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Digital Equipment DECcolorwriter 1000 Service Manual

Color printer
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Service Manual
DECcolorwriter 1000
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.
First printing February 1994
Order Number: EK-LF02E-FM.A01
Digital Equipment Corporation
Maynard, Massachusetts U.S.A.

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Summary of Contents for Digital Equipment DECcolorwriter 1000

  • Page 1 Service Manual DECcolorwriter 1000 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.
  • Page 2 ® PANTONE * Colors generated by the DECcolorwriter 1000 are three-color process simulations and may not match PANTONE-identified solid color standards. Use current PANTONE Color Reference Manuals for accurate colors. PANTONE Color simulations are only obtainable on these products when driven by qualified Pantone-licensed software packages.

  • 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

    Regulatory specifications 1-16 Installing the Printer and Drivers Pre-install questions for customers 2-2 Unpacking 2-5 Inventory for the DECcolorwriter 1000 printer 2-5 Setting up the printer 2-7 Cabling the printer 2-8 Connecting the printer to a Macintosh 2-8 LocalTalk connection to a Macintosh 2-8...
  • Page 6 Creating colors 5-5 Engine control board block description 5-6 CPU 5-7 Interface buffers 5-7 Data controller and line buffers 5-7 Heat controller (dot compensation) 5-7 Thermal head controller 5-8 Thermal head 5-8 Mechanical controller 5-8 Internal test pattern generator 5-8 DECcolorwriter 1000...
  • Page 7 Paper pick-up 5-9 Drum loading 5-11 Printing 5-12 Print unloading 5-14 Power supply 5-15 DECcolorwriter 1000 image processor 5-17 Image rendering technology 5-17 Troubleshooting System power-up sequence 6-1 Print engine troubleshooting 6-2 Verifying image processor operation by using the Test Pattern Generator 6-2...
  • Page 8 The rear panel LED flashing in a regular one flash-per-second rate means no errors were detected and that the image processor's CPU is running. 6-31 Printing the configuration page 6-31 Resetting the DECcolorwriter 1000’s NVRAM 6-32 Cleaning and Maintenance Cleaning 7-1...
  • Page 9 FRU Disassembly/Assembly Required tools 8-1 Lower tray assembly 8-2 Printer cabinet panels 8-3 Paper-feed module 8-5 Accessing the pick roller, aligning roller, and the lower feed roller 8-6 Paper-pick roller, clutch, and paper-empty flag 8-9 Lower aligning roller, clutch, and paper-pass sensorþ1þflag 8-11 Removing the upper aligning roller 8-13 Removing the feedþroller 8-14 Removing the exitþrollers 8-15...
  • Page 10 Adjusting for best print quality 9-14 Thermal head temperature adjustment 9-14 Thermal head pitch (to correct speckle and wrinkle) 9-16 Paper clamp adjustment (to correct misregistration) 9-18 Field Replaceable Units List Test Patterns Wiring Diagrams Test Pattern Generator Index DECcolorwriter 1000...
  • Page 11 Service Manual...
  • Page 12 Figures Figure 1-1. The DECcolorwriter 1000 (shown with the Lower Tray Assembly) 1-1 Figure 1-2. Internal features of the DECcolorwriter 1000 print engine 1-3 Figure 1-3. Sensors and switches on the DECcolorwriter 1000 print engine 1-4 Figure 1-4. Features of the DECcolorwriter 1000 image processor board 1-7 Figure 1-5.
  • Page 13 The printer exterior FRUs A-3 Figure A-2. Exploded view of the printer A-7 Figure B-1. Inspection/check test pattern showing samples of defective printing B-1 Figure B-2. Saturation dither pattern B-2 Figure B-3. Wrinkle 2 pattern showing wrinkle B-3 DECcolorwriter 1000...
  • Page 14 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 xiii Service Manual...
  • Page 15 Table C-2. Connector CN4 C-2 Table C-3. Connector CN5 C-2 Table C-4. Table C-5. Connector CN6 C-2 Connector CN7 C-3 Table C-6. Connector CN8 C-3 Table C-7. Test Pattern Generator DIP Switch settings for DECcolorwriter 1000 D-3 Table D-1. DECcolorwriter 1000...
  • Page 16 Service Manual...

  • Page 17: General Information

    General Information This service manual contains information useful to verify operation, troubleshoot, repair, adjust, and maintain the DECcolorwriter 1000. The first half of this manual familiarizes you with the printer and provides information on installing and verifying the printer and training printer users.

  • Page 18: Deccolorwriter 1000

    LocalTalk port. Plain-paper printing The DECcolorwriter 1000 prints on a specially coated paper with a very smooth, even surface, optimized for wax-transfer printing. The printers can also print on ordinary Bond paper, using a special 4-pass plain-paper transfer roll. During printing, a special primer coating is applied to the paper in its first pass past the thermal head.

  • 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 8699-02B Figure 1-2. Internal features of the DECcolorwriter 1000 print engine Service Manual...

  • Page 20: Figure 1-3. Sensors And Switches On The Deccolorwriter 1000 Print Engine

    Transfer roll Tray sensors (3) mark sensor Top-cover- Paper-exit sensor Paper clamp open sensor sensor Front-cover-open sensor Paper-empty Aligning roller Paper-pass sensor solenoid sensor (1) Paper-pick solenoid 8699-03B Figure 1-3. Sensors and switches on the DECcolorwriter 1000 print engine DECcolorwriter 1000...

  • Page 21: Combination Sensors And Their Meanings

    General Information Combination sensors and their meanings Combinations of sensors are used by the DECcolorwriter 1000 to determine the type of transfer roll and the type of media tray installed in the printers. Transfer roll type sensing The combinations of the two transfer roll core sensors “tell” the print engine what type of transfer roll is installed.

  • Page 22: Media Tray Type Sensing

    Letter – Perforated paper Open Open Closed Letter – Perforated transparency film Open Closed Closed Letter – Plain paper Closed Open Open A4 – Perforated paper Closed Open Closed A4 – Perforated transparency film Closed Closed Closed A4 – Plain Paper DECcolorwriter 1000...

  • Page 23: Image Processor Boards

    General Information Image processor boards Font SIMM SIMM I/O connector Interconnect board connector 8699-05 Figure 1-4. Features of the DECcolorwriter 1000 image processor board Service Manual...

  • Page 24: Rear Panel

    General Information Rear panel Connectors The rear panel of the DECcolorwriter 1000 printer features the host interface connectors to the printer. They include the following connectors: Standard parallel RS-232 serial LocalTalk The DECcolorwriter 1000 rear panel also features DIP switches to control certain aspects of the printers’...

  • Page 25: Figure 1-5. Deccolorwriter 1000 Rear Panel

    General Information The following figure illustrate the rear panel of the DECcolorwriter 1000. Health DIP switches Status LocalTalk® Reset Color Correction * See Below Parallel Serial (RS-232) DECcolorwriter 1000 8699-07 Figure 1-5. DECcolorwriter 1000 rear panel Table 1-3. DECcolorwriter 1000 rear panel DIP Switches...

