is parked in the service station In service mode 1 press Carriage Axis Test Reprint Key The test will start and the carriage moves towards the right hand side of the printer It then begins cycles of moving from side to side over the drive roller If the test passes the Fast LED LED A will light up after the first cycle If you are viewing information via the serial port you will see output similar to the following 2 Y AXIS TEST Test Mode Y axis cycle 26 67 speed and 66 pwm Test Mode Y axis cycle 50 00 speed and 100 pwm Test Mode Y axis cycle 26 67 speed and 68 pwm If th
46. e the Cartridges and print the Print Quality Plot again to see if there has been any improvement If the error is still present replace the failing cartridge and print the Print Quality Plot again If the error continues try the following e Replace the Trailing Cable page 8 8 e Replace the Carriage Assembly p page 8 37 e Replace the Electronics Module p page 8 13 Only replace one component at a time and check if the problem has gone before replacing another component Using this procedure you will be able to determine exactly which component failed 6 6 HP DesignJet 430 450C and 455CA Printers Print Quality Test Pattern 3 Vertical Line Straightness Test Vertical line straightness is a measure of the horizontal distance between the segments of a vertical line plotted in two consecutive swaths If the Printer is working correctly this distance should be less than 2 mils see Figure 2 Swath Printing Direction Swath n 1 Swath Printing Direction gt Swath n Swath Printing Direction o Swath n 1 l Hs Maximum allowable VLS Error 2 mils Figure 2 Customer Expectations Although the VLS specification satisfies the expectations of most customers some may complain even when the Printer is working within this specification If the VLS error is already less than 2 mils do not try to improve it The VLS error is composed of two parts see Figure 3 e Theta Zeta error e Bidirectiona
47. ectronics module the factory spittoon value is reset to 0 used Keep in mind that the value printed on the service configuration plot may greatly underestimate the amount of ink in the spittoon Belt Swelling To prevent new belts from swelling incorrectly keep them in their bags with dissicant until you need to install them Preventive Maintenance HP DesignJet 430 450C and 455CA Printers 9 3 Cleaning the Printer To maintain the Printer in good operating condition keep it free of dust accumulation ink and other contamination Cleaning intervals are determined by the Printer environment and by the types of Printer supplies used WARNING Disconnect the Printer from the power source prior to performing any cleaning DO NOT allow liquid to run on to electrical components or circuits or through openings in the enclosure as this can create a shock hazard leading to death or injury General Cleaning Proper general cleaning should include the following 1 Blow away dust accumulation with compressed air if available 2 Clean the outer surface of the Printer with a damp sponge or cloth Use a mild soap and water solution if necessary Do not use abrasive cleaners 3 Wipe the Printer dry with a soft lint free cloth Cleaning the Drive Roller Due to the ink s reflectance ink spilled on the roller can disrupt the Printer s edge sensing function To remove any ink from the roller perform the following procedure 1 C
48. el and Media Type keys down switch the Printer ON 3 Once the the LEDs begin to light up one by one release the keys Clearing Just the User Defined Setup Parameters 1 Switch the Printer OFF 2 While holding down the Reprint Cancel Media Type and Media Source keys down switch the Printer ON 3 Once the the LEDs begin to light up one by one release the keys a ER DERIAED SETUR 4 32 HP DesignJet 430 450C and 455CA Printers Service Tests Clearing All Parameters 1 Switch the Printer OFF 2 While holding down the Setup Form Feed Reprint Print Quality and Media Type keys down switch the Printer ON 3 Once the the LEDs begin to light up one by one release the keys Service Tests HP DesignJet 430 450C and 455CA Printers 4 33 Service Calibrations and Adjustments HP DesignJet 430 450C and 455CA Printers 5 1 Calibrations The only Calibration that the Printer requires is the Accuracy Calibration which must be performed under certain conditions Accuracy Calibration Purpose The accuracy calibration X axis calibration procedure is used to correct the end point accuracy of the media axis The carriage axis does not require calibration and is used to calibrate the media axis The accuracy calibration also includes calibration of the optical line sensor on the carriage The accuracy calibration is also used to correct the error of the X axis movement to avoid banding Perform the
49. ere is a Y axis shutdown the Fast LED LED A will start to flash If you are viewing information via the serial port you will see output similar to the following 2 Y AXIS TEST Test Mode Y axis cycle 26 67 speed and 0 pwm Test Mode Error 2 on y axis test The test continuously repeats itself until you press the Cancel and Media Source keys The test is continued on the next page 4 10 HP DesignJet 430 450C and 455CA Printers Service Tests If the test fails to resolve the problem try one of the following 1 Clear any binding due to a media jam 2 Turn the Printer off Manually move the carriage along the carriage axis Check for any areas where the carriage may be binding 3 Ensure that the belt and belt pulley are in correct working order Remove dirt from the pulley that could cause the belt to slip 4 Remove dirt from the slider rod and chassis beam Apply oil Anderol 4068 HP part number 6040 0858 to the carriage bushings 5 At high temperatures and if the fan is not working correctly the internal resistance of the motor driver may increase causing a decrease in the voltage between the motor contacts and a shutdown of the motor 6 Ensure that the encoder strip is not inverted damaged or absent 7 Reconnect or replace the trailing cable page 8 8 8 Replace the carriage assembly page 8 37 Only replace one component at a time and perform the test again before replacing another component U
50. error is still present replace the failing cartridge and print the Print Quality Plot again 4 If the error continues try the following e Replace the Trailing Cable page 8 8 e Replace the Carriage Assembly p page 8 37 e Replace the Electronics Module page 8 13 Only replace one component at a time and check if the problem has gone before replacing another component Using this procedure you will be able to determine exactly which component failed Test Pattern 4 Color Alignment Quality Test Upper Test The first of these patterns tests alignment between the cyan and magenta cartridges it should be blue with no cyan or magenta shadows The second tests alignment between the cyan and yellow cartridges it should be green with no cyan or yellow shadows The third tests alignment between the magenta and yellow cartridges it should be red with no magenta or yellow shadows Lower Test This test pattern is to check the color alignment and produces 6 patterns each with 2 different primary colors In each pattern you will see primary color circles If there is misalignment between the primary colors the composite color will be present in one part of the circle and white will be visible at the opposite side of the circle There are two types of misalignment see Figures 5 and 6 e Horizontal when the misalignment is in the horizontal axis e Vertical when the misalignment is in the vertical axis Print Quality HP Design
51. es 404 0 ow aS Bs EREA 3 2 HP DesignJet 430 450C and 455CA Printers Contents iii 4 Service Tests Introd tio ser srne ansien yeti scawes hin cher bee saemva et eade 4 2 Power On 2t2icctavehs Wide oueeeandec a eNA EEN EEEE TEETE EEEE 4 2 Self Test and Normal Initialization 00 0 cece cee cee ees 4 2 Service LOGS we nnieeedideasrtwlbevereen tens Seveusidaedrerechouenneeyes 4 3 Which Service Vest to Perform as lt c cccantiwsn dont ddnateewdsswetectenes 4 3 Service Tests DiagnGstits 6 156 203 snd ei dee kd Nha Kaeo R REDE DRESS Sw OR 4 4 Service Mode is ticucecessiat vattutecustiedus dion dd soe EENE 4 6 Stopping a T ste suis ede cove eta ewts Shanes sewed beer em ewsese eles ees 4 6 Entering Service Mode 1 0 ccc ccc cc ttntnt eee e nes 4 6 Viewing Test Output via the Serial Port 0 ccc cece eens 4 7 Bail Cycle Test o astisicadsesndosareuseleedeniae sees EREE EA Eai 4 8 Front Panel Test oe cadens chess ceukaidiee ee ew aas ainia inani RERA nE aai 4 9 Carriage Axis Y axis Test beste seebed ten ttsaeadseeedsuatdends 4 10 Carriage TeSt 42228a eves iune s ttOO ee TEM SEERNE eek E E TET EEEE 4 12 Sensors TEST ar eramen EEE SAREE a N E E 4 15 Media Axis X Axis Test nnnnnn nuunuu nnne errn r rrr 4 16 Bench RUM sorerreorerti setana Eo ERER E G E ENE 4 18 Mod lar Testi rerresceprrenr aganin ni n E ex E A RN EOE EE 4 19 Electronics Test cc s 45ts ce dedteancustea ses E reda E ete a ETE
52. est The service tests are continuously repeated until you stop them To exit a test press any of the front panel keys To exit Service Mode 2 you must power OFF the Printer Entering Service Mode 2 1 While holding the Media Source key down switch the printer ON 2 Once the the LEDs begin to light up one by one release the Media Source key The printer performs the electrical power on tests and initializes the mechanics as in normal user mode When you are in Service Mode 2 All the LEDs will go off except the ones that have been selected Once inside a test all the LEDs except for the LEDs in the Error Group will begin to flash E a eH Tg Media Source SERVICE MODE 2 4 22 HP DesignJet 430 450C and 455CA Printers Service Tests Bail Test This tests the operation of the bail system Service Station and the Y axis by engaging and disengaging the bail lift mechanism and capping uncapping the cartridges Perform the Bail test as follows 1 In service mode 2 press Bail Test Setup Key 2 The test will start and the Carriage will move out of the Service Station and activate the engaging lever which causes the Bail Assembly to be gently raised and then lowered 3 Ifthe Printer does not raise the Bail Assembly then the test has failed 4 The test continuously repeats itself until you press any of the front panel keys If the bail fails the test try replacing the following component 1 B
