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HP C2858A/C2859A DRAFTING PLOTTERS

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1. C C2858 47b Figure 6 18 Removal and Replacement 6 25 PAPER MOTOR REMOVAL Note The drive roller gear and paper motor must be replaced at the same time To remove the paper motor and drive roller gear perform the following procedure 1 Un A N Remove the right endcover Remove the electronics enclosure cover Remove the carriage motor Remove the front panel assembly Disconnect the paper motor cable connector labeled P from the interconnect PCA Disconnect the encoder cable connector from the paper motor See Figure 6 19 Note Note the orientation of the mark 9 0 clock position on one side of the drive roller gear for installation purposes Using a TORX T 10 screwdriver remove the two screws that secure the drive roller gear to the drive roller shaft and remove the gear Using a TORX T 20 screwdriver remove the two screws that secure the ink drop well and remove the well Using a TORX T 15 screwdriver remove the two screws that secure the paper motor to its bracket 10 Pull the paper motor toward the rear of the plotter until the motor can be removed from the plotter If installing a new motor apply grease supplied with the motor to the motor worm gear Note Ensure that the mark on the drive roller gear faces to the front of the plotter 9 O clock position when the motor worm gear is fully engaged with the drive roller gear 6 26 Remova
2. Parts and Diagrams 10 19 Ref Des BLO6 ovoovoc o0ourso0liT N HP Part Number C2858 60006 C1633 40051 C2858 60005 C2858 40001 C2858 40032 C1676 40167 C2858 40002 C2858 40003 0616 0616 C2858 60013 C2858 60011 C1676 80010 Da OCONF WON WWANY WW Parts List Service Station Assembly Qty Ne eR Se ee eee gd Description CABLE ASSEMBLY BAIL SENSOR FLAG BAIL SENSOR BAIL SENSOR SERVICE STATION HOUSING WIPER SERVICE STATION CAP SERVICE STATION SLED SERVICE STATION COVER SERVICE STATION SCREW TAPTITE DROP DETECT SENSOR CABLE ASSEMBLY DROP DETECT SENSOR SPRING SERVICE STATION 10 20 Parts and Diagrams Service Station Assembly Illustrated Parts Breakdown C C2858 9 1 10 21 Parts and Diagrams Ref Des 1 16 17 18 19 20 21 22 HP Part Number C2858 60023 C2847 00029 1500 0856 C2858 00028 C2859 00005 9170 1536 C2858 00027 0515 0380 07570 60112 07550 40104 1460 2061 0515 1349 07575 40125 C2858 00007 C1633 60029 C2858 00006 C2847 00042 C2848 00011 3050 0026 0535 0031 C1633 20034 1500 0855 07570 60043 0515 2248 3140 0907 Parts List Carriage Axis Drive Right End C D NYNODDONTNANNAN WAN FHON r2c 1U 1 E Qty Ne a ee ee ee ee oe eo t Description PEN CARRIAGE ASSEMBLY SEE PAGE 10 25 BELT MAIN DRIVE MODEL C2858A MODEL C2859A TRAILING CABLE TRAY FRONT MODEL C2858A MODEL C2859A
3. re E Front Guide Screw Tensioner Housing C C2858 53 Left Side Ferrite Ring Trailing Cable Guide Screw Inside Ring f E I e n a siU Y drive bracket C C2858 73 Right Side Figure 6 24 Removal and Replacement 6 35 Y TENSIONER AND HOUSING REMOVAL To remove the Y tensioner and housing perform the following procedure 1 Remove the left endcover 2 Slide the pen carriage a few inches towards the center of the plotter in order to access the tensioner 3 Remove the trailing cable guide screw which attaches the guide to the tensioner housing 4 Using a TORX T 15 screwdriver remove the tensioner plate screw See Figure 6 25 CAUTION The tensioner plate is under spring tension Ensure that the plate does not spring back Hold the right end viewed from the rear of the tensioner plate to keep the tensioner spring compressed Move the plate to the right until it clears the slot in the housing 5 Carefully move right end of the tensioner plate up and clear of the retaining tab 6 Decompress the tensioner spring by allowing the tensioner plate to move toward the rear of the plotter 7 Remove the Y tensioner spring and Y tensioner from the housing 8 Using a TORX T 15 screwdriver loosen the Y tensioner housing screw 9 Remove the Y tensioner housing from the Y tensioner bracket 10 Release the main idler from the pen carriage belt 11 Lift the Y tensio
4. Removal and Replacement 6 45 Wiper Cap C C2858 79 Sled Rubber Tubes Through Sled Springs middle tubes between springs outer il tubes outside Tubes Through aa d ofsprings Slot In Bottom Of E Hl Service Station Housing Z o 3 IS i C C2858 80 Stops Sled Springs Bail Sensor C C2858 81 Figure 6 30 page 2 of 2 6 46 Removal and Replacement OVERDRIVE SUPPORT ASSEMBLY REMOVAL To remove the overdrive support assembly perform the following procedure 1 Remove the window assembly 2 Remove the left and right endcovers W Remove the encoder strip 4 Remove the front panel assembly 5 Remove the cutter assembly Remove the bail assembly Ny A Remove the service station assembly 8 Using a TORX T 15 screwdriver remove the gear shoulder screw that secures the overdrive cluster gear to the left sideplate See Figure 6 31 9 Pull the overdrive cluster gear out of the plotter The gear should move freely when properly installed 10 Using needle nose pliers and a small standard screwdriver remove the clutch re taining ring that secures the overdrive assembly clutch to the overdrive assembly shaft Note Note the position and orientation of the overdrive assembly clutch Markings are located on the outside edge of the clutch When correctly insta
5. X axis feedback operation is checked Remainder of DRAM tested Troubleshooting 8 3 ERROR MESSAGES AND CODES Two types of error messages can be viewed in the front panel display Worded error messages System error codes WORDED ERROR MESSAGES Worded error messages indicate that a user error or an internal error has occurred Some error messages require action to clear and others are only displayed until the next operation is per formed by the plotter See Table 8 1 Message Alignment error Continue Calibrate error Continue Edge not found Reload media Error lowering bail Lower lever to continue Table 8 1 Worded Error Messages Error Action The plotter experienced an internal alignment failure The window was lifted or the front panel was used to perform some other action while pen alignment was proceeding Press the down arrow to continue Rerun pen alignment The calibration plot was loaded incorrectly and it could not be measured Press the DOWN ARROW to continue then reload the calibration plot Follow front panel instructions Plotter could not find edge of media during loading procedure using the optical sensor on the carriage Note which carriage side failed left or right Check the leading edge of the media for unevenness cut a straight edge if nec essary and reload Be sure to position the right edge along the perforated line on the entry platen when loading Cle
6. C1633 80015 C1633 60034 C1633 40037 C2847 00011 C2848 00008 0515 2246 C2847 60017 C1633 60049 C1633 00078 C1633 40091 C2847 60007 C1633 60023 C1633 40090 1410 0708 C D BO IDA UNO U RR 20 UD tA F2 10 4 Q tA r2 d0o 0 u tu I tA Qty eRe PRE R DEKE GRC DR O E FANN RP NH HH ee ee RR Description SPRING ENGAGING LEVER SCREW TAPPING 4 20 WASHER 3 2MM GEAR ENGAGING LEVER GEAR CAM LEVER ENGAGING RETAINER RING 0 25 DIA SCREW SHOULDER GEAR CLUSTER OVERDRIVE OVERDRIVE GEAR CLUTCH ASSEMBLY WASHER TEFLON CAM AUTO SCREW 6 19X0 50 MOUNT BLOCK OVERDRIVE SCREW TAPTITE SCREW 6 19X0 375 PLST BRACKET BAIL LEFT BAIL MODEL C2858A MODEL C2598A SPRING CUTTER SHIM STARWHEEL MOUNT AY MODEL C2858A MODEL C2859A BRACKET BAIL RIGHT SHIM CUTTER MODEL C2858A MODEL C2859A SCREW TORX SLOT M3 OVERDRIVE SUPPORT AY MODEL C2858A MODEL C2859A BUSHING PAD SPACER BUSHING ROLLER OVERDRIVE AY MODEL C2858A MODEL C2859A BUSHING OVERDRIVE BEARING SLEEVE NYLON 10 28 Parts and Diagrams Bail and Overdrive Support Assemblies C C2858 13 1 Illustrated Parts Breakdown Parts and Diagrams 10 29 Ref HP Part C Des Number D 1 0515 1992 4 2 C1633 40029 3 3 0535 0026 5 4 C2847 20005 5 C1633 20012 4 5 C1633 60039 9 6 C1633 80005 2 7 C1633 40082 0 22 C1633 00024 23 C1633 40030 24 C1633 00059 8 0515 0382 4 9 C1633 00100 9 10 C1633 0
7. Included in Chapter 8 are service tests error codes and messages and diagnostic information to assist you in troubleshooting and solving plotter symptoms and failures Chapter 9 Product History Chapter 9 provides historical tracking of changes made to the plotters The differences between earlier versions of the plotters and the version described in the main body of this manual are identified Chapter 10 Parts and Diagrams In this chapter you will find drawings for purposes of identifying the various field replaceable assemblies Also in this chapter are associated parts lists for ordering replacement parts shown on the drawings Glossary The glossary contains a listing of terms used throughout the manual Index Use the index to find references and locate subject matter in this manual iv Using this Manual Contents Chapter Page 1 Product Information Introduction saem sara Kear oes teme El EEE EEE Ee EEE d ER Oe d 1 1 DeESCHPHON cu T P x p E mT 1 2 OPTIONS I CRT ig Spa sal di or diode cb a a L a SD 1 4 Plug in MemOfty upa pasa RO eR e SER ewe tp eae eeu 1 4 ROM Enhancement Modules 0 0 eee ernus 1 4 Modular Input Output MIO PCAS 0 ee eee 1 4 ACCESSOTIES cse coe aer uw Chea edb Bea oc bd MEd cos ey veru edes 1 5 Performance Characteristics cece cece n 1 6 Serial Number Information se eccceiesserokensie amie anatia aie naise 1 6 2 Site Planning and
8. SCREW LONG DOGPOINT SCREW BOLT METRIC SCREW THRD RLLG STARGUARD ASSEMBLY MODEL C2858A MODEL C2859A STARWHEEL ASSEMBLY MODEL C2858A MODEL C2859A MODEL C2858A MODEL C2859A PANEL WINDOW CUTTER ASSEMBLY BUSHING CUTTER SLIDER ROD REAR PART OF ITEM 11 SLIDER ROD FRONT PART OF ITEM 11 CHASSIS ASSEMBLY MODEL C2858A MODEL C2859A CUTTER ENCLOSURE AY MODEL C2858A MODEL C2859A GUIDE MEDIA MODEL C2858A MODEL C2859A 10 32 Parts and Diagrams Starwheel Starguard and Chassis Assemblies eee Illustrated Parts Breakdown Parts and Diagrams 10 33 Labels Label Name Part Number Media Bin Front C2847 00036 Serial Number C2858 00018 Name Plate C2858 00017 Roll Loading C1633 00084 Carriage Warning C1633 00104 Power Supply Insulator C1633 00105 Carriage Stripes C1633 00107 Media Loading C1633 00131 Pen Alignment C1633 90009 Pen Color Code C2858 00019 Trailing Cable C2858 60024 C2847 60019 Carriage PCA Encoder C2847 60021 Paper Motor Media Sensor C2847 60003 Interconnect PCA C2847 60022 Pinch Wheel Sensor Main PCA 2847 60044 ee C2858 60007 Primer Sensor Left Endcover ERE Cable Identification Drawing C2847 60005 Power Suppl oe pP C1633 60014 C2859A Cable Hamas Ay 3101 3153 AC Power Recept Ay C2858 60011 C1633 60020 E C2858 60006 Left Sideplate C2858 60003 C2858 60013 AC Power Switch Ay 10 34 Parts and Diagrams Glossary address The address spe
9. Vacuum fluorescent Display 5 7 W Waveforms Fire pulse 5 3 Window Sensor Removal 6 19 X X axis Motor 5 2 Pinion Gear 5 3 Position Feedback 5 3 Removal 6 26 Y Y Axis Motor 5 2 Y axis Motor Position Feedback 5 3 Removal 6 25 Y Tensioner Housing Removal 6 36 Index bar code here C2858 90000 PRINTED IN U S A
10. off will leave the area blank 2 A method for defining a plot directly in terms of the pixels rather than as vectors repeatability A measure of how closely a device can return a pen to the previously plotted point resolution A measure of image sharpness expressed as a number of lines per unit length When referring to plotters addressable resolution means the smallest move the plotter can make programmatically RS 232 C interface A serial interface standardized by the Electronic Industries Association Standard RS 232 C serial interface A serial interface uses a single data line to transfer data bits sequentially between devices RS 232 C is a serial interface G 2 Glossary Index A Accessories 1 5 Adjustments 7 2 Analysis Bar Pattern 8 20 ASIC Application Specific Integrated Circuit Carriage 5 2 Pen Interface 5 2 Data 5 3 Print Control 5 6 Data 5 6 Processor Support 5 2 Assemblies History of 9 2 Assembly Bail Removal 6 43 Cutter Removal 6 32 Cutter Enclosure Removal 6 49 Drive Roller Removal 6 53 Entry Platen Removal 6 51 Front Panel Removal 6 24 Left Rollfeed Module Removal 6 31 Overdrive Support Removal 6 47 Pen Carriage and Main Drive Belt Removal 6 38 Printed Circuit Interconnect Removal 6 8 Main Removal 6 9 Power Supply Removal 6 12 Rollfeed Cover Removal 6 30 Service Station Removal 6 44 Starguard Removal 6 42 Automatic Cutter
11. See Figure 6 28 6 Rotate the top of the starguard assembly toward the rear of the plotter so that it clears the sideplate 7 Slide the starguard assembly to the left and out of the plotter Right Starguard Screws 2 Left Starguard Screws 2 C C2858 64 C C2858 51a C C2858 71 CS E ae ee a S ee AE J 3 x Star Wheels oe Starguard Assembly C2859A 13 Figure 6 28 6 42 Removal and Replacement BAIL ASSEMBLY REMOVAL To remove the bail assembly perform the following procedure 1 Raise the window and move the pen carriage assembly to the extreme left 2 Slide the cutter assembly to the extreme right 3 Using aTORX T 15 screwdriver remove the three screws at the left and right ends of the bail that attach the bail to the left and right bail brackets See Figure 6 29 4 Lift the bail up and clear of the plotter Bail Screws 3 C C2858 11 Each End C C2858 11 Figure 6 29 Removal and Replacement 6 43 SERVICE STATION ASSEMBLY REMOVAL To remove the service station assembly see Figure 6 30 and perform the following procedure 1 2 Remove the window assembly Remove the left endcover Move the pen carriage to the center of its travel Using a 5 5 mm nut driver remove the nut and washer that attach the ground strap and encoder strip to the service station housin
12. Single Axis 1 3 Automatic Bail Lift Mechanism Removal 6 55 B Back Panel Removal 6 23 Bail Automatic Lift Mechanism Removal 6 55 Bail Assembly Removal 6 43 Bail Sensor Removal 6 40 Bar Pattern Analysis 8 20 C Cable Restrictions 2 4 Trailing Front Tray Removal 6 34 Removal 6 21 Calibration Bail 7 9 Drop Detect Sense 7 7 Edge Sense 7 8 Media Sense 7 6 Calibrations 7 2 Accuracy 7 4 Sheet Length 7 3 When Required 7 2 Carriage PCA Description 5 6 Channel Serial 5 3 Character Sets Kanji levels 1 and 2 1 2 Characteristics performance 1 6 Cleaning Drive Roller 4 3 General 4 2 Index Configuration Plot Description 8 19 confirming a menu option 3 19 Controller DRAM 5 2 Controllers HP IB See Input Output Controls Front Panel 3 17 Cover Electronics Enclosure Removal 6 7 6 11 Fixed Removal 6 14 Rollfeed Assembly Removal 6 30 Cutter Assembly Removal 6 32 Cutter Enclosure Assembly Removal 6 49 D Data Conversion 5 3 Description Carriage PCA 5 6 Configuration Plot 8 19 Front Panel PCA 5 7 Interconnect PCA 5 7 Line Sensor 5 6 Main PCA 5 5 PCA Overview 5 5 Power Supply PCA 5 8 Detection Media 5 3 Display Vacuum fluorescent 5 7 DRAM Dynamic Random Access Memory Main PCA Information 5 5 DRAM Controller 5 2 Drive Stepper 5 3 Drive Roller Assembly Removal 6 53 Drive Signals PA and PB 5 7 Driver Motor X axi
13. X axis Paper axis or the Y axis Carriage axis servo control system An X axis shutdown may cause either a system error code or the worded display Power Off Check media path For the X axis shutdown first check for binding in the X axis mechanics due to a paper jam Also check to see if the supply roll is out of media Tape which secures the media to the roll may cause a jam as it is pulled through the drive roller system Removing the two screws which attach the worm gear to the drive roller should allow the drive roller to be manually spun If it does not itis probably jammed Other areas to check would be the X axis motor encoder interconnect PCA and main PCA Use the X axis motor encoder and X axis motion control tests found in the service menu to help troubleshoot A Y axis shutdown may cause either a system error code or the worded display Power Off Check pen path For a Y axis shutdown first check for binding in the Y axis mechanics Binding may be caused by a paper jam When the plotter is switched OFF the carriage can be manually moved along the Y axis Check for any areas where the carriage may be binding Also check the reduction pulley small drive belt small belt tensioner main belt main idler and carriage bushings In addition to mechanical binding a problem in the servo feedback and motor drive systems should also be checked Check the encoder strip interconnect PCA main PCA and carriage Use the Y friction Y en
14. and Quick Reference Guide Power Cord U S 1 8120 1378 Media Sampler Roll CX Jet Series 24 x150 C2858A 1 51631D 36 x150 C2859A 1 51631E Pens Black 2 51640A Cyan 1 51650C Magenta 1 51650M Yellow 1 51650Y Hardware Kit 1 C2847 60061 Cable Management Hardware Kit 1 C2847 60030 Front Panel Overlay English 1 C2858 60026 Guide Cutter Holder 1 C1633 40094 Manual Cutter 1 17291C Supplies Catalog 1 5091 3485EUS Supplies Catalog Update 1 5091 6787EUS Unpackaging Instructions 1 C2858 90003 Spindle Assembly C2858A 1 C2847 60033 C2859A 1 07596 60060 Spindle Flange 1 07596 40076 Spindle Spacer 1 07596 40077 Product Information 1 5 PERFORMANCE CHARACTERISTICS Table 1 2 lists the performance characteristics of the plotters Table 1 2 Performance Characteristics Accuracy 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 RH on HP film monochrome mode only Throughput D sized loaded vertically plain paper special paper special paper monochrome monochrome color Draft mode 1 8 min 1 8 min 3 4 min Final mode 3 2 min 2 7 min 4 3 min Enhanced mode 6 5 min 6 5 min 8 7 min Resolution Draft Mode 300 dpi addressable Final Mode 300 dpi addressable Enhanced Mode 300 dpi addressable color 600 dpi addressable monochrome Margins Leading and Trailing 17 mm 2mm normal plot area 10 mm expanded plot area Sides 5 mm normal or expanded plot are
15. display 4 Use the arrow buttons to scroll to the Utilities main menu Press Enter If not already set to Full menu mode scroll to Full and press Enter 5 User accuracy Scroll to the Accuracy submenu Press Enter Service accuracy Simultaneously press the Enter and Up Arrow buttons 6 User accuracy Scroll to the Recalibrate submenu Press Enter Service accuracy Scroll to the Accuracy Calib submenu Press Enter The Create plot Measure plot message displays 7 Press the Up Arrow button to select Create plot A Creating calibration plot message displays while plotting 8 Wait until the Remove media Continue message displays No Press the Down Arrow button to Continue The Create plot Measure plot message displays 10 Press the Down Arrow button to select Measure plot 11 Rotate the plot so that the edge with arrows points to the leading edge then reload the plot with the arrow edge print side down Arrow edge Load arrow edge print side down C C2847 15a UM 12 The plotter will load the plot and then measure the alignment marks using the edge sensor on the pen carriage 13 Press the Down Arrow button to continue when the Calibrate done Continue message is displayed and the plot is fed out Accuracy calibration is complete A Calibration Plot may be saved and reused for future calibrations by selecting Measure plot when c
16. iuissnso eie ER a nda ex ERRORS RO 7 7 Edge Sensor Calibration 0 0 0 cece cee teens 7 8 Bail Calibration ss sad cae bad cree sb eee ened x wes beau eee 7 9 Adjustmenis Calibrations 7 1 ADJUSTMENTS There are no electrical or mechanical adjustments required on the HP C2858A and C2859A DesignJet 650C plotters CALIBRATIONS DesignJet 650C plotters have several calibration procedures that must be performed under certain conditions Refer to Table 7 1 to determine when calibrations are required Table 7 1 Calibration Requirements Indications or Repairs Performed Hardclip limits not within specification Platen drive roller is replaced X axis motor encoder is replaced Config Plot X mark distance is not 500mm Imm mono on inkjet film Media sensor is replaced Plotter does not detect media presence Plotter tries to load media none present Drop Sensor is removed or replaced Pen checking constantly rejects pens Pen service station is removed or replaced Carriage or Carriage LED is replaced Edge detect failures occur Bail failures occur during media loading EEROM is cleared or replaced Calibration Required Sheet Length Calib Accuracy Calib Accuracy Calib Accuracy Calib Media Sensor Calib Media Sensor Calib Media Sensor Calib Drop Detect Calib Drop Detect Calib Drop Detect Calib Edge Sensor Calib Edge Sensor Calib Bail Calib All in the following order 1 Media Sensor Calib 2 Bail Ca
17. perform steps 1 and 2 above then pull on both ends of the spindle to remove it from the plotter 3 10 Installation and Configuration LOADING SHEET MEDIA To load sheet media perform the following steps 1 Ensure that the pinchwheel lever is down and the roll cover is closed 2 Load the leading edge of the sheet making sure to push the sheet in straight not skewed while aligning the right edge of the sheet with the perforated line on the entry platen See Figure 3 8 Align Media with Perforation Line C C2847 15a UM Loading Sheet Media Figure 3 8 3 Push the sheet in until it buckles slightly as it hits the stops inside the plotter The buckling should be even across the width of the sheet Let go as soon as the plotter begins to pull the media in 4 When the front panel displays Sheet load Roll load press the Up Arrow button to select Sheet load 5 When the front panel displays SELECT MEDIA press the Up or Down Arrow button to scroll through and select the media choice Press the Enter button to set the plotter for the media type being used The plotter will now load the sheet of media 6 The plotter moves the sheet in and out to check its size and alignment then advances it to the start of the page When sheet loading is complete the STATUS Ready to plot message is displayed Installation and Configuration 3 11 If difficulty in loading sheet media is experienc
18. pull it away from the plotter Removal and Replacement 6 15 Left Front Trim Right Front Trim Screw Screw C C2858 37 C C2858 38 C C2858 33 C C2858 34 Bottom Right Screw hidden Bottom Left Screw hidden Figure 6 10 6 16 Removal and Replacement PRIMER ASSEMBLY AND SENSOR REMOVAL To remove the primer assembly and sensor perform the following steps 1 Remove the window assembly 2 Remove the left endcover 3 Disconnect the primer assembly and sensor cable connector 4 Disconnect the four rubber tubes from the primer assembly 5 Using a TORX T 20 and extension bit remove the two bottom screws and loosen the top screw that attach the primer assembly to the left sideplate See Figure 6 11 6 Slide the primer assembly out from the plotter 7 Toremove the optical sensor from the primer assembly use a TORX T 10 screwdriv er and remove the two screws that attach the sensor to the primer assembly Screw Tubes 4 Optical Sensor Cable Connectors Primer Assembly Screws 2 C C2858 76 Figure 6 11 Removal and Replacement 6 17 PINCH WHEEL SENSOR REMOVAL To remove the pinch wheel sensor perform the following procedure pa Remove the electronic enclosure cover 2 Remove the right endcover W Disconnect the pinch wheel sensor cable co
19. E E dake t ders 3 20 Front Panel Languages 0 0 0 cece eee eee teens 3 21 Front Panel Messages sa gama ie epe ad nig eau ebacebid E m op nega 3 22 Operational Verification sss 3 26 Power On Self Est i caes essas re hee eR Ce e RI bene cea p 3 26 Demonstration Plot 3 6 00 cenas usas qua v RE ERG wend ERA 3 26 Installation and Configuration 3 1 INSTALLATION INSTRUCTIONS USER INSTALLABLE MODULES Expansion sockets located behind a panel at the rear of the plotter allow the user to install additional memory modules These SIMMs single in line memory modules are available in 4MB and 8MB sizes Installation is accomplished by removing the access panel 4 screws installing the module s and reattaching the access panel ROM sockets are also provided for use with ROM enhancements as developed Installation instructions are pro vided with the modules and also provided in Chapter 6 of this manual Information on order ing the memory expansion and ROM modules is provided in Chapter 1 of this manual An interface port on the back of the plotter allows the user to select one of several available modular interfaces at a time The modular I O cards can be easily changed to match the de sired application Installation instructions are provided with the modules and also provided in Chapter 6 of this manual Information on ordering the modular I Os is provided in Chapter 1 of this manual CONNECTIVITY Depending up
20. FERRITE RING WASHER TOROID SCREW MACH M4X10 IDLER DRIVE PULLEY CAM TENSIONER SPRING DRIVE TENSIONER SCREW MACH M3 BRACKET TENSIONER BRACKET ENCODER SPRING BRACKET Y DRIVE ASSEMBLY SPRING ENCODER ENCODER STRIP MODEL C2858A MODEL C2859A WASHER 3 2MM NUT HEX M3X0 5 BEARING DOUBLE PULLEY BELT Y AXIS DRIVE SMALL DOUBLE PULLEY SCREW THRD RLLG MOTOR CARRIAGE 10 22 Parts and Diagrams ES Pen Carriage Assembly See Page 10 25 Carriage Axis Drive Right End C C2858 10 1 Illustrated Parts Breakdown Parts and Diagrams 10 23 Parts List Pen Carriage Assembly Ref HP Part C Des Number D 1 C2858 60023 4 2 C2858 40016 3 3 C1633 80014 2 4 C2858 40017 4 5 0624 0737 4 6 C2858 60010 9 7 C2858 60014 3 8 07575 40013 3 9 07575 40014 4 10 C2847 00029 1 1500 0856 4 Qty Beer ee Ree Ne Description PEN CARRIAGE ASSEMBLY BUSHING FRONT SPRING PRELOAD BUSHING REAR SCREW 2 28 X 375 PLASTITE IC ENCODER ASSEMBLY LINE DETECT ASSEMBLY LEFT CLAMP MAIN BELT RIGHT CLAMP MAIN BELT BELT MAIN DRIVE MODEL C2858A MODEL C2859A 10 24 Parts and Diagrams Pen Carriage Assembly C C2858 11 1 Illustrated Parts Breakdown Parts and Diagrams 10 25 Ref Des 12 13 14 15 16 17 18 19 20 21 22 23 HP Part Number C2847 00041 C2848 00010 C2858 60054 C2859 60004 0515 2246 0515 2337 0515 0380 C1633 00009 C2847 60019 05
21. Media Format Byte EEROM Media Type Byte EEROM Sheet Length MIO Initialized MIO Storage Begin ROM Location DRAM Location MIO Storage End Swath RAM Location Servo Processor Location KIBIS Location FIBIS Location Centronics Location NVRAM Location EEROM Page Count Low 8 22 Troubleshooting Address Location gt A A N N oO N N A A A A A O on a A Un Un Un Qa Qa Qa ta Qa Qa ta Qa un d A LH LH OQ O0 o0 200 5 0 0unu1npmou vm Table 8 4 EEROM Map Continued Definition EEROM Page Count High EEROM PostScript Block 1 Start EEROM PostScript Block 1 End EEROM Pen Source Byte EEROM Pen Palette Byte EEROM Flag Byte EEROM Media Sense Threshold EEROM Flag Byte 2 EEROM Flag Byte 3 EEROM Plotsetup Byte EEROM Flag Byte 4 EEROM Edge Sense Info EEROM Cal Pattern EEROM Pen Cal Spare EEROM Pen K X Offset EEROM Pen C X Offset EEROM Pen M X Offset EEROM Pen Y X Offset EEROM Pen K Y Offset EEROM Pen C Y Offset EEROM Pen M Y Offset EEROM Pen Y Y Offset EEROM Pen Bidir Offset EEROM Pen Bidir Delay EEROM Pen Bidir Offset Raw EEROM Pen Bidir Delay Raw EEROM High Vel Factor EEROM Low Vel Factor Troubleshooting 8 23 Address Location 5 E 6 0 6 1 6 2 6 2 6 4 6 5 6 6 6 7 6 8 6 9 6 A 6 B 6 C 6 D 6 E 7 E 7 F D 4 10 1 14 0 14 1 17 F 96 Table 8 4 EEROM Map Continued Definition EEROM Pen 1 Pen 2 First Nozzle EEROM New Align EEROM Platen Factory EEROM Plat
