HP DesignJet 200 Service Manual
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HP DesignJet 200 Service Manual

HP DesignJet 200 Service Manual

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Summary of Contents for HP DesignJet 200

  • Page 1 Service Manual HP DesignJet 220 and HP DesignJet 200 Plotters...
  • Page 2 For HP Internal Use Warranty WARNING :nly The information contained The procedures described R Copyright Hewlett in this document is subject in this manual are to be Packard Company 1994 to change without notice. performed by HP qualified service personnel only.
  • Page 3 Service Manual HP DesignJet 220 and HP DesignJet 200 Plotters...

  • Page 4: Using This Manual

    D HP DesignJet 220 plotters (models C3187A and C3188A) For information about using these plotters, refer to the corresponding user guides. Readership The procedures described in this manual are to be performed by HP qualified service personnel only. Training The HP ongoing training course CEV2 TIJ provides training for HP Customer Engineers, on servicing the complete HP DesignJet series of large format, thermal inkjet plotters.

  • Page 5: Table Of Contents

    ..........Upgrading a DesignJet 200 .
  • Page 6 (more ' User's Guide) DesignJet 200 Front Panel ......... .
  • Page 7 5 15 DesignJet 200 ...........
  • Page 8 Servo Processor System ..........5 26 Servo Processor .
  • Page 9 Removing the Automatic Cartridge Adjust Linkage ....6 20 Removing the Stepper Motor ........6 21 Removing the Pinch Arm Sensor .
  • Page 10 8 Troubleshooting Power On ............. Power On Self Test .
  • Page 11 8 16 HP GL Timeout ........... .
  • Page 12 9 Product History Introduction ............Serial Number Format .

  • Page 13: Safety Symbols

    General Definition of Safety Symbols International caution symbol (refer to manual): the product is marked with this symbol when it is necessary for the user to refer to the instruction manual in order to protect against damage to the instrument. Indicates dangerous voltage (terminals fed from the interior by voltage exceeding 1000 volts must also be marked).
  • Page 14 Notes Safety C3187 90000...

  • Page 15: Product Information

    Product Information...

  • Page 16: Description

    Description Applications HP DesignJet 200 and HP DesignJet 220 plotters are large format, monochrome, ink jet plotters that provide hardcopy output of computer program data. Large format plots of high resolution and quality are generated for applications such as D Computer aided design (CAD)

  • Page 17: Accuracy

    23 C (73 F) at 50 60% relative humidity, on HP special polyester film. Resolution The resolution of the plotter output is measured in dots per inch (dpi). (Explanation ' chapter 5.) The plotter resolutions for different plot quality settings are as follows:...

  • Page 18: Media Sizes

    D Automatic cartridge alignment, testing and servicing D Built in diagnostic and demonstration plots Upgrading a DesignJet 200 Users can order an upgrade kit to upgrade a DesignJet 200 to a DesignJet 220. The kit should be installed by HP qualified service personnel only. Product Information...

  • Page 19: Site Planning And Requirements

    Site Planning and Requirements...

  • Page 20: Power Requirements

    Power Requirements HP C3180A and C3181A DesignJet 200 and HP C3187A and C3188A DesignJet 220 plotters have self adjusting power supplies and do not require a voltage selector or switch settings prior to use. The table below lists the power requirements for the plotters.

  • Page 21: Choosing A Suitable Plotter Environment (More ' User's Guide)

    Choosing a Suitable Plotter Environment (Instructions ' User's Guide, chapter 1, w Positioning the plotter.) Environmental Specifications Hardware: Environmental Class B2 Operating environment: Temperature Relative Humidity Plotter 0 to 55_C (32 to 131_F) 20-80% With cartridges and media: 10 to 40_C (50 to 104_F) 20-80% Optimal print quality and media handling:...
  • Page 22 Notes Site Planning and Requirements C3187 90000...

  • Page 23: Installation And Configuration

    Installation and Configuration...

  • Page 24: Unpacking And Assembling The Plotter

    Unpacking and Assembling the Plotter When the plotter arrives at the user site: 1 Inspect the shipping container for damage. If the shipping container shows signs of damage, retain it until you have checked the contents of the shipment and verified the performance of the plotter. 2 Unpack and assemble the plotter, following the series of illustrations below.

  • Page 25: Inspecting The Plotter For Damage

    Visually inspect the plotter for damage, scratches, dents, or other mechanical defects. If the plotter is damaged in transit, notify the carrier and the nearest HP Sales and Support Office. Retain the shipping container and insulation material for the carrier's inspection. The Sales and Support Office will arrange for the repair or replacement of the plotter.

  • Page 26: Assembling The Legs And Bin (Optional)

    Assembling the Legs and Media Bin (Optional) If the user has purchased the optional legs and media bin for the plotter, assemble them following the series of illustrations below: 45 kg (99 lb) Installation and Configuration C3187 90000...
  • Page 27 6 mm (0.25 in) C3187 90000 Installation and Configuration...

  • Page 28: Installing The Plotter (More ' User's Guide)

    Line Cord Set for the geographical area. However, different power cords (international options) are available. (Cable part numbers ' Service Manual, chapter 10.) Using the Plotter (Instructions ' User's Guide, chapter 2, Using the plotter.) DesignJet 200 Access Align Front Panel Setup...

  • Page 29: Configuring The Plotter (More ' User's Guide)

    - Language of demonstration plot and setup sheet - Baud rate and parity of serial interface - Graphics language - HP GL timeout period - Plot orientation (rotate and mirror) - Line merging - Pen palette settings (width and density) An example of a setup sheet is given on the following page.

  • Page 30: Example Of Setup Sheet

    Example of Setup Sheet The following is a scaled version of a DesignJet 200 setup sheet: Installation and Configuration C3187 90000...

  • Page 31: Preventive Maintenance

    Preventive Maintenance...

  • Page 32: Cleaning The Plotter

    Cleaning the Plotter To maintain the plotter in good operating condition, keep it free of dust accumulation, ink, and other contamination. Cleaning intervals are determined by the plotter environment and by the types of plotter supplies used. As with any precision electronics equipment, proper maintenance will help to ensure reliability and prolong product life.

  • Page 33: Functional Overview

    Functional Overview...

  • Page 34: Loading The Media

    Loading the Media Entry Platen The media load path begins with the entry platen, which provides a loading surface. (Illustration ' page 10 23.) When you assemble the plotter, it is important to correctly position the entry platen to ensure that the dashed lines exactly indicate the permitted right edge loading area.
  • Page 35 The media not loaded state can be summarized as follows: D Media: not inserted or has not yet reached the primary flag D Primary flag: vertical position (idle) D Secondary flag: resting on plastic detector housing (idle) D Optical sensor: optical path closed by both flags D Drive roller: stopped D Front panel: Load Media LED on 2.
  • Page 36 3. Front Edge Reaches Secondary Flag Drive roller full speed inwards Media inserted Primary flag Secondary flag Photo sensor window D Media: reaches the secondary flag D Primary flag: rotated 90 counter clockwise (active) D Secondary flag: rotated 35 counter clockwise (active) D Optical sensor: optical path cleared by both flags D Drive roller: full speed inwards, engaging media D Front Panel: Load Media LED off, Busy LED on...
  • Page 37 4. Rear Edge Clears Primary Flag Drive roller slow speed inwards Media inserted Leading edge of media Secondary flag Primary flag Photo sensor window D Media: clears the primary flag D Primary flag: rotates 90 clockwise (original position active) D Secondary flag: still in previous position (active) D Optical sensor: optical path blocked by falling edge of primary flag D Driver roller: slows down but still rotating inwards...

  • Page 38: Gripping The Media

    5. Rear Edge Measured Drive roller slow speed outwards Media inserted Leading edge of media Secondary flag Primary flag Photo sensor window D Media: pushes the primary flag D Primary flag: rotates 90 clockwise (active) D Secondary flag: still in previous position (active) D Optical sensor: optical path cleared by primary flag D Driver roller: rotates slowly outwards...

  • Page 39: Advancing The Media

    Advancing the Media Media Drive Mechanics The media is advanced by the media drive (X drive) system. Components include: D Media motor (X axis motor) D Worm pinion and helical drive roller gear D Drive roller (Illustration ' page 10 23.) The main component of the drive system is a full width, 6.4 cm (2.5 inch) diameter roller with an elastomer skin.

  • Page 40: Providing A Force On Top Of The Media

    Providing a Force on Top of the Media Bail The bail provides a normal force on top of the media. (Illustration ' page 10 25.) When the pinch wheels grip the media and the drive roller advances it, the plotter raises the bail. This enables the leading edge of the media to pass below the bail.

  • Page 41: Stretching The Media

    Stretching the Media Overdrive The overdrive roller stretches the media slightly as it is moved through the plotter. It thus reduces bubbling and media cockle caused by media expansion due to the absorption of water based ink into the media. Even though the geometry chosen for the plotters minimizes the occurrence of this phenomena, it still could occur on very dense plots.