  • 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. DECcolorwriter 1000 front panel 1-10 DECcolorwriter 1000...

  • Page 27: Front Panel Led Service Mode Error Codes

    General Information Front panel LED service mode error codes Detected error conditions 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 DECcolorwriter 1000 printer. Table 1-5. 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: Table 1-7. Functional Specifications

    General Information Table 1-7. Functional specifications Characteristic Specification Printing process Sequential surface thermal transfer printing (thermal-wax transfer). Transfer rolls Wax-impregnated transfer rolls. The printer automatically senses the transfer roll type by the coding on the leading edge of the yellow band. 3-Color Transfer Roll features sequential bands of yellow, cyan, and magenta;...

  • Page 30: Table 1-8. Electrical Specifications

    – 26 ~ 27.4 V), (V – 10.6 ~ 11.0) high RF emissions Both 115 and 220 VAC-configured instruments pass these standards: FCC Part 15 Class B VDE 0871/6.78 Class B EN55022 (CISPR 22) Class B VCCI (CISPR 22) Class B 1-14 DECcolorwriter 1000...

  • Page 31: Table 1-9. Environmental Specifications

    General Information Table 1-9. 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 20 to 80% relative humidity, non-condensing...

  • Page 32: Regulatory Specifications

    General Information Regulatory specifications The DECcolorwriter 1000 is a recognized component in conformance with the following regulatory standards: The packaged product meets National Safe Transit Committee Test Procedures. UL 1950 Information Processing & Business Equipment. CSA C22.2 No. 950 Safety of Information Technology Equipment, Including electrical Business Equipment.

  • Page 33: Installing The Printer And Drivers

    Chapter Installing the Printer and Drivers This chapter discusses installing the printer and its drivers. Installation 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: Pre-installation interview.

  • Page 34: Pre-Install Questions For Customers

    Installing the Printer and Drivers Pre-install questions for customers Prior to installing a DECcolorwriter 1000, 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 Installing the Printer and Drivers Customers must provide the particular interface cable or network adapter they need to use with the printer. 10 ft. parallel cable Serial, 25-pin to 25-pin, 3 m (10 ft.), null modem Serial, 9-pin to 25-pin, 3 m (10 ft.), null modem For AppleTalk installations, customers must provide the appropriate network adapter to the printer's 9-pin circular LocalTalk connector.
  • Page 36 DOS 3.1 or later An application that supports color PostScript or HP-GL Windows systems Windows 3.1 2 Mbytes of hard disk space Workstation UNIX workstations: The X Windows System, SUN workstations: OpenWindows recommended 750 kbyte hard disk space for files DECcolorwriter 1000...

  • Page 37: Unpacking

    Installing the Printer and Drivers Unpacking Inventory for the DECcolorwriter 1000 printer Printer Paper tray Power cord Getting Started folder Cleaning kit Supplies information sheet Transfer roll Paper Transparencies User manual Printer drivers and utilities reference manual Printing utilities and driver diskettes...

  • Page 38: Figure 2-1. The Deccolorwriter 1000 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 DECcolorwriter 1000 packaging DECcolorwriter 1000...

  • Page 39: Setting Up The Printer

    Installing the Printer and Drivers Setting up the printer Installing the printer is explained in detail in either the DECcolorwriter 1000 User Manual. The following is a brief list of the steps you follow to unpack and set up the printer.

  • Page 40: Cabling The Printer

    This topic explains making a hardware connection between a DECcolorwriter 1000 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. This topic is divided into three main parts: Macintosh, PC, and workstation.

  • Page 41: Connecting The Printer To A Workstation

    Installing the Printer and Drivers Connecting the printer to a workstation Direct connection to a workstation Turn off the printer. Turn off the host computer. Attach the parallel interface cable to the workstation. Attach the other end to the printer. Alternatively, attach the serial cable to the workstation's serial port.

  • Page 42: Turning On The Printer

    Turning on the printer The startup page When you turn on a DECcolorwriter 1000 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 not been disabled. (The factory default condition is to have the startup page enabled.) After running self-tests and printing the...

  • Page 43: The Configuration Page

    Color settings such as Vivid Blue. Serial port settings Parallel port settings LocalTalk port settings Table 2-1. Configuration page settings for DECcolorwriter 1000 printers Parameter Description Saved Default Limits or alternate choices...
  • Page 44 Installing the Printer and Drivers Table 2-1. Configuration page settings for DECcolorwriter 1000 printers (cont'd.) Parameter Description Saved Default Limits or alternate choices NVRA Color Indicates the type of color adjustments None User Defined, Vivid Blue, Correction used to simulate different color uses...

  • Page 45: Driver And Communication Setup

    LaserWriter 7.0.x and its support files (Laser Prep, Backgrounder, and PrintMonitor) are required to use the DECcolorwriter 1000 driver and to print in the background. The Installer automatically copies these files to your hard disk drive if you are using system 6.0.7 or higher.

  • Page 46: Installing The Custom Driver For Windows 3.1

    Printers icon in the Control Panel. Choose your printer from the list of installed printers. Choose the Set As Default Printer button if you want to select your printer as the default. Choose the Connect button; the Connect dialog box appears. 2-14 DECcolorwriter 1000...
  • Page 47 Installing the Printer and Drivers Select the port the printer is connected to. Your printer is connected to your computer through one of the computer's communications ports. You need to tell the driver which port your printer uses so that the driver can print your documents.
  • Page 48 This option is only available to applications that use this custom driver with DECcolorwriter 1000 printer. When this box is checked, the Compress Bitmaps option is unavailable (grayed out).

  • Page 49: Updating The Standard Microsoft Windows Postscript Driver

    Open the Control Panel. Double–click on the Printers icon. Choose the Add>> button; a list of printers is displayed. Highlight the DECcolorwriter 1000 printer. Select Install Unlisted or Updated Printer. Choose the Install button. When prompted, insert the provided standard Windows 3.1 Printer Driver diskette into your computer’s disk drive.
  • Page 50 At this point, a list of possible PostScript printers are displayed for your selection. Using the scroll bars, move down through the alphabetical listing until you find the selection PSCRIPT. DECcolorwriter 1000. Click on the correct printer name and then click on Install. The system will install your printer driver.
  • Page 51 Select Options and make sure that it is set to DECcolorwriter 1000. If not, repeat the previous steps. While in this screen, set Job and Wait to 0, if they aren't already.

  • Page 52: Configuring The Printer's Serial Port For A Pc

    9600. In the example below, the changes are persistent across print jobs and across power cycles; they remain in effect until specifically changed again. Note CTRL-D is the ASCII End-Of-Text (EOT) character. DECcolorwriter 1000 CTRL-D systemdict/languagelevel known{languagelevel 2 eq {true}{false}ifelse}{false}ifelse (%Serial_NV%) <</Password ()

  • Page 53: Table 2-2. Values For Modifying The Devparams.ps File

    Installing the Printer and Drivers 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. 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.