22. ON Release the Enter button 3 Using the arrow buttons scroll to the desired language to be displayed and press the Enter button Installation and Configuration 3 21 FRONT PANEL MESSAGES In addition to the menus that appear in the front panel display three types of messages may also appear in the display They are state messages action messages and error messages State messages do not require any action and serve to notify the user of any current plotter actions occurring State messages are listed in Table 3 2 Action messages do require user interaction Typically the user is prompted to press a button move a lever or load pens or media Action messages are listed in Table 3 3 Error messages indicate that either a user er ror or internal plotter error has occurred Some error messages require user action to clear and others are only displayed until the next operation is performed by the plotter Error messages and their recommended actions are a part of the troubleshooting information presented in Chapter 8 of this manual Message Accessing pens Aligning pens Cancelling Checking media Creating calibration plot Ink drying xxx seconds Loading roll Loading sheet Measuring plot Pen palette loaded Table 3 2 State Messages State You have pressed the Access Pens button The pen carriage is moving out so you can access it Machine is aligning pens You have pressed the Cancel button and the plotter is
23. Requirements Introduction za emas adie rottene oee RU REA es ETETA eRe de NEAN AUS 2 1 Electrical Specifications 0 cece rr 2 2 Power Requirements sacas coaches Cobo Ree e RR Ee VC EXE 2 2 Lins COTE SEE E 2 2 Environmental Specifications secsec smeca cece eee teens 2 3 Physical SpecificatiOnS 2 04 ses ere cota RI HR CO Cea EEES 2 3 Cable Restrictions 2 0 0 0 m n 2 4 R5 232 C terface usem gana sede Free Pre ud es e ed tote bos e gue cbe e gun 2 4 Centronics Interface iios cere eee RR tana nid Ue d eed d re are se eee 2 4 HP IB Interface 0253 So tease tal oe CR Rr dre CAR tk enata Pe UR ete ent 2 4 3 Installation and Configuration Introduction sa ssa eer RE sae Chee ee weed eH OPES KOREA EO ane 3 1 Installation Instructions sesesesrosesasiricre rora giia IIR 3 2 User Installable Modules 20 0 0 cece eee e 3 2 Connectivity e peed esee e ue ri RR Few Fan REF EE a ER Vd E 3 2 Line Voltage and Fusing seeeeeeeee e 3 2 Power Cord Configurations 0 0 0 ccc eee ad iiaia 3 2 User Information and Operation 0 0 cece cece eee eee 3 4 Media Guidelines uai ge deg eet ts antag die we LA ota a ORE a Ree 3 4 Media Type and Print Quality 0 eee eee 3 4 Media Cutting and Stacking 0 0 cece eects 3 5 Usable Media SIZES a assa ada ds as a PUER mead VIRG CR ESQ Ru E waa 3 6 Contents v Chapter Page Loading Roll Media eeeeeeee II 3 6 Unloading Roll Media 0 0 c
24. THE PEN NOZZLE TEST BLOCK The blocks of numbers on the lower right portion of the plot can be used to determine particu lar pen nozzle problems From left to right the blocks represent the black magenta cyan and yellow pens Each block has a matrix of 5 digit codes These codes are used to determine a pen nozzle pass or fail condition Each code digit represents a pen squirt test For the black pen all the codes in the block should read 00001 indicating a good pen If any of the nozzle position codes read a code of 2 or higher that pen nozzle is defective Forthe color pens the codes should read 00005 A code of 5 indicates the pen nozzle passed 5 out of 5 tests A code of A means the pen nozzle passed 5 out of 10 tests while a code of 8 means 8 of 10 tests passed A code of B in the matrix means that particular pen nozzle has failed the test Troubleshooting 8 21 Address Location 0 0 0 1 0 2 0 3 0 4 0 5 0 6 7 0 8 0 9 0 F 1 0 1 1 1 2 1 3 1 5 1 7 1 8 1 A 1 B 1 C 2 0 Table 8 4 EEROM Map Definition EEROM Initialized A Value 55 Read by Servo Processor EEROM Initialized B Value AA Read by Servo Processor EEROM Initialized C Value 5B Read by Servo Processor Power up Mode FP General Byte FP PostScript Byte EEROM Pen C DT Offset EEROM Baud Byte EEROM Handshake Byte EEROM Parity Byte EEROM Pen Y DT Offset EEROM Language Byte EEROM Cutter Mode Byte EEROM Print Mode Byte EEROM
25. a TORX T 9 screwdriver remove the four screws that secure the service sta tion cover to the service station housing While holding the sled in position with one hand lift the service station cover up Slowly release the sled and lift the cover clear of the service station housing Toremove the drop detect sensor pull the drop detect sensor up and out of the service station housing To remove the bail sensor use a small flat blade screwdriver to carefully pry up on the bail sensor and lift the sensor out of the service station housing Note When installing be sure the small bail flag properly actuates by manually raising and lowering the bail 6 40 Removal and Replacement Service Station Cover Sled 9 z j EN Drop Detect O Sensor ea Bail Sensor Screws 4 Service Station Housing Figure 6 27 Removal and Replacement 6 41 STARGUARD ASSEMBLY REMOVAL To remove the starguard assembly perform the following procedure pa Remove the window assembly 2 Remove the left and right endcovers sa Remove the cutter assembly 4 Remove the front panel assembly 5 Using a TORX T 20 screwdriver loosen the upper of the two screws that attach the the starguard assembly to the left and right sideplates until the ends of the screws are flush with the inner surfaces of the sideplates
26. and spring in place while removing the cutter 13 Remove the pen carriage assembly with main drive belt from the plotter 14 Set the pen carriage assembly top side down on a flat surface 15 Using a small standard screwdriver remove the left and right belt clamps from the pen carriage assembly 16 Remove the main drive belt from the pen carriage assembly When reinstalling the encoder strip remember to properly adjust the strip so that it does not touch the pen carriage assembly To adjust loosen the encoder spring bracket screws and move the bracket up or down as necessary to center the strip in the pen carriage apertures 6 38 Removal and Replacement Ml Trailing Cable Trailing Cable Bracket Connector C C2858 77 Encoder Stri Nut amp Washer Encoder Strip Spring Encoder Strip Encoder Strip Bracket CQ 4 a Cutter Assembly T Small Drive Belt ZAO Y Drive Bracket C C2858 47a Figure 6 26 Removal and Replacement 6 39 DROP DETECT AND BAIL SENSORS REMOVAL To remove the drop detect or bail sensor refer to Figure 6 27 and perform the following procedure 1 2 Remove the window assembly Remove the left endcover Move the pen carriage to the middle of the platen Disconnect the drop detect sensor cable connector from the wire harness Release the drop detect sensor cable from the Y tensioner bracket and let the cable hang down Using
27. check the media sensor The Service Test submenu should now be acces sible so that the media sensor calibration may be performed 7 6 Adjustments Calibrations DROP DETECT CALIBRATION In this procedure the position of the drop detect sensor relative to the four print cartridges is calibrated Four values are calculated and stored in the plotter EEROM Perform the drop detect calibration whenever the the EEROM is cleared or replaced drop detect sensor is removed or replaced pen checking algorithm continues to reject pens service station is removed or replaced Drop Detect Calibration is accessible through the Service Tests menu To perform the drop detect calibration do the following 1 Press Enter at the Status display 2 Use the arrow buttons to scroll to the Utilities main menu Press Enter 3 Simultaneously press the Enter and the Up Arrow buttons to access the Service Test submenu 4 Scroll to the Drop Detect Calib submenu Press Enter 5 Messages in the plotter display will inform you that the calibration is in process and to press the Enter button after a successful calibration Adjustmenis Calibrations 7 7 EDGE SENSE CALIBRATION The edge sense calibration is used to calibrate the intensity of the line sensor in the carriage PCA A flag is cleared and set in the EEROM after the calibration and is used until recali brated An improper calibration can result in ed
28. configurations can be stored in memory Demo Plot Accesses the internal demonstration plot routine Utilities Accesses accuracy calibration procedures Also contains front panel menu configuration information plotter statistic information plot size memory size firmware revision level ROM SIMMs present and default menu options Complete information on using the various menu and submenu options is contained in the HP C2858A and C2859A DesignJet 650C Using Your Plotter s Front Panel Guide Additional setup information is available in the DesignJet 650C Setting Up For Plotting Guide Refer to Chapter 1 in this manual for more information regarding these guides Figure 3 12 located at the end of this chapter provides a diagram of the menu tree showing the various menus and submenus ofthe DesignJet 650C plotters Both the short and full menu structures are presented on the diagram 3 20 Installation and Configuration FRONT PANEL LANGUAGES DesignJet 650C plotter menus and messages can be configured to display in English French Francais German Deutsch Spanish Castell Italian Italiano Portuguese Portuguese and Japanese Katakana characters To change the display language or if the display is in a language you cannot understand use the following procedure to get to a language you do understand 1 Turn the plotter OFF 2 Press and hold down the Enter button while turning the plotter
29. cuts each nest The automatic cutter can be programmatically disabled When cutting is disabled the plotter draws tick marks at the plot margins to indicate the end of a plot or nest The automatic cutter can be enabled programmatically or by cycling power e Manual cutting The front panel Form Feed Cut button can be used to feed the media out and cut it after a plot is completed e Media stacking Unattended stacking of cut sheets is provided by the adjustable media bin The user must adjust the movable shelf of the bin according to the length of the cut sheets Bin capacity is 20 sheets e Manual cutter A manual cutter is provided with the plotter for hand cutting of media and is stored in the manual holder on the back of the plotter Installation and Configuration 3 5 USABLE MEDIA SIZES Media of different types and sizes can be used on the plotters Refer to Table 3 1 for the media sizes usable on each plotter Table 3 1 Media Sizes C2858A C2859A ISO A4 Al ISO A4 AO ANSI A D ANSIA E ARCH A D ARCH A E JIS B4 B2 JIS B4 Bl Oversize A2 Oversize Al 24 in Wide Roll 24 in Wide Roll 36 in Wide Roll LOADING ROLL MEDIA If the spindle is already loaded into the plotter remove the spindle by opening the roll cover and pulling on both ends of the spindle to remove it from the plotter To load roll media into the plotter put a roll of media on the plotter spindle and insert the spindle in the plotter by performi
30. data to control pen energy and pen calibration It communicates with the servo processor on the main PCA using a serial port The print control carriage ASIC receives pixel data from the processor support ASIC on the main PCA via a synchronous serial channel and on board line driver Signals from the print control ASIC fire the nozzles in the print heads Whenever a print head nozzle is fired a com parator outputs a pulse to a counter in the carriage microprocessor 5 6 Functional Overview The dual voltage remote sense circuitry sends a or sense signal to the dual voltage regu lators on the interconnect PCA when the voltage to the print heads deviates from the opti mum pen voltages The regulator will then adjust the voltage to bring it back to the optimum value Pen voltages are ON when printing a swath and briefly at power up but OFF when idle Or accessing pens INTERCONNECT PCA The interconnect PCA contains an X axis paper motor drive a Y axis carriage motor drive a switching pre regulator two linear regulators for the black and color pen voltages and direct paths for the MIO lines to the main PCA The drivers and the voltage regulator receive 24 Vdc viathe main PCA The pre regulator steps down the 24V to 19 5V for the two linear regulators The two linear regulators output voltages from 9 to 15V and receive and sense signals that originate at the carriage PCA and then routed through the main PCA on their w
31. dd ed fd Oe le 2e 3e 4e 5e 6e Te 8e 9e ae be ce de ee fe Of 1f 2f 3f 4f 5f 6f TE 8f 9f af bf cf df ef ff Troubleshooting 8 25 The block of text on the configuration plot that shows the contents of the EEROM appears in the form shown in Table 8 6 This table is a sample portion of the text block from a configura tion plot The contents of the EEROM that you are testing may differ from this sample Table 8 6 EEROM Contents Text Block 0 1 2 3 4 5 6 7 8 9 a b c f 0 55 aa Sb 0 4 0 4 f6 60 2c eb fl e 0 0 4 10 0 0 0 0 0 1 dO 7 3c 1 63 73 7a 4f O 20 24 0 0 0 0 0 0 0 0 3 0 0 0 0 0 O0 0 0 0 0 0 0 0 0 40 0 0 0 40 25 41 0 61 48 83 8c 0 0 0 50 0 0 7 6 7 7 Se 6 3d O 0 0 0 0 0 60 50 0 0 0 f0 ec O c7 0 1 0 c 47 1 el O 70 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 8 80 55 aa 5b 0 4 0 4 f6 60 2c eb fle 0 0 4 90 0 0 0 0 0 1 dO 7 3 63 1 73 7a 4f O0 a0 24 0 0 0 0 0 0 0 0 0 b 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 c 0 0 0 40 25 41 O 61 48 83 8c 0 0 0 dd 0 0 7 6 7 7 Se 6 3d O 0 0 0 0 0 e0 50 0 0 f ec 0 c7 0 1 0 c 47 1 el O0 f 0 0 0 0 0 O0 0 0 0 0 0 0 0 0 8c 8 26 Troubleshooting Chapter 9 Product History INTRODUCTION This chapter describes the differences between earlier versions of the HP C2858A C2859A DesignJet 650C plotters and the latest version documented in this manual Versions are iden tified by their serial number and the date codes on their printed circuit assemblies PCAs Introduction S
32. e Plots As a plot is received from an external controller by way of one of the plotter interfaces it is stored in DRAM When the complete plot is in DRAM the main processor converts it one swath at a time to a format suitable for storage and sends it to swath RAM by way of the processor support ASIC A swath is 96 dots high and extends from border to border across the width of the plot The processor support ASIC extracts the plot data from the swath RAM converts it to pixels and sends the pixels serially by way ofthe trailing cable to the carriage ASIC on the carriage PCA Functional Overview 5 5 CARRIAGE PCA The carriage PCA contains an application specific integrated circuit ASIC that controls the operation of the pens and pen drivers that switch power pulses from the ASIC to fire the pens It also provides feedback to the main PCA as to the current position of the carriage as sembly A line sensor module mounted on the carriage PCA monitors the lines produced by the pens and is used for pen alignment The line sensor also provides an edge sensing capabil ity used to identify the media loaded in the plotter Voltage sense circuitry senses deviations in the pen voltages supplied to the print heads and sends signals to the voltage regulators on the interconnect PCA The carriage processor and the print control ASIC on the carriage PCA are driven by a 12 288 MHz on board clock At power on time the main PCA reset circuit delays th
33. endcover Using a 5 5 mm nut driver remove the nut and washer that hold the right end of the encoder strip to the encoder strip spring bracket Press the encoder strip spring bracket inward and release the encoder strip from the spring bracket Using a TORX T 15 screwdriver remove the encoder spring bracket Note The cutter carriage preload arms are spring loaded Hold the cutter wheels toward the center of the cutter carriage assembly while performing step 5 Holding the cutter wheels in toward the center of the cutter carriage assembly move the cutter assembly to the right and off of the front slider bar Slowly release the wheels to relax the spring tension on the wheel arms and lift the cutter assembly clear of the plotter To install the cutter assembly do the following ER Rotate the wheel preload arms against the spring tension to the center of the cutter carriage and hold them in position while performing the next step Move the cutter assembly s lower wheels onto the overdrive support assembly Slide the cutter assembly along the overdrive support assembly and guide the upper wheels into the starguard groove Guide the cutter blade in front of the linear blade See Figure 6 23 Slide the bushing into the cutter assembly and move the cutter so that the bushing slides onto the front slider rod Verify correct installation by sliding the cutter assembly along its travel path Verify t
34. error messages The Busy LED is lit whenever the plotter is processing information Installation and Configuration 3 17 Front panel controls and LEDs are described below Menu buttons Previous DO ill L C2847 1a Enter Use the Previous button to move to the next highest level and to return to the Status display Use the up arrow and down arrow buttons to scroll through menu options or respond to action or error messages Use the Enter button to activate the current menu option access additional submenus as indicated and to enter the first level of the menu structure from the Status display Plot Mode Color Mono and print quality buttons E Enhanced Emm Color mm Final Em Mono mm Draft E E mH Plotter set to plot in Enhanced Final or Draft modes LED will be lit for mode selected Sets the resolution quality parameter for the media type being used Select Color mode or Mono black and white mode Plot Type Media Type Print Quality Resolution dpi Passes Pass Density Mono Paper Draft 300 addressable 1 50 Final 300 addressable il 10096 Enhanced 600 addressable 2 50 Mono Trans Vel Draft 300 addressable if 50 Final 300 addressable 2 50 Enhanced 600 addressable 4 25 Mono Film Draft 300 addressable 2 50 Final 300 addressable 2 50 Enhanced 600 addressable 4 25 Color Special Draft 300 addressable 1 50 Final 300 addressable 1 100
35. find the left and right media edges during media loading and the presence of lines during accuracy and pen calibrations The reflectivity of the drive roller can also be checked by stepping the pen carriage along the Y axis using the UP ARROW and DOWN ARROW buttons The DOWN ARROW button moves the carriage to the right and the UP ARROW button moves the carriage to the left The sensor reading 3 digit number and Y axis encoder position 5 digit number are displayed Media can be placed under the sensor to change the sensor reading A large number indicates a low reflectivity Verifies operation of the pinch wheel position sensor When this test is run a readout at the front panel indicates whether the pinch wheels are UP or DOWN Verifies operation of the drop sensing system When this test is selected the front panel instructions are to press ENTER and block the sensor beam path Raise the window press the enter button and insert a small object through the drop sense aperture in the drop sense PCA at the service station The message SENSOR GOOD will appear on the front panel if the sensor is working Assemblies Tested Window Sensor Switch Sensor Switch Path to Main PCA Drop Sensor Drop Sense Cable Main PCA Pinch Wheel Sensor Sensor Cable Main PCA Drop Sensing System Troubleshooting 8 17 Test Cutter Button Test X motion Control Bail Cycle Test Line Detect Sensor Table 8 3
36. given later in this chapter ROM CODE REVISION LEVEL When powered on the plotter scans the ROM SIMM slots from top to bottom in sequence and determines the presence of any code revision level upgrades If any upgrade modules are present the plotter executes the first code upgrade encountered and overrides the code level resident in the ROM on the main PCA Typically any ROM SIMM code upgrade will be a higher level than that on the main PCA The only way this could be reversed is if new main PCA ROMS were installed while an older revision level ROM SIMM was left in the plotter This latter situation should be avoided and checked whenever new ROMS are installed on the main PCA If a code upgrade ROM and an enhancement ROM ie KANJD are both installed the code upgrade ROM must be in the upper ROM slot If the code upgrade ROM SIMM is placed in the wrong slot the plotter will lock up displaying a two dot pattern Firmware code revision levels can be checked using the Utilities main menu and Statistics submenu accessible through the front panel menu structure 8 12 Troubleshooting SERVICE TESTS HP DesignJet 650C plotters have numerous internal service tests that can be used in trouble shooting To access the service tests menu perform the following steps 1 Switch the plotter ON Note Certain plotter failures that can occur will prevent the plotter from reaching the STATUS Ready for Media state If one of these p
37. in the process of cancelling the procedure You may continue when this message is no longer displayed Machine is checking to see if media is properly positioned with respect to the perforated line of the entry platen Machine is performing accuracy calibration The ink on your plot is drying Wait the indicated number of seconds be fore removing the plot If you need to remove it before the indicated time has passed use caution to avoid smearing the ink Machine is loading roll media Machine is loading sheet media Machine is measuring the accuracy calibration plot you just loaded The pen palette you just entered Palette A Palette B or Factory has been loaded 3 22 Installation and Configuration Message Pen palette saved Returning pens Roll feed Edge trim RS 232 config loaded RS 232 config saved STATUS Initializing STATUS Out of media STATUS Plotting STATUS Ready for media STATUS Ready to plot STATUS Receiving Testing pens Table 3 2 State Messages Continued State The pen source pen number widths and pen number shades you just en tered have been saved as either Palette A or Palette B whichever you specified The pen carriage is returning to its station at the left of the plotter Machine is trimming the edge of roll media The RS 232 C configuration you just entered Config A Config B or Factory has been loaded The baud handshake and parity settings you ju
38. is also available when the PostScript ROM SIMM upgrade is installed The HP C2858 9A DesignJet 650C plotters see Figure 1 1 are large format color and monochrome ink jet plotters designed to plot monochrome plots on commonly available opaque bond paper translucent Japanese tracing paper vellum or special inkjet compat ible drafting film Quality color output is only supported when using HP special inkjet paper C2858 9A DesignJet 650C plotters can produce plots on single sheet media or roll feed me dia Large format plots of high resolution and quality are generated for applications such as computer aided design CAD computer aided manufacturing CAM mapping mechani cal and architectural drawings and general drafting Five high capacity ink cartridges are provided with the C2858 9A plotters Selectable pen width settings are modified to ISO standard pen widths The cartridges simultaneously scan across the media providing 300 dpi resolution in draft and final modes 300 dpi addressable resolution for color in enhanced mode and 600 dpi addressable resolution for monochrome in enhanced mode C2858A plotters can plot on media sizes ranging from International Standards Organization ISO sizes A1 through A4 American National Standards ANSI sizes A through D and architectural media sizes C and D Model C2859A plotters can plot on media sizes ranging from International Standards Organization ISO sizes AO through A4 American Nationa
39. is down when it should be up troubleshoot Check for a sticky sensor flag 010013 Bail is falling down missing Check for Mechanical problems the detent Perform the Bail Calibration 010020 ROM test failure Replace EPROMs Replace main PCA 010021 DRAM test failure Replace main PCA 010022 Swath RAM test failure Replace main PCA 010023 EEROM test failure Replace EEROM Replace main PCA Troubleshooting 8 7 Error Code 010024 010025 010026 010027 010028 010029 01002a 01002b 01002c 01002f 010030 010031 010032 010033 010040 Table 8 2 System Error Codes Continued Problem Description Pen interface ASIC test failure Communication failure between the main and servo processors Communication occurs through the processor support ASIC Servo interrupts not occurring or not reaching the main processor through the processor support ASIC Error in servo drive calculations Error in EEROM checksum calculations Error in EEROM write RS 232 C loopback test failure Centronics test failure Servo processor communication error DRAM test failure Failed communications between the carriage and main processors Carriage ASIC test failure Pen interface ASIC and carriage ASIC link test failure Error detected in X axis servo feedback loop Corrective Actions Replace main PCA Replace main PCA Replace main PCA Replace main PCA Replace or clear
40. its bushing Insert the front end of the spring into the hole in the pinch arm assembly with the pinch arm 90 degrees from its normal position Press the pinch arm assembly back and rotate it to the vertical position Then slide the cam bar to the right until the pinch arm assembly is captured in the chassis The cam bar must be positioned between the left and right sideplates or the lift mechanism will not work Cam Cam Journal Screw Manual Lift Lever Cam Journal Rear Wire Link Washer amp Screw Front Wire Link Rocker Plate Pinch Arm Sensor Shoulder Screw Rocker Plate Tension Spring d Bushing Spring Pinch Arm Assembly Pinch Arm C C2858 75 Figure 6 37 6 58 Removal and Replacement Chapter 7 Adjustments Calibrations INTRODUCTION This chapter describes any adjustments and or calibration procedures to be performed on Models C2858A and C2859A DesignJet 650C plotters Also provided is a listing of when each procedure is required Introduction aaa as meranie arai tens add RUE a Rae OUR RS ada aE 7 1 Adjustments seese eee ani ccc eh hh hh 7 2 Calibration seeds ese Re gabe On e ne ghee s adda aed cse Ds e gaye ded aan 7 2 Sheet Length Calibration ssseeeeeeeeee eee 7 3 Accuracy Calibration paes ana ds hr pte exe Meme Rem RR fe ne RD bg 7 4 Media Sensor Calibration lleeeee ees 7 6 Drop Detect Calibration
41. left to right and right to left A POSITION readout at the front panel indicates carriage position to the user Verifies operation of the optical bail sensor After the test is selected manually raise and lower the bail the window sensor is disabled during this test and verify the display changes in accordance to the bail position STOP the test by pressing the DOWN ARROW button Verifies operation of the optical media sensor After the test is selected manually insert a sheet of media so that it covers the media sensor The display should change as the media is inserted and removed STOP the test by pressing the DOWN ARROW button Assemblies Tested Pens Primer Assembly Optical Sensor Pens X axis Encoder X axis Encoder Cable Main PCA Y axis Encoder Y axis Encoder Cable Main PCA Encoder Strip Drop Sensor Drop Sense Cable Bail Sensor Flag Main PCA Mechanical Interference Media Sensor Main PCA Reflector Label Media Opacity 8 16 Troubleshooting Test Cover Sensor Edge Detect Pinch Whl Snsr Drop Detect Table 8 3 Service Tests Continued Description Verifies the operation of the window interlock microswitch After the test is selected manually raise and lower the window The display should change as the window is raised and lowered Stop the test by pressing the DOWN ARROW button Verifies operation of the optical sensor in the pen carriage This sensor is used to