  • Page 42: Detecting The Media Edges

    Detecting the Media Edges Line Sensor The plotter detects the left and right media edges using the line sensor located on the carriage. The sensor is composed of D Red LED D Two lenses (caution required when handling) D Collector plate Operation 1 The sensor finds the left media edge when it detects the light from the red LED reflected off the media surface.

  • Page 43: Providing Ink

    (Carriage Illustration ' page 10 21) Print Cartridges The plotters use two HP DeskJet type cartridges, each containing 50 nozzles. The cartridges are staggered such that two nozzles on each one are not used. The main components of a cartridge are the...

  • Page 44: Important Parameters

    Important Parameters The geometry of the nozzle is important to maintain drop shape and direction. The distance of the head from the writing surface can determine image sharpness. As the distance increases, the drop shape and directionality degrade and are more difficult to predict. Cartridge Chutes The two black print cartridges snap into the cartridge chutes (carriage snaps).

  • Page 45: Producing An Image

    300 dpi Enhanced Mode Final Mode Both DesignJet 200 and DesignJet 220 plotters use two 300 dpi print cartridges. However, the DesignJet 220 has an Enhanced print mode enabling it to address a 600 dpi grid. C3187 90000 Functional Overview...

  • Page 46: Dot Size

    Dot Size Each dot produced by a 300 dpi cartridge has a diameter of 0.0055 in. The dot size must be larger than 1/300th of an inch (0.0033 in.) so that when a single dot wide line is printed, dots overlap and the line appears to be continuous.

  • Page 47: Print Mode Characteristics

    Print Mode Characteristics DesignJet 200 Media Type Print Resolution # of Passes Carriage Swath Pass Quality (DPI) Speed Delay Density Paper Draft 300x300 24ips Final 300x300 16.7ips 1sec 100% Vellum/ Transl Draft 300x300 24ips Vellum/ Transl/Film Final 300x300 16.7ips 1sec...

  • Page 48: Aligning The Cartridges

    Aligning the Cartridges The cartridge alignment system is composed of D Stepper motor D Adjustment linkage D Adjustment cam D Adjustable cartridge chute D Carriage drive (Illustrations ' pages 10 15 and 10 21.) Operation The following operation is used to align one cartridge with respect to the other in the X axis (media axis).

  • Page 49: Servicing The Cartridges

    Servicing the Cartridges Service Station (Illustration ' page 10 17.) Various important cartridge maintenance operations are performed at the service station: D Cartridge wiping D Cartridge capping D Nozzle spitting Wiping During operation of the cartridge, ink accumulates on the nozzle plate along with paper dust and other substances foreign to the cartridge.

  • Page 50: Capping

    Capping Ink evaporates if you expose non firing nozzle plates to the open environment. Vapor loss changes the physical properties of the ink remaining in the area of the nozzle plate. The ink may form viscous plugs that fully or partially clog nozzles. To reduce the loss of ink vapor and thus prevent the nozzles from drying out when the cartridges sit idle, the service station automatically places a cap over the nozzle plates.

  • Page 51: System Data Flow

    System Data Flow Firmware Graphics Data characters Module One at a time Parser I/O Buffer Physical Graphic Swath Area Data characters objects 500 Bytes Display List I/O Interrupt Swath Graphic objects Firmware VRC, RRC Physical Print-Engine Input/Output Control Module Rasterized object Swath Swath...

  • Page 52: Converters

    Converters The vector to raster converter (VRC) or raster to raster converter (RRC), depending on the data format sent, rasterizes the data from the display list, swath by swath, and sends the swaths to a swath holding area. Swath Holding Area The swath holding area is part of the DRAM that is specially allocated for this purpose.

  • Page 53: Plotter Architecture

    Plotter Architecture The plotters have the multiprocessor architecture shown in the following diagram: Main Internal Expansion Processor Memory (Centronics) Memory (RS–232) (80960KA) (ROM/RAM) (SIMM DRAM) 80960 bus Encoders Swath RAM Shuffler Support (256 KB) ASIC ASIC Motor Drivers Carriage Servo Nozzle EEPROM Processor...

  • Page 54: Main Pca

    Main PCA (Part illustration ' page 10 9.) PCA and Sensor Interconnections Centronics RS–232 Media-axis encoder MAIN PCA Front panel PCA Carriage PCA Pinch-arm sensor Window sensor Media sensor Stepper motor Bail sensor Media motor Power supply SIMM socket Carriage motor The main PCA contains most of the plotter electronics, that is: D Main processor system D Servo processor subsystem...

  • Page 55: Main Processor System

    Main Processor System The main processor system consists of the following: D Main processor (80960) D ROM D Processor support ASIC D Shuffler ASIC with swath memory D Input/output interfaces D DRAM Swath To Servo Processor System Processor Shuffler 80960 RS-232 Support ASIC...

  • Page 56: Processor Support Asic

    Processor Support ASIC The processor support ASIC provides support for the main processor, and an interface between the main processor and the servo processor. Shuffler ASIC and Swath Memory The shuffler ASIC and the swath memory shuffle the row oriented image data in the system memory into column oriented nozzle data needed by the print cartridges.

  • Page 57: Serial Hardware

    The main processor controls the DTR (Data Terminal Ready) signal using Serial Hardware a bit in the parallel I/O control register. Whenever the power to the plotter is on, RTS (Request To Send) is set active. No other modem signals are controlled or monitored. The reset state of the DTR signal is undefined.

  • Page 58: Servo Processor System

    Servo Processor System The servo processor system consists of the following: D Servo processor (8052) D Processor support ASIC D Front panel interface D Stepper motor driver D Carriage processor interface D Various sensor inputs D EEROM Motor Front-Panel Position Interface Encoders Sensors...

  • Page 59: Front Panel Interface

    Front Panel Interface The front panel consists of nine LEDs and eight switches. The servo processor interface to the front panel consists of nine control signals and two sense signals. Stepper Motor Driver The servo processor controls a stepper motor used for print cartridge servicing and alignment.

  • Page 60: Power Components

    Power Components The following are the power components on the main PCA: Carriage and Media Motor Drivers Two motor driver ICs and heatsinks. Print Cartridge Voltage Regulator To regulate the amount of energy given to the print cartridge heating resistors, a precise voltage regulator controls the print cartridge voltage supply.

  • Page 61: Carriage Pca

    Carriage PCA The carriage PCA has four main functions: D The nozzle timing ASIC controls the firing of the print cartridges, using data from the shuffler ASIC on the main PCA. D A linear encoder senses the carriage position. D A line sensor enables automatic print cartridge calibration. D A thermistor monitors the temperature near the print cartridges.

  • Page 62: Nozzle Timing Asic

    Nozzle Timing ASIC The carriage processor dedicates its address/data bus to interface with the nozzle timing ASIC. The ASIC is also connected to the shuffler ASIC by a synchronous serial channel. The nozzle timing ASIC applies the shuffled data it receives from the shuffler ASIC to the cartridge drivers, controlling the firing time and sequence of the print cartridge nozzles.

  • Page 63: Front Panel Pca

    Front Panel PCA The plotters use the same front panel PCA as the DeskJet 550. The front panel consists of nine LEDs and eight switches, mounted on the PCA, which is deeply recessed behind a plastic housing containing the key pad. The keys act on the switches through push rods. Light pipes transmit the light from the LEDs to the display area.

  • Page 64: Power Supply

    Power Supply An auto ranging power supply is located in the electronics enclosure. It accepts and automatically adjusts to an ac input of 90 V through 264 V and produces regulated voltages of +5 V , +12 V and -12 V , and an unregulated +24 V . These voltages are used as follows: Voltage +24 V Motor drivers and voltage regulator on the main PCA.
  • Page 65 DPmdiHl HcM DPplHJPmPcg...

  • Page 66: Removal And Replacement

    Safety Precautions (Safety symbols D Immediately after the table of contents.) Review WARNING and CAUTION symbols and instructions before you service the plotters. Follow these warnings and cautions for your protection and to avoid damaging the plotter. Ucrgnus sfnai fW Wrb kcWbgme tn bcWtf nr gmhurz lWz rcsukt gd SO OLOGOHOGOF znu bn mnt tWic tfc dnkknygme orcaWutgnms: Rmsurc tfWt tfc Wa onycr nutkct ,lWgms.

  • Page 67: Required Tools

    Required Tools The following are the tools required to disassemble and repair the plotters. D Long Torx screwdriver with the indicated attachments: D 90 Torx 15 key: D Pozidriv PZ1 screwdriver: D Small flat blade screwdriver: C3187 90000 Removal and Replacement...
  • Page 68 D Nut driver with indicated attachments: 3/16 inch 5.5 mm D Needle nose pliers D Cutting pliers D Spring hook D Loopback connector (HP Part Number 07440 60302) D 10X Magnifier Removal and Replacement C3187 90000...

