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Fiery E100 Service Manual

Color server
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Fiery
®
E100 Color Server
Service Guide
A guide for service technicians
45098285
29 July 2011

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Summary of Contents for Fiery E100

  • Page 1 Fiery ® E100 Color Server Service Guide A guide for service technicians 45098285 29 July 2011...
  • Page 2 © 2011 Electronics For Imaging, Inc. This documentation is protected by copyright, and all rights are reserved. No part of it may be reproduced or transmitted in any form or by any means for any purpose without express prior written consent from Electronics For Imaging, Inc. (“EFI”), except as expressly permitted herein.

  • Page 3: Table Of Contents

    ONTENTS ONTENTS ONTENTS About the E100 How the E100 operates Precautions Standard electrostatic discharge precautions Notices Servicing the E100 Shutting down the E100 Starting the E100 Opening the E100 Restoring functionality after service Printing E100 pages Checking the network connection...
  • Page 4 ONTENTS System software Installing system software through an Ethernet port Installing system software through a USB flash drive Backing up the system configuration Restoring the system configuration Installing software patches System software installation error messages Specifications Hardware features Physical specifications Networking and connectivity User software Safety and emissions compliance...
  • Page 5 IST OF FIGURES IST OF FIGURES IST OF FIGURES Printing system IGURE Functional diagram IGURE E100 installed in the copier IGURE Power switch and power button IGURE Opening the E100 IGURE Steps to verify the E100 IGURE Network connectors IGURE...
  • Page 6 IST OF FIGURES Location of the power supply IGURE Replacing the power supply IGURE Removing the HDD assembly IGURE Removing the HDD from the bracket IGURE Creating an isolated Ethernet network using a crossover cable IGURE...

  • Page 7: About The E100

    About the E100 The Fiery E100 Color Server embeds computer connectivity and highly efficient PostScript and PCL printing capacity in the copier. In this guide, the Fiery E100 Color Server is referred to as the E100. The following information is included: •...

  • Page 8: How The E100 Operates

    One 1GB high-speed DIMM (dual in-line memory module) on the motherboard holds the image data during printing. When Fiery Scan uses the copier as a scanner, the E100 acquires image data from the copier, stores the data in memory, and then transmits it to the computer that requested the scan.

  • Page 9: Precautions

    • Do not place objects on the power cord. • Do not plug the E100 into a 2-hole, ungrounded outlet by means of a 3-prong adapter. • Do not plug the E100 into a circuit connected to heating or refrigeration equipment...
  • Page 10 RECAUTIONS • Do not plug the E100 into a switchable outlet. • Do not pull the cord to unplug the E100. Instead, pull the plug. • Do not tamper with or disable the power cord grounding plug. • Do not use an extension cord.

  • Page 11: Standard Electrostatic Discharge Precautions

    RECAUTIONS Standard electrostatic discharge precautions Electrostatic discharge (ESD), is a concern when working with electronic components, since it can destroy circuits, or damage them, reducing their life span. The area around the copier is probably not static-free. When you handle electronic components, do the following: •...

  • Page 12: Notices

    RECAUTIONS Notices Power supply cord notice The power supply cord is used as the main disconnect device. Ensure that the socket-outlet is located/installed near the equipment and is easily accessible. Le cordon d’alimentation doit être débranché pour une mise hors tension totale du produit. La prise de ATTENTION: courant doit être située ou installée à...
  • Page 13 RECAUTIONS Short circuit protection notice This product relies on the building’s installation for short-circuit (overcurrent) protection. Ensure that a fuse or circuit breaker no larger than 120 VAC, 15A U.S. (240 VAC, 10A international) is used on the phase conductors (all current-carrying conductors). ATTENTION: La protection contre les courts-circuits (surtension) du produit est assurée par l’installation électrique du local où...

  • Page 14: Servicing The E100

    Servicing the E100 To service the E100 hardware, do the following: • Shut down the E100. • Disconnect the AC power cable from the E100. • Power off the copier. • Unplug the copier. • Remove the E100 from the copier.

