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14140 NE 200th St. Woodinville, WA. 98072 PH: (425) 398-8282 FX: (425) 398-8383
Notices:
Warning! Ensure that all AC power cables are removed from the printer before attempting these procedures.
Attention! The discharge of static electricity may damage the carriage and logic board components. Use the included
ground strap during all procedures. Keep plastic objects away from the carriage and logic board assemblies.
Warning! The FlexJet is heavy and could cause serious injury or death if it falls or rolls over. Make sure that a minimum of
two people move it, especially when detached from the stand.
Tools Required:
Philips screwdriver
9/64 (3.5mm) Allen wrench
5/16 (8mm) open end wrench
Small flat tipped screwdriver
1
Prepare the printer
a) Turn the FlexJet power off.
b) Clear paper from around the carriage.
c) Remove inkjet cartridges. Do NOT cover the
cartridge heads with anything.
d) Remove the AC power cable and any other
cables connected to the rear of the printer.
2
Remove the end cover
a) Unplug the roll feed motor under the right end
cover.
b) Remove the 5 screws that hold the plastic end
cover on to the right end of the printer. There
are two on the flat surface of the endplate,
one screw in the back, and 2 screws on the
bottom.
FlexJet Carriage upgrade
Remove Cover
Included with the upgrade kit
1) Screws for mounting the new board (3)
2) New daughter board
3) Standoffs (2 short, 1 long)
4) Flex cables (1 short, 4 long)
5) Carriage assembly with flex cables
6) Belt tensioner assembly
7) Tyraps (8)
8) Double stick foam tape
9) Grounding wrist strap
10) This procedure
3
Loosen the Carriage Belt
a) Find the belt tensioner on the right side above
the white cables.
b) Loosen the carriage belt tensioner by rotating
the 9/64" HEX screw 4 full counterclockwise
turns.
Loosen this screw
(9/64")
P/N: 108384 R0
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Related Manuals for Ioline FlexJet Series
Summary of Contents for Ioline FlexJet Series
- Page 1 P/N: 108384 R0 14140 NE 200th St. Woodinville, WA. 98072 PH: (425) 398-8282 FX: (425) 398-8383 FlexJet Carriage upgrade Notices: Warning! Ensure that all AC power cables are removed from the printer before attempting these procedures. Attention! The discharge of static electricity may damage the carriage and logic board components. Use the included ground strap during all procedures. Keep plastic objects away from the carriage and logic board assemblies. Warning! The FlexJet is heavy and could cause serious injury or death if it falls or rolls over. Make sure that a minimum of two people move it, especially when detached from the stand. Tools Required: Included with the upgrade kit Philips screwdriver 1) Screws for mounting the new board (3) 9/64 (3.5mm) Allen wrench 2) New daughter board 5/16 (8mm) open end wrench 3) Standoffs (2 short, 1 long) Small flat tipped screwdriver...
- Page 2 Remove the Logic Board Cover c) Find the white flex cable connections. Gently Attention! The carriage and logic board components are sensi- pull the locking clips on the connector shrouds tive to the discharge of static electricity. Attach one end of the down to unlock the flex cable connectors. ground strap (included) to your wrist and the other end to a d) Remove all white flex cables from connectors. bare metal portion of the printer like the frame the holds the service station. Keep plastic objects away from the carriage and logic board assemblies. Remove the wrist strap only after the new carriage is attached to the traverse, the cover is installed, and the metal cover is secured over the main logic board. a) Remove the 4 screws that hold the sheet metal logic board cover plate. Attention! The cover will swing down when the last screw is removed. Make sure to support it with one hand and let it slowly rotate. Unplug ribbon cables Remove the Old Flex Cables a) With the carriage secured, clip the plastic ties that hold the white flex cables against the right side of the printer. b) Pull the bundle of cables out of the grey clips (if present). c) Pull the bundle away from the end plate if it secured with foam tape. Lift the carriage belt tensioner out of the way if necessary. Remove screws d) From the front of the machine, pull the bundle 2 - Front Short Screw...