  • Page 69: Repair Procedures

    Repair Procedures Removing the Electronics Enclosure Cover 1 Ensure that the plotter is switched off 2 At the back of the plotter, ensure that and that the power cord and interface the two small wire clamps of the parallel cable(s) are not connected to it. port are positioned vertically.
  • Page 70 5 Push the cover up so that its tabs can 6 Carefully pull the cover clear of the slide out of the slots at the top of the plotter. electronics enclosure. Removal and Replacement C3187 90000...

  • Page 71: Removing The Memory Module ,Dram Simm

    Removing the Memory Module ,DRAM SIMM. The user may have installed an optional DRAM SIMM in the plotter. Perform the following procedure, if you need to remove it: 3 Locate the DRAM SIMM slot at the 1 Read ESD Precautions D page 6 2. bottom of the main PCA.
  • Page 72 To reinstall the SIMM, perform the following procedure: 1 Hold the memory module by its edges 2 Tilt the non metallic edge downwards with the non metallic edge toward you and firmly push the module into the slot. and the notch to your left. Gradually tilt the module upwards and push it in until it clicks into place.

  • Page 73: Removing The Main Pca

    Removing the Main PCA 2 Remove the two screws from the serial 1 Remove the electronics enclosure (RS 232 C) connector. cover D page 6 5. 3/16 inch 3 Remove the two screws from the parallel 4 D/A1 size plotters only: Open the connector.
  • Page 74 5 Disconnect all 12 cable connectors from the main PCA. Do not force the front panel PCA cable out of its clamp. First pull the C A U T I O N clamp gently towards you to release the cable; then pull the cable easily out of the clamp.
  • Page 75 If you are installing a new PCA, perform the following extra steps: 8 Remove the original EPROMs or masked ROMs from their sockets, and install them EPROMs on the new PCA. Empty pair of holes Masked ROMs The original PCA contains DithDr four EPROMs or two masked ROMs.

  • Page 76: Removing The Power Supply Pca

    Removing the Power Supply PCA 1 Remove the electronics enclosure 2 Open the flexible, DANGER HIGH cover D page 6 5. VOLTAGE," insulation cover. Flex the cover to open it Do not detach the cover from the plotter 10 Disconnect the ac connector and the dc power distribution connector from the power supply PCA.
  • Page 77 3 Remove the six screws that secure the 4 Lift the power supply PCA clear of the power supply PCA to the electronics plotter. enclosure. Torx-10 C3187 90000 Removal and Replacement 6 13...

  • Page 78: Removing The Fan

    Removing the Fan 1 Remove the electronics enclosure 3 Disconnect the fan connector from the cover D page 6 5. main PCA and holding clip. 2 Open the flexible, DANGER HIGH VOLTAGE," insulation cover. F Hx thH covHr to opHn t Do not dHtach thH covHr rom thH p ottHr Fan connector 4 Remove the two screws that secure the...

  • Page 79: Removing The Window

    Removing the Window 1 Open the window. 2 Loosen the top screw of the right front trim (two full turns). Torx-15 3 Carefully push the right endcover and 4 Move the window to the right so that the the window apart, far enough to lift the left pivot slides out of its socket, and lift window up so that the right pivot just the window clear of the plotter.

  • Page 80: Removing The Center Cover

    Removing the Center Cover 1 Remove the window D page 6 15. In the following steps, take care not to cut SO OLOGOHOGOF yourself on the encoder strip inside the plotter. 2 Loosen the two latch screws on the underside of the center cover. Torx-15 3 Slide the two latches horizontally towards the center of the plotter, clear of the two endcovers.
  • Page 81 4 Remove the screws from the back of the center cover. ha H ha H Torx-15 5 Slide the center cover vertically upwards, and lift it clear of the plotter. C3187 90000 Removal and Replacement 6 17...

  • Page 82: Removing The Left Endcover

    Removing the Left Endcover 1 Remove the window D page 6 15, and the center cover D page 6 16. 2 Remove the two screws on the left front trim and the two screws on the left back trim. Torx-15 Reassembling: When replacing screws on any plastic part, always begin C A U T I O N by gently twisting the screw in anticlockwise with your hand, until the...

  • Page 83: Removing The Right Endcover

    Removing the Right Endcover 1 Remove the window D page 6 15, and the center cover D page 6 16. 2 Remove the two screws on the right front trim and the two screws on the right back trim. Torx-15 Reassembling: When replacing screws on any plastic part, always begin C A U T I O N by gently twisting the screw in anticlockwise with your hand, until the...

  • Page 84: Removing The Automatic Cartridge Adjust Linkage

    Removing the Automatic Cartridge Adjust Linkage 4 Detach the linkage spring from the 1 Remove the window D page 6 15. Y tensioner bracket. 2 Remove the center cover D page 6 16. Reassembling: Attach the spr ng through 3 Remove the left endcover D page 6 18. the two small holes, as n the d agram.

  • Page 85: Removing The Stepper Motor

    Removing the Stepper Motor 1 Remove the electronics enclosure 5 Open the flexible, DANGER HIGH cover ' page 6 5. VOLTAGE," insulation cover. 2 Remove the window ' page 6 15. Carefully flex the cover to open t Do not 3 Remove the center cover ' page 6 16.
  • Page 86 8 Loosen the right screw and remove the 9 Move the stepper motor toward the rear left screw that attaches the stepper of the plotter. motor to the left sideplate. Torx-10 Loosen Remove C A U T I O N 10 Pull the stepper motor cable gently out from the electronics enclosure, through the hole in the left side of the electronics...

  • Page 87: Removing The Pinch Arm Sensor

    Removing the Pinch Arm Sensor 1 Remove the electronics enclosure 5 Disconnect the pinch arm sensor cable cover ' page 6 5. connector from the main PCA and from the ferrite on the right sideplate. 2 Remove the window ' page 6 15. The fe i e h lde en f m he 3 Remove the center cover ' page 6 16.

  • Page 88: Removing The Window Sensor

    Removing the Window Sensor 1 Remove the electronics enclosure 5 Disconnect the window sensor cable cover D page 6 5. connector from the main PCA. 2 Remove the window D page 6 15. 3 Remove the center cover D page 6 16. 4 Remove the right endcover D page 6 19.
  • Page 89 7 Slide the cable and connector up through 8 Remove the screw that attaches the the fastener near the right front trim. window sensor to the right front trim. Torx-8 Sensor Fastener C A U T I O N Reassembling: Do not cross thread or over tighten the screw.

  • Page 90: Removing The Media Sensor

    Removing the Media Sensor 1 Remove the electronics enclosure 5 Disconnect the media sensor cable cover D page 6 5. connector from the main PCA, and from the holding clip and ferrite on the right sideplate. 2 Remove the window D page 6 15. The ferrite holder opens from the top 3 Remove the center cover D page 6 16.
  • Page 91 7 Remove the screws that attach the 8 Pull the media sensor straight out bottom cover to the plotter, and lift the towards you, freeing it from the cover clear of the plotter. underside of the entry platen. D/A1 size plotters have 8 screws. E/A0 size plotters have 10 screws.

  • Page 92: Replacing The Media Sensor Flags

    Replacing the Media Sensor Flags 1 Insert the t shaped flag in the indicated 2 Let the t shaped flag rotate to its correct position. position. 3 Insert the bell shaped flag in the 4 Let the bell shaped flag rotate to its indicated position.

  • Page 93: Removing The Trailing Cable

    Removing the Trailing Cable If you are installing a new trailing cable, 5 Disconnect the trailing cable connector from the main PCA. make sure the main PCA is compatible with it. (Details D chapter 9.) 1 Remove the electronics enclosure cover D page 6 5.
  • Page 94 8 Disconnect the trailing cable connector from the cartridge carriage PCA. Cartridge-carriage PCA Trailing-cable connector 9 If you need to change the trailing cable: b Free the cable from the rear tray and bracket, pulling it up through the slot at a Cut the two plastic ties that hold the the top of the electronics enclosure assembly.
  • Page 95 10 If you don't need to change the trailing b Carefully remove the right hand cable, but do need to remove it to access cartridge spring from the cartridge other parts: carriage. a Remove the two screws that attach the trailing cable rear tray to the top of the electronics enclosure.

  • Page 96: Removing The Front Panel Assembly

    Removing the Front Panel Assembly 1 Remove the electronics enclosure 6 Unclip the window sensor cable and cover ' page 6 5. front panel cable from their holding clip on the underside of the front panel 2 Remove the window ' page 6 15. assembly.
  • Page 97 8 Carefully feed the front panel cable out from the electronics enclosure, through the flat ferrite on the right sideplate, and out from under the motor assemblies. 9 Remove the two screws and washers that attach the front panel assembly to the right side plate, and lift the front panel assembly, with cable, clear of the plotter.