53. est LEDs LEDs ABC will light up 5 Using a suitable tool short circuit pins 1 and 2 the first two pins on the right of the media motor encoder connector ENC X The Cartridges Data and Media LEDs LEDs KLM should light up as you short circuit the two pins 6 Once you have short circuited the two pins the Fast Normal and Best LEDs LEDs ABC should light up again 7 Press the Cancel and Media Source keys together to exit the deconfiguration mode Remember that the printer MUST HAVE the A 01 05 FW release installed I 4 27 8 Configure the Printer with the correct model ID as follows Only one opportunity is given to perform this procedure and there is no indication that it was successful If the Printer is to be configured as a DesignJet 488CA LFP Asia Printer press the three LFP Asia Configuration Form Feed Reprint Cancel keys at the same time 9 Turn the Printer OFF 10 Reconnect the media motor encoder cable to the main PCA connector ENC X 11 Turn the Printer ON After initializing error code DLM will appear because the Accuracy Calibration must still be performed 12 Press the Cancel key and print the Demo Plot to check if the Printer has been correctly configured as a DesignJet 488CA If the Printer is still incorrectly configured then Error Code EKL will be displayed on the front panel Turn the Printer OFF and perform the EEROM Model ID configuration procedure again from step 2
54. figuration plot in report System Error Codes HP DesignJet 430 450C and 455CA Printers 2 7 Steady EKL Steady EK Load Media Cartridges Data Problems when initializing the carriage Possible causes Carriage assembly is not present Faulty or badly connected trailing cable Faulty carriage PCA Faulty electronics module Align Media Cartridges Data Model ID not configured After replacing a new electronics module it must be configured either as a DesignJet 430 450C or 455CA Ifa new module does not show this error it means that it has been installed previously and was probably calibrated with other parameters After configuring the module Error code Steady DLM will appear which means the accuracy calibration must be done After the accuracy calibration is done all other calibrations must be done If configuring the module does not remove the error even after switching the Printer OFF and ON then the EEROM in the main PCA is probably defective Before trying to replace the electronics module try clearing the EEROM and perform all the calibrations again and see if that solves the problem Refer to page 4 27 in order to configure the correct model ID For more information page 1 8 Align Media Cartridges EEROM test error Possible causes Switch the Printer OFF and ON again and see if the error remains If the error appears continuously replace the Electronics Module The Cal
55. he main PCA or a flash ROM SIMM installed in the inner most socket at the back of the Printer If both are present the Printer recognizes the code on the ROM SIMM instead of that on the in built ROM The power on LED sequence tells you whether the Printer is using code from in built ROM or from a ROM SIMM If the LEDs begin to light up from the right then the Printer is using the ROM SIMM If the LEDs begin to light up from the left then the Printer is using the built in ROM To find out the firmware code revision level that the Printer is using print a user setup sheet or a service configuration plot RAM The Printers have a standard four megabytes of on board RAM They also have one RAM expansion socket which can hold an optional 4 8 16 or 32 megabyte DRAM SIMM The socket is the outer most one at the back of the Printer Functional Overview HP DesignJet 430 450C and 455CA Printers 10 7 EKEROM EEROM is used as nonvolatile storage for calibration and configuration data Useful information from the EEROM is printed on the service configuration plot The EEROM is soldered to the Main PCA in both new and rebuilt electronic modules If you clear the EEROM or replace the electronics module perform all calibrations Also note that the factory spittoon value on the cleared or new EEROM is 0 Keep in mind that the value printed on the service configuration plot may greatly underestimate the amount of ink in the spittoon Inpu
56. hermal Turn On Energy has not been performed because of incorrect cartridge change With the power ON open the top cover and reseat the cartridge INK SMEARING Symptoms Ink smears on the media See also User s Guide chapter 9 Product Fault The media touches the print heads This can occur because e The media holding mechanism is not holding the media correctly and the media buckles e The carriage to media distance is too small Adjustment chapter 5 Print Quality HP DesignJet 430 450C and 455CA Printers 6 17 HUE CHANGES Symptoms Changes of hue are noticed when printing in color Cartridge Fault One or more of the print cartridges is running out of ink Typically the inks of the four cartridges are used at different rates Solution Replace the print cartridge with a new one 6 18 HP DesignJet 430 450C and 455CA Printers Print Quality ot6 n 1 05 m6 HP DesignJet 430 450C and 455CA Printers 7 1 Exchange Assemblies Exchange assemblies are factory repaired and tested assemblies that you can order they are listed in the following table Exchange assemblies are available only on a trade in basis therefore you must return the defective assemblies for credit Exchange Assemblies HP Part Number Qty Description C4713 60037 1 Electronics Module Replacement Parts Parts shown in the drawings in this chapter are listed in the corresponding part lists Match the app
57. ia Bail The bail provides a normal force on top of the media There is no bail sensor on the Printer to detect if the bail is up or down Bail Lift Mechanism The bail features an automatic lift mechanism driven by the media motor using a series of gears and actuated by the cartridge carriage The cable based design eliminates the torque on the axle of the bail lift cam and thus improves reliability This mechanism is also more accessible Removal page 8 28 Detecting the Lines and Media Edges Line Sensor The line sensor on the cartridge carriage is used to e Detect the left and right media edges e Detect and measure lines drawn on media when performing accuracy calibration e Scan the setup and alignment sheets e Find the platen roller reference mark Functional Overview HP DesignJet 430 450C and 455CA Printers 10 3 Moving the Carriage Carriage Drive Mechanics Motor Belt and Pulley e The carriage Y axis drive consists of a DC motor directly driving a single belt and the carriage e The motor assembly itself provides the tension needed on the belt eliminating the need for a separate pulley tensioner e The belt clamps itself to the carriage there are no separate belt clamps e The interface between the motor shaft and belt is friction based e You can remove the belt without having to remove the pulley on the left end of the belt Carriage Guidance The carriage moves along on just one sta
58. ibrations in the EEROM have been lost Perform the Accuracy Calibration refer to Chapter 5 2 8 HP DesignJet 430 450C and 455CA Printers System Error Codes Steady EM Steady DEM Load Media Cartridges Electronics Module Failure Possible causes Fan faulty or badly connected Faulty ROM SIMM Faulty RAM SIMM Faulty Electronics Module Align Media Media Y axis Shutdown Possible causes Problems with the Cutter Assembly Clear any binding due to a media jam Turn the Printer off Manually move the carriage along the carriage axis Check for any areas where the carriage may be binding Ensure that the belt and belt pulley are in correct working order Remove dirt from the pulley that could cause the belt to slip Perform the carriage axis test and the servo encoder test to check for problems with the carriage motor encoder strip and electronics module Remove dirt from the slider rod and chassis beam Apply oil Anderol 4068 HP part number 6040 0858 to the carriage bushings At high temperatures and if the fan is not working correctly the internal resistance of the motor driver may increase causing a decrease in the voltage between the motor contacts and a shutdown of the motor Ensure that the encoder strip is not inverted damaged or absent Reconnect or replace the trailing cable page 8 8 Replace the carriage assembly page 8 37 Ready Align Media Media Y axis
59. idges are rejected or not 4 Faulty cartridge Some black cartridges 51640A with USE BEFORE dates of April 96 and earlier may have thin film damage This means that the material used for channeling ink behind the nozzles can crack with aging When this happens ink seepage may cause many nozzles to fail eight or more Replace the black cartridge with one with USE BEFORE date of May 96 or later 5 Ifthe Cartridges are not inserted correctly into the Carriage the Cartridges will be rejected Make sure that the springs that hold the Cartridges in the Carriage are not broken or misplaced 6 Perform the Carriage Test page 4 12 7 Replace the Trailing Cable page 8 8 8 Replace the Carriage Assembly page 8 37 Troubleshooting HP DesignJet 430 450C and 455CA Printers 1 5 What can I do if the Media continuously crashes 1 Check if the media loaded is HP approved If the media is not HP approved advise the customer to use HP media and check to see if the problem is now solved 2 Anti static brush If this brush located under the entry platen is damaged or removed static charge can build up on the media A charge can cause the media to stick to itself and jam the Printer 3 The Carriage is at the incorrect height in relation to the Drive Roller Check and if necessary adjust the carriage to media distance page 5 5 and try to load the media again 4 The Drive Roller is installed incorrectly Remove the Drive Ro
60. ills There are two types of banding e Negative Banding This means that consecutive swaths overlap each other creating dark bands e Positive Banding This means that consecutive swaths do not touch thus leaving a small gap between each other This then causes white or lighter bands e Sah Negative Banding J Swath Positive 4 Swath Banding CORRECT INCORRECT Figure 9 6 12 HP DesignJet 430 450C and 455CA Printers Print Quality Cartridge Fault e A nozzle is blocked or faulty and is not firing ink drops e The ink drops of one nozzle are of smaller volume than those of the other nozzles e A nozzle s ink drop volume varies while plotting e A nozzle s ink drops are misdirected e Defect in manufacture of cartridge e Dirt or debris on the nozzle plate e Ink puddling on the nozzle plate e An electrical contact is misaligned or damaged on the cartridge so that it doesn t make correct contact with the circuit on the carriage See p page 4 12 Carriage Test Printer Fault e Incorrect swath advance angle of the drive roller This could be caused by a e Faulty roller irregular roller radius defective bearings e Media axis inaccuracy defective media motor or driver circuit calibration lost e An electrical contact is faulty in one of the Printer cartridge chutes so that it doesn t make correct contact with the cir