- Page 3 Remove the Old Carriage Using a 5/16 (8mm) open end wrench loosen the #6-32 hex nut ½ turn under the RIGHT and LEFT swing arms until the washers and round spacers can Remove the Phillips head screw at the right move freely. side of the carriage cover. This screw holds the carriage cover on. With one hand to each side of the carriage, gently pull the carriage cover tabs out that are Loosen this nut located near where the carriage belts attach to the carriage and remove the cover Remove carriage cover screw Hold the carriage at the right and left side of the metal base with both hands. Important: Do not hold the carriage by the inkjet head Unclip the carriage belt ends at the left and stalls or the sensor. right sides of the carriage base. Keeping the top two carriage v-wheels on the tra- verse, gently push the carriage down and rotate the bottom of the carriage towards the front of the Belt Clips machine until the lower v-wheels slip off of the lower traverse rail. Lift the carriage up and away from the machine. The long flex cable bundle should follow the carriage as you pull it off. Set the whole assembly aside. Rotate bottom Press down here towards you and on the other side Left Right...
- Page 4 Attach the New Carriage to the Tra- Attention! Do not hold the carriage by the cartridge stalls verse or the silver sensor assembly. Important: Please read the next steps fully before d) Feed the new ribbon cable bundle into the channel attempting to attach the carriage. in the traverse so that there is a loop to the left of the carriage. Lightly press the loop into the groove a) Wipe the traverse rails with an isopropyl alcohol at the back of the traverse so that it is in the cable dampened cloth to remove dust. Perform this channel. important maintenance step often, even every week depending on machine use. b) While holding the carriage and ribbon cable bundle, insert the end of the bundle through Ribbon Cable loop the hole in the endplate at the right end of Carriage the traverse. Continue feeding about 20” of the bundle through the hole. Pull ribon cable through hole in right side Ensure that the black drive belt is between the tra- verse rails and behind the carriage base. Hold the car- riage at the right and left side of the metal base with both hands and slip the top two carriage v-wheels over the top rail of the traverse. c) Move to the center of the machine and hold the new Keeping the top two carriage v-wheels on the tra- carriage up near the traverse with the blue lever(s) verse, gently push the carriage down and rotate...
- Page 5 Tighten the Carriage Swing Arms Gently hold the spacer up against the bottom of one of the upper v-wheel swing- arms. The spacer can be held up with a finger or a small screwdriver inserted from Make sure tensioner is in holes the right side of the carriage. While keeping gentle upward pressure on the spacer, securely tighten the nylock nut using a 5/16 (or 8mm) open end wrench. Repeat this process for the other swing arm on the carriage. Tighten this nut Push up on Cylinder Flathead Screwdriver Install the Carriage Cover 5/16” box wrench Install the carriage cover by aligning it with the base and pushing back until the tabs by the belt ends grab onto the carriage base. Press against the cover tabs to ensure that they ‘snap’ into the slots in the carriage Replace tensioner and Attach the carriage base.
- Page 6 Secure and Arrange the Ribbon Cable Bundle To the right of the carriage, hold the ribbon cable - Part 1 bundle down firmly in the traverse channel with the left hand. Note: The wrist ground strap can be removed With the right hand, smooth the ribbon cable now, but will need to be worn again later in this bundle beyond the tape at the middle of the tra- procedure. verse so that the black sleeving is stretched and lays relatively flat and taut. Important: This process is important for proper operation of Firmly push the black sleeving into the tape at the the FlexJet. The sleeved ribbon cables require a firm connection middle of the traverse. If it does not stick, apply the to the traverse at the middle of the printer and at the right end of supplied non-foam backed tape over the foam tape the traverse. Leave existing foam tape if the pieces are still sticky and repeat the process. and not bunched up. Apply the included foam adhesive tape to the existing foam tape if necessary. Move the carriage to the right 10” then slide it back to the left end plate and ensure that the loop in the Hold the ribbon cable bundle out of the cable bundle is still not touching the left endplate. way and attach a 10 cm piece of the sup- plied double sided foam tape to the traverse channel to the right of the existing tape Ribbon Cable (if present) at the middle of the machine. Remove the tape backing so that the side facing up is exposed.