42. may occur If ink is spilled on the drive roller remove the ink Due to the ink s reflectance ink on the roller can disrupt the plotter s edge sensing function To remove any ink from the roller per form the following procedure 1 2 9 Connect the plotter to an ac power source Switch the plotter ON Press the Enter button on the front panel Using the arrow buttons scroll to the utilities menu display then press the Enter button Using the arrow buttons scroll to the statistics submenu display Simultaneously press the Enter and the Up Arrow buttons to access the service tests menu Using the Up Arrow button scroll to reach the following display SERVICE TESTS X motion control Press the Enter button and the following display will appear REMOVE MEDIA PRESS ENTER Remove any media from the plotter 10 Raise the window Holding the window sensor down with a pen pencil or small screwdriver press the Enter button The display will show that the arrow buttons can be used to control the roller speed for cleaning Press the Up Arrow button sev eral times until the drive roller reaches a convenient speed for cleaning Preventive Maintenance 4 3 Note The speed of the drive roller can be reduced or speeded up by pressing the appropriate arrow button 11 Apply any common household cleaning solution e g BonAmi aerosol Simple Green to a soft lint free rag and apply it to the d
43. six screws that secure the power supply PCA to the electronics enclosure assembly See Figure 6 7 o e Q0 Cone 2000 00 DO On Le a ERES 4 op 00 Screws 6 60 1 Q oO Q cQ ere O s C C2858 43 o o Connector To Main PCA Connector To ac Power Figure 6 7 6 12 Removal and Replacement FAN REMOVAL To remove the fan refer to Figure 6 8 and perform the following procedure 1 Remove the electronic enclosure cover 2 Disconnect the fan connector at the main PCA 3 For model C2858A plotters remove the outer electronics enclosure assembly 4 Using a TORX T 10 screwdriver remove the two screws that secure the fan to the electronics enclosure assembly See Figure 6 8 5 Lift the fan clear of the plotter o Fan Connector ced i AM C Fan Screws 2 C C2858 44 Figure 6 8 Removal and Replacement 6 13 WINDOW ASSEMBLY REMOVAL To remove the window assembly perform the following steps 1 Using a TORX T 15 screwdriver remove the left and right rear trim pieces from the plotter 2 Using a TORX T 15 screwdriver remove the two screws that connect the window assembly
44. the cutter enclosure assembly to the left and right sideplates See Figure 6 32 Using a TORX T 20 screwdriver loosen the wedge screws at the left and right ends of the cutter enclosure assembly out of the left and right sideplates until the screws are flush with the inner side of the sideplates Pull the cutter enclosure assembly forward and clear of the plotter To remove the media guides from the cutter enclosure grasp each one firmly twist counter clockwise and pull it clear of the enclosure Note The rear edge of the cutter enclosure assembly slides in between the two rear pins on the left and right sideplates during replacement Removal and Replacement 6 49 C C2858 71 Media Guides C2858A 3 Cutter Enclosure Assembly C2859A 4 Upper Screw Left Side Wedge Screw C C2858 31b Upper Screw Right Side Wedge Screw UNS C C2858 3 IS Figure 6 32 6 50 Removal and Replacement ENTRY PLATEN ASSEMBLY REMOVAL To remove the entry platen assembly perform the following procedure 1 Remove the window assembly 2 Remove the left and right endcovers 3 Remove the electronics enclosure cover 4 Disconnect the media sensor cable from the main PCA 5 Disengage the media sensor cable from all clamps and remove the media sensor from the entry platen 6 Lower the rollfeed cover to the open position 7 Using a TORX T 15 sc
45. the front panel display Recheck the MIO configuration settings The flow of data from the computer to the plotter was prematurely stopped e g by switching OFF the computer before all of the data was sent Press the ENTER button to clear the message from the front panel display The modular interface is configured incorrectly Press the ENTER button to clear the message from the front panel display Check the handshake settings in the plotter s front panel in the hardware configuration and in the application software configuration Adjust the settings as needed to ensure compatibility The current plot is too large for the plotter s buffer Additional memory must be installed to plot drawing Pen checking is ON and an error has been detected Press the UP ARROW if you want to load the pen Press the DOWN ARROW if you want to continue without loading the pen An attempt to load media was made while the media load lever at the right of the plotter was raised Remove the media lower the lever and reload media with the lever down Troubleshooting 8 5 Message Roll misaligned Reload roll RS 232 error Baud parity RS 232 error Handshake Service pens Continue Sheet misaligned Reload sheet Switch power off Check media path Switch power off Table 8 1 Worded Error Messages Continued Error Action Roll media is skewed Unload roll media Open the roll cover and push the media roll all the way to the
46. the plotter The fan is primari ly used to cool the power supply PCA when plotting When the plotter is not plotting the fan is switched OFF At high temperatures the fan is switched ON The window sensor is a switch mounted on the right sideplate at its top front edge Feedback about the window s position up or down is sent to the main PCA through the front panel An optical pinch wheel sensor is mounted on the lower rear portion of the plotter s right side plate and is electrically connected to the main PCA When the pinch arms are raised acam in the pincharm lift mechanism interrupts the beam of the optical sensor and when the pin charms are lowered the beam is not interrupted Thus the position of the pincharms can be determined from the electrical state of the sensor The media sensor is also an optical sensor and is mounted toward the right end of the entry platen A reflective label located under the cutter enclosure provides a reflective surface for the sensor A base intensity level for reflected light is determined for the sensor in the absence of media This intensity level is stored in the EEROM It is calculated when a new main PCA with a blank EEROM is first powered up or after the EEROM has been cleared When media is loaded a difference between the new intensity level and the base intensity level indicates that media is present This sensor provides a leading and trailing edge sensing capability for media length mea
47. to the back panel See Figure 6 9 CAUTION Exercise care to avoid contacting or damaging the encoder strip while removing the window assembly 3 Raise the rear portion of the assembly until the front portion drops down slightly and slide the assembly slightly toward the front of the plotter Then lift the assembly clear of the plotter Window Assembly Back Panel L C2858 32d Figure 6 9 6 14 Removal and Replacement ENDCOVERS LEFT AND RIGHT REMOVAL To remove the endcovers perform the following procedure 1 Raise the plotter window to the open position 2 Remove the window assembly 3 Lower the rollfeed cover to the open position 4 Using a TORX T 15 screwdriver remove the two front screws that connect each endcover and front sideplate trim to the plotter See Figure 6 10 5 Using a TORX T 15 screwdriver remove the bottom rear screw hidden that con nects each endcover to the sideplate Note When removing the left endcover pull the endcover out until you can reach under the cover and disconnect the internal ac power cord from the internal ac receptacle Reconnect the cord during reassembly When removing the right endcover do not stress or apply pressure to the front panel assembly Note the upper and lower grooves the endcover en gages on the front panel for reassembly 6 Maintaining an even pressure on the top and bottom of the endcover
48. us amais cise dei pede Oba web eea weld oe 8 12 ROM Code Revision Level 0 0 0 0 cece ccc e 8 12 Nine M Tm 8 13 Configuration Plot a asa cesses be o ga breed a bru rud 8 19 Bar Pattern AnalysiS e iius px e a Dee eR a bia Eae Ge dd added 8 20 Reading the EEROM Text Block sese 8 21 Analyzing the Pen Nozzle Test Block 0 0 0 0 cece ee eee ee 8 21 viii Contents Chapter Page 9 Product History Introduction ssa trans eae eere ee hee RO aw A as oa aS 9 1 History of Assemblies by Serial Number 0 00 0 0 0c e eee 9 2 History of Printed Circuit Assemblies PCAs 0 cece eee eee eee 9 3 10 Parts and Diagrams Introduction 12 camada sa PES do FERE EE Pipas a CERE ET Y E 10 1 Exchange Assemblies sussa tas eR agi wade Sid dead ipi a Da 10 2 Replaceable Parts i4 eee bores xod Da medo Dra e needa wa 10 2 Illustrated Parts Breakdown Drawings eeeeee A 10 2 Labels and Cables x c rk ew nana d cea E RATEERA Heme CX Ee 10 2 Contents ix General Definitions of Safety Symbols WARNING CAUTION International caution symbol refer to manual the product will be 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 must also be marked Protective conductor termin
49. 0076 8 11 C1633 40079 5 12 C1633 80007 3 13 C1633 20021 5 14 0624 0647 5 15 C2847 60022 0 16 C1633 00075 7 17 0624 0704 3 18 2190 0760 4 19 C1633 40078 7 20 0515 2278 4 21 1400 1021 8 6 8 7 Parts List Pincharm Assembly Qty NEP NNAF RP REPRE NFR RBBB HDB ADABRARER stt t t Description SCREW M2 5X20 CAM JOURNAL NUT HEX DBL CHAM CAM MANUAL PINCHARM LIFT MODEL C2858A MODEL C2859A MODEL C2858A MODEL C2859A MODEL C2858A MODEL C2859A MODEL C2858A MODEL C2859A PINCHARM ASSEMBLY SPRING PINCHARM BUSHING PINCHARM SCREW METRIC MEDIA EDGE DIRECTOR WIRE LINK REAR PLATE ROCKER SPRING ROCKER SCREW SHOULDER SCREW TAPPING 4 20 SENSOR PINCHARM WIRE LINK FRONT SCREW 6 19X0 375 PLST WASHER 5 1MM CAM DRIVE LEVER SCREW MACH CLAMP CABLE PAN LEVER MANUAL LIFT MEDIA DIVERTER MODEL C2858A MODEL C2859A 10 30 Parts and Diagrams 174 Pincharm Assembly Illustrated Parts Breakdown C C2858 14 1 10 31 Parts and Diagrams Ref Des BON 10 11 12 13 Parts List Starwheel Starguard and Chassis Assemblies HP Part Number 0515 2337 0515 2304 0515 2333 C2847 60009 C1633 60032 C1633 60051 C2858 00014 C2859 00004 C2858 60021 C1633 40067 C2858 60025 C2859 60003 C2847 60011 C1633 60047 C1633 40077 C D UNU NO NO O N AN WANAOA Qty BWP BPR EP eB eB eB BR DOAamnme ANN Description
50. 0C field replaceable assemblies InttOdUClOH uad nc duo x coque x Roo S x rop Rd ba mete coa bere 6 1 Safety Considerations 0 0 0 0 eect eens 6 3 BSD Considerations assa secedere x eae bed seed alg eee baw ee 6 3 Required Tools ss ma i244 sans eua PEGUE Rh er RE Eia Urpbente eas Redes 6 4 Repair Procedures iiu Rp VR hPa Dee wee eee Re fe ea eee 6 4 DRAM SIMM and ROM Module Removal 0 0 000005 6 5 MIO Card Removal as pusipa mis RR eb ER tase nda head RE LIU dL 6 6 Electronics Enclosure Cover Removal eeleeeeeeees 6 7 Interconnect PCA Removal 0 0 2c eee ee eh 6 8 Main PCA Removal suas osu m eae nea ee eae ox RAE ER RR RS a 6 9 Outer Electronics Enclosure Assembly Removal C2858A Only 6 11 Power Supply PCA Removal 0 0 cece cece eee 6 12 Fan Removal sua siga pad tan tte Re Eo nh ORS oO edd Had SEE WU eL da 6 13 Window Assembly Removal 1 0 0 0 0 0 cece eee ee 6 14 Endcovers Left and Right Removal 0 0 0 c eee eee eee ee 6 15 Primer Assembly and Sensor Removal 0 00 0 e cece ee eee ee 6 17 Pinch Wheel Sensor Removal 0 00 c smri inia iE a EOR E 6 18 Window Sensor Removal eseeee eens 6 19 Media Sensor Removal 00 cece eee tee eee eee 6 20 Trailing Cable Removal 0 00 c eee nidie thi nitas 6 21 Back Panel Removal sssass ceed nes sas ewe eed oe EEE ea ES 6 23 Front Panel Removal ceed ci
51. 128 Ibs 70 kg 155 Ibs Packaging Plotter Body Length 1270 mm 50 in 1574 mm 62 in Width 584 mm 23 in 584 mm 23 in Height 635 mm 25 in 635 mm 25 in Weight 68 kg 150 lbs 68 kg 150 Ibs Leg Pack Length 940 mm 37 in_ 1219 mm 48 in Width 711 mm 28 in 762 mm 30 in Height 229 mm 9 in 229 mm 9 in Weight 21 kg 45 Ibs 25 kg 55 Ibs Site Planning and Requirements CABLE RESTRICTIONS Cable restrictions for the plotter are determined by the type of interface being used Recom mendations for each interface are supplied in the following paragraphs RS 232 C INTERFACE The use of short cables each less than 15 metres or 50 feet is recommended for the RS 232 C Interface Longer cables are permissible provided the load capacitance does not exceed 2500 picofarads CENTRONICS INTERFACE The use of short cables each less than 2 metres or 6 6 feet is recommended for the Centron ics Interface HP IB INTERFACE The HP IB Hewlett Packard Interface Bus allows up to 15 devices to be connected The maximum cable length is restricted to 2 metres 6 6 ft per device up to a total of 20 metres 65 8 ft The devices may be connected in a star or linear bus network 2 4 Site Planning and Requirements Chapter 3 Installation and Configuration INTRODUCTION This chapter contains the information required to configure and verify proper operation of the HP C2858A and C2859A DesignJet 650C plotters Print c
52. 15 1723 07570 40250 QEDS 9500 C2848 60003 0515 0382 0515 1349 C2847 20012 0515 2333 1400 1021 0624 0748 C2847 60021 C1633 40064 C1633 20006 2190 0760 C2858 00078 C2858 40039 Ua oo ww Un NDA IV WwW ONA eN Ow 00 1 100 XO t2 NO Parts List Paper Drive Assemblies Qty eee dm eH ok d dm kr ee AQ nlt t t2 Description PLATEN ENTRY MODEL C2858A MODEL C2859A PLATEN ROLLER ASSEMBLY MODEL C2858A MODEL C2859A SCREW TORX SLOT M3 SCREW LONG DOGPOINT SCREW MACH M4X10 PLATE AXIAL BIAS CABLE ASSEMBLY X ENCODER SCREW M2 5X45X16 COVER ENCODER IC ENCODER MOTOR ASSEMBLY PAPER X AXIS includes items 8 9 10 and 14 SCREW METRIC SCREW MACH M3 GEAR WORM SCREW THRD RLLG CLIP CABLE 1 IN LG SCREW 1 32 PLASTITE SENSOR MEDIA MOUNT SENSOR MEDIA MOUNT PAPER X MOTOR WASHER 5 1MM ABSORBENT MATERIAL INK DROP RESERVOIR RIGHT SPITTOON 10 26 Parts and Diagrams Paper Drive Assemblies C C2858 12 1 Illustrated Parts Breakdown Parts and Diagrams 10 27 Ref Des BLO6ovoovoc o0unaroliT amam o IAN tn FW WV 19 20 21 22 23 24 25 26 27 28 29 Parts List Bail and Overdrive Support Assemblies HP Part Number C1633 80006 0624 0647 3050 0026 C1633 40028 C1633 40027 C2847 40013 0510 0083 C1633 20021 C1633 40019 C1633 60030 3050 1381 C1633 40052 0624 0520 C1633 40089 0515 1743 0624 0704 C1633 40038 C2858 60017 C2859 60001
53. 2859A DesignJet 650C plotters have self adjusting power supplies and do not require voltage selector or switch settings prior to use Table 2 1 lists the power require ments for the plotters Table 2 1 Power Requirements Voltage Requirements Voltage Current max 100 Vac 14A 120 Vac 1 2 A 220 Vac 650 mA 240 Vac 600 mA Frequency 47 53 Hz and 57 63 Hz Consumption 140 Watts maximum LINE CORD SET WARNING The ac power outlet mains must have a protective earth ground terminal Serious shock hazard leading to death or injury may result if the plotter is not prop erly grounded The configuration of the ac line cord set required for use with the plotters is determined by the country of destination for the plotters Refer to Chapter 3 for a listing of the available ac line cord connectors 2 2 Site Planning and Requirements ENVIRONMENTAL SPECIFICATIONS Table 2 2 lists environmental specifications for the plotters Table 2 2 Environmental Specifications Temperature Storage 40 to 70 C 40 to 158 F Operating O to 55 C 32 to 131 F Optimal Operating 15 to 30 C 59 to 86 F Relative Humidity Operating 20 to 80 RH PHYSICAL SPECIFICATIONS The plotter physical specifications are listed in Table 2 3 Table 2 3 Physical Specifications C2858A C2859A Length 1092 mm 43 in 1372 mm 54 in Depth 711 mm 28 in 711 mm 28 in Height 1169 mm 46 in 1219 mm 48 in Weight 58 kg
54. 30 cm of media out from the roll Check the leading edge of the media If it appears uneven or to ensure a straight edge the edge will need to be trimmed WARNING The cutter blade is very sharp Use caution when using the cutter to trim or cut media Keep hands away from the blade when cutting Retract the blade into the cutter after use 8 Trim the leading edge if it s uneven Pull it over the top of the plotter and lay it over the cutting track Using the cutter located in the holder at the back of the plotter cut off the first few inches of the media See Figure 3 5 Return the cutter to the holder 9 Load the leading edge aligning the right edge with the perforated line on the entry platen Push the media in until it buckles slightly as it hits the stops inside the plotter Let go when the plotter begins to pull the media in See Figure 3 6 3 8 Installation and Configuration Cutting Track C C2847 7 UM Trimming the Leading Edge of the Media Figure 3 5 Insert Media Until it Buckles Evenly Align Media with C C2847 15 UM Perforation Line Loading the Leading Edge of the Media Figure 3 6 10 When the front panel displays Sheet load Roll load press the Down Arrow button to select Roll load 11 When the front panel displays SELECT MEDIA press the Up or Down Arrow button to scroll through and select the media choice Press the Enter button to set the plotter for the media type be
55. 51 Drive Roller Assembly Removal 0 0 0 0 eee ee eee eee nee 6 53 Automatic Bail Lift Mechanism Removal 00 000 e eee eee 6 55 Media Diverter Removal a 2 etes uc ee tes ae ee Bae Ee 6 56 Pinch Arm and Lift Mechanism Removal lseleee eese 6 57 7 Adjustments Calibrations Introduction ires re Chas owe Chae dbs BOL IE Shaw Hew Shwe Fed ee 7 1 Adjustments esce ace e ble re GE deca Br avin ER a A RU d e Re Reg 7 2 CalibratlOns soca a c ntimo qe oed Pete desc esee bea diee tending sed a brs 7 2 Sheet Length Calibration 0 0 0 cara e 7 3 Accuracy Calibration seas rere ew ex Rer pa Ele tae que 7 4 Media Sensor Calibration ssseeeeee ee eens 7 6 Drop Detect Calibration 0 0 eee eee cece nee 7 7 Edge Sensor Calibration 0 0 0 0 cece cee eee 7 8 Bail Calibration 2 vice betas bequem tr be tes a e bene 7 9 8 Troubleshooting Introduction ss xis dae heme Had da mcs ged ye eue RR reb Rs 8 1 IET EE 8 2 Power On Self Tests i eee na eS Ce owed e dU ead 8 2 Power On Self Test usinas ssepe beret ete ae NR ca Ree RR TR RC E ses 8 2 Mechanical Initialization ose saoi ieee a a e eee 8 3 Error Messages and Codes crrrere cics sesi res ecsa rr 8 4 Worded Error Messages eee 8 4 System Error Codes eseis secas eus boe bs a A bade 8 7 Display Data Plot ss sussa RR er Eee eed t eitia een EEE 8 11 Servo System Control Failures 0 0 0 eee ee 8 11 Troubleshooting TIPS
56. 515 0390 C1633 60020 C1633 00080 0950 2417 9170 1533 9170 1535 C2858 60024 C2847 00019 C1633 00105 C2847 00027 C2858 69104 156474 C2858 18012 C2858 18013 C2858 18014 C2858 18015 0535 0043 C2847 60005 C2847 40007 C2065A C2066A C2847 00010 C2858 60011 Parts List C2858A Electronics Enclosure C Qty D 2 15 1 20 1 1 1 10 MP OONDMFwWNHNTUFUOUNUNAANAFAWHOHHAUNUNNYNWUNADwW HNN Ke pai pa Oe a p ee ee OO Description GUIDE MIO SUPPORT SCREW MACH M4X10 SUPPORT MIO SCREW MACH PCA INTERCONNECT ENCLOSURE OUTER MAIN PCA COVER MIO SCREW TORX SLOT M3 SCREWLOCK FEMALE RS 232 SCREW MACH M3X12 SCREW MACH M3 FAN TUBEAXIAL GROMMET CHANNEL ENCLOSURE INNER POWER SUPPLY CLIP CABLE FLAT SCREW MACH M4X6 AC POWER RECEPTACLE ASSEMBLY INSULATOR BOTTOM PCA POWER SUPPLY CLAMP FERRITE FERRITE SPLIT RECT CABLE ASSEMBLY TRAILING INSULATOR POWER SUPPLY LABEL INSULATOR COVER SIMM PCA MAIN REBUILT C2858 60104 CD 2 NEW IC EPROM U42 IC PROGRAMMED EPROMO U31 IC PROGRAMMED EPROMI U30 IC PROGRAMMED EPROM U33 IC PROGRAMMED EPROMG U32 NUT HEX M4X0 7 CABLE ASSEMBLY MAIN BD PWR BARRIER SIMM SIMM 4MB OPTION SEE CHAPTER 1 SIMM 8MB OPTION SEE CHAPTER 1 MODULE ROM OPTION SEE CHAPTER 1 COVER ELECTRONICS ENCLOSURE CABLE ASSEMBLY WIRE HARNESS 10 10 Parts and Diagrams C2858A Electronics Enclosure C C2858 4 1 Illustrated Par
57. 8 7 1 Illustrated Parts Breakdown Parts and Diagrams 10 17 Ref Des o 10 tn FW WN 10 11 12 13 14 15 16 17 18 19 20 21 HP Part Number C2847 00029 1500 0856 07570 60105 07570 40105 1460 2139 C1633 40065 0515 0380 C1633 00068 C2858 00028 C2859 00005 0515 2248 C1633 00057 1400 1021 C2847 00042 C2848 00011 3050 0026 0535 0031 0624 0647 C2858 60007 C2858 60003 C2858 00077 C2858 40038 C2858 00076 C2858 00012 Parts List Carriage Axis Drive Left End C Qty D ND O Rt roc r o0000taO 1U 00 l2 ONO qm D m m e e a O e e i a O o U o a a a a a a a a i BELT MAIN DRIVE Description MAIN IDLER ASSEMBLY TENSIONER MAIN SPRING COMP 1 07 OD HOUSING MAIN TENSIONER SCREW MACH M4X10 DOOR TENSIONER HOUSING TRAILING CABLE TRAY FRONT SCREW THRD RLLG BRACKET Y AXIS TENSIONER CLAMP CABLE 1 IN LG ENCODER STRIP WASHER 3 2MM NUT HEX M3X0 5 SCREW 6 20 PLASTITE SENSOR PRIMER PRIMER ASSEMBLY GROUND STRAP MODEL C2858A MODEL C2859A MODEL C2858A MODEL C2859A MODEL C2858A MODEL C2859A INK DROP RESERVOIR LEFT SPITTOON ABSORBENT MATERIAL TUBES RUBBER 10 18 Parts and Diagrams Service Station See Page 10 21 EN C C2858 8 1 Sesssese se SSS EM s bc OE EN EX E Ny INI b ENT NET aa E is 2 2 t V v Carriage Axis Drive Left End Illustrated Parts Breakdown
58. 9 Media Diverter 6 56 Media Sensor 6 20 Overdrive Support Assembly 6 47 Pen Carriage Assembly and Main Drive Belt 6 38 Pinch Arm and Lift Mechanism 6 57 Pinch Wheel Sensor 6 18 Power Supply PCA 6 12 Primer Assembly 6 17 Rollfeed Cover Assembly 6 30 Service Station Assembly 6 44 Starguard Assembly 6 42 Trailing Cable 6 21 Trailing Cable Front Tray 6 34 Window Sensor 6 19 X axis Motor 6 26 Index Y axis Motor 6 25 Y Tensioner Housing 6 36 Restrictions Cable 2 4 Centronics Interface 2 4 HP IB Interface 2 4 RS 232 C Interface 2 4 Rollfeed Plotting 1 2 Rollfeed Cover Assembly Removal 6 30 ROM Main PCA Information 5 5 S Safety Considerations 6 3 Selecting a Menu Option 3 19 Self Tests Normal Power on 8 2 Power on 8 2 Sensor Bail 5 8 Line 5 3 Media Removal 6 20 Pinch Wheel Removal 6 18 Window Removal 6 19 Sensors Status Conditions 5 2 Service Station Assembly Removal 6 44 Service Tests 8 13 Shutdown X axis 8 11 Y axis 8 11 Signals PA and PB Drive 5 7 Software 1 2 Specifications 2 2 Electrical 2 2 Starguard Assembly Removal 6 42 Stepper Drive 5 3 Stepper Motor 5 3 Strip Encoder Removal 6 28 Swath 5 5 T Tensioner Y Housing Removal 6 36 Tests Service 8 13 Tools Required 6 4 Trailing Cable Removal 6 21 Trailing Cable Front Tray Removal 6 34 Tray Trailing Cable Front Removal 6 34 Troubleshooting Tips 8 12 V
59. 9 0 50 3 07575 40012 2 2 HINGE MALE 4 07575 40111 2 2 HINGE FEMALE 5 C2847 60008 2 1 BLADE RUNNER ASSEMBLY MODEL C2858A C1633 60053 7 1 MODEL C2859A 6 C2847 00009 7 1 COVER FIXED Y ARM MODEL C2858A C1633 00030 4 1 MODEL C2859A 7 0624 0744 3 4 SCREW CRIMPTITE 8 C2847 40003 5 1 WINDOW MODEL C2858A C1633 40075 1 1 MODEL C2859A 9 C2858 00011 4 1 BACK PANEL MODEL C2858A C2859 00002 3 1 MODEL C2859A 10 0515 0380 2 2 SCREW MACH M4X10 11 0515 0390 4 5 SCREW MACH M4X6 12 0515 2304 9 6 SCREW BOLT METRIC 6 1 13 C2858 00005 TRAILING CABLE TRAY REAR 10 6 Parts and Diagrams To Pen Carriage Electronics Enclosure C2858A See Page 10 9 C2859A See Page 10 11 Window and Back Cover Assemblies C C2858 2 1 Illustrated Parts Breakdown Parts and Diagrams 10 7 Parts List C2859A Electronics Enclosure Ref HP Part C Qty Description Des Number D I 0515 1249 4 19 SCREW MACH 2 C2858 60105 3 1 PCA INTERCONNECT 3 156474 2 1 IC EEROM U42 4 C2065A 4 SIMM 4MB OPTION SEE CHAPTER 1 C2066A 5 SIMM 8MB OPTION SEE CHAPTER 1 5 C2847 40007 9 1 BARRIER SIMM 6 0535 0043 6 2 NUT HEX M4X 0 7 7 C2858 18012 2 1 IC PROGRAMMED EPROM 0 U31 C2858 18013 3 1 IC PROGRAMMED EPROM 1 U30 C2858 18014 4 1 IC PROGRAMMED EPROM 2 U33 C2858 18015 5 1 IC PROGRAMMED EPROM 3 U32 8 MODULE ROM OPTION SEE CHAPTER 1 9 C2858 69104 0 1 PCA MAIN REBUILT C2858 60104 CD 2 NEW 10 0515 0380 2 15 SCREW M
60. ACH M4X10 11 C1633 00033 7 1 SUPPORT MIO 12 C1633 40059 1 2 GUIDE MIO SUPPORT 13 9170 1535 8 2 FERRITE SPLIT RECT 14 C2858 60024 5 1 CABLE ASSEMBLY TRAILING 15 9170 1533 6 2 CLAMP FERRITE 16 0400 0369 4 1 GROMMET CHANNEL 17 C1633 00031 5 1 COVER MIO 18 0570 1316 2 2 SCREWLOCK FEMALE RS 232 19 0515 1084 5 2 SCREW MACH M3X12 20 C2848 60001 6 1 ELECTRONICS ENCLOSURE ASSEMBLY 21 1400 1642 9 2 CLIP CABLE FLAT 22 0515 2246 3 10 SCREW TORX SLOT M3 23 0515 0390 4 1 SCREW MACH M4X6 24 C1633 60020 8 1 AC POWER RECEPTACLE ASSEMBLY 25 1400 1021 8 1 CLIP CABLE 1 IN LG 26 C1633 00080 4 1 INSULATOR BOTTOM 27 3160 0814 7 1 FAN TUBEAXIAL 28 0515 1349 5 2 SCREW MACH M3 29 0950 2417 2 1 PCA POWER SUPPLY 30 C2847 00019 9 1 INSULATOR POWER SUPPLY 31 C1633 00105 4 1 LABEL INSULATOR 32 C1633 60014 0 1 CABLE ASSEMBLY MAIN BD PWR 33 C2848 00002 1 1 COVER ELECTRONICS ENCLOSURE 34 C2847 00027 9 1 COVER SIMM 35 C2858 60011 0 1 CABLE ASSEMBLY WIRE HARNESS 10 8 Parts and Diagrams C2859A Electronics Enclosure C C2858 3 1 Illustrated Parts Breakdown Parts and Diagrams 10 9 Ref Des Zoe wr rnrnanaunsewne NNNNNNNNN e RRP em eK eK o IAN 2 C tl2 TO ANA NF WwW F2 29 30 31 32 33 34 35 HP Part Number C1633 40059 0515 0380 C1633 00033 0515 1249 C2858 60105 C2847 60004 C1633 00031 0515 2246 0570 1316 0515 1084 0515 1349 3160 0814 0400 0369 C2847 60018 1400 1642 0
61. BAR PATTERN ANALYSIS The configuration plot has several special diagnostic features built in The four sets of color bars printed along the top represent the four specific pen locations being checked Each pen position is tested for missing nozzles nozzle directionality and vertical line straightness A 10X magnifier should be used to look at the patterns Perfect patterns should be parallel lines equally spaced Some slight errors in direction meaning the ink dots are not being fired straight are due to nozzle imperfections and cannot be fixed Others may be caused by nozzle contamination These can sometimes be corrected by cleaning the nozzles The solid area fill checks for ink flow problems There should not be any white space or fad ing of color through the pattern The lower portions of the bars can be used to check nozzle directionality and vertical line straightness If a problem occurs try wiping and or replacing the pen The vernier scales show how well pens are aligned to each other The center lines should match If they don t a pen alignment is needed Horizontal lines next to the vernier scales are composed of separate line segments created with different nozzles A missing segment indicates a defective nozzle Patterns of missing segments indicate a poor connection between the pen and the pen carriage Use the samples below to assist you in analyzing possible print quality problems Problem Nozzle pattern out with corresp
62. C HEWLETT PACKARD SERVICE MANUAL HP C2858A C2859A DRAFTING PLOTTERS SERIAL NUMBERS This manual applies directly to HP C2858A and C2859A plotters with serial numbers prefixed USA For additional information about serial numbers see SERIAL NUMBER INFORMATION in Chapter 1 OHEWLETT PACKARD COMPANY 1993 16399 W BERNARDO DRIVE SAN DIEGO CALIFORNIA 92127 1899 C2858 90000 Printed March 1993 Using this Manual This service manual contains information necessary to test adjust and service the Hewlett Packard Models C2858A and C2859A DesignJet 650C plotters It is designed to help you easily find the cause of a C2858A C2859A hardware problem and to perform the necessary repairs and adjustments to get the plotters into proper operating condition Service strategy for this manual is to support the products to the field replaceable unit For ease of reference this manual is divided into ten chapters as follows Chapter Product Information Chapter2 Site Planning and Requirements Chapter3 Installation and Configuration Chapter4 Preventive Maintenance Chapter5 Functional Overview Chapter6 Removal and Replacement Chapter7 Adjustments Calibrations Chapter8 Troubleshooting Chapter9 Product History Chapter10 Parts and Diagrams Chapter 1 Product Information This chapter contains general information regarding the C2858A and C2859A DesignJet 650C plotters A description of the plotters features options and acce
