Service Manual
HP DesignJet 220 and
HP DesignJet 200
Plotters
Service Manual
HP DesignJet 220 and
HP DesignJet 200
Plotters
Using this Manual
Purpose
This manual contains information necessary to test, calibrate andservice
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.
Readership
The procedures described in this manual are to be performed by HPĆqualified service
personnel only.
Training
The HP ongoing training course CEV2ĆTIJ provides training for HP Customer Engineers, on
servicing the complete HP DesignJet series of largeĆformat, thermalĆinkjet plotters.
Part Numbers
Part numbers for plotter options, accessories andservice parts are locatedin chapter 10.
Conventions
The term D/A1Ćsize plotters refers generically to models C3180A and C3187A.
The term E/A0Ćsize plotters refers generically to models C3181A and C3188A.
A small arrow ' is used to indicate other parts of the Service Manual or User's Guide where
you can findinformation relatedto the topic you are consulting.
The w symbol is usedto indicate the name of a referencedparagraph.
ii Using this Manual
C3187Ć90000
Contents
Using this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
1
Product Information
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ć2
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ć2
Graphic Languages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ć2
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ć2
Network Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ć2
Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ć2
Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ć3
Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ć3
Plotting Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ć3
Legs and Media Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ć3
Media Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ć3
Media Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ć4
Media Margins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ć4
Other Plotter Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ć4
Upgrading a DesignJet 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ć4
2
Site Planning and Requirements
Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Ć2
Choosing an Interface Cable (more ' User's Guide) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Ć2
Choosing a Suitable Plotter Environment (more ' User's Guide) . . . . . . . . . . . . . . . 2Ć3
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Ć3
Plotter Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Ć3
3
Installation and Configuration
Unpacking and Assembling the Plotter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Ć2
Inspecting the Plotter for Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Ć3
Repacking the Plotter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Ć3
Assembling the Legs and Bin (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Ć4
Installing the Plotter (more ' User's Guide) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Ć6
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Using the Plotter (more ' User's Guide) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Ć6
DesignJet 200 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Ć6
DesignJet 220 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Ć6
Configuring the Plotter (more ' User's Guide) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Ć7
Verifying Plotter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Ć7
PowerĆOn SelfĆTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Ć7
Demonstration Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Ć7
Example of Setup Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Ć8
4
Preventive Maintenance
Cleaning the Plotter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Ć2
General Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Ć2
Cleaning the Drive Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Ć2
5
Functional Overview
Loading the Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć2
Entry Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć2
Sensing Media Presence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć2
Media Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć2
Gripping the Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć6
Pinch Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć6
PinchĆArm Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć6
Advancing the Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć7
MediaĆDrive Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć7
MediaĆDrive Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć7
Providing a Force on top of the Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć8
Bail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć8
BailĆLift Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć8
Bail Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć8
Stretching the Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć9
Overdrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć9
Moving the Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć9
CarriageĆDrive Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć9
Detecting the Media Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć10
Line Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć10
Media Margins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć10
Media Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć10
Providing Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć11
Print Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć11
Drop Growth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć11
Important Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć12
Cartridge Chutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć12
Electrical Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć12
Carriage PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć12
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Producing an Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć13
Raster Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć13
Resolution (Dots Per Inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć13
Dot Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć14
Too Much Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć14
Dot Depletion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć14
Print Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć14
Draft Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć14
Final Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć14
Enhanced Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć14
PrintĆMode Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć15
DesignJet 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć15
DesignJet 220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć15
Aligning the Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć16
Servicing the Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć17
Service Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć17
Wiping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć17
Capping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć18
Spitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć18
Cooling the Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć18
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć18
System Data Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć19
Input/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć19
Parser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć19
Display List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć19
Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć20
Swath Holding Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć20
Swath Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć20
PrintĆEngine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć20
Swath RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć20
CartridgeĆInterface ASIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć20
Carriage ASIC and Cartridge Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć20
Plotter Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć21
Main PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć22
Main Processor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć23
Main Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć23
ROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć23
Processor Support ASIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć24
Shuffler ASIC and Swath Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć24
Input/Output Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć24
Parallel Input/Output Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć24
What is BiĆTronics ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć24
Serial Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć25
Serial Input/Output Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć25
DRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć25
PowerĆOn Reset Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć25
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Servo Processor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć26
Servo Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć26
Processor Support ASIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć26
FrontĆPanel Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć27
StepperĆMotor Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć27
CarriageĆProcessor Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć27
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć27
EEROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć27
Power Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć28
Carriage and Media Motor Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć28
PrintĆCartridge Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć28
Fan Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć28
Carriage PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć29
Carriage Processor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć29
Carriage Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć29
Nozzle Timing ASIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć30
Servo Processor Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć30
A/D Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć30
Print Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć30
Line Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć30
Front Panel PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć31
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć31
Key Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć31
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ć32
6
Removal and Replacement
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć2
ESD Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć2
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć2
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć3
Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć5
Removing the ElectronicsĆEnclosure Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć5
Removing the Memory Module (DRAM SIMM) . . . . . . . . . . . . . . . . . . . . . . . . 6Ć7
Removing the Main PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć9
Removing the PowerĆSupply PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć12
Removing the Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć14
Removing the Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć15
Removing the Center Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć16
Removing the Left Endcover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć18
Removing the Right Endcover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć19
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Removing the Automatic CartridgeĆAdjust Linkage . . . . . . . . . . . . . . . . . . . . 6Ć20
Removing the Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć21
Removing the PinchĆArm Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć23
Removing the Window Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć24
Removing the Media Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć26
Replacing the MediaĆSensor Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć28
Removing the Trailing Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć29
Removing the FrontĆPanel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć32
Removing the FrontĆPanel PCA and LED Assembly . . . . . . . . . . . . . . . . . . . . 6Ć34
Removing the Carriage (YĆAxis) Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć35
Removing the Media (XĆAxis) Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć37
Removing The Encoder Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć39
Reinstalling the Encoder Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć41
Removing the TrailingĆCable Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć43
Removing the YĆTensioner and Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć45
Removing the Cartridge Carriage and Main Drive Belt . . . . . . . . . . . . . . . . . 6Ć48
Removing the Bail Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć55
Removing The Bail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć56
Removing the Service Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć57
Removing the Overdrive Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć60
Removing the Overdrive Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć62
ReĆinstalling the Overdrive Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć63
Removing the Entry Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć65
ReĆinstalling the Entry Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć67
Removing the Drive Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć69
Removing the Automatic BailĆLift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć71
Removing the PinchĆArm Lift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Ć72
7
Calibrations
When to Calibrate the Plotter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Ć2
Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Ć2
Entering Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Ć2
FrontĆPanel Keys in Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Ć3
Performing Tests and Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Ć3
Cartridge Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Ć4
Accuracy Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Ć6
Bail Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Ć8
MediaĆSensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Ć9
SetupĆSheet Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Ć10
Contents vii
C3187Ć90000
8
Troubleshooting
Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć2
PowerĆOn Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć2
Extended PowerĆOn Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć3
Mechanical Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć3
What You Should See and Hear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć4
Errors Indicated by LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć5
User Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć5
Error and Cartridges flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć5
Error and Ready flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć5
Error and Busy flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć6
Error and Load Media flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć6
System Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć7
Error and Busy lit and steady: Input/output errors . . . . . . . . . . . . . . . . . . 8Ć7
Error and Ready lit and steady: Memory errors . . . . . . . . . . . . . . . . . . . . . 8Ć8
Error and Load Media lit and steady: MediaĆpath/servo errors . . . . . . . . 8Ć9
Error and Cartridge lit and steady: Miscellaneous errors . . . . . . . . . . . . . 8Ć10
FirmwareĆCode Revision Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć11
Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć11
Repair + Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć11
Print Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć11
Diagnosing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć11
Other Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć11
Servo ControlĆSystem Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć12
MediaĆAxis (XĆAxis) Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć12
CarriageĆAxis (YĆAxis) Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć12
Frequent Cartridge Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć12
Remove Tape and Align Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć12
Damaged Encoder Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć12
Incompatibility between Carriage and Firmware . . . . . . . . . . . . . . . . . . . . . . . 8Ć12
Misaligned Cartridge Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć13
Function of the Cartridge Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć13
What can Cause Cap Misalignment? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć13
Checking CartridgeĆCap Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć13
BailĆLiftĆMechanism Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć14
Normal BailĆLift Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć14
Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć14
Teflon Washers versus CamĆGear Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć14
Cartridge Carriage Rubbing against Encoder Strip . . . . . . . . . . . . . . . . . . . . . . . . 8Ć15
Premature Wearing of Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć15
Sensor does not Correctly Find Media Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć15
Last Swath is Clipped when Replotting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć15
Ink Smearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć16
Add Starwheel Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć16
Change Carriage Rear Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć16
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C3187Ć90000
Plots Joined or Not Plotted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć16
HPĆGL Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć16
Incompatibility between Trailing Cable and Main PCA . . . . . . . . . . . . . . . . . 8Ć16
Incorrect Line Widths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć16
Plotter won't Read Setup Sheet; Plots Solid Black Area Fill . . . . . . . . . . . . . . . . 8Ć17
Problems in Loading Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć17
Long Media doesn't Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć17
Translucent Media doesn't Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć17
Binding, or Missing Sensor Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć17
Media Skews Badly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć17
Service Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć18
Description
Bail Cycle Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć18
BailĆSensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć18
Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć18
Input/Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć18
MediaĆSensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć19
PinchĆArmĆSensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć19
Service Configuration Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć19
Service Monitor (Data Display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć19
Servo/Encoder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć19
StepperĆMotor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć20
WindowĆSensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć20
Which Service Test to Perform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć21
Performing the Service Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć22
Bail Cycle Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć22
BailĆSensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć22
Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć22
Input/Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć23
MediaĆSensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć23
PinchĆArmĆSensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć23
Service Configuration Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć23
Service Monitor (Data Display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć24
Servo/Encoder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć24
StepperĆMotor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć24
WindowĆSensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć24
Interpreting the Service Configuration Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć25
Analyzing the Bar Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć25
First Four Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć25
Fifth and Sixth Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć25
Seventh Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć25
Parameters Printed Below EEROM Text Block . . . . . . . . . . . . . . . . . . . . . . . . 8Ć26
Reading the EEROM Text Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć26
Clearing the EEROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ć29
Contents ix
C3187Ć90000
9
Product History
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Ć2
SerialĆNumber Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Ć2
Identifying a Printed Circuit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Ć3
Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Ć3
Revision Letter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Ć3
Firmware Revision Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Ć3
Potential Ink Smearing Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Ć4
Problems Corrected by Firmware Release A.01.01 . . . . . . . . . . . . . . . . . . . . . . . . . 9Ć7
Problems that will be Corrected by Firmware Release A.01.02 . . . . . . . . . . . . . . 9Ć8
EPROMs and Masked ROMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Ć9
ReĆinstalling Teflon Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Ć10
New BailĆLiftĆMechanism Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Ć11
Change in Trailing Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Ć13
Change in Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Ć14
Change in Bail and Overdrive Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Ć14
10 Parts and Diagrams
Exchange Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Ć2
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Ć3
Part Lists and ExplodedĆView Diagrams:
Legs and Media Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Ć4
Window, Center and Bottom Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Ć6
Electronics Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Ć8
Left Endcover and Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Ć10
Right Endcover and Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Ć12
CarriageĆAxis Drive (Left End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Ć14
Service Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Ć16
CarriageĆAxis Drive (Right End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Ć18
Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Ć20
Media Drive Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Ć22
Bail and Overdrive Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Ć24
PinchĆArm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Ć26
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Ć28
Line Cord Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Ć30
Interface Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Ć32
x
Contents
C3187Ć90000
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).
Protective conductor terminal. For protection against electrical
shock in case of a fault. Used with field wiring terminals to
indicate the terminal that must be connected to ground before
operating equipment.
OR
Low-noise or noiseless, clean ground (earth) terminal. Used for a
signal common, as well as providing protection against electrical
shock in case of a fault. A terminal marked with this symbol must
be connected to ground in the manner described in the installation
(operating) manual, and before operating the equipment.
Frame or chassis terminal. A connection to the frame (chassis) of
the equipment, which normally includes all exposed metal.
OR
Alternating current
Direct current
Alternating or direct current
The WARNING sign denotes a hazard. It calls attention to a
procedure, practice, or the like, which, if not correctly performed
or adhered to, could result in personal injury.
WĂAĂRĂNĂIĂNĂG
Take care not to cut yourself on the encoder strip inside the plotter.
The CAUTION sign denotes a hazard. It calls attention to an
operating procedure, practice, or the like, which, if not correctly
performed or adhered to, could result in damage to or destruction
of part or all of the product.
C A U T I O N
Safety xi
C3187Ć90000
Notes
xii Safety
C3187Ć90000
1
Product
Information
1Ć1
Description
Applications
HP DesignJet 200 and HP DesignJet 220 plotters are largeĆformat, monochrome, inkĆjet
plotters that provide hardcopy output of computer program data.
LargeĆformat plots of high resolution and quality are generated for applications such as
D ComputerĆaided design (CAD)
D ComputerĆaided manufacturing (CAM)
D Mapping
D Mechanical and architectural drawings
D General drafting
Graphic Languages
The plotters accept drawing data from CAD software programs supporting the following
languages:
D HewlettĆPackard Graphics Language (HPĆGL), a vector language
D HPĆGL/2, an enhanced version of HPĆGL
D HewlettĆPackard Raster Transfer Language (HPĆRTL), a raster language
D Printer Job Language (PJL)
The plotters support HPĆGL/2 with both the Japanese Kanji and the Roman character sets.
Interfaces
The plotters operate with a number of computer systems and graphic terminals, using either
RSĆ232ĆC or Centronics/BiĆTronics interfaces. (More ' chapter 5, w Input/Output Interfaces.)
Network Connections
Customers can connect their plotters to a network through an optional HP JetDirect EX
external network interface. The following network operating systems are then supported:
D Novell Netware (Ethernet and Token Ring networks)
D LAN Manager (Ethernet and Token Ring networks)
D TCP/IP (Ethernet networks only)
D Apple Ethertalk (Ethernet networks only)
Memory
The plotters have a standard 2 megabytes of onĆboard random access memory (RAM). They
also have one RAMĆexpansion socket, which can hold an optional 2Ćmegabyte, 4Ćmegabyte or
8Ćmegabyte, single inĆline memory module (SIMM). The maximum RAM is therefore 10 MB.
1Ć2 Product Information
C3187Ć90000
Accuracy
The accuracy ofthe plotters in drawing a vector is "0.38 mm (0.015 in) or "0.2% ofthe
specified vector length, whichever is greater, at 23 _C (73 _F) at 50Ć60% relative humidity, on
HP special polyester film.
Resolution
The resolution ofthe plotter output is measured in dots per inch (dpi). (Explanation '
chapter 5.) The plotter resolutions for different plotĆquality settings are as follows:
Plot/Print Quality
HP DesignJet 200
HP DesignJet 220
Draft
300 x 300 dpi, dot depleted
300 x 300 dpi, dot depleted
True 300 x 300 dpi
Final
True 300 x 300 dpi
–
Enhanced
Addressable 600 x 600 dpi.
Plotting Time
The plotting time for one plot on paper is as follows:
Plot/Print-Quality
HP DesignJet 200
HP DesignJet 220
D/A1-size plot
E/A0-size plot
D/A1-size plot
E/A0-size plot
Draft
approx 3.8 min
approx 5.0 min
–
approx 7.5 min
approx 10.0 min
–
approx 2.3 min
approx 3.1 min
approx 6.5 min
approx 3.9 min
approx 5.3 min
approx 10.6 min
Final
Enhanced
Legs and Media Bin
The plotter legs and media bin are optional.
Media Types
Media type
Characteristics
Cost
Plotter paper
Translucent bond
Vellum
Smooth surface, good for everyday use.
Low
Good for diazo reproductions and preliminary drawings.
Diazo-reproducible, archivable, translucent.
Low
Moderate
High
Single-matte inkjet
polyester film
Diazo-reproducible, archivable, very stable,
pencil-writable on the matte side.
(Further advice ' User's Guide, chapter 2, w Choosing and using media.)
C3187Ć90000
Product Information 1Ć3
Media Sizes
The plotters handle only sheet media, not roll media. Supported standard sizes are as follows:
D/A1-size plotters
(C3180A and C3187A)
A, B, C, D
E/A0-size plotters
(C3181A and C3188A)
A, B, C, D, E
ANSI
ISO
A4, A3, A2, A1
A2, A1
A4, A3, A2, A1, A0
A2, A1, A0
Metric Oversize
Architectural
JIS
C, D
C, D, E, E1
A4, A3, A2, A1
B4, B3, B2
A4, A3, A2, A1, A0
B4, B3, B2, B1, B0
The plotters handle media that
does not exceed the following
maxima and minima:
C3181A
C3188A
plotters
C3180A
C3187A
plotters
210 – 625 mm
8.3 – 24.6 in
210 – 917 mm
8.3 – 36.1 in
Media Margins
The media margins define the
real available plotting area on
the media:
5 mm
5 mm
landscape
portrait
5 mm
5 mm
17 mm = 0.67 in
5 mm = 0.2 in
All measurements +/– 2mm (0.08 in)
Other Plotter Features
D Automatic mediaĆedge sensing
D Automatic cartridge alignment, testing and servicing
D BuiltĆin 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 HPĆqualified service personnel only.
1Ć4 Product Information
C3187Ć90000
2
Site Planning and
Requirements
2Ć1
Power Requirements
HP C3180A andC3181A DesignJet 200 andHP C3187A andC3188A DesignJet 220 plotters
have selfĆadjusting 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.
Power Requirements
Source Voltage Requirements:
Voltage
Max current (rms)
100 V ac
120 V ac
220 V ac
240 V ac
1.4 A
1.2 A
650 mA
600 mA
Frequency:
47-53 Hz and 57-63 Hz
140 watts maximum
Consumption:
The ac power outlet (mains) must have a protective
earth (ground) terminal. Serious shock hazard leading
to death or injury may result if the plotter is not
properly grounded.
W A R N I N G
The power cordsuppliedwith the plotter shouldmeet the plug requirements for the
geographical area. However, different power cords (international options) are available.
(Cable part numbers ' chapter 10.)
Choosing an Interface Cable
(Instructions ' User's Guide, chapter 1, w Choosing an interface cable.)
Serial (RSĆ232ĆC) Interface A short cable (less than 15 meters or 50 feet) is recommended
for the RSĆ232ĆC interface. A longer cable is permissible, providedthe loadcapacitance does
not exceed2500 picofarads.
Parallel (BiĆTronics/Centronics) Interface Use a short cable (less than 2 meters or 6.6 feet)
for the parallel interface.
(Interface descriptions ' Service Manual, chapter 5, w Input/Output Interfaces.)
(Pin specifications ' User's Guide, chapter 6, w Interface specifications.)
(Cable part numbers ' Service Manual, chapter 10.)
2Ć2 Site Planning and Requirements
C3187Ć90000
Choosing a Suitable Plotter Environment
(Instructions ' User's Guide, chapter 1, w Positioning the plotter.)
Environmental Specifications
Hardware:
Environmental Class B2
Temperature
Operating environment:
Plotter
Relative Humidity
20-80%
0 to 55_C (32 to 131_F)
10 to 40_C (50 to 104_F)
With cartridges and media:
20-80%
Optimal print quality and media
handling:
15 to 30_C (59 to 86_F)
20-80%
Storage environment:
Temperature
Relative Humidity
Plotter/media
–40 to +70_C
(–40 to +158_F)
5-95%
Cartridges
–40 to +60_C
(–40 to +140_F)
Acoustics:*
Operating
Idle
Sound Pressure
54 dB (Acoustic)
< 20 dB (A)
Sound Power
6.5 bels (A)
< 3.6 bels (A)
*These specifications are typicalsound pressures at a oneĆmeter bystander position. Idle specification
assumes fan is off.
Plotter Dimensions and Weight
Plotter Model:
C3180A/C3187A
C3181A/C3188A
Length
Depth
Height (window closed)
Height (window open)
1076 mm (42.36 in)
380 mm (14.96 in)
355 mm (13.97 in)
505 mm (19.88 in)
1375 mm (54.13 in)
380 mm (14.96 in)
355 mm (13.97 in)
505 mm (19.88 in)
Weight
39.1 kg (86.2 lbs)
46.7 kg (103.0 lbs)
C3187Ć90000
Site Planning and Requirements 2Ć3
Notes
2Ć4 Site Planning and Requirements
C3187Ć90000
3
Installation and
Configuration
3Ć1
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.
The packaging is due to change in late 1994.
(Part number of future unpacking instructions ' Chapter 10)
1
3
2
4
7
5
8
6
3Ć2 Installation and Configuration
C3187Ć90000
9
10
12
1
2
11
1
2
2
2
A
A
B
A
B
1
1
2
1
13
14
1
2
1
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.
Repacking the Plotter
You can order a repacking kit if you need to repack the plotter and don't have the shipping
container and insulation material. (Part numbers ' chapter 10.)
C3187Ć90000
Installation and Configuration 3Ć3
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:
1
2
3
45 kg
(99 lb)
3Ć4 Installation and Configuration
C3187Ć90000
4
1
2
6 mm
(0.25 in)
3
4
5
5
1
2
A
A
A
B
B
B
A+B
3
4
5
X X
X
C3187Ć90000
Installation and Configuration 3Ć5
Installing the Plotter
(Instructions ' User's Guide, chapter 1, Setting up the plotter.)
LineĆCord Set The power cord supplied with the plotter should meet the plug requirements
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
Front Panel
Access
Cartridges
Align
Cartridges
Setup
Replot
Error
Final
Draft
Cartridges
Paper
Load Media
Ready
Busy
Transl
Vellum
Film
Form
Feed
Plot
Quality
Media
Type
Cancel
Replot
DesignJet 220
Front Panel
Access
Cartridges
Align
Cartridges
Setup
Error
Draft
Final
Cartridges
Paper
Load Media
Ready
Busy
Transl
Vellum
Both ON =
Enhanced
Both ON
Film
=
Form
Feed
Cancel
Print
Quality
Media
Type
3Ć6 Installation and Configuration
C3187Ć90000
Configuring the Plotter
(Instructions ' User's Guide, chapter 2, w Reconfiguring the plotter.)
The User's Guide describes how to
D Switch Interface Ports
D Configure the following settings using a setup sheet :
- Language of demonstration plot and setup sheet
- Baud rate and parity of serial interface
- Graphics language
- HPĆGL timeout period
- Plot orientation (rotate and mirror)
- Line merging
- PenĆpalette settings (width and density)
An example of a setup sheet is given on the following page.
Verifying Plotter Operation
The plotters contain several types of internal operational checks and tests to ensure that the
plotter is properly functioning and to help identify problems if any are detected.
PowerĆOn SelfĆTests
Whenever you switch the plotter on, it automatically performs a series of internal selfĆtests
and mechanical initialization sequences. If a failure occurs, an error is indicated on the
frontĆpanel LEDs. You can perform a failure analysis by interpreting the LED error code.
(Details ' chapter 8.)
Demonstration Plot
You can check proper plotter operation by plotting and examining the demonstration plot,
which is resident in the plotters. This plot shows different plotter capabilities including pen
line widths and shading. You can set the demonstration plot, to plot in any of the languages
listed in the Language box of the setup sheet on the following page.
(Instructions' User's Guide, chapter 1, w Setting a language,
' User's Guide, chapter 1, w Plotting a demonstration plot.)
C3187Ć90000
Installation and Configuration 3Ć7
Example of Setup Sheet
The following is a scaled version of a DesignJet 200 setup sheet:
3Ć8 Installation and Configuration
C3187Ć90000
4
Preventive Maintenance
4Ć1
Cleaning the Plotter
To maintain the plotter in good operating condition, keep it free of dust accumulation, ink,
andother contamination. Cleaning intervals are determinedby the plotter environment and
by the types of plotter supplies used. As with any precision electronics equipment, proper
maintenance will help to ensure reliability andprolong product life.
Disconnect the plotter from the power source prior
W A R N I N G
to performing any maintenance. DO NOT allow
water to runonto electrical components or circuits,
or through openings in the enclosure, as this can
create a shock hazard leading to death or injury.
General Cleaning
Proper general cleaning shouldinclude the following:
1 Blow away dust accumulation with compressed air if available.
2 Clean the outer surface of the plotter with a damp sponge or cloth. Use a mild soap and
water solution if necessary. Do not use abrasive cleaners on the window.
3 Wipe the plotter dry with a soft lintĆfree cloth.
Cleaning the Drive Roller
Due to the ink's reflectance, ink spilled on the roller can disrupt the plotter's edgeĆsensing
function. To remove any ink from the roller, perform the following procedure:
1 Connect the plotter to the ac power source.
2 Switch the plotter ON andwait for it to finish initialization.
3 With the window closed and no media loaded, press Form Feed repeatedly until the
stainedarea of the drive roller is positionedat the top where it can be cleaned.
4 Turn the plotter OFF, disconnect it from the ac power source andraise the window.
5 Apply any common householdcleaning solution to a soft, lintĆfree rag andapply it to the
driveĆroller surface.
6 Thoroughly clean the roller surface.
7 If other areas of the roller have been stainedby ink, repeat the above steps.
8 Allow the drive roller to dry.
9 Lower the window, reconnect the plotter to the ac source, turn the plotter on, and load
paper to test that no ink reflections disrupt operation of media loading.
4Ć2 Preventive Maintenance
C3187Ć90000
5
Functional Overview
5Ć1
Loading the Media
Entry Platen
The media load path begins with the entry platen, which provides a loading surface.
(Illustration ' page 10Ć23.)
When you assemble the plotter, it is important to correctly position the entry platen to ensure
that the dashed lines exactly indicate the permitted rightĆedge loading area. The left side of
the entry platen should be pressed up against the left sideĆplate. (Details ' chapter 6.)
(Loading Instructions ' User's Guide, chapter 2, w Loading media.)
Sensing Media Presence
Media Sensor
The media sensor is an optosensor and is mounted towards the right end of the entry platen.