61. in order to understand any problems Last System Error Data Information on exactly which line of the firmware the error occurred in This information might be requested in the event of an escalation in order to understand any problems Bench Run Whether the Bench Run has been performed Bench Run Maximum Y Axis Carriage Axis PWM This Value should be less than 144 Typical Value 90 100 Bench Run Maximum X Axis Media Axis PWM This Value should be less than 100 Typical Value 60 70 Encoder Tests Maximum Y Axis Carriage Axis PWM This Value should be less than 144 Typical Value 90 100 Encoder Tests Maximum X Axis Media Axis PWM This Value should be less than 100 Typical Value 60 70 X axis Calibration This shows the information related to the Accuracy Calibration This information might be requested in the event of an escalation in order to understand any problems Service Tests HP DesignJet 430 450C and 455CA Printers 4 31 Clearing the EEROM If you clear the calibration parameters you will then need to perform the Printer calibrations Details chapter 5 Clearing the EEROM also resets the factory spittoon value to 0 used Keep in mind that the value printed on the service configuration plot may greatly underestimate the amount of ink in the spittoon CAUTION Clearing Just the Benchrun and Calibration Parameters 1 Switch the Printer OFF 2 While holding down the Form Feed Canc
62. inless steel slider rod It is guided by two integrated bronze bushings which are self lubricating and a back wheel Positional Feedback An encoder strip provides feedback on the position of the carriage The strip does not require adjustment Carriage PCA The carriage PCA is based on that of the DesignJet 650C It connects to the main PCA through a long 60 conductor 2x30 trailing cable The carriage PCA contains Optical line sensor Thermistor circuit Linear encoder Cartridge nozzle firing circuit Some electronic components on the DesignJet 450C and 450CA carriage PCA are not present on the DesignJet 430 carriage PCA At power on the Printer firmware identifies whether the carriage is for a color or a monochrome model and behaves accordingly 10 4 HP DesignJet 430 450C and 455CA Printers Functional Overview Providing Ink Print Cartridges The HP DesignJets 430 450C and 455CA use the same cartridges as does the HP DesignJets 330 and 350C Distance between Carriage and Media The distance between the carriage and the writing surface can determine image sharpness As the distance increases the drop shape and directionality degrade and are more difficult to predict You can change the distance using the adjusting screw on the carriage details page 5 5 Carriage Side View i Adjusting Screw Back Slider Engaging Tab Beam A Cross section Integrated Vt Ja ib Line Sensor
63. inter Is the Printer Using the Latest Firmware Revision Before spending time troubleshooting the problem by doing the various tests or replacing parts which may not need replacing check which firmware revision the printer is using To check which firmware revision the printer is using Print the Service Configuration Plot page 4 29 Some problems which occurred in earlier firmware releases may have been solved in later revisions So if there is a new firmware revision then replace the Firmware SIMM before replacing any parts Important Information The Printer firmware is contained either on a flash ROM SIMM at the back of the Printer or on a masked ROM inside the electronics module The firmware revision level for example A 01 03 is printed by the Printer on the setup sheet and on the service configuration plot The revision level is also printed on a label on any flash ROM SIMM Do not open the electronics module Important When replacing the electronics module always remember to check the firmware revision level of the new electronics module The revision level will be printed on the top surface of the module Also check the firmware revision level of the ROM SIMM installed in the old electronics module With this information you must do the following 1 If the firmware revision level of the ROM SIMM in the old electronics module is lower than the firmware revision level of the new electronics module then you must not insta
64. ittoon and Electronics Module Reference HP Part Number Quantity Description jeene 1 C4713 60091 1 Front Panel Assembly 2 0515 1743 1 Screw 3 1 Washer Included with Item 2 4 C4713 60017 1 Spittoon Assembly 5 0515 2282 2 Screw 6 2 Washer Included with Item 5 7 C4713 60037 1 Electronics Module 7 10 HP DesignJet 430 450C and 455CA Printers Parts and Diagrams wD Figure 5 Front Panel Spittoon and Electronics Module 7 11 HP DesignJet 430 450C and 455CA Printers Parts and Diagrams Figure 6 X and Y axis Motors and Encoder Strip Reference HP Part Number Quantity Description Deas 1 0535 0031 2 Nut 3050 1267 2 Washer 2 C4713 60098 1 Encoder Strip D A1 size C4714 60098 1 Encoder Strip E A0 size 3 C4699 00016 1 Encoder Spring 4 0515 2765 1 Screw M4 2 x 35 Pan Torx stl 5 C4713 40017 1 Right Bracket 6 C3190 00013 1 Right Strap clip T C4713 60092 1 Carriage Motor Assembly 8 0515 1349 2 Screw M3 x 30 Mach T10 9 0515 2248 3 Screw 10 3 Washer Included with Item 9 11 C4713 60094 1 Media Motor Assembly Includes Helical Gear 12 C3180 60012 1 Media Motor Cable 6040 0858 AR Lubricant C3190 60155 AR Lubricant Grease 7 12 HP DesignJet 430 450C and 455CA Printers Parts and Diagrams C 00 of WY7 TT 11 10 Fig 6 X and Y axis Motors and Encoder Strip 7 13 HP DesignJet 430 450C and 455CA Printers Parts and Diagrams Figure 7 Primer Assembly and Servic
65. l error Correct Theta Zeta Bi Directional gt VLS l Print Quality HP DesignJet 430 450C and 455CA Printers 6 7 Bidirectional Error You can see an example of a bidirectional error in Figure 3 If you print the same plot using a unidirectional print mode the error should not appear This error can occur for various reasons including Incorrect distance between nozzles and media Adjustment chapter 5 Encoder strip slots are damaged or dirty Dirt on the pulley is causing the belt to slip Friction between carriage bushings and slider rod Theta Zeta Error You can see an example of a Theta Zeta error in Figure 3 They appear when the rows of nozzles on a cartridge are not perpendicular to the carriage axis Y axis This error can occur for various reasons including e Badly seated cartridge e Faulty cartridge e Faulty carriage an A 0 WO i l it AN i 6 8 HP DesignJet 430 450C and 455CA Printers Print Quality VLS Problem If the line is not perfectly straight at Bias 0 in the test image see Figure 4 Corrective Action Try the following steps 1 Perform the Cartridge Alignment Calibration Details p Users Guide using genuine HP media then print the Print Quality Plot again to see if there has been any improvement 2 Ifthe problem continues perform the Accuracy Calibration Details page 5 2 and print the Print Quality Plot again to see if there has been any improvement 3 Ifthe
66. ll LEDs remain off for a few seconds Then all LEDs begin to flash waiting for you to perform a test If there are any system failures during Service Mode 1 initialization the Sheet LED LED O will be lit This failure means that the Electronics Module has failed and needs to be replaced Reprint i SERVICE MODE 1 a i z Sale 4 6 HP DesignJet 430 450C and 455CA Printers Service Tests Viewing Test Output via the Serial Port Some of the tests in service mode 1 send test information to the printer s serial port To view the information via the Serial Port Using Windows 3 1 1 2 3 Turn the printer and PC OFF Connect the Printer to the PC using a serial interface cable and switch the PC ON Select the Terminal Icon in the Accessories Group in Windows In Terminal select Settings and then select Communications from the pull down menu Make sure you use the following configuration e Baud Rate 9600 e Data Bits 8 e Stop Bits 1 e Parity None e Flow Control None e Connector Select the Communications Port that you are using 6 Select OK and Switch the Printer ON 7 Perform the service tests on the Printer Using an HP Palmtop PC 1 O qoaa A amp WW 9 Use HP cable number F1015 80002 and adapter number 5181 6640 to connect the Palmtop to the Printer s serial interface port Both cable and adaptor are included in the HP F1021B Connectivity Pack Turn the Pri
67. ll the ROM SIMM into the module 2 If the firmware revision level of the ROM SIMM in the old electronics module is higher than the firmware revision level of the new electronics module then you must install the ROM SIMM into the module Example 1 The ROM SIMM firmware revision level is A 01 03 and the firmware revision level of the electronics module is A 01 04 You would use the electronics module without the ROM SIMM installed Example 2 The ROM SIMM firmware revision level is A 01 05 and the firmware revision level of the electronics module is A 01 04 You would use the electronics module with the ROM SIMM installed 1 2 HP DesignJet 430 450C and 455CA Printers Troubleshooting What Can I do when a System Error Code Appears on the Front Panel Display Chapter 2 contains a list of system error codes and their respective descriptions and recommended corrective actions Only try one recommended action at a time and check if the error code has disappeared If you have an error code which is not documented in this Service Manual or you have an error which you cannot resolve then report the error to the HP Response Center or the nearest HP Support Office When reporting the error have the following information ready Model and Serial Number of the printer Which firmware revision the printer is using The complete error code The Service Configuration Plot The Current configuration sheet Which software application th