63. CA Remove the right endcover Using a TORX T 10 screwdriver remove the screw that attaches the media sensor to the entry platen The screw is accessible from underneath the entry platen Remove the sensor through the access hole in the right sideplate See Figure 6 14 Note During installation ensure that the sensor is properly aligned to its mounting hole in the entry platen before screwing it down Perform the sensor calibra tion procedure when completed Media Sensor Cable Access Hole Figure 6 14 6 20 Removal and Replacement TRAILING CABLE REMOVAL While removing the trailing cable see Figure 6 15 To remove the trailing cable perform the following procedure 1 2 Remove the window assembly For models C2858A remove the main PCA For models C2859A remove the outer electronics enclosure assembly Using a TORX T 10 screwdriver remove the two screws that attach the toroid to the rear of the electronics enclosure assembly Separate the two endcaps of the toroid and remove the toroid from the trailing cable Using a TORX T 15 screwdriver remove the five screws that attach the trailing cable rear tray to the back panel See Figure 6 15 Note For models C2859A remove the trailing cable tray center bracket screw to release the tray from the bracket Cut the tie wrap and free the trailing cable from the trailing cable rear tray Disconnect the trailin
64. CA POWER SUPPLY PCA An auto ranging power supply for the DesignJet 650C plotter is located in the electronics enclosure assembly It accepts and automatically adjusts to an ac input of 90 V through 264 V and produces regulated voltages of 5 V 12 V and 12 V and an unregulated 24 V These voltages produced by the power supply are used as follows e 424 V Motor drivers and voltage regulator on the interconnect PCA Regulated 9 to 15 V for pen circuits on the carriage PCA e 12 V Fan power MIO and RS 232 driver e 12V RS 232 driver e 5 V IC power and sensors drop sense PCA In the primary portion of the supply are contained fusing and input protection circuitry line filters and a rectifier The primary output is converted to a pulse width modulated PWM unidirectional current by a flyback dc to dc converter The secondary portion of the power supply contains the four secondary windings of the trans former that convert the PWM current in the primary to four ac voltages which are rectified to the 5 V 12 V 12 V and 24 V dc voltages required by the plotter Standard 12 V and 12 V regulators are included in the secondary portion of the power supply 5 8 Functional Overview Chapter 6 Removal and Replacement INTRODUCTION This chapter contains repair information including safety and ESD precautions a list of tools required for plotter repair and procedures for the removal and replacement of HP DesignJet 65
65. CONSIDERATIONS The Safety Symbols used with Hewlett Packard instruments are illustrated in the front mat ter of this manual WARNING and CAUTION symbols and instructions must be reviewed before service work is performed These warnings and cautions must be followed for your protection and to avoid damage to the plotter The ac power outlet mains must have a protective earth WARNIDG ground terminal Serious shock hazard leading to death or injury may result if the plotter is not properly grounded DO NOT allow water to run onto electrical components and circuits or through openings in the enclosure as this can create a shock hazard Disconnect the plotter from the power source prior to performing any maintenance ESD CONSIDERATIONS Integrated circuits can be damaged by electrostatic discharge To prevent damage to the plot ter circuits from high voltage electrostatic discharge take the following precautions e Do not wear clothing that is subject to static build up 2 Do not handle integrated circuits ICs in carpeted areas 3 Do not remove an IC or a PCA from its conductive foam pad or conductive packag ing until you are ready to install it 4 Ground your body while disassembling and working on the plotter 5 After removing acover from the plotter attach a clip lead between the PCA common and earth ground Touch all tools to earth ground to remove static charges before using them on the plotter 6 Afte
66. EEROM Replace main PCA Perform all calibrations Press Enter to temporarily clear Replace or clear EEROM Replace main PCA Perform all calibrations Replace main PCA Replace main PCA Replace main PCA Replace main PCA For all 01003X codes check trailing cable connections and continuity If needed replace the main PCA or the carriage assembly Refer to 010030 Refer to 010030 Check X encoder encoder cable main PCA 8 8 Troubleshooting Error Code 010041 010050 010051 010052 010080 020001 020002 030000 030001 030002 030003 030010 04xxxx Table 8 2 System Error Codes Continued Problem Description Error detected in Y axis servo feedback loop Uppermost SIMM indicates a failure Next to uppermost SIMM indicates a failure Both upper and lower SIMMs indicate a failure RS 232 C data overflow Firmware problem Bad EPROMS X axis shutdown Y axis shutdown Y axis friction too high Y axis failure Excess friction in pen capping assembly MIO interface error Corrective Actions Check encoder strip carriage assem bly trailing cable main PCA Replace uppermost SIMM Replace next to uppermost SIMM Replace both upper and lower SIMMs Data byte was not read before another was entered into the UART Replace main PCA If problem remains report the firmware problem to the HP Response Center or the nearest HP Sales and Support Office For a
67. Enhanced 600 addressable 2 50 3 18 Installation and Configuration Action buttons Cancel stops current operation plotting accuracy calibration Cancel FormFeed Cut Access Pens NI Pause pen alignment and media loading mmm ee ee Form Feed Cut advances the page and if roll media cuts it Access Pens brings the pen carriage out to the Pause stops plotter after plotting area for pen access Plotter window plotting current drawing must be closed Press again to continue To select and confirm a menu option do the following 1 Press the Enter button to move from the Status display to the menu structure 2 Press either theup T or down 4 arrow button to review the options at the current menu level 3 When the menu or option you want is displayed press the Enter button 4 Repeat from step 2 to reach the next level or sublevel of options you want to set Note Many menus contain subgroups of plotter options Pressing Enter then dis plays the next level of options When you have reached the final level of your option pressing Enter confirms your menu selection or value In many instances your choice is saved in the plotter s continuous memory This means it is not erased or reset when you turn OFF the plotter To exit to a previous menu press the Previous button Continuous pressing of the Previous button will move you to higher levels of the menu structure until yo
68. M and the stepper drive It sends configuration information to the car riage processor via its serial port The EEROM stores plotter calibration and configuration information while power is OFF The stepper drive moves the stepper motor The stepper mo tor is used to raise the pen wiper for wiping pens or to operate the pen service station A line sensor on the carriage PCA provides the servo processor with information used to align the pens It also provides a media edge sensing capability to the plotter for width mea surement The carriage ASIC controls the firing of the pens It receives pixel data from the processor support ASIC over a synchronous serial channel It contains a 100 bit shift register one bit per pen nozzle which performs a serial to parallel conversion on the data It contains tim ing sequencing and delay circuitry to ensure that pen nozzles are fired in the correct se quence and at the correct time It also contains fire waveform generators to create the fire pulse waveforms used to fire the pens Pen drivers provide the power necessary to fire the pens under the control of the carriage ASIC During pen testing the processor support ASIC provides a means to generate a fire position pulse when the carriage is docked in the service station The carriage ASIC will receive this signal and fire selected nozzles If a drop is sensed by the drop detector each time a nozzle is fired the nozzle is working properly The indep
69. OWER ON SELF TEST Self tests normally run when the plotter is switched on are 1 Servo processor initialization The display will read Servo processor initialized when initialization is complete If the servo processor cannot initialize replace the main PCA 2 The main processor initializes One dot will be displayed when complete If this portion of the test fails replace the main PCA 3 The main processor to servo processor communication path is tested If this portion of the test fails replace the main PCA 4 The ROM checksum is tested Successful completion of this test will cause two dots to be displayed If this portion of the test fails first replace the EPROMs If re placing the EPROMs does not correct the error replace the main PCA 5 The main processor initializes certain firmware modules and communicates with the 6 0 carriage processor If these tests pass three dots will be displayed and the Pa per LED will be turned ON 8 2 Troubleshooting a The EEROM checksum is tested If this portion of the test fails clear or re place the EEROM and run the calibration adjustments described in chapter 7 If replacing the EEROM and running the adjustments does not fix the problem replace the main PCA b The servo processor transfer buffer and interrupt tracking abilities are tested If this test fails replace the main PCA c Another communication test between the processors
70. Press Enter 5 Messages in the plotter display will inform you to load cut sheet media in a land scape orientation Any standard size or type of media may be used 6 The plotter will scan across the media accurately locating the media edges 7 The sheet must then be removed rotated 90 and reloaded into the plotter 8 The media edges are again scanned and the calibration is completed 9 Check the margins by measuring the hardclip limit borders on the Configuration Plot Adjustments Calibrations 7 3 ACCURACY CALIBRATION Performance of these accuracy procedures allow you to either restore the plotter to the facto ry accuracy settings or to recalibrate the plotter to the current environment Accuracy calibra tion constants are stored in the plotter EEROM When performing the accuracy calibration from the Service Test menu the factory correction value will be recalculated This will be the new factory default calibration value The calibration performed from the Utilities menu will calculate a new user calibration value This value will override the factory value until the plotter is reset from the Resets submenu Once reset the plotter will use the factory default until another user calibration is run Check the accuracy calibration whenever the e EEROM IC is replaced or erased platen drive roller is replaced X axis motor encoder is replaced Before performing an accuracy calibration run a configur
71. Service Tests Continued Description Verifies operation of the cutter Allows either single or continuous cut operation An offset value can be entered to determine how much margin the cutter system has The display indicates which button the servo processor interprets as being pressed Button code is matched against a look up table Three failure modes are possible 1 Button indicated on display is incorrect 2 Display does not change when button is pressed 3 Button Fail shown on display if no code match was found EXIT by pressing UP ARROW and DOWN ARROW at the same time The X axis motor is continuously driven forward in swath advance increments Pressing the UP ARROW increases speed Pressing the DOWN ARROW decreases speed EXIT by pressing the ENTER button Continuously raises and lowers the bail Tests and verifies operation of color detection capability Also checks line detect LED Assemblies Tested Cutter Assembly Pen Carriage Cutter Assembly Operation Rotary Blade Overdrive Support Assembly Front Panel Front Panel Cable Main PCA X Motor Encoder Interconnect PCA Main PCA Overdrive Drive Roller Drop Sensor Drop Sense Cable Bail Sensor Flag Bail Drive Mechanics Main PCA Line Detect LED Pens 8 18 Troubleshooting CONFIGURATION PLOT The configuration plot aids in the analysis of plotter problems by providing a hardclip border around the plot so the margin
72. a Media Dimensions Sheet and Roll Maximum Widths D A1 size 619 mm 24 in E A0 size 917 mm 36 in Roll Maximum Media Length 150 feet 125 ft for film SERIAL NUMBER INFORMATION If the plotter serial number has a lower revision letter than the one shown on the title page information in the Product History chapter Chapter 9 will adapt this manual to that plotter 1 6 Product Information Chapter 2 Site Planning and Requirements INTRODUCTION This chapter contains information concerning the electrical requirements for the installation of HP C2858A and C2859A plotters Also included is information on environmental operat ing conditions and physical specifications for the plotters Introduction ssa uud es boxe Had ed E a RAG ERE Edu EDS RS 2 1 Electrical Specifications o scrisrnreinit int tnan Ena EN eee nee 2 2 Power Requirements us san aura Mr Pee eed e ex e b aa 2 2 Eme Cord Sel ouo camas Sen thee exe RU EEG dee deba qd Wake ds 2 2 Environmental Specifications sesse netis enu eee cece 2 3 Physical Specifications ell xe RR A ee ae ete 2 3 Cable RestriCtlons ss te esxden os eR e beds teas ES NEUE MAR A EUR 2 4 RS 232 C Interface eeaeee meaai E ei ehh eh heb hah eee e 2 4 Centronics Interface siue cea dees eR e RET ERO ER Hee Eee eee 2 4 HP IB Interface ussekeske ex ex RE US EE aO O ex rk rS 2 4 Site Planning and Requirements 2 1 ELECTRICAL SPECIFICATIONS POWER REQUIREMENTS HP C2858A and C
73. al For protection against electrical shock in case of a fault Used with field wiring terminals to indi cate the terminal which 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 pro cedure practice or the like which if not correctly performed or adhered to could result in personal injury The CAUTION sign denotes a hazard It calls attention to an op erating 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 X Safety Chapter 1 Product Informatio INTRODUCTION n This chapter contains a listing of documentation supplied with the HP C2858A and C2859A DesignJet 650C plotters Also provided are descriptions of the plotters information on t he plotter features options and accessories performance characteristics and plotter serial numbe
74. alibration is necessary Adjustments Calibrations 7 5 MEDIA SENSOR CALIBRATION This procedure calibrates the optical media sensor threshold value stored in the EEROM The value represents what the sensor should detect without media present Perform the media sensor calibration whenever the the EEROM is cleared or replaced media sensor is replaced plotter does not recognize that media is present plotter tries to load media when none is present Media Sensor Calibration is accessible through the Service Tests menu To perform the me dia sensor calibration do the following en Press Enter at the Status display Use the arrow buttons to scroll to the Utilities main menu Press Enter Either the Short or Full menu mode will access the Service Test submenu Simultaneously press the Enter and the Up Arrow buttons to access the Service Test submenu Scroll to the Media Sens Calib submenu Press Enter Messages in the plotter display will inform you to remove media if present and to press the Enter button before and after calibration After completion of the calibration cycle plotter power to invoke the new threshold value in the EEROM Note Ifthe Service Test submenu cannot be accessed because of the media sen sor failure press the Enter and the Up Arrow buttons simultaneously while powering on the plotter The initialization routine will be altered so as to
75. an the roller Check the line sensor The bail sensor did not properly detect the bail position Check for an obstruction under the bail or bail flag or if the cutting carriage is not pushed all the way to the right Check the drop sense PCA and cable connectors The lever at the right of the plotter was lifted while the processor was busy Lower the lever to continue 8 4 Troubleshooting Message Media too small Mispositioned Reload roll Mispositioned Reload sheet MIO data error MIO error Comm break MIO error Handshake Out of memory Data was lost Pen C Y M K not loaded Remove media Lower lever Table 8 1 Worded Error Messages Continued Error Action Media loaded for accuracy calibration or pen alignment is too small Reload appropriate media Roll is mispositioned Unload roll media Open the roll cover and push the media roll all the way to the right so that it is flush against the media stop on the roll core Reload media with the right edge no more than 0 2 inches 0 5 cm from the perforated line on the entry platen Remove any ink deposits on the drive roller Ink deposits are reflective and can give false indications for detecting media edges Sheet is mispositioned Remove it and reload it with the right edge no more than 0 2 inches 0 5 cm from the perforated line on the entry platen The modular interface is configured incorrectly Press the ENTER button to clear the message from
76. and replace an MIO card refer to Figure 6 2 and perform the following steps 1 If an MIO card is not already installed use a small flat blade or Torx T10 screwdriver to remove the two screws that attach the cover plate to the top back of the plotter Remove the cover plate 2 If an MIO card is already installed loosen the MIO card thumbscrews Carefully pull the MIO card straight up and remove the MIO card from the plotter 3 To install an MIO card insert the card into the MIO slot and push the card firmly in until fully seated in the slot 4 Tighten the MIO card thumbscrews MIO Slot C C2858 32 Figure 6 2 6 6 Removal and Replacement ELECTRONICS ENCLOSURE COVER REMOVAL To remove the electronics enclosure cover perform the following procedure 1 Switch the plotter OFF and disconnect the ac power cord and interface cable from the plotter 2 Ifa modular input output MIO card is installed remove the MIO from the plotter 3 Using a TORX T 15 screwdriver remove the rear sideplate trim pieces and electron ics enclosure cover shown in Figure 6 3 The C2858A has 10 cover screws and the C2859A has 12 cover screws The trim pieces have two screws each 4 Gently pull the trim pieces and then the cover off of the plotter Rear Trim Ac Le Rear Trim C C2858 32a Electronics Enclosure Cover Figu
77. annot freely rotate The plotter may be jammed with media Switch the plotter s power OFF Check the media path and clear it if necessary If necessary troubleshoot the X axis mechanics and circuitry A servo shutdown has occurred in the Y axis The pen Check pen path carriage cannot move The plotter may be jammed with media Switch the plotter s power OFF Check the pen path and clear if necessary If necessary troubleshoot the Y axis mechanics and circuitry 8 6 Troubleshooting SYSTEM ERROR CODES System error codes are hexadecimal based numbers generally caused by internal system er rors See Table 8 2 for a list of system error codes and their respective descriptions and rec ommended corrective actions Table 8 2 System Error Codes Error Code Problem Description Corrective Actions 010001 Window sensor circuitry not Check window sensor switch operating correctly Check that the sensor cable is connected to the front panel PCA Disconnect the sensor cable connector from the front panel PCA and read the resistance between the pins Values should read as follows Window Pins Up Down 1 2 oQ oQ 1 3 09 oQ 243 o 00 Replace defective wires or assembly Replace front panel to main PCA cable Replace front panel PCA Replace the main PCA 010011 Bail sensor indicates the bail Use the bail sensor test to help is up when it should be down troubleshoot 010012 Bail sensor indicates the bail Use the bail sensor test to help
78. ap anese users who require the Kanji character sets A PostScript upgrade is also available in ROM SIMM The part numbers for the kits are e Kanji ROM Kit P N C2847 60031 PostScript ROM Kit P N C2882A MODULAR INPUT OUTPUT MIO PCAs Interface circuitry is provided on the plotters which allows the user to install HP supported modular I O MIO cards for several interface applications Although multiple protocols may reside on an MIO they are not simultaneously supported only one protocol at at time can be used The MIO card part numbers are Multi protocol Ethernet for Novell TCP IP LAN Manager Ethertalk with RJ 45 twisted pair and BNC ThinLAN connectors P N J2372A with RJ 45 twisted pair connector only P N J2371A Multi protocol Token Ring for Novell LAN Manager P N J2373A HP IB P N C1642A Apple LocalTalk P N J2341A 1 4 Product Information ACCESSORIES The items listed in Table 1 1 are supplied with each plotter Miscellaneous application notes flyers and driver disks are also provided Depending upon the country of destination the part numbers of items listed as English or U S will differ Accessories available for use with the C2858 9A DesignJet 650C plotters are listed in the Supplies Catalog Table 1 1 Accessories Supplied Description Qty HP Part Number C2858A C2859A Manual Kit English 1 C2858 90051 includes Using Your Plotter s Front Panel Guide Setting Up For Plotting Guide
79. artridge and media loading pro cedures as well as front panel menu structures are also provided Introductio a aus d sa Guardo x CR CS ld RE ada S xo Siad wea edd e cod abe se 3 1 Installation Instructions lsseleeee RII 3 2 User Installable Modules 0 0 00 cece eee B 3 2 CONMECUVILY asas dana dad Caan deen da p tobe cide aba wens eedees s 3 2 Line Voltage and Fusing spesa ar RR See eae a eee 3 2 Power Cord Configurations sss ssoi eresas cece es 3 2 User Information and Operation 0 0 0 c eee cece eee 3 4 Media Guidelines socs crire 0 cece cee es 3 4 Media Type and Print Quality 0 0 0 ee eee ee 3 4 Media Cutting and Stacking 0 0 0 c eee eects 3 5 Usable M dia S1Z68 tne ter xa EE SUR I Re ADE E 3 6 Loading Roll Media asa ssa sera rori Rer Re e RR ema 3 6 Unloading Roll Media sseeleeeeeee ene 3 10 Loading Sheet Media leeeeeee e 3 11 Unloading Sheet Media 0 0 cece cece eee 3 12 Clearing Media Jams usa era sexe Rh br pd gula qua da QURE RE RA 3 12 Pen CheckiBgx outer vU Ue e Mud sas ete a efe 3 13 Accessing Pens case cama Ree dur pe Ley nego BERT CP EE eH ERR Rowe els a 3 14 Replacing Pens 2023 4 is bu EROR VE a O eas Seale A O DD dE RS 3 14 Selectable Ink Drying Times 3 16 Configuration 2 629 etek eae hed Ee S RU CP Rd e RE Re PIED 3 17 Front Panel Controls qua ata emana aus e eR ERR RE edad RR E EE RS 3 17 Front Panel Menus inerte Exe aw ux pr
80. as a clogged nozzle You must replace the defective pen to continue Defective pen position is indicated by a flashing icon in the display Y C M or K pen has not made proper contact in the pen slot Remove the appropriate pen and reseat it in the slot Defective pen position is indicated by a flashing icon in the display Press Up Arrow to load sheet media Press Down Arrow to load roll media You have chosen Sheet mode while loading roll media Reload media You have loaded a sheet more than 51 inches 130 cm long Trim sheet and reload Installation and Configuration 3 25 OPERATIONAL VERIFICATION DesignJet 650C plotters contain several types of internal operational checks and tests to en sure that the plotter is properly functioning and to help identify problems if any are detected POWER ON SELF TEST Whenever the plotter is switched ON it automatically performs a series of internal self tests and initialization sequences which check the basic electrical and mechanical functions of the plotter Among the items checked are the processors motors and sensors If an error is de tected a message or system error code will be visible in the front panel display Error codes and messages are presented in Chapter 8 of this manual Self tests are listed in Chapter 8 DEMONSTRATION PLOT Two demonstration plot samples are resident in the HP DesignJet 650C plotters Proper plot ter operation can be checked through use of th
81. ation plot An accuracy calibration is needed if the distance between the centers of the X marks on the configuration plot is not 500 mm 20 in 3 1 mm 0 04 in under normal environmental conditions Media expansion and thickness can affect endpoint accuracy The plotter endpoint accuracy is specified on ink jet polyester film only at 0 2 of the specified vector length If the measured accuracy media thickness or environmental conditions vary greatly from the factory standards recalibrate the plotter using the following procedure To perform the accuracy calibration use the following steps Note User and service accuracy calibration procedures are similar Follow the appropriate user or service noted paths in the steps 1 Place a sheet of media over the top of the plotter for 10 minutes to let it stabilize to the environmental conditions Use a sheet approximately 24 x 36 inches 61 x 91 cm Roll media may also be used Use polyester film when performing the Accuracy Calibration from the Service menu If using inkjet polyester film load the film with the matte dull side down 2 Load the media If using D size media load the short edge as the leading edge in C2858A plotters and the long edge as the leading edge for C2859A plotters The C2859A can also use E size media Both plotters can use polyester film roll media for this procedure 7 4 Adjustments Calibrations 3 Press Enter at the Status
82. ay of either a Centronics or an RS 232 C interface If an approved modular input output MIO printed circuit assembly PCA is installed the circuits can communicate by way of an HP IB interface or be connected to a network The main processor reads Centronics HP IB and Ethernet communications through the port it uses to read memories ROM or DRAM RS 232 C communications are handled by a universal asynchronous receiver transmitter UART and baud rate generator built into the processor support application specific inte grated circuit ASIC HP DesignJet 650C plotters accept plots in Hewlett Packard Graphics Language HP GL Hewlett Packard Graphics Language 2 HP GL 2 or Hewlett Packard Raster Transfer Lan guage HP RTL form The main processor converts the plot into an internal format and stores the entire plot in its dynamic random access memory DRAM Then it transfers the plot a swath at a time into the swath RAM by way of the processor support ASIC On the main PCA the processor support ASIC is designed to manipulate swath data into the actual firing order for the pen nozzles on the four pen cartridges that are mounted on the car riage assembly The processor support ASIC receives pixels from the physical swath RAM and sends them serially to the carriage ASIC A main processor on the main PCA controls all plotter operations with the help of the proces sor support ASIC and the servo processor Communications between the servo pro