(Illustration ' page 10Ć23). Two articulated levers block the optical path between emitter
and receiver when media is not loaded. When media is loaded, both levers are rotated, thus
clearing the optical path and changing the sensor state from open to closed. This
doubleĆlever system provides a leading and trailing edgeĆsensing capability (for mediaĆlength
measurement) to the plotter. The media sensor is electrically connected to the main PCA.
1. Media Not Loaded
Drive roller
stopped
Secondary flag
Primary flag
Photo sensor area
Sensor housing
(cross-section)
5Ć2 Functional Overview
C3187Ć90000
The mediaĆnotĆloaded 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. Media Inserted (Beginning)
Drive roller
stopped
Media inserted
Primary flag
Photo sensor window
Secondary flag
D Media: inserted but has not yet reached the secondary flag
D Primary flag: rotated 90° counter clockwise (active)
D Secondary flag: resting on plastic detector housing (idle)
D Optical sensor: optical path blocked by secondary flag
D Drive roller: stopped
D Front panel: Load Media LED on
C3187Ć90000
Functional Overview
5Ć3
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 Opticalsensor: optical path cleared by both flags
D Drive roller: full speed inwards, engaging media
D Front Panel: Load Media LED off, Busy LED on
D Media Length Measurement: front edge detected
When the secondary flag clears the optical path, the roller is activated. As the secondary flag
is closer to the roller, paper skew is minimized allowing a deeper media insertion
5Ć4 Functional Overview
C3187Ć90000
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 Ć active)
D Secondary flag: still in previous position (active)
D Opticalsensor: optical path blocked by falling edge of primary flag
D Driver roller: slows down but still rotating inwards...
D Front Panel: Load Media LED off, Busy LED on
D Media Length Measurement: rear edge detected
As soon as the opticalsensor detects that the primary flag is back in it's originalposition, the
roller motion slows down but needs some time to overcome the system's inertia before being
able to reverse the direction of rotation.
C3187Ć90000
Functional Overview
5Ć5
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...
D Front Panel: Load Media LED off, Busy LED on
D Media Length Measurement: rear edge detected when primary flag clears the sensor
The rear edge's position is located when the primary flag, pushed by the rear media edge,
clears the optical path.
If you pull the media parallel to the plotter length, while attempting to
clear a media jam, you could break the flags.
C A U T I O N
Gripping the Media
Pinch Arms
When you load media, it is gripped by the pinchĆarms. (Illustration ' page 10Ć27.)
PinchĆArm Sensor
The pinchĆarm sensor is an optical sensor that is attached to the right sideĆplate. It is used to
detect the position of the pinchĆarm lever. Linkage, attaching the lever to a sensor flag,
causes the flag to block and unblock the sensor as the pinchĆarms are raised and lowered.
The pinchĆarm sensor is electrically connected to the main PCA.
5Ć6 Functional Overview
C3187Ć90000
Advancing the Media
MediaĆDrive Mechanics
The media is advanced by the media drive (XĆdrive) system. Components include:
D Mediamotor (XĆaxis motor)
D Worm pinion and helical driveĆroller gear
D Drive roller
(Illustration ' page 10Ć23.)
The main component of the drive system is a fullĆwidth, 6.4Ćcm (2.5Ćinch) diameter roller
with an elastomer skin. This roller directly drives the media and provides the surface that
references the mediato the printĆhead.
The mediaĆmotor position control uses an encoder feedback loop. The encoder wheel is
mounted to the motor shaft, and the optical reader is mounted inside a bell housing attached
to the back of the motor.
MediaĆDrive Accuracy
The main purpose of the media drive system is to accurately move media such that the
alignment of adjacent print swaths is of high enough precision that the plotter specifications
are met and print quality is maintained. The mediaĆdrive accuracy (endĆpoint accuracy, or
XĆaxis accuracy) specifies how accurately a plotter can draw a line of a given length.
(Specifications ' chapter 1.)
The configuration plot draws crossĆhairs 500mm apart that you can use to measure the
plotter's accuracy. (Details ' chapter 7, w Accuracy Calibration.)
Contributors to the Accuracy
All the above components of the media drive system contribute to the mediaĆdrive accuracy.
The following also contribute:
D Radius variations produced by the way the media wraps around the drive roller, and the
way the pinchĆwheels and starĆwheels maintain this radius
D Errors in the media motor's opticalĆencoder feedback system (this system gives feedback
to the motorĆcontrol circuitry)
Dimensional changes in the media will affect lines drawn in both axes either during plotting
or after the plot is drawn. For this reason, media other than polyester film does not support
the mediaĆdrive accuracy specification. Polyester film is the only media that maintains
dimensional stability to within the plotter specification ranges.
C3187Ć90000
Functional Overview
5Ć7
Providing a Force on Top of the Media
Bail
The bail provides a normal force on top of the media. (Illustration ' page 10Ć25.) When the
pinchĆwheels 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. The plotter then lowers the bail
and advances the media to the overdrive roller. The star wheels on the bail are coated with a
substance resistant to wet ink, so that they do not leave marks on the media.
BailĆLift Mechanism
The bail features an automatic lift mechanism driven by the media motor using a series of
gears and actuated by the cartridge carriage.
Operation
(Part illustrations ' page 10Ć25)
1 The cartridge carriage presses down on the engaging lever.
2 The engagingĆlever gear and cam gear (which are always in contact) engage the
driveĆroller gear on the left end of the drive roller.
3 The mediaĆdrive system drives the drive roller, and also the cam and engagingĆlever
gears. The autoĆcam, which is attached to the cam gear, turns with the gear.
4 The autoĆcam contacts the left bail bracket and pushes up on the bracket. As the bracket
is pushed, the bail lifts.
5 The bailĆsensor switch opens and the resulting bail logic level is sent to the main PCA.
6 The mediaĆdrive rotates the autoĆcam to a detent position. The detent position allows the
bail bracket to rest on the autoĆcam after the carriage moves away from the engaging
lever.
7 The mediaĆdrive drives the media through the media path.
8 Once the media has passed the bail, the carriage again engages the bailĆlift mechanism to
lower the bail.
Bail Sensor
The bail sensor informs the processor of the bail position (Up or Down). It is a mechanical
microswitch located on the right sideĆplate. (Illustration ' page 10Ć25)
5Ć8 Functional Overview
C3187Ć90000
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
waterĆbased ink into the media. Even though the geometry chosen for the plotters minimizes
the occurrence ofthis phenomena, it still could occur on very dense plots.
Operation
(Part illustrations ' page 10Ć25)
The overdrive roller is geared to the mediaĆdrive system and has a surface speed 10% greater
than that ofthe drive roller. The lower star wheels on the bail provide a normal force
between the media and the overdrive roller. The resulting friction force creates media
tension in the area between the upper pinchĆwheels and the overdrive roller (the print zone).
The overdrive roller is segmented into small rollers made ofpolyurethane. A clutch
(overdrive gear assembly) is geared to the speedĆratio gear (overdrive gear cluster) and drives
the overdrive roller in the forward direction only.
Moving the Carriage
CarriageĆDrive Mechanics
The Carriage (YĆaxis) drive consists ofa DC motor driving the carriage by means ofa dual,
kevlar belt system incorporating three pulleys and two tensioner assemblies.
Operation
(Part illustrations ' pages 10Ć19 and 10Ć21)
1 A gear pinion, pressed onto the carriageĆmotor shaft, drives a small belt tensioned with a
selfĆcompensating, springĆloaded idler.
2 The small belt drives a double pulley which transfers the motor drive to the main belt.
3 The main belt is attached to the carriage via frictionĆfit belt clamps. It is tensioned using
a selfĆcompensating, springĆloaded tensioner wedge and main idler. (Illustration ' page
10Ć15.) The belt moves the carriage along slider rods, which are part ofthe chassis
assembly. The carriage bearing system consists ofthree bushings.
4 Positional feedback is obtained using a 150ĆlineĆperĆinch linear encoder strip that is
spring loaded and passes through the carriage where the small slots are read by an
optical encoder. The feedback is used by the carriageĆmotor servoĆcontrol system.
C3187Ć90000
Functional Overview
5Ć9
Detectingthe 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. The black surface of the drive roller absorbs the light.
Excessive ink deposits on the driveĆroller can fool the sensor by reflecting the light.
2 The sensor goes on to find the right media edge.
3 The media is advanced and the sensor checks for media skew (crooked loading).
Other Functions
The line sensor on the cartridge carriage is also used to
D Detect and measure lines drawn on media when performing cartridge alignment
D Detect and measure lines drawn on media when performingaccuracy calibration
D Scan the setup sheet
Media Margins
HardĆclip side margins provide protection against writing on the drive roller due to media
expansion/contraction or skew. Top and bottom margins are set according to the physical
spacingbetween the pinchĆwheels, overdrive and writinghead. (Specifications ' chapter 1.)
Media Sizes
You can use a wide variety of media sizes, due to the
D Continuous roller
D Spacingof the pinchĆwheels and starĆwheels
D EdgeĆdetection capability
(Specifications ' chapter 1.)
5Ć10 Functional Overview
C3187Ć90000
Providing Ink
(Carriage Illustration ' page 10Ć21)
Print Cartridges
The plotters use two HP DeskJetĆtype cartridges, each containing 50 nozzles. The cartridges
are staggered suchthat two nozzles on eachone are not used.
The main components of a cartridge are the
D Plastic housing
D SpringĆbag ink reservoir
D Flex circuit
The spring bag provides a negative pressure inside the ink supply to prevent ink from flowing
out through the nozzles. The print head (flex circuit), located on the cartridge, contains the
cartridge interface (interconnect) and nozzles.
Drop Growth
Inkjet cartridges invoke a thermal dropĆonĆdemand technology.
Nozzle
2
1
3
4
1 A voltage is applied to a resistive area on the head superheating the bottom layer of the
ink droplet and causing nucleation (similar to boiling water).
2 The ink boils producing a bubble of water vapor that forces the ink droplet out of the
small nozzle orifice.
3 As the ink droplet leaves the orifice, the surface tension of the ink draws more ink into
the chamber.
4 The bubble collapses as the water vapor cools.
C3187Ć90000
Functional Overview 5Ć11
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).
Electrical Contact
A goldĆplated, dimpled flex circuit mates with the flat tab circuit on each cartridge to make
the electrical contact between the plotter and the cartridges. The elastomer spring pads
behind each flex circuit ensure the dimples contact the tab circuits with enough pressure.
Carriage PCA
The carriage PCA is part of the carriage assembly. It connects to the main PCA through the
trailing cable, which passes through a split torroid to reduce radioĆfrequency interference.
The Carriage PCA contains
D Line sensor
D Thermistor circuit
D Linear encoder
D Cartridge nozzle firing circuit
The thermistor circuit informs the carriage processor if the temperature of the carriage PCA
is above or below a certain value.
(Further information ' later in this chapter, w Carriage PCA.)
5Ć12 Functional Overview
C3187Ć90000
Producing an Image
Raster Technology
The plotters are raster based. They plot using dots to represent the data. Thus a line is
made up of a series of dots.
Vector
Raster
95
45
B
C
D
14
A
Resolution (Dots Per Inch)
The resolution of a raster plotter is the number of dots per inch (dpi) it can place along one of
two orthogonal axes.
True Dpi refers to the ability of the plotter to print a single dot at every location on a grid.
Addressable Dpi is the ability of the plotter to selectivity position dots on a grid finer than
the trueĆdpi grid. It is used to produce higher print quality output.
600 addressable dpi
Enhanced Mode
300 dpi
Final Mode
BothDesignJet 200 and DesignJet 220 plotters use two 300Ćdpi print cartridges. However,
the DesignJet 220 has an Enhanced print mode enabling it to address a 600Ćdpi grid.
C3187Ć90000
Functional Overview 5Ć13
Dot Size
Each dot produced by a 300Ćdpi 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 singleĆdotĆwide line is printed, dots
overlap andthe line appears to be continuous.
Too Much Ink
A 600Ćdpi grid contains four times as many dots as a 300Ćdpi grid. This means that four
times as much ink can be laid down on a 600Ćdpi grid. Media cannot absorb that much ink
effectively; it puddles, runs, and dries slowly.
Dot Depletion To solve the ink problem, sophisticated algorithms produce asymmetrical dot
arrangements to selectively reduce (deplete) the number of dots placed on the addressable
600Ćdpi grid in enhanced mode. (The same happens on the 300Ćdpi grid in draft mode, but to
increase plotting speed.) Dot size is not varied in any of the print modes.
Print Quality
Draft mode is fast anduses half the ink of true 300Ćdpi resolution. Special algorithms control
dot placement, creating a virtual 300Ćdpi image, rather than skipping every other dot. The
image appears considerably lighter than the true 300Ćdpi print quality.
Final mode uses true 300Ćdpi resolution. Plotters set to plot on a 300x300Ćdpi grid directly
map 90,000 raster image dots per square inch to 90,000 drops of ink.
Enhanced mode (on the DesignJet 220) uses addressable 600Ćdpi resolution. This involves
300Ćdpi cartridges on a 600x600Ćdpi grid. Dot depletion results in the same amount of drops
used as in true 300Ćdpi mode. Print quality improves because the dot centers may be located
anywhere on the 600Ćdpi grid. This results in smoother curves, straighter lowĆangle lines,
smoothĆedgedarea fills andeasily readable small text.
5Ć14 Functional Overview
C3187Ć90000
PrintĆMode Characteristics
DesignJet 200
Media Type
Print
Quality
Resolution
(DPI)
# of Passes
Carriage
Speed
Swath
Delay
Pass
Density
Paper
Draft
Final
300x300
300x300
1
1
24ips
0
50%
16.7ips
1sec
100%
Vellum/
Transl
Draft
Final
300x300
300x300
1
2
24ips
0
50%
50%
Vellum/
Transl/Film
16.7ips
1sec
DesignJet 220
Media Type
Print
Quality
Resolution
(DPI)
# of Passes
Carriage
Speed
Swath
Delay
Pass
Density
Paper
Draft
Final
300x300
300x300
1
1
2
24ips
16.7ips
16.7ips
0
50%
100%
50%
1sec
0.5sec
Enhanced
addressable
600x600
Vellum/
Transl
Draft
Final
300x300
300x300
1
2
4
24ips
16.7ips
16.7ips
0
50%
50%
25%
1sec
0.5sec
Enhanced
addressable
600x600
Film
Final
300x300
2
4
16.7ips
16.7ips
3sec
50%
25%
Enhanced
addressable
600x600
1.5sec
A swath is the amount of data printed in one pass of the carriage. The swath delay is the
time between completing one swath and beginning to print the next swath.
C3187Ć90000
Functional Overview 5Ć15
Aligning the Cartridges
The cartridgeĆalignment system is composed of
D Stepper motor
D Adjustment linkage
D Adjustment cam
D Adjustable cartridge chute
D Carriage drive
(Illustrations ' pages 10Ć15 and 10Ć21.)
Operation
The following operation is used to align one cartridge with respect to the other in the XĆaxis
(media axis). (YĆaxis and ZĆaxis realignments are done by varying the firing timing of each
nozzle resistor.)
1 The stepper motor presses up on the lower link of the three adjustmentĆlinkage pieces by
means of the plastic actuator pressed onto the motor shaft.
2 This action lowers the top link of the adjustment linkage.
3 The carriage moves, and the adjustment cam, which comes into contact with the top link,
is rotated.
4 The cam action causes the adjustable cartridge chute to move in either the plus or minus
XĆaxis direction relative to the fixed cartridge chute.
(Instructions ' chapter 7, w Cartridge Alignment.)
5Ć16 Functional Overview
C3187Ć90000
Servicingthe Cartridges
Service Station
(Illustration ' page 10Ć17.)
Various important cartridgeĆmaintenance operations are performed at the service station:
D Cartridge wiping
D Cartridge capping
D Nozzle spitting
Wiping
Duringoperation of the cartridge, ink accumulates on the nozzle plate alongwith paper dust
and other substances foreign to the cartridge. If not removed, this buildup can affect nozzle
directionality and lead to nozzle failure.
Periodically during operation of the cartridge, this buildup is removed by dragging a wiper
across the nozzle plate.
Operation
(Illustration ' page 10Ć15.)
1 The stepper motor presses down on the lower link of the wiper assembly by means of the
plastic actuator pressed onto the motor's shaft.
2 As the lower link is pushed down, the upper linkage is raised.
3 The carriage moves over the small rubber blade, attached to the top of the upper linkage,
causingthe blade to wipe excess ink and crustingfrom the nozzle plates.
C3187Ć90000
Functional Overview 5Ć17
Capping
Ink evaporates if you expose nonĆfiring 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.
Operation
1 Aligning the Caps
Alignment between the cartridge caps and the nozzles is necessary, because the cap seals
on a very small area of the cartridge's plate. Misalignment can cause the ink to wick
from the cartridge.
The springĆloaded sled aligns directly to the carriage by means of a beveled plate that
mates to a notch on the carriage. This notch establishes X and Y alignment. A flat
feature on the sled butts against the carriage to establish the Z alignment.
(Checking correct alignment ' chapter 8, w Frequent Cartridge Failure.)
2 Sealing the Nozzles
a The cartridge cap creates a closed volume of air around the nozzles, which is
humidified by firing one drop per nozzle.
b The air volume in the cap is compressed, resulting in a positive pressure at the
nozzles. This pressure must be held within a set tolerance. Not enough pressure and
the cartridges can leak, too much and the cartridges can deprime.
Spitting
The cartridge fires (spits) ink droplets periodically to keep a clean nozzle condition. Spitting
also takes place to humidify the cartridges before capping and to detect missing nozzles. The
cartridges spit into spittoons located in the service station area.
Cooling the Electronics
Fan
A single DC fan provides cooling for all electronics inside the electronics enclosure. The fan
is processor controlled and runs only when the plotter is plotting. The fan connects to the
Main PCA.
5Ć18 Functional Overview
C3187Ć90000
System Data Flow
Firmware Graphics
Module
Data characters
One at a time
Parser
I/O Buffer
Physical
Graphic
objects
Swath Area
Data characters
500 Bytes
Display List
I/O Interrupt
Swath
Graphic
objects
Firmware
Print-Engine
Control Module
VRC, RRC
Physical
Input/Output
Rasterized
object
Swath
Swath
Data
Swath Holding Area
Manager
Input/Output
The user's computer is connected to the plotter through a physical input/output (I/O)
connection. The I/O interrupt process removes data from the I/O port, 500 bytes at a time,
and places it into the I/O buffer.
Parser
The parser removes data from the I/O buffer, one byte at a time, interprets the data and
transforms it into graphic objects, which are mapped onto the display list. The parser can
interpret either raster or vector data. It adds positional information to the data indicating
where it is placed on the display list. It continues building the display list until the entire
plot has been sent or until memory is full.
Display List
The graphic objects are geometrical shapes (arcs, vectors, etc.), which are placed on the
display list. The display list is a logical map. It is built in a swath format. The information
that builds the display list is stored in DRAM (Dynamic RandomĆAccess Memory). The more
DRAM the system contains, the larger and more dense the display list can be.
C3187Ć90000
Functional Overview 5Ć19
Converters
The vectorĆtoĆraster converter (VRC) or rasterĆtoĆraster 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 ofthe DRAM that is specially allocated for this purpose. The
swath holding area is large enough to hold up to three swaths at a time.
Swath Manager
The swath manager firmware algorithm removes data from the swath holding area and
reorganizes the data for more efficient plotting. This enables the plotter to sweep the
carriage to areas that require ink and to conserve motion by not sweeping blank areas ofthe
media. Variables are calculated and stored during this optimization.
The swath manager then replaces the data into the swath holding area.
PrintĆEngine Controller
The printĆengine controller removes the organized data from the swath holding area and
copies it to the physical swath RAM area. The plotter's microprocessor has a feature called
burst mode," enabling data to be copied from one area of memory to another very quickly.
The printĆengine controller uses the variables calculated by the swath manager to determine
the stop and start positions ofthe swath and thus control the carriage movement.
Swath RAM
The swath RAM is dedicated RAM memory and not part ofthe DRAM.
CartridgeĆInterface ASIC
The cartridgeĆinterface ASIC (ApplicationĆSpecific Integrated Circuit) controls the shuffling
of pure swath data to the actual firing order of the cartridge nozzles. It fetches pixels from
the physical swath RAM and sends it serially through the trailing cable to the carriage ASIC.
This sending ofpixel data is initiated by means ofa signal sent to the cartridgeĆinterface
ASIC by the processorĆsupport ASIC, so as to synchronize the motion ofthe media motor and
carriage motor with the firing of the printĆhead drivers.
Carriage ASIC and Cartridge Drivers
The carriage ASIC generates the select and enable signals to drive the cartridgeĆdriver
integrated circuits.
The cartridge drivers provide the firing pulses for the printĆhead nozzles.
5Ć20 Functional Overview
C3187Ć90000
Plotter Architecture
The plotters have the multiprocessor architecture showninthe following diagram:
I/O
Main
Processor
(80960KA)
Internal
Memory
(ROM/RAM)
Expansion
Memory
(SIMM DRAM)
(Centronics)
(RS–232)
80960 bus
Encoders
Swath RAM
(256 KB)
Shuffler
ASIC
Support
ASIC
Motor Drivers
Carriage
Processor
(8051)
Servo
Processor
(8052)
Nozzle
Timing ASIC
EEPROM
(256)
Sensors
Cartridge
Drivers
Line Detector
Front Panel
Plotter Architecture
The plotter electronics, besides sensors and cables, consist of the following assemblies:
D MainPCA
D Carriage PCA
D FrontĆPanel PCA
D Power Supply
These are described onthe following pages.
C3187Ć90000
Functional Overview 5Ć21
Main PCA
(Part illustration ' page 10Ć9.)
PCA and Sensor Interconnections
RS–232
Centronics
Media-axis encoder
Front panel PCA
MAIN PCA
Carriage PCA
Pinch-arm sensor
Window sensor
Media sensor
Bail sensor
Stepper motor
Fan
Media motor
Carriage motor
Power supply
SIMM socket
The main PCA contains most of the plotter electronics, that is:
D Main processor system
D Servo processor subsystem
D Some power components
5Ć22 Functional Overview
C3187Ć90000
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
RAM
To Servo Processor
System
Processor
Support
ASIC
Shuffler
ASIC
80960
CPU
RS-232
Interface
To Carriage
Processor
System
DRAM
SIMM
Socket
Demultiplexed
Bus Interface
Centronics
Interface
4x8-Mbit
ROM
2-MB
DRAM
Main-Processor-System
Main Processor
The main processor interprets graphicsĆlanguage commands received through the
input/output (I/O), prepares a bit map of the data to be printed, and issues commands to the
servo processor to synchronize the carriage androller movements for each swath printed.
ROM
The firmware code is containedin either two maskedROMs or four EPROMs on the main
PCA.
The EPROM integrated circuits are socketed; Move them from the old Main PCA to the new
one, when you replace the Main PCA.
C3187Ć90000
Functional Overview 5Ć23
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 rowĆoriented image data in the system
memory into columnĆoriented nozzle data needed by the print cartridges. The shuffling is
accomplished by copying an entire swath of image data from the system memory into the
swath memory, then fetching the pixel data from swath memory for each cartridge nozzle
according to the shuffle pattern in the ASIC address sequencer. The shuffled data is
transferred serially to the nozzleĆtiming ASIC located on the carriage.
Input/Output Interfaces
The plotters have both a parallel (BiĆTronics) and a serial (RSĆ232) interface. These I/Os are
controlled by the main processor.
Parallel Input/Output Hardware The parallel interface is compliant with IEEE standard
1284 (BiĆTronics).
The parallel port has a standard female 1284ĆB 36Ćpin connector (the same connector as
standard Centronics).
Hosts with 1284Ćcompliant parallel interfaces (including standard PCs with the appropriate
parallelĆport software) are able to communicate with the plotter bidirectionally. Hosts with
standard Centronics hardware (such as traditional PCs) are able to operate with the plotter
as they do with standard Centronics devices.
What is BiĆTronics BiĆTronics is a signaling method for a speedĆadaptive, fully interlocked,
bidirectional parallel communications channel between a peripheral and a host. The features
of BiĆTronics are:
D Provides the capability to send data from the host computer to the plotter at a higher
speed, by shortening the signal timing values.
D Provides a path for data to be sent from the plotter to the host, such as solicited and
unsolicited status (media jam, plot finished, etc.)
D Reduced user interaction: The host software can request information of the plotter
directly (such as amount of available memory?") instead of prompting the user.
D The specification allows PCs with existing parallelĆport hardware to participate in
bidirectional communication with a peripheral by installing new parallelĆport driver
software; no new PC hardware is necessary.
The IEEEĆ1284 specification provides for two levels of compliance for the electrical
characteristics of an interface. The interface for the plotters meets the Level 1 electrical
requirements.
The IEEEĆ1284 specification defines five modes of operations for an interface. The interface
for the plotters implements Compatibility and Nibble modes.
HostĆtoĆperipheral dataĆtransfer handshaking is performed by a hardware state machine.
PeripheralĆtoĆhost handshaking is performed by the main processor in response to an
interrupt.
5Ć24 Functional Overview
C3187Ć90000
Serial Hardware The main processor controls the DTR (Data Terminal Ready) signal using
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.
Serial Input/Output Initialization The reset state of the DTR signal is undefined. During
initialization, the main processor first sets the DTR control bit to 1, which signals the host
that the interface cannot accept data. Later the processor sets the UART configuration
register and the baudĆrate select register using the configuration data from the EEROM.
DRAM
Two MBytes of DRAM for system use and I/O data storage reside permanently on the Main
PCA. In addition, a 72Ćpin socket for the industryĆstandard DRAM SIMM is provided for
optional memory. The socket supports a DRAM SIMM of 2 MB, 4 MB, or 8 MB.
PowerĆOn Reset Signals
PowerĆon reset signals are used to initialize the processorĆsupport ASIC, shuffler ASIC and
servo processor. The processor support ASIC generates a reset signal to initialize the main
processor. A powerĆon reset signal disables the EEROM to prevent loss of data during power
transitions. The components that generate the reset signals guarantee valid signals once the
logic supply (+5V) exceeds 2.0 V.