  • Page 98: Removing The Front Panel Pca And Led Assembly

    Removing the Front Panel PCA and LED Assembly 1 Remove the electronics enclosure cover D page 6 5. 2 Remove the window D page 6 15. 3 Remove the center cover D page 6 16. 4 Remove the right endcover D page 6 19. 5 Remove the front panel assembly D page 6 32.

  • Page 99: Removing The Carriage (Y Axis) Motor

    Removing the Carriage ,Y Axis. Motor 5 Disconnect the carriage motor cable from 1 Remove the electronics enclosure the main PCA (connector labelled Y), and cover D page 6 5. from the lowest ferrite holder on the right hand side of the plotter. 2 Remove the window D page 6 15.
  • Page 100 8 Rotate the motor in the indicated 9 Pull the motor down, clear of its bracket. direction. Rotate Pull 6 36 Removal and Replacement C3187 90000...

  • Page 101: Removing The Media (X Axis) Motor

    Removing the Media ,X Axis. Motor 7 Disconnect the media motor cable from E Remove the electronics enclosure the main PCA (connector labeled X) and cover D page 6 5. from the uppermost ferrite holder on the right hand side of the plotter. F Remove the window D page 6 15.
  • Page 102 10 Remove the two screws that secure the 11 Pull the media motor towards the rear of media motor to the media motor mount. the plotter. 12 Disconnect the flat encoder cable from the motor, and lift the motor clear of the plotter.

  • Page 103: Removing The Encoder Strip

    Removing the Encoder Strip 1 Remove the window D page 6 15. W A R N I N G 2 Remove the center cover D page 6 16. 3 Remove the right endcover D page 6 19 The encoder strip has very sharp 4 Remove the left endcover D page 6 18.
  • Page 104 7 Compressing the encoder spring bracket to release tension on the encoder strip, carefully release the encoder strip from the service station. Encoder strip Spring bracket Compress Release Service station 8 Carefully pull the encoder strip through and out of the carriage assembly. 9 Lay the encoder strip on a flat surface.

  • Page 105: Reinstalling The Encoder Strip

    Reinstalling the Encoder Strip 1 Ensure that the encoder strip is oriented 2 Thread the strip through the apertures with the transparent area up, and with in the cartridge carriage assembly. three holes on the left side and one hole on the right side.
  • Page 106 5 With washer and nut, secure the encoder strip to the encoder spring bracket. 5.5 mm 6 Slide the carriage back and forth the length of its travel to ensure free movement. The encoder strip should not bind or rub on the carriage. 6 42 Removal and Replacement C3187 90000...

  • Page 107: Removing The Trailing Cable Guide

    Removing the Trailing Cable Guide 6 Remove the screw that attaches the C A U T I O N trailing cable guide to the tensioner housing. Handle the trailing cable and the trailing cable guide with care. Torx-15 1 Remove the window D page 6 15. Trailing-cable guide 2 Remove the center cover D page 6 16.
  • Page 108 9 Remove the screw inside the ferrite ring. 10 Slightly lift up the guide and carefully remove the ferrite ring. Torx-15 11 Move the trailing cable guide towards the rear of the plotter, rotate it to clear the arm of the cartridge adjustment cam on the cartridge carriage, and lift the trailing cable guide clear of the plotter.

  • Page 109: Removing The Y Tensioner And Housing

    Removing the Y Tensioner and Housing 1 Remove the window D page 6 15. 5 Remove the screw that attaches the trailing cable guide to the tensioner 2 Remove the center cover D page 6 16. housing. 3 Remove the left endcover D page 6 18. Torx-15 4 Slide the cartridge carriage towards the center of the plotter in order to access the...
  • Page 110 8 Carefully move the right end of the 7 Carefully move the tensioner plate to the tensioner plate up and clear of the right until it clears the slot in the retaining tab. housing. Slot Tensioner plate Tensioner plate 9 Decompress the tensioner spring by 10 Remove the Y tensioner spring and allowing the tensioner plate to move Y tensioner from the housing.
  • Page 111 11 Loosen the Y tensioner housing screw. 12 Slide the Y tensioner housing out from the Y tensioner bracket. Torx-15 Y-tensioner Y-tensioner Loosen bracket housing 13 Release the main idler from the 14 Lift the Y tensioner housing clear of the cartridge carriage belt.

  • Page 112: Removing The Cartridge Carriage And Main Drive Belt

    Removing the CWrtridge CWrriWge Wnd MWin Drive Belt 8 Remove the two screws that secure the encoder strip bracket to the service C A U T I O N station housing. Torx-15 If you are installing a new cartridge carriage or a new carriage PCA, ensure that the plotter firmware is compatible with it.
  • Page 113 11 Holding the service station sled about 1 cm (or about 1/2 inch) to the left of its normal position with one hand, tilt the forward edge of the service station cover up and lift the cover clear of the service station housing. Sled Cover 12 Lift the service station sled up slightly and release the sled spring from the service station...
  • Page 114 13 Lift the service station sled clear of the service station housing and the plotter. 15 Remove the screw and washer that 14 Move to the right side of the plotter. attach the encoder strip spring to the Pressing the small drive belt against the spring bracket.
  • Page 115 16 Remove the encoder strip spring. 17 Remove the double pulley from the Y drive bracket. While doing this keep the palm of one hand beneath the double pulley to catch the double pulley bushing. Washer Bracket Double pulley Bushing 0D2 DmbtinJ: Don't orgHt thH bushing.
  • Page 116 19 Remove the right spring from the 20 Remove the screw that attaches the cartridge carriage assembly. trailing cable bracket to the carriage assembly. Torx-10 22 Slide the cartridge carriage to the left 21 Lift the trailing cable and bracket clear side of the plotter.
  • Page 117 In the following step, take care when moving the cartridge carriage over C A U T I O N the plastic projection at the top left end of the service station housing. Too much force may damage the housing or the carriage. 23 Grasp the carriage rear preload bushing (rides on the rear slider rod), and move the carriage to the left and free of the slider rods.
  • Page 118 25 Set the carriage assembly upside down on a flat surface. 26 Using a small, standard screwdriver, remove the left and right belt clamps from the carriage assembly. Belt clamp C A U T I O N Be careful not to damage the clamps. Reassembling: Correctly install the clamps, so that they don't fall out during plotter operation!

  • Page 119: Removing The Bail Sensor

    Removing the Bail Sensor 1 Remove the electronics enclosure 5 Note the position of the bail sensor cable cover D page 6 5. for reassembly. Incorrect positioning could cause obstruction of the cartridge 2 Remove the window D page 6 15. carriage and motor gears.

  • Page 120: Removing The Bail

    Removing The Bail 1 Open the window. 2 Move the cartridge carriage to the extreme left. Cartridge carriage In the following step, take care not to cut yourself SO OLOGOHOGOF on the encoder strip. 3 Push both of the plastic ends of the bail towards each other to release them from the holes in the sideplates, and lift the bail up and clear of the plotter.

  • Page 121: Removing The Service Station

    Removing the Service Station 5 Remove the nut and washer that attach In performing this procedure, be carefu to the encoder strip to the encoder strip avoid staining your hands and c othing bracket. with ink deposited in the service station. 1 Remove the window D page 6 15.
  • Page 122 9 Holding the service station sled about 8 Remove the three screws that secure the 1 cm (or about 1/2 inch) to the left of its service station cover to the normal position with one hand, tilt the service station housing. forward edge of the service station cover up and lift the cover clear of the service station housing.
  • Page 123 11 Lift the service station sled clear of the 12 Remove any wet ink from the wiper in service station housing and the plotter. the service station housing. 13 Remove the wiper from the top of the wiper rod by pulling the wiper up. Wiper 14 Remove the screw and washer that 15 Remove the three screws that attach the...

  • Page 124: Removing The Overdrive Roller

    Removing the Overdrive Roller 6 Remove the clutch retaining ring that secures the overdrive clutch to the overdrive roller. Overdrive roller You can do this with a needle nose pliers, without having to remove the service station. (The service station is not shown in the diagram.) 1 Remove the window D page 6 15.
  • Page 125 8 Move the overdrive roller to the right until it has completely cleared the left sideplate but not entered the hole in the right sideplate. 9 Release the overdrive roller from the overdrive bushing (small black clips underneath the media separator), and lift the overdrive roller clear of the plotter. C3187 90000 Removal and Replacement 6 61...

  • Page 126: Removing The Overdrive Enclosure

    Removing the Overdrive Enclosure 6 Remove the three indicated screws from 1 Remove the window D page 6 15. the left sideplate. 2 Remove the center cover D page 6 16. 3 Remove the left endcover D page 6 18. 4 Remove the right endcover D page 6 19.