83. ay to the interconnect PCA When the pen voltages delivered to the pen car tridges deviate above or below their respective values the sense signals will cause the volt age regulator outputs to move to counter the deviation Part of the pen shutdown circuitry resides on the interconnect PCA The pens are shutdown when the 5V falls below a certain value during power up down when the carriage ASIC asserts shutdown during an access pens command between swath printing or when idle The interconnect PCA receives PA and PB drive signals for the paper motor driver and the carriage motor driver from the processor support ASIC on the main PCA PA and PB are pul se width modulated PWM signals The PA signal to the paper motor driver causes the pa per motor to drive the paper up and out of the front of the plotter The PB signal to the paper motor driver causes the paper motor to drive the paper down over the entry platen and out of the the plotter The PA signal to the carriage motor driver causes the carriage motor to drive the carriage toward the right side of the plotter The PB signal to the carriage motor driver causes the carriage motor to drive the carriage toward the left side of the plotter FRONT PANEL PCA The front panel consists of a 2 row by 20 character vacuum fluorescent display VFD seven LED indicators and a 10 button key pad The servo processor on the main PCA writes serially to the VFD and the LEDs and reads the key pad on it
84. beam path is clear The resulting BAIL logic level is sent to the main PCA by way of the service station cable The service station cable assembly consists of the drop detect and bail sensors the stepper motor and the primer sensor 5 4 Functional Overview PRINTED CIRCUIT ASSEMBLY PCA OVERVIEW MAIN PCA There are two clocks on the main PCA The main clock provides a 31 85 MHz signal directly to the main processor The 31 85 MHz is divided by the main processor and the resulting signal is provided to the processor support ASIC A separate clock provides a 12 MHz signal to the servo processor In order to perform its functions the main processor must have access to its memories ROM and DRAM To create plots at the direction of an external controller it must be able to com municate with the controller by way of its interfaces MIO Centronics and RS 232 C To address the ROM or DRAM interface the main processor places the appropriate address on the address bus and reads or writes the data directly Datais passed to the main processor by a transceiver in the case of ROM or DRAM SIMM data MIO or Centronics input and output data pass through another transceiver on its way to the main processor The main PCA ROM contains the following types of information Programs Program constants Character sets Demonstration plot The main PCA DRAM is used to store the following types of information e Variables e Temporary constants
85. bleshooting Test Parallel I O MIO Y friction Pen nozzle Pen ID Table 8 3 Service Tests Continued Description The data and status registers of the Centronics PAL are read A successful test completes very quickly lt 1 s PASS TEST PRESS ENTER will be indicated If the test fails the system will hang up A system error error code will NOT be displayed and power to the plotter must be recycled This tests only a small portion of the Centronics I O functionality To EXIT press ENTER button The MIO is tested during power on This test checks to see if the MIO is present and reads the results of the power on test An MIO PRESENT PRESS ENTER display indicates a successfull test result EXIT by pressing the ENTER button The pen carriage is moved along the slider rods with and without the cutter assembly A range of PWM signals required to move the carriage is measured and displayed for both cases with and without the cutter This test 1s used to check for excessive friction in the Y axis Excessive friction could cause poor print quality or servo shutdowns EXIT by pressing the ENTER button Drops are fired past the drop sensors of the print cartridges A PASS TEST PRESS ENTER display indicates that all nozzles are functioning correctly A failure including failed pen identity is displayed on the front panel The failed pen should be reinserted and retested If a failure is still indicated wipe
86. cessor and the main processor take place through registers in the processor support ASIC The processor support ASIC provides pulse width modulated signals to the Y axis motor driver and the X axis motor driver to drive the Y axis carriage motor and the X axis paper motor The linear encoder connected to the carriage PCA gives the processor support ASIC feedback about the position of the carriage The X axis motor encoder on the X axis motor gives the processor support ASIC feedback about the position of the X axis motor In addition the processor support ASIC contains a DRAM controller that generates multi plexor control and enable strobes for the DRAM row and column addresses during a memory access The DRAM controller also arbitrates between a memory request and a refresh re quest and it performs the refresh operation The servo processor communicates with the main processor through registers in the proces sor support ASIC The servo processor writes information into the registers and sends an in terrupt to the main processor The main processor then reads the registers and the interrupt is automatically cleared Using this procedure the servo processor provides the main processor with information from the plotter sensors The sensors give the main processor the ability to check status conditions 5 2 Functional Overview The servo processor controls the servo motors front panel fan electrically erasable read on ly memory EERO
87. ch screw in step 2 relieve the spring Woe AS tension slightly by holding the spring with one hand to avoid possible personal injury 2 Using a TORX T 10 screwdriver remove the screws and washers that attach the left and right springs to the pivot spring anchor pins See Figure 6 21 3 Using a7 mm wrench loosen the two nuts that secure each end of the rollfeed cover to the pivots 4 Pull the rollfeed cover clear of the plotter C C2858 37 C C C2858 38 Nuts 2 each side Left Pivot Spring Right Pivot Spring Anchor Pin Screw Anchor Pin Screw Figure 6 21 6 30 Removal and Replacement ROLLFEED MODULE ASSEMBLIES LEFT AND RIGHT REMOVAL To remove the left or right rollfeed module assembly perform the following procedure 1 Remove the appropriate left or right endcover as required 2 Remove the rollfeed cover assembly 3 Using a TORX T 20 screwdriver remove the three screws that secure the rollfeed module assembly to the sideplate See Figure 6 22 Left Rollfeed Module Assembly C C2858 52 C C2858 37 Module Assembly Screws 3 Each Side Right Rollfeed Module Assembly C C2858 52a C C2858 38 Rollfeed Cover Figure 6 22 Removal and Replacement 6 31 CUTTER ASSEMBLY REMOVAL To remove the cutter assembly refer to Figure 6 23 and perform the following steps pa Remove the right
88. cifies the plotter s location on the HP IB IEEE 488 interface cable bus ASCII American Standard Code for Information Interchange An 8 bit code that uses 7 bits to represent character data such as letters punctuation symbols and control characters Bit 8 can be used for parity baud rate For an RS 232 C interface the data transmission rate between a computer and a peripheral bits per second bitmap 1 A set of bits that represents the graphic image of an original document in memory 2 A set of bits that represents the positions and states of a corresponding set of items such as pixels In QuickDraw a pointer to a bit image the row width of that image and its boundary rectangle Used by the Macintosh to construct graphic images and fonts buffer A part or parts of computer or device memory where data is held until it can be processed Usually refers to a memory area reserved for I O operations bus Short for HP IB IEEE 488 interface byte Eight bits the size of a computer word Used by ASCII binary code to represent alphanumeric characters Centronics A parallel interface standard cockle Wrinkling of media due to ink saturation configuration The way in which computer equipment and software is interconnected and set up to operate as a system continuous memory Plotter memory which stores certain plotter conditions even when the plotter is turned off data communication The exchange of data between
89. coder Edge detect and Cutter tests found in the service menu to help troubleshoot Excessive Y axis friction can be caused by binding in the Y axis or in the cutter Use the Y friction test found in the service menu to determine it the problem is caused by the cutter Troubleshooting 8 11 TROUBLESHOOTING TIPS Certain failures such as the media sensor and pinchwheel sensor will not allow access to the service menu after the normal initialization process occurs The front panel will be locked at this point To alleviate this situation perform the following steps 1 Unload media if present 2 Switch OFF the plotter 3 Simultaneously press the ENTER and UP ARROW buttons while switching ON the plotter Performing the above steps will cause the plotter to stop short of complete initialization The display will read STATUS Initializing The Service Tests menu can now be accessed from the Utilities menu in the normal way After a repair has taken place consider if any calibrations were affected The demonstration plot and configuration plot can be used to help diagnose problems Proce dures for running the demonstration plot are given in chapter 3 of this manual The demon stration plot has no special diagnostic features built in but can be used to look at overall print quality including smoothness and straightness of lines arcs circles and characters Proce dures for running the configuration plot are
90. devices default A value or condition that is assumed if no other value or condition is specified device control instruction The portion of the plotter s instruction set that controls internal plotter conditions such as buffer size input output conditions RS 232 C interface conditions and handshakes dpi Dots per inch the plotter s resolution of raster images on the media driver Configuration data used by software to control input and output between the computer and a peripheral device e g a plotter handshake RS 232 C communication between a computer and the plotter about the availability of I O buffer space A handshake ensures correct and complete data transfer HP GL 2 Hewlett Packard s standard graphics language for its plotters HP IB Short for Hewlett Packard Interface bus Hewlett Packard s version of IEEE Standard 488 1978 for interfacing programmable devices e g computers plotters and printers Glossary G 1 IEEE 488 1978 interface A parallel interface standardized by Electronic Industries Association Standard 488 1978 initialize To set plotter conditions to known default values interface Anything a cable for example used to join components of a computer system so they function in a compatible and coordinated fashion Also standards which allow systems to connect with each other e g HP IB RS 232 C T O error A data transmission error between a computer and a peripheral E
91. e Page 10 9 Right End ee Page 10 19 See Page 10 23 Primer and Service Station Window and Back Cover Assemblies Paper Drive Assemblies See Page 10 21 See Page 10 7 See Page 10 27 Rollfeed Components Bail and Overdrive Support Assemblies See Page 10 17 See Page 10 29 Pen Carriage Assembly Starwheel Starguard and Chassis See Page 10 25 Assemblies See Page 10 33 Pinch Arm Assembly See Page 10 31 Stand Assembly See Page 10 5 C2858A C2859A Major Assembly Identification Drawing Parts and Diagrams 10 3 Parts List Stand Assemblies Ref HP Part C Qty Description Des Number D 1 C2847 60002 6 2 LEG ASSEMBLY MODEL C2858A C2848 60002 7 2 MODEL C2859A 2 C2847 00013 3 1 STAND BRACE MODEL C2858A C1633 00046 2 1 MODEL C2859A 3 C2847 60061 7 1 HARDWARE KIT 4 0515 0380 2 6 SCREW MACH M4X10 5 1492 0145 5 4 CASTER ASSEMBLY 6 C2847 00006 4 1 MEDIA BIN FRONT MODEL C2858A C1633 00020 2 1 MODEL C2859A 7 C2847 00012 2 1 MEDIA BIN ADJUST MODEL C2858A C1633 00044 0 1 MODEL C2859A 8 C2847 00005 3 1 MEDIA BIN BACK MODEL C2858A C1633 00019 9 1 MODEL C2859A 9 C2847 60030 0 4 CABLE MANAGEMENT HARDWARE KIT 10 4 Parts and Diagrams Stand Assemblies Illustrated Parts Breakdown C C2858 1 1 10 5 Parts and Diagrams Parts List Window and Back Cover Assemblies Ref HP Part C Qty Description Des Number D 1 C2858 60024 5 1 CABLE ASSEMBLY TRAILING 2 0620 0520 3 1 SCREW 6 1
92. e demo plots The demo plots show different plotter capabilities including pen line widths and shading The demo plot can be set to plot in any of the available front panel languages To plot a demo plot perform the following steps 1 Turn the plotter ON and load a sheet of media N From the Status display press the Enter button Using the arrow buttons scroll to the Demo plot main menu display gt QU Press the Enter button CA Using the arrow buttons scroll to select either the Sample or Palette demo plot 6 Press the Enter button 7 The Busy LED will light indicating that the demo plot is being accessed 8 The demonstration plot will be plotted 3 26 Installation and Configuration Chapter 4 Preventive Maintenance INTRODUCTION This chapter contains information on keeping the HP C2858A and C2859A DesignJet 650C plotters in good operating condition Included are general cleaning procedures to be per formed by the user Introduction sagas eR kad E Rr E ed P eat eDE A Raa ERE eee Eda eee 4 Effect on Product Reliability 0 0 2 4 2 Preventive Maintenance Procedures 0 c cece eee eee eens 4 2 General Cleaning verses hase Rh hr p qua QB aba a RE Ceiba 4 2 Drive Roller Cleaning cea bb a Ree RR RARE ST a 4 3 Preventive Maintenance 4 1 EFFECT ON PRODUCT RELIABILITY To maintain the plotter in good operating condition keep it free of dust accu
93. e operation of the print control ASIC until the 5 V reaches a steady state The line sensor module is used to calibrate the writing system for mechanical tolerances as well as to sense the left and right edges of the media It consists of a photo diode device whose photo current is amplified by a transimpedance amplifier connected to the PCA through a ZIF connector The resulting voltages are coupled and then measured by an eight bit analog to digital A D converter whose bits are sent serially to the carriage micropro cessor Illumination of the surface being read by the line sensor is provided by two green high intensity LEDs A dual lens unity conjugate ratio system directs the light from the illu minated surface to the sensor phase plate combination A temperature sensor IC is used to measure ambient temperature near the print heads Energy used to fire the pens is based on temperature This temperature reading is also used to deter mine when to switch the fan ON Normally the fan only runs when plotting At high tempera tures it is left ON A linear encoder detects pen carriage position as the carriage assembly moves along the en coder strip The linear encoder IC is connected to the carriage PCA via a 5 pin ZIF connector The carriage processor operates at 12 288 MHz The clock signal is generated by a crystal oscillator circuit internal to the ASIC The primary task of the processor is to configure the print control ASIC and read
94. eb ga ate cate th Gia Be we de we a ae Be wa ete 9 1 History of Assemblies by Serial Number 0 00 0 00 e eee eee 9 2 History of Printed Circuit Assemblies PCAs 0 00 cee eee eee eee 9 3 Product History 9 1 HISTORY OF ASSEMBLIES BY SERIAL NUMBER C2858A and C2859A plotters use a serial number format as follows USAxxyyyyy where US indicates country of manufacture A indicates the plotter revision level xx indi cates the month 1 9 A B C and week 1 4 of manufacture and the remaining digits y y are the individual sequential numbers of the plotters as they are manufactured Table 9 1 is a quick reference table that lists by plotter serial number the assemblies that differ from those documented in this manual Also referenced are Item Numbers under which these differences are described in this chapter Table 9 1 Assembly Reference by Serial Number Prefix Serial Number Prefix Assemblies Items NO CHANGES Table 9 2 lists the assemblies other than PCAs under each item in this chapter Table 9 2 Item Description Item Assemblies NO CHANGES 9 2 Product History HISTORY OF PRINTED CIRCUIT ASSEMBLIES Hewlett Packard s PCAs have three major identification features Part Number PCAs having the same part number are directly interchangeable If a PCA is revised in any way that makes it non interchangeable with previously issued PCAs of a particular part number a new part number
95. ece ccc aien 3 10 Loading Sheet Media versine certes ek a dtedie vga lia GERE wed eed 3 11 Unloading Sheet Media sarau pa Ee nt RR Rem EUR eee a e 3 12 Clearms Media Jams uu iamos E er e es e eet eie 3 12 Pen Checking a cix ihnen E RIP DESA O oda Mead QU D QE 3 13 Accessing PENS MP 3 14 Replacing Pens 1 22 eere Drs dee rd dede a 3 14 Selectable Ink Drying Times 3 16 Sonic PU 3 17 Front Panel Controls as secs eren Bus x mee Roc ad ww aoe Ww Wade Sa 3 17 Front Panel MENUS 4 rea s Re SR amma gd Ru SURG NON adus 3 20 Front Panel Languages leseeeeee t nds erai eri wi 3 21 Front Panel Messages sisse see bee braces I eie An Re Pa bus 3 22 Operational Verificatlon zo evel e ae ter ceed Sido CDL Dea b OE 3 26 Power On Self Test cuatro ENO DANDO ta eG c n 0 eT aa 3 26 Demonstration Plot us esee re e cere teat FREE TU Y EST 3 26 4 Preventive Maintenance TAtROGU CONN pei iee ET 4 Bifect on Product Reliability usas st e er e de RR S 4 2 Preventive Maintenance Procedures 0 0 c cece eee eee eee eee 4 2 General Cleaning sereas niae raain eee ee kee eee sense ene ene eee 4 2 Drive Roller Cleaning 0 0 0 0 cece eee eee 4 3 5 Functional Overview InttOductiOn 5 uad eee ree home deerit RR dead RR eod 5 1 Simplified Description of Circuits llle ee 5 2 Mechanical Overview i e ev e e RACER E RE E RELIER E E 5 3 Printed Circuit Assembly PCA Overview llle 5 5 Maim PCA Cc TEE 5 5 Carriage PCA su
96. eck the endpoint accuracy after installing the drive roller assembly Removal and Replacement 6 53 Drive Roller Assembly Drive Roller Gear Left Side O Screws 2 Sy C C2858 10 p 2 Right Side a o S O Gr cei Drive Roller Worm Gear an a p Paper Drive Motor L E g PEA o G C C2858 49c Paper Motor Screws 3 CL Drive Roller Bearing Axial Bias Plate C C2858 27 5 Figure 6 34 6 54 Removal and Replacement AUTOMATIC BAIL LIFT MECHANISM REMOVAL To remove the bail lift mechanism perform the following steps 1 2 Remove the window assembly Remove the left and right endcovers Remove the encoder strip 4 Remove the bail assembly d Oc Engagement Lever Screw Remove from inside Engagement Lever Spring Remove the overdrive support assembly Remove the drive roller assembly Using needle nose pliers remove the engagement lever spring See Figure 6 35 Using a TORX T 10 screwdriver remove the engagement lever screw from inside the left sideplate Note Note the placement and position of the parts to be removed in the next step for reassembly Remove the spring lever and screw from the plotter C C2858 31b Figure 6 35 Removal and Replacement 6 55 MEDIA DIVERTER REMOVAL To remove the media diverters perform the following procedure 1 2 Remove the window assembl
97. ed an alternate method of loading is possible Do the following 1 Ensure that the pinchwheel lever is down and the roll cover is closed 2 Raise the window on the plotter 3 Insert the sheet into the plotter until the leading edge hits the stops inside the platen area Align the right side of the sheet with the perforation line on the entry platen 4 While holding the sheet against the stops and aligned with the perforation line lower the window on the plotter Let go as soon as the plotter begins to pull the media in Perform steps 4 through 6 of the sheet loading procedure on the previous page to set the plot ter for the media type being used UNLOADING SHEET MEDIA To remove an unplotted sheet press the Form Feed Cut button and remove the sheet when the plotter is finished feeding it out Another way to remove unplotted sheet media is to raise the pinchwheel lever at the right remove the sheet and lower the lever CLEARING MEDIA JAMS To clear a media jam first press the Form Feed Cut button to see if the plotter will cut and advance the media out Should the jam remain turn the plotter OFF and raise the pinchwheel lever and window to the up position ee ae The steel encoder strip and automatic cutter blade inside the WARNING P i plotter are very sharp Use caution when inserting hands into the plotter to clear media If necessary push the ink cartridge carriage and the cutter carriage away from the jammed media Ha
98. ed ae pad pa 8 11 Servo System Control Failures 2 1 0 0 eee 8 11 Troubleshooting Tips oce e rr awe Pee a ADE RL 8 12 ROM Code Revision Level leseeeeeeeee e 8 12 DErvice Tests pias seg Dbee deua pado UOS qubd Gia dad MO cod E dod 8 13 Configuration Plot 2 usasse cere de re de ea a needed en en RD RR alee 8 19 Bar Pattern Analysis casser cee bee esa etit EERDER O EEEE RR 8 20 Reading the EEROM Text Block 1 1 0 0 0 0 0 c eee eee eee 8 21 Analyzing the Pen Nozzle Test Block 0 0 0 0 eee ee eee eee 8 21 Troubleshooting 8 1 DIAGNOSTICS Several types of built in diagnostic and service tests reside in the DesignJet 650C plotters These troubleshooting aids include power on self tests and mechanical initialization rou tines In addition worded error messages system error codes and internal service menu tests are provided POWER ON SELF TESTS HP C2858A 9A DesignJet 650C plotters will automatically perform a series of internal self tests as well as certain initialization sequences whenever the plotter is switched ON These self test and initialization sequences are described in the following paragraphs As the plotter moves through the tests a series of dots will quickly appear on the display During a failure condition a failure analysis may be performed by either noting the number of dots present on the display or interpreting the worded message or system error code message displayed P
99. ed to replace or reseat a pen is if your print quality is poor Use the ink level indicators on the cartridges to check ink levels Perform the following steps to change the current pen checking selection 1 Press the Enter button and use the arrow buttons to scroll to the Utilities menu 2 Press the Enter button and use the arrow buttons to scroll to Menu Mode Press the Enter button 3 Use the arrow buttons to toggle to Full and press the Enter button 4 Use the Previous button to return to the Status display 5 Press the Enter button and use the arrow buttons to scroll to the Plotter setup menu Press the Enter button 6 Using the arrow buttons scroll to Pen check and press the Enter button 7 Using the arrow buttons to toggle the options select the option you want OFF or ON and press the Enter button Installation and Configuration 3 13 Figure 3 9 shows you how to visually check the ink level in a cartridge Label color indicates ink color Green area will diminish as ink is dispensed Replace pen when area is all black Checking the Ink Level Figure 3 9 ACCESSING PENS Press the Access Pens button to access the pen carriage when you need to replace reseat or clean pens The pen carriage will move into the platen area to allow easy access to the pens Each time the pen carriage moves out from its service station so that you can access the pens the pen nozzles are exposed to
100. eference designators Match the appropriate reference designator on the drawing with the same reference designator Ref Des in the associated parts list for information on that part The total quantity for each part on the drawing is given as well as the part number and check digit CD To obtain replacement parts address an inquiry to the nearest HP Sales and Support Office The order must include the part number check digit and part description Also include the plotter model and serial number on the parts order ILLUSTRATED PARTS BREAKDOWN DRAWINGS Field Replaceable parts and assemblies for the plotters are shown in the illustrated parts breakdown drawings in this chapter Use the drawings to locate and identify parts that you wish to order Then use the associated parts lists for the drawings to obtain parts ordering information Use the major assembly identification drawing on the next page to quickly de termine which drawing the part you need to identify is located on LABELS AND CABLES Labels used on the plotters are listed at the end of this chapter A cable identification drawing is also provided at the end of this chapter should you need to order a cable for the plotter 10 2 Parts and Diagrams Left Endcover and Trim C2858A Electronics Enclosure Assembly Right Endcover and Trim See Page 10 13 See Page 10 11 See Page 10 15 Carriage Axis Drive C2859A Electronics Enclosure Assembly Carriage Axis Drive Left End Se
101. en User EEROM Cut Count Low EEROM Cut Count High EEROM Pen K DT Offset EEROM Pen M DT Offset EEROM Bail Errors Bail Up Pos Offset EEROM Page Format Byte EEROM Plot Manage Byte EEROM Block Flag EEROM Block Checksum EEROM Block Address EEROM Block Size EEROM Block Data EEROM Block Data End CHKSUM Byte EEROM Size EEROM Checksum Value EEROM Palette Start EEROM Palette End EEROM PostScript Block 2 Start EEROM PostScript Start EEROM PostScript End EEROM PostScript Block 2 End EEROM PostScript LEN 8 24 Troubleshooting A sample portion of the memory location key is provided in Table 8 5 Use it as a key to the EEROM memory text block on the configuration plot The first column depicts the block of text shown on the plot and in Table 8 6 but the remaining blocks show the memory location number instead of the contents at each position on the text block 10 20 30 40 50 60 70 80 90 a0 b0 c0 do e0 f0 02 12 22 32 42 52 62 72 82 92 a2 b2 c2 d2 e2 f2 Table 8 5 Memory Location Key 4 5 05 15 25 35 45 55 65 75 85 95 a5 b5 c5 d5 e5 f5 6 06 7 8 08 18 28 38 48 58 68 78 88 98 a8 b8 c8 d8 e8 f8 9 a Oa la 2a 3a 4a 5a 6a Ta 8a 9a aa ba ca da ea fa Ob 1b 2b 3b 4b 5b 6b 7b 8b 9b ab bb cb db eb Oc Ic 2c 3c 4c 5c 6c Te 8c 9c ac bc ec dc ec fc Od ld 2d 3d 4d 5d 6d 7d 8d 9d ad bd cd
102. endently generated fire position pulse is also used for warm up pulse generation and for firing to clear clogged nozzles MECHANICAL OVERVIEW The Y axis carriage motor is mounted under the plotter s right endcover It is electrically connected to the interconnect PCA which contains a Y axis motor driver Its drive shaft is mechanically connected to the carriage by way of a small drive belt double pulley and main drive belt When the carriage motor rotates it moves the carriage assembly An optical en coder located on the carriage assembly provides position feedback for Y axis servo control The line sensor also mounted on the carriage assembly is used to detect and measure lines when performing pen alignment and the accuracy calibration The line sensor is also used to detect media width and skew during media loading The X axis paper motor is also mounted under the right endcover and is electrically con nected to the interconnect PCA which contains an X axis motor driver It has a worm style pinion gear which meshes with a gear at the right end of the drive roller When the paper mo tor rotates it moves the drive roller and consequently the media The encoder mounted on the motor sends feedback about the X axis motor position to the main PCA Functional Overview 5 3 An internal cooling fan is supplied with 12 V It is switched ON and OFF by the servo pro cessor and is mounted in the electronics enclosure at the rear of