C3187Ć90000
Functional Overview 5Ć25
Servo Processor System
The servo processor system consists of the following:
D Servo processor (8052)
D Processor support ASIC
D FrontĆpanel interface
D StepperĆmotor driver
D CarriageĆprocessor interface
D Various sensor inputs
D EEROM
Motor
Position
Encoders
Front-Panel
Interface
Sensors
To Main
Processor
System
8052
Servo
Processor
Processor
Support
ASIC
Stepper-Motor
Driver
Motor
Drivers
EEROM
To Carriage
Processor
System
Servo Processor System
Servo Processor
The servo processor controls all of the plotter actuators. Executing the commands issued by
the main processor, it reads the carriage and roller position from the processor support ASIC
and writes the needed control data to the PWM (Pulse Width Modulation) generators in that
ASIC. Through a serial link, the servo processor sends nozzleĆtiming data to, and receives
carriageĆsensor data from, the carriage processor.
Processor Support ASIC
The processor support ASIC provides support for the servo processor, and an interface
between the main processor andthe servo processor.
5Ć26 Functional Overview
C3187Ć90000
FrontĆPanel Interface
The front panel consists of nine LEDs andeight switches. The servo processor interface to
the front panel consists of nine control signals andtwo sense signals.
StepperĆMotor Driver
The servo processor controls a stepper motor usedfor printĆcartridge servicing and
alignment.
CarriageĆProcessor Interface
The servoĆprocessor serial port is usedto communicate with the carriage processor.
Sensors
Four sensors provide input to the servo processor:
D The window sensor is a mechanical switch that detects if the window has been raised.
This serves the purpose of a safety interlock. While the window is raised, the servo
processor halts any carriage movement.
D The media sensor detects the presence of media in the media path. It is also used to
determine media size.
D The pinchĆarm sensor detects whether the pinchĆarms have been raised. The servo
processor uses the sensor to determine the pinchĆarm position during the initialization
sequence.
D The bail sensor detects whether the bail has been raised. The servo processor uses the
sensor to determine the bail position during the initialization sequence.
EEROM
A serial EEROM is usedas nonvolatile storage for calibration andconfiguration data. This
data is typically unique for the plotter. It includes the following information:
D RSĆ232 configurations
D Certain frontĆpanel selections
D PenĆpallet information
D Constants createdduring the various plotter calibrations
The EEROM is solderedto the Main PCA (both new andrebuilt). Shouldthe EEROM be
clearedor the Main PCA replaced, perform all calibrations. (Details ' chapter 7.)
The servo processor drives the EEROM control signals, chip select and shift clock. A reset
signal disables the chip select during power transitions to reduce loss of data.
C3187Ć90000
Functional Overview 5Ć27
Power Components
The following are the power components on the main PCA:
Carriage and Media Motor Drivers
Two motor driver ICs and heatsinks.
PrintĆCartridge Voltage Regulator
To regulate the amount of energy given to the printĆcartridge heating resistors, a precise
voltage regulator controls the printĆcartridge voltage supply. The regulator power device is
located on the main PCA, but the cartridge resistors and drivers are located on the carriage
PCA. To reduce the effect of the long path between the voltage regulator output and the
cartridge resistors, an active sense circuit on the carriage PCA feeds back an error signal to
the main PCA. On the carriage PCA, the cartridge supply voltage is sensed by a precision
resistor divider and compared with 2.5V reference. This error is amplified, buffered, and
transmitted to the main PCA through the trailing cable. The voltage is regulated by a
regulator on a heatsink.
Fan Driver
The plotter electronics are cooled by a fan, which may be turned on and off by the main
processor. A twoĆpin connector is used for the fan. Pin 1 connects to the black wire of the fan
harness and to the drain of a driver FET on the Main PCA. Pin 2 connects to the red wire of
the fan harness and to +12V on the Main PCA.
5Ć28 Functional Overview
C3187Ć90000
Carriage PCA
The carriage PCA has four main functions:
D The nozzleĆtiming 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 printĆcartridge calibration.
D A thermistor monitors the temperature near the print cartridges.
The carriage PCA is installed in the carriage assembly, componentĆside down to accommodate
the operation of the linear encoder. A long 28Ćconductor cable (trailing cable) connects the
carriage PCA to the main PCA.
Voltage and Energy The carriage PCA requires 5 V @ 670 mA and 20 V @ 61 to 218 mA.
The regulator for the 20ĆV supply is located on the main PCA, but an active sense circuit on
the carriage PCA senses the voltage at the highĆfrequency bulk charge source capacitors.
Carriage Processor System
The carriage processor system consists of the following:
D Carriage processor
D Nozzle timing ASIC
D Servo processor interface
D AnalogĆtoĆDigital (A/D) Converter
D Print cartridges
Carriage-Processor-System
D Line sensor
Thermistor
A/D Converter
8052
Carriage
Processor
To Servo
Processor
System
Line Sensor
Cartridge
From Main
Processor
System
Nozzle
Timing ASIC
Cartridge
Drivers
Carriage Processor
The carriage processor's primary task is to configure the nozzleĆtiming ASIC. It receives the
configuration data from the servo processor. It controls the A/D converter used in the line
and temperature sensors, and senses printĆcartridge identity and continuity. It returns
status and sensor data to the servo processor.
C3187Ć90000
Functional Overview 5Ć29
Nozzle Timing ASIC
The carriage processor dedicates its address/data bus to interface with the nozzleĆtiming
ASIC. The ASIC is also connected to the shuffler ASIC by a synchronous serial channel. The
nozzleĆtiming ASIC applies the shuffled data it receives from the shuffler ASIC to the
cartridge drivers, controlling the firing time and sequence of the printĆcartridge nozzles.
The outputs controlling the print cartridge drivers are disabled while the reset signal is
active. A voltage supervisor monitors the logic supply (+5V) and generates a reset signal to
prevent firing nozzles during power transitions. The falling threshold for reset is 4.71V
worst case.
Servo Processor Interface
The carriageĆprocessor serial port is used to communicate with the servo processor. The
servo processor controls the carriageĆprocessor reset signal.
A/D Converter
The carriage processor controls an eightĆchannel serial A/D converter. The processor drives
the A/DĆconverter control signals, chip select and shift clock.
Print Cartridges
Nozzle Testing The carriage processor can verify the firing of each printĆcartridge nozzle.
Firing a nozzle causes a voltage drop at the ballast resistor for that nozzle. A comparator
senses the voltage drop at each ballast resistor and outputs a pulse to a processor counter.
This enables the processor to determine whether each print cartridge is inserted properly.
Temperature Sensing A thermistor mounted on the carriage PCA allows the carriage
processor to sense ambient temperature. The processor can adjust the amount of energy
delivered to a print cartridge by changing the nozzle firing time though the nozzle timing
ASIC. The plotters compensate for changes in ambient temperature and self heating of the
print cartridges based on the data provided by the carriage processor.
Line Sensor
The plotters calibrate the writing system to compensate for alignment errors due to
mechanical tolerances using an optical line sensor. The sensor is capable of precisely
measuring, within the field of view of the sensor, the position of one line relative to another.
The sensor measures both horizontal and vertical line positions. The plotters also use this
sensor to determine the location of the media edges in the carriage sweep axis.
Operation The sensor employs a quad photo diode array with illumination from a diffuse
LED. A simple optical system employing two lenses forms an image of the test pattern on the
photo diode array. A transimpedance amplifier converts the current generated in each photo
diode to a voltage. The carriage processor samples the resulting voltage through the A/D
converter.
Accuracy The accuracy of the line sensor after selfĆcalibration when measuring lines spaced
at 1/300 inches is 0.3 mil. When determining the position of the left or right media edge, the
sensor accuracy is 6 mil.
5Ć30 Functional Overview
C3187Ć90000
Front Panel PCA
The plotters use the same frontĆpanel PCA as the DeskJet 550. The frontĆpanel 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.
LEDs
The LEDs are driven by drivers on the main board, under the control of the servo processor.
The LED layout is shown below:
led[4]
led[5]
led[7]
led[1]
led[2]
led[8]
led[9]
led[3]
led[6]
Front-Panel LEDs
Key Pad
The keypad layout is shown below:
led[2]
led[3]
led[6]
led[7]
key[0]
key[1]
Switch[1]
Switch[4]
Switch[2]
Switch[3]
Switch[6]
Switch[7]
Switch[8]
Switch[5]
Front-Panel Key Pad
The switches are connected as a 4x2 matrix. The switch matrix, when scanned, is driven by
the four LED control signals led[2], led[3], led[6] and led[7]. The servo processor scans the
switch matrix by setting, in turn, each of the four control signals to `0' while holding the
other three at `1'. While driving the switch matrix, the processor reads the signals key[0],
and key[1]. A `1' on a key signal indicates a closed switch.
C3187Ć90000
Functional Overview 5Ć31
Power Supply
An autoĆranging 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
Use
+24 V
Motor drivers and voltage regulator on the main PCA.
(Regulated +20 V for cartridge circuits on the carriage PCA).
+12 V
–12 V
+5 V
Fan power and RS-232 driver.
RS-232 driver.
IC power and sensors.
The primary portion of the supply contains fusing and input protection circuitry, line filters,
and a rectifier. The primary output is converted to a pulseĆwidthĆmodulated (PWM),
unidirectional current by a flyback dcĆtoĆdc converter.
The secondary portion of the power supply contains the four secondary windings of the
transformer that convert the PWM current in the primary to four ac voltages, which are
rectified to the +5 V, +12 V, -12 V and +24 V dc voltages required by the plotter. Standard
+12 V and -12 V regulators are included in the secondary portion of the power supply.
The primary side of the power supply contains rectified line voltage
W A R N I N G
that can be lethal when touched even if the ON/OFF switch is OFF.
Remove the power plug before working inside the electronics
enclosure. Also, leave the powerĆsupply insulating door closed when
you need to work on the main PCA only.
5Ć32 Functional Overview
C3187Ć90000
6
Removal and
Replacement
6Ć1
Safety Precautions
(Safety symbols ' 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.
Serious shock hazard leading to death or injury may result if
you do not take the following precautions:
WĂAĂRĂNĂIĂNĂG
Ensure that the ac power outlet (mains) has a protective earth
(ground) terminal.
Disconnect the plotter from the power source prior to
performing any maintenance.
Prevent water or other liquids from running onto electrical
components or circuits, or through openings in the enclosure.
ESD Precautions
To prevent damage to the plotter circuits from highĆvoltage electrostatic discharge (ESD)
1 Do not wear clothing that is subject to static buildĆup.
2 Do not handle integrated circuits (ICs) in carpeted areas.
3 Do not remove an IC or a printed circuit assembly (PCA) from its conductive foam pad or
conductive packaging until you are ready to install it.
4 Ground your body while disassembling and working on the plotter.
5 After removing a cover from the plotter, attach a clip lead between the PCA common and
earth ground. Touch all tools to earth ground to remove static charges before using them
on the plotter.
6 After removing any PCA from the plotter, place it on a conductive foam pad or into its
conductive packaging to prevent ESD damage to any ICs on the PCA.
Reassembly
Most of the procedures in this chapter describe how to disassemble the plotter. Unless
otherwise specified, reassemble the parts in the reverse order of disassembly.
6Ć2 Removal and Replacement
C3187Ć90000
Required Tools
The following are the tools required to disassemble and repair the plotters.
D Long Torx screwdriver with the indicated attachments:
T8
T9
T10
T15
T25
T20
d
D 90 TorxĆ15 key:
D Pozidriv PZ1 screwdriver:
D Small flatĆblade screwdriver:
C3187Ć90000
Removal and Replacement 6Ć3
D Nut driver with indicated attachments:
and
3/16 inch
5.5 mm
D NeedleĆnose pliers
D Cutting pliers
D Spring hook
D Loopbackconnector (HP Part Number 07440Ć60302)
D 10X Magnifier
6Ć4 Removal and Replacement
C3187Ć90000
Repair Procedures
Removing the ElectronicsĆEnclosure Cover
1 Ensure that the plotter is switched off
and that the power cord and interface
cable(s) are not connected to it.
2 At the back of the plotter, ensure that
the two small wire clamps of the parallel
port are positioned vertically.
No interface
cables connected.
Power inlet: cord
not connected
4 Gently lift open the electronicsĆenclosure
d
3 Remove the screws that attach the
electronicsĆenclosure cover to the
electronics enclosure.
cover to an angle of 45 .
D/A1Ćsize plotters have four screws.
E/A0Ćsize plotters have five screws.
or
Flat
Torx-20
C3187Ć90000
Removal and Replacement 6Ć5
5 Push the cover up so that its tabs can
slide out of the slots at the top of the
electronics enclosure.
6 Carefully pull the cover clear of the
plotter.
Tab
6Ć6 Removal and Replacement
C3187Ć90000
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 DRAMĆSIMM slot at the
bottom of the main PCA.
1 Read ESD Precautions ' page 6Ć2.
2 Remove the electronicsĆenclosure
cover ' page 6Ć5.
Slot for
DRAM SIMM
4 While pushingthe two metal springs
apart at the ends of the slot, tilt the outer
edge of the DRAM SIMM downwards.
5 Once the DRAM SIMM is released from
the springs, gently pull it clear of the slot.
C3187Ć90000
Removal and Replacement 6Ć7
To reinstall the SIMM, perform the following procedure:
1 Hold the memory module by its edges
with the nonĆmetallic edge toward you
and the notch to your left.
2 Tilt the nonĆmetallic edge downwards
and firmly push the module into the slot.
Gradually tilt the module upwards and
push it in until it clicks into place.
Notch
6Ć8 Removal and Replacement
C3187Ć90000
Removing the Main PCA
2 Remove the two screws from the serial
(RSĆ232ĆC) connector.
1 Remove the electronicsĆenclosure
cover ' page 6Ć5.
3/16 inch
3 Remove the two screws from the parallel
connector.
4 D/A1Ćsize plotters only: Open the
flexible, DANGER HIGH VOLTAGE,"
insulation cover.
Flex the cover to open it. Do not detach the
cover from the plotter.
Pozidriv PZ1
C3187Ć90000
Removal and Replacement 6Ć9
5 Disconnect all 12 cable connectors from the main PCA.
Do not force the frontĆpanel PCA cable out of its clamp. First pull the
C A U T I O N
clampgently towards you to release the cable; then pull the cable easily
out of the clamp.
Reassembling: Make sure to connect all cables in the correct orientation and to the correct
sockets.
Media-axis encoder
Carriage PCA
Front-panel PCA
Pinch-wheel sensor
MAIN PCA
Window sensor
Media sensor
Stepper motor
Bail sensor
Fan
X = Media motor
Power supply
Y = Carriage motor
6 Remove the five screws that secure the
main PCA to the electronics enclosure.
7 Lift the main PCA clear of the plotter.
Reassembling: Temporarily leave the screws
loose; tighten the serial and parallel connector
screws first; then tighten the PCA screws.
Torx-10
6Ć10 Removal and Replacement
C3187Ć90000
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
on the new PCA.
EPROMs
U28
U9
U29
U4
Empty pair of holes
Masked ROMs
U28
The original PCA contains either four
EPROMs or two masked ROMs. The
U29
U4
U9
Empty
Empty
EPROMs eachhave one pair of pins less
than the masked ROMs; if you are
installing EPROMs, leave the rightmost
pair of holes empty in each socket.
(Part numbers ' chapter 10.)
9 If a SIMM is installed on the original PCA, remove it and install it on the new PCA.
Calibrations: After having installed a new main PCA, perform the following calibrations in
the given order (Details ' chapter 7):
1. Bail calibration
2. MediaĆsensor calibration
3. Cartridge alignment
4. Accuracy calibration
5. SetupĆsheet calibration
C3187Ć90000
Removal and Replacement 6Ć11
Removing the PowerĆSupply PCA
1 Remove the electronicsĆenclosure
cover ' page6Ć5.
2 Open the flexible, DANGER HIGH
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 powerĆdistribution connector from the powerĆsupply
PCA.
dc power-distribution
connector
ac connector
6Ć12 Removal and Replacement
C3187Ć90000
3 Remove the six screws that secure the
powerĆsupply PCA to the electronics
enclosure.
4 Lift the powerĆsupply PCA clear of the
plotter.
Torx-10
C3187Ć90000
Removal and Replacement 6Ć13
Removing the Fan
1 Remove the electronicsĆenclosure
cover ' page6Ć5.
3 Disconnect the fan connector from the
main PCA and holding clip.
2 Open the flexible, DANGER HIGH
VOLTAGE," insulation cover.
Flex the cover to open it. Do not detach the
cover from the plotter.
Fan connector
4 Remove the two screws that secure the
fan to the electronics enclosure.
5 Lift thefan clear of theplotter.
Torx-20
Reassembling: Airflow should be inwards.
See indication on fan.
6Ć14 Removal and Replacement
C3187Ć90000
Removing the Window
1 Open the window.
2
Loosen the topscrew of the right front
trim (two full turns).
Torx-15
3 Carefully push the right endcover and
the window apart, far enough to lift the
window upso that the right pivot just
clears its socket.
4 Move the window to the right so that the
left pivot slides out of its socket, and lift
the window clear of the plotter.
Do not let the windowĆpivot springs drop
out of the endcovers.
Do not lever the window up more than is
necessary, so as not to strain or break the
left pivot.
C3187Ć90000
Removal and Replacement 6Ć15
Removing the Center Cover
1 Remove the window ' page 6Ć15.
In the following steps, take care not to cut
yourself on the encoder strip inside the
plotter.
WĂAĂRĂNĂIĂNĂG
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.
6Ć16 Removal and Replacement
C3187Ć90000
4 Remove the screws from the back of the center cover.
D/A1Ćsize plotters have two screws. E/A0Ćsize plotters have four screws.
Torx-15
5 Slide the center cover vertically upwards, and lift it clear of the plotter.
C3187Ć90000
Removal and Replacement 6Ć17
Removing the Left Endcover
1 Remove the window ' page 6Ć15, and the center cover ' page 6Ć16.
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
screw finds the thread path and clicks, and then twisting the screw in
clockwise with your hand, before using a screwdriver. This is to avoid
crossĆthreading. Do not overĆtighten the screws.
6 Remove the three screws from the left
side of the left endcover.
4 Maintaining an even pressure on the top
and bottom of the endcover, pull it to the
left, away from the plotter.
Do not let the windowĆpivot spring drop out
of the endcover.
Torx-15
3 If the plotter is mounted on legs, loosen
the twoleftĆhand screws that attach the
plotter to the legs.
6Ć18 Removal and Replacement
C3187Ć90000
Removing the Right Endcover
1 Remove the window ' page 6Ć15, and the center cover ' page 6Ć16.
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
screw finds the thread path and clicks, and then twisting the screw in
clockwise with your hand, before using a screwdriver. This is to avoid
crossĆthreading. Do not overĆtighten the screws.
5 Remove the three screws from the right
side of the right endcover.
4 Maintaining an even pressure on the top
and bottom of the endcover, pull it to the
right, away from the plotter.
Torx-15
C A U T I O N
Do not stress or apply pressure to the
frontĆpanel assembly.
Do not let the windowĆpivot spring drop out
of the endcover.
Reassembling: Note the upper and lower
grooves the endcover engages on the front
panel.
3 If the plotter is attached to a plotter
stand, loosen the tworightĆhand screws
that attach the plotter to the stand.
C3187Ć90000
Removal and Replacement 6Ć19
Removing the Automatic CartridgeĆAdjust Linkage
4 Detach the linkage spring from the
YĆtensionerbracket.
1 Remove the window ' page 6Ć15.
2 Remove the centercover ' page 6Ć16.
3 Remove the left endcover ' page 6Ć18.
Reassembling: Attach the spring through
the two small holes, as in the diagram.
5 Remove the two shoulderscrews that
attach the automatic cartridgeĆadjust
linkage to the left sideplate and lift the
linkage clearof the plotter.
C A U T I O N
Reassembling: Do not crossĆthread or
overĆtighten the screws.
Torx-15
Reassembling: Rest the bottom arm of the
linkage on top of the stepperĆmotor shaft.
Bottom arm
of linkage
Stepper-motor
shaft
6Ć20 Removal and Replacement
C3187Ć90000
Removing the Stepper Motor
1 Remove the electronicsĆenclosure
cover ' page6Ć5.
5 Open the flexible, DANGER HIGH
VOLTAGE," insulation cover.
2 Removethewindow
'
page6Ć15.
Carefully flex the cover to open it. Do not
detach the cover from the plotter.
3 Remove the center cover ' page6Ć16.
4 Remove the left endcover ' page6Ć18.
7 Remove the bottom shoulder screw on
the cartridgeĆadjust linkage, and lower
the lever arm below the stepper motor.
6 Disconnect the stepperĆmotor cable
connector from the main PCA and the
holding clip.
Torx-15
Stepper-motor
connector
Reassembling: Rest the bottom arm of the
linkage on top of the stepperĆmotor shaft.
C3187Ć90000
Removal and Replacement 6Ć21
8 Loosen the right screw and remove the
left screw that attaches the stepper
motorto the left sideplate.
9 Move the steppermotortoward the rear
of the plotter.
Torx-10
Loosen
Remove
C A U T I O N
10 Pull the stepperĆmotor cable gently out
from the electronics enclosure, through
the hole in the left side of the electronics
enclosure, and lift it and the stepper
motorclearof the plotter.
Reassembling: Do not crossĆthread or
overĆtighten the screws.
6Ć22 Removal and Replacement
C3187Ć90000
Removing the PinchĆArm Sensor
1 Remove the electronicsĆenclosure
cover ' page 6Ć5.
5 Disconnect the pinchĆarmĆsensor cable
connector from the main PCA and from
the ferrite on the right sideplate.
2 Remove the window ' page 6Ć15.
The ferrite holder opens from the top.
3 Remove the center cover ' page 6Ć16.
4 Remove the right endcover ' page 6Ć19.
Pinch-arm-
sensor connector
Reassembling: The cable goes through the
ferrite indicated in the diagram below.
6 Remove the two screws that attach the pinchĆarm sensor to the right sideplate.
Torx-10
KEEP THIS AREA
FREE OF CABLES
Ferrite
Pinch-arm
sensor
7 Lift the pinchĆarm sensor, with cable, clear of the plotter.
C3187Ć90000
Removal and Replacement 6Ć23
Removing the Window Sensor
1 Remove the electronicsĆenclosure
cover ' page 6Ć5.
5 Disconnect the windowĆsensor cable
connector from the main PCA.
2 Remove the window ' page 6Ć15.
3 Remove the center cover ' page 6Ć16.
4 Remove the right endcover ' page 6Ć19.
Window-sensor
connector
6 Carefully feed the windowĆsensor cable out from the electronics enclosure and from under
the motor assemblies, unclipping it from the holding clips and ferrite.
The ferrite holder opens from the top.
Clip
Reassembling: Position the cable correctly
as indicated. Incorrect positioning could
cause obstruction of the cartridge carriage or
Ferrite
Clip
motor gears.
6Ć24 Removal and Replacement
C3187Ć90000
7 Slide the cable and connector up through
the fastener near the right front trim.
8 Remove the screw that attaches the
window sensor to the right front trim.
Torx-8
Sensor
Fastener
C A U T I O N
Reassembling: Do not crossĆthread
or overĆtighten the screw.
Torque = 3 l b in. ( 0.35 Nm)
≅
9 Lift the sensor, with cable, clear of the plotter.
C3187Ć90000
Removal and Replacement 6Ć25
Removing the Media Sensor
1 Remove the electronicsĆenclosure
cover ' page 6Ć5.
5 Disconnect the mediaĆsensor cable
connector from the main PCA, and from
the holding clip and ferrite on the right
sideplate.
2 Remove the window ' page 6Ć15.
The ferrite holder opens from the top.
3 Remove the center cover ' page 6Ć16.
4 Remove the right endcover ' page 6Ć19.
Media-sensor
connector
Reassembling: The cable goes through the
same ferrite as for the window sensor ' page 6Ć24.
10 If the plotter is mounted on legs, remove
the four screws that attach it to the legs.
6 Place the plotter on a flat surface and
turn it on its back.
It requires two people to lift the plotter.
WĂAĂRĂNĂIĂNĂG
Take care that the plotter does not
fall and injure you.
Torx 15
6Ć26 Removal and Replacement
C3187Ć90000
7 Remove the screws that attach the
bottom coverto the plotter, and lift the
coverclearof the plotter.
8 Pull the media sensorstraight out
towards you, freeing it from the
underside of the entry platen.
D/A1Ćsize plotters have 8 screws.
E/A0Ćsize plotters have 10 screws.
Torx-20
9 Cut the plastic tie that fastens the
mediaĆsensorcable to the underside of
the entry platen.
10 Lift the media sensorand cable clearof
the plotter
Reassembling: Ensure that the two
flags on the media sensor are correctly
positioned (see following procedure).
C A U T I O N
Take care not to cut the mediaĆsensor cable
itself.
Plastic tie
Calibration: After having reassembled the
plotter, perform the mediaĆsensor calibration
(Details ' chapter 7).
C3187Ć90000
Removal and Replacement 6Ć27
Replacing the MediaĆSensor Flags
1 Insert the tĆshaped flag in the indicated
position.
2 Let the tĆshaped flag rotate to its correct
position.
3 Insert the bellĆshaped flag in the
indicated position.
4 Let the bellĆshaped flag rotate to its
correct position.
6Ć28 Removal and Replacement
C3187Ć90000
Removing the Trailing Cable
If you are installing a new trailing cable,
make sure the main PCA is compatible
with it. (Details ' chapter 9.)
5 Disconnect the trailingĆcable connector
from the main PCA.
1 Remove the electronicsĆenclosure
cover ' page 6Ć5.
2 Remove the window ' page 6Ć15.
3 Remove the center cover ' page 6Ć16.
Trailing-cable
connector
4 D/A1Ćsize plotters only: Open the
flexible, DANGER HIGH VOLTAGE,
insulation cover.
Flex the cover to open it. Do not detach
the cover from the plotter.
6 Remove the two screws that attach the
toroidto the rear of the electronics
enclosure.
7 Pull off the two endcaps of the toroid and
remove the toroidfrom the trailing cable.
Torx-10
C3187Ć90000
Removal and Replacement 6Ć29
8 Disconnect the trailingĆcable connector from the cartridgeĆcarriage PCA.
Cartridge-carriage PCA
Trailing-cable connector
b Free the cable from the rear tray and
bracket, pulling it up through the slot at
the top of the electronics enclosure
assembly.