  • Page 127: Re Installing The Overdrive Enclosure

    Re installing the Overdrive Enclosure The order in which you replace the screws on the overdrive enclosure is important 1 Position the overdrive enclosure between the two sideplates. Take care not to damage the media sensor flags. The overdrive enclosure C A U T I O N should not touch them.
  • Page 128 3 Insert the two indicated screws, but DO NOT tighten them. (Long dog point screws.) Torx-15 LEAVE LOOSE LEFT HAND SIDE RIGHT HAND SIDE 4 Replace the indicated screw and tighten it, 5 Tighten the two screws you inserted in thus aligning the overdrive enclosure with step 3.

  • Page 129: Removing The Entry Platen

    Removing the Entry Platen 1 Remove the window D page 6 15. 8 Remove the three indicated screws from the left sideplate. 2 Remove the center cover D page 6 16. 3 Remove the left endcover D page 6 18. 4 Remove the right endcover D page 6 19.
  • Page 130 13 Detach the media sensor holder from 12 Pull the entry platen out from the plotter the underside of the entry platen by in order to access the media sensor. pulling the holder straight out. 15 Lift the entry platen clear of the plotter. 14 Cut the plastic tie that fastens the media sensor cable to the underside of the entry platen.

  • Page 131: Re Installing The Entry Platen

    Re installing the Entry Platen The order in which you replace the screws on the entry platen is important. 1 If the plotter is attached to a support, detach it. 2 Turn the plotter on its back. 3 Reconnect the media sensor to the entry platen (see also page 6 26). 4 Position the entry platen between the two sideplates.
  • Page 132 8 Replace the two indicated screws. (Long dog point screws.) Torx-15 RIGHT HAND SIDE LEFT HAND SIDE 7 Replace the indicated screw. 9 Replace the screws on the bottom cover. Torx-20 D/A1 size plotters have four screws. E/A0 size plotters have five screws. 10 Turn the plotter to its correct position.

  • Page 133: Removing The Drive Roller

    Removing the Drive Roller 1 Remove the electronics enclosure In the following step, take care C A U T I O N cover D page 6 5. not to damage the bail sensor. 2 Remove the window D page 6 15. 14 Remove the three screws that attach the media motor mount to the right sideplate.
  • Page 134 19 Remove the drive roller from the plotter. Reassembling: Ensure that the bearing assembly at the right end of the drive roller is seated in the right sideplate and completely on the right side of the axial bias plate. Bearing assembly Axial bias plate Calibration: Perform the accuracy calibration after installing the drive...

  • Page 135: Removing The Automatic Bail Lift Mechanism

    The cam gear support is a new part, introduced with the DesignJet 220 to help solve failures in the bail lift mechanism. It replaces the Teflon washer solution of the DesignJet 200. A service note describes how to remove the Teflon washers and install the cam gear support and associated parts on a DesignJet 200.

  • Page 136: Removing The Pinch Arm Lift Mechanism

    Removing the Pinch Arm Lift Mechanism Pinch arm assembly 1 Remove the drive roller D page 6 69. 2 Push the pinch arm lever (located on the right side of the entry platen) into the vertical position. 3 Remove the screws on the entry platen, D page 6 65, and pull it slightly forward. 4 On the right side of the plotter, disconnect the rocker plate tension spring to relieve any remaining tension on the pinch arm lift mechanism.
  • Page 137 5 On the right side, loosen the cam journal screw 12 turns counter clockwise and push the screw in towards the center of the plotter. Cam journal screw Torx-8 Cam journal Rear wire link 6 Repeat the previous step and try to pull the cam journal and rear wire link to the right and clear of the bar cam.
  • Page 138 7 Grasp the cam journal on the left side of the plotter with your left hand. 8 Reach around to the front of the plotter and push the top of the bar cam slightly towards the rear of the plotter, simultaneously pulling the cam journal to the left, so that the bar cam can begin to slide out of the left sideplate.
  • Page 139 DHPMJcHtMond...

  • Page 140: Calibrations

    When to Calibrate the Plotter Indications or Repairs Performed Calibration Required Jagged lines on plots Cartridge Alignment Cartridges are reseated or replaced Cartridge Alignment Drive roller is removed or replaced Accuracy Calibration Media (X-axis) motor is replaced Accuracy Calibration Configuration-plot X-mark distance is not Accuracy Calibration 500mm ("1mm) Carriage or carriage LED is removed or replaced...

  • Page 141: Front Panel Keys In Service Mode

    Front Panel Keys in Service Mode Pressing any single front panel key in service mode performs the same operation as in normal mode. However, in service mode, you can also use combinations of keys, to perform the various service tests and calibrations. With this intent, the key acts as a key, Replot...

  • Page 142: Cartridge Alignment

    Cartridge Alignment When to Align Cartridges If you suspect that the plotter is not producing plots of the highest quality, you can run a simple cartridge alignment routine that will ensure that the print cartridges are aligned. Perform this routine also after clearing a media jam. The alignment is also automatically performed after each time you replace or reseat the print cartridges.
  • Page 143 The lines on the paper serve two purposes: Some lines have already been optically read by the plotter and used to perform cartridge alignment; others are now to be inspected by you. An example of the cartridge alignment plot sheet is shown below. The two pairs of lines that you should inspect are indicated on this example.

  • Page 144: Accuracy Calibration

    23 C (73 F), at 50 60% relative humidity on HP special polyester film. Use the following formula to calculate the plotter's accuracy: Measured length – Desired length x 100 = %Error Desired length What can Affect the End Point Accuracy ? Various part tolerances inside the plotter affect the accuracy (in particular the drive roller).
  • Page 145 Performing the Accuracy Calibration , Enter service mode D page 7 2. . Plot a service configuration plot D page 8 23. A Measure the distance between the centers of the X" marks on the configuration plot. An accuracy calibration is needed if this distance is not 500 mm (20 in) 1 mm (0.04 in) under normal environmental conditions.

  • Page 146: Bail Calibration

    ,0 When the LED lights up, hold down the SHIFT Ready key and press SHIFT Accuracy Calib. Read, LED lights up. The plotter takes about Busy 3 minutes to read the calibration sheet, to calculate the calibration data, and to save the data in the Accuracy EEROM.

  • Page 147: Media Sensor Calibration

    Media Sensor Calibration The media sensor calibration measures the position of the media sensor levers with respect to the drive roller. A value is stored in the EEROM when the procedure is completed. Perform the media sensor calibration whenever: D The EEROM is cleared D The main PCA is replaced D The media sensor is removed or replaced D The leading and trailing margins of a plot are greater than 17 mm (0.67 in).

  • Page 148: Setup Sheet Calibration

    Setup Sheet Calibration This calibration calibrates the power of the LED situated on the cartridge carriage, for better scanning of the setup sheet. Perform the setup sheet calibration whenever: D The EEROM is cleared D The cartridge carriage is replaced D The optical sensor on the cartridge carriage is replaced D Problems frequently occur with setup sheet scanning To calibrate the LED, perform the following procedure:...

  • Page 149: Troubleshooting

    Troubleshooting...

  • Page 150: Power On

    Power On The plotters automatically perform a series of internal self tests and mechanical initialization sequences whenever the user switches the plotter on. These are completed after about 30 seconds. If a failure occurs, an error is indicated on the front panel LEDs. You can perform a failure analysis by interpreting the LED error code.

  • Page 151: Extended Power On Self Test

    Extended Power On Self Test Perform the extended power on test whenever the plotter passes the normal power on test, but does not function properly. To begin the extended power on test, perform the following procedure: , Switch the plotter off. Access Cartridges .

  • Page 152: What You Should See And Hear

    What You Should See and Hear When you turn on the plotter, the following happens: 1 All six LEDs light up for a brief moment; then the LED remains on. Busy If you have activated the extended power on self tests, all six LEDs remain off for a few seconds before the LED lights up.

  • Page 153: Errors Indicated By Leds

    Errors Indicated by LEDs LED on the front panel works in combination with the other Error Error LEDs to specify the type of error that has occurred. The three possible states of any LED are represented like this: Flashing User Errors User errors are associated with user settings or user actions and may be solved by the user without calling a Customer Engineer.
  • Page 154 flashing Error Busy Error Busy Possible Causes Corrective Action The serial interface settings are different on the 1. Print a setup sheet and check the plotter's plotter and on the software. current settings for Baud Rate and Parity. 2. Compare these with the current settings of the same two items for your application software.

  • Page 155: System Errors

    PCA. If the problem remains, consult UART. recent service notes for a possible solution. If no service note deals with this error, report the problem to the HP Response Center. 276. Failure of RS 232 C Ensure the loopback connector is the loopback test.
  • Page 156 If it does occur, consult recent service notes for a possible solution. If no service note deals with this error, report the problem to the HP Response Center. 145. Out of memory Install a larger DRAM SIMM.
  • Page 157 LEDs lit and steady: Error Load Media Media path/servo errors. LEDs lit Error Number and steady Description Corrective Options 82. Shutdown of media axis See D later in this chapter, w Servo Control (X axis) System Failures. 22. Shutdown of carriage axis See D later in this chapter, w Servo Control (Y axis) System Failures.
  • Page 158 If it does occur, consult recent service notes for a possible solution. If no service note deals with this error, report the problem to the HP Response Center. Note conditions before error occurred. Include setup sheet and service configuration plot in report.