  • Page 15: Shutting Down The E100

    If the E100 is not responding, and it is not possible to shut it down from the copier touch panel, you can force the E100 to shut down. Only force the E100 to shut down as a last resort, after an unsuccessful attempt at a normal shutdown.

  • Page 16: Starting The E100

    E100 ERVICING THE Starting the E100 The E100 has a power switch and a power button. When the E100 is powered on, the power button is green. Power switch Power button Power switch and power button IGURE E100 O START THE 1.

  • Page 17: Opening The E100

    For detailed information about removing/installing the E100, see the installation instructions that accompany the copier (not included in this document). 5. Place the E100 on a flat surface and remove the two screws that secure the cover of the E100 to the chassis (see Figure Set aside the screws so that you can replace them later.

  • Page 18: Restoring Functionality After Service

    E100 to the copier and then to the network and/or USB port. E100 O REASSEMBLE AND VERIFY THE 1. Reseat any cables, devices, DIMMs, or other parts of the E100 assembly that you may have loosened or removed during inspection or service (see “Checking connections”...

  • Page 19: Printing E100 Pages

    For more information, see Configuration and Setup, which is part of the user documentation set. • E-mail Log • Font List identifies fonts on the HDD, including the default fonts shipped with the E100 and any customer-installed fonts. • FTP Log •...

  • Page 20: Checking The Network Connection

    Checking the network connection The E100 provides twisted pair connectivity to an Ethernet network. This topic describes how to connect the E100 to the network and print a few test documents to verify the connection. Depending on your network speed, the following unshielded twisted pair (UTP) network cables are supported: •...
  • Page 21 The site administrator should perform any additional Network Setup, verify the network connection, verify that the E100 appears in the list of printers, and print a few test documents from a networked computer that will use the E100. For more information, see...

  • Page 22: Components

    To locate internal and external components, including cables and ports, use the following: • “” on page 23 • “Checking connections” on page 24 • “Connector panel” on page 26 • “The E100 front panel includes the LED display and service switches.” on page 27 • “Front panel” on page 27...

  • Page 23: Figure 8: Exploded View

    OMPONENTS 1. Chassis cover 2. Network switch board 3. Copier interface board 4. CPU cooling assembly 5. DIMM (1 GB) 6. CPU (2.66 GHz) 7. Battery 8. Security chip 9. Motherboard 10. 160GB SATA HDD (hard disk drive) 11. HDD bracket 12.

  • Page 24: Checking Connections

    OMPONENTS Checking connections The most common cause of a hardware problem is a faulty or loose connection. Before you replace a component, check all external connections, and then check all internal connections. Enclosed fan Connect one wire to A and the other wire to B. Power supply Power switch detail, inside view...
  • Page 25 14). Make sure to remove the AC power cable from the power outlet before opening the E100. 2. Make sure that all E100 cables, devices, and the DIMM (dual in-line memory module) are present, intact, properly aligned, and well-seated in their connectors.

  • Page 26: Connector Panel

    OMPONENTS Connector panel With the connector panel, you can connect the E100 to the copier and the network. You can also control the power supply of the E100 using the AC power switch and the power button. When installing system software with a...

  • Page 27: Front Panel

    During startup, the E100 advances through a standard diagnostic sequence. Codes flash rapidly on the LED display during this time, until the E100 reaches Idle. In the Idle state, 00 displays. If the LED display hangs with a code other than 00 , one or more diagnostic tests may have failed.

  • Page 28: Motherboard

    Transferring options permanently customizes the new motherboard so that it cannot be returned to inventory and cannot be installed in another E100. If the new motherboard does not solve the problem, do not transfer options to it. Instead, return the new motherboard to inventory.
  • Page 29 Not included in the motherboard kit • USB 2.0 flash drive (32MB) with write-protection turned off. – Not all USB 2.0 flash drives are validated for use with the E100. If a flash drive does not work, try another brand.
  • Page 30 Four wires left to right: red, black, red, yellow SW LED 6. Remove the five screws that secure the E100 motherboard to the chassis. 7. Slide the motherboard away from the connector panel cutouts. Make sure to note the position of the “metal fingers” on the USB connectors so that you can...
  • Page 31 OMPONENTS 8. Lift the motherboard out of the chassis at a 45-degree angle and set it on a flat, antistatic surface. As you remove it, be careful to avoid stressing the motherboard or the surrounding cables in the chassis. 9. If you are replacing the motherboard with a new motherboard, proceed to “To prepare a replacement motherboard”...