- Page 7 Prepare the Daughter Card Insert the four longer flex cables into the daughter card connectors. Attention! Attach one end of the ground strap (included) to your NOTE: It is very important that the conductive side of wrist and the other end to a bare metal portion of the printer like the cables align with the conductive pads in the the frame the holds the service station. Keep plastic objects away connector. from the carriage and logic board assemblies. Press the locking collar back down after each cable is inserted. Remove the three screws indicated. Insert the shorter flex cable into the white connector Install the included long spacer in the hole in on the bottom of the daughter card as shown. It is the corner of the lower logic board as shown. very important that the conductive side of the cable aligns with the conductive pads in the connector. Long Long Short Short Remove the 3 Replace with standoffs screws Notch Short Attach the Daughter Card Install the two short spacers in the holes in the upper logic board as shown. Lift the locking collars up from the white Install the long ribbon cables in the daughter ribbon cable connectors on the motor con- card...
- Page 8 Insert all five ribbon cables into their corresponding Make 90 degree folds in the cable ends as shown white sockets on the main logic board. then connect them to the daughter card. Press the locking collars back down after each cable Topmost (longest) cable - plug into connector J9 is inserted (long cables only). (PWR/SENS) with the blue cable edge facing the Gently fold the cables toward the center of the center of the printer. machine then press the board down toward the main Important: Make sure the cable plugs into the connector correctly and are not shifted by a row or column logic boards. of pins. Insert and tighten the screws removed in step 1 above to secure the daughter board. Extra screws are Next cable in the bundle - plug into connector J1 included in the upgrade kit. (PRT 1) with the blue cable edge facing away from the printer. Continue attaching cables in the order that they are stacked making sure that the connectors are folded as shown. Daughter board installed Attach the Ribbon Cables Connect the ribbon cable ends with folds Attention! The ribbon cable connectors are small. Make sure that the connector is correctly aligned with the header pins before inserting. Pull the ribbon cables out straight from the right endplate and pull them toward the Attach the ribbon cable bundle to the end plate with bottom edge of the board. cable ties as shown. A small fold in the bundle is The connector numbers can be seen next required to take up slack in the cables. Slide the to the connector by looking up at the logic...
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Page 9: Carriage Belt
Attach the Logic Board Cover and Tighten the Carriage Belt Hang the metal logic board cover over the end of the service station frame. NOTE: Make sure the logic board cover edges are OUT- SIDE of the service station frame on the front and back. Make sure the ribbon cable bundle fits through the slot at the end of the cover and in the daughter card. If needed shift the cables to the side to avoid pinching them. Connect the take up motor power and encoder cables as shown in. Plug in Take-up wires... -
Page 10: Manually Updating The Firmware
Procedure: Firmware update for the Ioline FlexJet Manually Updating the firmware Updating the firmware Note: Use this procedure if your current firmware is lower than version 253.2 Prepare the FlexJet to Update the Firmware Prepare to Update the Firmware Determine what version of firmware you have 1. Power on the PC and FlexJet. 1. Power on the PC and FlexJet. 2. Ensure that the serial cable connects the PC to the 2. Ensure that the serial cable connects the PC to the... -
Page 11: Update Firmware
Update Firmware 1. Press the CAPS LOCK key on the keyboard so that the CAPS LOCK light is lit. 2. With TeraTerm open, turn FlexJet power off then back on. A message should appear in the TeraTerm window. 3. Within 8 seconds of turning on power, press the ‘Y’ key on the keypad. This prepares the FlexJet to accept new software. The carriage should NOT move after pressing the ‘Y’ key. 4. In TeraTerm, choose File>Send File. 5. Use the window to browse to c:\Ioline\Firmware and double click on the firmware file (usually xxxxx.mot, where xxxxx is the version number). A window will appear that shows the transfer progress. 6. When the transfer window closes, press the ‘Z’ key. The FlexJet will finish updating the firmware for approximately 2 minutes. A few messages will appear indicating progress. When the process is complete, the carriage will go through the power on sequence then enter the ser- vice station. TeraTerm will show that the new soft- ware is installed by displaying the version number. Reset Calibration Values 1. Turn power off on the FlexJet. 2. Manually pull the carriage out of the storage position to the middle of the machine. 3. Copy the factory calibration values from the white sticker inside the service station opening. If no... -