  • Page 159: Firmware Code Revision Level

    Firmware Code Revision Level To check the firmware code revision level that the plotter is using, print a setup sheet or a service configuration plot. Troubleshooting Tips Repair + Calibrate After you have made a repair, consider if any calibrations have been affected. Print Quality You can use the user demonstration plot to look at overall print quality including smoothness and straightness of lines, arcs, circles, and characters.

  • Page 160: Servo Control System Failures

    Servo Control System Failures Media Axis (X Axis) Shutdown In the case of a media axis shutdown, try one or more of the following corrective actions: D Clear any binding in the media axis mechanics due to a media jam. (Do not pull the media along the carriage axis.

  • Page 161: Misaligned Cartridge Caps

    Misaligned Cartridge Caps If a customer is complaining about shortened cartridge life or frequent cartridge failure, you should check the cartridge cap alignment (procedure below). This is especially true if the problem is always happening to the same cartridge. A sure sign of a misaligned cap is excess ink around the cap and inside the ink reservoir.

  • Page 162: Bail Lift Mechanism Failure

    Problems can arise if the lift mechanism is too loose or too tight. The solution in the DesignJet 200 involved the use of teflon washers. A new solution comes with the introduction of the DesignJet 220 and involves a new part called the cam gear support.

  • Page 163: Cartridge Carriage Rubbing Against Encoder Strip

    Excessive ink deposits on the drive roller surface can fool the sensor by reflecting the light. (Cleaning roller D chapter 4.) Last Swath is Clipped when Replotting This bug on DesignJet 200 plotters will be solved in firmware revision A.01.02. (Details D chapter 9.) C3187 90000...

  • Page 164: Ink Smearing

    Ink Smearing Add Starwheel Mount Ink may smear in DesignJet 200 plotters and early DesignJet 220 plotters due to cockle in the media caused by the geometry of the media path. The problem is more evident when loading A/A4 size media. (Solution D chapter 9, w Change in Bail and Overdrive Parts.)

  • Page 165: Plotter Won't Read Setup Sheet; Plots Solid Black Area Fill

    Plotter won't Read Setup Sheet; Plots Solid Black Area Fill This problem can occur on DesignJet 200 plotters with the old style cartridge carriage. Install a new carriage. (Details D chapter 9, w Chang in Carriag .) Problems in Loading Media...

  • Page 166: Service Tests

    Service Tests Test Description Bail Cycle Test This tests the following: Bail Bail sensor switch Drive Mechanics Main PCA Bail-Sensor Test This tests the following: Bail sensor switch Main PCA Mechanical interference Electrical Test The electrical test performs all of the following: Carriage communications test Carriage ASIC test: Values stored in the carriage ASIC registers are temporarily stored.
  • Page 167 Test Description Media-Sensor Test This tests the following: Media sensor on entry platen Main PCA Media opacity Pinch-Arm- This tests the following: Sensor Test Pinch-arm sensor Pinch-arm-sensor cable Main PCA Service The service configuration plot contains the following: Configuration Plot Hard-clip border around the plot enabling you to measure the margins.
  • Page 168 Test Description Stepper-Motor Test The stepper-motor test continuously cycles the stepper motor, thus raising and lowering the wiper and the lever mechanism. It tests the following: Stepper motor Main PCA Cartridge-adjust linkage Wiper linkage Window-Sensor Test This tests the following: Window sensor Window-sensor cable Main PC.
  • Page 169 Which Service Test to Perform The following table indicates the service tests that you can perform on particular assemblies: Assembly Tested by ... Bail Bail cycle test Bail-sensor Bail-sensor test, Bail cycle test Carriage-axis encoder/motor Servo/encoder test Carriage-axis encoder cable Servo/encoder test Cartridge-adjust linkage Stepper-motor test...

  • Page 170: Bail Cycle Test

    Performing the Service Tests The following paragraphs describe how to perform the various service tests. You know that a test has failed if a system error is indicated by means of the front panel LEDs. Bail Cycle Test Bail Cycle Test , Enter service mode (see page 7 2).

  • Page 171: Input/Output Test

    Input/Output Test 1 Connect a loopback connector (part number 07440 60302) to the serial port of the plotter. If a connector is not available, you can place a jumper between pins 2 and 3 of the serial port for the test. SHIFT 2 Enter service mode (see page 7 2).

  • Page 172: Service Monitor (Data Display)

    Service Monitor (Data Display) 1 Enter service mode (see page 7 2). Service 2 Hold down the keys and press Monitor SHIFT Service Monitor SHIFT 3 Send the file or files from the computer through the serial or parallel ports. 4 Press any front panel key when the file(s) have been transferred to the plotter.

  • Page 173: Interpreting The Service Configuration Plot

    Interpreting the Service Configuration Plot AnalyzinN the Bar Pattern The configuration plot has special built in diagnostic features. It includes seven bars printed along the top that enable you to detect print quality problems. First Four Bars Use the first four bars (from left to right) to detect D Problems with nozzle firing direction D Missing nozzles These bars are a series of straight horizontal lines, four pixels apart.

  • Page 174: Parameters Printed Below Eerom Text Block

    Parameters Printed Below EEROM Text Block (Decimal Values) Number of Power Cycles Number of times plotter has been switched on. Number of Pages Printed Number of Bail Lifts Number of Bail Errors Number of System Errors Last System Error See System Errors earlier in this chapter for correspondence of numbers to errors. Last System Error Data Bail Up Position Offset Calculated during bail calibration.
  • Page 175 Table 8-1. EEROM Map Address Definition Location Value=55 if EEROM has been initialized (Read by servo processor) Value=AA if EEROM has been initialized (Read by servo processor) Value=5A if EEROM has been initialized (Read by servo processor) Byte 0 of the number of bench-run cycles completed Byte 1 of the number of bench-run cycles completed Number of stepper cycles per bench-run cycle Byte 0 of the total number of bench-run cycles...
  • Page 176 Table 8 2 is a key to the EEROM memory text block on the service configuration plot. The first column is the same as on the plot; the remaining columns show the memory location number instead of the contents at each position on the text block. Table 8-2.

  • Page 177: Clearing The Eerom

    The block of text on the service configuration plot that shows the contents of the EEROM, appears in the form shown in Table 8 3. This table is a text block from a sample plot. The contents of the EEROM that you are testing will differ from this sample. Table 8-3.
  • Page 178 Notes 8 30 Removal and Replacement C3187 90000...

  • Page 179: Product History

    Product History and Service Notes...

  • Page 180: Introduction

    D In the third position is the revision letter of the plotter. The letter A identifies the original version of the plotter. The next revision would have the letter B and so on. All DesignJet 200 plotters have revision letter A. The original version of the DesignJet 220 also has revision letter A.

  • Page 181: Identifying A Printed Circuit Assembly

    Identifying a Printed Circuit Assembly DesignJet 200 and DesignJet 220 PCAs have the following major identification features: Part Number PCAs having the same part number are directly interchangeable. If a PCA is revised in any way that makes it non interchangeable with previously issued PCAs of a particular part number, a new part number is assigned to the revised PCA.

  • Page 182: Potential Ink Smearing Problem

    Situation: The media motor mount, C1633 20006, must be removed to troubleshoot several assemblies associated with the media path of the DesignJet 200. This service note is intended to describe the print quality problem resulting from incorrect reassembling of this part and to provide a cartridge to roller distance specification for the DesignJet 200.
  • Page 183 A) How/Where to Measure the Distance a) Power off the unit. b) Ensure that the pinch arm lever is in the UP position. c) Open the window and remove the bail. d) Slide the carriage (with both cartridges loaded) to the right until the right black and yellow strip of the carriage is above the right sideplate (see figure 1.c).
  • Page 184 4) What to Do with Units Exhibiting Ink Smearing Problems If the unit is exhibiting an ink smearing problem using HP recommended media and under proper environmental conditions, do the following: i) Ensure the glue bed of each cartridge is as specified in item (b) of the table in figure 1.

  • Page 185: Problems Corrected By Firmware Release A.01.01

    C3180 18009 A.01.01 EPROM (U4) Situation: Firmware version A.01.00 of the DesignJet 200 exhibits the following problems: 1) The unit is not able to load 1.6 m cut sheet media. 2) In the absence on an IN command in the plot files, the resulting line widths are not consistent with the selected values.

  • Page 186: Problems That Will Be Corrected By Firmware Release A.01.02

    Fixed by increasing the tolerance on sheet length before clipping by 0.15 in. when replotting. The previous tolerance was only 1/1200 in. CANCEL: In firmware versions A.01.01 (DesignJet 200) and B.02.00 (DesignJet 220) the user could not cancel while plotting non flow mode plots (plots that don't exceed maximum memory available in plotter).