9 If you need to change the trailing cable:
a Cut the two plastic ties that hold the
cable to the rear tray and bracket.
Plastic ties
Rear tray
Bracket
c Use the old trailing cable as a template
to bend and crease the new trailing cable
to exactly match the creases inthe old
trailing cable.
Reassembling: Replace the ties with
new ones.
6Ć30 Removal and Replacement
C3187Ć90000
b Carefully remove the rightĆhand
cartridge spring from the cartridge
carriage.
10 If you don't need to change the trailing
cable, but do need to remove it to access
otherparts:
a Remove the two screws that attach the
trailingĆcable rear tray to the top of the
electronics enclosure.
Torx-20
Rear tray
d Pull the trailing cable up through the
slot at the top of the electronics
c Remove the trailingĆcableĆbracket
screw from the cartridge carriage.
enclosure assembly and lift it, with rear
tray and bracket, from the plotter.
Torx-10
Rear tray
Bracket
C3187Ć90000
Removal and Replacement 6Ć31
Removing the FrontĆPanel Assembly
1 Remove the electronicsĆenclosure
cover ' page 6Ć5.
6 Unclip the windowĆsensor cable and
frontĆpanel cable from their holding clip
on the underside of the frontĆpanel
assembly.
2 Remove the window ' page 6Ć15.
Window-sensor
cable
3 Remove the center cover ' page 6Ć16.
Front-panel
cable
4 Remove the right endcover ' page 6Ć19.
5 Take note of the correct positioning of
the frontĆpanel cable for reassembling.
Incorrect positioning could cause
obstruction of the cartridge carriage or
motor gears.
Clip
7 Release the frontĆpanel cable from its clamp on the main PCA, and from its holding clip on
the right side of the plotter.
Do not force the cable out of its clamp. First pull the clamp gently towards
C A U T I O N
you to release the cable; then pull the cable easily out of the clamp.
Do not release the frontĆpanel cable from its clamp on the frontĆpanel PCA.
Front-panel
connector clamp
6Ć32 Removal and Replacement
C3187Ć90000
8 Carefully feed the frontĆpanel 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 frontĆpanel assembly to the right
sideĆplate, and lift the frontĆpanel assembly, with cable, clear of the plotter.
Torx-20
C3187Ć90000
Removal and Replacement 6Ć33
Removing the FrontĆPanel PCA and LED Assembly
1 Remove the electronicsĆenclosure cover ' page 6Ć5.
2 Remove the window ' page 6Ć15.
3 Remove the center cover ' page 6Ć16.
4 Remove the right endcover ' page 6Ć19.
5 Remove the frontĆpanel assembly ' page 6Ć32.
6 On the underside of the frontĆpanel assembly, press the four transparent plastic tabs inwards
and remove the PCA and LED assembly.
The frontĆpanel PCA and LED assembly (keyboard assembly) is one orderable part,
which includes the frontĆpanel keys and the cable.
6Ć34 Removal and Replacement
C3187Ć90000
Removing the Carriage (YĆAxis) Motor
5 Disconnect the carriageĆmotor cable from
1 Remove the electronicsĆenclosure
cover ' page 6Ć5.
the main PCA (connector labelled Y), and
from the lowest ferrite holder on the
rightĆhand side of the plotter.
2 Remove the window ' page 6Ć15.
3 Remove the center cover ' page 6Ć16.
4 Remove the right endcover ' page 6Ć19.
Carriage-motor
connector
6 Pressing the small drive belt against the
tensioner wheel in the belt tensioner to
loosen the belt, slide the belt off of the
motor gear; then carefully release your
hand from the the tensioner wheel.
7 Loosen the two carriageĆmotor screws
about 1/2 cm (about 1/4 inch).
Torx-15
Double pulley
Loosen
1
Tensioner wheel
Motor gear
2
Small drive belt
Reassembling: Ensure that the belt is
correctly positioned around the
carriageĆmotor gear and the lower part of
the double pulley.
C3187Ć90000
Removal and Replacement 6Ć35
8 Rotate the motor in the indicated
direction.
9 Pull the motor down, clear of its bracket.
Rotate
Pull
6Ć36 Removal and Replacement
C3187Ć90000
Removing the Media (XĆAxis) Motor
7 Disconnect the mediaĆmotor cable from
the main PCA (connector labeled X) and
from the uppermost ferrite holder on the
rightĆhand side of the plotter.
1 Remove the electronicsĆenclosure
cover ' page 6Ć5.
2 Remove the window ' page 6Ć15.
3 Remove the center cover ' page 6Ć16.
4 Remove the right endcover ' page 6Ć19.
5 Remove the frontĆpanel
assembly ' page 6Ć32.
6 Remove the carriage motor ' page 6Ć35.
Paper-motor
connector
9 Remove the driveĆroller gear from the
driveĆroller shaft.
WĂAĂRĂNĂIĂNĂG
The gear may be stiff to remove.
In the following steps, take care not to
cut yourself on the encoder strip.
8 Remove the two screws that secure the
driveĆroller gear to the driveĆroller
shaft.
Torx-10
Reassembling: Push the gear onto the
shaft as far as it will go. Align the holes
on the gear with the holes on the shaft.
C3187Ć90000
Removal and Replacement 6Ć37
10 Remove the two screws that secure the
media motor to the mediaĆmotor mount.
11 Pull the media motor towards the rear of
the plotter.
12 Disconnect the flat encoder cable from
the motor, and lift the motor clear of the
plotter.
Reassembling: The worm pinion and
driveĆroller gear mesh slightlyduring use.
Don't install a new motor and an old gear,
or vice versa: install the gear that comes
with the motor. Applythe grease that
comes with the new motor to the worm
pinion and driveĆroller gear.
Torx-15
Calibration: After having reassembled the
plotter, perform the accuracycalibration
(Details ' chapter 7.)
6Ć38 Removal and Replacement
C3187Ć90000
Removing the Encoder Strip
1 Remove the window ' page 6Ć15.
WĂAĂRĂNĂIĂNĂG
2 Remove the center cover ' page 6Ć16.
3 Remove the right endcover ' page 6Ć19
The encoder strip has very sharp
edges; exercise care when handling
to avoid personal injury.
4 Remove the left endcover ' page 6Ć18.
C A U T I O N
The encoder strip is fragile. Do not
damage it. Lay it on a flat surface when
it isnot in the plotter.
6 Remove the nut and washer that secure
the encoder strip to the service station on
the left side of the plotter.
5 Remove the nut and washer that secure
the encoder strip to the encoder
springĆbracket on the right side of the
plotter.
5.5 mm
5.5 mm
C3187Ć90000
Removal and Replacement 6Ć39
7 Compressing the encoder springĆbracket to release tension on the encoder strip, carefully
release the encoder strip from the service station.
Encoder strip
Spring
bracket
1
2
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.
Reinstalling: See following procedure.
6Ć40 Removal and Replacement
C3187Ć90000
Reinstalling the Encoder Strip
1 Ensure that the encoder stripis oriented
with the transparent area up, and with
three holes on the left side and one hole
on the right side.
2 Thread the stripthrough the apertures
in the cartridgeĆcarriage assembly.
3 With washer and nut, secure the encoder
stripto the service station.
4 Press the forward end of the encoder
springĆbracket slightly inward and place
the encoder stripbetween the tabs and
over the threaded post on the encoder
springĆbracket.
Spring bracket
5.5 mm
Threaded post
Compress
Tabs
C3187Ć90000
Removal and Replacement 6Ć41
5 With washer and nut, secure the encoder strip to the encoder springĆbracket.
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.
6Ć42 Removal and Replacement
C3187Ć90000
Removing the TrailingĆCable Guide
6 Remove the screw that attaches the
trailingĆcable guide to the tensioner
housing.
C A U T I O N
Handle the trailing cable and the
trailingĆcable guide with care.
Torx-15
1 Remove the window ' page 6Ć15.
Trailing-cable guide
2 Remove the center cover ' page 6Ć16.
3 Remove the left endcover ' page 6Ć18.
4 Remove the right endcover ' page 6Ć19.
5 If the maintenance you need to perform
requires you to remove the trailing cable
as well as the trailingĆcable guide, then
remove the trailing cable now ' page 6Ć29.
Tensioner
housing
8 Using a screwdriver, compress and
C A U T I O N
release the spring frombetween the
inside surface of the ferrite ring and the
trailingĆcable guide.
Exercise care to avoid damaging the ferrite
ring when carrying out the following
instructions.
7 Cut the plastic tie, on the spring in the
ferrite ring, located where the trailingĆ
cable guide attaches to the YĆdrive
bracket.
Trailing-cable
guide
Spring
and tie
Ferrite ring
Reassembling: Attach a new plastic tie.
C3187Ć90000
Removal and Replacement 6Ć43
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 trailingĆcable guide towards the rear of the plotter, rotate it to clear the arm of the
cartridgeĆadjustment cam on the cartridge carriage, and lift the trailingĆcable guide clear of
the plotter.
C A U T I O N
Be careful not to scrape the cartridgeĆcarriage
PCA with the trailingĆcable guide if you are
sliding the guide under the trailing cable.
6Ć44 Removal and Replacement
C3187Ć90000
Removing the YĆTensioner and Housing
1 Remove the window ' page 6Ć15.
5 Remove the screw that attaches the
trailingĆcable guide to the tensioner
housing.
2 Remove the center cover ' page 6Ć16.
3 Remove the left endcover ' page 6Ć18.
Torx-15
4 Slide the cartridge carriage towards the
center of the plotter in order to access the
tensioner.
Trailing-cable guide
Tensioner
housing
6 Remove the tensionerĆplate screw.
Torx-15
The tensioner plate is under spring tension. Ensure that the plate does
not spring back suddenly. Hold the right end (viewed from the rear) of
the tensioner plate to keep the tensioner spring compressed.
C A U T I O N
C3187Ć90000
Removal and Replacement 6Ć45
8 Carefully move the right end of the
tensioner plate up and clear of the
retaining tab.
7 Carefully move the tensioner plate to the
right until it clears the slot in the
housing.
Tab
Slot
Tensioner plate
Tensioner plate
9 Decompress the tensioner spring by
allowing the tensioner plate to move
toward the rear of the plotter.
10 Remove the YĆtensioner spring and
YĆtensioner from the housing.
Tensioner plate
Tensioner
spring
6Ć46 Removal and Replacement
C3187Ć90000
11 Loosen the YĆtensioner housing screw.
12 Slide the YĆtensioner housing out from
the YĆtensioner bracket.
Torx-15
Y-tensioner
bracket
Y-tensioner
housing
Loosen
13 Release the main idler from the
cartridgeĆcarriage belt.
14 Lift the YĆtensioner housing clear of the
plotter.
C3187Ć90000
Removal and Replacement 6Ć47
Removing the Cartridge Carriage and Main Drive Belt
8 Remove the two screws that secure the
encoderĆstrip bracket to the serviceĆ
station housing.
C A U T I O N
Torx-15
If you are installing a new cartridge carriage or
a new carriage PCA, ensure that the plotter
firmware is compatible with it.
Incompatibilities could destroy the cartridges.
(Details ' chapter 9.)
Encoder-strip
bracket
1 Remove the window ' page 6Ć15.
2 Remove the center cover ' page 6Ć16.
3 Remove the left endcover ' page 6Ć18.
4 Remove the right endcover ' page 6Ć19.
5 Remove the encoder strip ' page 6Ć39.
6 Remove the trailingĆcable guide ' page 6Ć43.
7 Remove the YĆtensioner and
housing ' page 6Ć45.
Service-station
housing
9 Lift the encoderĆstrip bracket clear of the
plotter.
10 Remove the three screws that secure the
serviceĆstation cover to the
serviceĆstation housing.
Torx-15
Cover
Reassembling: Do not overĆtighten the
three screws. Manually move the
serviceĆstation sled to ensure that it
moves freely beneath the cover.
6Ć48 Removal and Replacement
C3187Ć90000
11 Holding the serviceĆstation 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 serviceĆstation cover up and lift the cover
clear of the serviceĆstation housing.
Sled
1
2
Cover
12 Lift the serviceĆstation sled up slightly and release the sled spring from the serviceĆstation
housing.
C3187Ć90000
Removal and Replacement 6Ć49
13 Lift the serviceĆstation sled clear of the serviceĆstation housing and the plotter.
15 Remove the screw and washer that
attach the encoderĆstripspring to the
spring bracket.
14 Move to the right side of the plotter.
Pressing the small drive belt against the
tensioner wheel to loosen the belt, slide
the belt off of the motor gear; then
carefully release your hand from the the
tensioner wheel.
Torx-15
Double pulley
Encoder-strip spring
1
Tensioner wheel
Motor gear
2
Small drive belt
Reassembling: Ensure that the belt is
correctly positioned around the carriageĆ
motor shaft and the lower part of the
double pulley.
6Ć50 Removal and Replacement
C3187Ć90000
16 Remove the encoderĆstripspring.
17 Remove the double pulley from the
YĆdrive bracket. While doing this keep
the palm of one hand beneath the double
pulley to catch the doubleĆpulley
bushing.
Washer
Bracket
Double pulley
Bushing
Reassembling: Don't forget the bushing.
Also, ensure that the belt is correctly
positioned around the carriageĆmotor
gear and the lower part of the double
pulley.
18 Disconnect the trailingĆcable connector from the cartridgeĆcarriage PCA.
Cartridge-carriage PCA
Trailing-cable connector
C3187Ć90000
Removal and Replacement 6Ć51
19 Remove the right spring from the
cartridgeĆcarriage assembly.
20 Remove the screw that attaches the
trailingĆcable bracket to the carriage
assembly.
Torx-10
22 Slide the cartridge carriage to the left
side of the plotter.
21 Lift the trailingĆcable and bracket clear
of the carriage assembly.
Bracket
Cartridge carriage
Trailing cable
6Ć52 Removal and Replacement
C3187Ć90000
In the following step, take care when moving the cartridgeĆcarriage over
the plastic projection at the top left end of the serviceĆstation housing.
Too much force may damage the housing or the carriage.
C A U T I O N
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.
Slider rods
Cartridge carriage
Rear preload bushing
24 Separate the rear bushing and preload spring fromthe carriage assembly, and carefully
remove the carriage assembly and main drive belt from the plotter.
Main drive belt
Cartridge carriage
Preload spring
Rear bushing
C3187Ć90000
Removal and Replacement 6Ć53
25 Set the carriage assembly upsideĆdown 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!
27 Remove the main drive belt from the carriage assembly.
Main drive belt
Calibration: After having reassembled the plotter, perform the cartridgeĆalignment
routine ' chapter 7.
6Ć54 Removal and Replacement
C3187Ć90000
Removing the Bail Sensor
1 Remove the electronicsĆenclosure
cover ' page 6Ć5.
5 Note the position of the bailĆsensor cable
for reassembly. Incorrect positioning
could cause obstruction of the cartridge
carriage and motor gears.
2 Remove the window ' page 6Ć15.
3 Remove the center cover ' page 6Ć16.
4 Remove the right endcover ' page 6Ć19.
Bail sensor
6 Disconnect the bailĆsensor cable
connector from the main PCA, and from
its ferrite and holding clip on the right
sideplate.
8 Unclip the bail sensor from its holder,
and lift it, with cable, clear of the plotter.
Bail-sensor
holder
The ferrite holder opens from the top.
Bail sensor
Bail-sensor
connector
Reassembling: The cable goes through
the same ferrite as for the windowĆsensor
cable ' page 6Ć24.
Calibration: After having
reassembled the plotter, perform
the bail calibration ' chapter 7.
7 Carefully feed the bailĆsensor cable out
from the electronics enclosure and from
under the motor assemblies.
C3187Ć90000
Removal and Replacement 6Ć55
Removing The Bail
1 Open the window.
2 Move the cartridgeĆcarriage to the
extreme left.
Cartridge carriage
In the following step, take care not to cut yourself
on the encoder strip.
WĂAĂRĂNĂIĂNĂG
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.
Reassembling: If there are Teflon washers on
the inside of the left sideplate, take care not to
damage them.
1
Push
2
1
Push
6Ć56 Removal and Replacement
C3187Ć90000
Removing the Service Station
5 Remove the nut and washer that attach
the encoder strip to the encoderĆstrip
bracket.
In performing this procedure, be careful to
avoid staining your hands and clothing
with ink deposited in the service station.
1 Remove the window ' page 6Ć15.
2 Remove the center cover ' page 6Ć16.
5.5 mm
3 Remove the left endcover ' page 6Ć18.
4 Move the cartridge carriage to the center
of itstravel.
Cartridge carriage
6 Loosen the two screws that attach the
encoderĆstrip bracket to the
7 Remove the encoderĆstrip bracket from
the service station.
serviceĆstation assembly, until tension
can be relieved on the encoder strip, and
it can be detached from the bracket.
Encoder strip
2
Bracket
1
1
C3187Ć90000
Removal and Replacement 6Ć57
9 Holding the serviceĆstation 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 serviceĆstation cover
up and lift the cover clear of the
8 Remove the three screws that secure the
serviceĆstation cover to the
serviceĆstation housing.
serviceĆstation housing.
Torx-15
Cover
Sled
1
Reassembling: Do not overĆtighten the
three screws. Manually move the
serviceĆstation sled to ensure that it
moves freely beneath the cover.
2
Cover
10 Lift the serviceĆstation sled slightly up and release the sled spring from the serviceĆstation
housing.
6Ć58 Removal and Replacement
C3187Ć90000
11 Lift the serviceĆstation sled clear of the
serviceĆstation housing and the plotter.
12 Remove any wetink from the wiper in
the serviceĆstation 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
secure the wiper rod and rocker to the
leftsideplate, and liftthe rod and rocker
clear of the plotter.
15 Remove the three screws that attach the
serviceĆstation housing to the left
sideplate.
Torx-20
Torx-15
wiper rod
wiper rocker
16 Lift the serviceĆstation housing slightly
up and pull itclear of the leftsideplate.
C3187Ć90000
Removal and Replacement 6Ć59
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 needleĆnose pliers,
without having to remove the service
station. (The service station is not shown
in the diagram.)
1 Remove the window ' page 6Ć15.
2 Remove the center cover ' page 6Ć16.
3 Remove the left endcover ' page 6Ć18.
4 Liftthe leftfronttrim clear of the
plotter.
5 Remove the bail ' page 6Ć56.
Clutch retaining ring
Note the position and orientation of the overdrive clutch. When correctly installed, the
overdrive roller can be manually rotated forward only.
7 While flexing the media separator upwards, slide the overdrive roller horizontally to the
right until the overdrive clutch and sideplate bushing can drop free of the roller.
Media separator
1
2
3
Sideplate bushing
Overdrive roller
Overdrive clutch
6Ć60 Removal and Replacement
C3187Ć90000
8 Move the overdrive roller to the right until it hascompletely 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.
C3187Ć90000
Removal and Replacement 6Ć61
Removing the Overdrive Enclosure
6 Remove the three indicated screws from
the left sideplate.
1 Remove the window ' page 6Ć15.
2 Remove the center cover ' page 6Ć16.
3 Remove the left endcover ' page 6Ć18.
4 Remove the right endcover ' page 6Ć19.
5 Remove the overdrive roller ' page 6Ć60.
1
2
3
Torx-15
Torx-20
LEFTĆHAND SIDE
7 Remove the two indicated screws from
the right sideplate.
8 Lift the overdrive enclosure clear of the
plotter.
Torx-15
Torx-20
Overdrive enclosure
1
2
RIGHTĆHAND SIDE
Reassembling: See following procedure.
6Ć62 Removal and Replacement
C3187Ć90000
ReĆinstalling 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 mediaĆsensor flags. The overdrive enclosure
should not touch them.
C A U T I O N
2 Replace the two indicated screws. (Short dogĆpoint screws.)
Torx-15
1
2
LEFTĆHAND SIDE
RIGHTĆHAND SIDE
C3187Ć90000
Removal and Replacement 6Ć63
3 Insert the two indicated screws, but DO NOT tighten them. (Long dogĆpoint screws.)
Torx-15
LEAVE LOOSE
3
4
LEFTĆHAND SIDE
RIGHTĆHAND SIDE
4 Replace the indicated screw and tighten it,
thus aligning the overdrive enclosure with
the left sideplate.
5 Tightenthe two screws you inserted in
step 3.
Torx-20
Torx-15
5
LEFTĆHAND SIDE
6Ć64 Removal and Replacement
C3187Ć90000
Removing the Entry Platen
1 Remove the window ' page 6Ć15.
8 Remove the three indicated screws from
the left sideplate.
2 Remove the center cover ' page 6Ć16.
3 Remove the left endcover ' page 6Ć18.
4 Remove the right endcover ' page 6Ć19.
5 Remove the overdrive roller ' page 6Ć60.
6 Unscrew the pinchĆarm lever and right
front trim and lift them clear of the
entry platen, taking care not to damage
the window sensor.
1
2
Torx-20
7 Remove the overdrive enclosure
' page 6Ć62.
Torx-15
3
Torx-20
9 Remove the two indicated screws from
the right sideplate.
10 Underneath the plotter, remove the screws
from the front of the bottom cover.
Torx-15
Torx-20
D/A0Ćsize plotters have four screws.
E/A1Ćsize plotters have five screws.
11 Unscrew the power switch from the left
sideplate.
1
2
Torx-20
C3187Ć90000
Removal and Replacement 6Ć65
13 Detach the mediaĆsensor holder from
the underside of the entry platen by
pulling the holder straight out.
12 Pull the entry platen out from the plotter
in order to access the media sensor.
15 Lift the entry platen clear of the plotter.
14 Cut the plastic tie that fastens the
mediaĆsensor cable to the underside of
the entry platen.
C A U T I O N
Take care not to cut the mediaĆsensor cable
itself.
Plastic tie
Reassembling: See following procedure.
6Ć66 Removal and Replacement
C3187Ć90000
ReĆinstalling 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 6Ć26).
4 Position the entry platen between the two sideplates.
Position the top of the entry platen under all of the small pivots on the inside
of both sideplates, except the back pivot. Rest the entry platen against the back pivot.
Position the bottom of the entry platen above the bottom cover of the plotter.
5 Replace the indicated screw on the
leftĆhand side. (Long dogĆpoint screw.)
Tighten this screw, making sure that the
entry platen is aligned tight against the
left sideplate.
6 Replace the indicated screw on the
rightĆhand side. (Long dogĆpoint screw.)
There must be no space between the entry
platen and the left sideplate. It doesn't
matter if there is a small space between
the entry platen and the right sideplate.
Torx-15
Torx-15
1
2
LEFTĆHAND SIDE
RIGHTĆHAND SIDE
C3187Ć90000
Removal and Replacement 6Ć67
8 Replace the two indicated screws. (Long dogĆpoint screws.)
Torx-15
3
4
RIGHTĆHAND SIDE
LEFTĆHAND SIDE
7 Replace the indicated screw.
9 Replace the screws on the bottom cover.
Torx-20
D/A1Ćsize plotters have four screws.
E/A0Ćsize plotters have five screws.
10 Turn the plotter to its correct position.
5
Before reĆinstalling the overdrive
enclosure, ensure that both flags on the
media sensor move freely when you pass
a sheet of media over them.
Torx-20
Calibration: After having reassembled
the plotter, perform the mediaĆsensor
calibration.
LEFTĆHAND SIDE
6Ć68 Removal and Replacement
C3187Ć90000
Removing the Drive Roller
1 Remove the electronicsĆenclosure
cover ' page 6Ć5.
In the following step, take care
not to damage the bail sensor.
C A U T I O N
2 Remove the window ' page 6Ć15.
3 Remove the center cover ' page 6Ć16.
4 Remove the left endcover ' page 6Ć18.
14 Remove the three screws that attach the
mediaĆmotor mount to the right sideplate.
Reinstalling: Press down on the media
mount as you replace the three screws.
This is to ensure correct spacing between
the drive roller and the cartridge nozzles.
(Details ' chapter 9.)
5 Lift the left front trim clear of the
plotter.
6 Remove the right endcover ' page 6Ć19.
Press down here as
you tighten screws
7 Remove the frontĆpanel
assembly ' page 6Ć32.
8 Remove the carriage motor ' page 6Ć35.
9 Remove the media motor ' page 6Ć37.
10 Remove the encoder strip ' page 6Ć39.
11 Remove the bail ' page 6Ć56.
Torx-20
12 Remove the service station ' page 6Ć57.
MediaĆmotor mount
13 Remove the overdrive
roller ' page 6Ć60.
15 Unclip the cables from the holding clip
underneath the mediaĆmotor mount.
18 Pull the pinchĆarm lever forward to raise
the pinchĆarm assembly.
16 Lift the mount clear of the plotter.
17 Remove the screw that attaches the
media director to the chassis assembly
and remove the media director.
Torx-15
Media director
Pinch-arm lever
C3187Ć90000
Removal and Replacement 6Ć69
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
roller. (Details ' chapter 7.)
6Ć70 Removal and Replacement
C3187Ć90000
Removing the Automatic BailĆLift Mechanism
The camĆgear support is a new part, introduced with the DesignJet 220 to help solve failures
in the bailĆlift mechanism. It replaces the TeflonĆwasher solution of the DesignJet 200.
A service note describes how to remove the Teflon washers and install the camĆgear support
and associated parts on a DesignJet 200. (Details ' chapter 9.)
YĆtensioner bracket
CamĆgear support
Engaging lever
EngagingĆlever spring
Left sideplate
Auto cam
Screw
(Remove from inside)
To remove the bailĆlift mechanism, perform the following procedure:
1 Remove the drive roller ' page 6Ć69.
2 Remove the engagingĆlever spring.
Reinstalling: Connect the spring to the upper rung on the leg of the YĆtensioner
bracket. Connecting to one of the lower rungs overtightens the spring and can cause
failure of the bailĆlift mechanism.
3 Remove the two screws from the camĆgear support. (Torx 15)
Reinstalling:
a. Remove the screw from the front leg of the YĆtensioner bracket. (Torx 20)
b. Reinstall the two screws on the camĆgear support. (Torx 15)
c. Reinstall the screw on the YĆtensioner bracket. (Torx 20)
4 Slide the support to the left.
5 Remove the engagingĆlever screw from inside the left sideplate. (Torx 15)
6 On the inside of the left sideplate, pull the cam to the right and off the lever assembly.
7 Remove the engagingĆlever assembly from the plotter.
Calibration: Performthe bail calibration after reassembling the plotter. (Details ' chapter 7.)
