Tektronix Phaser 440 Service Manual
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Tektronix Phaser 440 Service Manual

Tektronix Phaser 440 Service Manual

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Service Manual

Phaser
440
™
Color Printer
Warning
The following servicing instructions are for
use by qualified service personnel only. To
avoid personal injury, do not perform any
servicing other than that contained in
operating instructions unless you are qualified
to do so.
This printing
May 1995
070-9015-01

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Summary of Contents for Tektronix Phaser 440

  • Page 1: Service Manual

    Service Manual Phaser ™ Color Printer Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in operating instructions unless you are qualified to do so. This printing May 1995 070-9015-01...
  • Page 2 Tektronix, Inc., Wilsonville, Oregon. Printed in the United States of America. All rights reserved. Contents of this publication may not be reproduced in any form without permission of Tektronix, Inc. This instrument, in whole or in part, may be protected by one or more U.S. or foreign patents or patent applications.

  • Page 3: Users Safety Summary

    Users safety summary Terms in manual: CAUTION Conditions that can result in damage to the product. WARNING Conditions that can result in personal injury or loss of life. Power source: Do not apply more than 250 volts RMS between the supply conductors or between either supply conductor and ground.
  • Page 4 Service safety summary For qualified service personnel only: Refer also to the preceding Users Safety Summary. Do not service alone: Do not perform internal service or adjustment of this product unless another person capable of rendering first aid or resuscitation is present. Use care when servicing with power on: Dangerous voltages may exist at several points in this product.

  • Page 5: Table Of Contents

    Contents General Information Phaser 440 overview 1-2 Dye sublimation printing 1-2 Print engine assemblies 1-3 Printer image processor board 1-5 Combination sensors and their meanings 1-6 Transfer roll type sensing 1-6 Media tray type sensing 1-7 Rear panel 1-8 Front panel 1-10...
  • Page 6 Connecting the printer to a workstation 2-10 Direct connection to a workstation 2-10 Networked connection to a workstation 2-10 Installing a SCSI hard disk drive on a Phaser 440 2-11 Turning on the printer 2-12 The startup page 2-12 The configuration page 2-13...
  • Page 7 Verifying the Printer and Host Connections Verifying printing from a Macintosh 3-1 Selecting the printer via the Chooser 3-1 Print the directory from Macintosh 3-2 Verifying that an application communicates to the printer 3-3 Using the Error Handler utility 3-3 Verifying printing from a PC 3-4 DOS connection verification 3-4 Windows 3.1 driver verification 3-4...
  • Page 8 Verifying print engine operation by using its self-test print 6-3 Verifying power supply operation 6-3 Measuring power supply voltages 6-3 Inspecting the power supply fuses 6-5 Testing for a shorted motor 6-6 +24 VDC safety interlocks 6-6 Testing motor resistances 6-8 viii Phaser 440 Color Printer...
  • Page 9 Macintosh printing problems 6-25 PC DOS printing problems 6-26 Windows printing problems 6-28 Workstation printing problems 6-29 Phaser 440 image processor 6-30 Image processor normal operation indicators 6-30 Image processor hard and soft error indicators 6-30 Verifying the image processor's operation 6-30...
  • Page 10 Paper-pass sensor 1 and paper-empty sensor 8-31 Paper clamp sensor 2 8-31 Thermal head position sensors 8-31 Transfer roll mark sensors 8-31 Tray sensor circuit board 8-32 Paper-pass sensor 2 8-33 Paper clamp sensor 1 8-35 Card cage and power supply 8-36 Phaser 440 Color Printer...
  • Page 11 Circuit boards 8-38 Power supply circuit board 8-38 Engine control board 8-40 Paper-feed circuit board 8-41 Card cage interconnect board 8-42 I/O board 8-43 Image processor board 8-44 RAM SIMM 8-45 Ethernet card 8-46 Checks and Adjustments Required tools summary 9-1 Printing test patterns 9-2 Printer self-checks 9-4 Thermal head motor check 9-5...
  • Page 12 Figures Figure 1-1 The Phaser 440 printer (shown with the Lower Tray Assembly) 1-1 Figure 1-2 Internal features of the Phaser 440 print engine 1-3 Figure 1-3 Sensors and switches on the Phaser 440 print engine 1-4 Figure 1-4 Features of the Phaser 440 image processor board 1-5...
  • Page 13 Figure 8-5 Removing the paper-feed unit screws 8-8 Figure 8-6 Separating the paper-feed unit 8-9 Figure 8-7 Removing the pick roller and clutch 8-10 Figure 8-8 Removing the paper-empty flag 8-11 Figure 8-9 Removing the lower aligning roller 8-12 Figure 8-10 Removing the paper-pass sensor 1 flag 8-13 Figure 8-11 Removing the upper aligning roller 8-14...
  • Page 14 Saturation dither pattern B-2 Figure B-3 Wrinkle pattern B-3 Figure C-1 Print engine control board connector diagram C-4 Figure C-2 Print engine wiring diagram C-5 Figure D-1 Plugging the Test Pattern Generator into the printer's parallel port D-2 Phaser 440 Color Printer...
  • Page 15 Tray switch sensor combinations (main engine feeder) 1-7 Table 1-3 Tray switch sensor combinations (Lower Tray Assembly) 1-7 Table 1-4 Phaser 440 rear panel DIP Switches 1-9 Table 1-5 Service mode error code summary 1-11 Table 1-6 Physical dimensions 1-12...
  • Page 16 Connector CN3 C-1 Table C-3 Table C-4 Connector CN5 C-2 Table C-5 Connector CN6 C-2 Connector CN7 C-3 Table C-6 Connector CN8 C-3 Table C-7 Table D-1 Test Pattern Generator DIP Switch settings for Phaser 440 D-3 Phaser 440 Color Printer...

  • Page 17: General Information

    FRU list. To ensure complete understanding of the product, we recommend participation in Phaser 440 service training, if available. 8699-01 Figure 1-1 The Phaser 440 printer (shown with the Lower Tray Assembly) Service Manual...

  • Page 18: Phaser 440 Overview

    General Information Phaser 440 overview The Phaser 440 Color Printer is an Adobe PostScript Level 2 (version 1.3) color, dye sublimation printer with Tektronix color matching extensions (TekColor 3.0). Printing at an addressability of 300 dots-per-inch, the printer features a single paper tray (Universal size) that holds A, A4, and Letter Extra media with an optional Lower Tray Assembly (A or A4 only) which gives the printer a dual-tray capability.

  • Page 19: Print Engine Assemblies

    Engine control board Lower exit roller Paper-feed module Interconnect board Feed roller Drum motor Drum belt Power supply Paper-feed motor Transfer roll take-up motor Pick roller Print-feed circuit board 9015-11 Figure 1-2 Internal features of the Phaser 440 print engine Service Manual...

  • Page 20: Figure 1-3 Sensors And Switches On The Phaser 440 Print Engine

    (3) Top-cover- Paper-exit sensor Paper clamp open sensor sensor 1 Front-cover-open sensor Paper-empty Aligning roller Paper-pass sensor solenoid sensor (1) Paper-pick solenoid 9015-01 Figure 1-3 Sensors and switches on the Phaser 440 print engine Phaser 440 Color Printer...

  • Page 21: Printer Image Processor Board

    General Information Printer image processor board RAM SIMM µp Ethernet card I/O interconnect cables 9015-03 Figure 1-4 Features of the Phaser 440 image processor board Service Manual...

  • Page 22: Combination Sensors And Their Meanings

    General Information Combination sensors and their meanings Combinations of sensors are used by the Phaser 440 print engine to determine the type of transfer roll and the type of media tray installed in the printer. Transfer roll type sensing The combinations of the three transfer roll core sensors “tell” the print engine what type of transfer roll is installed.

  • Page 23: Media Tray Type Sensing

    General Information Media tray type sensing The combinations of the three tray sensors “tell” the Phaser 440 print engine what type of paper tray is installed. (The print engine does not detect the type of media installed in the tray; it only detects the particular tray being used.) The tray sensors are located on the right-side interior of the paper tray slot.

  • Page 24: Rear Panel

    General Information Rear panel Connectors The rear panel of the Phaser 440 printer features the host interface connectors to the printer. It includes the following connectors: Standard parallel RS-232 serial LocalTalk SCSI (font hard disk drive only) Ethernet The Phaser 440 rear panel also features DIP switches to control certain aspects of the printer’s imaging.

  • Page 25: Figure 1-5 Phaser 440 Rear Panel

    General Information The following figures illustrate the rear panel of the Phaser 440. 2 3 4 Reset Skip 1200 Diagnostics Start Job Baud Rate Color Correction Variable SCSI Disk See User Manual Status Ethernet ® Parallel LocalTalk ® Serial Not Installed...