  • Page 32: Figure 12: Aligning The Security Chip

    OMPONENTS Security chip If you replace the E100 motherboard, you must transfer the security chip from the old motherboard to the new motherboard. Make sure to remove the security chip from the old motherboard before returning the old motherboard to your authorized service/support center. If you fail to install the security chip on the new motherboard, the E100 will not start up and all customer-purchased software options will be lost.
  • Page 33 • Power supply cables: 20-pin cable for MB power; 4-pin cable for CPU power 4. Install the copier interface board (see page 36). 5. Reassemble the E100 (see page 18) and start the E100. 6. Configure the date and time in Setup (for details, see the Configuration and Setup, which is part of the user documentation set).

  • Page 34: Motherboard Battery

    For instructions, see page 3. Locate the battery on the E100 and the metal clip that holds the battery in the socket. 4. Push the metal clip away from the battery. Use caution when bending the clip; excessive force could cause the clip to lose its tension.
  • Page 35 Make sure that the battery snaps into place and the clip holds it securely in the socket. 7. Reinstall the copier interface board. 8. Reassemble the E100 and verify functionality (see page 18). The date and time of day are lost when the old battery is removed. For instructions on entering Server Setup to program the system date and time, see Configuration and Setup, which is part of the user documentation set.

  • Page 36: Copier Interface Board

    You must follow standard electrostatic discharge (ESD) precautions when you handle electronic components. For more information, see “Standard electrostatic discharge precautions” on page 11. 1. Shut down and open the E100 (see page 14). 2. Remove the mounting screws that connect the copier interface board bracket to the connector panel.

  • Page 37: Network Switch Board

    OMPONENTS Network switch board The E100 connects to the copier by means of a network switch board. With this board, you can create separate IP addresses for the E100 and the copier, which is a required step when enabling some functions on the E100.

  • Page 38: Dimm

    OMPONENTS DIMM The E100 includes a 1GB DIMM (dual in-line memory module) in the DIMM1 socket. It is held in place on the motherboard by levers at each end of each the socket. Approved DIMMs are available from your authorized service support center.
  • Page 39 5. If you installed a new DIMM, clear the CMOS (see page 57). Make sure to remove the AC power cable from the power outlet before opening the E100 and clearing the CMOS. To clear the CMOS, remove the battery (see...

  • Page 40: Cpu And Cpu Cooling Assembly

    OMPONENTS CPU and CPU cooling assembly The CPU is installed in a Zero Insertion Force (ZIF) socket on the motherboard. Before removing the CPU from its socket, remove the motherboard from the chassis (see page 28), disconnect the CPU fan cable from the motherboard, and remove the cooling assembly from the CPU socket (see page 41).

  • Page 41: Figure 18: Removing The Cpu Cooling Assembly

    You must follow standard electrostatic discharge (ESD) precautions when you handle electronic components. For more information, see “Standard electrostatic discharge precautions” on page 11. 1. Shut down and open the E100 (see page 14). 2. Remove the motherboard components (see page 30).

  • Page 42: Figure 19: Removing/Replacing The Cpu

    OMPONENTS 8. Unlock the CPU socket lever and place it in the open position (flex the lever away from the retention post, and then raise it). 9. Open the load plate (see Figure 19). Yellow triangle Socket lever in the open position Flat corner of socket border Socket lever in the locked position...

  • Page 43: Figure 20: Locating The Flat Corner Of The Cpu Socket

    OMPONENTS O REPLACE A You must follow standard electrostatic discharge (ESD) precautions when you handle electronic components. For more information, see “Standard electrostatic discharge precautions” on page 11. 1. Do one of the following: • If you are installing a new CPU cooling assembly on an existing CPU, clean the contact surface of the CPU to remove any old thermal compound residue.