103. ervicing The four icons represent the following pen positions outer left Y yellow inner left M magenta inner right C cyan outer right K black Note In monochrome mode only the black pen icon will appear solid while the remaining icons are outlined In color mode all pen icons will appear solid Place your hand on top of the pen you are replacing and press down slightly as you pull the pen toward you See Figure 3 10 Lift the pen out of its slot Removing a Pen Figure 3 10 Installation and Configuration 3 15 6 Remove the protective tape from the new pen Insert the pen into the empty pen slot 7 Press down slightly and push the pen away from you until it snaps into the pen slot See Figure 3 11 Installing a Pen Figure 3 11 8 Repeat steps 4 through 7 for each pen being replaced 9 Close the plotter window When Load media to align pens is displayed load good quality media into the plotter Special paper must be used to properly align the color pens The pen alignment procedure takes about three minutes to complete Note The plotter tests the pens to ensure proper operation The test runs approxi mately one minute and the display indicates the pens being tested After test ing the pen alignment procedure is automatically performed Allow the alignment procedure to complete before resuming normal plotter operation SELECTABLE INK DRYING TIMES User selectable i
104. for locating identifying and ordering replacement parts for the HP C2858A and C2859A plotters Parts lists with associated illustrated parts break down drawings are provided Intro dUCON 4 2x na ore sa coUa Mabaso xo da d wea mead e cca be dre 10 1 Exchange Assemblies 1 1 0 0 0 0 00 cece cee eee eee nee 10 2 Replacement Parts 1 20 00s eonsebeaegdeed anda ag buen eed ali pecie dd 10 2 Illustrated Parts Breakdown Drawings eese 10 2 Labels and Cables 1 21 Re RR PER Ea a REM ee eee a ee ae 10 2 Note Repacking kits are available for the DesignJet 650C plotters Order these kits if the plotters are to be shipped from one destination to another The kits contain all packaging materials and instructions needed to properly pack the plotters for shipment Model Repacking Kit Part Number C2858A C2847 60109 C2859A C2848 60007 Parts and Diagrams 10 1 EXCHANGE ASSEMBLIES Factory rebuilt assemblies that can be exchanged are listed in the following Table Exchange factory repaired and tested assemblies are available only on a trade in basis therefore the defective assemblies must be returned for credit Exchange Assemblies HP Part Number CD Qty Description C2858 69104 0 1 PCA MAIN REBUILT REPLACEMENT PARTS Parts shown on the illustrated parts breakdown drawings in this chapter are listed in the associated parts listings for the drawings Parts are listed by number keyed designations known as r
105. g Remove the encoder strip from the service station assembly Disconnect the four rubber tubes from the primer assembly Using a TORX T 9 screwdriver remove the four screws that secure the service sta tion cover to the service station housing Holding the sled about 1 2 inch to the left of its normal position with one hand tilt the forward edge of the service station cover up and lift the cover clear of the service station housing Note Observe the orientation of the service station sled for installation Liftthe service station sled up slightly and observe where the sled springs engage the slots in the service station housing Lift the service station sled clear of the service station housing 10 Disconnect the drop detect and bail sensor cables from the wire harness 11 Lift the drop detect sensor up and out of the service station housing 12 Using a small flat blade screwdriver carefully pry up on the bail sensor and lift the sensor out of the service station housing 13 Remove the two sled springs from the service station housing by rotating the springs to the left and then pressing the ends together to release them from the tabs 14 Using a TORX T 20 screwdriver remove the three screws that attach the service station housing to the left sideplate Lift the service station housing slightly up and pull it clear of the left sideplate 6 44 Removal and Replacement To install the sled duri
106. g cable connector from the pen carriage PCA Using a TORX T 15 screwdriver remove the trailing cable bracket screw from the pen carriage assembly Pull the trailing cable up through the slot at the top of the electronics enclosure as sembly and lift the trailing cable brackets with trailing cable from the plotter Ifinstalling a new trailing cable use the old trailing cable as a template to bend and crease the new trailing cable to exactly match the creases in the old trailing cable Make sure that the cable is properly aligned in the front trailing cable tray and does not bind or scrape the tray Removal and Replacement 6 21 Toroid Toroid Endcaps in Trailing Cable p C C2858 62 C C2858 42 Bracket Screw C C2858 77 Figure 6 15 6 22 Removal and Replacement BACK PANEL REMOVAL To remove the back panel perform the following procedure 1 Remove the window assembly 2 Using a TORX T 15 screwdriver remove the 5 screws that attach the trailing cable rear tray to the back panel 3 Using a TORX T 15 screwdriver remove the screws that attach the back panel to the electronics enclosure assembly The C2858A has three screws and the C2859A has four screws Lift the back panel clear of the plotter Trailing Cable Rear Tray Screws 5 C C2858 42 Back Panel Screws C2858A 3 C2859A 4 C C2858 2 Fig
107. ge detection failures during media loading The pen alignment procedure is also performed as a part of this calibration Perform the edge sense calibration whenever the edge detect failures occur during media loading the carriage is replaced the carriage LED sensor assembly is replaced the EEROM is cleared or replaced Edge Sense Calibration is accessible through the Service Tests menu To perform the edge sense calibration do the following Note You must use paper when performing this calibration oy Press Enter at the Status display 2 Use the arrow buttons to scroll to the Utilities main menu Press Enter 3 Simultaneously press the Enter and the Up Arrow buttons to access the Service Test submenu 4 Scroll to the Edge Sense Calib submenu Press Enter 5 Messages in the display will inform you to load media for the calibration to proceed Part of the calibration procedure is an automatic performance of the pen alignment procedure This process takes approximately four minutes to complete 7 8 Adjustments Calibrations BAIL CALIBRATION In this procedure the up position of the bail assembly is calibrated A value is stored in the EEROM when the procedure is completed Perform the bail calibration whenever the the EEROM is cleared or replaced the bail falls during media loading Bail Calibration is accessible through the Service Tests menu To perform
108. he cutter assembly pick up function works by sliding the pen carriage into the cutter assembly so that the pen carriage will engage the cutter assembly 6 32 Removal and Replacement Bottom Finger of Slider Rod Cutter Assembl Bushin Starguard ON Upper Wheels Cutter Blade Linear Blade Lower Wheels Side View C C2858 55 Overdrive Support Assembly Starguard Cutter Blade Cutter Assembly Right Pre load Arm Overdrive Support Assembly C C2858 66 Linear Cutter Blade Front View Figure 6 23 Removal and Replacement 6 33 TRAILING CABLE GUIDE REMOVAL To remove the trailing cable guide perform the following steps 1 Remove the left and right endcovers 2 Using a TORX T 15 screwdriver remove the screw that attaches the ground strap and trailing cable guide to the tensioner housing See Figure 6 24 CAUTION Exercise care to avoid damaging the ferrite ring during this procedure 3 Using a TORX T 15 screwdriver remove the screw inside the ferrite ring that at taches the trailing cable guide to the Y drive bracket 4 Lift up the guide and carefully remove the ferrite ring 6 34 Removal and Replacement Trailing Cable Guide
109. heck that the sensor housing opening is clear of obstructions Use the Pen nozzle and Drop detect tests found in the service menu to help troubleshoot Use the Drop detect calibration found in the service menu to recalibrate the position of the sensor Check the drop sense cable connections Replace the drop sensor Of0000 Firmware error Notify the HP Response Center or the nearest HP Sales and Support Office 8 10 Troubleshooting DISPLAY DATA PLOT Display data is a plot feature located under the Utilities Menu that allows you to plot the first and last 1000 bytes of graphic instructions of a plot file sent This feature can be used to ensure proper data reception The instructions will be plotted in ASCH format To use the Display Data feature do the following 1 Remove any media from the plotter and make sure the plot queue is empty 2 Enter the Utilities menu and select Display Data A front panel message will instruct you to send the plot file to the plotter 3 When the plot file has been completely sent press the front panel Enter button 4 Load a sheet of A or A4 size media portrait orientation The first 1000 bytes of the plot file will be plotted 5 Remove the sheet and load another sheet of A or A4 size media The last 1000 bytes of the plot file will be plotted SERVO CONTROL SYSTEM FAILURES All 0300XX error codes indicate a failure of the hardware or associated electronics of the
110. ing used The plotter will now load the roll of media 12 When indicated on the front panel raise the pinchwheel lever to the up position 13 When Pull Align edges to roll is displayed on the front panel pull the left and right edges of the roll toward you until taut Then align the left and right edges of Installation and Configuration 3 9 the media so that they are flush with the left and right edges of the roll See Figure 3 7 C C2847 97 UM C C2847 97a UM Aligning the Left and Right Edges of the Media Figure 3 7 14 When the front panel instructs you lower the pinchwheel lever The plotter checks to make sure the roll is properly aligned 15 When Close roll cover Continue is displayed rewind the media stop to take up any slack in the roll Make sure the leading edge of the media is outside the roll cov er then close the roll cover Press the Down Arrow button to continue The plotter trims off the first few inches of media When roll loading is complete the STATUS Ready to plot message is displayed UNLOADING ROLL MEDIA To unload roll media from the platen without removing the spindle from the plotter do the following steps 1 Raise the pinchwheel lever to the up position 2 Open the roll cover and turn the media stop to wind the media back onto the spindle 3 Close the roll cover 4 Lower the pinchwheel lever to the down position To remove the spindle with roll media
111. ion 5 5 Power Supply Description 5 8 Removal 6 12 Pen Carriage Assembly and Main Drive Belt Removal 6 38 Pens Accessing 3 14 Firing 5 3 Nozzles 5 3 Replacing 3 14 Index Pinch Arm and Lift Mechanism Removal 6 57 Pinch Wheel Sensor Removal 6 18 Plot Configuration Description 8 19 Steps 8 19 Conversion 5 5 Demonstration Running 3 26 Transfer 5 2 Plotter Color 1 2 Description 1 2 Features 1 3 Ink jet 1 2 Installing 3 2 Languages 5 2 HP GL2 5 2 RTL 5 2 Large format 1 2 Monochrome 1 2 Sensors 5 2 Plotting Modes Color 3 18 Monochrome 3 18 Power 2 2 Power Supply Autoranging 5 8 Primary 5 8 Removal 6 12 Secondary 5 8 Power Supply PCA Description 5 8 Primer Assembly Removal 6 17 Printed Circuit Assemblies History of 9 3 Processor Carriage 5 6 Main 5 2 Servo 5 2 Controlled Elements 5 3 R RAM Random Access Memory 1 3 Registers 5 2 Processor Support ASIC 5 2 Remote Sense Circuitry 5 7 Removal Procedures Automatic Bail Lift Mechanism 6 55 Back Panel 6 23 Bail Assembly 6 43 Bail Sensor 6 40 Cutter Assembly 6 32 Cutter Enclosure Assembly 6 49 Drive Roller Assembly 6 53 Drop Detect Sensor 6 40 Electronics Enclosure Cover 6 7 6 11 Encoder Strip 6 28 Entry Platen Assembly 6 51 Fan 6 13 Fixed Cover 6 14 Front Panel Assembly 6 24 Interconnect PCA 6 8 Left Endcover 6 15 Left Rollfeed Module Assembly 6 31 Main PCA 6
112. is assigned to the revised PCA Revision Letter This letter identifies the most recent revision to the etched circuit pattern The original issue is identified with the letter A If the master art work for a printed circuit board is revised in order to alter performance or manufacture the revision letter is changed to the next letter in the alphabetical sequence Assembly Date Code The date code on the PCA is a four digit number which identifies the assembly level by date code The PCA date code is changed when a component or component part number is changed which alters the performance of the PCA The first two digits represent the last two digits of the current year and are derived by subtracting 60 from the current year the last two digits represent the week in that year ie 3302 second week in 1993 Any digits following a hyphen in the date code represent the division that manufactured the printed circuit assembly Table 9 3 is a quick reference table that lists PCAs by part number and date code Listed next to the part number and date code of the PCAs are the Items located in this chapter that de scribe the differences between the PCA in question and the level of that PCA described in the main body of this manual Table 9 3 PCA Reference by Date Code PCA Date Code Items NO CHANGES Product History 9 3 Notes 9 4 Product History Chapter 10 Parts and Diagrams INTRODUCTION This chapter contains information
113. is performed Check the trailing cable and connect or replace it If these actions do not fix the prob lem replace the main PCA and rerun the tests If replacing the main PCA does not fix the problem replace the carriage assembly d The carriage ASIC is tested If this test fails replace the carriage assembly If all tests pass four dots will be displayed and the mechanical initializa tion will begin MECHANICAL INITIALIZATION During mechanical initialization the following tests are performed 1 The window sensor is checked The initialization will not continue unless the win dow is in the down position The bail sensor is checked and the pen primer assembly is initialized The Y axis is initialized First the left stop is found then the right contact with the cutter is made The carriage then parks in the service station The pinch wheel position sensor is checked If the optical sensor does not see light the plotter will act as if the pinch wheel lift lever is UP The media sensor is checked If the optical sensor does not see light the plotter will act as if media is already present A bad sensor could cause the plotter to try to load media with media present or drop media out of the plotter during the rear edge search if sheet media is loaded at power ON After the mechanical initialization is com plete the plotter is placed into a ready state either to accept media or to plot
114. jury or plotter damage 6 4 Removal and Replacement DRAM SIMM AND ROM MODULE REMOVAL To install or remove and replace a module perform the following steps 1 Using asmall flat blade or Torx T10 screwdriver remove the four screws that attach the cover plate to the back of the plotter and remove the cover plate See Figure 6 1 Cover Plate C C2858 32 Figure 6 1 2 After removing the cover plate you will see four module slots 2 larger ROM expan sion slots above 2 smaller DRAM SIMM memory expansion slots 3 Attach a conductive wristband if available to yourself and a good chassis ground on the plotter or touch the outer metal surface of the plotter 4 To remove a module press the two retaining clips outward grasp the module by its edges and carefully pull it out of the slot Note When only one DRAM SIMM is to be installed it must be inserted into the lower SIMM slot When only one ROM module is to be installed it must be inserted into the upper ROM slot 5 To install a module hold the module by its edges with the non metallic edge toward you and the notch to your right 6 Tilt the non metallic edge down about 45 and firmly push the module into the slot Gradually tilt the module up and push it in until it clicks into place 7 Install the cover plate with its four screws Removal and Replacement 6 5 MIO CARD REMOVAL To install or remove
115. l 00 c cece cece OENE 6 18 Window Sensor Removal cesus aoi eteeni aia eee cece ee 6 19 Media Sensor Removal 0 0 00 e ee eee riea EAE S PARRES 6 20 Trailing Cable Removal 0 0 0 cece cece eens 6 21 Back Panel Removal is asas tese Reed Rees deer bate 6 23 Front Panel Removal leeeeeeeee eretia Tois EEEE 6 24 Carriage Motor Removal ss esee eR Re eR e epee e ala oes 6 25 Paper Motor Removal auras suas are unicat Pea ce Rae a e 6 26 Encoder Strip Removal seeeeeee e 6 28 Rollfeed Cover Assembly Removal 0 0 00 0c cece eee eee nee 6 30 Rollfeed Module Assemblies Left and Right Removal 6 31 Cutter Assembly Removal leeeeeeee ee 6 32 Trailing Cable Guide Removal sleeeleeeeeeeeeA 6 34 Y Tensioner and Housing Removal 0 0 0 0 cece ee ee eens 6 36 Pen Carriage Assembly and Main Drive Belt Removal 6 38 Drop Detect and Bail Sensors Removal 0 000000 ee eee eee 6 40 Starguard Assembly Removal 2 0 0 0 cee eee eee eee 6 42 Bail Assembly Removal 0 0 cece eects 6 43 Service Station Assembly Removal eee eee eee 6 44 Overdrive Support Assembly Removal 0 00 c eee eee ee eee 6 47 Contents vii Chapter Page Cutter Enclosure Assembly Removal 0 0 0 cece eee eee 6 49 Entry Platen Assembly Removal 0 0 0 c eee eee eee eee ee 6
116. l Standards ANSI sizes A through E and architectural media sizes C through E Roll feed capability allows the plotters to perform long axis plotting in lengths up to 50 feet 1 2 Product Information The standard HP C2858 9A DesignJet 650C has four megabytes of on board random access memory RAM Memory expansion upgrades to 20 MB are available as well as various ROM enhancement and modular I O options Other features that are standard include Automatic media edge sensing Automatic pen alignment testing and servicing Automatic media stacking with adjustable media bin An automatic single axis cutter Queueing nesting and expanded margin capabilities Easy to read 2 row by 20 character vacuum fluorescent display VFD Built in diagnostic and demonstration plot routines Product Information 1 3 OPTIONS PLUG IN MEMORY C2858 9A DesignJet 650C plotters have two memory expansion sockets Each can hold ei ther a four megabyte or eight megabyte Single In line Memory Module SIMM There fore memory can be expanded by 4 8 12 or 16 megabytes The SIMM part numbers are Four Mbyte SIMM P N C2065A e Eight Mbyte SIMM P N C2066A ROM ENHANCEMENT MODULES Two ROM expansion sockets are also provided in the C2858 9A DesignJet 650C plotters Each will hold a single ROM enhancement SIMM The ROM SIMMS could include firm ware revision upgrades or language enhancements A Kanji ROM SIMM is available for J
117. l and Replacement Mark must face toward front of E S plotter when 8 paper motor is OS U fully installed E m Encoder q MN Connector Drive Roller Gear a nsn p AR EN 2 Jr nz Paper Motor Worm Gear ESG rl p o Th Paper Motor C C2858 47a i Front View C C2858 66 Motor Screws 2 Figure 6 19 Removal and Replacement 6 27 ENCODER STRIP REMOVAL To remove the encoder strip refer to Figure 6 20 and perform the following steps 1 6 7 Remove the window assembly 2 Remove the left and right endcovers WARNING Do not damage the encoder strip Lay the encoder strip on a flat surface when it is not in the plotter The encoder strip has very sharp edges exercise care when handling to avoid personal injury 3 Usinga 5 5 mm nut driver remove the nut and washer that secure the encoder strip to the right side encoder spring bracket See Figure 6 20 Using a 5 5 mm nut driver remove the nut and washer that secure the ground strap and encoder strip to the service station Compress the encoder spring bracket to release tension on the encoder strip Carefully release the encoder strip from the encoder spring bracket Carefully pull the encoder strip through and out of the carriage assembly When installing the encoder strip do the following 1 Ensure that the encoder strip is oriented with the transparent area down Thread the st
118. l set up values Main PCA clears calibration values and calculates a new EEROM checksum The EEROM should only be cleared in event of a checksum failure After clearing cycle power without media and do the following calibrations in the order listed bail calibration media sensor calibration drop detect sensor calibration edge sensor calibration and accuracy calibration It is recommended that a configuration plot be run from the Utilities menu for setup reference Reconfigure front panel set ups Reads all EEROM constants into RAM for temporary storage Writes and then reads the numbers AA hex and 55 hex into the EEROM The EEROM constants are restored when the test is complete THE TEST MUST BE ALLOWED TO COMPLETE Switching the power OFF during the test will cause all EEROM constants to be lost EXIT by pressing the ENTER button Verifies the RS 232 interface s ability to send Main PCA and receive data The special loopback connector P N 07440 60302 must be used with this test If a connector is not available you can place a jumper between pins 2 and 3 of the plotter RS 232 port for the test Any display other than PASS TEST PRESS ENTER indicates the test failed Refer to the system error code table for error code interpretation if a system error is displayed To EXIT press the ENTER button Produces a special plot used for determining All Pens specific interconnection pad failures Pen Carriage 8 14 Trou
119. lib 3 Drop Detect Calib 4 Edge Sensor Calib 5 Accuracy Calib 7 2 Adjustments Calibrations All calibration procedures are accessible through the front panel menu structure Procedures accessed by users are available through the Utilities main menu These procedures include Pen Alignment and Accuracy submenus The Accuracy submenu contains two lower subme nus Restore Factory settings and Recalibrate procedures The Config Plot function also lo cated in the Utilities menu is used in conjunction with the Accuracy procedures for com parison purposes Procedures reserved for service use are available through the Service Tests menu which is a subset of the Utilities menu SHEET LENGTH CALIBRATION This calibration uses the X axis to correct for tolerances in x axis components that are used to measure media length during media loading Perform this calibration if the hardclip margins are not within the 2 mm specification Sheet Length Calibration is accessible through the Service Tests menu To perform the sheet length calibration do the following en Press Enter at the Status display 2 Use the arrow buttons to scroll to the Utilities main menu Press Enter Either the Short or Full menu mode will access the Service Test submenu 3 Simultaneously press the Enter and the Up Arrow buttons to access the Service Test submenu 4 Scroll to the Sheet Length Calib submenu
120. ll 2X XXX errors report the firmware problem to the HP Response Center or the nearest HP Sales and Support Office Note conditions before the error occurred Include system configuration in the report All 300XX errors indicate a failure of hardware or electronics of the X or Y Axis Refer to SERVO CONTROL SYSTEM FAILURES in this chapter Refer to code 030000 Check mechanical parts in pen cap ping assembly for binding If an MIO is installed check the MIO setup Then replace the MIO Troubleshooting 8 9 Table 8 2 System Error Codes Continued Error Code Problem Description Corrective Actions 05xxxx Plotter system errors found MIO problem is indicated The most likely cause is the main PCA or the interconnect PCA Replace the interconnect PCA Replace the main PCA 060111 Line sensor LED not bright The optical sensor on the carriage has enough failed to locate lines drawn during the pen calibration routine Reduce the ambient light If the media is not clean and reflective change the media If the lines are faint replace the pens Clean lenses Replace LED Use the Edge detect test found in the service menu to help troubleshoot 060302 Large final residual correction Refer to code 060111 0700xx Could not calibrate for the Check that the sensor and the sensor drop detect sensor location housing are properly aligned Check that the service station cover is correctly seated over the sensor housing C
121. lled the overdrive rollers can be manually rotated forward only 11 Remove the overdrive assembly clutch and the two Teflon washers behind it from the overdrive assembly shaft 12 Using a TORX T 10 screwdriver remove the screws that secure the left and right ends of the overdrive support assembly to the overdrive support assembly mounts 13 While lifting the right end of the overdrive support assembly slightly rotate the bot tom end of the overdrive assembly to fit in the cutter enclosure channel Lift the left end slightly and slide the overdrive support assembly to the right until the overdrive shaft clears the left sideplate 14 Lift the overdrive support assembly clear of the plotter Removal and Replacement 6 47 Overdrive Assembly Clutch Overdrive Assembly Shaft Shoulder Screw Overdrive Cluster Gear C C2858 10 Clutch Retainer Left Side Overdrive Support Mount C C2858 14 Right Side C C2858 12 Figure 6 31 6 48 Removal and Replacement CUTTER ENCLOSURE ASSEMBLY REMOVAL To remove the cutter enclosure assembly perform the following procedure 1 Using a TORX T 15 screwdriver remove the screws that attach the front trim pieces to the left and right sideplates Remove the front trim pieces Remove the overdrive support assembly Using a TORX T 15 screwdriver remove the upper of the two screws that attach the left and right ends of
122. mulation ink and other contamination Cleaning intervals are determined by the local conditions under which the plotter is operated and by the types of plotter supplies used As with any precision electronics equipment proper maintenance will help to ensure reliability and prolong prod uct life PREVENTIVE MAINTENANCE PROCEDURES The following general cleaning procedure can be performed by the user Follow normal safety precautions and prevent water or other cleaning materials from entering the electron ics enclosure of the plotter wanpvriw o Disconnect the plotter from the power source prior to WARNING performing any maintenance DO NOT allow water to run on to electrical components and circuits or through openings in the enclosure as this can create a shock hazard 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 plotter with a damp sponge or cloth Use a mild soap and water solution if necessary Wipe the plotter dry after cleaning Note Do not use abrasive cleaners on the plastic carriage cover Clean the cover with a mild solution of soap and water and wipe it dry with a soft lint free cloth to prevent scratching 4 2 Preventive Maintenance DRIVE ROLLER CLEANING WARNING The drive roller cleaning procedure should be performed only by service trained personnel otherwise personal injury
123. n the cam journal screw two more turns counter clockwise push the screw in toward the center of the plotter and try again to pull the cam journal and rear wire link to the right and clear of the cam lift bar Repeat the last two actions until successful 10 Grasping the cam journal on the left side with your left hand reach around to the front of the plotter and push the top of the cam lift bar slightly toward the rear of the plotter and simultaneously pull the cam journal to the left The cam lift bar will begin to slide out of the chassis on the left side 11 Slide the cam lift bar about three inches out of the chassis with your left hand Press ing the right most pinch arm assembly toward the rear of the plotter against its spring tension with your right hand slide the cam lift bar left until it clears that pinch arm assembly Then remove the pinch arm assembly and spring from the chassis by rotating it 90 degrees clockwise Take care that the spring does not fall 12 Press the next right most pinch arm assembly toward the rear of the plotter against its spring tension and slide the cam lift bar left until it clears that pinch arm assembly Then remove the pinch arm assembly and spring from the chassis Repeat this step until all of the pinch arm assemblies have been removed or until you have removed the pinch arm assembly that is to be replaced Removal and Replacement 6 57 To install place the pinch arm assembly spring into