  • Page 26: Front Panel

    ERROR: On indicates a hardware engine error has occurred. Blinking indicates a data processing error has occurred with the image processor board. ERROR MEDIA RIBBON COVER READY POWER Figure 1-6 Phaser 440 front panel 1-10 Phaser 440 Color Printer...

  • Page 27: Front Panel Led Service Mode Error Codes

    General Information Front panel LED service mode error codes Detected error conditions in the print engine are displayed on the front panel as LED patterns. The following table lists the service mode error codes which are displayed while the printer is in service mode. (Service mode is explained in Chapter 9, “Checks and Adjustments.”) These codes are more specific than the error codes displayed during normal operation (see the previous topic “Rear panel”).

  • Page 28: Specifications

    General Information Specifications These specifications apply to the Phaser 440 printer. Table 1-6 Physical dimensions Dimensions Value Height: 28 cm. (11 ins.) 37 cm (14.5 ins.) with Lower Tray Assembly Width: 342 cm (13.4 ins.) Depth: 42.5 cm (16.7 ins.) Weight: Approximately 18 kgs (40 lbs).
  • Page 29 General Information Table 1-8 Functional specifications Characteristic Specification Printing process Sequential dye sublimation transfer printing. Transfer rolls Dye-impregnated transfer rolls. The printer automatically senses the transfer roll type by the combination of lengths (short or long) on the transfer roll cores. 3-Color Transfer Roll features sequential bands of yellow, magenta, and cyan;...

  • Page 30: Table 1-9 Electrical Specifications

    VH – thermal head voltage (9.5 V to 18.5 V variable) RF emissions Both 115 and 220 VAC-configured instruments pass these standards: FCC Part 15 Class A EN55022 (CISPR 22) Class B VCCI (CISPR 22) Class B 1-14 Phaser 440 Color Printer...
  • Page 31 General Information Table 1-10 Environmental specifications Characteristic Specification Temperature ° ° Operating to 30 C (59 to 86 ° ° ° Non-operating to 40 C (32 to 104 (power off) ° ° Storage to 60 C (-4 to 140 (without transfer roll) Humidity Operating 10 to 80% relative humidity, non-condensing...

  • Page 32: Regulatory Specifications

    General Information Regulatory specifications The Phaser 440 printer is a recognized component in conformance with the following regulatory standards: FCC Part 15 Class B (for 115 VAC equipment) EN55022 (CISPR 22) Class B VCCI (CISPR 22) Class B The packaged product meets National Safe Transit Committee Test...

  • Page 33: Service Manual

    Drivers This chapter discusses installing the printer and its drivers as a part of the S0 installation option. Tektronix Service Option S0 consists of three main functions detailed in this and the next two chapters of this manual: Chapter 2 “Installing the Printer and Drivers.” The first portion of installation instructions, this chapter, consists of five basic processes:...

  • Page 34: Pre-Install Questions For Customers

    Installing the Printer and Drivers Pre-install questions for customers Prior to installing a Phaser 440, you should contact the customer and verify that he or she has prepared an appropriate location for the printer. You will also want to ensure that you have all the information you need to install the printer at the customer's site.
  • Page 35 _______ Swiss Option A5 (161-0154-00) Customers must provide the particular interface cable or network adapter they need to use with the printer. Customers can purchase the following from the Tektronix Graphics Supplies Order Desk by calling 1-800-835-6100. 10 ft. parallel cable 012-1214-00 Serial, 25-pin to 25-pin, 3 m (10 ft.), null modem...
  • Page 36 750 kbyte hard disk space for files Based on the results of the pre-install interview with the customer, you may wish to access the Tektronix Highly Automated Library (HAL) during business hours, at 1-800-835-6100 (ask to be transferred to HAL) for articles that may help with installing the printer into a customer's network.

  • Page 37: Unpacking

    Installing the Printer and Drivers Unpacking Inventory for Phaser 440 printer Printer Universal paper tray Power cord Getting Started envelope Cleaning kit Supplies information sheet Sample transfer roll Paper sampler User manual Installation instructions Printer drivers and utilities reference manual...

  • Page 38: Figure 2-1 The Phaser 440 Packaging

    This prevents the bail rollers from “denting” the soft material of the drum. In normal operation, the paper clamp is automatically parked in this position when the printer is not printing. 8699-69 Figure 2-1 The Phaser 440 packaging Phaser 440 Color Printer...

  • Page 39: Figure 2-2 The Drum Shipping Blocks

    Installing the Printer and Drivers To protect the drum and side frame from damage during shipping, be sure to reinstall the drum shipping blocks on both sides of the drum. 9015-34 Figure 2-2 The drum shipping blocks Service Manual...

  • Page 40: Setting Up The Printer

    Installing the Printer and Drivers Setting up the printer Installing the printer is explained in detail in the Phaser 440 Color Printer User Manual . The following is a brief list of the steps you follow to unpack and set up the printer.

  • Page 41: Cabling The Printer

    This topic explains making a hardware connection between a Phaser 440 and its host computer, setting the communication parameters for the printer's serial and parallel ports to be compatible with the user's host computer and driver installation.

  • Page 42: Connecting The Printer To A Pc

    In the case of an Ethernet network, connect the interface cable to the printer’s Ethernet AAUI connector. You will need to use a network transceiver on the end of the interface cable to adapt it to the AAUI connector. Turn on the printer. 2-10 Phaser 440 Color Printer...

  • Page 43: Installing A Scsi Hard Disk Drive On A Phaser 440

    MODEL 4681 PXi SCSI SCSI Figure 2-3 Connecting a SCSI hard disk drive to a Phaser 440 Turn on the disk drive first, and then the printer. Refer to the Phaser 440 Driver and Utilities Printing Reference for details on formatting a SCSI disk, controlling Sys/Start job files, and using the LaserWriter Utility to load fonts onto the disk drive.

  • Page 44: Turning On The Printer

    Turning on the printer The startup page When you turn on a Phaser 440 printer, it executes a series of self-tests to determine if there are any problems with the PostScript interface. After running self-tests, the printer prints a startup page if it has been enabled.
  • Page 45 Saved Default Limits or alternate choices NVRAM Printer type The name of the product Phaser 440 Printer name The current name of the printer as <printer name> Any name defined by the user seen on a network the default is the...
  • Page 46 19200, 9600, 4800, 2400 Serial port Hardware or software flagging XonXoff DTR, DTR low, Etx Ack, flagging Robust Xon Xoff, Xon Xoff2 Serial port Parity check encoding method None Space, Even, Odd, Mark check parity 2-14 Phaser 440 Color Printer...
  • Page 47 NetWare port Indicates the type of interpreters in use Auto Select Disabled, <interpreter> interpreter at the port (Phaser 440 only) Strip control Also known as filtering; “Yes” means Yes, No characters Adobe intelligent selection routines are...
  • Page 48 AppSocket Strip Set whether lpr will filter out CTRL-D Yes (interpreter-based) Control characters from print jobs Characters AppSocket Port number for bi-directional 9100 1024 through 65535 Data Port transmission of printer language jobs Number 2-16 Phaser 440 Color Printer...
  • Page 49 Simple Network Management Protocol (SNMP) utilities System name Printer name Phaser 440 String of 0 to 255 characters System contact name and phone number or address of String of 0 to 255 characters person responsible for the printer...
  • Page 50 If true, data parity should be checked False True Disk Address SCSI address of disk for the SCSI 0 to 7 communication channel Printer address SCSI address of printer when it is the 0 to 7 initiator 2-18 Phaser 440 Color Printer...

  • Page 51: Driver And Communication Setup

    Turn off any anti-virus software running on the Macintosh before installing the Tektronix software. A Phaser 440 printer uses the Adobe PostScript Level 2 language. To take advantage of the Level 2 features, Tektronix developed the Tektronix Phaser driver which appears in the Chooser, along with the LaserWriter 7.0.x driver.

  • Page 52: Installing The Tektronix Driver For Windows 3.1

    2-21. If you have other Tektronix printer drivers already installed If you still have an earlier version of the Tektronix Windows driver, you can use the INSTALL.EXE program on that diskette to remove the older driver software.

  • Page 53: Configuring The Tektronix Windows Printer Driver

    Drivers and Utilities Printing Reference to delete the files. When you are finished removing the old driver files, restart Windows. Go on to the topic “Installing the Tektronix driver” in this chapter, to install all of your Tektronix printers with the latest driver software.
  • Page 54 This option is only available to applications that use this Tektronix driver with Tektronix PostScript Level 2 printers. When this box is checked, the Compress Bitmaps option is unavailable (grayed out).