C3187Ć90000
Removal and Replacement 6Ć71
Removing the PinchĆArm Lift Mechanism
PinchĆarm assembly
1 Remove the drive roller ' page 6Ć69.
2 Push the pinchĆarm lever (located on the right side of the entry platen) into the vertical
position.
3 Remove the screws on the entry platen, ' page 6Ć65, and pull it slightly forward.
4 On the right side of the plotter, disconnect the rockerĆplate tension spring to relieve any
remaining tension on the pinchĆarm lift mechanism.
Rocker plate
RockerĆplate tension spring
6Ć72 Removal and Replacement
C3187Ć90000
5 On the right side, loosen the camĆjournal screw 12 turns counterĆclockwise and push the
screw in towards the center of the plotter.
CamĆjournal 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 clearof the barcam.
If unsuccessful, turn the camĆjournal screw two more turns
counterĆclockwise, push the screw in towards the center of the
plotter, and try again to pull the journal and rear wire link
to the right and clear of the bar cam. Repeat these actions
until successful.
Reassembling: Before reinstalling the cam journal, tighten the
nut and screw just to the point where the nut is inside the
journal. Reinstall the journal and slightly tighten the screw.
Reassembling: Do not overtighten the camĆjournal screw. Doing
so could break the journal, cause the bar cam to enter the sideplate
hole, and thus restrict the action of the pinchĆarm lever.
C A U T I O N
C3187Ć90000
Removal and Replacement 6Ć73
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.
Left sideplate
Bar cam
Cam journal
Reassembling: Position the bar cam between the left and right sideplates, or the lift
mechanism will not work.
9 While pressing the rightĆmost pinchĆarm assembly towards the rear of the plotter against
its spring tension, slide the bar cam left until it clears that pinchĆarm assembly.
10 Remove the pinchĆarm assembly and spring from the chassis.
Take care that the spring does not fall.
Bushing
Spring
PinchĆarm assembly
Pinch arm
11 Repeat the previous two steps until all of the pinchĆarm assemblies have been removed or
until you have removed the pinchĆarm assembly that is to be replaced.
6Ć74 Removal and Replacement
C3187Ć90000
7
Calibrations
7Ć1
When toCalibrate the Plotter
Indications or Repairs Performed
Calibration Required
Jagged lines on plots
Cartridge Alignment
Cartridge Alignment
Accuracy Calibration
Accuracy Calibration
Accuracy Calibration
Cartridges are reseated or replaced
Drive roller is removed or replaced
Media (X-axis) motor is replaced
Configuration-plot X-mark distance is not
500mm ("1mm)
Carriage or carriage LED is removed or replaced
Cartridge Alignment
and Setup-Sheet Calibration
Edge-detect failures occur
Cartridge Alignment
Bail Calibration
Bail failures occur during media loading
Bail sensor is removed or replaced
Bail-lift mechanism is removed or replaced
Media sensor is removed or replaced
Bail Calibration
Bail Calibration
Media-Sensor Calibration
Media-Sensor Calibration
Leading and trailing margins of a plot are greater
than 17 mm (0.67 in)
Problems occur scanning a setup sheet.
EEROM is cleared or main PCA is replaced
Setup-Sheet Calibration
(In this order:)
1. Bail Calibration
2. Media-Sensor Calibration
3. Cartridge Alignment
4. Accuracy Calibration
5. Setup-Sheet Calibration
Service Mode
Align
Cartridges
Entering Service Mode
1 Switch the plotter off.
2 While holding the Align Cartridges key down,
switch the plotter on.
3 Once the Busy LED lights up, release the Align Cartridges key.
The plotter performs the normal powerĆon self tests and mechanical initialization.
The plotter is now in service mode.
DesignJet 220 plotters: Four LEDs (Draft, Final, Paper and Transl/Vellum) flash when
you enter service mode. Press any key and they stop flashing.
7Ć2 Calibrations
C3187Ć90000
FrontĆPanel Keys in Service Mode
Pressingany single frontĆpanel 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 Replot key acts as a SHIFT key,
and the Cancel key acts as an ALT key.
The followingillustration indicates which service tests and calibrations are assigned to which
frontĆpanel keys. A frontĆpanel overlay is provided with this manual; you can place it over
the actual keys on the plotter. The designation of keys for service tests is also shown on the
service configuration plot.
Bail Cycle
Test
Bail
Calibration
Bail Sensor
Test
with ALT
Service
Configuration
Accuracy
Calib. Print
Electrical
Test
with SHIFT
SHIFT
Service Monitor
with Shift + Alt
ALT
Setup-Sheet
Calibration
Media-Sensor
Calibration
Servo/Encoder
Test
with ALT
Stepper
Motor Test
Accuracy
Calib. Read
Input/Output
Test
with SHIFT
To check whether a DesignJet 220 plotter is in service mode, press the ALT and SHIFT keys
together, and then release them. If the plotter is in service mode, four LEDs (Draft, Final, Paper
and Transl/Vellum) flash. Press any key and they stop flashing.
Performing Tests and Calibrations
The general procedure to perform a service test or calibration is as follows:
1 Once in service mode (see previous page), hold down the SHIFT or ALT key, whichever is
appropriate for the service test you want to perform.
2 Without releasingthe SHIFT or ALT key, press the key correspondingto the service test or
calibration you want to perform.
3 Release the keys once the Busy LED lights up.
Procedures specific to each calibration are given on the following pages.
(Service tests ' chapter 8.)
C3187Ć90000
Calibrations 7Ć3
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 cartridgeĆalignment 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. In this case, the plotter uses the first sheet of media that you load to perform the
alignment.
CarriageĆLED Calibration
The cartridgeĆalignment routine includes calibration of the carriage LED. This is the optical
sensor on the cartridge carriage, used to find the left and right media edges during media
loading. (This calibration is independent of the setupĆsheet calibration. The setupĆsheet
calibration calibrates the same LED, but the values stored are used only for scanning a setup
sheet and are separate from the values strored during the cartridge alignment.)
Aligning Cartridges
You do not have to enter service mode to align cartridges.
Paper
Load
Media
1 With the plotter switched on, ensure the mediaĆjam
lever (pinchĆarm lever) is up and the window down.
The Load Media light should be on.
Media
Type
2 Choose the correct Media Type on the front panel: If you are using plotting paper, as
recommended in the following step, turn the Paper LED on. The Final and Draft lights
have no significance for this procedure and either can be on.
3 Load an AĆsize or A4Ćsize sheet of good quality plotting paper. (You can also use larger
media sizes.) The Ready LED lights up.
4 Press the Align Cartridges key.
Align
Cartridges
The plotter takes 3 to 4 minutes to perform its alignment
routine using the sheet of paper you have just loaded.
Paper
In the course of the routine, it draws lines and shaded
areas and then ejects the paper.
Ready
5 Wait one minute for the ink to dry and unload the paper.
7Ć4 Calibrations
C3187Ć90000
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 cartridgeĆalignment plot sheet is shown below. The two pairs of
lines that you should inspect are indicated on this example.
Gap
}
}
Left cartridge
Right cartridge
6 If any of the leftĆcartridge or rightĆcartridge lines includes gaps, then the corresponding
print cartridge should be either cleaned or replaced as appropriate.
C3187Ć90000
Calibrations 7Ć5
Accuracy Calibration
Purpose
The accuracy calibration procedure is used to correct the endĆpoint accuracy of the media
axis. The cartridge axis does not require calibration and is used to calibrate the media axis.
Perform the accuracy calibration whenever the:
D EEROM is erased
D Main PCA is replaced
D Drive roller is removed or replaced
D Media (XĆaxis) motor is replaced
What is the EndĆPoint Accuracy Specification ?
The endĆpoint accuracy specifies how accurately a plotter can draw a given length of line.
The endĆpoint accuracy specification for the plotters is ± 0.38 mm (0.015 in) or ± 0.2% of the
d
d
specified vector length, whichever is greater, at 23 C (73 F), at 50Ć60% 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 EndĆPoint Accuracy ?
Various part tolerances inside the plotter affect the accuracy (in particular the drive roller).
Other outside influences include:
D Mediathickness. Thicker mediacreates longer lines.
D Mediaexpansion. As the mediagrows, so do the lines.
D Application software. The software may be instructing the plotter to draw an incorrect
line length.
D The EEROM has been cleared. The accuracy constants are stored in this nonĆvolatile
memory component.
(Further information ' chapter 5, w MediaĆDrive Accuracy.)
7Ć6 Calibrations
C3187Ć90000
Performing the Accuracy Calibration
1 Enter service mode ' page 7Ć2.
2 Plot a service configuration plot ' page 8Ć23.
3 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.
If the measured accuracy, media thickness, or environmental conditions vary greatly from
the factory standards, recalibrate the plotter by continuing with the following steps.
4 Place a sheet of media (preferably inkjet polyester film) over the top of the plotter for 10
minutes to let the sheet stabilize to the environmental conditions.
Use a sheet approximately 61 x 91 cm (24 x 36 in).
5 Select the appropriate Media Type on the front panel.
6 Loadthe media in portrait orientation into the plotter.
If using inkjet polyester film, load the film with the matte (dull) side down.
Accuracy
Calib. Print
7 When the Ready LED lights up, holddown the
SHIFT key andpress Accuracy Calib. Print.
SHIFT
The Busy LED lights up and the plotter plots a
calibration plot. The plotter ejects the sheet,
and the Load Media LED lights up.
8 Unloadthe sheet.
9 Reloadthe sheet facedown into the plotter, in the direction indicated by the arrows on
the calibration plot.
If the plotter is D/A1 size, the sheet does not fit in the entry slot in the orientation
indicated by the arrows. In this case, cut the blankend off the media so that it fits.
(Cut along the long line on the plot; the cut must be very straight so that the sheet can
be loaded.)
For D/A1-size plotters,
cut along this line
C3187Ć90000
Calibrations 7Ć7
SHIFT
10 When the Ready LED lights up, holddown the
SHIFT key andpress Accuracy Calib. Read,
The Busy LED lights up. The plotter takes about
3 minutes to read the calibration sheet, to calculate
the calibration data, and to save the data in the
EEROM. (During this time, the plotter appears
almost motionless for short intervals.) The plotter
then ejects the sheet.
Accuracy
Calib. Read
11 Unloadthe sheet.
Bail Calibration
In this procedure, the `up' position of the bail assembly is calibrated. A value is stored in the
EEROM when the procedure is completed.
Perform the bail calibration whenever the:
D EEROM is cleared
D Main PCA is replaced
D Bail falls during media loading
D Bail switch is replaced
D BailĆlift mechanism is removedor replaced
To calibrate the bail, perform the following procedure:
1 Enter service mode ' page 7Ć2.
Bail Calibration
2 Holddown the ALT key andpress Bail Calibration.
ALT
The Busy LED lights up and the bail begins cycles of being raised and lowered.
During a number of the cycles, the bail is let fall instead of being gently lowered.
The calibration ends after about a minute and a half.
7Ć8 Calibrations
C3187Ć90000
MediaĆSensor Calibration
The mediaĆsensor calibration measures the position of the mediaĆsensor levers with respect
to the drive roller. A value is stored in the EEROM when the procedure is completed.
Perform the mediaĆsensor 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).
To calibrate the media sensor, perform the following procedure:
1 Enter service mode ' page7Ć2.
2 Hold down the ALT key and press Media Calibration.
Any loaded media is ejected by the plotter.
ALT
Media-Sensor
Calibration
3 When the Load Media LED begins to flash, load a sheet of media in landscape orientation.
The loading process takes longer than usual because the sheet margins are measured
several times. Once the sheet is loaded, it is ejected again.
4 When the Load Media LED begins to flash again, load the same sheet in portrait
orientation.
Again, the loading process takes longer than usual because the sheet margins are
measured several times. Once the sheet is loaded, it is ejected again, and the Ready
LED lights up.
C3187Ć90000
Calibrations 7Ć9
SetupĆSheet Calibration
This calibration calibrates the power of the LED situated on the cartridge carriage, for better
scanningof the setup sheet.
Perform the setupĆsheet 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 setupĆsheet scanning
To calibrate the LED, perform the followingprocedure:
1 Enter service mode ' page 7Ć2.
2 Load a blank sheet of paper.
Do not use vellum, transparent or polyester media, or recycled paper.
3 Hold down the ALT key and press Setup-Sheet Calibration.
ALT
Setup-Sheet
Calibration
The plotter positions the cartridge carriage over the media. The carriage remains
there for about 1 minute with the red LED lit, while the plotter performs the
calibration. The plotter then ejects the sheet.
To verify that the calibration has been performed correctly, plot a service configuration
plot, ' page 8Ć23, and look at the field entitled Setup Sheet LED Calibration formula."
A formula appears in this field. If the calibration has not been performed correctly, a
message, saying that the LED has not been calibrated for setup sheet, appears.
7Ć10 Calibrations
C3187Ć90000
8
Troubleshooting
8Ć1
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 frontĆpanel LEDs. You can perform a
failure analysis by interpreting the LED error code. (Details ' later in this chapter.)
PowerĆOn Self Test
The powerĆon self test does the following:
1 Initializes the servo processor.
2 Initializes the main processor .
3 Tests communication between the main processor and the servo processor.
4 Tests the ROM checksum.
5 Causes the main processor to initialize certain firmware modules and communicate with
thecarriageprocessor.
6 Tests the EEROM checksum.
7 Tests the servoĆprocessor transfer buffer and interruptĆtracking abilities.
8 Tests the communication between the processors again.
9 Tests thecarriageASIC.
10 Begins mechanical initialization of the plotter.
8Ć2 Troubleshooting
C3187Ć90000
Extended PowerĆOn Self Test
Perform the extended powerĆon test whenever the plotter passes the normal powerĆon test,
but does not function properly.
To begin the extended powerĆon test, perform the following procedure:
Access
1 Switch theplotter off.
Cartridges
2 Whileholding the Access Cartridges key down,
switch theplotter on.
3 Oncethe Busy LED lights up, release the
Access Cartridges key.
As well as carrying out the normal powerĆon tests, the extended powerĆon test does the
following:
1 Tests the processorĆsupportĆASIC motion control circuitry. (These circuits control the
media and carriage motors.)
2 Tests the swath RAM.
3 Tests the communication link between the cartridgeĆinterface ASIC and the carriage
ASIC.
4 Tests the available DRAM not being used by the system. (The length of this test is
dependent on how much DRAM is installed.)
5 Begins mechanical initialization of the plotter.
Mechanical Initialization
The automatic mechanical initialization of the plotter begins at the end of the powerĆon test.
Theinitialization proceduredoes thefollowing:
1 Checks the window sensor.
2 Locates the initial position of the stepper motor.
3 Initializes thecarriageaxis (YĆaxis).
4 Ejects any loaded sheet of media.
5 Checks the pinchĆarm sensor.
6 Checks the media sensor.
7 Sets the plotter to accept media.
8 Tests the remainder of the DRAM.
C3187Ć90000
Troubleshooting
8Ć3
What You Should See and Hear
When you turn on the plotter, the followinghappens:
1 All six LEDs light up for a brief moment; then the Busy LED remains on.
If you have activated the extended powerĆon self tests, all six LEDs remain off for a few
seconds before the Busy LED lights up.
2 The stepper motor makes a buzzingnoise.
3 The cartridge carriage knocks against the leftĆhand side.
4 The carriage moves across the plotter and knocks three times against the rightĆhand side.
5 The carriage returns to the leftĆhand side.
6 Any loaded sheet of media is ejected.
7 If either cartridge is not correctly positioned, the carriage moves to a position where you
can access it; the Cartridges LED lights up indicating that you have to load, reseat or
replace the cartridges. (Instructions ' User's Guide.)
8 The cartridges are cleaned in the service station on the leftĆhand side of the plotter.
Duringthe cleaningprocess, the carriage moves slightly a number of times for the wiper
to wipe the nozzles.
9 The carriage then parks in the service station on the leftĆhand side of the plotter.
10 If you have loaded or reseated the cartridges, the Cartridges and Load Media LEDs flash,
indicatingthat the first sheet of media that you load will be used to run the
cartridgeĆalignment procedure (Details ' chapter 7.)
11 If the cartridges are already aligned, the Load Media LED lights up to indicate that the
plotter is ready for you to load media.
8Ć4 Troubleshooting
C3187Ć90000
Errors Indicated by LEDs
The Error LED on the front panel works in combination with the other
LEDs to specify the type of error that has occurred. The three possible
states of any LED are representedlike this:
Error
Off
On
Flashing
User Errors
User errors are associatedwith user settings or user actions andmay be solvedby the user
without calling a Customer Engineer. They are indicated by the Error LED flashing.
(Further Information ' User's Guide, chapter 4, Troubleshooting.)
Error and Cartridges flashing
Error
Cartridges
Possible Causes
Corrective Action
An error was detected during the
cartridgeĆalignment routine.
1. Remove the cartridges.
2. Ensure that the protective tape has been removedand
that the contacts are clean.
3. Replace the cartridges.
4. If the LEDs do not stop flashing when you lower the
window, replace both cartridges with new ones.
See also ' later in chapter, w Frequent Cartridge Failure.
An error was detected while scanning a
setup sheet.
1. Check the quality of the media and print of the setup
sheet.
2. If the quality appears acceptable, try loading the sheet
again face down. If not, use a newly printed setup sheet.
3. If the error persists, perform the setupĆsheet calibration.
Error
Ready
Error and Ready flashing
Possible Causes
Corrective Action
The current plot is too large for the
plotter's memory
To be able to perform this plot, you have to install more
memory. (If the plot is a raster plot, it might work if you
sendit with a no negative motion RTL command.)
C3187Ć90000
Troubleshooting
8Ć5
Error and Busy flashing
Error
Busy
Possible Causes
Corrective Action
The serialĆinterface settings are different on the
plotter and on the software.
1. Print a setup sheet and check the plotter's
current settings for Baud Rate and Parity.
2. Compare these with the current settings of
the same two items for your application
software. They must be the same.
3. If necessary, change the plotter's settings.
The serialĆinterface cable is not correctly
connected.
Connect the cable correctly.
The computer is ignoring the plotter's handshake
signals.
If the computer is using hardware handshake,
ensure that the serialĆinterface cable has a
handshake wire.
Error
Load Media
Error and Load Media flashing
Possible Causes
Corrective Action
The media does not advance around the roller
when loaded.
Remove the media and reload it.
You loaded the media too far from the right
side.
Remove the media and reload it, aligning the
right edge between the two dashed lines on the
loading area.
The leading edge of the media is not parallel to
the roller.
Reload the media, aligning it correctly.
The media is too small for the plotter.
Use an AĆsize or A4Ćsize sheet or larger. Load
in portrait orientation for setup and
alignĆcartridge routines.
See also ' later in this chapter, w Problems in Loading Media.
8Ć6 Troubleshooting
C3187Ć90000
System Errors
System errors are associated with plotter hardware failure that needs to be repaired by a
Service or Customer Engineer. System errors are indicated by the Error LED lit and steady.
In the tables on the following pages, the symbol
LEDs, where, in this case, the Error, Paper and Ready LEDs arelit and steady, and theother
LEDs areoff.
represents the frontĆpanel
Align
Cartridges
Access
Cartridges
Setup
Replot
Error
Ready
Paper
Plot
Quality
Form
Feed
Media
Type
Cancel
Error and Busy LEDs lit and steady: Input/output errors.
LEDs lit and
steady
Error Number and
Description
Corrective Options
336. RSĆ232ĆC data overflow.
Data byte was not read before
another was entered into the
UART.
At thetimeof printing of this manual, this
error should be solved by replacing the main
PCA. If the problem remains, consult
recent service notes for a possible solution.
If no service note deals with this error,
report the problem to the HP Response
Center.
276. Failureof RSĆ232ĆC
loopback test.
Ensuretheloopback connector is the
appropriate one. / Replace main PCA.
340. Failureof centronics READ.
Replace main PCA.
C3187Ć90000
Troubleshooting
8Ć7
Error and Ready LEDs lit andsteady: Memory errors.
LEDs lit
and
steady
Error Number and
Description
Corrective Options
81. Failure of ROM test
Replace EPROMs. If problem remains,
replace main PCA.
21. Failure of DRAM quick test
85. Failure of DRAM full test
49. Failure of Swath RAM test
113. Failure of EEROM test
53. DRAM SIMM failure
Replace main PCA.
Replace main PCA
Replace main PCA
Replace main PCA.
Replace DRAM SIMM. If problem remains,
replace main PCA.
117. Sensor structure -
firmware failure
At the time of printing of this manual, this
error shouldnot occur. 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.
8Ć8 Troubleshooting
C3187Ć90000
Error and Load Media LEDs lit and steady:
MediaĆpath/servo errors.
LEDs lit
and
steady
Error Number and
Description
Corrective Options
82. Shutdown of media axis
(XĆaxis)
See ' later in this chapter, w ServoĆControl
System Failures.
22. Shutdown of carriage axis
(YĆaxis)
See ' later in this chapter, w ServoĆControl
System Failures.
86. CarriageĆaxis failure
50. CartridgeĆcap failure
Check encoder strip, carriage assembly,
trailing cable, main PCA.
See ' later in this chapter, w Frequent
Cartridge Failure. / Check the service
station, encoder strip and media motor.
114. Error detected in mediaĆaxis Check media motor, mediaĆmotor encoder
servo feedback loop.
cable, main PCA.
54. Error detected in
Check encoder strip, carriage assembly,
carriageĆaxis servo feedback loop. trailing cable, main PCA.
118. Bail sensor indicates the bail See ' later in this chapter, w BailĆLiftĆ
is up when it should be down or
vice versa, or the bail drops
suddenly (missing the notch on
the auto cam).
Mechanism Failure. / Use the bailĆsensor
test to help troubleshoot. / Check for
mechanical problems. / Perform the bail
calibration.
146. AccuracyĆcalibration error
Did you load the media in the correct
orientation? / Ensure that the marks are
visible on the plot. If not, check cartridges. /
Ensure that the sheet is cut correctly. /
Perform a cartridge alignment: if alignment
is correct, the problem may be in the main
PCA, media motor or media motor gear; if
alignment is incorrect, the problem may be
in the carriage.
210. MediaĆsensorĆcalibration
error. One of the flags on the
media sensor may be positioned
too far forward or too far back.
Replace the media sensor. If the error
persists, there may be a problem with the
LED on the cartridge carriage: Perform a
cartridge alignment / Replace LED.
C3187Ć90000
Troubleshooting
8Ć9
Error and Cartridge LEDs lit and steady: Miscellaneous errors.
LEDs lit
and
Error Number and Description
steady
Corrective Options
88. Processor fault
At the time of printing of this manual,
this error should not occur. 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.
28.Communication failure between the
main and servo processors.
Replace main PCA.
Communication occurs through the
processorĆsupport ASIC.
92. Servo interrupts not occurring or not Replace main PCA.
reaching the main processor support
ASIC.
56. Error in servoĆdrive calculations.
Replace main PCA.
Replace main PCA.
120. ServoĆprocessor communication
error.
60. Failed communications between the
carriage and main processors.
Check trailing cable connections and
continuity. If needed, replace trailing
cable, main PCA or carriage assembly.
124. The optical sensor on the carriage
has failed to locate lines drawn during
the cartridge calibration routine.
Reduce ambient light. / If media is not
clean and reflective, change media. / If
lines are faint, replace cartridges. / Clean
lens. / Replace LED.
152. Failure of cartridgeĆinterface-
ASIC test.
Replace main PCA.
216. Firmware failure.
At the time of printing of this manual,
this error should not occur. 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.
8Ć10 Troubleshooting
C3187Ć90000
FirmwareĆCode Revision Level
To check the firmwareĆcode 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. The procedure for plotting the
demonstration plot is given in the User's Guide.
Diagnosing Problems
You can usetheserviceconfiguration plot to help diagnoseproblems. Theprocedurefor
plotting theconfiguration plot is given on page8Ć23.
Other Tips
On thefollowing pages aretips about solving thefollowing problems:
D Servo controlĆsystem failures
D Frequent cartridge failure
D BailĆliftĆmechanism failure
D Cartridgecarriagerubbing against encoder strip
D Premature wearing of drive belts
D Sensor does not find media edge
D Last swath is clipped when replotting
D Ink smearing
D Plots joined or not plotted
D Incorrect line widths
D Plotter won't read setup sheet; Plots solid black area fill
D Problems in loading media
C3187Ć90000
Troubleshooting 8Ć11
Servo ControlĆSystem Failures
MediaĆAxis (XĆAxis) Shutdown
In the case of a mediaĆaxis shutdown, try one or more of the following corrective actions:
D Clear any binding in the mediaĆaxis mechanics due to a media jam. (Do not pull the
media along the carriage axis. Doing so could break the mediaĆsensor flags.)
D Remove the two screws that attach the driveĆroller gear to the drive roller. This should
enable you to manually spin the drive roller. If it does not, the roller is probably jammed.
D Perform the servo/encoder service test to check for problems with the mediaĆaxis motor
encoder and main PCA.
CarriageĆAxis (YĆAxis) Shutdown
In the case of a carriageĆaxis shutdown, try one or more of the following corrective actions:
D Clear any binding in the carriageĆaxis mechanics due to a media jam.
D Turn the plotter off. This should enable you to manually move the carriage along the
carriageĆaxis. Check for any areas where the carriage may be binding.
D Ensure that the double pulley, small drive belt, small belt tensioner, main belt, main idler,
and carriage bushings are in correct working order.
D Perform the servo/encoder service test to check for problems with the servoĆfeedback and
motor drive systems.
Frequent Cartridge Failure
Remove Tape and Align Cartridges
One frequent cause of cartridge problems is that the user has forgotten to remove the tape
from new cartridges. Remove the tape and perform a cartridge alignment.
Damaged Encoder Strip
Another cause of apparent frequent cartridge failure may be a damaged encoder strip. If the
small slots on the strip are damaged, the plotter cannot position the carriage correctly during
cartridge checking. Try replacing the encoder strip.
Incompatibility between Carriage and Firmware
In combination, cartridge carriage C2847Ć60071 (carriage PCA C2847Ć60125) and plotter
firmware A.01.00 destroy the cartridges. Update the plotter firmware and replace the
cartridges. (Details ' chapter 9 w Problems Corrected by Firmware Release A.01.01.)