  • Page 54: Using Printcap To Configure A Unix Workstation For The Printer's Serial Port

    The content of the file should look like this: #!/bin/sh /bin/cat Give the if file executable permission: 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. 2-22 DECcolorwriter 1000...

  • Page 55: Service Manual

    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 2-23 Service Manual...
  • Page 56 Installing the Printer and Drivers 2-24 DECcolorwriter 1000...

  • Page 57: Verifying The Printer And Host Connections

    Macintosh. Select the driver icon DECcolorwriter 1000 by clicking on it once. If the host and the printer are a part of a zone, you should first select the printer driver and then pick the zone that the printer resides in.

  • Page 58: Print The Directory From Macintosh

    (such as both LocalTalk and Ethernet). Refer to Chapter 6, “Troubleshooting” for more information about networks. More troubleshooting tips are included in the reference manual DECcolorwriter 1000 Drivers and Utilities Printing Reference. Print the directory from Macintosh Make sure that you have an open window displayed on the screen (such as the hard disk drive's window).

  • Page 59: Using The Error Handler Utility

    Verifying the Printer and Host Connections If problems occur at this point, download the error handling utility to the printer as explained in the next procedure. Refer to the DECcolorwriter 1000 Drivers and Utilities Printing Reference which provides information on using the printer with specific applications.

  • Page 60: Windows 3.1 Driver Verification

    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 DECcolorwriter 1000 from the displayed list of available printer drivers. Click OK. Click File and select Print. A print file will be transmitted to the printer.

  • Page 61: Os/2 Connection Verification

    Verifying the Printer and Host Connections OS/2 connection verification Note The Print Screen function is controlled from within the OS/2 System folder. Open the System folder, then open the System object. Click on the Print Screen Tab to view the Print Screen settings. Be sure that Enable has been selected.

  • Page 62: Veryifing Printing To A Pc Using The Error Handler Utility

    This loads the error handling utility into the printer's memory where it remains until the printer is turned off. Send a file to the printer as explained in the previous procedure. If an error occurs, the printer will print a page listing the error. DECcolorwriter 1000...

  • Page 63: Verifying Printing To A Workstation Using The Error Handler Utility

    Verifying the Printer and Host Connections Verifying printing to a workstation using the Error Handler utility If the workstation host does not print to the printer, download the Advanced Error Handler utility to the printer. Locate the ADVEHAND.PS file in the PrinterUtility diskette. Copy the file ADVEHAND.PS to the workstation's hard disk or use the file from the diskette.
  • Page 64 Verifying the Printer and Host Connections DECcolorwriter 1000...

  • Page 65: Key Operator Training

    Chapter Key Operator Training This section covers the last portion of the printer 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. Service Manual...

  • Page 66: 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. DECcolorwriter 1000...

  • Page 67: 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. Explain that the customers should not bend the media (especially transparency film) too sharply.

  • Page 68: 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. DECcolorwriter 1000...

  • Page 69: Supplies Ordering

    Key Operator Training Supplies ordering The printer is shipped with the latest version of the supplies information sheet. It lists all the available supplies for the printer, as well as printer accessories, such as software and printer stands, that customers may be interested in. Additionally, some supplies are listed in the user manual.
  • Page 70 Key Operator Training DECcolorwriter 1000...

  • Page 71: Theory Of Operation

    Chapter Theory of Operation This chapter provides a high-level description of the thermal-wax 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.

  • Page 72: Print Engine

    And because the row of thermal elements span the width of the page, the print engine prints an entire line at one time; this accounts for the print engine's fast print time. The printer uses a special clay-coated paper which presents a smooth, flat surface for the wax to adhere to. DECcolorwriter 1000...

  • Page 73: Figure 5-1. The Thermal-Wax Transfer Print Process

    Theory of Operation During printing, the print engine moves the paper past the thermal head three times. During each pass, individual thermal head elements melt tiny dots of wax from the transfer roll's colored bands; first from the yellow band, then the magenta band, and finally, cyan.

  • Page 74: Plain-Paper Printing

    In addition, a greater demand is made on the image processor board's memory for plain-paper printing. The image processor board must generate a composite bitmap of the cyan, magenta, and yellow bitmaps. The composite bitmap guides the print engine on where to apply the precoat on the plain paper. DECcolorwriter 1000...

  • Page 75: Image Data

    Theory of Operation Image data DECcolorwriter 1000 print engines 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 76: Engine Control Board Block Description

    Engine control board Sensors Mechanical Motors controller Solenoids Image Test processor pattern generater Heat Line Interface Line Thermal control memory buffers buffer head (dot compen- buffer sation) Thermal head controller 8699-09A Figure 5-2. Print engine board block diagram DECcolorwriter 1000...

  • Page 77: Cpu

    Theory of Operation All DECcolorwriter 1000 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.

  • Page 78: Thermal Head Controller

    This circuit produces the print engine's internal test patterns. The test pattern algorithms are stored in ROM. The internal test pattern data are routed to the interface block and pass through the rest of the print engine just as regular image data would. DECcolorwriter 1000...

  • Page 79: Paper Path In Operation

    Theory of Operation Paper path in operation This topic discusses the movement of a piece of paper from the paper tray, through the printing process, to the printer's output tray. Paper pick-up Paper pick-up takes place at the paper-feed unit. It begins when the pick-up solenoid energizes and the paper-feed motor rotates forward.

  • Page 80: Figure 5-3. The Paper Pick Process

    Paper- clamp pass sensor 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 DECcolorwriter 1000...

  • Page 81: 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 detects the paper loaded in the clamp, and then speeds up to draw more of the paper around the drum. This continues until the leading edge of the paper (the clamped end) is beneath the thermal head, ready for printing.

  • Page 82: Figure 5-7. Printing On The Paper

    This process repeats once more for cyan printing and then the print is ready to be unloaded to the printer's output tray. (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 DECcolorwriter 1000...

  • Page 83: Figure 5-8. Raising The Thermal Head Between Passes

    Theory of Operation Unlike other thermal wax printers, the DECcolorwriter 1000 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 DECcolorwriter 1000's faster print times.

  • Page 84: Figure 5-9. Ejecting The Print

    (to prevent them from denting the drum). Then the paper-feed motor is turned off, completing the print process. Upper exit rollers Paper- exit Bail rollers sensor Lower exit rollers 8699-16 Figure 5-9. Ejecting the print 5-14 DECcolorwriter 1000...

  • Page 85: Power Supply

    Theory of Operation Power supply The printer power supply is a combination power supply. It outputs the following voltages: +5 VDC generated from a chopper system. +5 VDC is used for the digital logic systems. ±12 VDC generated from a flyback converter system. ±12 VDC is supplied to the image processor board for specialized circuitry.

  • Page 86: Figure 5-10. Power Supply Block Diagram

    SW circuit -12 V smoothing circuit 25 V 25 V 25 V output rectifying/ SW circuit smoothing circuit VHON 5 V output chopper circuit Overheat Control circuit protecting Control circuit circuit 8699-61A Figure 5-10. Power supply block diagram 5-16 DECcolorwriter 1000...