  • Page 55: Updating The Standard Microsoft Windows Postscript Driver

    This update procedure provides printer page size information for applications within Windows using the standard driver. However, color adjustments and other PostScript Level 2 features are available only with the Tektronix Windows 3.1 driver and are not supported by the standard driver.
  • Page 56 Using the scroll bars, move down through the alphabetical listing until you find the selection PSCRIPT.Tektronix Phaser 440. Click on the correct printer name and then click on Install. The system will install your printer driver. Click OK.
  • Page 57 Select Options and make sure that it is set to Phaser 440. If not, repeat the previous steps. While in this screen, set Job and Wait to 0, if they aren't already. Select the Output Tab. Ensure that the proper port is selected.

  • Page 58: Configuring The Printer's Serial Port For A Pc

    /Baud 9600 >> setdevparams ) if CTRL-D When you change the settings for the serial port, the baud rate DIP Switch 7 on the printer's back panel must be down before the changes will take effect. 2-26 Phaser 440 Color Printer...
  • Page 59 Installing the Printer and Drivers Use a text editor or word processor to modify the DEVPARAMS.PS file. (Be sure to save the file as a text-only file.) Substitute the values you want for the values used in the sample DEVPARAM.PS file. The possible values for each parameter are listed in the following table.

  • Page 60: Using Printcap To Configure A Unix Workstation For The Printer's Serial Port

    /bin/cat Give the if file executable permission, type: chmod +x if If communication to the serial port uses 7 data bits, the value for xs changes as follows. All other setup parameters remain the same. 2-28 Phaser 440 Color Printer...

  • Page 61: Configuring A Novell Netware Server For The Printer

    Installing the Printer and Drivers px:\ :br#9600:rw:\ :fc#00000374:fs#00000003:\ :xc#0:xs#0040040:\ :mx#0:sf:sh:\ :sd=/var/spool/px:\ :if=/var/spool/px/if:\ :lp=/dev/ttya: To print a PostScript file type: lpr -Ppx filename Configuring a Novell NetWare server for the printer This is a brief overview of the steps you follow to configure a Novell NetWare file server and to set up a print queue to support the printer on a Novell network.

  • Page 62: Configuring Tcp/Ip

    AppSocket, the printer language(s) supported by the printer (if the customer site uses AppSocket). syslog, a system’s log collect printer information for the network administrator. SNMP (Simple Network Management Protocol), allows the system administrator to query and control the printer’s status remotely. 2-30 Phaser 440 Color Printer...

  • Page 63: Verifying The Printer And Host Connections

    Displayed on the right side of the dialog box are a list of printers that the selected driver will print to. Select the newly installed printer Phaser 440 . (If, for example, a Phaser 440 is already on the network with the name Phaser 440 , then the newly installed printer will be named Phaser 4401 .)

  • Page 64: Print The Directory From Macintosh

    Close the Chooser by clicking on the small box in the upper-left corner of the dialog box. The Phaser 440 is now your chosen printer. You have now verified that the printer is on the network and is communicating with the Macintosh.

  • Page 65: Verifying That An Application Communicates To The Printer

    Contact the Customer Support Hotline at 1-800-835-6100. Refer to the appropriate reference manual for your printer: the Phaser 440 Drivers and Utilities Printing Reference . Each provides information on using the printer with specific applications.

  • Page 66: Verifying Printing From A Pc

    Type in a line of text such as THIS IS A TEST . Click the File menu item and select Printer Setup... from the menu list. Select Phaser 440 , whichever applies) from the displayed list of available printer drivers. Click OK .

  • Page 67: Os/2 Connection Verification

    (Point to any printer object, click the right mouse button, click on Select Default, and click on Phaser 440.) This is a simple way to be sure that all printers are set up correctly. Service Manual...

  • Page 68: Novell Netware Verification

    files created and sent for printing from other workstations on the network. The printer, in turn, finds all file servers with Phaser 440 queues and extracts its print files from them. You must determine if a station can communicate a print file to the file server.

  • Page 69: Using The Error Handler Utility

    Verifying the Printer and Host Connections Using the Error Handler utility If a PC has trouble printing directly to the printer, download one of the Tek Error Handler utility files to the printer. Locate the TEKEHAND.PS file in the PHSR440 directory on the Printer Utility diskette.

  • Page 70: Verifying Printing From A Workstation

    Verifying printing from a workstation Verifying and printing using the TCP/IP protocols The Phaser 440 accepts files from networked UNIX and VMS workstations using TCP/IP communications. The printer supports BSD UNIX 4.3, AT&T's UNIX System V with BSD 4.3 lpr extensions, and DEC VMS with Tektronix PhaserSym software.

  • Page 71: Using The Error Handler Utility

    Verifying the Printer and Host Connections To print to the Phaser 440 in the VMS environment, you must have the symbiont PhaserSym running on the host. To print to the printer from the host, you must first have the printer’s queue established. This is site-dependent and requires the aid of the site’s network administrator.

  • Page 73: Key Operator Training

    Chapter Key Operator Training This chapter covers the last portion of the Tektronix Service Option S0 installation: training the printer's key operator. The steps you follow here place an emphasis on encouraging the key operator to read and use the printer's user manual and to clean and care for the printer.

  • Page 74: Printer Controls And Indicators

    You can open the top cover, and then press the TEST button, to demonstrate an error condition. Show where the TEST button is explained in the user manual. Phaser 440 Color Printer...

  • Page 75: Loading Media

    Key Operator Training Loading media Paper/transparency: Demonstrate how to load paper or transparency film into a paper tray. Emphasize to the customers not to touch the printing surface of the media; handle it by the edges only. Fingerprints can affect print quality.

  • Page 76: Clearing Paper Jams

    Exit (exit jams): Show how you open the front cover to clear an exit jam. Show where this is explained in the user manual. Warranty information Review the warranty information with customers to ensure that they are aware of the printer's warranty and the duration of its coverage. Phaser 440 Color Printer...

  • Page 77: Supplies Ordering

    Graphics Supplies Order Desk) to place a supplies order. Open Monday through Friday, 6:00 am to 5:00 pm (PST). Shipments are made within 24 hours. Outside the United States: Contact your nearest Tektronix dealer. If you need help HAL information system As an alternative to using the Customer Support Hotline, customers can call the Highly Automated Library (HAL).

  • Page 78: Customer Support Hotline

    Tektronix drivers and software. To connect to the BBS phone, call (503) 685-4504 and use 9600 baud, 8 bits, 1 stop bit, and no parity.

  • Page 79: Theory Of Operation

    Chapter Theory of Operation This chapter provides a high-level description of the sublimation dye transfer printing technology and how the printer employs it. Following that is a high-level discussion of the image processor board and how it receives data from a host computer and transforms it into data for the print engine. Service Manual...

  • Page 80: Print Engine

    After the three passes, the finished copy is ejected from the printer. The dye transfer roll is supplied on one spool, feeds past the thermal head and drum for printing, and collects on a take-up spool. Phaser 440 Color Printer...

  • Page 81: Continuous-Tone Printing

    Theory of Operation Continuous-tone printing The dye sublimation process can overlay precise amounts of dye onto each printer dot with much more precision than its cousin, the thermal-wax printer. Consequently, each dot is the exact color it should be, not an approximation. This results in what is called continuous-tone printing.

  • Page 82: Image Data

    Theory of Operation Image data A Phaser 440 print engine must receive data in a specific format to correctly print the image that the data represents. The printer's image processor board must convert the data into the correct format. The following topics describe some of the data formatting that the host or the interface module must perform.

  • Page 83: Engine Control Board Block Description

    Theory of Operation Engine control board block description The engine control board receives color bitmaps from the image processor board. It also controls the print engine's printing process, including all motors, sensors, and the thermal head. The block diagram shown in Figure 5-2 illustrates the functional operation of the print engine control board.

  • Page 84: Cpu

    Theory of Operation Phaser 440 print engine CPUs consist of a microprocessor, ROM, RAM and a clock circuit. The CPU is the heart of the print engine. It controls the timing controller, the mechanical controller, and print engine diagnostics. Interface buffers...

  • Page 85: Thermal Head Controller

    Theory of Operation Thermal head controller The thermal head controller uses the information received from the heat controller, in conjunction with timing signals, to drive the thermal head with the data stored in the line memory buffer. The head controller generates several different strobes.

  • Page 86: Paper Path In Operation

    Lower Tray Assembly. Picking paper in a manner identical to the printer's paper-feed unit, the Lower Tray Assembly's front door routes the sheet of paper to the feed roller in the paper-feed unit. Phaser 440 Color Printer...