68. ller and install in the correct position page 8 44 and try to load the media again 5 The overdrive wheels turn free in both directions creating bubbles in the media Make sure that the Clutch assembly is installed correctly and is not faulty 6 Missing or damaged starwheels Make sure that all the starwheels on the bail assembly are correctly installed and turn properly 7 Missing Media Deflectors Make sure that all the Media deflectors are installed on the Printer otherwise there could be media crashes What can I do if the Printer does not Power ON 1 Check that the power cord is connected correctly 2 Check that the ROM SIMM firmware is installed correctly in the correct slot the slot furthest from you at the back of the Printer 3 Try to disconnect all the cables apart from the Front Panel Cable from the Electronics Module and then try to power ON the Printer again If nothing appears on the front panel display then replace the Electronics Module page 8 13 If the Printer does Power On with the cables disconnected then the problem must be with another component of the Printer To find the faulty component power OFF the Printer and connect one of the cables and power ON again Once the faulty component is connected it will not allow the Printer to power ON This component should then be replaced 1 6 HP DesignJet 430 450C and 455CA Printers Troubleshooting What can I do if the Printer has problems with Media
69. m D A1 size media plot a drawing that contains two X marks nominally positioned 500 mm 19 69 in apart 2 Measure the distance between the centers of the X marks on the plot Accuracy calibration is needed if this distance is not 500 mm 19 69 in 1 mm 0 04 in If the measured accuracy media thickness or environmental conditions vary greatly from the factory standards recalibrate the Printer by continuing with the following procedure Performing the Accuracy Calibration 1 Place a sheet of HP Matte Film over the top of the Printer for 10 minutes to let the sheet stabilize to the environmental conditions Use a sheet of approximate size Al or D You must use HP Matte Film Otherwise the optical sensor on the carriage will be calibrated incorrectly and the Printer will have problems loading some types of media 2 Enter into Service Mode 2 by powering ON the Printer while holding down the Media Source key 3 Set the Media Type on the front panel to Coated Paper 4 Load the film with the matte dull side down in portrait orientation into the Printer 5 When the Ready LED lights up press Reprint key The Ready LED begins to flash and the Printer takes several minutes to plot the calibration plot see Figure 1 The Printer ejects the sheet and the Load Media LED lights up 6 Unload the sheet 7 Wait until the ink on the sheet is dry 8 Cut the sheet along the dotted line and reload the sheet facedown
70. must also be marked Protective conductor terminal For protection against electrical shock in case of a fault Used with field wiring terminals to indicate the terminal that must be connected to ground before operating equipment Low noise or noiseless clean ground earth terminal Used for a signal common as well as providing protection against electrical shock in case of a fault A terminal marked with this symbol must be connected to ground in the manner described in the installation operating manual and before operating the equipment Frame or chassis terminal A connection to the frame chassis of the equipment which normally includes all exposed metal Alternating current Direct current Alternating or direct current The WARNING sign denotes a hazard It calls attention to a procedure practice or the like which if not correctly performed or adhered to could result in personal injury Take care not to cut yourself on the encoder strip inside the plotter The CAUTION sign denotes a hazard It calls attention to an operating procedure practice or the like which if not correctly performed or adhered to could result in damage to or destruction of part or all of the product viii Contents HP DesignJet 430 450C and 455CA Printers Troubleshooting HP DesignJet 430 450C and 455CA Printers Introduction This chapter will guide you through the relevant steps to take when troubleshooting the pr
71. ncludes calibration of the line sensor on the carriage You must use HP Matte film when performing the accuracy calibration Details p Chapter 5 Otherwise the line sensor will have problems loading some types of media 3 The Line Sensor is faulty Replace the Carriage Assembly page 8 37 What can I do if the Carriage is Noisy 1 Dirty Carriage bushings Remove dust particles from the Carriage bushings and from the slider rod along which the Carriage moves If necessary apply lubricant to the slider rod 2 Make sure that the belt is correctly positioned on the Y axis motor 3 Remove dust particles from the Back Beam and if necessary apply grease 4 Check for a faulty Carriage Perform the Carriage Axis Test page 4 10 What can I do if the Cover Sensor isn t Working The cover sensor is part of the front panel assembly 1 Before troubleshooting make sure that you are not in Service Mode 1 because the Cover sensor is disabled and Printer will think that the cover is always closed Power OFF the Printer and switch it back ON again and check if the Cover sensor works 2 Check if the cable for the front panel assembly is connected correctly to the electronics module 3 Replace the front panel assembly page 8 12 What can I do if the Carriage Assembly has problems parking in the Service Station 1 Mispositioned trailing cable The trailing cable may be preventing the carriage from reaching the left hand stop Make sure
72. nd 250C look identical their characteristics are different Installing the incorrect primer can damage the cartridges or reduce the servicing of the cartridges For the correct part numbers for the primers b chapter 7 10 6 HP DesignJet 430 450C and 455CA Printers Functional Overview Electronics Module The electronics module includes the main PCA power supply and fan It is one exchangeable part you do not need to open it If you replace the electronics module remember to swap any SIMMs from the old module to the new one Sensors There is no bail sensor for the HP DesignJets 430 450C and 455CA There is a pinch arm sensor which is different to the one installed on the HP DesignJets 330 and 350C The following sensors connect to the main PCA e The cover sensor is a mechanical switch that detects if the Printer cover has been raised If you open the cover while the Printer is plotting the plot is cancelled e The media sensor detects the presence of media It is also used to determine media length e The line sensor sends signals to the carriage and is used to detect the mark encoder and read alignment patterns It is also used to determine media width e The pinch arm sensor detects whether the pinch arms have been raised The servo processor uses the sensor to determine the pinch arm position during the initialization sequence ROM The Printer firmware code is contained on either an in built masked ROM soldered to t
73. nese ehades 7 24 Users Guide and Quick Reference Guide Bundle 4 7 25 Front Panel Overlays 5 2603 naudidedai dada svtindane ohana ee eeeans 7 25 Compatible Docimentanion 1 21 6 w0iso01 dhe seed bacevedanetacat dee os 7 26 Plug in memory RAM SIMM 0 ccc cece ene ene n ee enes 7 26 Cartridges 2 occ enc gusernaauwasnedceteane habe delaaeunen E RRE 7 26 Exter al Print Servers lt lt 2ccv2s0teresivetetdesseveasesarensigae en oe 7 27 HP DesignJet 430 450C and 455CA Printers Contents v 8 Removal and Installation Introduction sersriris anit EEEn A cheeses hein wiser esac vee eeads 8 3 Re assembly payee tenehs ibs Rueuee inen ten caries icn ser ERE TENA EN EEDA 8 3 Safety Precadti ns sonei rreri aiia EENE RENE EEO A EEEE ENE T es 8 3 Electrostatic Discharge ESD Precautions 0 c eee eens 8 4 Required Tools o2 ecccs ove ecasweertovstenteiwnerninoueee EENE sE Eoas 8 5 Installing a RAM or ROM SIMM oc4c005 022sseunbeasddaaddaeaeaerane wan 8 6 Removing the Bail Assembly i ccivuwyss IV resit ser tra Headed EErEE EE i 8 7 Removing the Top Cover susssssssessrrrrnnrnnnrnnn rrer rreren 8 8 Removing the Rollfeed Assembly 00 0 ccc cee ence eee ee eens 8 9 Removing the Left End Cover 0404 4 s6 446 0006 0s0sesse04eeeadasusdsoes 8 10 Removing the Right End Cover issccccceoeiwitetacadiacerdeestabedsn oes 8 11 Removing the Front Panel Assembly 000 cece cece eee
74. ng of any given file size Memory is used not just to hold the input data but also for system overhead processing work space and storage of the internal representation of the plot Some types of graphics require relatively large amounts of memory Examples are wide lines raster fill patterns polygons and user defined lines Plot Orientation The output orientation of the drawing also has an impact on memory usage Compare a plot of horizontal lines with one of vertical lines Lines plotted parallel to the carriage axis take up considerably less memory than those plotted perpendicular to it The Printer builds graphic display objects on a swath by swath basis A horizontal line can be contained in one swath A vertical line spans many swaths and therefore requires more entries in the Printer s internal display list Raster Image Processor The raster transfer language RTL provides a solution to insufficient memory on the Printer When all the data is sent to the Printer in the order left to right and top to bottom the Printer is able to plot the data as it receives it For this to happen software a raster image processor in the computer must first rasterize all the data The software issues a command referred to in RTL as no negative motion telling the Printer that it will not receive data for any media location on which it has already plotted The use of no negative motion is called flow mode Data flows through the Printer witho
75. nt Panel Overlay Spanish Front Panel Overlay Italian Front Panel Overlay Japanese Front Panel Overlay Portuguese Front Panel Overlay Chinese Front Panel Overlay Parts and Diagrams HP DesignJet 430 450C and 455CA Printers 7 25 Compatible Documentation HP Part Number Description C4713 90009 Software Application Notes 5965 9424 Accessories Guide 5965 9477 Media Swatch Book 5959 9733 HP GL 2 and RTL Programmer s Reference Guide English 5959 9734 The product Comparison Guide for HP GL 2 and HP RTL Peripherals English 5010 3997 PJL Technical Reference Manual English Plug in memory RAM SIMM HP Part Number Description C3132A 4MB RAM SIMM C31338A 8MB RAM SIMM C3146A 16MB RAM SIMM D3578A 32MB RAM SIMM eveacv hencf wuvi he rl atetv ee flePSC Cartridges HP Part Number Description 51640A Black 51644C Cyan 51644M Magenta 51644Y Yellow 7 26 HP DesignJet 430 450C and 455CA Printers Parts and Diagrams External Print Servers HP Part Number Description J2591A Jetdirect EX Plus Ethernet J2593A Jetdirect EX Plus 3 Ethernet J2594A Jetdirect EX Plus 3 Token Ring Parallel Bi Tronics Centronics Interface Cables Computer HP Part Cable length Connector type at Number computer end of cable HP 9000 workstations series 300 400 700 C2950A 2 0 m 6 9 ft 25 pin male IBM AT IBM PS 2 IBM PC XT and C2951A 3 0 m 9 8 ft 25 pin male compatible computers Serial RS 232 C Interface Cables Computer HP P