124. ndle only the solid plastic part of the ink cartridge carriage and the extension on the left end of the cutter carriage Carefully remove the jammed media from the plotter When finished lower the window and pinchwheel lever before turning the plotter back ON 3 12 Installation and Configuration PEN CHECKING Ink usage for cartridges may vary depending upon the ratio of color versus monochrome plotting and the extent of each color used Cartridge replacement is necessary only when any of the following conditions occur e Pen Checking is ON and you elect to replace the cartridges when the plotter prompts you e Poor plot quality indicates an out of ink condition or the cartridges appear clogged When Pen Checking is ON default the plotter checks the pens both before and after each plot for proper electrical contact and nozzle function If either of the problems exist the plotter displays the message Service pens Continue You may elect to either ignore the message and continue by pressing the Down Arrow or select Service pens by pressing the Up Arrow button If you select Service pens the display tells you whether a pen needs to be replaced nozzles aren t working or reseated poor electrical contact The defective pen position is indicated by a flashing icon in the front panel display When Pen checking is OFF the plotter does not check the pens for the above problems the only way you ll be able to tell if you ne
125. ne ves see ERRARE edad RR GU a 6 24 Carriage Motor Removal casas araras ns dEn eR eae eae ea eae 6 25 Paper Motor Removal 0 0 0c eee ec eee es 6 26 Encoder Strip Removal 2s c2c0 p0nt 4s da ons eb Ra OPERA Xa peal 6 28 Rollfeed Cover Assembly Removal 0 0 0 cece eee eee eee 6 30 Rollfeed Module Assemblies Left and Right Removal 6 31 Cutter Assembly Removal eeeeeee ees 6 32 Trailing Cable Guide Removal seeeeeeeeeeee 6 34 Y Tensioner and Housing Removal lsleleleeeeeeeeA 6 36 Pen Carriage Assembly and Main Drive Belt Removal 6 38 Drop Detect and Bail Sensors Removal eleleeeeeees 6 40 Starguard Assembly Removal lleeseeeeeeee eee 6 42 Bail Assembly Removal eeeeeeeeee ees 6 43 Removal and Replacement 6 1 Service Station Assembly Removal 0 0 0 c cece eee eee 6 44 Overdrive Support Assembly Removal 00 000 e eee eee eee 6 47 Cutter Enclosure Assembly Removal 0 0 00 ee eee eee eee 6 49 Entry Platen Assembly Removal ellen 6 51 Drive Roller Assembly Removal 0 0 0 0c eee eee eee nee 6 53 Automatic Bail Lift Mechanism Removal 0 000 eee eens 6 55 Media Diverter Removal pcrreriyparipars arere ctra koe e kA Eaa E eee 6 56 Pinch Arm and Lift Mechanism Removal 000000 eese 6 57 6 2 Removal and Replacement SAFETY
126. ner housing clear of the plotter 6 36 Removal and Replacement Trailing Cable Guide Main Idler Guide Screw Y Tensioner Housing Y Tensioner Spring It Y Tensioner Housing Screw 31 Y Tensioner Bracket 7 Tensioner Plate Screw C C2858 53 Y Tensioner Tensioner Plate Figure 6 25 Removal and Replacement 6 37 PEN CARRIAGE ASSEMBLY AND MAIN DRIVE BELT REMOVAL To remove the pen carriage assembly see Figure 6 26 and perform the following procedure 1 Remove the window assembly 2 Remove the left and right endcovers 3 Disconnect the trailing cable from the carriage PCA 4 Using a TORX T 15 screwdriver remove the screw that secures the trailing cable bracket to the pen carriage assembly and lift the trailing cable assembly clear of the pen carriage assembly Remove the trailing cable guide Remove the encoder strip YN QN tA Remove the Y tensioner and housing 8 Slide the main idler out of the housing 9 Remove the encoder spring bracket 10 Remove the double pulley from the Y drive bracket While doing this keep the palm of one hand beneath the double pulley to catch the double pulley bushing 11 Using a TORX T 20 screwdriver remove the three screws that attach the Y drive bracket to the sideplate Position the Y drive bracket assembly out of the way so that the pen carriage assembly can be removed 12 Remove the cutter assembly making sure to hold the rear cutter bushing
127. ng 906 For use in Switzerland DHCK 107 250 Vac 10 A Single Phase plug rating 912 For use in Denmark 250 Vac 10 A Single Phase plug rating 917 For use in India Republic of South Africa MITI 41 9692 125 Vac 12 A Single Phase plug rating 918 For use in Japan NOTE All plugs are viewed from the power outlet connector end L Line or Active Conductor also called live or hot N Neutral or Identified Conductor E Earth or Safety Ground Figure 3 1 Installation and Configuration 3 3 USER INFORMATION AND OPERATION MEDIA GUIDELINES Guidelines on media handling are e The leading edge must be straight and each side must be loaded evenly If the leading edge is jagged trim it with the media knife located in the manual holder at the back of the plotter using the track on top of the plotter as a guide e If media is curled load it with the curl up The exception to this is film media which must always be loaded with the plotting side matte side down e Roll media must be flush with the right edge of the core e Film should be handled by the edges or when wearing cotton gloves Load film with the matte side down shiny side up MEDIA TYPE AND PRINT QUALITY DesignJet 650C plotters have several combinations of plotting modes Each mode is depen dent upon the color monochrome setting media type and print quality settings input through the front panel Interaction between the settings produces the
128. ng reassembly see Figure 6 30 and do the following 1 Set the sled springs to their full upright position with the curved part of the springs resting against the stops inside the service station housing Feed the rubber tubes through the slot in the bottom of the service station housing while lowering the sled into position Ensure that the outer two tubes go on the out side of the springs while the inner two tubes go through the gap between the springs Place the sled on top of the springs aligning the springs in the slots under the sled While pushing the sled slightly toward the rear of the service station housing slide the sled toward the right until it drops slightly down and is fully seated in the service station housing Note When installing the drop detect sensor make sure the sensor alignment pin is positioned in the sensor Ensure that the sled is positioned to the right forward position after assembly If left toward the left sideplate back position the pen carriage will crash into the sled Be sure to reconnect the rubber hoses and cable connectors when reassembling Manually move the pen carriage in and out of the service station housing to ensure proper operation Service Station Cover Sled Screws 2 Service Station Housing Screws 2 C C2858 78 Figure 6 30 Page 1 of 2
129. ng the following steps Be sure that the plotter wheels are locked to prevent WARNING the plotter from moving while loading roll media To lock the wheels press the locking levers on the wheels to the down position 1 Standing the spindle on the end opposite the large scalloped media stop pull the scalloped media stop to release the spindle from the used roll Set the spindle aside Turn the used roll over and slip the endcap out with your finger See Figure 3 2 2 Slide the roll onto the spindle with the leading edge winding clockwise Push the endcap into the media core making sure the tabs are flush against the edge of the roll See Figure 3 3 3 6 Installation and Configuration C C2847 10 UM Removing the Media Stop and Endcap J Figure 3 2 C C2847 16 UM Sliding the New Roll onto the Spindle Figure 3 3 Installation and Configuration 3 7 3 Open the roll cover and insert the spindle with the endcap at the left and the media stop at the right Firmly push on both ends See Figure 3 4 Roll Cover Pinchwheel Lever C C2847 31 UM Installing the Spindle Figure 3 4 4 Once the roll is in place push the media all the way to the right so that it s flush against the media stop 5 Ensure that the pinchwheel lever at the right of the plotter is down 6 Turn the plotter ON if it is not already ON 7 Grasp the leading edge of the media and pull about one foot
130. nk drying times are available on the DesignJet 650C plotters through the front panel menus Dry time determines how long the plotter waits before cutting the plot Users should be cautioned that insufficient dry time can result in plot smearing as plots are stacked in the media bin Dry time choices are accessible through the Plotter setup menu 3 16 Installation and Configuration CONFIGURATION FRONT PANEL CONTROLS Plotter set up and plot management functions are input through the front panel The front panel contains a 2 row by 20 character vacuum fluorescent display Menu scrolling and im plementation are accomplished through 4 menu buttons Plotting modes are initiated through the color monochrome select buttons and print quality buttons User interaction is available through 3 pen media action buttons LEDs associated with various buttons are used to indi cate whether the function is enabled or disabled The front panel is shown in Figure 3 12 message display menu buttons AAA ONA Previou EE Enhanced EH Color EE Final BB Pause Mono EE Draft P J L4 LJ Sm action buttons plot mode buttons L C2858 1 Front Panel Controls Figure 3 12 Cancel Form Feed Cut Access Pens The front panel display is used for plotter set up and management messages including menu selections and operator interaction messages It also provides various plotter status messages and
131. nnector from the main PCA A Pull the pinch wheel sensor cable clear of any clamps 5 Using a Torx T 10 screwdriver remove the two screws that attach the toroid to the bracket See Figure 6 12 6 Using a Torx T 20 screwdriver remove the two screws that attach the toroid bracket to the right sideplate Don t cross thread or over tighten the screws when installing 7 Using a TORX T 10 screwdriver remove the screws that attach the pinch wheel sen sor to the right sideplate and lift the pinch wheel sensor clear of the plotter Toroid Pinch Wheel Sensor 5 SL el Toroid Bracket Ss EEE N Pinch Wheel Sensor Cable L C2858 48 Figure 6 12 6 18 Removal and Replacement WINDOW SENSOR REMOVAL To remove the window sensor perform the following procedure 1 Remove the right endcover 2 Disconnect the window sensor cable connector from the front panel PCA 3 Using a TORX T 8 screwdriver remove the two screws that attach the window sen sor to the right sideplate and lift the sensor clear of the plotter See Figure 6 13 Don t cross thread or over tighten the screws when installing Window Sensor Cable Window Sensor C C2858 49b Figure 6 13 Removal and Replacement 6 19 MEDIA SENSOR REMOVAL To remove the media sensor perform the following steps 1 2 Remove the electronics enclosure cover Disconnect the media sensor cable connector from the main P
132. on SCREW FLAT TAPTITE M4 SCREW FLAT M4X16 TRIM RIGHT FRONT TRIM RIGHT REAR SCREW BOLT METRIC SIDEPLATE part of chassis assembly see page 10 32 WINDOW SENSOR ASSEMBLY SCREW 4 20X0 625 IN LG PLST HOLDER HELP CARD HARDWARE KIT ENDCOVER RIGHT SCREW TORX SLOT M3 CLAMP FERRITE BRACKET TOROID SCREW METRIC CABLE ASSEMBLY FRONT PANEL FRONT PANEL ASSEMBLY OVERLAY FRONT PANEL ENGLISH GERMAN SPANISH FRENCH JAPANESE ITALIAN PORTUGUESE EXTENSION SIDEPLATE SCREW MACH SCREW MACH 10 14 Parts and Diagrams Right Endcover and Trim C C2858 6 1 Illustrated Parts Breakdown Parts and Diagrams 10 15 Ref Des 1 nu BO on 10 11 12 HP Part Number C2847 60013 C1633 60064 C2847 80001 C1633 80004 0515 2253 C1633 20021 0380 3073 C2847 60033 07596 60060 C2847 60063 0515 2248 C2847 60064 C1633 00084 C1633 00131 07596 40077 Da FD WTO ONW OMY ON CO Parts List Rollfeed Components Qty Be SEE DFP REPRE NNNNNHYE Description ROLLCOVER ASSEMBLY SPRING ROLLCOVER SCREW TAPTITE W WASHER M3 SCREW SHOULDER SPACER SPRING SPINDLE ASSEMBLY ROLLFEED ASSEMBLY LEFT SCREW THRD RLLG ROLLFEED ASSEMBLY RIGHT LABEL ROLL LOADING LABEL MEDIA LOADING SPINDLE SPACER MODEL C2858A MODEL C2859A MODEL C2858A MODEL C2859A MODEL C2858A MODEL C2859A 10 16 Parts and Diagrams 2A Rollfeed Components C C285
133. on the interface and hardware being used to drive the plotters different cables could be required A listing of cables and other connectivity related issues is provided in the DesignJet 650C documentation listed in Chapter 1 of this manual LINE VOLTAGE AND FUSING The HP C2858 9A DesignJet 650C plotter s power supply automatically adjusts to the input voltage The plotter s autoranging power supply accepts an input of 90 to 264 Vac POWER CORD CONFIGURATIONS Power cord configurations shipped with the plotter depend upon the country of destination for the plotter See Figure 3 1 for information on the power cord configurations available for use with the plotters When connecting the plotter to the ac source ensure that the appropriate power cord is used 3 2 Installation and Configuration BS 1363A Option No 250 Vac 13 A Single Phase plug rating 900 E For use in United Kingdom Cypress l Nigeria Zimbabwe Singapore AS C112 250 Vac 10 A Single Phase plug rating 901 For use in Australia New Zealand CEE 7 VII j 250 Vac 10 16 A Single Phase plug rating 902 For use in East and West Europe Egypt NEMA 5 15P 125 Vac 15 A Single Phase plug rating 903 lj For use in Canada Mexico Philippines Taiwan Saudi Arabia UL approved in the United States NEMA 6 15P o 250 Vac 15 A Single Phase plug rating 904 amp For use in Canada UL approved in the United States SEV 1011 250 Vac 10 A Single Phase plug rati
134. onding light band Cause Defective pen interconnect Problem One nozzle out on pen missing nozzle Cause Defective pen nozzle EE Problem Pen short diagonal pattern of nozzles out Cause Defective pen Problem Intermittent printing lines not straight Cause Defective pen 8 20 Troubleshooting READING THE EEROM TEXT BLOCK Contents of the EEROM IC are printed during the configuration plot in hexadecimal form Sample portions of the EEROM contents block and the pen nozzle test block are presented in the following pages of this chapter to assist you in interpreting the configuration plot results To read the EEROM contents block perform the following steps 1 Examine the sample EEROM memory map Table 8 4 to find the memory address of the data you want to read 2 Locate the position of the memory address in the contents text block using the memory location key in Table 8 5 3 Read the contents of the memory address from the configuration plot EEROM text block Suppose you are interested in knowing the factory platen correction factor Examining the EEROM memory map you would find that the memory address of the factory platen correc tion factor is 60 Using the memory location key Table 8 5 you would locate address 60 just to the right of the 60 entry On the sample contents block Table 8 6 address 60 contains the factory platen correction factor of hexadecimal number 50 ANALYZING
135. op CI Front Interconnect PCA Sensor Media Sensor Ei rae OD Sd C cs Main PCA Cable Connectors L C2858 3 Figure 6 5 6 10 Removal and Replacement OUTER ELECTRONICS ENCLOSURE ASSEMBLY REMOVAL C2858A ONLY To remove the outer electronics enclosure assembly perform the following procedure 1 Remove the electronics enclosure cover 2 Disconnect all the cables from the PCAs shown in Figure 6 6 3 Using a Torx T 15 screwdriver remove the bottom three and loosen the top three electronics enclosure assembly screws shown in Figure 6 6 4 Carefully lift up and pull the electronics enclosure assembly from the plotter making sure to ease the cables through the slots in the assembly Loosen Screws Screw accessed through hole L C2858 32c Remove screws Figure 6 6 Removal and Replacement 6 11 POWER SUPPLY PCA REMOVAL To remove the power supply PCA perform the following procedure 1 Remove the electronics enclosure cover 2 For model C2858A plotters remove the outer electronics enclosure assembly 3 Remove the flexible DANGER HIGH VOLTAGE protective cover from the elec tronics enclosure Carefully flex the cover and pull it out of the plotter 4 Disconnect the ac connector and the dc power distribution connector at the power supply PCA 5 Using aTORX T 10 screwdriver remove the
136. r information InttOdUCtlonB sia dos deno beato dee Pe xo ER Eee Pe dera que por ads 1 1 Description sserrep nerasite eee pee Sea e t PRO e c Rees ad 1 2 OPHONS e sce x trees ca S ato Sah te he ae ctu sca wee Bie 1 4 Plug in Memory eee er ooh Woe oe hee ae e eto e e RN a 1 4 ROM Enhancement Modules 0 0 00 cece eee eee eens 1 4 Modular Input Output MIO PCAS 0 0 eee eee eee 1 4 AJNOCeSSOPIGS oii sido eden ee doe adus det doles boc don ord a duet Bros 1 5 Performance Characteristics eeeeeeee eh 1 6 Serial Number Information 00 00 00 ccc ccc cece eee eee 1 6 Product Information 1 1 DESCRIPTION HP C2858A and C2859A DesignJet 650C plotters provide graphic displays of computer pro gram output data They operate with a number of computer systems and graphic terminals using either RS 232 C or Centronics external controllers With one of several optional mod ular input output MIO cards installed the plotter can operate with an HP IB external con troller within a Novell Ethernet or Token ring network as a TCP IP host workstation witha LAN Manager with Ethertalk and with Apple LocalTalk The C2858 9A DesignJet 650C plotters will accept drawing data from Computer Aided De sign CAD software programs supporting the HP GL vector the HP GL 2 vector HP RTL raster and PJL languages HP GL 2 is available with Kanji character sets when the Kanji ROM SIMM is installed Postscript
137. r removing any PCA from the plotter place it on a conductive foam pad or into its conductive packaging to prevent ESD damage to any ICs on the PCA Removal and Replacement 6 3 REQUIRED TOOLS Tools required to disassemble and repair the HP DesignJet 650C plotters are listed in Table 6 1 Table 6 1 Tools Required Item Size Torx Screwdriver with bits T8 T9 T10 T15 T20 T25 T30 Screwdriver flat blade Small Nut Drivers 1 4 in 3 16 in 5 5 mm or 7 32 in Pliers needle nose Medium Wrenches socket or open end 3 8 in 9 32 in or 7mm REPAIR PROCEDURES Unless otherwise specified reassembling should be performed in the reverse order of disas sembly Be sure to read and perform any precautions given in the procedures Certain repairs will require you to perform calibration procedures to return the plotter to cer tain performance parameters or ensure proper operation after repairs are completed Refer to the table of calibration requirements in Chapter 7 and perform the calibrations listed after the appropriate repairs are made Many repair procedures require other assemblies to be removed to perform the desired repair Assemblies to be removed will be referenced in the procedure To remove those assemblies refer to the appropriate removal procedures in this chapter WARNING Disconnect the plotter from the power source prior to performing any maintenance Failure to remove power may result in death personal in
138. re 6 3 Removal and Replacement 6 7 INTERCONNECT PCA REMOVAL To remove the interconnect PCA refer to Figure 6 4 and perform the following steps 1 Remove the electronic enclosure cover Note The cable connectors disconnected in the next step are labeled P for paper axis and C for carriage axis Note the orientation of the cable connectors for assembly 2 Disconnect the paper axis and carriage axis connectors from the interconnect PCA 3 Usinga TORX T 10 screwdriver remove the two screws that secure the interconnect PCA to the electronics enclosure assembly 4 Gently pull the interconnect PCA clear of its main PCA connection and lift the PCA clear of the plotter H Screw Locating Pin MLS C C2858 46 Paper Axis Connector Seay Main PCA Connector Carriage Axis Connector Figure 6 4 Note When installing the Interconnect PCA ensure the locating hole in the upper left corner of the PCA engages the locating pin on the electronics enclosure 6 8 Removal and Replacement MAIN PCA REMOVAL To remove the main PCA perform the following procedure pa 8 Remove the electronic enclosure cover Remove the interconnect PCA Using a 3 16 nut driver remove the two screws on top of the electronics enclosure from the RS 232 C connector Using a TORX T 10 screwdriver remove the two screws on top of the electronics enclosure f
139. re 6 33 6 52 Removal and Replacement DRIVE ROLLER ASSEMBLY REMOVAL While removing the drive roller assembly see Figure 6 34 To remove the platen roller assembly perform the following procedure 1 Bw QN tA 9 Remove the window assembly Remove the left and right endcovers Remove the encoder strip Remove the bail assembly Remove the overdrive support assembly Remove the carriage drive motor assembly Remove the paper drive motor assembly Usinga TORX T 10 screwdriver remove the two screws that secure the drive roller worm gear to the drive roller shaft See Figure 6 34 Pull the drive roller worm gear clear of the drive roller shaft 10 Using a TORX T 15 screwdriver remove the two drive roller collar screws that at tach the drive roller assembly axial bias plate to the inside of the right sideplate 11 Using a TORX T 20 screwdriver remove the three screws that attach the paper mo tor mount to the right sideplate 12 Using a TORX T 15 screwdriver remove the screw that attaches the media director to the chassis assembly and remove the media director 13 Using the manual lever raise the pinch arm assembly and remove the drive roller assembly from the plotter Note When replacing the drive roller assembly ensure the bearing assembly at the right end of the drive roller is seated in the right sideplate and completely on the right side of the axial bias plate Ch
140. rewdriver loosen the wedge screws that attach the entry plat en to the left and right sideplates until the screws are flush with the sideplates See Figure 6 33 8 Using a TORX T 15 screwdriver remove the screw that attaches the pinch wheel lift mechanism lever to the right sideplate and remove the lever 9 Using a TORX T 15 screwdriver remove the screws that attach the front trim pieces to the left and right sideplates Remove the front trim pieces 10 Remove the cutter enclosure assembly 11 Using a TORX T 15 screwdriver remove the top screw that attaches the entry plat en to the right sideplate 12 Pull the entry platen down forward and clear of the plotter To install the entry platen do the following 1 Install the entry platen such that the back of the platen rests on the back pins 2 Loosely install the left and right wedge screws 3 Install the screw that attaches the entry platen to the right sideplate 4 Tighten the left and right wedge screws Removal and Replacement 6 51 5 When correctly installed the right side of the entry platen will be against the right sideplate and the top of the platen should be against the top reference pins in the left and right sideplates Left Side Wedge Screw Top Screw Pinch Arm Lift Lever Screw ERR Rear Locating Pins Outside View e M Re Top Screw Front Locating Pin Outside View Wedge Screw Right Side C C2858 30b Figu
141. right so that it is flush against the media stop on the roll core Reload making sure that the left right media edges are even with the left right roll core edges The RS 232 C interface is configured incorrectly Press the ENTER button to clear the message from the front panel display Check the baud rate and parity settings in the plotter s front panel in the hardware configuration and in the application software configuration Adjust the setting as needed to ensure compatibility This error can also indicate a framing error caused by the wrong number of start stop bits sent or the wrong data word length The plotter expects 1 start bit 7 data bits 1 parity bit and 1 stop bit The RS 232 C interface is configured incorrectly Press the ENTER button to clear the message from the front panel display Check the handshake settings in the plotter s front panel in the hardware configuration and in the application software configuration Adjust the settings as needed to ensure compatibility Pen checking is ON and an error has been detected Press the UP ARROW if you want to service the pens replace or reseat Press the DOWN ARROW if you want to continue without servicing the pens Sheet media is skewed Remove it and reload it so that the left right edges being loaded into the plotter are square The leading edge must be straight A servo shutdown has occurred in the X axis The drive roller cannot move or the roll feed spindle c
142. rip through the apertures in the pen carriage assembly Using a5 5 mm nut driver install the ground strap washer and nut that secure the encoder strip to the service station Make sure the encoder strip engages the two small tabs adjacent to the threaded post on the service station Press the forward end of the encoder spring bracket slightly inward and place the encoder strip between the tabs of the encoder spring bracket and over the threaded post on the encoder spring bracket Using a5 5 mm nut driver install the washer and nut that secure the encoder strip to the encoder spring bracket Slide the carriage back and forth the length of its travel to ensure free movement The encoder strip should not bind or rub on the carriage To adjust the encoder strip loos en the spring bracket screws and move the bracket up or down as necessary Center the encoder strip in the pen carriage apertures and tighten the spring bracket screws 6 28 Removal and Replacement Nut and Washer Ground Strap Service Station Left Side Q C C2858 76 Nut and Washer Encoder Spring Encoder Strip S Encoder Spring Bracket Right Side C C2858 47a Figure 6 20 Removal and Replacement 6 29 ROLLFEED COVER ASSEMBLY REMOVAL To remove the rollfeed cover assembly perform the following procedure 1 Lower and hold the rollfeed cover about halfway open While removing ea
143. rive roller surface while it is rotat ing Thoroughly clean the roller surface 12 Stop the roller by pressing the Enter button when through cleaning 13 Press the Enter button to return to the SERVICE TESTS menu display 14 Using the Previous button scroll to the STATUS Ready for Media display 15 Allow the drive roller to dry before inserting media in the plotter 4 4 Preventive Maintenance Chapter 5 Functional Overview INTRODUCTION This chapter contains a simplified description of the HP C2858A and C2859A DesignJet 650C plotters circuits and mechanical functions Mechanical and Printed Circuit Assembly PCA overviews present a functional description of how the plotter operates IntroduCiOM ea suada ada goad oae seam obo Sea opa d maa OUR ebd oa ire de 5 1 Simplified Description of Circuits l llle eee 5 2 Mechanical Overview 2s esset e bee du b gore d b dba SCR a 5 3 Printed Circuit Assembly PCA Overview llle 5 5 Man PC A rotura ato setate ato s iu me a me NLIS a 5 5 Carnase PCA ise Ee e eat Le ds etae bt ud 5 6 Interconnect PCA 220 ciacdanciadadditadasaa iad eUam eda h 5 7 Front Panel PCA 2 0 een nents 5 7 Drop and Bail Sensors 0 0 0 eee eA 5 8 Power Supply PCA is qua maps a edes RR exw nae E RA see KOREA RR RD RE eee 5 8 Functional Overview 5 1 SIMPLIFIED DESCRIPTION OF CIRCUITS HP C2858A 59A DesignJet 650C circuits communicate with an external controller by w