  • Page 44: Figure 21: Replacing The Cpu Cooling Assembly

    OMPONENTS 5. Lower the socket lever and place it in the locked position under the retention post. 6. Prepare the CPU cooling assembly for installation. • Make sure that the motherboard is placed on a padded, static-free work surface. • Apply fresh thermal compound, as described in step 1 on page 43. •...

  • Page 45: Figure 22: Inspecting The Cooling Assembly Pins On The Underside Of The Motherboard

    You should clear the CMOS after installing a new CPU to ensure compatibility between the new component and previous settings stored in the BIOS. Be sure to remove the power cable from the E100 before clearing CMOS. • Remove the battery (see page 34).

  • Page 46: Enclosed Fan

    “Precautions” on page 9. Rivet (1 of 4) Location of the enclosed fan IGURE O REPLACE THE ENCLOSED FAN 1. Shut down and open the E100 (see page 14). 2. Remove the E100 from the copier (see page 17). 3. Note the orientation of the fan and the arrow indicating the air flow out of the vent.

  • Page 47: Power Button

    Location of the power button IGURE O REMOVE THE POWER BUTTON ASSEMBLY 1. Shut down and open the E100 (see page 14). 2. Remove the power button cables (SW and SW LED) from J14 on the motherboard. 3. Use needlenose pliers to pinch the beveled sides of the button casing, and push the button assembly out through the cutout in the chassis.
  • Page 48 3. Connect the power button cables to the correct pins on J14 • SW LED cable—pins 2 and 4 • SW cable—pins 6 and 8 SW LED Four wires left to right: red, black, red, yellow. J14 on the motherboard 4. Reassemble the E100 and verify its functionality (see page 18).

  • Page 49: Power Supply

    OMPONENTS Power supply The power supply in the chassis is dedicated to the E100. It supplies power to the motherboard, power button, and HDD. To remove or replace the power supply, use the following procedures and follow “Precautions” on page 9.
  • Page 50 OMPONENTS O REPLACE THE POWER SUPPLY 1. Place the power supply into the chassis and secure it with the four screws that you removed earlier. When replacing the screw inside the chassis, see the following illustration. It is not necessary to install a screw in this area.
  • Page 51 OMPONENTS Power supply connectors The following table describes the power supply cables that are required in the E100. For more information about the power supply, see “Specifications” on page 71. Cable connector Pin(s) Wire color Voltage Connection All voltages listed in this table are direct current voltages (VDC).

  • Page 52: Hard Disk Drive

    • Configuration page records the customer’s current Setup configuration (custom settings are lost when you install system software). • Font List details what fonts are resident on the E100. Along with the fonts that are provided on the System Software DVD, the customer may have installed additional fonts that are deleted when the system software is installed.
  • Page 53 For information about how to print the Configuration page and Font List, see Configuration and Setup, which is part of the user documentation set. 2. Shut down and open the E100 (see page 14).
  • Page 54 OMPONENTS 6. Carefully lift the HDD assembly to release its lower edge from the mounting posts in the chassis, and then remove the HDD assembly from the chassis. Screw (1 of 3) HDD assembly Removing the HDD assembly IGURE...
  • Page 55 OMPONENTS 7. If you are replacing the HDD with a new HDD, remove the HDD from its bracket. Remove the four screws that secure the HDD to the HDD bracket (see Figure 28). Remove the HDD bracket and set it aside so that you can replace it later. Make sure to support the HDD as you remove the screws.
  • Page 56 10. If you replaced the HDD with a new HDD, install system software (see page 58). If, after installing a new HDD and system software, you notice that the E100 takes longer than usual to start up, clear the CMOS (see page...

  • Page 57: Clearing The Cmos

    O CLEAR THE 1. Shut down and open the E100 (see page 14). Make sure to remove the AC power cable from the power outlet before opening the E100 and clearing the CMOS. 2. Remove the battery (see page 34).

  • Page 58: System Software

    To save FreeForm master jobs, ask the network administrator to archive them to a location on the network, so that the jobs can be imported back into the E100 queue after system software installation. For more information, see Command WorkStation Help.