76. nter on in service mode 1 Turn the Palmtop on Open the Data Comm application on the Palmtop and press MENU Move to the Connect menu and press ENTER Ensure that Settings are the same for both Printer and Palmtop Again move to the Connect menu and press ENTER With Connect highlighted in the Connect menu press ENTER Perform the service tests on the Printer To stop communication between the Printer and the Palmtop highlight Hangup in the Connect menu and press ENTER Service Tests HP DesignJet 430 450C and 455CA Printers 4 7 Bail Cycle Test This tests the operation of the bail system Service Station and the Y axis by engaging and disengaging the bail lift mechanism and capping uncapping the cartridges The test will perform the number of cycles as specified in the EEROM but if the EEROM is cleared this test will not function This Test has been designed to be used during the manufacturing stage and not in the field If the Bail needs to be tested please use the Bail Test in Service Mode 2 If a system error prevents you from entering into Service Mode 2 you may try this test instead Perform the Bail Cycle test as follows 1 In service mode 1 press Bail Cycle Test Setup Key 2 The test will start and the Carriage will move out of the Service Station and activate the engaging lever which causes the Bail Assembly to be gently raised and then lowered 3 The test repeats the number of cycles as defined in the
77. og box Otherwise you may need to install more memory to print this print For information on available memory expansion modules see Chapter 7 Or there is a problem with the serial interface The printer s settings for baud rate and parity must be the same as those of the computer sending the data Either the sheet you loaded is misaligned Realign it again See the Users Guide for a short tutorial on loading media Or it is an invalid size For supported media sizes refer to the Users Guide Or the media lever is lowered Raise the lever Or the cover is open when the printer is initializing Lower the cover 3 4 HP DesignJet 430 450C and 455CA Printers User Messages Service Tests HP DesignJet 430 450C and 455CA Printers 4 1 Introduction This chapter explains how to use the built in Service Tests Diagnostics and what to do if the tests fail If possible always perform a Service Test on the component that you are about to replace just to make sure that is the component that has failed If the test on that component passes there is no need to replace it Power On The Printers automatically perform a series of internal self tests and mechanical initialization sequences whenever the user switches the Printer on If a failure occurs an error is indicated on the front panel LEDs You can perform a failure analysis by interpreting the LED error code Details Chapter 2 Self Te
78. on in the Service Station System Error Codes HP DesignJet 430 450C and 455CA Printers 2 5 Ready Align Media Load Media Media Error in bail lift mechanism The bail lift system is unable to raise or lower the bail It is the carriage that tests to see whether the bail is in the correct position by trying to knock against it Possible causes e Check the bail lift system to see if it is working correctly e Use the bail cycle test to help troubleshoot Ready Data Media Error in X axis calibration Possible causes e Is X axis calibration done details Chapter 5 e Did you load media in correct orientation e Are the marks visible on the plot If not check cartridges e Are cartridges correctly aligned If so the problem may be in the electronics module media motor or drive roller gear if alignment is incorrect the problem may be in the carriage Load Media Data Firmware has a problem interacting with some of the characteristics of the print The Printer is using an old Firmware revision Install the latest firmware revision e If this error remains report the problem to your HP Response Center Note conditions and actions before error occurred Include setup sheet and service configuration plot in report Ready Align Media Load Media Data This is a generic System Error that covers about 600 error codes e Report the problem to your HP Response Center Note conditions and a
79. onnect the Printer to the ac power source N Switch the Printer ON and wait for it to finish initialization ve Open the top cover rN Keep the cover switch pressed while pressing Form Feed repeatedly until the stained area of the drive roller is positioned at the top where it can be cleaned Turn the Printer OFF and disconnect it from the ac power source Apply IPA alcohol to a soft lint free rag Use the rag to clean the roller surface Allow the drive roller to dry O 10 oO If other areas of the roller have been stained by ink repeat the above steps 10 Reconnect the Printer to the ac source turn the Printer on and load paper to test that no ink reflections disrupt operation of media loading 9 4 HP DesignJet 430 450C and 455CA Printers Preventive Maintenance 10 Functional Overview HP DesignJet 430 450C and 455CA Printers 10 1 Introduction The HP DesignJets 430 450C and 455CA follow on from and replace the DesignJet 330 and 350C The HP DesignJets 430 450C and 455CA like the DesignJets 230 330 250C and 350C have inherited much of the system architecture and features of the DesignJet 220 Their writing system however is based on that of the DesignJet 650C This chapter describes some of the main features of the HP DesignJets 430 450C and 455CA Before reading it read the functional overview of the DesignJet 220 HP DesignJet 220 and HP DesignJet 200 Printers
80. oy 6 16 Uneven Pill Density stcceceeetsanatitandverconeeaswesandacdieawaetes 6 16 ODLIV spark neat aek asennad dap ba gees ene eewhembadanei ween tans 6 16 Bleeding Blooming and Wicking 6i024 c14 case babidsScleebadesaiaws ys 6 17 Ink Smear ax sntureeticeseuioneecneoakeee eee NERDE eases 6 17 Ge NAN GCS ooo ice ttn wdaneraadnned oedoatennhedateedanehedss eaanagen 6 18 7 Parts List Exchange Assemblies oi icky ckisn dmb entecdednw es nacdeeuiebeatsexerbaenes 7 2 Replacement PAIS 2 1 0440 5442eceuwerederweueres doteee se veusneeeek cues 7 2 Figure 1 General View cprsisiiosocsreiirid perst PEC RREO eaves oes 7 3 Figure 2 Printer Support 44 44 icatscceaumnnes au edad eadb ac acarawens 7 4 Figure 3 Rollfeed Assembly a0 o6 dass baCdeew desc sa eed esdnetdsatindes 7 6 Pipure 4 COVErS gcsascetedecn aide sate B84 ta Gee gale ae Ae Ee ha eR a N 7 8 Figure 5 Front Panel Spittoon and Electronics Module 7 10 Figure 6 X and Y axis Motors and Encoder Strip 00 05 7 12 Figure 7 Primer Assembly and Service Station Assembly 7 14 Figure 8 Carriage Assembly and Trailing Cable 7 16 Figure 9 Bail and Overdrive Mechanisms 0 ee eee eee 7 18 Figure 10 Pincharm Assembly 00 cece cee ete een eee eens 7 20 Figure 11 Entry Platen Drive Roller Bail and Overdrive Assembly 7 22 Printer Labels csusaneteceusetierstetwe teens barbededseoun
81. p cover 2 Move the carriage out of the service station 3 Remove the Yellow cartridge from the carriage 4 Check the gauge to determine the GO and NO GO sides JE 5 Place the gauge on the drive roller on the left hand side of the carriage with the GO side facing the carriage in the position shown below Service Calibrations HP DesignJet 430 450C and 455CA Printers 5 5 Gauge Gauge must be parallel to the center line of the Drive Roller Drive Roller 6 With the gauge held in place manually move the carriage over the GO side of the gauge The ledge indicated below should easily pass over the GO side of the gauge WARNING Make sure that the carriage is in the down position at all times when passing over the gauge Ledge If the ledge does not go over the GO side of the gauge adjust the carriage to media distance page 5 7 7 Remove the gauge and replace it on the drive roller with the NO GO side facing the carriage 8 With the gauge held in place manually try to pass the carriage over the NO GO side of the gauge The ledge indicated above should NOT pass over the NO GO side of the gauge If the ledge does go over the NO GO side of the gauge adjust the carriage to media distance page 5 7 9 Replace the Yellow cartridge in the carriage 10 Move the carriage back into the service station 11 Close the top cover 5 6 HP DesignJet 430 450C and 455CA Printers Service Calibration
82. peration of the electronics carriage axis system media axis system bail lift mechanism and service station The bench run is performed at the manufacturing site by sending special commands to the Printer and then pressing the indicated front panel keys If the Printer is switched OFF during the Bench Run the Bench Run will be resumed at exactly the same point before the Printer was switched OFF until the Bench Run is completed THIS TEST HAS BEEN DESIGNED TO BE USED DURING THE MANUFACTURING STAGE AND NOT IN THE FIELD DO NOT AT ANYTIME ENTER THIS TEST WHEN TROUBLESHOOTING THE PRINTER 1 The way to enter to Bench Run is to press the Media Source and Form Feed keys in Service Mode 1 If these keys are accidently pressed you must immediately EXIT the Bench Run by switching OFF the Printer and powering ON again while pressing the Print Quality and Media Source keys 4 18 HP DesignJet 430 450C and 455CA Printers Service Tests Modular Test This test has been created to check the interaction between various components of the Printer It combines the following tests e Carriage axis test e Carriage test e Media axis test e Front panel test e Sensors test This Service Mode does not include carriage axis initialization If the carriage starts somewhere out of the Service Station it will hit the right hand side of the Printer when the test begins and the test will fail Always make sure that the carriage is parked in the