8Ć12 Troubleshooting
C3187Ć90000
Misaligned Cartridge Caps
If a customer is complaining about shortened cartridge life or frequent cartridge failure, you
should check the cartridgeĆcap 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. You should clean the caps and reservoir
usingonly water. You should also clean the wiper.
Seating area
Cartridge caps
Function of the Cartridge Caps
The cartridge caps (also called serviceĆstation caps) are located in the service station.
Lookingclosely at a cartridge's printĆhead reveals two parallel rows of nozzles. The cap
should form a seal that surrounds the rows. If the caps are mispositioned, the seal may be
touchingone or more of the nozzles. The result is premature cartridge failure and a messy
service station.
What can Cause Cap Misalignment?
The most common cause is that the cap is not seated properly on the serviceĆstation sled.
Any of the serviceĆstation parts could cause misalignment if defective or installed incorrectly.
Checking CartridgeĆCap Alignment
The followingtools are recommended for this procedure:
D Soft lintĆfree wipes
D NonĆpermanent ink marker (dry erase type works best)
D 10X magnifier
D Print cartridges
To check the alignment of the caps with respect to the printĆhead nozzles
1 Remove the window, center cover and left endcover.
2 Manually move the carriage out of the service station.
3 Load very clean cartridges into the carriage.
Use lintĆfree wipes dampened with water to clean the cartridges.
4 Apply ink to the seatingarea of the cartridge caps with the ink marker.
5 Manually move the carriage slowly into the service station, then out again.
6 Remove the cartridges and observe where the ink mark is positioned with respect to the
nozzles. A 10X magnifier is very useful for this step. If one is not available, you should
look at how centered the mark is within the gold pad area.
7 If the ink mark is touchingany nozzle, you need to check and reseat the cartridge caps
and repeat the test.
C3187Ć90000
Troubleshooting 8Ć13
BailĆLiftĆMechanism Failure
Normal BailĆLift Sequence
The following is what should happen during a normal bailĆlift sequence:
1 The cartridge carriage positions over the engagement lever. This connects the autoĆlift
mechanism to the driveĆroller gear. The media motor becomes the driving force for the
autoĆlift.
2 The media motor drives the drive roller, which in turn drives the bail autoĆlift. The bail
begins raising up until the UP" position is reached.
3 The carriage moves away from the engagement lever so that the media may be driven by
the drive roller without affecting the position of the bail. (The bail is kept in the up
position by the left bail arm resting in the notch on the gear cam.)
4 After the media is moved forward, the carriage again positions over the engagement lever.
The media motor then drives the bail autoĆlift and the bail lowers to the down position.
When the bail is down, it presses on the bail sensor switch. This is how the plotter knows the
position of the bail.
Problems
D The cam gear and engaging gear detach from the driveĆroller gear even though the
carriage is still actuating the engaging lever. This can happen due to excessive part
tolerances or wear.
D The engaging lever spring is installed on the lower rung of the YĆdrive bracket, creating
too much spring tension. Excessive spring tension accentuates any looseness in the bail
lift parts. Install the spring on the upper rung.
D The carriage does not properly locate the engagement lever, preventing the gears from
engaging. Any problems with the carriageĆmotor control system (for example, the
encoder strip) or associated mechanics could cause this problem. Also, if the carriage
cannot find the true left stop during initialization (caused by interference), the engaging
lever cannot be located. Possible causes of interference are the serviceĆstation sled and
the main tensioner bracket.
D The bail falls from the up position. This can result if the cam is over or underĆrotated.
The notch on the cam, used to catch the left bail bracket, is not properly located for the
bail up" condition, and the bail falls abruptly. A bail calibration may correct this
problem.
Teflon Washers versus CamĆGear Support
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 camĆgear support.
(Details ' chapter 9, w New BailĆLiftĆMechanism Support.)
8Ć14 Troubleshooting
C3187Ć90000
Cartridge Carriage Rubbing against Encoder Strip
When properly installed, the encoder strip should pass through the cartridgeĆcarriage
assembly without touching it. Sometimes excessive rubbing may be experienced, causing the
encoder strip to buckle or vibrate, and thus causing errors in the carriageĆaxis servo feedback
system and poor carriageĆaxis position tracking.
You can adjust the encoderĆstrip position by adjusting the position of the encoder spring
bracket. To do this, perform the following procedure:
1 Remove the power cord from the plotter.
2 Remove the window, center cover and right endcover.
3 Manually position the carriage assembly in the center of the plotter.
4 Loosen the top and bottom screws of the adjustable encoderĆspring bracket.
5 Manually move the bottom of the bracket about the bracket's top screw until the encoder
strip is centered in the carriage; then tighten the screws.
Premature Wearing of Drive Belts
The main belt or the small YĆdrive belt may wear prematurely if the plotter is placed near a
diazo copier that uses ammonia to produce blueĆline copies. The material used in the belts is
very reactive to ammonia vapor. The vapor is very corrosive and can damage other parts as
well. It is recommended to move the plotters away from such copiers.
Sensor does not Correctly Find Media Edge
Excessive ink deposits on the driveĆroller surface can fool the sensor by reflecting the light.
(Cleaning roller ' chapter 4.)
Last Swath is Clipped when Replotting
This bug on DesignJet 200 plotters will be solved in firmware revision A.01.02.
(Details ' chapter 9.)
C3187Ć90000
Troubleshooting 8Ć15
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/A4Ćsize media. (Solution ' chapter 9, w Change in Bail and Overdrive Parts.)
Change Carriage Rear Bushing
Another reason for ink smearing in DesignJet 200 plotters is an insufficient distance between
the cartridges and the media. This problem is solved in the DesignJet 220 plotters, using a
new rear bushing on the cartridge carriage. You can order this bushing for a DesignJet 200.
(Part number ' chapter 10.)
Plots Joined or Not Plotted
HPĆGL Timeout
If the user is using an HP 7586B (HPĆGL) driver, it may not end files properly with the result
that several plots may be joined, or not plotted at all. In this case you need to choose an
HPĆGL Timeout period. (Instructions ' User's Guide.) The timeout tells the plotter how long
to wait before assuming a plot is complete.
Short timeout period: A timeout setting that is too short results in incomplete plots.
Long timeout period: If the plotter has finished receiving the plot data (Busy LED stops
flashing and remains on) and is waiting for the timeout period to finish before plotting, you
can command it to plot immediately by pressing Form Feed.
Incompatibility between Trailing Cable and Main PCA
The shielded trailing cable C3180Ć60033 (blue and white) is NOT compatible with old main
PCAs (C3180Ć60101, C3180Ć68101, C3180Ć69101). Nothing is printed if you use them in
combination. Update the main PCA.
Incorrect Line Widths
DesignJet 200 plotters with firmware version A.01.00 may plot line widths that are
inconsistent with the selected values if an IN command is absent in the plot files. Update the
firmware. (Details ' chapter 9, w Problems Corrected by Firmware Release A.01.01.)
8Ć16 Troubleshooting
C3187Ć90000
Plotter won't Read Setup Sheet; Plots Solid Black Area Fill
This problem can occur on DesignJet 200 plotters with the oldĆstyle cartridge carriage.
Install a new carriage. (Details ' chapter 9, w Change in Carriage.)
Problems in Loading Media
User's Guide
The Troubleshooting section of the User's Guide lists mistakes you may be making if the
plotter continually rejects your media.
Long Media doesn't Load
DesignJet 200 plotters with firmware version A.01.00 cannot load 1.6Ćm media. Update the
firmware. (Details ' chapter 9, w Problems Corrected by Firmware Release A.01.01.)
Translucent Media doesn't Load
Some DesignJet 200 carriage PCAs have problems sensing translucent media. The solution is
to install a new cartridge carriage. (Further Information ' chapter 9, w Change in Carriage.)
Binding, or Missing Sensor Flags
MediaĆload failures can also occur due to binding in the mediaĆaxis mechanics or missing
mediaĆsensor flags. Clear any binding in the mediaĆaxis mechanics due to a media jam. (Do
not pull the media along the carriage axis. Doing so could break the mediaĆsensor flags.)
Media Skews Badly
Ensure that the media diverters (part number ' page 10Ć26) are correctly installed. If one is
missing or broken, replace it. To access this part, you need to remove the drive roller !
C3187Ć90000
Troubleshooting 8Ć17
Service Tests
Test
Description
Bail Cycle Test
This tests the following:
D
D
D
D
Bail
Bail sensor switch
Drive Mechanics
Main PCA
Bail-Sensor Test
Electrical Test
This tests the following:
D
D
D
Bail sensor switch
Main PCA
Mechanical interference
The electrical test performs all of the following:
D
D
Carriage communications test
Carriage ASIC test: Values stored in the carriage ASIC registers are
temporarily stored. All registers are tested by writing, then reading, the
numbers AA(hex) and 55(hex). When the test is complete, previously
stored values are restored.
D
Cartridge interface ASIC test: Verifies the functionality of the cartridge
interface ASIC.
D
D
D
D
Cartridge ASIC / carriage ASIC link test
EEROM checksum
On-board SIMM RAM test
ROM CRC test: Performs a ROM checksum and compares it to a
checksum value previously stored.
D
Swath RAM test: Tests the RAM used by the cartridge interface ASIC to
store the swath.
Input/Output Test
The input/output test performs the following:
D
Parallel input/output test: Reads the data and status registers of the
Bi-Tronics PAL. (Tests only a small portion of the Bi-Tronics input/output
functionality.)
D
Serial input/output test: Verifies the ability of the RS-232 interface to send
and receive data. This test uses a special loopback connector (part number
07440-60302) to connect the output to the input.
8Ć18 Troubleshooting
C3187Ć90000
Test
Description
Media-Sensor Test
This tests the following:
D
D
D
Media sensor on entry platen
Main PCA
Media opacity
Pinch-Arm-
Sensor Test
This tests the following:
D
D
D
Pinch-arm sensor
Pinch-arm-sensor cable
Main PCA
Service
The service configuration plot contains the following:
Configuration Plot
D
D
D
Hard-clip border around the plot enabling you to measure the margins.
Unique bar patterns enabling you to detect print-quality problems
Four X-shaped marks (crosshairs) for measuring the accuracy of the
media-axis calibration. (The centers of the crosshairs should be 500 mm
apart.)
D
D
Contents of EEROM, dumped in hexadecimal format.
Explanation of important EEROM parameters, including a mileage monitor
and information on the last system error.
D
Designation of front-panel keys for service tests.
Service Monitor
(Data Display)
Use the service monitor to compare the code sent by the computer with that
received by the plotter. Instead of plotting the drawing that you send, the plotter
prints part of the code that would otherwise have been used to plot the drawing.
This code is useful when you suspect that there is a problem with the
communication between the computer and the plotter.
Servo/Encoder Test
The servo/encoder test performs the following:
D
D
D
MediaĆaxis encoder test: Verifies the operation of the servo loop
(Media-axis feedback).
CarriageĆaxis encoder test: Verifies the operation of the servo loop
(Carriage-axis feedback).
Records the maximum pulse-width modulations used. You can view this
information on the service configuration plot.
C3187Ć90000
Removal and Replacement 8Ć19
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:
D
D
D
D
Stepper motor
Main PCA
Cartridge-adjust linkage
Wiper linkage
Window-Sensor Test
This tests the following:
D
D
D
Window sensor
Window-sensor cable
Main PCA
8Ć20 Removal and Replacement
C3187Ć90000
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
Servo/encoder test
Servo/encoder test
Stepper-motor test
Electrical test
Carriage-axis encoder/motor
Carriage-axis encoder cable
Cartridge-adjust linkage
Cartridge carriage
Communication between computer and plotter
Double pulley
Service monitor
Servo/encoder test
Electrical test
DRAM SIMM
Drive belt
Servo/encoder test
Bail cycle test
Drive mechanics
Drive roller
Servo/encoder test
Electrical test
EEROM
Main belt
Servo/encoder test
Servo/encoder test
Main idler
Main PCA
Electrical test, Input/output test, Stepper-motor
test, Servo/encoder test, Bail-sensor test,
Media-sensor test, Window-sensor test,
Pinch-arm-sensor test, Bail cycle test
Mechanical interference
Media-axis encoder/motor
Media-axis encoder cable
Media sensor
Bail-sensor test
Servo/encoder test
Servo/encoder test
Media-sensor test
Servo/encoder test
Pinch-arm-sensor test
Pinch-arm-sensor test
Electrical test
Overdrive
Pinch-arm sensor
Pinch-arm-sensor cable
ROM
Slider rods
Servo/encoder test
Stepper-motor test
Electrical test
Stepper motor
Trailing cable
Window sensor
Window-sensor cable
Wiper linkage
Window-sensor test
Window-sensor test
Stepper-motor test
C3187Ć90000
Removal and Replacement 8Ć21
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 frontĆpanel LEDs.
Bail Cycle Test
Bail Cycle Test
1 Enter service mode (see page 7Ć2).
ALT
2 Hold down the ALT key and press Bail Cycle Test.
The Busy LED lights up and the bail begins cycles of being gently raised and lowered.
3 Press the ALT (Cancel) key when you want to stop the test.
Bail Sensor Test
BailĆSensor Test
1 Enter service mode (see page 7Ć2).
ALT
2 Hold down the ALT key and press Bail Sensor Test.
The Busy LED lights up.
3 Open the window within 120 seconds.
Otherwise the Busy LED goes off and the test ends.
4 Manually raise the bail.
The Ready LED flashes.
5 Press the ALT (Cancel) key when you want to stop the test, and lower the window.
Electrical Test
SHIFT
Electrical Test
1 Enter service mode (see page 7Ć2).
2 Hold down the SHIFT key and press Electrical Test.
The Busy LED lights up and remains lit for about 30 seconds while the tests are being
performed.
8Ć22 Removal and Replacement
C3187Ć90000
Input/Output Test
1 Connect a loopback connector (part number 07440Ć60302) to the serial port of the plotter.
If a connector is not available, youcan place a jumper between pins 2 and 3 of the
serial port for the test.
SHIFT
2 Enter service mode (see page 7Ć2).
3 Hold down the SHIFT key and press Input/Output Test.
Input/Output
An error is displayed on the front panel if the test fails.
Test
MediaĆSensor Test
When the Load Media LED is lit, manually insert a sheet of media, so that it covers the media
sensor.
The Load Media LED should turn off, and the Busy LED should light up. (The plotter then
loads the sheet.)
PinchĆArmĆSensor Test
1 With the window closed and the Load Media LED lit, pull the mediaĆjam lever (pinchĆarm
lever) forward.
This raises the pinch arms. The Ready LED should flash.
2 Push the mediaĆjam lever back to its original vertical position.
This lowers the pinch arms. The Ready LED should stop flashing, and the Load Media
LED should light up again.
Service Configuration Plot
1 Enter service mode (see page 7Ć2).
2 Set the Plot Quality to Final on the front panel.
3 Load a sheet of A1Ćsize or DĆsize media in portrait orientation.
If you use a smaller sheet (minimum A4 or A size), all information will be plotted, except
theX" marks, used for accuracy calibration in chapter 7.
Service
4 When the Ready LED lights up, hold down the SHIFT key
Configuration
and press Service Configuration.
SHIFT
The Busy light first begins to flash and then remains on
and steady. The plotter plots the service configuration
plot and ejects the media.
5 Unload the media.
6 See Interpreting the Service Configuration Plot" on page 8Ć25 for how to analyze the bar
pattern and how to read the EEROM text block.
C3187Ć90000
Removal and Replacement 8Ć23
Service Monitor (Data Display)
1 Enter service mode (see page 7Ć2).
Service
Monitor
2 Hold down the SHIFT and ALT keys and press Service Monitor.
SHIFT
ALT
3 Send the file or files from the computer through the serial
or parallel ports.
4 Press any frontĆpanel key when the file(s) have been
transferred to the plotter.
5 Load a sheet of media (A3 size or B size minimum) in portrait orientation.
Instead of plotting the drawings that you sent, the plotter plots the first and last
Kbytes of the code for those drawings. The code is printed in hexadecimal and ASCII
format. (If the total size of the file(s) sent is not bigger than one Kbyte, only the first
buffer is printed.) The plotter exits the service monitor mode if the file(s) sent contain
PJL universal exit language.
6 Compare the code printed with the code sent from the computer to check if
communication between the computer and the plotter is functioning correctly.
Servo/Encoder Test
1 Enter service mode (see page 7Ć2).
ALT
2 Hold down the ALT key and press Servo/Encoder Test.
Servo/Encoder Test
The Busy LED lights upand the carriage moves to the center of the plotter. Both the
carriage and the roller then move backwards and forwards in cycles of six short steps,
changing direction between cycles.
3 Press any frontĆpanel key to stop the test.
SHIFT
StepperĆMotor Test
1 Enter service mode (see page 7Ć2).
2 Hold down the SHIFT key and press Stepper Motor Test.
Stepper
Motor Test
The Busy LED lights up and the stepper motor switches on, continuously raising and
lowering the wiper and the lever mechanism.
3 Press the ALT key when you want to stop the test.
WindowĆSensor Test
1 With the Load Media LED lit, open the window.
The Ready LED should flash.
2 Close the window again.
The Ready LED should stopflashing, and the Load Media LED should light upagain.
8Ć24 Removal and Replacement
C3187Ć90000
Interpreting the Service Configuration Plot
Analyzing the Bar Pattern
The configuration plot has special builtĆin diagnostic features. It includes seven bars printed
along the top that enable you to detect printĆquality 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. Different nozzles are
used to create each of the four bars.
Use a 10X magnifier to look at the patterns. Perfect patterns should be parallel lines equally
spaced. Some slight errors in direction (meaning the ink dots are not being fired straight) are
due to nozzle imperfections and cannot be fixed. Others may be caused by nozzle
contamination. You can sometimes correct these by cleaning the nozzles (' User's Guide).
Fifth and Sixth Bars
Use the fifth and sixth bars to detect
D Banding
D Problems with nozzle firing direction
D Misalignment between the cartridges
In the following two diagrams, F denotes a dot and f denotes a white space.
The fifth bar is a 25% area fill pattern that looks as follows,
FfFfFfFfFfFfF
fffffffffffff
FfFfFfFfFfFfF
The sixth bar is also a 25% area fill pattern that looks as follows:
FfFfFfFfFfFfF
fffffffffffff
fFfFfFfFfFfFf
These bars should look solid gray.
Seventh Bar
Use the seventh bar to detect misalignment between the cartridges.
This bar is a series of vertical lines, 8 pixels apart. The lines should be straight with a
deviation of no more than 2 mils.
C3187Ć90000
Removal and Replacement 8Ć25
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.)
Bench Run (Whether the bench run has been performed or not.)
Bench Run Maximum YĆAxis PWM (YĆaxis = carriage axis.)
Bench Run Maximum XĆAxis PWM (XĆaxis = media axis.)
Encoder Tests Maximum YĆAxis PWM
Encoder Tests Maximum XĆAxis PWM
Last XĆAxis Calibration (XĆaxis calibration = accuracy calibration)
Factory Calibration Factor
(This is the driveĆroller correction factor, calculated during accuracy calibration.)
Setup Sheet LED Calibration formula.
(The values in the formula are calculated during the setupĆsheet calibration.)
Reading the EEROM Text Block
The contents of the EEROM integrated circuit are printed in hexadecimal form in a text
block on the service configuration plot.
To read the EEROM text block, perform the following procedure:
1 Examine the EEROM memory map in Table 8Ć1 to find the memory address of the data
you want to read.
2 Use the memory location key in Table 8Ć2 to locate the position of the memory address on
the service configuration plot.
3 Read the contents of the memory address from the service configuration plot.
Example: Searching for the mediaĆsensor correction factor
1 The EEROM memory map (Table 8Ć1) indicates that the memory address of the
mediaĆsensor correction factor is 1b.
2 The memory location key (Table 8Ć2) indicates that address 1b is located in the second row
from the top, in the fifth column from the right.
3 On the sample EEROM text block(Table 8Ć3), address 1b contains the number 0.
Therefore, in this case, the mediaĆsensor correction factor is hexadecimal 0 (= decimal 0).
8Ć26 Removal and Replacement
C3187Ć90000
Table 8-1. EEROM Map
Definition
Address
Location
00
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
01
02
10
11
15
16
Byte 0 of the total number of bench-run cycles
17
Byte 1 of the total number of bench-run cycles
18
Number of waits per bench-run cycle
19
Number of bail cycles per print in bench run
1a
Number of swaths per bench-run cycle
1b
Media-sensor correction factor. (Calculated during media-sensor calibration)
Bit 1 (MSB) of bail-calibration (00 = not calibrated; 11 = calibrated;
33 (bit 6)
status..
01 and 10 = calibration in process)
33 (bit 7)
36 (bit 7)
37 (bit 0)
39
Bit 0 (LSB) of bail-calibration status.
Need-cartridge-alignment flag. (1 = needs cartridge alignment)
Valid-cartridge-alignment flag. (1 = alignment performed OK)
PWM for carriage LED (calculated during cartridge alignment)
Byte 1 of media-axis alignment distance. (Positions engagement lever.)
Byte 0 of media-axis alignment distance.
3d
3e
Constants at address locations 3F through 4D are loaded
when the cartridge-alignment routine is performed.
3f
Value used to correct position of carriage LED relative to media axis.
Value used to correct position of carriage LED relative to carriage axis.
Cartridge offset. (Used to correct distance between the two cartridges.)
40
41
42
Bi-directional offset in columns. (Used to compensate for differences between ink-drop
trajectory when carriage is moving from left to right and that when carriage is moving
from right to left.)
4b
4d
High-velocity factor, scaled by 64. (Used to adjust the bidirectional offset when the plot
quality is set to draft mode.)
Cartridges’ first nozzles (Not all of the nozzles are used; there may be an overlap
between the two cartridges to allow for alignment. Bits 0 and 1 indicate the first nozzle
used on the right cartridge. Bits 2 and 3 indicate the first nozzle used on the left
cartridge.)
4e
Drive-roller correction factor. (Calculated during accuracy calibration.)
C3187Ć90000
Removal and Replacement 8Ć27
Table 8Ć2 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
numberinstead of the contents at each position on the text block.
Table 8-2. Memory Location Key
EEROM Text Block Memory Locations
0: 00
10: 10
20: 20
30: 30
40: 40
50: 50
60: 60
70: 70
80: 80
90: 90
a0: a0
b0: b0
c0: c0
d0: d0
e0: e0
f0: f0
01
11
21
31
41
51
61
71
81
91
a1
b1
c1
d1
e1
f1
02
12
22
32
42
52
62
72
82
92
a2
b2
c2
d2
e2
f2
03
13
23
33
43
53
63
73
83
93
a3
b3
c3
d3
e3
f3
04
14
24
34
44
54
64
74
84
94
a4
b4
c4
d4
e4
f4
05
15
25
35
45
55
65
75
85
95
a5
b5
c5
d5
e5
f5
06
16
26
36
46
56
66
76
86
96
a6
b6
c6
d6
e6
f6
07
17
27
37
47
57
67
77
87
97
a7
b7
c7
d7
e7
f7
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
08
18
28
38
48
58
68
78
88
98
a8
b8
c8
d8
e8
f8
09
19
29
39
49
59
69
79
89
99
a9
b9
c9
d9
e9
f9
0a
1a
2a
3a
4a
5a
6a
7a
8a
9a
aa
ba
ca
da
ea
fa
0b
1b
2b
3b
4b
5b
6b
7b
8b
9b
ab
bb
cb
db
eb
fb
0c
1c
2c
3c
4c
5c
6c
7c
8c
9c
ac
bc
cc
dc
ec
fc
0d
1d
2d
3d
4d
5d
6d
7d
8d
9d
ad
bd
cd
dd
ed
fd
0e
1e
2e
3e
4e
5e
6e
7e
8e
9e
ae
be
ce
de
ee
fe
0f
1f
2f
3f
4f
5f
6f
7f
8f
9f
af
bf
cf
df
ef
ff
8Ć28 Removal and Replacement
C3187Ć90000
The block of text on the service configuration plot that shows the contents of the
EEROM, appears in the form shown in Table 8Ć3. 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. Sample EEROM Contents Text Block
EEROM contents:
0: 55
aa
0
5a
44
3
0
20
0
0
0
0
a3
0
f2
0
0
0
ff
0
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
2b
0
0
0
0
3a
0
0
0
0
10:
20:
0
3
31
a3
21
25
0
0
0
0
0
0
0
0
0
20
a3
0
a3
0
a3
0
a3
81
9
a3
88
9
a3
35
e0
ed
0
a3
0
a3
0
a3
0
a3
e0
5
a3
fe
0
a3
1d
0
30: a3
40: f2
0
2
27
0
f2
8d
0
e1
57
0
f0
3e
ca
0
0
50:
60:
70:
0
e
0
0
0
1
de
2
d3
c
8e
4
db
39
0
3d
0
ed
0
b
3a
0
16
0
0
0
0
0
0
0
0
0
0
c9
ff
80: ff
90: ff
a0: ff
b0: ff
c0: ff
d0: ff
e0: ff
f0: ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
ff
Clearing the EEROM
Careful: If you clear the EEROM, you will then need to perform all of the plotter
calibrations. (Details ' chapter7.)
Replot
To clear the EEROM, perform the following procedure:
1 Switch the plotter off.
2 While holding both the Cancel and Replot keys down,
switch the plotter on.
Cancel
3 Once the Busy LED lights up, release the Cancel and Replot keys.
C3187Ć90000
Removal and Replacement 8Ć29
Notes
8Ć30 Removal and Replacement
C3187Ć90000
9
Product History and
Service Notes
9Ć1
Introduction
This chapter describes the differences between earlier versions of the plotters and the latest
version documented in this manual.
SerialĆNumber Format
The plotter serial number is composed of 10 letters and digits, for example ESA4800248.
D In thefirst two positions is thecodefor thecountry of manufactureof theplotter. In the
example above, this is ES, which is the code for Spain.
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.
D In thefourth position is thelast digit of theyear of manufacture. This is 4 for plotters
madein 1994, as in theexampleabove.
D In the fifth position is the month of the year. (October is represented by the letter A,
November by B, and December by C.) In the example above, the digit is 8, that is,
August.