Page 12: Tools Required
Procedure: Y fine adjustment for the Service Station. **Note: This procedure is only required if your firmware is older than version 264.0 Notices: Attention! The discharge of static electricity may damage the keypad and components. Use the included ground strap during all procedures. Keep plastic objects away from the keypad and logic board assemblies. Tools Required: Scotch Tape 2) Remove the (four) Phillips screws that hold the keypad on. Let the keypad hang. Make sure both ends are still Service Station centering plugged in. 1) Remove the right side cover of the machine. Keypad 3) Remove the carriage cover. (One screw on the right side, 4) Make sure the ink cartridges are installed and power un-clip the back right and left sides). the machine on. Pull out on the tabs Screw to remove the cover. - Page 13 6) Place a piece of scotch tape on the service station 5) Loosen (do not remove) the carriage “catch bracket”. spit wells. Tape covering the holes Carriage catch bracket in the spit wells Loosen nut 8) If the lines don’t appear in the middle of the holes, turn the plastic thumbscrew on the side of the service 7) Press the “Clean” button on the keypad. You should see station (clock-wise if the lines are to the right. Counter- two lines in the middle of the spit well holes. Clockwise if the lines are to the left.) Spit well centering thumb screw Lines on the tape 9) Turn the power off and remove the ink cartridges. WARNING: After removing the ink cartridges lower the blue ink doors before continuing.
- Page 14 Y Fine Adjustment The purpose of the Y fine axis adjustment is to get the bottom of the carriage as close as possible to the ink wells without leaving a gap or pressing too hard. Also, proper adjustment assures the inkjet heads will be capped so the heads do not dry out. 1) Turn on the FlexJet and let it initialize. 5) Click the “Move carriage out from SS” button. The 2) Open the “FlexJet Control Center” software. carriage will move out of the Service Station. 3) When the window opens press Ctrl-Alt-B. You should 6) Change the “Y fine adjust” number to -800 and click see the following window. the “Set fine adjust” button. 7) Click on the “Return carriage to SS” button. The car- riage will move back into the Service Station. 8) Follow steps 4 thru 6 again adding 100 to the “Y fine adjust” number each time until the bottom of the carriage is just close to touching the grey ink wells. WARNING: Do not let the bottom of the carriage “Press” against the ink wells. This can cause failure of the machine to initialize. 9) Reduce the gap further by adding smaller numbers. Note: A Y fine adjust change of 25 mils results in a gap change that is equivalent to the thickness of a piece of paper. 10) Press and hold the “UP” arrow on the keypad of the plotter. While holding the button turn the machine back on. When the carriage starts to move let go of the button. 11) Once the carriage is back in the service station check the gap one more time to make sure they are touch- 4) Look at the gap between the bottom of the carriage ing. and the service station. With the Y fine adjust set there will be a large gap between the top of the grey ink wells and the bottom of the carriage. Look at the gap between the carriage and service station.
- Page 15 Final screw adjustment 1) If you are happy with the spacing between the carriage 2) Back the screw off one half turn until you can see a and the service station turn the service station stop little bit of light between the screw and the service screw on the side of the machine until it just touches station. Apply Lock-Tite or Super-Glue to the screw so the service station. it won’t back out while the machine is running. Service station “stop screw”. Very small gap 3) Move the carriage catch bracket until it hits the 4) If you are happy with all the adjustments, turn the magnet. Tighten the nut to hold the stop bracket. power off on the machine. Note: It’s best to use a nut driver that can reach 5) Let the FlexJet sit for 10 seconds, then turn the power the nut while the carriage is in the service station. back on while holding the “Up” arrow on the keypad. Otherwise tighten the nut enough to hold the bracket When the carriage starts to move let go of the button. and move the carriage out of the service station to 6) When the carriage initializes into the service station check all the gaps and stop brackets to make sure the adjustments are still right. 7) Re-install the keypad. Run a test plot to the machine before putting the covers back on. 8) If problems arise contact Ioline Tech Support. Magnet w/ rubber bumpers Carriage catch bracket...