  • Page 87: Figure 5-3 The Paper Pick Process

    Theory of Operation Caution Never rotate the pick rollers in the reverse direction or you may damage them. Path from Aligning Feed paper tray roller Paper- Paper- roller Path from pass pass second sensor 2 sensor 1 feeder paper tray Pick-up rollers Paper...

  • Page 88: Drum Loading

    2 Aligning roller Paper Paper clamp opens as it pushes Drum stop against stop (attached to engine frame, not drum) 8699-11A Figure 5-4 Paper clamp opening to receive a sheet of paper 5-10 Phaser 440 Color Printer...

  • Page 89: Figure 5-5 Clamping The Paper

    Theory of Operation The drum slowly rotates forward (clockwise, viewed from the left side), automatically closing the spring-loaded clamp until the paper-clamp sensor 1 detects the paper loaded in the clamp, and then speeds up to draw more of the paper around the drum.

  • Page 90: Printing

    (During forward rotation, the drum stops are simply pushed out of the way. The drum stops can only open the clamp during reverse drum rotation.) 5-12 Phaser 440 Color Printer...

  • Page 91: Print Unloading

    Theory of Operation The Phaser 440 does not reverse the drum to “back up” the print to the start position for each pass during printing. This is one of the reasons for the Phaser 440's fast print times. Between passes,...

  • Page 92: Power Supply

    The voltage is varies based on several factors including: media selected, thermal head temperature, and ambient temperature. An externally accessible switch allows you to select from line voltages of 115 VAC and 220 VAC. 5-14 Phaser 440 Color Printer...

  • Page 93: Figure 5-10 Power Supply Block Diagram

    Theory of Operation Fusing is provided by two in-line fuses on the AC input line. Overvoltage protection for the VH, +24 VDC and +5 VDC supplied is provided by a “crowbar” circuit formed by a Zener diode and an SCR. VH overcurrent is sensed and regulated by altering the oscillations of the pulse-width-modulator that generates the voltage.

  • Page 94: Image Processor

    Color planes are bitmaps of the primary colors cyan, magenta and yellow that make up the image. The engine driver outputs the color bitmaps to the print engine. It handles the data transfer buffering and basic input/output functions. 5-16 Phaser 440 Color Printer...

  • Page 95: Figure 5-11 The Image Processor Graphics Pipeline

    Theory of Operation The control loop , which oversees the operation of the graphics pipeline, routes the color planes to the engine driver that transmits the color plane data to the print engine. The control loop also monitors the control and error signals fed back from the print engine. Control loop Local- LocalTalk...

  • Page 97: Troubleshooting

    Chapter Troubleshooting This chapter discusses troubleshooting a Phaser 440 printer. Troubleshooting is discussed with two approaches: A step-by-step verification procedure that systematically confirms that particular components of a printer are properly functioning until a problem is found. A symptom/cause scheme that lists particular printer failures and error codes and their possible causes.

  • Page 98: Print Engine Troubleshooting

    In this case, the printer should be able to print from another port, except the non-functioning port.) Phaser 440 Color Printer...

  • Page 99: Verifying Print Engine Operation By Using Its Self-Test Print

    Troubleshooting If the printer does not print a test pattern, then a problem exists with the printer's image processor board or the print engine. Proceed with the topic “Verifying print engine operation by using its self-test print” on the next page. Verifying print engine operation by using its self-test print If not already on, turn on the printer.

  • Page 100: Figure 6-1 Measuring The Dc Voltages (Test Points)

    If the +5 VDC and +24 VDC voltages measure correctly, but the printer does not operate correctly, then proceed to the procedure “+24 VDC safety interlocks.” CN 5 Pin 10 GND Pin 2 +24 VDC Pin 15 +5 VDC 9015-33 Figure 6-1 Measuring the DC voltages (test points) Phaser 440 Color Printer...

  • Page 101: Inspecting The Power Supply Fuses

    Troubleshooting Inspecting the power supply fuses Four fuses are mounted on the power supply. Refer to the Chapter 8 topic “Card cage and power supply” on page 8-36 for the procedure to follow to access the fuses. Visually, and with a VOM, check to determine that the fuses are good. If the fuses are good, but the printer's power supply does not output DC voltages, proceed to the topic “Testing for a shorted motor”...

  • Page 102: Testing For A Shorted Motor

    If you find a switch that does not function correctly, replace it. If the switches work correctly and the DC voltages are correct, then the problem may be an opened or otherwise bad motor. Proceed to the topic “Testing motor resistances” on page 6-8. Phaser 440 Color Printer...

  • Page 103: Figure 6-3 24 Vdc Safety Interlocks (Top And Front Covers)

    Troubleshooting If motor resistances are correct, replace the engine control board. Refer to the Chapter 8 topic “Engine control board” on page 8-40. Top cover Front cover interlock interlock 8345-21 Figure 6-3 24 VDC safety interlocks (top and front covers) Service Manual...

  • Page 104: Testing Motor Resistances

    Ensure that the correct media is in the correct paper tray. The tray indicates the size and the type of media loaded in the tray; the printer does not directly sense the size or type of media. Phaser 440 Color Printer...

  • Page 105: Paper-Pick Errors

    Troubleshooting Paper-pick errors Paper-pick errors occur when the media in the paper tray mis-picks or the printer double-picks two sheets of paper. Clean the interior of the paper tray. When installing paper, push the stack of paper down until the tray's lift-plate locks to the bottom of the tray.

  • Page 106: Paper-Clamping Errors

    Inspect the idler rollers on the inside of the top-front cabinet panel; they should rotate freely. Check that the exit roller rotates smoothly and that the front cover is fully closed and seated. Check the paper eject path for obstructions. 6-10 Phaser 440 Color Printer...

  • Page 107: Checking The Paper-Feed Motor And Drive Train

    Troubleshooting Checking the paper-feed motor and drive train Determine if the paper-feed motor runs. If it does not rotate, go to Step 2. If it does rotate, go to Step 5. Ensure that the top and front cover safety interlock switches are closed and operating correctly.

  • Page 108: Media Skews Passing Through The Paper Path

    Ensure that the motor operates correctly and that its gear, which meshes with the take-up roll is mounted securely to the shaft of the take-up motor. Check the transfer roll gear train for smooth operation. 6-12 Phaser 440 Color Printer...

  • Page 109: Printing And Print Quality Problems

    Troubleshooting Printing and print quality problems Required tools #1 POSIDRIV® screwdriver Volt-ohm - meter (VOM) Print problems fall into the following five categories: Streaks or lines in the prints No printing Printing too light or too dark Image is offset or cut off Wrinkling Streaks or lines in the print parallel to the long axis of printing Clean the thermal head.

  • Page 110: White Portion Of Print Is Colored

    The set screws should be driven against the flat cutouts in the drum shaft. Ensure that one of the set screws fits into a countersunk recess in its flat cutout. Refer to the Section 8 topic “Drum” on page 8-20 6-14 Phaser 440 Color Printer...

  • Page 111: Not Printing

    Troubleshooting Be sure that the thermal head leaf spring (which presses against the right end of the thermal head when it's in its print position) is in good contact with the thermal head. If it isn't, bend the leaf spring until it makes good contact and keeps the thermal head from making any side-to-side motion during printing.

  • Page 112: Printing Too Light Or Too Dark

    Refer to the Chapter 8 topic “Engine control board” on page 8-40. Image is offset or cut off Check the application for the correct image sizing. Ensure that Letter, A4 or Letter Extra is the selected paper size. 6-16 Phaser 440 Color Printer...

  • Page 113: Wrinkling

    Troubleshooting Wrinkling An example of wrinkling is shown in Appendix B “Color Test Patterns.” Wrinkling occurs when the transfer roll is not maintaining smooth, even contact between the thermal head and the paper; instead, it is wrinkling and rippling. Clean the thermal head. Refer to the Chapter 7 topic “Cleaning.” If necessary, use the service cleaning kit (order number 016-1058-02) to “deep clean”...

  • Page 114: Print Engine Self-Diagnostics

    Table 6-2 Decoding the front panel display ERROR PAPER TRANSFER COVER READY POWER ROLL Always on Example: equals hex code means light is on in normal operation, or blinking in service mode. ERROR MEDIA RIBBON COVER READY POWER 6-18 Phaser 440 Color Printer...