D The remaining five digits distinguish the plotter from others manufactured in the same
country in thesamemonth. In theexampleabove, theseare00248.
9Ć2 Product History and Service Notes
C3187Ć90000
Identifying aPrinted 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 nonĆinterchangeable with previously issued PCAs of a particular part
number, a new part number is assigned to the revised PCA.
Revision Letter
This letter identifies the most recent revision to the etched circuit pattern. The original issue
is identified with the letter A. If the master artwork for a printed circuit board is revised in
order to alter performance or manufacture, the revision letter is changed to the next letter in
the alphabetical sequence.
Firmware Revision Code
The firmware revision code is printed on the EPROMs or masked ROMs on the main PCA,
for example B.02.01. This code is also printed by the plotter on the setup sheet and on the
service configuration plot.
The DesignJet 200 old firmware revision A.01.00 is not forward
C A U T I O N
compatible with the new carriage C2847Ć60071 (carriage PCA
C2847Ć60125). In combination they destroy the cartridges.
The DesignJet 200 old main PCA C3180Ć60101 is not forward
compatible with the new shielded trailing cable C3180Ć60033 (colored
blue on one side).
C3187Ć90000
Product History and Service Notes 9Ć3
Potential Ink Smearing Problem
Date:
29 July 1994
Service Note: C3180AĆ01
C3181AĆ01
Supersedes:
Products:
None
HP C3180A DesignJet 200 Drafting Plotter (D/A1 Size)
HP C3181A DesignJet 200 Drafting Plotter (E/A0 size)
Serial Numbers: ESA30000000/ESA3C99999
Parts required: None
Situation:
The mediaĆmotor mount, C1633Ć20006, must be removed to troubleshoot several assemblies
associatedwith the media path of the DesignJet 200.
This service note is intended to describe the printĆquality problem resulting from incorrect
reassembling of this part and to provide a cartridgeĆtoĆroller distance specification for the
DesignJet 200.
Solution/Action:
1) Impact of CartridgeĆtoĆRoller Distance on Print Quality
This distance is a critical parameter that dramatically impacts the print quality of the
DesignJet 200.
The acceptable height range is from 0.9 mm (0.035 in) to 1.3 mm (0.05 in).
Values below the lower limit are likely to cause inkĆsmearing, especially when using A or A4
media sizes.
Values above the upper limit result in ink spraying andoverall poor print quality.
2) How does the MediaĆMotor Mount Affect this Distance ?
If this part is not mountedcorrectly, the drive roller may be assembledslightly higher than
its correct position, thus decreasing the cartridgeĆtoĆroller distance on the right side of the
unit.
9Ć4 Product History and Service Notes
C3187Ć90000
3) How/Where to Measure the Distance
a) Power off the unit.
b) Ensure that the pinchĆarm 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 ofthe carriage is above the right sideplate (see figure 1.c).
e) Carefully try to insert, one at a time, the following gauges below the left cartridge,
(figure 1.b):
* 0.6 mm (0.025 in) - gauge should enter without any effort
* 0.7 mm (0.027 in) - gauge rubs slightly
* 0.8 mm (0.031 in) - gauge may enter but the carriage is lifted when you insert the
gauge.
Ifthe results are as described above, the distance is within specifications
Figure 1
a)
Cartridge
Chute
Cartridge
Front View
c)
b
c
a
d
90
Drive Roller
Surface
Insert the gauges centered
below the left (fixed) cartridge.
b)
Right Side Cover
Carriage
side-view
Gauge
90
d
Ref.
Description
specs (mm)
0.9 to 1.3
a
b
c
nozzle platen to roller
Drive Roller
side-view
0.2
glue bed to platen
glue bed to roller
0.7 to 1.1
C3187Ć90000
Product History and Service Notes 9Ć5
4) What to Do with Units Exhibiting InkĆSmearing Problems
If the unit is exhibiting an inkĆsmearing problem using HPĆrecommended 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.
ii) If both cartridges are okay, do the following:
a) Verify the carriageĆtoĆroller height as in (3) above:
* If within specs refer to note below.
* If out of specs continue the procedure.
b) Remove the right endĆcover
c) Remove the carriage and media motors from their support.
d) Loosen (one turn) the three screws holding the mediaĆmotor mount in place.
e) Retighten them while applying a downward pressure as shown in the figure 2.
Apply pressure while
tightening screws 1, 2 & 3
Figure 2
3
1
2
f) Check the carriage height as in (3) above.
g) If the value is within specs, reassemble the unit. If still out of specs redo steps (b) to (f).
h) Verify proper operation of the unit by plotting a demo plot on A/A4Ćsize media.
Note: This procedure is intended to troubleshoot only those inkĆsmearing problems caused
by incorrect cartridgeĆtoĆroller distance. Make sure that proper humidity conditions are met
and also check for mediaĆrelated factors that may influence this distance (for example
wetĆcockle effect).
Administrative Information
Classification: Information Only
Author/Entity: PP/F900
9Ć6 Product History and Service Notes
C3187Ć90000
Problems Corrected by Firmware Release A.01.01
Date:
29 July 1994
Service Note:
C3180AĆ02
C3181AĆ02
Supersedes:
Products:
None
HP C3180A DesignJet 200 Drafting Plotter (D/A1 size)
HP C3181A DesignJet 200 Drafting Plotter (E/A0 size)
Serial Numbers: ESA30000000/ESA3C99999
To be performed by: HPĆQualified Personnel
Parts required:
Situation:
C3180Ć18006 A.01.01 EPROM (U28)
C3180Ć18007 A.01.01 EPROM (U29)
C3180Ć18008 A.01.01 EPROM (U9)
C3180Ć18009 A.01.01 EPROM (U4)
Firmware version A.01.00 of the DesignJet 200 exhibits the following problems:
1) The unit is not able to load 1.6 m cutĆsheet media.
2) In the absence on an IN command in the plot files, the resulting line widths are not
consistent with the selected values.
3) Carriage startĆup pulses may damage the print cartridges causing early cartridge failures.
Solution/Action:
Whenever a unit exhibits a problem as described above, replace firmware version A.01.00 by
firmware version A.01.01.
Production units may have the A.01.00 code implemented in two different sets of devices:
1) EPROM/OTP devices:
P/Ns:
1818Ć5724 A.01.00 (U28)
1818Ć5725 A.01.00 (U29)
1818Ć5726 A.01.00 (U9)
1818Ć5727 A.01.00 (U4)
2) Mask ROM devices:
P/Ns:
1818Ć5484 A.01.00 (U28) Mask
1818Ć5485 A.01.00 (U29) Mask
C3187Ć90000
Product History and Service Notes 9Ć7
All the part numbers associated with both A.01.00 implementations are obsoleted and
replaced by A.01.01 part numbers.
Usage of a DIPĆ40 ICĆextracting tool or similar is highly recommended to prevent damage to
the Main PCA traces.
Note that firmware version A.01.01 is available only on EPROMs. Make sure that proper
ESD safety procedures are followed and that the devices are correctly plugged into their
sockets, leaving the rightmost pair of holes free.
Administrative Information
Classification: Modification recommended
Standards: Labor hours 0.5, Travel authorized
Action Category: On specified failure
Location Category: OnĆsite
Service Inventory: Scrap
Used Parts: Scrap
HP Responsible Until: 15ĆJuneĆ96
Author/Entity: PP/F900
Problems that will be Corrected by Firmware Release A.01.02
Date:
29 July 1994
Bug Fixing
RTL: Fix bitmap on negative YĆcoordinates. (Jail effect)
STARSHIP: PJL enter language = HPGL/2 was going back to HPGL; now goes to HPGL/2.
REPLOT: Replot clips last swath. When doing replot (same size as the original plot),
sometimes the last swath of the plot is clipped. This is because the mediaĆload sheet length
measurement is not exact, so the plotter recognizes the sheet as shorter than it actually is.
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 nonĆflowĆmode plots (plots that don't exceed maximum
memory available in plotter). Fixed.
This firmware is not yet available at the time of printing of this manual.
9Ć8 Product History and Service Notes
C3187Ć90000
EPROMs andMaskedROMs
The DesignJet 200 oldfirmware revision A.01.00 is not forward
C A U T I O N
compatible with the new carriage C2847Ć60071 (carriage PCA
C2847Ć60125). In combination they destroy the cartridges.
DesignJet 200 EPROMs
DesignJet 200 MaskedROMs
(Firmware code A.01.00, obsolete)
(Firmware code A.01.00, obsolete)
1818Ć5724
cd: 1
1818Ć5725
cd: 2
1818Ć5484
cd: 0
1818Ć5485
cd: 1
U28
U9
U28
U9
U29
U4
U29
U4
1818Ć5727
cd: 4
1818Ć5726
cd: 3
Empty
Empty
DesignJet 200 EPROMs
(Firmware code A.01.01)
C3180Ć18006
C3180Ć18007
cd: 8
U28
U29
U4
cd: 7
C3180Ć18009
cd: 0
C3180Ć18008
cd: 9
U9
DesignJet 220 EPROMs
(Firmware code B.02.00, obsolete)
DesignJet 220 MaskedROMs
(Firmware code B.02.00, obsolete)
C3187Ć18014
cd: 4
C3187Ć18015
cd: 5
1818Ć5971
cd: 0
1818Ć5972
cd: 1
U28
U9
U28
U9
U29
U4
U29
U4
C3187Ć18017
cd: 7
C3187Ć18016
cd: 6
Empty
Empty
DesignJet 220 MaskedROMs
(Firmware code B.02.01)
1818Ć6016
cd: 6
1818Ć6017
cd: 7
U28
U9
U29
U4
Empty
Empty
C3187Ć90000
Product History and Service Notes 9Ć9
ReĆinstalling Teflon Washers
Normally, you should not have to reĆinstall teflon washers on a DesignJet 200. Instead, you
should install a camĆgear 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.
Problems can occur if the bailĆlift mechanism is too loose or too tight. Typically the number
of teflon washers to install is two. However, the ideal reassembly procedure is as follows:
1 ReĆinstall the lift mechanism using two washers.
2 With the engagingĆlever spring installed, press down on the lever and slowly let it rise.
3 If the lever does not completely lift up using the spring tension alone, remove one washer.
Teflon
Washers
9Ć10 Product History and Service Notes
C3187Ć90000
New BailĆLiftĆMechanism Support
Date:
01 August 1994
Service Note:
Draft
Supersedes:
Products:
None
HP DesignJet 200 C3180A & C3181A
Serial Numbers:
C3180A ESA0000000/ESA4507951
C3181A ESA0000000/ESA4508541
To Be Performed By: HPĆQualified Personnel
Parts Required: C2858Ć60209 Bail Mechanism Assembly
Situation:
The bail features an automatic lift mechanism driven by the media motor using a series of
gears and actuated by the carriage. The lift mechanism is composed of the engagement lever,
cam gear, engagement gear, autoĆcam and teflon washers.
When it is necessary to lift the bail, the carriage positions itself over the engaging lever,
pressing it down (the lever is spring loaded). As the lever is pressed down, the gear cam and
the engaging gear are connected to the left drive roller gear. Once connected, the driver
roller rotates (via the MediaĆdrive motor), causing the cam to rotate. As the cam rotates, it
pushes against the left bail pivot, raising the bail.
The teflon washers are installed between the autoĆcam and the sideĆplate to act as shims
which reduce looseness between the different parts of the assembly. 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.
Solution
A new solution has been introduced in order to improve the serviceability of the bailĆlift
mechanism and which avoids the use of teflon washers. The looseness of the mechanism is
reduced by a new part, the camĆgear support. This part attaches to the YĆtensioner bracket
and fits into the center of the cam gear preventing the movement of this gear during the
engaging process.
A new liftĆmechanism kit has been created that includes all the necessary parts to implement
this new solution. The part number of the kit is C2858Ć60209. It is expected to be available
at the beginning of September 1994.
C3187Ć90000
Product History and Service Notes 9Ć11
Installing the New BailĆLift Mechanism
YĆtensioner bracket
CamĆgear support
Engaging lever
EngagingĆlever 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 endĆcover.
2. Remove the the bail assembly, the encoder strip and the service station.
3. Remove the primer assembly.
4. Remove the YĆtensioner bracket and related assemblies.
5. Using scissors or a cutter, cut the teflon washers.
6. Using needleĆnose pliers, remove the teflon washers.
IMPORTANT: Ensure that you have removed all the teflon washers and that you are not
leaving any fragment between the sideĆplate and the autoĆcam.
If you are not able to remove them, perform the following additional steps:
a. Disassemble the plotter to access the automatic bailĆlift mechanism following the
procedure described in chapter 6.
b. ReĆinstall the bailĆlift mechanism WITHOUT the teflon washers.
7. Place the camĆgear support into the slot on the NEW YĆtensioner bracket included in the
bailĆmechanism assembly.
8. Install the YĆtensioner bracket on the left sideplate. Tighten the two left screws and leave
the right one loose.
9Ć12 Product History and Service Notes
C3187Ć90000
9. While softly pushing the camĆgear support all the way into the center of the gear, tighten
the two screws that attach the camĆgear support to the YĆtensioner bracket.
IMPORTANT: Ensure that the bailĆlift mechanism easily performs the engaging and
disengaging movement, by pushing the cam gear with your fingers.
10. Tighten the right screw of the YĆtensioner bracket.
11.ĆReĆassemble the plotter and perform the calibrations in the following order:
a. Cap alignment (chapter 9)
b. Bail calibration (chapter 8)
c. Accuracy calibration (chapter 8)
Administrative Information DRAFT SERVICE NOTE
Classification: Modification available
Reason: Serviceability & Reliability Enhancement
Action Category:
Location Category: OnĆSite
Availability: Product Support Life
Author/Entity: EV/F900
Change in Trailing Cable
Early DesignJet 200 plotters were manufactured with the following trailing cable and
associated parts:
D Unshielded Trailing Cable, C3180Ć60007 (colored white on both sides)
D TrailingĆCable Rear Tray, C3180Ć00006
D Four Ferrites, 9170Ć1535
(two inside electronics enclosure, two on trailingĆcable rear tray)
D Four Ferrite Clamps, 9170Ć1533
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 trailingĆcable rear tray:
D Shielded Trailing Cable, C3180Ć60033 (colored white on one side, blue on the other side)
D TrailingĆCable Rear Tray, C3180Ć00040
D Two Ferrites, 9170Ć1535, inside the electronics enclosure
D Two Ferrite Clamps, 9170Ć1533
The shielded trailing cable is NOT compatible with old main PCAs (C3180Ć60101,
C3180Ć68101, C3180Ć69101).
C3187Ć90000
Product History and Service Notes 9Ć13
Change in Carriage
Early DesignJet 200 plotters were manufactured with the following cartridge carriage:
D Cartridge Carriage, C1633Ć60120 (including Carriage PCA, C2847Ć60103), now obsolete.
Later DesignJet 200 plotters, and DesignJet 220 plotters, have a new cartridge carriage:
D Cartridge Carriage, C2847Ć60071 (including Carriage PCA, C2847Ć60125).
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.
Later firmware revisions can be installed with either carriage.
Change in Bail and Overdrive Parts
DesignJet 200 plotters, and early DesignJet 220 plotters, were manufactured with 9
starwheel mounts on D/A1Ćsize models, and 13 starwheel mounts on E/A0Ćsize models.
To reduce the risk of the mediaĆpath geometry sometimes causing media to cockle and ink to
smear, later DesignJet 220 plotters include an extra starwheel mount towards the rightĆhand
side of the bail. (The problem was greatest when loading A/A4Ćsize media.)
If you are ordering a new bail, overdrive roller or overdrive enclosure, ensure that you order
the appropriate part corresponding with the number of starwheel mounts on the plotter. A
service rework kit is available if you need to replace all 9Ć or 13ĆstarwheelĆmount parts with
10Ć or 14ĆstarwheelĆmount parts respectively. (Part numbers ' page 10Ć24b.)
9Ć14 Product History and Service Notes
C3187Ć90000
10
Parts and Diagrams
10Ć1
Exchange Assemblies
Exchange assemblies are factoryĆrepaired and tested assemblies that you can order; they are
listed in the following table. Exchange assemblies are available only on a tradeĆin basis;
therefore, you must return the defective assemblies for credit.
Exchange Assemblies
HP Part Number
C3180-69102
CD
1
Qty
Description
1
Main PCA (Rebuilt)
10Ć2 Parts and Diagrams
C3187Ć90000
Replacement Parts
Parts shown in the drawings in this chapter are listed in the corresponding part lists. Match
the appropriate number on the drawing with the same number in the parts list for
information on that part. 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.
C3187Ć90000
Parts and Diagrams 10Ć3
Parts List: Legs and Media Bin
Reference HP Part Number Check Quantity
on
Digit
Description
Drawing
1
C2847-60002
C2848-60002
C3185-00034
C3186-00034
C2847-60061
1492-0145
6
7
9
0
7
8
4
2
2
0
3
9
2
2
1
1
1
4
1
1
1
1
1
1
4
Leg Assembly
Stand Brace
(D/A1 Size)
(E/A0 Size)
(D/A1 Size)
(E/A0 Size)
2
3
4
5
Hardware Kit
Caster Assembly
Media Bin Front
C2847-00006
C1633-00020
C2847-00012
C1633-00044
C2847-00005
C1633-00019
no part number
(D/A1 Size)
(E/A0 Size)
(D/A1 Size)
(E/A0 Size)
(D/A1 Size)
(E/A0 Size)
6
7
8
Media Bin Adjust
Media Bin Back
M3 Thread-Forming Screw
Complete Legs and Media Bin
Part NumberC3185A = Complete legs and media bin forD/A1Ćsize plotters.
Part NumberC3186A = Complete legs and media bin forE/A0Ćsize plotters.
10Ć4 Parts and Diagrams
C3187Ć90000
1
2
3
3
3
1
8
7
3
4
3
3
3
6
8
5
4
3
Legs and Media Bin
C3187Ć90000
Parts and Diagrams 10Ć5
Parts List: Window, Center and Bottom Covers
Reference HP Part Number Check Quantity
on
Digit
Description
Drawing
1
2
C3180-00005
C3181-00005
0515-0380
9
0
2
1
1
2
4
2
2
1
1
2
4
1
Center Cover
Screw
(D/A1 Size)
(E/A0 Size)
(D/A1 Size)
(E/A0 Size)
3 and 4 C3180-40019
9
3
5
6
1
Center-Cover Latch Assembly
Window-Pivot Spring
Window
5
6
C3180-80001
C3180-60039
C3181-60039
0515-2278
(D/A1 Size)
(E/A0 Size)
(D/A1 Size)
(E/A0 Size)
7
8
Screw
C3180-60033
9
Shielded Trailing Cable
D Not compatible with main PCAs:
C3180-60101, C3180-68101, C3180-69101.
D DesignJet 200 ' chapter 9.
C3180-60064
C3180-00040
6
2
Shielded Trailing-Cable Assembly.
(Includes shielded trailing cable, three plastic ties,
and trailing-cable bracket.)
9
1
Trailing-Cable Rear Tray.
(DesignJet 200 ' chapter 9.)
10
11
12
13
14
1400-0577
7
5
5
5
8
9
6
2
1
Trailing-Cable Tie
Trailing-Cable Bracket
Torx-10 Screw
C1633-00015
0624-0647
1
0515-2248
6
Torx-20 Screw
C3180-60008
C3181-60008
0624-0771
1
Bottom Cover
(D/A1 Size)
(E/A0 Size)
(D/A1 Size)
(E/A0 Size)
1
15
8
Plastite Screw
10
10Ć6 Parts and Diagrams
C3187Ć90000
To Carriage
Window, Center and
Bottom Covers.
C3187Ć90000
Parts and Diagrams 10Ć7
Parts List: Electronics Enclosure
Reference HP Part Number Check Quantity
on
Digit
Description
Drawing
1
1
2
3
4
C3180-68102
C3180-69102
0515-2253
See illustration
C2064A
9
1
2
1
Main PCA (New)
Main PCA (Rebuilt, Exchange Assembly)
Machine Screw
11
4 / 2
4 EPROMs or 2 Masked ROMs
DRAM SIMM (Optional)
3
4
5
2
2
7
8
(2 Mbytes)
(4 Mbytes)
(8 Mbytes)
C2065A
C2066A
5
6
7
2200-0145
0570-1316
C3180-00003
C3181-00003
2
2
1
1
Machine Screw, 4-40
Female Screwlock (RS-232)
Electronics Enclosure
(D/A1 Size)
(E/A0 Size)
(Associated part: 8160-0770 RFI strip, attaches to the
enclosure to improve electromagnetic compatibility of
the plotter.)
8
1400-1648
5
7
6
2
6
5
1
9
5
8
9
4
1
1
2
1
1
4
1
1
1
1
1
4
5
2
1
2
Cable Clip
9
3160-0814
Tubeaxial Fan
10
11
12
13
14
15
16
17
0515-2405
Tapite Fan Screw
0950-2417
Power Supply
C3180-60006
0515-2149
AC Power Receptacle Assembly
Screw, M3.0X0.5X8
0515-2278
Torx-20 Screw
C2847-60005
C3180-60013
C3180-00004
C3181-00004
0515-2429
Cable Assembly: Power supply to main PCA
Power Supply Insulator (with label and tie)
Electronics-enclosure Cover
(D/A1 Size)
(E/A0 Size)
(D/A1 Size)
(E/A0 Size)
18
Torx-15 Screw
19
20
21
9170-1533
6
8
Ferrite Clamp
Trailing Cable
Split Ferrite
See page 10-6.
9170-1535
10Ć8 Parts and Diagrams
C3187Ć90000
5
6
1
7
2
3
8
4
9
13
20
19
11
10
15
13
21
2
12
16
14
17
18
DesignJet 200 EPROMs
(Firmware code A.01.01)
3
DesignJet 220 Masked ROMs
(Firmware code B.02.01)
3
C3180-18006
cd: 7
C3180-18007
cd: 8
1818-6016
cd: 6
1818-6017
cd: 7
U29
U4
U28
U9
U28
U9
U29
U4
C3180-18008
cd: 9
C3180-18009
cd: 0
Empty
Empty
Empty pair of holes
Electronics Enclosure
C3187Ć90000
Parts and Diagrams 10Ć9
Parts List: Left Endcover and Trim
Reference HP Part Number Check Quantity
on
Digit
Description
Drawing
1
2
C3180-40003
C3187-00015
C3180-40005
0624-0771
1
8
3
6
6
7
2
0
6
6
3
1
1
1
4
1
1
1
1
1
1
3
Left Endcover
Serial-Number Label
Rear Left Trim
3
4
Torx-15 Screw
5
C3180-00010
0515-2282
Nameplate
6
Tapite Screw
7
C3180-40012
5041-1203
Switch Mount
9
Power Key Cap
10
11
12
C3180-60006
C3180-40008
0515-2337
AC Power Receptacle Assembly
Front Left Trim
Endcover Lower Screw
10Ć10 Parts and Diagrams
C3187Ć90000
Left Endcover and Trim
C3187Ć90000
Parts and Diagrams 10Ć11
Parts List: Right Endcover and Trim
Reference HP Part Number Check Quantity
on
Digit
Description
Drawing
1
2
0624-0771
6
4
4
1
–
4
5
9
4
2
4
7
5
2
6
4
1
1
1
1
2
1
Torx-15 Screw
C3180-40006
1400-0293
Rear Right Trim
3
Cable Guide (Fastener)
Torx-20 Screw
4
0515-2278
5
–
Right Sideplate (Not Orderable)
Shoulder Washer
6
07090-20020
C3180-40007
C3180-60009
0624-0745
7
Front Right Trim
8
Window-Sensor Assembly
Torx-8 Screw
9
1
1
1
2
1
1
1
1
1
10
11
12
13
14
15
C3180-40004
C3180-40014
0515-2282
Right Endcover
Front-Panel Bezel
Tapite Screw
C3180-40015
C3180-60010
C3180-40016
Front-panel Door
Keyboard Assembly
Help-Cards Lock
16 and 17 see below
18 C3180-00033
Overlay and Help Cards
Media-Load Label
3
Front-Panel Overlay and Help Cards
DesignJet 200
Check DesignJet 220
Check
Chinese
English
French
C3180-60030
C3180-60021
C3180-60025
C3180-60024
C3180-60027
C3180-60028
C3180-60022
C3180-60029
C3180-60026
C3180-60023
6
5
9
8
1
2
6
3
0
7
C3187-60010
C3187-60001
C3187-60005
C3187-60004
C3187-60007
C3187-60008
C3187-60002
C3187-60009
C3187-60006
C3187-60003
9
8
2
1
4
5
9
6
3
0
German
Italian
Japanese
Korean
Portuguese
Spanish
Taiwanese
10Ć12 Parts and Diagrams
C3187Ć90000
Right Endcover and Trim
C3187Ć90000
Parts and Diagrams 10Ć13
Parts List: CarriageĆAxis Drive (Left End)
Reference HP Part Number Check Quantity
on
Digit
Description
Drawing
1
C2847-00029
1500-0856
1
7
1
9
7
9
2
8
4
4
5
9
8
4
5
3
5
5
3
6
1
1
1
1
1
1
4
1
1
1
3
1
3
1
1
1
2
1
1
1
Main Drive Belt
(D/A1 Size)
(E/A0 Size)
2
3
4
5
6
7
8
07570-60105
07570-40105
1460-2139
Main Idler Assembly
Main Tensioner
Tensioner Spring
C1633-40065
0515-0380
Main-Tensioner Housing
Torx-15 Screw
C1633-00068
C2847-00014
C1633-00056
0515-2248
Tensioner-Housing Door
Trailing-Cable Front Tray (Guide)
(D/A1 Size)
(E/A0 Size)
9
Torx-20 Screw
10
11
12
13
14
15
16
17
18
C2847-00051
1400-1021
Y-Tensioner Bracket
Cable Clip
C1633-80016
C1633-20021
C1633-60033
0624-0647
Linkage Spring
Shoulder Screw
Automatic Cartridge-Adjust Linkage
Torx-10 Screw
C3180-60005
3050-1415
Stepper Motor Assembly
Washer
C3180-60014
Wiper Assembly
(Wiper, Wiper Rod, and Rocker)
19
20
21
C1633-40006
C1633-40093
C2858-60208
C2859-60208
3050-0026
8
3
7
8
0
2
1
1
1
1
3
2
Wiper Only
Encoder-Strip Bracket
Encoder Strip
(D/A1 Size)
(E/A0 Size)
22
23
Washer 3.2mm
0535-0031
Nut, Hex, W/LKWR M3
10Ć14 Parts and Diagrams
C3187Ć90000
Carriage-Axis Drive
(Left End)
C3187Ć90000
Parts and Diagrams 10Ć15
Parts List: Service Station
Reference HP Part Number Check Quantity
on
Digit
Description
Drawing
1
2
3
4
5
6
7
0624-0704
5
5
7
3
8
6
5
12
1
Plastite Screw #6-19x.375
C1633-40003
C1633-40005
C1633-40001
C1633-80002
C1633-40004
C2847-40011
Service-Station Cover
Service-Station Cap
Service-Station Housing
Sled Spring
2
1
1
2
Cap Fitting
1
Service-Station Sled
10Ć16 Parts and Diagrams
C3187Ć90000
1
2
3
3
7
6
6
5
4
Service Station
C3187Ć90000
Parts and Diagrams 10Ć17
Parts List: CarriageĆAxis Drive (Right End)
Reference HP Part Number Check Quantity
Drawing
Digit
Description
1
2
see page 10-21
C2847-00029
1500-0856
1
1
1
1
1
1
4
1
1
3
1
1
1
1
1
1
1
3
2
1
1
1
4
1
1
Cartridge Carriage
Main Drive Belt
1
7
(D/A1 Size)
(E/A0 Size)
3
4
see page 10-14
9170-1536
Trailing-Cable Front Tray
Ferrite Ring
9
9
2
0
4
4
5
8
7
7
0
7
8
0
2
0
6
7
5
5
7
5
C1633-80003
0515-0380
Blade Spring
6
Torx-15 Screw
7
07570-60112
07550-40104
1460-2061
Drive-Pulley Idler
Drive-Tensioner Cam
Drive-Tensioner Spring
M3 Machine Screw
Drive-Tensioner Bracket
Encoder-Spring Bracket
Y-Drive-Assembly Bracket
Encoder Spring
8
9
10
11
12
13
14
15
0515-1349
07575-40125
C1633-00132
C1633-60029
C1633-00002
C2858-60208
C2859-60208
3050-0026
Encoder Strip
(D/A1 Size)
(E/A0 Size)
16
17
18
19
20
21
22
23
24
25
26
Washer 3.2mm
0535-0031
Nut, Hex, W/LKWR M3
Double-Pulley Bushing
Carriage-Axis Small Drive Belt
Double Pulley
C1633-20034
1500-0855
C3170-60009
0515-2248
Y-Arm Screw
C2858-60206
1400-0577
Carriage Motor (includes item 26)
Cable Tie
See table opposite
3050-1415
Ferrite Assemblies
Washer
3
6
1
2
0515-0433
Screw, M4.0 X 0.7 X 8 mm
10Ć18 Parts and Diagrams
C3187Ć90000
Carriage Axis Drive
(Right End).