144. roblems occurs switch the plotter OFF Press and hold down the ENTER and the UP ARROW buttons while switching the plotter ON This will allow access to the service tests 2 Press the ENTER button 3 Use the ARROW buttons to scroll to the Utilities menu display Either the Short or Full menu mode will access the Service Tests submenu 4 Press the ENTER button 5 Simultaneously press the ENTER and the UP ARROW buttons to access the Service Tests submenu 6 Use the ARROW buttons to scroll through the test selections 7 Press the ENTER button to begin a specific test when the desired test is displayed Note If no button is pressed for 1 5 minutes the front panel will return to the Status menu In some cases a quick press of a button may not be recognized by the proces sor When pressing a button be sure to press it deliberately and all the way to the bottom of its travel If the plotter hangs up during a test cycle plotter power and restart the test In some cases the plotter may revert to the STATUS message upon exiting a test To return to the service menu perform the above steps Service test names descriptions and the assemblies tested are listed in Table 8 3 Troubleshooting 8 13 Test EEROM Clear EEROM Test Serial I O Nozzle Print Table 8 3 Service Tests Description Assemblies Tested Allows you to either clear or test the EEROM EEROM Clearing defaults al
145. rom the parallel connector Disconnect all the cable connectors from the main PCA Using a TORX T 10 screwdriver remove the 12 screws securing the main PCA to the electronics enclosure assembly See Figure 6 5 Using a 7mm socket or open end wrench remove the two nuts that secure the main PCA to the electronics enclosure assembly Lift the main PCA clear of the plotter If installing a new PCA do the following 1 Remove the original EEROM 8 pin IC from the socket and install it on the replace ment PCA Remove the original EPROMs from their sockets and install them on the replace ment PCA Remove any SIMMs that were installed on the original PCA Remove the plastic SIMM guard from the original PCA and install it on the replace ment PCA Install any SIMMs removed from the original PCA Note When installing the main PCA temporarily leave the screws and nuts that attach the main PCA and the interconnect PCA loose Tighten the I O con nectors first then tighten the PCA screws and nuts Removal and Replacement 6 9 Screws 12 zen oo LI O A OU gl 3 li IJ B W JU C C2858 44 Nuts 2 EPROMs O Fan x axis Encoder RS 232 C Parallel Trailing U J JOUL Power Dist Pinch Wheel Sensor Cable Dr
146. rrow to create a calibration plot Press Down Arrow to measure a calibration plot Lift the media lever at the right of the plotter Remove accuracy calibration plot turn it so that the edge with arrows printed on it is print side down then load that edge into the plotter You pressed the Cancel button while media loading was in progress Remove media Load media to proceed with pen alignment When you ve finished aligning the roll media as instructed lower the media lever at the right of the plotter You have lifted the window while the processor is busy Close the win dow to continue Lift the window to access the pens Close the window to proceed with pen alignment Y Axis servo shutdown Troubleshoot and repair X Axis servo shutdown Troubleshoot and repair 3 24 Installation and Configuration Message Pull Align edges to roll e Remove media Continue gt Replace Y C M K pen Reseat Y C M K pen Sheet load Roll load Sheet Roll Reload media Table 3 3 Action Messages Continued Action Grasp the left and right free edges of the roll media and pull toward you until the media is taut At the same time align the left and right edges of the media so that they are flush with the left and right edges of the roll Ink is dry you can remove the accuracy calibration plot the plotter just produced Press Down Arrow to continue with accuracy calibration Y C M or K pen h
147. s 5 2 Y axis 5 2 Drivers Pen 5 3 Drop Detect Sensor Removal 6 40 E EEROM Electrically Erasable Read Only Memory Text Block Reading 8 21 Electrical Specifications 2 2 Encoder Linear 5 2 Encoder Strip Removal 6 28 Entry Platen Assembly Removal 6 51 ESD Considerations 6 3 F Failures Servo Control System 8 11 Fan 5 4 Removal 6 13 Fixed Cover Removal 6 14 Front Panel Controls 3 17 Menus 3 20 Messages 3 22 Front Panel Assembly Removal 6 24 Front Panel PCA Description 5 7 G Guidelines Media Handling 3 4 Index H Handling Media 1 3 Media Guidelines 3 4 Housing Y Iensioner Removal 6 36 Identification Procedures 9 3 Indicators LED 5 7 Initialization Mechanical 8 3 Ink Cartridges 1 2 Input Output See MIO Cards Interconnect PCA Description 5 7 Removal 6 8 Interface Centronics Cable Restrictions 2 4 HP IB Cable Restrictions 2 4 RS 232 Cable Restrictions 2 4 Interfaces Centronics 1 2 RS 232 C 1 2 K Key Pad 5 7 L Languages 3 21 LED indicators 5 7 Left Endcover Removal 6 15 Left Rollfeed Module Assembly Removal 6 31 Line Cord Set 2 2 Required 2 2 Line Sensor 5 3 Description 5 6 Linear Encoder 5 2 Loading Roll Media 3 6 Sheet Media 3 11 M Machine Languages HP RTL raster 1 2 HP GL vector 1 2 HP GL 2 vector 1 2 PJL 1 2 Main PCA Description 5 5 Removal 6 9 Mechanism Bail Lif
148. s can be measured unique patterns for use in detecting pen nozzle problems pen to pen align ment problems ink flow problems and vertical line straightness four X shaped marks crosshairs for measuring plotter pen to pen accuracy The centers of the crosshairs should be 500 mm apart pen palette set up information the plotter statistics including code rev and ROM SIMM information the page format and plotter set up information the RS 232 C MIO configurations the text blocks of the contents stored in the EEROM Draft Mode should not be used when performing the configuration plot as the patterns drawn will be different than described above To run the configuration plot perform the following steps 1 Bow QN tA Switch the power ON Load D size or E size media either sheet or rollfeed Ensure that the plotter is in the Full long menu mode Ensure that the plotter is in the Final as opposed to the Draft mode From the Status menu display press the ENTER button Using the ARROW buttons scroll to the Utilities menu Press the ENTER button Using the ARROW buttons scroll to the Config Plot menu Press the ENTER button Troubleshooting 8 19 10 The busy LED on the front panel will light to show that a configuration plot is being generated the pens will be tested at the service station and the configuration plot will automatically run to completion
149. s input output lines It provides for local control configuration and testing of the plotter and serves to display various plotter conditions Functional Overview 5 7 DROP AND BAIL SENSORS The drop sensor is located in the drop detect assembly Its purpose is to detect ink drops dur ing pen testing The drop sensor contains a detector system capable of detecting the presence of a drop shortly after one is fired into the detector In order for the drop to be fired into the detector the pen must be positioned over the sensor An infrared LED sends a beam across an aperture The beam is received at the other side by a photo sensitive diode When a drop passes through the beam it causes a disturbance in the reception The slight modulation in power output by the receiving diode is amplified by the pre amplifier further amplified by the amplifier and sent to the processor support ASIC on the main PCA The processor sup port ASIC can measure the time between the firing of a print head nozzle and reception of the amplified drop detect signal typically less than 900 microseconds The bail sensor consists of a photo emitting diode and a collector When the bail is down the path between the diode and the collector is interrupted by a small plastic flag and the BAIL signal is 0 V When the bail is lifted the path between the diode and the collector is clear and the BAIL signal is 5 V The bail signal is sent to the servo processor on the main P
150. sess cenneed sere ce P pe a eR RR eee EIE FUE 5 6 Interconnect PCA sssluseeeeeeeeee ehh 5 7 Front Panel POA iios csse bee bebe Peur bes add adda ag dea eras Qus 5 7 Drop and Bail Sensors 25 4 Rr REG cea Re eda TERR 5 8 Power Supply PCA ssepe ESSE O SGA eR E ae wees 5 8 vi Contents Chapter Page 6 Removal and Replacement Introduction escassas RR taes ORE hey PER Hees PP REA v a CERE TUE 6 1 Safety Considerations 2st mbi ep Ree wie pA UE DER GR RUE obi deg 6 3 BSD Considerations sere oce bauer eae anon ng bnew medo duane nee E 6 3 Required Tools sussa Ree nee e DRE Ce ered ees ETE 6 4 Repair Procedures sc sac dies eas Edad eed haga re p qua Candida RE vehe d 6 4 DRAM SIMM and ROM Module Removal 0 000005 6 5 MIO Card Removal sas esa case e hee sebo eR IRR Keowee eS 6 6 Electronics Enclosure Cover Removal 00 00 c eee eee eee eee 6 7 Interconnect PCA Removal 0 0 c cece eee eee 6 8 Mai PCA Removal i 252 e cee beet bed edb nee EE KC ED pesa 6 9 Outer Electronics Enclosure Assembly Removal C2858A Only 6 11 Power Supply PCA Removal seseee ee 6 12 Fan Removal i 255 2229 eR oo RERO Yr Ry Rand see ewe ERR Rowe ees 6 13 Window Assembly Removal lleeeeeeeeee ees 6 14 Endcovers Left and Right Removal 2 00 eee eee eee 6 15 Primer Assembly and Sensor Removal 00 0000 eee ee eee eee 6 17 Pinch Wheel Sensor Remova
151. ssories performance characteristics and serial number information is included in this chapter Chapter 2 Site Planning and Requirements Included in this chapter is pre installation information regarding the physical environmental and electrical requirements for proper installation and operation of the plotters Chapter 3 Installation and Configuration In this chapter you will find installation configuration and plotter verification procedures Included is information on ink cartridge and media loading accessing the front panel menu structures for plotter configuration and instructions on how to perform built in demonstration plots to verify proper plotter operation Using this Manual iii Chapter 4 Preventive Maintenance Chapter 4 contains information you will need to keep the plotters in their best operating condition Included are procedures that can be performed by the user Chapter 5 Functional Overview This chapter contains a simplified description of the plotter circuits and mechanical functions Chapter 6 Removal and Replacement Procedures for the removal and replacement of field replaceable units are provided in this chapter along with electrostatic discharge information and recommended tools to perform repairs Chapter 7 Adjustments Here you will find descriptions of any adjustments and calibrations that may be required to return the plotter to proper operating condition Chapter 8 Troubleshooting
152. st entered for your RS 232 C configuration have been saved as either Config A or Config B whichever you specified Machine is doing internal checking upon power up The plotter has detected that the roll is empty you must be in Roll mode for this to happen If desired remove the old roll and insert a new one Machine is plotting Machine is ready for you to load media Machine is ready to plot Machine has received plot data The machine is testing the pens for problems i e clogged pen or bad electrical connection improper seating Installation and Configuration 3 23 Message Special Media Mono Media Calibrate done Continue Can t replot Resend plot Close roll cover Continue Create plot Measure plot Lift lever Load arrow edge print side down Load cancelled Remove media Load media to align pens Lower lever after aligning Lower window to continue Open window to access pens Pen alignment Close window Power OFF Check Pen Path Power OFF Check Paper Path Table 3 3 Action Messages Action Press Up Arrow for Color plotting on Special CX paper Press Down Arrow for Monochrome plotting Accuracy calibration is complete Press Down Arrow to continue Replot buffer doesn t have enough memory to hold the entire plot Re send the plot Rewind the media to take up any slack in the roll close the roll cover then press Down Arrow to continue Press Up A
153. surement to the plotter The media sensor is electrically connected to the main PCA The drop sensor is an infrared detector mounted in the service station It is used to test that the nozzles in the pen cartridge are operating properly It is part of a drop detection system that measures the time from the firing of a nozzle to the sensing of a drop typically lt 900 usec The operation of the sensor system depends upon an illuminated infrared optical path in which the received power is modulated a small amount by a drop passing through an aperture on the way to the waste containment system The illumination is provided by an infrared LED which is regulated by an automatic power control to provide a fixed operating point in the optical receiver photo diode The automatic power control compensates for contamination device aging and environmental effects An optical sensor mounted on the primer assembly is used to determine the initial position of the primer assembly cam When the stepper motor that drives the primer assembly rotates in one direction it obtains the values for selecting each pen for priming When rotated in the opposite direction a clutch engages a diaphragm to provide the vacuum for priming An optical sensor on the service station housing is used to determine the position of the bail When the bail is in the down position the photo beam is interrupted by a small plastic flag actuated by the bail When it is up the photo
154. t Automatic Removal 6 55 Pinch Arm and Lift Removal 6 57 Media 1 2 bond paper 1 2 Detection 5 3 Diverter Removal 6 56 Handling 1 3 Handling Guidelines 3 4 Ink jet Drafting Film 1 2 Roll Loading 3 6 roll feed 1 2 Sheet Loading 3 11 single sheet 1 2 translucent Japanese Tracing Paper 1 2 Type and Print Modes 3 4 vellum 1 2 Index Media Diverter Removal 6 56 Media Sensor Removal 6 20 Memory Expansion Sockets 1 4 Main PCA RAM Information 5 5 Main PCA ROM Information 5 5 Plug in 1 4 RAM 1 3 Single In line 1 4 Menus Front Panel 3 20 Messages Error 8 4 Front Panel 3 22 MIO Ethertalk 1 2 HP IB 1 2 LAN Manager 1 2 LocalTalk 1 2 Novell ethernet See Input Output TCP IP See Input Output Token Ring 1 2 MIO Cards See Input Output Module Assembly Left Rollfeed Removal 6 31 Motor Stepper 5 3 X axis 5 2 Pinion Gear 5 3 Position Feedback 5 3 Removal 6 26 Y axis 5 2 Position Feedback 5 3 Removal 6 25 Motor Driver X axis 5 2 Y axis 5 2 O Options 1 4 Overdrive Support Assembly Removal 6 47 P Panel Back Removal 6 23 PCA Identification Procedures 9 3 Overview Description 5 5 PCA Printed Circuit Assembly Carriage Description 5 6 Front Panel Description 5 7 History of 9 3 Interconnect Description 5 7 Removal 6 8 Main 5 2 Description 5 5 Removal 6 9 Main ROM Read Only Memory Information 5 5 Overview Descript
155. ten modes Each mode has a unique combination of print resolution number of passes and resultant ink drying time Media Type is set through the front panel when media is loaded into the plotter The front panel display prompts the user to select for sheet or roll loading and then to scroll through the menu and select for one of the five media types listed below The menu selection should be set to match the media type being used Opaque bond paper Film Special paper Vellum Translucent A front panel button allows you to plot in one ofthree Plot Quality modes Continuous press ing of the button toggles through the modes and the associated LEDs are lit indicating the current print quality mode selection The Plot Quality modes are e Draft e Final e Enhanced 3 4 Installation and Configuration Real time switching between plotting modes is not supported If the user selects another mode while plotting the plotter waits until the current plot is finished and then switches to the newly selected mode MEDIA CUTTING AND STACKING Automatic and manual cutting of plots is available on the C2858 9A In roll media opera tions the user can choose between continuous plotting or cutting plots off the roll automati cally as they are completed e Automatic cutting When roll media is loaded whether or not queueing is ON the plotter automatically cuts plots and drops them into the media bin When queueing and nesting are ON the plotter
156. the pen interconnect surfaces and retest EXIT by pressing the ENTER button Displays each pen ID code and resistance value Used by plotter to set pen warm up sequences and nozzle firing energy Assemblies Tested Main PCA MIO PCA Interconnect PCA Main PCA Pen Carriage Cutter Bushings Main Idler Double Pulley Main Belt Drive Belt Slider Rods All Pens Pen Pen Carriage Interface Pen CArriage Trailing Cable Main PCA Interconnect PCA All Pens Troubleshooting 8 15 Test Primer Pen Continuity X axis encoder Y axis encoder Bail Sensor Media Sensor Table 8 3 Service Tests Continued Description Verifies the ability of the primer to select individual pens and run the pump for testing priming capability Also tests the optical sensor s ability to initialize the primer cam Checks for proper interconnection between all four pens and the carriage Uses a matrix of primitives PS and addresses Addr Sel to select nozzles to fire and determine pen ID If PS 00 and Addr Sel 0000 connections are good Any other numbers indicate a poor contact Press DOWN ARROW to see results for each pen Pens may be removed or reseated while test is in progress STOP the test by pressing the ENTER button Verifies the operation of the servo loop X axis feedback STOP the test by pressing the DOWN ARROW Moves the pen carriage assembly close to the center of its travel and then moves the carriage
157. the air If the pen nozzles are exposed to the air except during plotting for more than a few minutes at a time they are susceptible to clogging and drying Each time you remove a pen from its slot and then put it back the plotter performs the pen alignment procedure automatically REPLACING PENS The pens should be replaced in response to a Pen Checking prompt or poor plot quality Four high capacity ink cartridges are used in the plotter Pen life expectancy is dependent on the type of media and plotting mode used To replace the pens perform the following steps Note The four pens must be loaded in their designated pen slots in the carriage Use the color label on the cartridges and color dots on the carriage to match positions The plotter should be powered on when changing pens If you se lected Service pens from the display skip step 1 3 14 Installation and Configuration ey Press the Access Pens button The pen carriage moves out from the pen service sta tion at the left of the plotter and stops in front of the slot in the bail When the pen carriage stops and the display reads Open window to access pens open the window Note If you don t open the window within 30 seconds after the message is dis played the pen carriage returns to the pen service station Refer to the plotter display The display indicates via flashing icon s which pen position s is are detected to be in need of s
158. the bail calibration do the following E Press Enter at the Status display Use the arrow buttons to scroll to the Utilities main menu Press Enter Simultaneously press the Enter and the Up Arrow buttons to access the Service Test submenu Scroll to the Bail Calib submenu Press Enter The bail will raise Press the Up Arrow button Each time the button is pressed the bail will raise up slightly Press the Up Arrow button until the bail makes a slight falling motion This is the correct up position Press Enter to store the calibration value in EEROM Adjustments Calibrations 7 9 Notes 7 10 Adjustments Calibrations Chapter 8 Troubleshooting INTRODUCTION This chapter contains diagnostic instructions error codes and messages service tests and troubleshooting information for use as an aid in solving Model C2858A and C2859A De signJet 650C plotter symptoms and failures INtrOdUCHON PTT 8 1 IE RE 8 2 Power On Self Tests asas db ce eder x ea bep bed pee alg Rech berg Een 8 2 Power On Self Test upa eua rex e RR cee cera qui rente x RE Reese 8 2 Mechanical Initialization 0 0 ee cece ee nee 8 3 Error Messages and Codes 0 00 e cece cece ees 8 4 Worded Error Messages aidan ccadudas ae pe teed nda ex E RIDERE RE 8 4 System Error Codes isse eu v Rhe eter cele ake SR S E ga Ra 8 7 Display Data Plot ss sans ese obedience rset come mapa ce ce
159. ts Breakdown Parts and Diagrams 10 11 Ref Des 2Svocdaurwn amam NU BWW HP Part Number C2858 40013 C2858 00018 C2858 40028 0515 2254 0515 2304 0515 2250 C2858 40026 0515 2246 C2847 60044 0515 0380 0510 0787 1400 0482 C1633 40096 5041 1203 C2858 00017 N DO 0 Utt hKl2 WMO OW Parts List Left Endcover and Trim Qty ee a Se on Oe ae Description ENDCOVER ASSEMBLY LEFT LABEL SERIAL NUMBER SIDEPLATE part of chassis assembly see page 10 32 TRIM LEFT REAR SCREW FLAT M4X16 SCREW BOLT METRIC SCREW FLAT TAPTITE M4 TRIM LEFT FRONT SCREW TORX SLOT M3 CABLE ASSEMBLY AC POWER SWITCH SCREW MACH M4X10 CLAMP CABLE 312D CLAMP CABLE COVER SWITCH KEY CAP POWER SWITCH NAME PLATE 10 12 Parts and Diagrams Left Endcover and Trim C C2858 5 1 Illustrated Parts Breakdown Parts and Diagrams 10 13 Ref Des BLO6ovoovoc o0unarorT amam o IAN tn FW WV 19 20 21 HP Part Number 0515 2250 0515 2254 C2858 40025 C2858 40027 0515 2304 3101 3153 0624 0616 C1633 40094 C2847 60061 C2858 40012 0515 2246 9170 1533 C1633 00093 0515 2278 C2858 60018 C2858 60057 C2858 60026 C2858 60027 C2858 60028 C2858 60029 C2858 60030 C2858 60031 C2858 60033 C2858 20007 0515 2282 0515 2248 Da oD FW OO MArAOADFWOUOAN FANF ODwW ONAN fw o Parts List Right Endcover and Trim Qty Fae ee eae ae a NS NS eo a ee a Descripti
160. u reach the Status dis play If you are in a menu that has variables pressing Previous returns you to the previous menu without changing any values or without saving any menu changes You can confirm menu changes only by pressing Enter Installation and Configuration 3 19 FRONT PANEL MENUS There are seven main menus each with an option or series of submenus Pressing the Enter button from the Status display will access the menu structure Both a short menu and a full menu are available in the plotter display The short menu is the default menu and displays the more commonly used menus Changing to the short or full menu Menu mode submenu is accessed through the Utilities main menu A brief description of the main menus is given below Plot Management Controls plot file management in the queue including queueing nesting and number of copy specifications Page Format Specifies the size orientation and margins for the plots Pen Settings Defines the pen attributes including the palette which contains individual pen width and shading color settings Two custom palettes of 16 pens each can be defined and stored by the user Plotter Setup Defines basic operating setup including graphics language dry time pen checking and media bypass conditions I O Setup Controls plotter I O configuration and interaction with the controller For configuring the RS 232 and MIO interfaces and parameters Two user customized RS 232
161. ure 6 16 Removal and Replacement 6 23 FRONT PANEL ASSEMBLY REMOVAL To remove the front panel assembly perform the following procedure 1 Remove the right endcover 2 Disconnect the window sensor connector and the front panel cable connector from the front panel assembly See Figure 6 17 3 Release the front panel cable from the clamp on the front panel assembly 4 Using a TORX T 20 screwdriver loosen the three screws that connect the front panel assembly to the right sideplate and slide the front panel assembly clear of the plotter Window Sensor Connector Front Panel Cable Connector 3 C C2858 49b Figure 6 17 6 24 Removal and Replacement CARRIAGE MOTOR REMOVAL To remove the carriage motor perform the following steps 1 Remove the right endcover 2 Remove the electronics enclosure cover 3 Disconnect the carriage motor cable connector labeled C from the interconnect PCA 4 Press the small drive belt against the tensioner wheel in the belt tensioner to loosen the belt and slide the belt off of the motor gear See Figure 6 18 5 Carefully release the tensioner wheel 6 Using a TORX T 15 screwdriver loosen the two carriage motor screws about 1 4 inch and rotate the motor until the motor can be pulled down clear of its bracket 7 Retain the two screws for use with the replacement motor Drive Belt Small Screws 2 Belt Tensioner Carriage Motor
162. xamples of I O errors are mismatched interface conditions such as baud rate and parity menu Messages and options displayed on the plotter s front panel display nest A group of compatible plots arranged next to each other horizontally vertically to save media when plotted network A collection of interconnected individually controlled computers together with the hardware and software used to connect them A network allows users to share data and peripheral devices such as printers and storage media to exchange electronic mail and so on overflow To exceed the capacity of a buffer s storage space When a buffer overflows the excess data is lost palette A set of sixteen pens numbered O through 15 for which width and shading are defined from the plotter s front panel parallel interface An interface type in which a separate wire is used for each data bit in a byte or word and all bits are transferred simultaneously HP IB and Centronics are parallel interfaces parity An error checking method for information transfer between a computer and a peripheral device Parity is used to check the accuracy of binary data peripheral device A device separate from but used with a computer For example a disc drive printer or plotter queue Order in which plot data is received raster 1 A matrix of dots or pixels where each pixel is defined by a bit A bit that is on will print a dot on the paper A bit that is
163. y Remove the left and right endcovers Remove the encoder strip Remove the bail assembly Remove the overdrive support assembly Remove the drive roller assembly Note The media diverters are made of a clear plastic Observe that the long tab on each of the media diverters is oriented vertically and toward the left side of the plotter before performing the next step Flex each media diverter and pull it free of the chassis assembly See Figure 6 36 Media Director SK Media Diverters C C2858 29a Figure 6 36 6 56 Removal and Replacement PINCH ARM AND LIFT MECHANISM REMOVAL To remove the pinch arm lift mechanism perform the following procedure 1 2 W Remove the window assembly Remove the left and right endcovers Remove the encoder strip 4 Remove the bail assembly Jo A Remove the overdrive support assembly Remove the drive roller assembly Place the manual lift lever in the down position Disconnect the rocker plate tension spring to relieve any remaining tension on the pinch arm lift mechanism See Figure 6 37 On the right side use a TORX T 9 screwdriver to turn the cam journal screw 12 turns counter clockwise and push the screw in toward the center of the plotter Repeat this step again and try to pull the cam journal and rear wire link to the right and clear of the cam lift bar If unsuccessful tur

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