  • Page 115: Problems And Solutions

    Troubleshooting Problems and solutions Print engine error codes and their causes These are the error codes displayed in service mode and their possible causes. These codes can also be displayed in normal mode, after an error occurs, when you press the TEST button. Table 6-3 Print engine error codes and their meanings Code Meaning...
  • Page 116 Refer to the topic roll jam. “Switch and interrupt sensor checks” on page 9-12 in Chapter 9, “Checks and Adjustments.” Check the transfer roll mark sensors and transfer roll motor for proper operation. 6-20 Phaser 440 Color Printer...
  • Page 117 Troubleshooting Table 6-3 Print engine error codes and their meanings (cont'd.) Code Meaning Check to see if the transfer roll is missing If not, check the Hex Code 13 No sensor and its wiring harness. Refer to the topic “Switch and transfer roll installed.
  • Page 118 The actual paper size is not sensed by the print engine. Ensure that paper-pass sensors 1 and 2 are operational and properly adjusted. Refer to the topic “Switch and interrupt sensor checks” on page 9-12. 6-22 Phaser 440 Color Printer...
  • Page 119 Troubleshooting Table 6-3 Print engine error codes and their meanings (cont'd.) Code Meaning o o o Check the paper-exit rollers for proper smooth operation. Hex Code 28 Paper eject sensor failed to Check for blockage at the paper-exit sensor or paper tray. turn off.

  • Page 120: Power Problems

    Run a sensor test. Refer to the Chapter 9 topic “Calibrating the reflective sensors” on page 9-15. If they continue to fail, the sensors or the sensor wiring are probably defective. 6-24 Phaser 440 Color Printer...

  • Page 121: Macintosh Printing Problems

    Troubleshooting Macintosh printing problems Table 6-6 Macintosh printing problems Image never prints. Make sure that the correct Phaser 440 icon was selected in Printer READY light the Chooser. Try printing the job again. flashes as if receiving data, but nothing comes In the Chooser, switch background printing to off .

  • Page 122: Pc Dos Printing Problems

    PostScript mode. Use the utility located on the Tektronix diskettes to change language emulation. Refer to the Phaser 440 Drivers and Utilities Printing Reference for complete instructions. Download TEKEHAND.PS file located on the Tektronix Utilities diskette.
  • Page 123 Troubleshooting Table 6-7 PC DOS printing problems (cont'd.) The printer may invoke head temperature waits if it detects thermal head over- or under-temperature conditions. The READY light blinks during these waits. Service Manual 6-27...

  • Page 124: Windows Printing Problems

    (CMY), blue is often printed as purple. To adjust blue from within Microsoft Windows: Within the Tektronix PostScript Windows driver you have an option, Vivid Blue, that alters to blue colors that are appearing purple. To Access this option, select:...

  • Page 125: Workstation Printing Problems

    Troubleshooting Workstation printing problems Table 6-9 Workstation printing problems Image never prints. For serial or parallel printing. Ensure that the print file ends Printer READY light with a “CTRL-D” character. CTRL-D indicates the end-of-file flashes as if receiving which the printer responds to by closing host-to-printer data, but nothing comes communications and then processing and printing the file.

  • Page 126: Phaser 440 Image Processor

    Troubleshooting Phaser 440 image processor Image processor normal operation indicators There are three indications that the print engine and its image processor are powered-up and operating normally: the front panel POWER and READY indicators are on (steady) and the rear panel STATUS light is blinking.

  • Page 127: Image Processor Self-Diagnostics

    Troubleshooting Image processor self-diagnostics Image processor rear panel switches for self-testing The image processor features several self-diagnostic modes. The type of self-diagnostics run depend upon the position of rear panel DIP Switches 2, 3 and 4. The switch combinations are listed here. The selected self-diagnostics begin upon power-up or after a hardware reset (DIP Switch 1 is toggled).

  • Page 128: Resetting Nvram

    2-13 for an explanation of the configuration page. Resetting NVRAM Resetting NVRAM returns all the Phaser 440 image processor's parameters to factory defaults except the print count (of images processed through the image processor) and the Adobe firmware serial number.

  • Page 129: Cleaning And Maintenance

    Chapter Cleaning and Maintenance A Phaser 440 printer requires cleaning for optimum operation. Follow the printer cleaning, lubricating and inspecting procedures in this chapter for the best printer performance. Cleaning Tools and supplies required #1 POSIDRIV® screwdriver Lint-free cloth 600 grit sandpaper 90% pure isopropyl alcohol Generally, the following three steps are performed by the customer.

  • Page 130: Lubrication

    The springs are very noisy if they lose lubricant. Disassemble the clutch and lubricate the spring with grease. For reassembly, the spring catch fits into the center hole of the clutch sleeve. Phaser 440 Color Printer...

  • Page 131: Inspecting

    Cleaning and Maintenance The two clutches used in the printer look slightly different but function and are serviced in the same manner. Refer to the Section 8 topics “Paper-pick roller, clutch, and paper-empty flag” on page 8-10 and “Lower aligning roller, clutch, and paper-pass sensor 1 flag” on page 8-12 for the procedures on removing the clutches.

  • Page 132: Replacements

    Transfer roll take-up motor: Replace after 20,000 prints Paper feed motor: Replace the paper feed motor after 20,000 prints. Drum belt: Replace the drum belt after 20,000 prints. Torque limiter: Replace the transfer roll torque limiter after 20,000 prints. Phaser 440 Color Printer...
  • Page 133 #2 POSIDRIV® tip 003-0336-00 Tweezers 003-0236-00 Hex wrench kit 003-1344-00 G-311S lubricating grease 006-7436-00 Antistatic mat 006-7056-00 Flat-blade screwdriver Needle-nose pliers Volt-ohm-meter such as a Tektronix DM250 Multimeter Magnifying lens such as Micronta (Radio Shack) Cat# 63-851 Spring removal tool Service Manual...

  • Page 134: Fru Disassembly/Assembly

    Its construction and operation is very similar to the paper feed unit in the print engine. Turn off the printer. Unplug the Lower Tray Assembly cable from the rear of the printer. Lift the printer off of the Lower Tray Assembly. Phaser 440 Color Printer...

  • Page 135: Figure 8-1 Removing The Lower Tray Assembly

    FRU Disassembly/Assembly Reverse these steps to reinstall the Lower Tray Assembly making sure that the printer is fully seated over the Lower Tray Assembly's guide pins. 8699-56 Figure 8-1 Removing the Lower Tray Assembly Service Manual...

  • Page 136: Printer Cabinet Panels

    Front cover panel – first remove the front cover. Top cover panel (exit tray) – open the top cover and remove the two screws securing it to the thermal head frame. Do not overtighten the screws during reinstallation. Phaser 440 Color Printer...

  • Page 137: Figure 8-2 Removing The Cabinet Panels

    FRU Disassembly/Assembly Top rear Top access panel cover panel Right side panel Rear cabinet panel Top front access panel Left side panel Front access panel Front access cover panel Bottom cabinet panel 8699-57A Figure 8-2 Removing the cabinet panels Service Manual...

  • Page 138: Paper-Feed Module

    Remove the two screws securing the paper-feed module to the printer frame. Slide the module out. Reverse this procedure to reinstall the paper-feed module. Tray sensor assembly Upper aligning rollers Feed roller Paper-feed module 9015-12 Figure 8-3 Removing the paper-feed module Phaser 440 Color Printer...

  • Page 139: Accessing The Pick Roller, Aligning Roller, And The Lower Feed Roller

    FRU Disassembly/Assembly Accessing the pick roller, aligning roller, and the lower feed roller Power down the printer and remove the power cord. Remove the paper-feed module as explained in the previous procedure “Paper-feed module” on page 8-6. Remove the two screws securing the paper-feed circuit board to the paper-feed module.

  • Page 140: Figure 8-5 Removing The Paper-Feed Unit Screws

    (For reassembly, note the alignment pins in the top half and the receiving holes in the bottom half. Ensure that they properly line up during reassembly.) Paper-feed module upper half Paper-feed module bottom half 9015-14 Figure 8-5 Removing the paper-feed unit screws Phaser 440 Color Printer...

  • Page 141: Figure 8-6 Separating The Paper-Feed Unit

    FRU Disassembly/Assembly Separate the two halves and flip the upper half over to expose all the rollers. 9015-15 Figure 8-6 Separating the paper-feed unit At this point you can proceed to any of the individual roller removal procedures explained on the following pages. Service Manual...

  • Page 142: Paper-Pick Roller, Clutch, And Paper-Empty Flag

    Remove the two E-rings securing the pick roller to the upper half of the paper-feed module. Rotate and remove the paper-pick roller. Pick roller Pick roller clutch 8699-27 Figure 8-7 Removing the pick roller and clutch Remove the flag stop secured in place by one screw. 8-10 Phaser 440 Color Printer...
  • Page 143 FRU Disassembly/Assembly Rotate and remove the paper empty flag. Paper empty flag Flag stop 8699-70 Figure 8-8 Removing the paper-empty flag Service Manual 8-11...