  • Page 87: Deccolorwriter 1000 Image Processor

    Theory of Operation DECcolorwriter 1000 image processor Image rendering technology The image processor board handles PostScript data sent from a host computer and transforms it into a format suitable for the print engine. The hardware/software structure that performs this function is called a graphics pipeline. The graphics pipeline is composed of five basic parts.

  • Page 88: Figure 5-11. The Image Processor Graphics Pipeline

    Control loop Local- LocalTalk Talk handler Serial PostScript Rasterizer Engine Print serializer interpreter driver Parallel engine SCSI Ethernet Ethernet SIMM Fonts in Image processor 8699-18 Figure 5-11. The image processor graphics pipeline 5-18 DECcolorwriter 1000...

  • Page 89: Troubleshooting

    Chapter Troubleshooting This chapter discusses troubleshooting the DECcolorwriter 1000. 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 90: Print Engine Troubleshooting

    Verifying print engine operation by using its self-test print If not already on, turn on the printer. If the printer does not power up, go to the topic “Verifying power supply operation” below. DECcolorwriter 1000...

  • Page 91: Verifying Power Supply Operation

    Troubleshooting Once the READY light is on (not blinking), press and hold the TEST button for 5 seconds. The printer should print out a test pattern. If the printer prints a test pattern, then the print engine is working correctly and the printer's problem resides with its image processor board.

  • Page 92: Figure 6-1. Measuring The Dc Voltages (Test Points)

    “+24 VDC safety interlocks.” Pin 28 +5 VDC CN 2 Pin 12 GND Pin 8 +24 VDC Pin 11 +5 VDC Pin 7 P-GND 8699-20 Figure 6-1. Measuring the DC voltages (test points) DECcolorwriter 1000...

  • Page 93: Figure 6-2. Locating The Fuses

    Troubleshooting Inspecting the power supply fuses Two 5 A fuses are mounted on the power supply. Refer to the Chapter 8 topic “Card cage and power supply” on page 8-35 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 94: 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. DECcolorwriter 1000...

  • Page 95: 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 8-39. Top cover Front cover interlock interlock 8345-21 Figure 6-3. 24 VDC safety interlocks (top and front covers) Service Manual...

  • Page 96: Table 6-1. Motor And Solenoid Resistances

    3-Color Transfer Roll, be sure that the coated side of the paper faces up in the tray. Fanning perforated media eliminates its tendency to double-pick due to the perforations interlocking with neighboring sheets. Inspect the paper for bent, torn or folded corners. DECcolorwriter 1000...

  • Page 97: Paper-Pick Errors

    Troubleshooting 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. 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.

  • Page 98: Paper-Clamping Errors

    9-8. If the sensor fails the test, replace it. Check to see if the upper eject roller drive belt is broken or slipped off of its pulleys. In such a case, the upper roller will not rotate when the lower roller rotates. 6-10 DECcolorwriter 1000...

  • Page 99: Checking The Paper-Feed Motor And Drive Train

    Troubleshooting 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. Checking the paper-feed motor and drive train Determine if the paper-feed motor runs.

  • Page 100: 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 DECcolorwriter 1000...

  • Page 101: 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 102: White Portion Of Print Is Colored

    Check for nicks or burrs in the paper path (particularly the front cover) that could impede the loading of a sheet of media into the paper clamp. 6-14 DECcolorwriter 1000...

  • Page 103: Not Printing

    Troubleshooting Perform the Chapter 9 procedure “Adjusting for best print quality” on page 9-14. Replace the thermal head. This is explained in the Chapter 8 topic “Thermal head” on page 8-17. Not printing The printer processes a sheet of paper, but no image is printed on it. Ensure that the thermal head temperature-adjust DIP switches are correctly set for the resistance of the thermal head.

  • Page 104: Printing Too Light Or Too Dark

    Perforated or A4 Perforated is the selected paper size. If Letter or A4 is selected, the image will be offset. Ensure that the perforated media is loaded correctly in the paper tray with the perforated end toward the front of the printer. 6-16 DECcolorwriter 1000...

  • Page 105: Figure 6-4. Proper Front Idler Roller-To-Drum Alignment (To Prevent 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.” Inspect the front idler roller.

  • Page 106: Table 6-2. Decoding The Front Panel Display

    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 DECcolorwriter 1000...

  • Page 107: 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.
  • Page 108 Z Z Z Z Thermistor is shorted or open. Check the wiring harnesses Hex Code 0F Thermal leading to the thermal head. Replace the thermal head. Refer Head thermistor failure. to the Chapter 8 topic “Thermal head” on page 8-17. 6-20 DECcolorwriter 1000...
  • Page 109 Troubleshooting Table 6-3. Print engine error codes and their meanings (cont'd.) Code Meaning o Z o o o o Determine if the transfer roll is empty. Hex Code 10 Transfer roll empty. Determine if the transfer roll is installed and is properly seated in the transfer roll holders.
  • Page 110 Ensure that the paper path is clear. If media reached the paper-pass sensor, ensure that the paper-pass sensor 2 operates properly. Refer to the topic “Switch and interrupt sensor checks” on page 9-8. Check the aligning roller clutch and solenoid for proper action. 6-22 DECcolorwriter 1000...
  • Page 111 Troubleshooting Table 6-3. Print engine error codes and their meanings (cont'd.) Code Meaning Z o o Z Z o Check to see that the paper clamp is opening properly when Hex Code 26 Clamp the drum is rotated backward into the drum stops. Determine error.

  • Page 112: Power Problems

    Run a sensor test. Refer to the Chapter 9 topic “Calibrating the transfer roll mark sensors (reflective sensors)” on page 9-10. If they continue to fail, the sensors or the sensor wiring are probably defective. 6-24 DECcolorwriter 1000...

  • Page 113: Macintosh Printing Problems

    In the print dialogue box, make sure the Color/Grayscale blackand-white. option has been selected. Make sure that the DECcolorwriter 1000 icon was selected in the Chooser. Try printing the job again. Check the version of your LaserWriter driver to ensure that it is version 6.0.7 or higher.

  • Page 114: Pc Dos Printing Problems

    HP-GL mode, then the printer needs to be changed back to the PostScript mode. Use the utility located on the diskettes to change language emulation. Refer to DECcolorwriter 1000 Drivers and Utilities Printing Reference for complete instructions. Download ADVEHAND.PS file located on the Utilities diskette.

  • Page 115: Windows Printing Problems

    Troubleshooting Windows printing problems Image never prints. Perform the same troubleshooting ideas suggested in the Printer READY light previous topic “PC DOS printing problems.” flashes as if receiving data, but nothing comes Under the printer's setup options set RETRY = 400 out of printer or the printer goes back to “Ready”...

  • Page 116: Workstation Printing Problems

    CTRL-D to the “Ready” mode without end of a print file. TCP/IP an Novell protocols do not accept printing an image. CTRL-D with the print files. Refer to the network manual. 6-28 DECcolorwriter 1000...