  • Page 187: Eproms And Masked Roms

    EPROMs and Masked ROMs The DesignJet 200 old firmware revision A.01.00 is not forward C A U T I O N compatible with the new carriage C2847 60071 (carriage PCA C2847 60125). In combination they destroy the cartridges. DesignJet 200 EPROMs DesignJet 200 Masked ROMs (Firmware code A.01.00, obsolete)

  • Page 188: Re Installing Teflon Washers

    Re installing Teflon Washers Normally, you should not have to re install teflon washers on a DesignJet 200. Instead, you should install a cam gear support and the associated parts as described later in this chapter. The following note is given in case you need to reassemble the plotter while you wait for these parts to arrive.

  • Page 189: New Bail Lift Mechanism Support

    Typically the number of Teflon Washers to install on a DesignJet 200 is two. However problems can occur if the bail lift is too loose or too tight. In some cases, it may be necessary to install between 1 and 3, thus complicating the repair procedure.
  • Page 190 InstallinN the New Bail Lift MeGhanism Y tensioner bracket Cam gear support Engaging lever Engaging lever spring Left sideplate Auto cam Screw (Remove from inside) IMPORTANT: You need a scissors as well as the tools listed in chapter 6. 1. Remove the window assembly and the left end cover. 2.

  • Page 191: Change In Trailing Cable

    (two inside electronics enclosure, two on trailing cable rear tray) D Four Ferrite Clamps, 9170 1533 Later DesignJet 200 plotters, and DesignJet 220 plotters, have a new trailing cable and associated parts, improving electromagnetic compatibility and rendering unnecessary the ferrites on the trailing cable rear tray:...

  • Page 192: Change In Carriage

    Later DesignJet 200 plotters, and DesignJet 220 plotters, have a new cartridge carriage: D Cartridge Carriage, C2847 60071 (including Carriage PCA, C2847 60125). The new carriage is not compatible with the DesignJet 200 firmware revision A.01.00. In combination, they destroy the cartridges. If you install a new carriage, ensure that the firmware revision of the EPROMs or masked ROMs on the main PCA is later than A.01.00.

  • Page 193: Parts And Diagrams

    Parts and Diagrams 10 1...

  • Page 194: Exchange Assemblies

    Exchange assemblies are factory repaired and tested assemblies that you can order; they are listed in the following table. Exchange assemblies are available only on a trade in basis; therefore, you must return the defective assemblies for credit. Exchange Assemblies HP Part Number Description C3180-69102 Main PCA (Rebuilt)

  • Page 195: Replacement Parts

    The total quantity for each part on the drawing is given as well as the part number and check digit. To obtain replacement parts, address an inquiry to the nearest HP Support Office. You must include the part number, check digit and part description in the order you send. Also include the plotter model and serial number.
  • Page 196 Parts List: Legs and Media Bin Reference HP Part Number Check Quantity Digit Description Drawing C2847-60002 Leg Assembly (D/A1 Size) C2848-60002 (E/A0 Size) C3185-00034 Stand Brace (D/A1 Size) C3186-00034 (E/A0 Size) C2847-60061 Hardware Kit 1492-0145 Caster Assembly C2847-00006 Media Bin Front...

  • Page 197: Legs And Media Bin

    Legs and Media Bin C3187 90000 Parts and Diagrams 10 5...

  • Page 198: Window, Center And Bottom Covers

    Screw (D/A1 Size) (E/A0 Size) C3180-60033 Shielded Trailing Cable Not compatible with main PCAs: C3180-60101, C3180-68101, C3180-69101. DesignJet 200 D chapter 9. C3180-60064 Shielded Trailing-Cable Assembly. (Includes shielded trailing cable, three plastic ties, and trailing-cable bracket.) C3180-00040 Trailing-Cable Rear Tray.
  • Page 199 To Carriage Window, Center and Bottom Covers. C3187 90000 Parts and Diagrams 10 7...
  • Page 200 Parts List: Electronics Enclosure Reference HP Part Number Check Quantity Digit Description Drawing C3180-68102 Main PCA (New) C3180-69102 Main PCA (Rebuilt, Exchange Assembly) 0515-2253 Machine Screw See illustration 4 / 2 4 EPROMs or 2 Masked ROMs C2064A DRAM SIMM (Optional)

  • Page 201: Electronics Enclosure

    DesignJet 200 EPROMs DesignJet 220 Masked ROMs (Firmware code A.01.01) (Firmware code B.02.01) C3180-18006 C3180-18007 1818-6016 1818-6017 cd: 7 cd: 8 cd: 6 cd: 7 C3180-18008 C3180-18009 Empty Empty cd: 9 cd: 0 Empty pair of holes Electronics Enclosure C3187 90000...
  • Page 202 Parts List: Left Endcover and Trim Reference HP Part Number Check Quantity Digit Description Drawing C3180-40003 Left Endcover C3187-00015 Serial-Number Label C3180-40005 Rear Left Trim 0624-0771 Torx-15 Screw C3180-00010 Nameplate 0515-2282 Tapite Screw C3180-40012 Switch Mount 5041-1203 Power Key Cap...

  • Page 203: Left Endcover And Trim

    Left Endcover and Trim C3187 90000 Parts and Diagrams 10 11...
  • Page 204 Parts List: Right Endcover and Trim Reference HP Part Number Check Quantity Digit Description Drawing 0624-0771 Torx-15 Screw C3180-40006 Rear Right Trim 1400-0293 Cable Guide (Fastener) 0515-2278 Torx-20 Screw – – Right Sideplate (Not Orderable) 07090-20020 Shoulder Washer C3180-40007 Front Right Trim...

  • Page 205: Right Endcover And Trim

    Right Endcover and Trim C3187 90000 Parts and Diagrams 10 13...
  • Page 206 Parts List: Carriage Axis Drive (Left End) Reference HP Part Number Check Quantity Digit Description Drawing C2847-00029 Main Drive Belt (D/A1 Size) 1500-0856 (E/A0 Size) 07570-60105 Main Idler Assembly 07570-40105 Main Tensioner 1460-2139 Tensioner Spring C1633-40065 Main-Tensioner Housing 0515-0380 Torx-15 Screw...

  • Page 207: Carriage Axis Drive (Left End)

    Carriage-Axis Drive (Left End) C3187 90000 Parts and Diagrams 10 15...
  • Page 208 Parts List: Service Station Reference HP Part Number Check Quantity Digit Description Drawing 0624-0704 Plastite Screw #6-19x.375 C1633-40003 Service-Station Cover C1633-40005 Service-Station Cap C1633-40001 Service-Station Housing C1633-80002 Sled Spring C1633-40004 Cap Fitting C2847-40011 Service-Station Sled 10 16 Parts and Diagrams...

  • Page 209: Service Station

    Service Station C3187 90000 Parts and Diagrams 10 17...
  • Page 210 Parts List: Carriage Axis Drive (Right End) Reference HP Part Number Check Quantity Drawing Digit Description see page 10-21 Cartridge Carriage C2847-00029 Main Drive Belt (D/A1 Size) 1500-0856 (E/A0 Size) see page 10-14 Trailing-Cable Front Tray 9170-1536 Ferrite Ring C1633-80003...

  • Page 211: Carriage Axis Drive (Right End)

    Carriage Axis Drive (Right End). Reference 24: Ferrite Assemblies HP Part Number Check Quantity Description Digit 9170-1400 Flat Ferrite 9170-1594 Large Ferrite 9170-1593 Small Ferrite 9170-1596 Large-Ferrite Holder 9170-1595 Small-Ferrite Holder 0515-2299 Holder Screw C3187 90000 Parts and Diagrams 10 19...
  • Page 212 Parts List: Carriage Assembly Reference HP Part Number Check Quantity Digit Description Drawing C2847-60071 Cartridge Carriage (Not compatible with plotter firmware version A.01.00.) Includes all items below except items 9, 10, and 13. 0624-0704 Plastite Screw #6-19x.375 2190-0760 Washer 5.1mm...

  • Page 213: Carriage Assembly

    Carriage Assembly C3187 90000 Parts and Diagrams 10 21...
  • Page 214 Parts List: Media Drive Assemblies Reference HP Part Number Check Quantity Digit Description Drawing C3180-00002 Entry Platen (D/A1 Size) C3181-00002 (E/A0 Size) Drive-Roller Assembly C2858-60054 (D/A1 Size) C2859-60004 (E/A0 Size) C3180-40010 Secondary Lever C3180-40011 Media-Sensor Holder 0515-2337 Torx-15 Screw C3180-60001...