83. ppear if the test passes or fails If the test fails to resolve the problem try one of the following 1 If the cover sensor fails check that the front panel assembly is correctly connected to the electronics module Try replacing the front panel assembly 2 Ifthe Pincharm sensor fails check that the sensor cable is correctly connected to the electronics module Try replacing the pincharm sensor 3 If the Media sensor fails check that the sensor cable is correctly connected to the electronics module Try replacing the overdrive assembly the media sensor is included as part of the overdrive assembly 4 Replace the Electronics Module page 8 13 Only replace one component at a time and perform the test again before replacing another component Using this procedure you will be able to determine exactly which component failed Service Tests HP DesignJet 430 450C and 455CA Printers 4 15 Media Axis X Axis Test The purpose of this test is to verify the operation of the components of the Media Axis Perform the Media Axis test as follows 1 In service mode 1 press Media Axis Test Media Load Button 2 The test will start and the drive roller rotates in steps each equivalent to one swath advance 3 Ifthe test passes the Glossy LED LED J will light up after the first cycle If you are viewing information via the serial port you will see output similar to the following 3 X AXIS TEST Test Mode X Axis Cycle
84. ppen if the cam is over or under rotated The notch on the cam used to engage the left bail bracket is not properly located for the bail up condition and the bail falls abruptly Perform a bail cycle test Adjust carriage Ifthe carriage moves over the engaging lever without raising it you may need to adjust the carriage angle on the slider rod Details page 5 5 However be careful not to jeopardize the print quality which is very sensitive to the carriage angle What is an EEROM error An EEROM error means that some of the internal tests that the firmware performs have detected that when re reading information from the EEROM it doesn t correspond to the information that had previously been written there or that the checksum of all the information is incorrect This failure has five possible causes Faulty electronics module Contact problems with the trailing cable connections Faulty trailing cable Faulty carriage The Printer was turned off while a test was writing to the EEROM thus leaving corrupt information or a communication cable was disconnected while sending information to the EEROM using software diagnostic tools It is generally not easy to discover the cause due to the intermittent character of the failure modes 1 8 HP DesignJet 430 450C and 455CA Printers Troubleshooting If you are sure that the failure occurred just after an electricity power cut or after turning off the Printer du
85. print quality mode then use Best print quality mode instead SPRAY Symptoms Smaller dots of sprayed ink located around the point at which the required dot is placed Product Fault The cartridges are positioned too far from the media Solution Check the carriage to media distance Details chapter 5 Replace the faulty cartridge s 6 16 HP DesignJet 430 450C and 455CA Printers Print Quality BLEEDING BLOOMING AND WICKING Symptoms Blurred lines See also User s Guide chapter 9 e Bleeding Different color inks printed side by side run into each other e Blooming Ink absorbs into the paper spreading beyond the desired ink dot e Wicking Ink spreads along a fiber or fibers in the paper creating a spider web effect Product Fault Printing in fast mode Media Fault e The ink is incompatible with the media type e Environmental conditions may affect the media Temperature or humidity levels are too high Solutions One or more of the following actions may be appropriate to solve the problem e Change the plot quality mode Plotting in Best mode slows plotting but improves quality e Use better quality media e If you are plotting on vellum or translucent media try using Hewlett Packard media e Recommended environmental conditions for optimum plot quality are in the range of 15 35 degrees Celsius 59 95 degrees Fahrenheit with 20 80 relative humidity e Pen problem TTOE T
86. r Cam D A1 size C1633 20012 1 Pincharm Bar Cam K A0 size 10 C1633 40082 5 Pincharm Bar Bushing D A1 size C1633 40082 7 Pincharm Bar Bushing E A0 size 11 C1633 80005 5 Pincharm Bar Spring D A1 size C1633 80005 7 Pincharm Bar Spring E A0 size 12 C4699 60081 5 Pincharm Assembly D A1 size C4699 60081 7 Pincharm Assembly E A0 size 7 20 HP DesignJet 430 450C and 455CA Printers Parts and Diagrams Oy reds LP VAN CW Os 12 Figure 10 Pincharm Assembly 7 21 HP DesignJet 430 450C and 455CA Printers Parts and Diagrams Figure 11 Entry Platen Drive Roller Bail and Overdrive Assembly Reference HP Part Number Quantity Description ee 1 C4713 60093 1 Bail Assembly D A1 size C4714 60093 1 Bail Assembly E A0 size 2 0515 2337 1 Screw Long Dogpoint 3 0515 2765 1 Screw 4 C3180 20001 2 Alignment Screw 5 C4713 60115 1 Overdrive Assembly D A1 size C4714 60115 1 Overdrive Assembly E A0 size 6 0515 2250 2 Screw Media Button Assy T C4713 60117 1 Media Button Assembly 8 0515 2250 1 Screw Media Deflector 9 C4713 40011 1 Media Deflector 10 C4699 60042 1 Driver Roller Assy D A1 size C4700 60042 1 Driver Roller Assy E A0 size 11 C4713 40023 1 Side Trim Left 12 0627 0769 1 Screw 13 C4713 40022 1 Side Trim Right 14 C3180 20001 1 Alignment Screw 15 C4713 60114 1 Entry Platen Assy D A1 size C4714 60114 1 Entry Platen Assy E A0 size 16 0515 1743 1 Screw 7 22 HP DesignJet 430
87. r ON After initializing error code DLM will appear because the Accuracy Calibration must still be performed 12 Press the Cancel key and print the Demo Plot to check if the Printer has been correctly configured as a DesignJet 430 450C or 455CA If the Printer is still incorrectly configured then Error Code EKPI will be displayed on the front panel Turn the Printer OFF and perform the EEROM Model ID configuration procedure again from step 2 13 Perform the accuracy calibration refer to Chapter 5 4 28 HP DesignJet 430 450C and 455CA Printers Service Tests HP DesignJet 400 Series Printers Service Manual Annex A EEROM Model ID Configuration Procedure for HP DesignJet 488CA To be included in pages 4 27 and 4 28 of Service Manual EEROM Model ID Configuration Procedure The EEROM model ID configuration procedure only needs to be carried out if e A pre configured board is being reused e The current board is incorrectly configured to the wrong model ID e The Printer shows an unconfigured model ID system error Steady EKL It is very rare that these situations will ever occur Configure the Printer model ID as follows 1 Remove the right end cover page 8 11 2 Disconnect the media motor encoder cable from the main PCA connector ENC X 3 Turn the Printer ON while holding the Reprint key down 4 Press the Media Source and Media Type keys together to enter the deconfiguration mode The Fast Normal and B
88. rcing use of RIOX method for Magenta 11361 1953 Pen BLACK continuity WORKS Pen CYAN continuity WORKS Pen MAGENTA continuity WORKS Pen YELLOW continuity WORKS Pen BLACK has 1cd4 identification Pen CYAN has 400 identification Pen MAGENTA has 1f00 identification Pen YELLOW has 1900 identification Optical sensor samples 253 255 255 254 253 252 252 250 249 248 247 246 245 244 243 241 Optical Sensor WORKS Carriage MUX WORKS Pen BLACK continuity WORKS The test is continued on the next page 4 12 HP DesignJet 430 450C and 455CA Printers Service Tests If you are viewing information via the serial port you will see output similar to the following if the Test Fails 4 Carriage Test 0x57c7c350 carrPCBTest Forcing use of RIOX method for Calvin 13643 1960 0x57c7c350 carrPCBTest Forcing use of RIOX method for Yellow 12160 1899 0x57c7c350 carrPCBTest Forcing use of RIOX method for Cyan 12160 1899 0x57c7c350 carrPCBTest Forcing use of RIOX method for Magenta 12160 1899 Pen BLACK continuity FAILS Pen CYAN continuity FAILS Pen MAGENTA continuity FAILS Pen YELLOW continuity FAILS Pen BLACK has 3ffe identification Pen CYAN has 3ffe identification Pen MAGENTA has 3ffe identification Pen YELLOW has 3ffe identification Optical sensor samples 215 252 243 232 221 208 194 179 166 151 135 119 103 87 71 54 Optical Sensor WORKS Carriage MUX FAILS Pen BLACK continuity FAILS 4
89. riage and the Cartridges Reseat the Cartridges and try the test again If the error is still present replace the cartridges and print the Print Quality Plot again If the error continues try the following e Replace the Encoder Strip page 8 15 e Replace the Trailing Cable page 8 8 e Replace the Carriage Assembly p page 8 37 e Replace the Electronics Module p page 8 13 Only replace one component at a time and check if the problem has gone before replacing another component Using this procedure you will be able to determine exactly which component failed 6 14 HP DesignJet 430 450C and 455CA Printers Print Quality No Printing Defects Found in the Print Quality Plot If all the test patterns from the Print Quality Plot are correct and you still experience print quality problems here are some of the other causes to check e The print mode used in your printer is incorrect this is defined by the printer s front panel menu selections e Non HP driver e The RIP If you are using one e The software applications you are using Refer to the User s Guide for further information on how to configure the system with correct settings Media Always make sure that the customer is using the appropriate media for the required image and that it is consistent with the software application being used To ensure color accuracy and print quality performance of the printer only media types that have been certified for the
90. ring the bench run or other service tests then the Printer is not faulty You just need to reset the EEROM In other cases you need to find the cause e There is always an EEROM error when you switch on the Printer e If it is easy to reproduce a Steady EKL error then try one or all of the following steps for a possible solution 1 Configure the EEROM with the correct model ID instructions page 4 27 2 If you cannot configure the EEROM with the correct model ID after several attempts and you continue getting the same error code replace the electronics module page 8 13 e There is sometimes an EEROM error when you switch on the Printer normally shows up as a Steady EK error 1 Switch on the Printer allow it to initialize until it has completed the power on LED sequence and switch off the Printer You are now sure that the EEROM has not been corrupted If a Steady EK error appeared it also corrects the EEROM contents and the next time you switch the Printer ON the error should not occur in good units 2 Leave the unit off for 15 minutes to detect if the EEROM is losing its information Then turn it on again and allow it to initialize If a Steady EK error appears during the initialization sequence and the carriage does not begin to move then the EEROM is probably faulty Replace the electronics module Troubleshooting HP DesignJet 430 450C and 455CA Printers 1 9 System Error Codes HP DesignJet 430 45