  • Page 117: Image Processor Hard And Soft Error Indicators

    Troubleshooting DECcolorwriter 1000 image processors 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 118: Image Processor Self-Diagnostics

    During the verification self-test the test results are transmitted out the serial port. Communication parameters for the serial port are 9600 baud, 8 data bits, no parity, 2 stop bits. The rear panel LED flashes irregularly as the tests are executed (on for one test, off for the next). 6-30 DECcolorwriter 1000...

  • Page 119: Printing The Configuration Page

    While the printer is idle, if you toggle Switch 4 up and then down, as detailed on the previous page, then the DECcolorwriter 1000 prints a configuration page. The configuration page shows a great deal of information regarding the data and set-up values stored in NVRAM.

  • Page 120: Resetting The Deccolorwriter 1000'S Nvram

    Troubleshooting Resetting the DECcolorwriter 1000’s NVRAM Resetting NVRAM returns all the image processor's parameters to factory defaults except the print count (processed through the image processor) and the Adobe firmware serial number. To reset the image processor to its factory default values, follow this procedure: Place the rear panel DIP Switch 4 in the on position (up).
  • Page 121 Chapter Cleaning and Maintenance The DECcolorwriter 1000 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 Phillips screwdriver Lint-free cloth 600 grit sandpaper 90% pure isopropyl alcohol Generally, the following three steps are performed by the customer.
  • Page 122 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. DECcolorwriter 1000...

  • Page 123: Figure 7-1. Lubricating The Clutches

    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 8-9 and “Lower aligning roller, clutch, and paper-pass sensorþ1þflag”...
  • Page 124 In such cases disassemble and check inside the suspect clutch for a lack of grease, a broken spring, or worn gear teeth. Replacements Drum belt: Replace the drum belt after 20,000 prints. Torque limiter: Replace the transfer roll torque limiter after 20,000 prints. DECcolorwriter 1000...

  • Page 125: Required Tools

    Chapter Disassembly/Assembly Required tools Magnetic tip screwdriver — 8.5 in. Extension tip #1 POSIDRIV® tip #2 POSIDRIV® tip Tweezers Hex wrench kit G-311S lubricating grease Antistatic mat 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 126: Figure 8-1 Removing The Lower Tray Assembly

    Lift the printer off of the Lower Tray 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 DECcolorwriter 1000...

  • Page 127: Printer Cabinet Panels

    FRU Disassembly/Assembly Printer cabinet panels Tools required #1 POSIDRIV® screwdriver The printer features cabinet panels. To a certain degree the cabinet panels interlock; you must remove some cabinet panels before you can remove others. You can remove the following panels anytime: Top rear panel (two screws).

  • Page 128: 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 8699-57 Figure 8-2 Removing the cabinet panels DECcolorwriter 1000...

  • Page 129: Paper-Feed Module

    FRU Disassembly/Assembly Paper-feed module Tools required #1 POSIDRIV® screwdriver Small flat-blade screwdriver Needle-nose pliers Power down the printer and remove the power cord. Remove the paper tray. Remove the front access cover. Also, remove the lower front cabinet panel and the left and right side cabinet panels. Refer to the earlier topic “Printer cabinet panels”...

  • Page 130: Figure 8-4 Removing The Paper-Feed Circuit Board

    Paper-feed module Paper-feed circuit board 8699-24 Figure 8-4 Removing the paper-feed circuit board When you reinstall the paper-feed circuit board, be sure to engage the two solenoid gear pawls with their respective clutches. DECcolorwriter 1000...

  • Page 131: Figure 8-5 Removing The Paper-Feed Unit Screws

    FRU Disassembly/Assembly Remove the four screws securing the top half of the paper-feed module. (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...

  • Page 132: Figure 8-6 Separating The Paper-Feedþunit

    Separate the two halves and flip the upper half over to expose all the rollers. 8699-26 Figure 8-6 Separating the paper-feedþunit At this point you can proceed to any individual roller removal procedures explained on the following pages. DECcolorwriter 1000...

  • Page 133: Figure 8-7 Removing The Pick Roller Andþclutch

    FRU Disassembly/Assembly Paper-pick roller, clutch, and paper-empty flag You must remove the paper-pick roller and clutch prior to removing the paper-empty flag. Removing the paper-empty flag is an optional step. Remove the E-ring securing the pick roller clutch. Remove the clutch. (For reassembly, note the keyed shaft the clutch fitsþonto.) Remove the two E-rings securing the pick roller to the upper half of the paper-feed module.

  • Page 134: Figure 8-8 Removing The Paper-Empty Flag

    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 8-10 DECcolorwriter 1000...

  • Page 135: Figure 8-9 Removing The Lower Aligningþroller

    FRU Disassembly/Assembly Lower aligning roller, clutch, and paper-pass sensor 1 flag You must remove the lower aligning roller and clutch prior to removing the paper-pass sensor 1 flag. Removing the paper-pass sensor 1 flag is an optional step. Remove the E-ring securing the aligning roller clutch. Remove the clutch. (For reassembly, note the keyed shaft the clutch fitsþonto.) Remove the two E-rings securing the lower aligning roller (black rubber) to the upper half of the paper-feed module.

  • Page 136: Figure 8-10 Removing The Paper-Pass Sensor 1 Flag

    FRU Disassembly/Assembly Paper-pass sensor 1 flag removal: Rotate the paper-pass sensor flag about 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 8-12 DECcolorwriter 1000...

  • Page 137: Figure 8-11 Removing The Upper Aligning Roller

    FRU Disassembly/Assembly Removing the upper aligning roller Flip over the upper half of the paper-feed unit to access the upper aligning roller (white nylon); refer to Figure 8-6. Remove the two tensioning springs holding down each end of the upper aligning roller.

  • Page 138: Figure 8-12 Removing The Feed Roller

    Remove the feed roller. If necessary, remove the right end bushing to create more clearance for removing the roller. Right end bushing Gear White nylon gear 8699-30 Figure 8-12 Removing the feed roller For reassembly, reverse the steps you performed to reinstall the rollers. 8-14 DECcolorwriter 1000...

  • Page 139: Figure 8-13 Removing The Exit Rollers

    FRU Disassembly/Assembly Removing the exit rollers Power down the printer and remove the power cord. Open the top cover and remove the front access cover. Also, remove the top front, left and right side cabinet panels as described in “Printer cabinet panels”...

  • Page 140: Figure 8-14 Removing The Bail Roller Assembly

    Reverse these steps to reinstall the bail roller. Bail roller assembly 8699-33 Figure 8-14 Removing the bail roller assembly Note Upon reassembly, make sure that the bail roller assembly metal frame does not contact the drum’s paper clamp. 8-16 DECcolorwriter 1000...

  • Page 141: Thermal Head

    FRU Disassembly/Assembly Thermal head Tools required #1 POSIDRIV® screwdriver Power down the printer and remove the power cord. Remove the top cabinet panel. Refer to the earlier topic “Printer cabinet panels” on page 8-3. Close the top cover. Remove the screws securing the thermal head fan and move the fan out of the way so that you can access the thermal head's guide pin.