  • Page 144: Lower Aligning Roller, Clutch, And Paper-Pass Sensor 1 Flag

    Remove the lower aligning roller. Be careful not to damage the paper-empty flag. Washer Aligning Lower aligning roller clutch roller Washer 8699-28 Figure 8-9 Removing the lower aligning roller 8-12 Phaser 440 Color Printer...
  • Page 145 FRU Disassembly/Assembly Paper-pass sensor 1 flag removal: Rotate the paper-pass sensor flag about 180 and slide it out of the paper feed unit. Paper-pass sensor 1 flag 8699-71 Figure 8-10 Removing the paper-pass sensor 1 flag Service Manual 8-13...

  • Page 146: Removing The Upper Aligning Roller

    Remove the two E-rings securing the upper aligning roller. Remove the aligning roller from the guide plate and bronze bushings. Guide plate Upper aligning roller 8699-29 Figure 8-11 Removing the upper aligning roller 8-14 Phaser 440 Color Printer...

  • Page 147: Removing The Feed Roller

    FRU Disassembly/Assembly Removing the feed roller If not already upright, flip over the upper half of the paper-feed unit to access the feed roller; refer to Figure 8-6. Remove the two E-rings securing the feed roller. Remove the white nylon gear and its pin. Remove the feed roller.

  • Page 148: Removing The Exit Rollers

    Also remove the E-ring securing the other end of the roller. Remove the upper exit roller pulley, roller and bushings. Reverse these steps to reinstall the exit rollers. Upper exit roller Lower exit roller 8345-31 Figure 8-13 Removing the exit rollers 8-16 Phaser 440 Color Printer...

  • Page 149: Bail Roller Assembly

    FRU Disassembly/Assembly Bail roller assembly Tools required #1 POSIDRIV® screwdriver Power down the printer and remove the power cord. Open the top access cover and remove the transfer roll. Remove the left and right side cabinet panels. Refer to the earlier topic “Printer cabinet panels”...

  • Page 150: Thermal Head

    Remove the two retainer screws (one at each end) of the thermal head frame. Lift and remove the thermal head. Retaining screw (2) Power and data wiring harness Thermal head Thermal head cover plate Remove springs 9015-04 Figure 8-15 Removing the thermal head 8-18 Phaser 440 Color Printer...
  • Page 151 FRU Disassembly/Assembly Disconnect the ground wire from the thermal head. Reverse these steps to reinstall the thermal head, then perform the Chapter 9 procedure “Adjusting for best print quality” on page 9-16. Route the ground wire and the head heater wiring harness behind the data and power wiring harnesses.

  • Page 152: Drum

    Remove the idler belt from the drum idler pulley and drum belt from the drum pulley. 8-20 Phaser 440 Color Printer...

  • Page 153: Figure 8-16 Removing The Drum Belt And Pulley

    FRU Disassembly/Assembly Use a 2 mm hex wrench to loosen the two set screws securing the drum pulley in place. Remove the drum pulley, spring and washers. Also, remove the drum shaft's brass bushing. (For reassembly, note the two keyed portions of the drum shaft that the drum pulley's set screws tighten into.) Drum belt tensioner...

  • Page 154: Figure 8-17 Removing The Front Idler Roller

    Remove the E-rings and bronze bushings from each end of the front idler roller. Remove the roller. Front Drum idler roller 8699-35 Figure 8-17 Removing the front idler roller Remove the bail roller assembly by removing the pair of screws at each end of the assembly. 8-22 Phaser 440 Color Printer...

  • Page 155: Figure 8-18 Removing The Drum's Right End Bushing

    FRU Disassembly/Assembly Remove the E-ring securing the right end of the drum's shaft to the print engine frame. Also, remove the shaft's bronze bushing. Drum Bail roller assembly 8699-36 Figure 8-18 Removing the drum's right end bushing Note During removal and replacement, be careful not to scratch or damage the drum.

  • Page 156: Figure 8-19 Removing The Drum

    Refer to the topic “Adjusting for best print quality” on page 9-16. If the belt is too loose, it will cause media pick and loading problems. Also adjust the drum’s paper clamp with the adjustments “Leading edge (top) margin adjustment” on page 9-10. 8-24 Phaser 440 Color Printer...

  • Page 157: Motors

    FRU Disassembly/Assembly Motors Paper-feed motor Tools required #1 POSIDRIV® screwdriver Power down the printer and remove the power cord. Remove the left side cabinet panel. Refer to the earlier topic “Printer cabinet panels” on page 8-4. Disconnect the wiring harness leading to the paper-feed motor. Remove the two screws securing the paper-feed motor to the print engine frame.

  • Page 158: Drum Motor

    Unclip the tensioner spring. Remove the drum motor belt from the drum motor shaft pulley. Remove the card cage as detailed in the later procedure “Card cage and power supply” on page 8-36. 8-26 Phaser 440 Color Printer...

  • Page 159: Figure 8-21 Removing The Drum Motor

    FRU Disassembly/Assembly Remove the four outer screws securing the drum motor to the print engine frame. one of the screws is the tensioner spring post. Reach in through the power supply cavity and remove the motor. Drum motor Drum motor belt Drum idler pulley 9015-17...

  • Page 160: Transfer Roll Take-Up Motor

    8-4. On the inside of the printer, loosen the transfer roll take-up gear's two set screws. Remove the gear. Gear, reverse side Transfer roll take-up gear 8699-47 Figure 8-22 Removing the transfer roll take-up gear 8-28 Phaser 440 Color Printer...

  • Page 161: Figure 8-23 Removing The Transfer Roll Take-Up Motor

    FRU Disassembly/Assembly On the outside of the printer, disconnect the wiring harness leading to the transfer roll take-up motor. Remove the two screws securing the transfer roll take-up motor to the print engine frame. Remove the motor. Transfer roll take-up motor 9015-39 Figure 8-23 Removing the transfer roll take-up motor Reverse these steps to reinstall the transfer roll take-up motor.

  • Page 162: Thermal Head Lift Motor

    9 topic “Head lift motor belt tension adjustment” on page 9-23 to properly tension the head lift motor belt. Right fan Left fan Set screw Head lift motor bracket Head lift motor Head lift motor belt 9015-19 Figure 8-24 Removing the thermal head lift motor 8-30 Phaser 440 Color Printer...

  • Page 163: Sensors And Switches

    FRU Disassembly/Assembly Sensors and switches The following topics explain how to remove sensors or switches that are difficult to reach, require considerable print engine disassembly, or require special cautions. Paper-pass sensor 1 and paper-empty sensor These sensors are located on the paper-feed module. The paper pass sensor 1 and the paper empty sensor are soldered on the paper-feed circuit board.

  • Page 164: Tray Sensor Circuit Board

    Remove the screw securing sensor board to the sensor assembly bracket. Tray sensor bracket Tray sensor circuit board 9015-18 Figure 8-25 Removing the tray sensor circuit board Reverse these steps to reinstall the tray sensor assembly. 8-32 Phaser 440 Color Printer...

  • Page 165: Paper-Pass Sensor 2

    FRU Disassembly/Assembly Paper-pass sensor 2 Tools required #1 POSIDRIV® screwdriver Paper-pass sensor 2 is located inside the paper-feed module. Power down the printer and remove the power cord. Remove the paper-feed module as explained in the previous procedure “Paper-feed module” on page 8-6. Remove the two screws securing the paper-feed circuit board to the paper-feed module.

  • Page 166: Figure 8-27 Removing The Paper-Pass Sensor 2

    Separate the two halves and flip over the upper half. Unclip paper-pass sensor 2 and remove it and its wiring harness leading to the paper-feed circuit board. 8699-50 Figure 8-27 Removing the paper-pass sensor 2 Reverse these steps to reinstall paper-pass sensor 2. 8-34 Phaser 440 Color Printer...

  • Page 167: Paper Clamp Sensor 1

    FRU Disassembly/Assembly Paper clamp sensor 1 Tools required #1 POSIDRIV® screwdriver This sensor is located under the drum. Power down the printer and remove the power cord. Open the top access cover and remove the transfer roll. Remove the drum as detailed in the earlier procedure “Drum” on page 8-20.

  • Page 168: Card Cage And Power Supply

    Disconnect the four screws securing the card cage to the print engine frame (two screws each on the left and the right sides). Card cage 9015-21 Figure 8-29 Disconnecting the wiring harnesses and removing the card cage 8-36 Phaser 440 Color Printer...