  • Page 215: Media Drive Assemblies

    Media Drive Assemblies C3187 90000 Parts and Diagrams 10 23...
  • Page 216 (Parts List: Bail and Overdrive Assemblies D pages 10 24a and 10 24b) 10 24 Parts and Diagrams C3187 90000...
  • Page 217 Parts List: Bail and Overdrive Assemblies Reference HP Part Number Check Quantity Digit Description Drawing 0624-0647 Torx-10 Screw 3050-0026 Washer 3.2 mm C1633-40028 Cam Gear C1633-40027 Engaging-Lever Gear C2847-40013 Engaging Lever C1633-80006 Engaging-Lever Spring 0510-0083 Ring Retainer, 0.25 Diameter C1633-60030...
  • Page 218 Reference HP Part Number Check Quantity on Drawing Digit Description Bail (Includes items 20, 21, 22, 23, 24) C3180-60017 with 9 starwheel mounts (D/A1 Size) C3180-60065 with 10 starwheel mounts (D/A1 Size) C3181-60017 with 13 starwheel mounts (E/A0 Size) C3181-60065...

  • Page 219: Bail And Overdrive Assemblies

    Bail and Overdrive Assemblies C3187 90000 Parts and Diagrams 10 25...

  • Page 220: Pinch Arm Assembly

    Parts List: Pinch Arm Assembly Reference HP Part Number Check Quantity Digit Description Drawing 0515-1992 Torx-9 Screw C3190-40053 Cam Journal 0535-0026 Hex Nut, DBL-CHAM C2847-20005 Pinch-Arm Bar Cam (D/A1 Size) C1633-20012 (E/A0 Size) C1633-60039 Pinch-Arm Assembly (D/A1 Size) (E/A0 Size)
  • Page 221 Pinch-Arm Assembly C3187 90000 Parts and Diagrams 10 27...

  • Page 222: Accessories

    Accessories Description HP Part Number Unpacking Instructions Until 30 Sept 1994: C3180-90020 (D chapter 3) From 01 Oct 1994: C2847-90030 (new packaging) Repacking Instructions From 01 Oct 1994: C2847-90032 (new packaging) Repackaging Kit C3180-60016 (D/A1 size) C3181-60016 (E/A0 size) User’s Guide...
  • Page 223 51626A Supplies Source (booklet) 5091-7378EUS Elsewhere 5091-7690E Supplies Source Update 5091-9802EUS Elsewhere 5091-9799E Upgrade Kit (DesignJet 200 to DesignJet 220) C3189A includes User’s Guide, Drivers, Help Cards, Overlay and: Upgrade Instructions C3187-90028 Nameplate C3187-00011 Upgrade Label C3189-00001 ROM Memory Kit...

  • Page 224: Line Cord Set

    Note the following abbreviations used in the power cord options table below: - Line or Active Conductor (also called live" or hot") - Neutral or Identified Conductor - Earth or Ground Plug Type Country HP Part Number NEMA 5-15P Latin America 8120-1378 North America Korea...
  • Page 225 Plug Type Country HP Part Number SEV 1011 Switzerland 8120-2104 DHCR-107 Denmark 8120-2956 SABS Republic of 8120-4211 South Africa C3187 90000 Parts and Diagrams 10 31...

  • Page 226: Interface Cables

    (9-pin connector). HP 9000 workstations using 9-pin connectors. IBM AT and compatible computers using 9-pin serial connectors. HP Vectra PC with HP 24541A/B dual serial 17255M 1.2 m (3.9 ft) 25-pin male interface card using the 25-pin connector.
  • Page 227 Glossary...
  • Page 228 ESD Electrostatic discharge cartridge Print cartridge (pen) FET Field Effect Transistor CD Check Digit HP GL/2 Hewlett Packard's standard Centronics A parallel interface standard. graphics language for its plotters. cockle Wrinkling of media due to ink HP RTL Hewlett Packard Raster saturation.
  • Page 229 IC Integrated Circuit PCA Printed Circuit Assembly IEEE Institute of Electrical and pen 1. Even though the inkjet plotter has Electronics Engineers no physical pens, the lines it draws match the attributes for pens numbered 1 through ISO International Standards 8 in the application software.
  • Page 230 TCP/IP Transmission Control Protocol / standardized by the Electronic Industries Internet Protocol Association Standard RS 232 C. Transl. Translucent media RTL see HP RTL " UART Universal Asynchronous Receiver RTS Request To Send Transmitter SIMM Single In line Memory Module...
  • Page 231 2JDHM 2JDHMP0...
  • Page 232 A/D converter, 5 30, G 2 bail, 5 8 calibration, 7 8 ac, G 2 change in, 9 14 accessories, part numbers, 10 28 cycle test description, 8 18 accuracy, 1 3, 5 7 performing, 8 22 calibration, 7 6, G 2 lift mechanism, 5 8, 9 10 acoustics, 2 3 failure, 8 14...
  • Page 233 cartridges (cont.), cables, capping, 5 18 interface, caps, choosing, 2 2 misaligned, 8 13 part numbers, 10 32 part number, 10 16 power, carriage. carriage part numbers, 10 30 distance to roller, 9 4 drivers, 5 20 CAD, G 2 frequent failure, 8 12 calibrations, chapter 7 interface ASIC, 5 20...
  • Page 234 10 28 depth of plotter, 2 3 stepper motor, 5 27 description of plotters, 1 2 drop growth, 5 11 DesignJet 200, DTR, G 2 upgrading to DesignJet 220, 1 4 detecting the media edges, 5 10 diagrams, chapter 10...
  • Page 235 electrical specifications, 2 2 LEDs Error Cartridge flashing, 8 5 electrical test lit and steady, 8 10 description, 8 18 performing, 8 22 LEDs Error Load Media flashing, 8 6 electronics enclosure, lit and steady, 8 9 part numbers, 10 8 cover, removing, 6 5 LEDs Error...
  • Page 236 9 10 HP GL, 1 2 insulator, power supply, timeout, 3 7, 8 16 part number, 10 8 HP GL/2, 1 2, G 2 interconnections, PCA and sensor, 5 22 HP RTL, 1 2, G 2 interface, bug fixed, 9 8...
  • Page 237 3 7 jam, media, 8 12 sensor, 5 10, 5 29, 5 30, G 3 JetDirect EX, HP , 1 2 widths incorrect, 8 16, 9 7 part numbers, 10 29 line cord, part numbers, 10 30 joined plots, 8 16...
  • Page 238 mechanical initialization, 8 3 memory (cont.), errors, 8 5, 8 8 mechanical overview, chapter 5 expansion module. See memory, random media, access axis, G 3. See media drive random access (RAM), 1 2, 5 25 bin, part numbers, 10 4 installing, 6 8 director, part number, 10 26 part numbers, 10 8...
  • Page 239 pen, G 3. cartridges pen palette, 3 7 operation, verifying plotter, 3 7 pinch arms, 5 6 options, part numbers, 10 28 lift mechanism, removing, 6 72 part numbers, 10 26 orientation, plot, 3 7 sensor, 5 6, 5 27, G 3 overdrive, 5 9 removing, 6 23 change in, 9 14...
  • Page 240 printed circuit assembly. ee PCA removing (cont.), front panel assembly, 6 32 problem solving, chapter 8 front panel PCA and LED assembly, 6 34 processor, left endcover, 6 18 carriage, 5 29 main drive belt, 6 48 main, 5 23 main PCA, 6 9 servo, 5 26 media motor, 6 37...
  • Page 241 rotate, 3 7 service station, 5 17 caps, misaligned, 8 13 RS 232 C, G 4. input/output interfaces part numbers, 10 16 RTL, 1 2, G 4 removing, 6 57 bug fixed, 9 8 servicing cartridges. service station RTS, G 4 servo errors/failures, 8 9, 8 12 processor, 5 26...
  • Page 242 10 28 symbols, safety, xi updates, firmware. See firmware code revision system data flow, 5 19 upgrading a Designjet 200, 1 4 errors, 8 7 kit part number, 10 29 user errors, 8 5 user's guide, part numbers, 10 28 using...
  • Page 243 wiper, part number, 10 14 wiping cartridges, 5 17 warning symbols, xi washers, reinstalling teflon, 9 10 weight of plotter, 2 3 width of lines, incorrect, 8 16, 9 7 X axis. See media drive window, part number, 10 6 removing, 6 15 sensor, 5 27 Y axis.
  • Page 244 .D,A Index 04 C3087 90000...
  • Page 245 ,Dou: AFGN .EG:Gon n ! ! " u !us t ut " v " ! !u $ su o #o 2 I" # to"u! o" u! us" " " u di cu! gu" JDD o t " t#su! " u di cu! gu"...
  • Page 246 What's in This Book This manual contains information necessary to test, calibrate and service D HP DesignJet 200 plotters (models C3180A and C3181A) D HP DesignJet 220 plotters (models C3187A and C3188A) For information about using these plotters, refer to the corresponding user guides.

This manual is also suitable for:

Designjet 220

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