  • Page 142: Figure 8-15 Removing The Thermal Head

    Removing the thermal head Warning Do not disconnect the ground strap from the back of the thermal head; only disconnect it from the head lift motor bracket. Not reconnecting the ground strap will damage the thermal head upon power-up. 8-18 DECcolorwriter 1000...

  • Page 143: Figure 8-16 Removing The Drum Belt And Pulley

    FRU Disassembly/Assembly Drum Tools required #1 POSIDRIV® screwdriver Needle-nose pliers Small flat-blade screwdriver 2 mm wrench 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 panels. Refer to the earlier topic “Printer cabinet panels”...

  • Page 144: Figure 8-17 Removing The Front Idlerþroller

    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 idlerþroller Remove the bail roller assembly by removing the pair of screws at each end of the assembly. 8-20 DECcolorwriter 1000...

  • Page 145: 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 146: Figure 8-19 Removing The Drum

    Also adjust the drum’s paper clamp with the two adjustments “Top margin adjustment” on page 9-12 and “Paper clamp adjustment (to correct misregistration)” on page 9-18. 8-22 DECcolorwriter 1000...

  • Page 147: Figure 8-20 Removing The Paper-Feedþmotor

    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 8-3. 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 148: Figure 8-21 Removing The Drum Motor

    Remove the four outer screws securing the drum motor to the print engine frame. Remove the motor. Reverse these steps to reinstall the drum motor. Belt tensioner Drum motor Drum pulley Drum belt 8699-46 Figure 8-21 Removing the drum motor 8-24 DECcolorwriter 1000...

  • Page 149: Figure 8-22 Removing The Transfer Roll Take-Up Gear

    FRU Disassembly/Assembly Transfer roll take-up motor 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 side cabinet panel. Refer to the earlier topic “Printer cabinet panels”...

  • Page 150: Figure 8-23 Removing The Transfer Roll Take-Up Motor

    Removing the transfer roll take-up motor Reverse these steps to reinstall the transfer roll take-up motor. When you install the take-up gear, be sure to position the gear's set screw over the keyed portion of the motor shaft. 8-26 DECcolorwriter 1000...

  • Page 151: Figure 8-24 Freeing The Thermal Head Drive Belt And Thermal Head Lift Motor Bracket

    FRU Disassembly/Assembly Thermal head lift motor Tools required #1 POSIDRIV® screwdriver Power down the printer and remove the power cord. Remove the cabinet top. Refer to the earlier topic “Printer cabinet panels” on page 8-3. Unloop the thermal head lift belt from the thermal head lift cam roller's pulley.

  • Page 152: Figure 8-25 Removing The Thermal Head Liftþmotor

    Remove the screw securing the thermal head lift motor in place. Remove the motor with an upward twisting motion. Disconnect the thermal head lift motor's wiring harness. Reverse these steps to reinstall the thermal head lift motor. Ground straps 8699-49 Figure 8-25 Removing the thermal head liftþmotor 8-28 DECcolorwriter 1000...

  • Page 153: 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 154: Figure 8-26 Removing The Paper-Feed Circuit Board

    Remove the two screws securing the paper-feed circuit board to the paper-feed module. (One screw is reached through an access hole.) Slide the board out of the way. Paper-feed module Paper-feed circuit board 8699-24 Figure 8-26 Removing the paper-feed circuit board 8-30 DECcolorwriter 1000...

  • Page 155: Figure 8-27 Removing The Paper-Passþsensor

    FRU Disassembly/Assembly Remove the four screws securing the top half of the paper-feed module. Separate the two halves and flip over the upper half. Paper-pass sensor 2: 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-passþsensor 2...

  • Page 156: Figure 8-28 Removing The Tray Sensors Circuit Board

    Remove the screw securing the paper tray sensor circuit board to the bracket. Remove the circuit board. Reverse these steps to reinstall paper-pass sensor 2 and the tray sensor circuit board. Unhinge Tray sensors here circuit board Tray sensors bracket 8699-51 Figure 8-28 Removing the tray sensors circuit board 8-32 DECcolorwriter 1000...

  • Page 157: Figure 8-29 Removing The Transfer Roll Low Sensor

    FRU Disassembly/Assembly Transfer roll low sensor Tools required #1 POSIDRIV® screwdriver This sensor is located inside the print engine near the power supply (below the supply-side transfer roll). Power down the printer and remove the power cord. Open the top access cover and remove the transfer roll. Remove the card cage and power supply as explained in the later topic “Card cage and power supply”...
  • Page 158 Reverse these steps to reinstall the paper clamp sensor. Run the calibration check “Calibrating the paper clamp sensor (reflective sensor)” on page 9-10 to ensure the sensor is properly adjusted Paper clamp sensor 8699-53 Figure 8-30 Removing the paper clamp sensor 8-34 DECcolorwriter 1000...

  • Page 159: Figure 8-31 Disconnecting The Wiring Harnesses And Removing The Card Cage

    FRU Disassembly/Assembly Card cage and power supply Tools required #1 POSIDRIV® screwdriver Power down the printer and remove the power cord. Disconnect all host interface connectors. Remove the rear and side cabinet panels. Refer to the earlier topic “Printer cabinet panels” on page 8-3. Disconnect all wiring harnesses from the card cage.

  • Page 160: Figure 8-32 Removing The Card Cage And Power Supply

    Engine fan: Note that the engine fan blows into the cardþcage. Reverse these steps to reinstall the power supply and card cage. Card cage 5 Power supply harness to printhead Fuses Power supply 8699-44A Figure 8-32 Removing the card cage and power supply 8-36 DECcolorwriter 1000...

  • Page 161: Circuit Boards

    FRU Disassembly/Assembly Circuit boards Power supply circuit board Tools required #1 POSIDRIV® screwdriver Warning Unplug the power cord to remove a possible electric shock hazard. Power down the printer. Unplug the power cord. Remove the power supply as detailed in the previous procedure “Card cage and power supply”...

  • Page 162: Figure 8-33 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” on page 9-14 to ensure that the printhead is calibrated to the new power supply. Power supply circuit board 8699-72A Figure 8-33 Removing the power supply circuit board 8-38 DECcolorwriter 1000...

  • Page 163: Figure 8-34 Disconnecting The Wiring Harnesses

    FRU Disassembly/Assembly Paper-feed circuit board The paper-feed circuit board can be removed as a part of the paper-feed module disassembly procedure. Refer to the earlier procedure “Paper-feed module” on page 8-5. Engine control board Tools required #1 POSIDRIV® screwdriver Power down the printer. Leave the power cord plugged in to provide a ground path for static discharges.

  • Page 164: Figure 8-35 Removing The Engine Control Board

    NVRAM IC, perform the procedures “Thermal head temperature adjustment” on page 9-14 and “Reflective sensor auto-calibration” on page 9-7. Reverse these steps to install the engine control board. 8699-54 Figure 8-35 Removing the engine control board 8-40 DECcolorwriter 1000...