91. ropriate number on the drawing with the same number in the parts list for information on that part The total quantity for each part on the drawing is given as well as the part number To obtain replacement parts contact the nearest HP Support Office You must include the part number and part description in the order you send Also include the Printer model and serial number 7 2 HP DesignJet 430 450C and 455CA Printers Parts and Diagrams Primer Assembly amp Service Station Bail amp Overdrive Mechanisms Page 7 14 Page 7 18 yy a eli ered Pincharm Assembl Page 7 16 Covers Page 7 20 y Page 7 8 5 J X amp Y axis Motors Page 7 12 Rollfeed Assembly Page 7 6 Front Panel Spittoon amp Electronics Module Page 7 10 Printer Support Page 7 4 Nidunb C pPbi bnal Ribo HP DesignJet 430 450C and 455CA Printers T3 Parts and Diagrams Nigune 2 pPmntemSuppont Reference HP Part Number Quantity Description jeene 1 C4704 60095 1 Hardware Kit Includes Screw Drivers 2 C4704 60086 2 Foot Assembly 3 C4704 60075 2 Legs Assembly 4 C6069 60002 1 X axis Brace D A1 size C4704 60077 1 X axis Brace E A0 size 5 C6069 40001 1 End Cap D A1 size C4704 40070 1 End Cap E A0 size 6 C6069 60001 1 X Bar Assembly D A1 size C4704 60074 1 X Bar Assembly E A0 size T C4704 60073 6 Paper Loop Assembly 7 4 HP DesignJet 430 450C and 455CA Printers Parts and Diagrams o lb F X AVUN LGT
92. s To adjust the carriage to media distance You will need to adjust the carriage to media distance if e The ledge on the carriage did not pass over the GO side of the gauge This means that the carriage is positioned too close to the drive roller e The ledge on the carriage did pass over the NO GO side of the gauge This means that the carriage is positioned too far from the drive roller Adjust the carriage to media distance as follows 1 Release the two indicated clips on the top of the cartridge carriage by pulling them slightly outwards Take care neither to cut yourself on the encoder strip nor to damage the strip Service Calibrations HP DesignJet 430 450C and 455CA Printers 5 7 3 Tighten or loosen the indicated screw on the carriage This will adjust the carriage angle on the slider rod thus increasing or decreasing the carriage to media distance Co Rotating Clockwise Gap Increases 1 4 Check the carriage to media distance page 5 5 5 Reinstall the top of the carriage 6 Check the trailing cable to make sure that it is positioned under the plastic tabs at the back of the carriage cover and not above them Trailing cable under tabs ZA Otherwise the Printer will not be able to load media 5 8 HP DesignJet 430 450C and 455CA Printers Service Calibrations Print Quality HP DesignJet 430 450C and 455CA Printers 6 1 Print Q
93. service station before starting this test If one part of the test fails the other parts continue regardless Perform the Modular test as follows 1 Make sure that the carriage is parked in the service station 2 In service mode 1 press Modular Test Media Source Key 3 The printer first performs the Front panel Test and once it is fully completed once all the keys are pressed then continues with the rest of the above tests in parallel 4 Refer to the following figure to check which LED is associated with which test If the test passes the following LEDs will be lit ON If the test fails the following LEDs will be flashing ANFI TENEO R Daan The test is continued on the next page Service Tests HP DesignJet 430 450C and 455CA Printers 4 19 5 The test continuously repeats itself until you press the Cancel and Media Source keys If you are viewing information via the serial port you will see output similar to the following if the Test Passes FRONT PANEL TEST Y AXIS TEST X AXIS TEST CARRIAGE TEST 5 SENSORS TEST Test Mode X axis cycle 87 pwm 0x57c7c350 carrPCBTest Forcing use of R10X method for Calvin 13643 1960 0x57 7c350 carrPCBTest Forcing use of R10X method for Yellow 11361 1953 0x57 7c350 carrPCBTest Forcing use of R10X method for Cyan 11361 1953 0x57 7c350 carrPCBTest Forcing use of R10X method for Magenta 11361 1953 Test Mode Y axis cycle 26 67 speed and 68 pwm Test Mod
94. signJet 430 450C 455CA Printers users should limit use to the following recommendations duty cycle Average number of plots per day Maximum number of plots per day 10 E AO CAD plots 20 E AO CAD plots The service configuration plot gives an indication of how much the Printer has been used number of plots number of cartridges number of times the Printer has been turned on Details page 4 29 Friction on Slider Rod The carriage bushings are made of a porous composite material Oil stays inside them by means of capillary action Never place the bushings on an absorbant material To prevent friction of the bushings on the slider rod remove dirt from the slider rod and chassis beam Apply oil Anderol 4068 HP part number 6040 0858 to the slider rod 3 drops and to the bushings if they are running dry Noisy Carriage Wheel To prevent noisy movement of the carriage remove aluminum or dust particles from the wheel at the back of the carriage and from the slider path along which the wheel moves 9 2 HP DesignJet 430 450C and 455CA Printers Preventive Maintenance Ink Spilling The service configuration plot gives an estimation of the amount of ink in the Printer s spittoon Details page 4 29 To prevent ink spilling replace both the spittoon and the ink separator when the spittoon is almost full About 880 primes are needed to fill up the ink separator Note that if you clear the EEROM or replace the el
95. sing this procedure you will be able to determine exactly which component failed Service Tests HP DesignJet 430 450C and 455CA Printers 4 11 Carriage Test The purpose of this test is to verify the operation of the Carriage subsystems like the Line Sensor and analog multiplexer This test also checks the connection between the carriage flex circuit and the cartridges Perform the Carriage test as follows 1 In service mode 1 press Carriage Test Print Quality Key 2 The test will start and all the LEDs will turn OFF There will be no movement in the Printer and you must wait for the Front Panel to indicate if the test has passed or failed 3 Refer to the following figure to check which LED is associated with which test If the test passes the following LEDs will be lit ON If the test fails the following LEDs will be flashing EE EE EE Ee SETUP FORM FEED REPRINT CANCEL BLACK CARTRIDGE CONTINUITY _ ERROR Keane AE OG MULTIPTE CONTINUITY ANALOG MULTIPLEXER PRIHT QUALITY MEDIA TYPE MEDIA SOURCE CARRIAGE TEST If you are viewing information via the serial port you will see output similar to the following if the Test Passes 4 Carriage Test 0x57c7c350 carrPCBTest Forcing use of RIOX method for Calvin 13643 1960 0x57c7c350 carrPCBTest Forcing use of RIOX method for Yellow 11361 1953 0x57c7c350 carrPCBTest Forcing use of RIOX method for Cyan 11361 1953 0x57c7c350 carrPCBTest Fo
96. st and Normal Initialization The power on self test and initialization procedure does the following Initializes the servo processor Initializes the main processor Tests communication between the main processor and the servo processor Tests the EEROM checksum Tests the servo processor transfer buffer and interrupt tracking Tests the ROM checksum Causes the main processor to initialize certain firmware modules Performs a subset of the electrical service test eomarnrank kt WO WN Checks the cover sensor If the cover is open nothing further happens until you close it 10 Initializes the carriage axis Y axis 11 Uses the mark encoder to check the start of the drive roller 12 Ejects any loaded sheet Does not eject roll media if loaded 13 Checks the media sensor 14 Sets the Printer to accept media 4 2 HP DesignJet 430 450C and 455CA Printers Service Tests Service Tests Which Service Test to Perform Use the following table as a rough guide Assembly Feature Bail system Carriage Carriage motor and drive system including belt pulley and slider rod Cartridge identification Cartridge nozzles Communication between computer and Printer Cover sensor DRAM SIMM EEROM Electronics module Encoder strip Front panel keys and LEDs Media axis encoder and cable Media motor and drive system including drive roller and overdrive Media sensor Pinch arm sensor Optical sensor on carriag
97. t Output Interfaces The Printers have both a parallel Bi Tronics and a serial RS 232 C interface Unlike the DesignJet 650C they have no modular input output MIO You can connect the Printers to a network by means of an HP JetDirect EX or HP JetDirect EX Plus3 external print server Bi Tronics In addition to the operating modes of the DesignJet 220 the Bi Tronics interfaces feature the extended capability port ECP forward and reverse operating modes providing for faster communication RS 232 C The supported baudrates are 1200 2400 4800 9600 19200 and 38400 with eight bits and no parity or seven bits with either odd or even parity Mark parity is not supported Both XON XOFF and DTR handshaking are supported ENQ ACK handshake is not supported Power Supply An auto ranging power supply is located in the electronics module The primary side of the power supply contains rectified line WARNING voltage that can be lethal when touched even if the ON OFF switch is OFF In any case you should not need to open the electronics module It is one exchangeable part Water Condensation In humid environments water may condense on the side plates A wick attached to the underside of the right side plate routes water drops away from the main PCA electronics 10 8 HP DesignJet 430 450C and 455CA Printers Functional Overview Memory Usage It is difficult to calculate the amount of Printer memory needed to plot a drawi
98. tained using the HP Solution is good and the one obtained through the 3rd party solution is bad HP support organization should e Communicate to the customer that the problem is not in the printer and that he should address it through the 3rd party vendor support structure 7 Accuracy Calibration details p Chapter 5 e Perform Accuracy calibration using HP Matte Film 6 2 HP DesignJet 430 450C and 455CA Printers Print Quality Print Quality Plot Introduction Whenever a Print Quality problem appears it is advisable to print the Print Quality Plot to help diagnose the problem The Print Quality Plot will help you differentiate between possible cartridge errors and other problems such as incorrect front panel selection driver or RIP configuration or mechanical problems To achieve the best performance from the printer advise the customer to only use genuine HP accessories and supplies whose reliability and performance have been thoroughly tested to give trouble free performance and best quality prints Using the Print Quality Plot 1 The size of the Print Quality Plot is A3 and B so you must use media roll or sheet that is this size or larger 2 Use the same type of media that the customer was using when the Print quality problem was discovered 3 Study each of the test patterns in the order listed to determine the type of Print quality problem 4 If the customer was reporting problems of Print Quality using non