  • Page 59: Installing System Software Through An Ethernet Port

    • Turn off the Windows firewall. • Disable all power-save and hibernation settings. 3. On the PC, insert the System Software DVD. The Fiery System Software Installer starts. If it does not, browse to the location of System Software DVD and double-click the DVD icon.
  • Page 60 Copier (Ethernet) port Windows 2000/XP/Vista/7 PC Creating an isolated Ethernet network using a crossover cable IGURE 9. On the E100, set the service switches to service mode (move both service switches to the ON position). For more information, see “Front panel”...
  • Page 61 For more information, see “Checking the network connection” on page 20. • On the E100, with the power switch is in the OFF (|) position, press the power button once. The E100 powers on. Wait for 00 to display on the LED display.

  • Page 62: Installing System Software Through A Usb Flash Drive

    The drive must have a minimum capacity of 5GB. Not all USB 2.0 flash drives are validated for use with the E100. If the drive that you are using does not work, try another brand.
  • Page 63 YSTEM SOFTWARE USB P O INSTALL THE OOL APPLICATION 1. Insert the USB Prep Tool CD into the media drive of the PC. 2. Navigate to the location of the CD and double-click Setup.exe to start the installer. Click Proceed. 3.
  • Page 64 YSTEM SOFTWARE 4. Follow the on-screen prompts: • Specify the drive to copy files from (the drive letter of the media drive). Start screen: Specify the drive to copy to (the drive letter of the USB flash drive). Click Proceed when the Proceed button is available.
  • Page 65 The E100 powers on. Files are copied from the USB flash drive to the E100 (requires 5-15 minutes, depending on the USB flash drive). 9. On the E100, with the E100 power switch in the switch in the ON (|) position, press and hold the power button for 5 seconds.
  • Page 66 20. Files install on the E100 (requires 3-4 minutes). 13. On the E100, with the power switch in the ON (|) position, press the power button once. The E100 powers on. Wait for 00 to display on the LED display.

  • Page 67: Backing Up The System Configuration

    If you back up the system configuration, you can restore it after you reinstall system software. When you back up the system configuration, you save a configuration file with E100 settings. If you cannot create a configuration file, ask the network administrator to archive custom color profiles, preflight templates, FreeForm masters, custom Paper Catalog entries, customer-installed fonts, and the Job Log to removable media or a network location.

  • Page 68: Restoring The System Configuration

    YSTEM SOFTWARE Restoring the system configuration You can restore the configuration of the E100 to its previous state using a configuration file. For more information about creating a configuration file, see “Backing up the system configuration” on page 67. If you were unable to create a configuration file, you must configure Setup. After you exit Setup and the E100 reboots, ask the network administrator to restore any archived settings and files that were saved.

  • Page 69: Installing Software Patches

    O DOWNLOAD SOFTWARE PATCHES YSTEM PDATE 1. On a client computer, click Start , and choose All Programs > Fiery > System Update. 2. Click Check Now. O DOWNLOAD SOFTWARE PATCHES ONFIGURE 1. On a client computer, right-click FieryBar, and choose WebTools from the Shortcut menu.

  • Page 70: System Software Installation Error Messages

    YSTEM SOFTWARE System software installation error messages If an error message displays when you install, reinstall, or upgrade system software, do the following: • If prompted, save the log. • If you are not prompted to save the log, record the error message. If you cannot correct the error, contact your authorized service/support center.

  • Page 71: Specifications

    8.90 cm (3.52 in.) x 34.60 cm (13.62 in.) x 29.70 cm (11.69 in.) • Weight: 5.58 kg (12.30 lb) Networking and connectivity The E100 includes the following network support features: • Supports AppleTalk and TCP/IP protocols simultaneously • Supports EtherTalk Phase 2 •...

  • Page 72: User Software

    PECIFICATIONS User software A complete description of E100 user software is provided in Welcome, which is part of the user documentation set. For optimal E100 performance, maintain current versions of the user software on every network computer that prints to the E100.