  • Page 165: Figure 8-36 Removing The Interconnectþboard

    FRU Disassembly/Assembly Card cage interconnect board Power down the printer. Leave the power cord plugged in to provide a ground path for static discharges. Remove all interface cables. Remove the left side, right side and top-rear cabinet panels. Refer to the earlier topic “Printer cabinet panels”...

  • Page 166: Figure 8-37 Removing The I/O Board

    Remove the screws securing the I/O board to the card cage. Disconnect the I/O board’s ribbon cable from the image processor board. Remove the I/O board. Reverse these steps to reinstall the I/O board and the image processor board. I/O board Figure 8-37 Removing the I/O board 8-42 DECcolorwriter 1000...

  • Page 167: Figure 8-38 Removing The Image Processor Board

    FRU Disassembly/Assembly Image processor board 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 interface cables. Remove the top-rear and rear cabinet panels. Refer to the earlier topic “Printer cabinet panels”...

  • Page 168: Figure 8-39 Installing The Ram Simm On The Image Processor Board

    Reinstall the image processor board in the card cage. Reinstall the I/O board. Reinstall the card cage top and the rear cabinet panels. Reconnect the host interface cables. Turn on the printer and make a test print. 8-44 DECcolorwriter 1000...

  • Page 169: Figure 8-40 Installing The Font Simm On The Image Processor Board

    FRU Disassembly/Assembly Font module 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 interface cables. Remove the I/O board and the image processor board as explained in the previous procedures “I/O board”...
  • Page 170 FRU Disassembly/Assembly 8-46 DECcolorwriter 1000...

  • Page 171: Required Tools Summary

    Chapter Checks and Adjustments This chapter describes how to make mechanical and electrical adjustments to the DECcolorwriter 1000 print engines. It also describes how to maximize print quality. Required tools summary Magnetic tip screwdriver -- 8.5 ins. Extension tip #1 POSIDRIV® tip #2 POSIDRIV®...

  • Page 172: Figure 9-1 Engine Control Board Dip Switches

    Alternatively, you can press and hold the TEST button for 5 seconds to start the selected pattern. Dip Switch 1 Dip Switch 2 (thermal head temperature) 8699-68A Figure 9-1 Engine control board DIP switches DECcolorwriter 1000...

  • Page 173: Table 9-1 Selecting Self-Test Print Patterns

    Checks and Adjustments Table 9-1 Selecting self-test print patterns Dip switches Print pattern and tests Color Test Pattern 0: Speckle detect ↑ Test Pattern 1: Rag patch (full step) ↑ Test Pattern 2: Bridging detect (orange) ↑ ↑ Test Pattern 3: Composite black fill (C, M, Y) ↑...

  • Page 174: Table 9-2 Self-Check Mode Summary

    Mechanical switch check 5: paper-pass sensors, paper exit sensor, drum home sensor. ↑ ↑ ↑ Mechanical switch check 6: transfer roll half used sensor. ↑ ↑ ↑ Transfer roll mark sensor adjust. ↑ ↑ ↑ ↑ Paper clamped sensor adjust. ↑ indicates switch is on. DECcolorwriter 1000...

  • Page 175: 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 8-3. Press and hold the TEST button and turn on the printer. Release the TEST button.

  • Page 176: Paper-Path Check

    Set DIP Switch 1-3 on to start the test. LEDs ERROR and JAM blink rapidly to indicate that tray selection is active. Toggle Dip Switch 1-8 on to select the tray you want. LED READY will blink rapidly if the second feeder tray is selected. DECcolorwriter 1000...

  • Page 177: Reflective Sensor Auto-Calibration

    Checks and Adjustments LED READY will turn off if the standard tray is selected. Set DIP Switch 1-3 off to exit the mode. Reflective sensor auto-calibration This procedure automatically calibrates the transfer roll mark sensors and the paper clamped sensor. These sensors can also be individually calibrated in the later procedures “Calibrating the transfer roll mark sensors (reflective sensors)”...

  • Page 178: Switch And Interrupt Sensor Checks

    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. Mode 6: Set DIP Switches 1-4, 1-5 and 1-7 on. DECcolorwriter 1000...

  • Page 179: Table 9-3 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, TRANSFER ROLL, COVER, or READY blink rapidly when each switch is actuated.

  • Page 180: Calibrating The Transfer Roll Mark Sensors (Reflective Sensors)

    Push the TEST button. The printer will pick a sheet of paper and pass it through the paper path. LED READY will blink rapidly as the paper clamp sensor is calibrated. Set DIP Switch 1-3 off to stop the test. 9-10 DECcolorwriter 1000...

  • Page 181: Figure 9-2 Tensioning The Drum Belt

    Checks and Adjustments Drum belt tension adjustment Tools required #1 POSIDRIV® screwdriver This adjustment should be made whenever the drum or drum belt has been removed or replaced. Power down the printer. Remove the left-side cabinet panel. Refer to the Chapter 8 topic “Printer cabinet panels”...

  • Page 182: Table 9-4 Top Margin Adjust Settings

    Top margin adjust settings TRANSFER COVER READY ROLL margin Switches adjust value -3 mm ↑ -2 mm ↑ -1 mm ↑ ↑ ↑ 1 mm ↑ ↑ 2 mm ↑ ↑ 3 mm ↑ ↑ ↑ 4 mm 9-12 DECcolorwriter 1000...
  • Page 183 Checks and Adjustments Set DIP Switches 1-5, 1-6 and 1-7 to correspond to the desired top margin adjustment. Positive numbers increase the distance the paper is inserted into the paper clamp, thereby increasing the top margin. The bottom margin will get correspondingly smaller.

  • Page 184: Adjusting For Best Print Quality

    14 steps with the color yellow. The human eye is somewhat insensitive to shade changes to the color yellow. On rare occasions, it may be difficult to achieve 14 levels of cyan or magenta. It may be necessary to compromise those shades to 13 levels. 9-14 DECcolorwriter 1000...
  • Page 185 Checks and Adjustments Use test pattern 5 to check and make the thermal head temperature adjustment. Table 9-5 Setting thermal head temperature (based on thermal head resistance) Dip Switches Resistance (Ω) printed on thermal head 1315 ↑ 1316 to 1345 ↑...

  • Page 186: Thermal Head Pitch (To Correct Speckle And Wrinkle)

    Rotate the pitch adjustment nut an additional 1/2 turn clockwise to finish the adjustment. Apply cement compound to the nut to lock it in its current position. Close the top cover and turn off the printer. Reinstall the rear top cabinet panel. 9-16 DECcolorwriter 1000...

  • Page 187: Figure 9-3 Adjusting The Thermal Head Pitch

    Checks and Adjustments Pitch adjustment Thermal head Pitch adjustment Thermal head elements Drum 8699-91A Figure 9-3 Adjusting the thermal head pitch 9-17 Service Manual...