99. that the trailing cable is positioned under the plastic tabs at the back of the carriage cover and not above them 2 The Carriage is not at the correct height Check and if necessary adjust the Carriage height Details chapter 5 3 The Belt is not correctly positioned over the idler pulley 4 Check for a faulty bail lever mechanism because the Carriage may have trouble passing over it 1 4 HP DesignJet 430 450C and 455CA Printers Troubleshooting What can I do if the Printer continuously rejects Cartridges If you are in Service Mode 1 the cover sensor is disabled In order to test a new Cartridge set the Printer must be powered OF and and ON again 1 Remove tape and align cartridges One frequent cause of cartridge problems is that the user has forgotten to remove the tape from new cartridges Remove the tape 2 Dirty pads The connection between the carriage PCA and the cartridge flex connector is made by means of a gold bubble on the flex connector that touches a gold pad on the PCA The Carriage Test details page 4 12 includes a test of this connection When nozzle failures occur clean the flex contacts on the cartridge and in the Carriage 3 Continuity Problem Remove all the cartridges from the Carriage and try installing just the rejected cartridge If the cartridge is still rejected then replace the cartridge with a new one If the new cartridge is not rejected then check one by one if the other cartr
100. the Medi lt 6 c 00s o 2eere ead eds eve tes iteiten atean nia e 10 3 Pinch Arm Sens t s 24do00nategarenneSedevnrusn rea yeoaind E E E G 10 3 Providing a Force on Top of the Media 00 c cece eee eee eens 10 3 Bail cat iaicke otk eeban cued EN teeters hen ck Kote N E E ET 10 3 Bail Lift Mechanism 24 ous ce sa hohe eReedde Se eee ee ew eee 4ceh3 089s 10 3 Detecting the Lines and Media Edges 00 c cece cence eens 10 3 Line Sensor 2c a te xaews Si ekeueurse des doeberesteteorseuaustadeeek Cues 10 3 Movitie th Carriage coc cecvcaksedoraeniieedenriesieeleasacseedeciedetes 10 4 Carriage Drive Mechanics 4 4 466064 444 caeans isn cearaaadnadadanea ane 10 4 Motor Belt and Pulley 2230 ccnbhedeas ats ed bewndxaensrenndeea sa GeGuat ss 10 4 Carriage Guidance 3 zara teams kere cba EEE EENT EPOE NEESER 10 4 Positional Feedback lt c cscscsnsscssicernicrrer rentes henii raian 10 4 Carriag PCA opi seus aaaiee pra Annee a Rae teed dae whe 4 Paced Mae Be 10 4 Providing INK occasetdschiedhen CUsreeRExreeveieen Ma E aioe wacko 10 5 Print Cartridges 2 iiecnkeaucbancenateectsetancRiwienwadannesee een RS 10 5 Distance between Carriage and Media 0 0 cece cence eee aes 10 5 Producing an Image iusterseksdx tices teen bdieeereeeeener en RAN SEEE EN 10 5 Print Mode Characteristics 024 0504 cscs0eaee see nanne 10 5 Servicing the Cartridges 0 ccc ccc eee nen e een EERI TE 10 6 Dervic Statii isoina he I AEE NE
101. the fan turns on and the carriage moves to the right side of the Printer Instead of printing the drawing that you sent the Printer prints the first and last Kbytes of the code for that drawing The code is printed in hexadecimal and ASCII format If the total size of the file s sent is not bigger than one Kbyte only the first buffer is printed The Printer exits the service monitor mode if the file s sent contain PJL universal exit language 4 26 HP DesignJet 430 450C and 455CA Printers Service Tests EEROM Model ID Configuration Procedure The EEROM model ID configuration procedure only needs to be carried out if e A pre configured board is being reused e The current board is incorrectly configured to the wrong model ID e The Printer shows an unconfigured model ID system error Steady EKL It is very rare that these situations will ever occur Configure the Printer model ID as follows 1 Remove the right end cover page 8 11 2 Disconnect the media motor encoder cable from the main PCA connector ENC X 3 Turn the Printer ON while holding the Reprint key down 4 Press the Media Source and Media Type keys together to enter the deconfiguration mode The Fast Normal and Best LEDs LEDs ABC will light up EERO MODEL ID COHFIGURATION 5 Using a suitable tool short circuit pins 1 and 2 the first two pins on the right of the media motor encoder connector ENC X The Cartridges Data and Media LEDs
102. ts flashing The printer is e waiting for the media to dry This can be Q terminated by pressing Form Feed e You are loading media and need to X ALIGN MEDIA o realign it even if it seems perfectly e aligned e e R g e e e Lower the media lever realign the media is and raise the media lever e The printer is ready but you need to load e media LOAD MEDIA J e e When you are ready to print load media e e e e e J e e The printer has a file in memory which it e is waiting to print but no media is loaded LOAD MEDIA e G e e Load media o e e e J User Messages HP DesignJet 430 450C and 455CA Printers 3 3 Lights Explanation and Action Error Group eee EEE CARTRIDG aS ee o Either one of the color or black print cartridges is faulty misplaced or missing Reseat or replace the cartridge Or you have loaded a print cartridge of the wrong type for this printer For the correct part numbers of the cartridges supported by this printer see Chapter 7 Either the current print is too large for the printer s memory Look on your computer screen for any error message some drivers for example the Microsoft Windows driver supplied with your printer allow you to choose a different printing mode and try to send the file again In the case of the Microsoft Windows 95 driver shipped with the printer the relevant field is called Process document in the Options dial
103. uality Troubleshooting Checklist When faced with a Print Quality problem use the following checklist as a guide in troubleshooting the problem 1 Problem reproduction e Reproduce the problem that the customer is seeing using their original settings 2 Printer configuration e Print Mode Set to Best in the printer and in the drivers e Select the correct media setting when loading the media 3 Hardware check list e Check if the latest version of the firmware is installed If not Install the latest firmware revision 4 Cartridges Cartridge Troubleshooting Process e If you don t have any samples yet reproduce the original problem with the correct printer settings e Print the Print Quality Plot using the exact settings and Media that the Customer used when faced with the Print Quality problem page 6 3 Cartridge Alignment e Perform the Cartridge Alignment procedure details p User s Guide 5 Media e Make sure that you use HP or HP approved media e Select the correct media type through the front panel when loading it 6 Driver print quality configuration To clarify if the reason of the problem is related with the print mode defined with the Non HP Driver try the following e Print the same sample using the Non HP driver and their normal media e Print the internal demo or print the Print Quality Plot details page 6 3 using HP Media and configuring the printer as indicated previously If the output ob
104. uncapping the cartridges to ensure a correct lifting action Front Panel Test page 4 9 The purpose of this test is to verify the operation of the front panel keys and LEDs Carriage Axis Y axis Test page 4 10 The purpose of this test is to verify the operation of the components of the Carriage Axis Carriage Test page 4 12 The purpose of this test is to verify the operation of the Carriage subsystems like the Line Sensor and analog multiplexer This test also checks the connection between the carriage flex circuit and the cartridges Sensors Test page 4 15 This tests the operation of the cover sensor pincharm sensor and media sensor Media Axis X Axis Test page 4 16 The purpose of this test is to verify the operation of the components of the Media Axis Bench Run page 4 18 This test has been designed to be used during the manufacturing stage and not in the field do not at anytime enter this test when troubleshooting the Printer Modular Test page 4 19 This test has been created to check the interaction between various components of the Printer It combines the following tests e Carriage axis test e Carriage test e Media axis test e Front panel test e Sensors test 4 4 HP DesignJet 430 450C and 455CA Printers Service Tests 9 Electronics Test page 4 21 The purpose of this test is to verify the operation of the FIBIS Column address and the shuffler 10 Bail Test
105. upper band is shaded from 100 scaling to 60 The purpose of this test is to determine at what percent the upper shading becomes visible from the lower band The best way to do this is to cover the box with a piece of paper and slide the paper horizontally across the box Stop as soon as you see a different shade in the upper box You can then determine the percentage scaling from the figure at the top or bottom of the box 60 70 80 90 100 Figure 7 Correct 60 70 80 90 100 Figure 8 Incorrect Print Quality HP DesignJet 430 450C and 455CA Printers 6 11 Variation Problem If the upper box shading is never visible or is visible at a very low percentage it is an indication that the cartridge is producing incorrect size ink drops see Figure 8 Corrective Action Try the following steps 1 Replace the failing cartridge and print the Print Quality Plot again 2 Ifthe error continues try the following e Replace the Trailing Cable page 8 8 e Replace the Carriage Assembly page 8 37 Only replace one component at a time and check if the problem has gone before replacing another component Using this procedure you will be able to determine exactly which component failed Test Pattern 6 Banding Test This Test pattern is a long dark stripe and is NOT numbered on the Print Quality plot It can be found on the left hand side of the other test patterns Symptoms Random dark or light bands in area f
106. ut being stored in a display list so the size of the file that you can send is almost unlimited Functional Overview HP DesignJet 430 450C and 455CA Printers 10 9

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