  • Page 169: Figure 8-30 Removing The Card Cage And Power Supply

    FRU Disassembly/Assembly Slide the card cage and power supply out the rear of the print engine. As you slide the card cage out you can disconnect the thermal head power supply harness from the power supply. Disconnect the power supply wiring harness leading to the thermal head.

  • Page 170: Circuit Boards

    Remove the four screws securing the power supply circuit board to the bottom pan of the card cage. Remove the ground screw. Remove the AC cord receptacle and AC voltage select switch. Disconnect connectors CN8 and CN9. 8-38 Phaser 440 Color Printer...

  • Page 171: Figure 8-31 Removing The Power Supply Circuit Board

    FRU Disassembly/Assembly Slide the power supply circuit board away from the card cage to disconnect it from the card cage interconnect board. Power supply circuit board AC shield 9015-22 Figure 8-31 Removing the power supply circuit board Reverse these steps to reinstall the power supply. After replacing the power supply, run the adjustment “Thermal head temperature adjustment”...

  • Page 172: Engine Control Board

    Remove the card cage top (held by 3 screws). Flip over the hinged card cage top. Disconnect the wiring harnesses leading to the engine control board. Card cage 9015-23 Figure 8-32 Disconnecting the wiring harnesses 8-40 Phaser 440 Color Printer...

  • Page 173: Paper-Feed Circuit Board

    FRU Disassembly/Assembly Lift out the engine control board. Note If you exchanged an old engine control board for a new engine control board, be sure to exchange the NVRAM (IC 2) from the old board into the new board. The NVRAM IC contains the thermal head temperature and sensor calibration setting.

  • Page 174: Card Cage Interconnect Board

    Remove the four screws securing the shield plate to the card cage. From underneath the card cage, remove the two screws securing the interconnect board in place. Remove the board. Reverse these steps to reinstall the interconnect circuit board. 8699-37 Figure 8-34 Removing the interconnect board 8-42 Phaser 440 Color Printer...

  • Page 175: I/O Board

    Remove the screws securing the I/O board to the card cage. Disconnect the I/O board’s ribbon cable(s) from the image processor board. The Phaser 440 I/O board has two ribbon cables. Remove the I/O board. Reverse these steps to reinstall the I/O board and the image processor board.

  • Page 176: Image Processor Board

    When you reinstall the card cage top, ensure that the tabs on the top edge of the image processor board fit into the slots in the card cage top. 8699-38 Figure 8-36 Removing the image processor board 8-44 Phaser 440 Color Printer...

  • Page 177: Ram Simm

    FRU Disassembly/Assembly RAM SIMM Tools required #1 POSIDRIV® screwdriver Power down the printer. Leave the power cord plugged in to provide a ground path for static discharges. Remove the top-rear and rear cabinet panels. Refer to the earlier topic “Printer cabinet panels” on page 8-4 Remove the card cage top (3 screws).

  • Page 178: Ethernet Card

    Ethernet card 9015-24 Figure 8-38 Installing the Ethernet card on the image processor board Reinstall the image processor and I/O board. Reinstall the card cage top and the rear cabinet panels. 8-46 Phaser 440 Color Printer...
  • Page 179 FRU Disassembly/Assembly Reconnect the interface cables. Turn on the printer and print the configuration page. It list information regarding the Ethernet interface Affix the Ethernet address label to the underside of the top cover where it can easily be accessed. Service Manual 8-47...

  • Page 181: Checks And Adjustments

    Chapter Checks and Adjustments This chapter describes how to make mechanical and electrical adjustments to the Phaser 440 print engine. It also describes how to maximize print quality. Required tools summary Magnetic tip screwdriver -- 8.5 ins. 003-0293-00 Extension tip 003-1388-00 #1 POSIDRIV®...

  • Page 182: Printing Test Patterns

    Switch 1-8 on prints the selected pattern continuously. Alternatively, you can press and hold the TEST button for 5 seconds to start the selected pattern. Dip Switch 2 Dip Switch 1 (thermal head temperature) 9015-25 Figure 9-1 Engine control board DIP switches Phaser 440 Color Printer...

  • Page 183: Table 9-1 Selecting Self-Test Print Patterns

    Checks and Adjustments Note Test pattern gray fills will not print gray. Because the test patterns are generated from memory and are not compensated by the image processor, gray fills will appear purple or “plum” colored due to the transfer rolls “hot” magenta bands. This is normal and does not indicate that the printer needs to be adjusted.

  • Page 184: Printer Self-Checks

    ↑ ↑ Mechanical switch check 5: paper-pass sensors, paper exit sensor, drum home sensor. ↑ ↑ ↑ Transfer roll mark sensor adjust. ↑ ↑ ↑ ↑ Pick roller cleaning mode. ↑ indicates switch is on . Phaser 440 Color Printer...

  • Page 185: Thermal Head Motor Check

    Checks and Adjustments Thermal head motor check Turn off the printer. Remove the rear cabinet panel to access the engine control board. Refer to the Chapter 8 topic “Printer cabinet panels” on page 8-4. Press and hold the TEST button and turn on the printer. Release the TEST button.

  • Page 186: Lower Tray Assembly Connection Test

    Lower Tray Assembly; the LED COVER turns on. LED READY indicates the condition of the paper empty sensor. Manipulate the paper empty flag to turn the LED READY on and off. Set DIP Switch 1-3 off to stop the test. Phaser 440 Color Printer...

  • Page 187: Paper-Path Check

    Checks and Adjustments Paper-path check Turn off the printer. Ensure that the paper tray is filled. Remove the rear cabinet panel to access the engine control board. Refer to the Chapter 8 topic “Printer cabinet panels” on page 8-4. Press and hold the TEST button and turn on the printer. Release the TEST button.

  • Page 188: Top Loss Adjustment

    Top loss adjust settings RIBBON COVER READY margin Switch adjust settings value -1.5 mm ↑ -1.0 mm ↑ -0.5 mm ↑ ↑ ↑ 0.5 mm ↑ ↑ 1.0 mm ↑ ↑ 1.5 mm ↑ ↑ ↑ 2.0 mm Phaser 440 Color Printer...
  • Page 189 Checks and Adjustments Set DIP Switches 1-5, 1-6 and 1-7 to correspond to the desired top margin adjustment. Choose a value that increases the top margin or decreases the margin by the amount necessary. Toggle DIP switch 2-8 to store the new value into the printer's memory.

  • Page 190: Leading Edge (Top) Margin Adjustment

    Top margin adjust settings RIBBON COVER READY margin Switch adjust settings value -1.5 mm ↑ -1.0 mm ↑ -0.5 mm ↑ ↑ ↑ 0.5 mm ↑ ↑ 1.0 mm ↑ ↑ 1.5 mm ↑ ↑ ↑ 2.0 mm 9-10 Phaser 440 Color Printer...

  • Page 191: Figure 9-2 Paper Top Loss Adjustment At The Paper Clamp

    Checks and Adjustments Set DIP Switches 1-5, 1-6 and 1-7 to correspond to the desired top margin adjustment. Choose a value that positions the leading edge of the paper in the clamp so that the edge just contacts the clamp’s paper edge stops without buckling.

  • Page 192: Switch And Interrupt Sensor Checks

    Mode 2: Set DIP Switches 1-4 and 1-7 on. Mode 3: Set DIP Switches 1-4 and 1-6 on. Mode 4: Set DIP Switches 1-4, 1-6 and 1-7 on. Mode 5: Set DIP Switches 1-4 and 1-5 on. 9-12 Phaser 440 Color Printer...

  • Page 193: Table 9-5 Mechanical And Interrupt Switch Check Summary

    Checks and Adjustments Set DIP Switch 1-3 on to start the test. LEDs ERROR and JAM blink rapidly to indicate the mode is active. Actuate the switches corresponding to the test mode you selected. LEDs PAPER, RIBBON, COVER, or READY blink rapidly when each switch is actuated.

  • Page 194: Tray Select

    Toggle Dip Switch 1-8 on to select the tray you want. LED READY blinks rapidly if the second feeder tray is selected. LED READY turns off if the standard tray is selected. Set DIP Switch 1-3 off to exit the mode. 9-14 Phaser 440 Color Printer...

  • Page 195: Calibrating The Reflective Sensors

    Checks and Adjustments Calibrating the reflective sensors Turn off the printer. Ensure that a 3-Color transfer roll is installed. Remove the rear cabinet panel to access the engine control board. Refer to the Chapter 8 topic “Printer cabinet panels” on page 8-4. Press and hold the TEST button and turn on the printer.

  • Page 196: Adjusting For Best Print Quality

    10 levels of cyan or magenta. It may be necessary to compromise those shades to 9 levels. Use test pattern 5 to check and make the thermal head temperature adjustment. 9-16 Phaser 440 Color Printer...