  • Page 188: Paper Clamp Adjustment (To Correct Misregistration)

    If the clamp grips the paper too tightly, misregistration can occur. This is characterized by magenta and cyan shifting (fringing) with respect to yellow in the two top corner crosshatch patterns of the inspection/check test pattern. (These are the corners closest to the paper clamp.) 9-18 DECcolorwriter 1000...

  • Page 189: Figure 9-4 Setting The Paper Clamp Adjustment

    Checks and Adjustments Paper clamp Access hole Eccentric High side mark on eccentric nut. Set it so the mark always faces toward the front of the printer. 8699-90A Figure 9-4 Setting the paper clamp adjustment 9-19 Service Manual...
  • Page 190 Checks and Adjustments 9-20 DECcolorwriter 1000...
  • Page 191 Appendix Field Replaceable Units List This appendix provides a list of field replaceable units for the DECcolorwriter 1000 Color Printer. Changes to the instruments are made to accommodate improved components as they become available. It is important when ordering parts to include the following information: Component's order number.
  • Page 192 CABINET: BACK UPPER A-1-4 118-8932-00 CABINET TOP: WITH OPEN LEVER A-1-5 118-8939-00 CABINET: RIGHT SIDE A-1-6 118-8933-00 CABINET FRONT: UPPER WITHOUT LED BOARD A-1-7 118-8934-00 CABINET FRONT: CENTER A-1-8 118-8935-00 CABINET FRONT: LOWER A-1-9 118-8841-00 DOOR: FRONT ACCESS DECcolorwriter 1000...

  • Page 193: Figure A-1. The Printer Exterior Frus

    Field Replaceable Units List 8699-76A Figure A-1. The printer exterior FRUs Service Manual...
  • Page 194 FRONT PANEL: LED UNIT A-2-29 118-8838-00 CLUTCH KIT: ALIGNING ROLLER, A-2-30 118-8839-00 CLUTCH KIT: PAPER PICK UP ROLLER, A-2-31 29-31558-01 118-8835-00 PAPER FEED UNIT A-2-32 118-8837-00 D ROLLER: RUBBER ONLY, A-2-33 DRUM, PAPER CLAMP 118-8836-00 FLAG SENSOR KIT 118-8840-00 HARDWARE KIT DECcolorwriter 1000...
  • Page 195 Field Replaceable Units List Service Manual...

  • Page 196: Figure A-2. Exploded View Of The Printer

    Field Replaceable Units List Figure A-2. Exploded view of the printer DECcolorwriter 1000...
  • Page 197 1000, ITALIAN ONLY. DON’T ORDER EK-LF02G-UM MANUAL,TECH: USER, DECcolorwriter 1000, GERMAN ONLY. DON’T ORDER EK-LF02S-UM MANUAL,TECH: USER, DECcolorwriter 1000, SPANISH ONLY. DON’T ORDER EK-LF02E-TR 070-8932-00 MANUAL,TECH: DECcolorwriter 1000 SW PRINTER TOOLS REFERENCE LF02X-AD 016-1288-70 CLEANING KIT 29-31587-01 063-1737-00 DRIVERS/UTILITIES S/W Service Manual...
  • Page 198 Field Replaceable Units List DECcolorwriter 1000...

  • Page 199: Table C-1. Connector Cn2

    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 CN2 Signal Signal Signal Signal CVOPN1-0...

  • Page 200: Table C-3. Connector Cn4

    Table C-4. Connector CN5 Signal Signal +5 VDC LJAM-0 LCOV-0 LERR-0 LTROLL-0 LRDY-0 LPAP-0 LPWR-0 Table C-5. Connector CN6 Signal Signal HTHR HTHRR +5 VDC STROBE4-0 LATCH-0 STROBE3-0 DATA2 STROBE2-0 DATA1 STROBE1-0 no connect CLOCK B.E.O DECcolorwriter 1000...

  • Page 201: Table C-6. Connector Cn7

    Wiring Diagrams Table C-6. Connector CN7 Signal Signal RHLFR RHLF Table C-7. Connector CN8 Signal Signal RTYP1 Service Manual...
  • Page 202 Front panel Core sensor, left Transfer roll sensor Core sensor, right Paper-clamp sensor Drum-home- position sensor Paper-feed circuit board ..Paper-feed motor Drum motor 8699-81A Figure C-1. Print engine control board connector diagram DECcolorwriter 1000...
  • Page 203 Wiring Diagrams Thermal Thermal head head lift motor Image processor Thermal head position sensor board Test Engine control switch board Transfer roll mark sensor Interconnect Drum board motor Core sensor, Drum-home- left position sensor Engine Transfer-roll- Paper clamp low sensor sensor Core sensor, right...
  • Page 204 Wiring Diagrams DECcolorwriter 1000...

  • Page 205: Test Pattern Generator

    The Test Pattern Generator allows you to test a printer as if it was receiving a file from a host computer. In the case of the DECcolorwriter 1000, the PostScript script causes the printer's image processor to forward a command to the print engine which generates and prints the test pattern.
  • Page 206 E th e rn N ot d re In st al le 1 2 3 4 5 Start button 1 2 3 4 5 8699-78 Figure D-1. Plugging the Test Pattern Generator into the printer's parallel port DECcolorwriter 1000...

  • Page 207: Table D-1. Test Pattern Generator Dip Switch Settings For Deccolorwriter 1000

    Test Pattern Generator Press the Test Pattern Generator's START button. Its green LED flashes as you press the button. The printer will print the transmitted print file. Besides print files, the test pattern generator also allows you to turn off and on the printer's startup page.
  • Page 208 Test Pattern Generator DECcolorwriter 1000...
  • Page 209 Front panel indicators 6-24 FRUs A-1 Dark prints, Light prints 6-16 functional specifications 1-13 data fuses buffer 5-7 location 8-36 controller 5-7 image 5-5 DECcolorwriter 1000, description 1-2 DIP switches print engine 9-2 rear panel 1-8 dithering 5-5 Index-1 Service Manual...
  • Page 210 Power problems 6-24 printing 3-1 power supply using the Error Handler utility 3-3 removing 8-35 mechanical controller 5-8 theory 5-15 Microsoft Windows verifying 6-3 standard PostScript printer driver 2-17 power-up sequence 6-1 misregistration 9-18 pre-installation interview 2-1 Index-2 DECcolorwriter 1000...
  • Page 211 print process 5-8 5-12 troubleshooting with 6-18 print quality service mode error codes 1-11 troubleshooting 6-13 skewed print print unloading troubleshooting 6-12 theory 5-14 soft error 1-8 printcap, configuring a workstation 2-22 specifications print-eject jams clearances 1-12 troubleshooting 6-11 electrical 1-14 printer environmental 1-15 assembly locations 1-3...
  • Page 212 White portion of print is colored 6-14 Windows 3.1 driver verification 3-4 Windows 3.1, Tektronix driver 2-14 Windows printer driver configuring 2-14 installing 2-14 wiring harnesses, pinouts and diagrams C-1 workstation printing 3-7 using the Error Handler utility 3-7 Wrinkled prints 6-17 Index-4 DECcolorwriter 1000...

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