  • Page 73: Troubleshooting

    Where problems occur The E100 is a built-in print server for the copier, and is generally part of a configuration like the one shown in Figure 3.

  • Page 74: Before Visiting A Customer Site

    Before you make a service call to a customer site, talk to the customer on the phone, and check the following items: 1. Does the copier work? If the copier works, but the user cannot print the E100 Test Page, a service call is probably required. 2. Is the failure caused by a simple operating problem? •...

  • Page 75: At A Customer Site

    Printing problems may arise if the network hardware or software is not set up properly or does not match the network settings on the E100. Problems may also arise when printing from a specific application or printing a particular file.

  • Page 76: Printing

    Solution Is the power on? Make sure the power switch is in the ON position, and then press the power button on the E100 to turn it on. When the E100 reaches Idle, power on the copier. Are the copier and the E100 Make sure that the copier interface cable is properly connected to the copier and the E100.
  • Page 77 ROUBLESHOOTING Other printing problems The following table lists other printing problems and what to do about them. Other printing problems ABLE Problem Action An image is printed on the reverse Reload the paper in the paper tray upside down. side of the paper. Multiple pages are fed through the Remove all the pages from the paper tray and fan them gently before reloading.

  • Page 78: Symptoms And Solutions

    If the E100 is turned on and hanging on a diagnostic code, first perform the following actions to see if they fix the problem: 1. Press and hold down the power button on the E100 for 5 seconds until the green light turns off and the system powers off.
  • Page 79 When the E100 is in the 1. Check and reseat all cable connections between the E100 and copier. Idle state and 2. Make sure that the E100 service switches are set to OFF (both away from in operational mode, the ON).
  • Page 80 • Faulty motherboard Startup E100 starts up One of the following: 1. Check and reseat the interface cable between the E100 and the copier. and then shuts down 2. Replace the interface cable. • Faulty connection between E100 and copier 3.
  • Page 81 E100 starts up, and stays One of the following: 1. Make sure that the E100 service switches are set to OFF for Normal mode (away from the numbers on the switch). on, but does not reach the • Service switches are not idle state 2.
  • Page 82 Suggested action System problems Clock is slow; time listed One of the following: 1. Replace the battery on the motherboard, and then update the time in E100 Setup. on Configuration page • Missing or dead battery is earlier or later than...
  • Page 83 System software installation USB flash drive method: One of the following: 1. Make sure that E100 service switch 1 is set to ON and service switch 2 is set to OFF. E100 remains on for • Service switches are set...
  • Page 84 If you suspect a network problem, keep in mind the following: • If the E100 does not appear in the list of printers on the network, there may be another device on the network with the same Ethernet hardware address.
  • Page 85 (seems to hang) and • Normal behavior Configuration page 2. If neither LED on the designated Ethernet port is lit on the E100, check the System is searching for displays an error on cable connection to the E100 and the network. Make sure that the cable is a non-existent DHCP the “IP Address”...
  • Page 86 2. Check the copier touch panel for indications or messages about the copier status. A problem with the 1. Make sure that the E100 power button LED is lit. If not, press and hold the power button for a few seconds to turn on the E100. connection between the E100 and the copier 2.
  • Page 87 2. If restoring default calibration fixes the color quality, the custom calibration may have been the cause of the problem. Ask the site administrator to recalibrate the E100. For details, see Color Printing, which is part of the user documentation set.
  • Page 88 Possible cause Suggested action Printing (continued) Pages come out blank, Loose cable connection 1. Recheck the copier interface cable and connection at the E100 and the copier. or tinted with green between the E100 and the or some other color copier 2.

  • Page 89: Index

    CMOS 39 enclosed 18 clock 82 Fiery controller CMOS, clearing 39 opening 17 configuration Fiery System Software Installer 59 restoring 68 flash drive, preparing 29 Configuration page 19 fonts connecting to the network 20 archiving and restoring 58...
  • Page 90 34 USB devices 61 DIMM 38 USB dongles 61 DIMMs 23 USB flash drive opening the Fiery controller 17 preparing with system software 62 USB Prep Tool CD 62 pin assignments 51 PLCC32 socket 25 voltages 51 power...

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