  • Page 197: Table 9-6 Setting Thermal Head Temperature (Based On Thermal Head Resistance)

    Checks and Adjustments Table 9-6 Setting thermal head temperature (based on thermal head resistance) Dip Switches Dip Switches 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 Resistance 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 Resistance (Ω) printed on (Ω) printed thermal head on thermal head...

  • Page 198: Thermal Head Skew (To Correct Speckle And Wrinkle)

    Rotate the pitch adjustment screw an additional one turn clockwise to finish the adjustment. Apply cement compound to the screws to lock it in its current position. 9-18 Phaser 440 Color Printer...

  • Page 199: Figure 9-3 Adjusting For Thermal Head Skew

    Checks and Adjustments Close the top cover and turn off the printer. Reinstall the rear top cabinet panel. Skew adjustment screws Caution: Never adjust this screw 9015-27 Figure 9-3 Adjusting for thermal head skew Service Manual 9-19...

  • Page 200: Vh Current Compensation Adjustment

    This is illustrated in Figure 9-3. If no color is apparent then the current compensation is good, go to Step 8. If color appears in the gray, continue with the next step. 9-20 Phaser 440 Color Printer...

  • Page 201: Figure 9-4 Vh Current Compensation Adjustment

    Checks and Adjustments Locate the VH current adjust potentiometer behind the drum idler pulley. Rotate the potentiometer clockwise to remove the color from the gray. Look for color in the gray printing at these locations VH current compensation adjust potentiometer 9015-40 Figure 9-4 VH current compensation adjustment Repeat Steps 4 through 6 until the ghosting disappears.

  • Page 202: Drum Belt Tension Adjustment

    Hold the belt tensioner in its position and tighten its screws to secure it in place. Tighten the lower drum belt tension set screw, then tighten the upper screw. Drum belt tensioner 9015-26 Figure 9-5 Tensioning the drum belt Reinstall the cabinet panels. 9-22 Phaser 440 Color Printer...

  • Page 203: Head Lift Motor Belt Tension Adjustment

    Checks and Adjustments Head lift motor belt tension adjustment Tools required #1 POSIDRIV® screwdriver This adjustment should be made whenever the head lift motor or belt has been removed or replaced. Power down the printer. Remove the top cover cabinet panel. Refer to the Chapter 8 topic “Printer cabinet panels”...

  • Page 205: Field Replaceable Units List

    Appendix Field Replaceable Units List This appendix provides a list of field replaceable units for the Phaser 440 Color Printer. Changes to Tektronix instruments are made to accommodate improved components as they become available. It is important when ordering parts to...

  • Page 206: Table A-1 Fru Exterior Parts List

    CABINET: BACK LOWER 118-8936-00 CABINET: BACK UPPER 118-9134-00 CABINET TOP: WITH OPEN LEVER 118-8939-00 CABINET: RIGHT SIDE 118-8933-00 CABINET FRONT: UPPER WITHOUT LED BOARD 118-8934-00 CABINET FRONT: CENTER 118-9133-00 CABINET FRONT: LOWER 118-8841-00 DOOR: FRONT ACCESS Phaser 440 Color Printer...

  • Page 207: Figure A-1 The Printer Exterior Frus

    Field Replaceable Units List 8699-76A Figure A-1 The printer exterior FRUs Service Manual...

  • Page 208: Table A-2 Fru Interior Parts List

    FUSE, F2 (5A, 250 VAC) 159-0296-00 1.000 FUSE, F3 (2A, 250 VAC) 118-8940-01 1.000 HARDWARE KIT 118-8836-00 1.000 FLAG SENSOR KIT 118-9144-00 1.000 GEAR KIT 118-9147-00 1.000 ROLLER KIT 118-8860-01 1.000 BAIL ROLLER AND SPRING KIT Phaser 440 Color Printer...

  • Page 209: Figure A-2 The Internal Printer

    FRU Replaceable Parts List Figure A-2 The internal printer 9015-07 Service Manual...
  • Page 210 TRANSFER ROLL TRAY 436-0295-00 1.000 TRAY, FEEDER: LOWER TRAY FEEDER 070-9015-01 1.000 MANUAL,TECH: SERVICE FOR PHASER 440 070-9016-00 1.000 MANUAL,TECH: PHASER 440 SW PRINTING REFERENCE 070-9014-00 1.000 MANUAL,TECH: USER, PHASER 440 070-9014-10 1.000 MANUAL,TECH: USER, PHASER 440, FRENCH ONLY 070-9014-20 1.000...

  • Page 211: Figure B-1 Inspection /Check Pattern

    Appendix Test Patterns Registration marks 100% fills Gray fill Vertical banding Horizontal banding: Check Y-motor action and drum belt tension (Chapter 9) Eight-step Thermal head temperature set: increments Gray fill This indicates the currently set (acceptable) value of DIP switches 2-1 through Note: Gray fill appears 2-8.

  • Page 212: Figure B-2 Saturation Dither Pattern

    In test patterns, gray fills appear purple because the prints are not compensated for the “hot” magenta band used in the transfer rolls. 10 step saturation gradation. If not, refer to thermal head temperature adjustments in Chapter 9. Gray fill ("plum-colored") 9015-42 Figure B-2 Saturation dither pattern Phaser 440 Color Printer...

  • Page 213: Figure B-3 Wrinkle Pattern

    Test Patterns Look for streaks of yellow in the red field and streaks of red in the purple lines. 9015-43 Figure B-3 Wrinkle pattern Service Manual...
  • Page 214 Index drum removing 8-20 adjusting for best print quality 9-16 theory 5-11 adjusting thermal head temperature 9-16 drum motor Adobe PostScript Level 2 1-2 theory 5-11 ARP 2-16 dye 1-2 dye sublimation printing 1-2 bail roller assembly removing 8-17 electrical specifications 1-14 BBS board 4-6 electronic bulletin board 4-6 belts...
  • Page 215 gears Macintosh inspecting 7-4 printing 3-1 Graphics Supplies Order Desk 2-3 using the Error Handler utility 3-3 grease mechanical controller 5-7 assembly 8-1 Microsoft Windows using 7-2 standard PostScript printer driver 2-23 motors removing 8-25 hard error 1-8 health LED 1-8 heat controller 5-6 no image on print 6-15 Highly Automated Library (HAL) 2-4...
  • Page 216 Error Handler utility 3-7 RAM SIMM Phaser 440, description 1-2 installing 8-45 physical dimensions 1-12 RARP 2-15 pick-up solenoid rear panel theory 5-8 description 1-8 power problems 6-24 regulatory standards 1-16 power supply replaceable parts A-1 removing 8-36...
  • Page 217 9-2 white portion of print is colored 6-14 thermal head 5-2 Windows 3.1 driver verification 3-4 pitch adjusting 9-18 Windows 3.1, Tektronix driver 2-20 removing 8-18 Windows printer driver temperature adjustment 9-16 configuring 2-21 thermal head controller 5-7...

  • Page 218: Wiring Diagrams

    Appendix Wiring Diagrams The tables below detail the signals carried through several of the print engine's wiring harness connectors at the print engine control board. Figure C-1 illustrates the print engine's control board connectors. Table C-1 Connector CN1 Signal Signal Signal Signal CVOPN1-0...
  • Page 219 DATA IN 1 COUNT CLK-0 DATA IN 2 BEO 1 DATA IN 3 COUN T CLK 2 DATA IN 4 BEO 2 DATA IN 5 THERM 1 DATA IN 6 THERM 2 THERM 3 DATA IN 7 THERMCOM Phaser 440 Color Printer...
  • Page 220 Wiring Diagrams Table C-6 Connector CN7 Signal Signal DRMCOM DRMAN-0 DRMCOM DRMB-0 DRMA-0 DRMBN-0 Table C-7 Connector CN8 Signal Signal +5 VDC LJAM-0 LCOV-0 LERR-0 LTROLL-0 LRDY-0 LPAP-0 LPWR-0 Service Manual...

  • Page 221: Figure C-1 Print Engine Control Board Connector Diagram

    Front panel Drum motor Core sensor, left Core sensor, front Core sensor, right Drum home-position Paper-clamp sensor sensor Paper-feeder motor ..Paper-feeder circuit board CN12 9015-05 Figure C-1 Print engine control board connector diagram Phaser 440 Color Printer...

  • Page 222: Figure C-2 Print Engine Wiring Diagram

    Wiring Diagrams Paper load sensor Head fan right Head fan left Thermal head lift motor Thermal head Thermal head Image position sensor board processor Thermal head heater Test Engine control Transfer roll switch board mark sensor Interconnect Drum board motor Core sensor, left Core sensor,...

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