Reference 24: Ferrite Assemblies
HP Part Number
Check
Quantity
Description
Digit
9170-1400
9170-1594
9170-1593
9170-1596
9170-1595
0515-2299
6
9
8
1
0
6
1
2
4
1
2
3
Flat Ferrite
Large Ferrite
Small Ferrite
Large-Ferrite Holder
Small-Ferrite Holder
Holder Screw
C3187Ć90000
Parts and Diagrams 10Ć19
Parts List: Carriage Assembly
Reference HP Part Number Check Quantity
on
Digit
Description
Drawing
C2847-60071
9
1
Cartridge Carriage (Not compatible with plotter
firmware version A.01.00.)
Includes all items below except items 9, 10, and 13.
1
2
0624-0704
5
4
1
1
1
4
7
5
7
2
0
5
1
7
4
3
1
4
6
0
1
1
1
1
1
2
1
5
1
1
2
1
1
1
1
1
2
10
1
2
Plastite Screw #6-19x.375
Washer 5.1mm
2190-0760
3
C1633-80013
C1633-00079
C1633-40009
1460-2061
Cam Preload Spring
Act Cam Washer
4
5
Cartridge-Adjust Cam
Cartridge-Adjust Tensioner Spring
Cam Base
6
7
C1633-40055
0624-0647
8
Tapping Screw 4-20
Rear Bushing
9
C3180-40025
C1633-80014
C1633-40066
1990-1615
10
11
12
13
Carriage Spring
Front Bushing
Hi-Intensity Red Led
C2847-00029
1500-0856
Main Drive Belt
(D/A1 Size)
(E/A0 Size)
14
15
16
17
18
19
07575-40014
07575-40013
1000-0909
Right Belt Clamp
Left Belt Clamp
Lens
0624-0745
Plastite Screw 2-28x0.375
Line-Detect Cover
C1633-40070
C2847-60204
Cartridge Chute
(also called carriage snap)
20
21
C1633-00104
C1633-00107
3
6
1
3
Carriage Warning Label
Carriage Striped Label
10Ć20 Parts and Diagrams
C3187Ć90000
1
2
3
4
5
6
6
8
7
9
8
11
10
*
20
16
21
12
17
11
19
18
15
17
14
13
Carriage Assembly
C3187Ć90000
Parts and Diagrams 10Ć21
Parts List: Media Drive Assemblies
Reference HP Part Number Check Quantity
on
Digit
Description
Drawing
1
2
C3180-00002
C3181-00002
6
7
1
1
Entry Platen
(D/A1 Size)
(E/A0 Size)
Drive-Roller Assembly
C2858-60054
C2859-60004
C3180-40010
C3180-40011
0515-2337
1
2
0
1
3
1
1
7
5
(D/A1 Size)
(E/A0 Size)
3
4
5
6
7
8
9
1
1
4
1
1
1
1
Secondary Lever
Media-Sensor Holder
Torx-15 Screw
C3180-60001
0515-2278
Media-Sensor Assembly
Torx-20 Screw
C1633-00009
C2847-60019
Axial Bias Plate
Media-Axis Encoder Cable
Assembly
10
C2848-60003
8
1
Media Motor Assembly
(includes item 15)
11
12
13
14
15
16
17
0515-2248
5
8
6
4
5
5
7
4
1
1
4
1
2
1
Torx-20 Screw
1400-1021
Cable Clip
C1633-20006
0515-0382
Media-Motor Mount
Torx-15 Screw
C2847-20013
0515-1349
Helical Gear (Drive-Roller Gear)
Torx-10 Screw
C3180-40009
Edge-Measuring Lever
10Ć22 Parts and Diagrams
C3187Ć90000
Media Drive Assemblies
C3187Ć90000
Parts and Diagrams 10Ć23
(Parts List: Bail and Overdrive Assemblies ' pages 10Ć24a and 10Ć24b)
10Ć24 Parts and Diagrams
C3187Ć90000
Parts List: Bail and Overdrive Assemblies
Reference HP Part Number Check Quantity
on
Digit
Description
Drawing
1
2
0624-0647
5
0
4
3
7
2
2
0
6
5
3
3
3
9
4
3
3
1
2
5
6
4
1
3
1
1
0
1
1
1
1
5
1
1
2
1
1
5
1
1
1
14
1
Torx-10 Screw
Washer 3.2 mm
Cam Gear
3050-0026
3
C1633-40028
C1633-40027
C2847-40013
C1633-80006
0510-0083
4
Engaging-Lever Gear
Engaging Lever
5
6
Engaging-Lever Spring
Ring Retainer, 0.25 Diameter
Overdrive Gear Assembly (Includes item 7)
Sideplate Bushing
7
8
C1633-60030
C3180-40024
C1633-20021
C1633-40019
3050-1415
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Shoulder Screw
Overdrive Gear Cluster
Washer
0515-2337
Torx-15 Screw
C2847-00051
C1633-40052
0624-0520
Y-Tensioner Bracket
Auto Cam
Screw 6-19 0.50
C3180-40013
0515-2278
Bail-Switch Holder
Torx-20 Screw
C3180-60002
0624-0704
Bail-Switch Assembly
Plastite Screw #6-19x.375
Left Bail Bracket
C1633-40038
C1633-60034
9 or 10 Starwheel Mount Assembly
13 or 14
(D/A1 Size)
(E/A0 Size)
C3187Ć90000
Parts and Diagrams 10Ć24a
Reference HP Part Number Check Quantity
on Drawing
Digit
Description
23
1
Bail (Includes items 20, 21, 22, 23, 24)
C3180-60017
C3180-60065
C3181-60017
C3181-60065
C1633-40037
0624-0400
9
7
6
8
5
8
with 9 starwheel mounts (D/A1 Size)
with 10 starwheel mounts (D/A1 Size)
with 13 starwheel mounts (E/A0 Size)
with 14 starwheel mounts (E/A0 Size)
24
25
1
4
6
1
Right Bail Bracket
Screw, Pozidriv 2
(D/A1 Size)
(E/A0 Size)
26
Overdrive Roller
C3180-60004
C3180-60035
C3181-60004
C3181-60035
4
1
5
2
for 9 starwheel mounts (D/A1 Size)
for 10 starwheel mounts (D/A1 Size)
for 13 starwheel mounts (E/A0 Size)
for 14 starwheel mounts (E/A0 Size)
Overdrive Enclosure (includes items 25, 27, 29)
for 9 starwheel mounts (D/A1 Size)
27
C3180-60015
C3180-60061
C3181-60015
C3181-60061
C3180-40002
7
3
8
4
0
1
1
1
1
2
3
2
2
1
2
1
1
for 10 starwheel mounts (D/A1 Size)
for 13 starwheel mounts (E/A0 Size)
for 14 starwheel mounts (E/A0 Size)
28
29
Overdrive Bushing
(D/A1 Size)
(E/A0 Size)
(D/A1 Size)
(E/A0 Size)
C3180-40018
C3181-40018
0515-2248
8
9
5
7
9
8
Media Guide
30
31
32
33
Torx-20 Screw
C3180-20001
C2847-40015
C2858-60209
Alignment Screw
Cam-Gear Support
Bail-lift-mechanism rework assembly ' chapter 9.
(includes items 1, 2, 3, 4, 5, 6, 14, 15, 16, 20, 32)
34
1
Overdrive and bail rework kit ' chapter 9.
(includes items 20, 21, 22, 23, 24, 25, 26, 27, 29)
C3180-60062
C3181-60062
4
5
for 10 starwheel mounts (D/A1 Size)
for 14 starwheel mounts (E/A0 Size)
10Ć24b Parts and Diagrams
C3187Ć90000
Bail and Overdrive
Assemblies
C3187Ć90000
Parts and Diagrams 10Ć25
Parts List: PinchĆArm Assembly
Reference HP Part Number Check Quantity
on
Digit
Description
Drawing
1
2
3
4
0515-1992
4
3
5
5
4
9
2
2
2
1
1
4
6
4
6
4
6
21
1
1
1
1
1
11
1
1
1
1
1
1
1
1
Torx-9 Screw
Cam Journal
C3190-40053
0535-0026
Hex Nut, DBL-CHAM
Pinch-Arm Bar Cam
C2847-20005
C1633-20012
C1633-60039
(D/A1 Size)
(E/A0 Size)
(D/A1 Size)
(E/A0 Size)
(D/A1 Size)
(E/A0 Size)
(D/A1 Size)
(E/A0 Size)
5
6
7
Pinch-Arm Assembly
Pinch-Arm Spring
Pinch-Arm Bushing
C1633-80005
C1633-40082
1
0
8
0515-0380
2
9
8
5
3
5
5
0
7
7
4
2
3
7
7
Torx-15 Screw
9
C1633-00100
C1633-00076
C1633-40079
C1633-80007
C1633-20021
0624-0647
Media Director
10
11
12
13
14
15
16
17
18
19
20
21
22
Rear Wire Link
Rocker Plate
Rocker Spring
Torx-15 Shoulder Screw
Torx-10 Screw
C3180-60034
C1633-00075
0515-2414
Pinch-Arm Sensor
Front Wire Link
Pinch-Arm-Lever Screw
Washer 5.1mm
2190-0760
C3180-40020
3050-1415
Pinch-Arm-Lever Cam
Shoulder Washer
Pinch-Arm Lever (Media-Jam Lever)
Media Diverter
C3180-40017
C1633-00059
10Ć26 Parts and Diagrams
C3187Ć90000
Pinch-Arm Assembly
C3187Ć90000
Parts and Diagrams 10Ć27
Accessories
Description
HP Part Number
Unpacking Instructions
Until 30 Sept 1994: C3180-90020 (' chapter 3)
From 01 Oct 1994: C2847-90030 (new packaging)
From 01 Oct 1994: C2847-90032 (new packaging)
C3180-60016 (D/A1 size)
Repacking Instructions
Repackaging Kit
C3181-60016 (E/A0 size)
User’s Guide
Chinese
English
DesignJet 200
C3180-90010
C3180-90001
C3180-90005
C3180-90004
C3180-90007
C3180-90008
C3180-90002
C3180-90009
C3180-90006
C3180-90003
DesignJet 220
C3187-90010
C3187-90001
C3187-90005
C3187-90004
C3187-90007
C3187-90008
C3187-90002
C3187-90009
C3187-90006
C3187-90003
French
German
Italian
Japanese
Korean
Portuguese
Spanish
Taiwanese
AutoCAD Driver, 3.5-inch Disk
+ Documentation
Chinese
English
French
C3187-60060
C3187-60051
C3187-60055
C3187-60054
C3187-60057
C3187-60052
C3187-60056
C3187-60053
German
Italian
Korean
Spanish
Taiwanese
10Ć28 Parts and Diagrams
C3187Ć90000
Description
HP Part Number
Windows Driver, 3.5-inch Disk + Documentation
English
French
C3187-60031
C3187-60035
C3187-60034
C3187-60037
C3187-60081
C3187-60036
German
Italian
Japanese
Spanish
HP CAD Plotters Software/Hardware Guide
Europe
5963-0997LE
5963-0998E
C3187-90080
51626A
Elsewhere
Software Application Notes
Print Cartridge
Supplies Source (booklet)
USA
5091-7378EUS
5091-7690E
Elsewhere
Supplies Source Update
USA
5091-9802EUS
5091-9799E
Elsewhere
Upgrade Kit (DesignJet 200 to DesignJet 220)
includes User’s Guide, Drivers, Help Cards, Overlay and:
Upgrade Instructions
C3189A
C3187-90028
C3187-00011
C3189-00001
C3189-60001
Nameplate
Upgrade Label
ROM Memory Kit
Plug-In Memory (DRAM SIMM)
2-Mbyte SIMM
C2064A
C2065A
C2066A
4-Mbyte SIMM
8-Mbyte SIMM
HP JetDirect EX, External Network Interface
Ethernet
J2382B
J2383B
Token Ring
C3187Ć90000
Parts and Diagrams 10Ć29
Line Cord Set
The power cord supplied with the plotter should meet the plugrequirements for the area.
However, different power cords (international options) are available (see followingtable).
Note the followingabbreviations used in the powerĆcord options table below:
L
N
E
-ăLine or Active Conductor (also called live" or hot")
-ăNeutral or Identified Conductor
-ăEarth or Ground
Plug Type
Country
HP Part Number
NEMA 5-15P
Latin America
North America
Korea
8120-1378
Philippines
Taiwan
E
L
N
MITI 41-9692
CEE 7-VII
Japan
8120-4753
8120-1689
Continental Europe
Egypt
India
Saudi Arabia
E
L
N
Hong Kong
Ireland
8120-1351
BS 1363A
United Kingdom
E
N
L
Argentina
8120-1369
ASC112
Australia
China (mainland)
New Zealand
E
N
L
10Ć30 Parts and Diagrams
C3187Ć90000
Plug Type
Country
HP Part Number
SEV 1011
Switzerland
8120-2104
N
E
L
DHCR-107
Denmark
8120-2956
L
N
E
SABS
Republic of
South Africa
8120-4211
E
N
L
C3187Ć90000
Parts and Diagrams 10Ć31
Interface Cables
Parallel (Bi-Tronics/Centronics) Interface Cables
Computer
HP Part
Number
Cable length
Connector type at
computer end of cable
HP Vectra with HP 24540A/B serial/parallel
interface card using the parallel connector.
92284A
2.1 m (6.9 ft)
25-pin male
HP 9000 workstations, series 300, 400, 700.
IBM AT, IBM PS/2, IBM PC/XT and
compatible computers.
Serial (RS-232-C) Interface Cables
Computer
HP Part
Number
Cable length
Connector type at
computer end of cable
HP Vectra or HP 24541A/B serial
24542G
3.0 m (9.8 ft)
9-pin female
interface card (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.
HP Apollo workstation using an SPE
(Serial/Parallel Expansion) option and
supplied adapter cable.
DEC VAX.
Sun workstation.
IBM PC, PC/XT, IBM PS/2 and compatible
computers
17255D
17355M
17302A
1.2 m (3.9 ft)
3.0 m (9.8 ft)
1.5 m (4.9 ft)
25-pin female
DEC VAX using DEC BC22D, BC03M, or
equivalent
Apple Macintosh Plus, SE, II
8-pin male mini-DIN
Apple Macintosh 128K and 512K
Extension cable
92219M
31391A
1.5 m (4.9 ft)
5 m (16.4 ft)
9-pin male
25-pin female
10Ć32 Parts and Diagrams
C3187Ć90000
Glossary
GĆ1
acąAlternating current
CRCąCyclic Redundancy Check
accuracy calibrationąXĆaxis calibration
A/DąAnalog to Digital converter
D/A1Ćsize plottersąModels C3180A and
C3187A
dcąDirect current
addressable dpiąA resolution higher
than the nominal value of the cartridges,
giving a finer grid on which the plotter can
selectively position dots and improve print
quality.
display dataąMonitor mode
DIPąDual InĆline Package
dpiąDots per inch, the plotter's resolution
of raster images on the media.
ANSIąAmerican National Standards
Institute
DRAMąDynamic RandomĆAccess Memory
ASCIIąAmerican Standard Code for
Information Interchange. An 8Ćbit code
that uses 7 bits to represent character data
such as letters, punctuation, symbols, and
control characters. Bit 8 can be used for
parity.
driverąConfiguration data used by
software to control input and output
between the computer and the plotter.
drive rollerąPlaten roller
ASICąApplicationĆSpecific Integrated
Circuit
DTRąDataĆTerminal Read
E/A0Ćsize plottersąModels C3181A and
C3188A
baud rateąFor the RSĆ232ĆC interface,
the data transmission rate between the
computer and the plotter (bits per second).
EPROMąErasable Programmable
ReadĆOnly Memory
BiĆTronicsąA parallel interface standard.
CADąComputerĆAided Design
CAMąComputerĆAided Manufacturing
carriage LEDąLine sensor
EEROMąElectrically Erasable ReadĆOnly
Memory
EPROMąErasable Programmable
ReadĆOnly Memory
ESDąElectrostatic discharge
cartridgeąPrint cartridge (pen)
CDąCheck Digit
FETąFieldĆEffect Transistor
HPĆGL/2ąHewlettĆPackard's standard
graphics language for its plotters.
CentronicsąA parallel interface standard.
cockleąWrinkling of media due to ink
saturation.
HPĆRTLąHewlettĆPackard Raster
Transfer Language
GĆ2 Glossary
C3187Ć90000
ICąIntegrated Circuit
PCAąPrinted Circuit Assembly
IEEEąInstitute of Electrical and
Electronics Engineers
peną1. Even though the inkjet plotter has
no physical pens, the lines it draws match
the attributes for pens numbered 1 through
8 in the application software. (See also
palette.")
ISOąInternational Standards
Organization
2. Sometimes used instead of print
cartridge"
KanjiąA Japanese character set.
LEDąLightĆEmitting Diode
pinchĆarm sensorąpinchĆwheel sensor
PJLąPrinter Job Language, developed by
HewlettĆPackard to give software
applications more jobĆlevel device control
and to provide device status information to
the application.
legs and binąPlotter stand and media bin
line sensorąCarriage LED
LSBąLeast Significant Bit
platen rollerąDrive roller
P/NąPart Number
media axisąXĆaxis (paper axis)
mediaĆlength calibrationąMediaĆsensor
calibration
PNPąPositive Negative Positive
PWMąPulseĆWidth Modulation
RAMąRandomĆAccess Memory
mediaĆsensor calibrationąMediaĆlength
calibration
MSBąMost Significant Bit
rasterą1. A matrix of dots, or pixels,
where each pixel is defined by a bit. A bit
that is on" will print a dot on the paper. A
bit that is off" will leave the area blank. 2.
A method for defining a plot directly in
terms of the pixels rather than as vectors.
NVRAMąNonvolatile RandomĆAccess
Memory
PALąProgrammable Array Logic
paletteą A set of pens for which width and
% shading are defined using the setup sheet
or the graphics software.
resolutionąA measure of image sharpness
expressed as a number of lines per unit
length. When referring to plotters,
addressable resolution means the smallest
move the plotter can make
paper axisąMedia axis (XĆaxis)
parityąAn errorĆchecking method for
information transfer between a computer
and a peripheral device. Parity is used to
check the accuracy of binary data.
programmatically.
rmsąRoot mean square
ROMąReadĆOnly Memory
PCąPersonal Computer
C3187Ć90000
Glossary GĆ3
RSĆ232ĆC interfaceąA serial interface
standardized by the Electronic Industries
Association Standard RSĆ232ĆC.
TCP/IPąTransmission Control Protocol /
Internet Protocol
Transl.ąTranslucent media
RTLąsee HPĆRTL"
UARTąUniversal Asynchronous Receiver
Transmitter
RTSąRequest To Send
SIMMąSingle InĆline Memory Module
SMTąSurfaceĆMount Technology
standąPlotter legs and media bin
XĆaxisąMedia axis
XĆaxis calibrationąAccuracy calibration
YĆaxisąCarriage axis
GĆ4 Glossary
C3187Ć90000
Index
IndexĆ1
A
B
A/D converter, 5Ć30, GĆ2
ac, GĆ2
bail, 5Ć8
calibration, 7Ć8
change in, 9Ć14
cycle test
accessories, part numbers, 10Ć28
description, 8Ć18
performing, 8Ć22
lift mechanism, 5Ć8, 9Ć10
failure, 8Ć14
accuracy, 1Ć3, 5Ć7
calibration, 7Ć6, GĆ2
acoustics, 2Ć3
addressable dpi, 5Ć13, GĆ2
advancingthe media, 5Ć7
new support, 9Ć11
normal sequence, 8Ć14
removing, 6Ć71
teflon washers, 9Ć10
part numbers, 10Ć24b
removing, 6Ć56
sensor, 5Ć8, 5Ć27
part number, 10Ć24a
removing, 6Ć55
test
aligning cartridges. See cartridges,
alignment
ANSI, GĆ2
Apple Ethertalk, 1Ć2
application notes, part number, 10Ć29
applications of the plotter, 1Ć2
architecture, microprocessor, 5Ć21
ASCII, GĆ2
description, 8Ć18
performing, 8Ć22
bar cam, part number, 10Ć26
bar pattern, analyzing, 8Ć25
baud rate, 3Ć7, GĆ2
ASIC, GĆ2
carriage, 5Ć20
cartridgeĆinterface, 5Ć20
nozzle timing, 5Ć30
processor support, 5Ć24, 5Ć26
shuffler, 5Ć24
belt,
main drive,
part number, 10Ć14
premature wearing, 8Ć15
removing, 6Ć48
small,
assembly instructions, 3Ć2
legs and bin, 3Ć4
auto cam, part number, 10Ć24a
part number, 10Ć18
autoĆbail. See bail, lift mechanism
benchĆrun information, 8Ć27
automatic bail lift mechanism. See bail, lift
BiĆTronics, 2Ć2, 5Ć24, GĆ2. See also
mechanism
input/output interfaces
automatic cartridgeĆadjust linkage. See
bottom cover, part number, 10Ć6
cartridges, alignment
Busy and Error LEDs
flashing, 8Ć6
lit and steady, 8Ć7
buttons. See keys
IndexĆ2
C3187Ć90000
C
cartridges (cont.),
capping, 5Ć18
cables,
interface,
caps,
choosing, 2Ć2
part numbers, 10Ć32
power,
misaligned, 8Ć13
part number, 10Ć16
carriage. See carriage
distance to roller, 9Ć4
drivers, 5Ć20
part numbers, 10Ć30
CAD, GĆ2
frequent failure, 8Ć12
interface ASIC, 5Ć20
part number, 10Ć29
servicing, 5Ć17
calibrations, chapter 7
CAM, GĆ2
cam gear, part number, 10Ć24a
cam journal, part number, 10Ć26
Cancel key, bug fixed, 9Ć8
spitting, 5Ć18
wiping, 5Ć17
Cartridge and Error LEDs
flashing, 8Ć5
capping cartridges, 5Ć18
misalignment, 8Ć13
part numbers, 10Ć16
lit andsteady, 8Ć10
caution symbols, xi
CD, GĆ2
cards, help,
part numbers, 10Ć12
center cover,
carriage,
part number, 10Ć6
removing, 6Ć16
ASIC, 5Ć20
change in, 9Ć14
drive,
centronics, 2Ć2, 5Ć25, GĆ2. See also
input/output interfaces
mechanics, 5Ć9
part numbers, 10Ć14, 10Ć18
shutdown, 8Ć12
LED, 5Ć10, GĆ2
calibration, 7Ć4, 7Ć10
motor, 5Ć9
character sets, 1Ć2
cleaning
drive roller, 4Ć2
plotter, 4Ć2
clearing the EEROM, 8Ć29
clippedplots when replotting, 8Ć15
cockle, GĆ2
part number, 10Ć18
removing, 6Ć35
part numbers, 10Ć20
PCA, 5Ć12, 5Ć29
processor, 5Ć29
interface, 5Ć27
code, firmware revision. See firmwareĆcode
revision
removing, 6Ć48
rubbing against encoder strip, 8Ć15
speed, 5Ć15
configuration plot, service,
description, 8Ć19
interpreting, 8Ć25
plotting, 8Ć23
cartridges, 5Ć11, 5Ć30, GĆ2
alignment, 5Ć16, 7Ć4
errors, 8Ć5, 8Ć12
configuring the plotter, 3Ć7
connections, PCA andsensor, 5Ć22
removing linkage, 6Ć20
C3187Ć90000
IndexĆ3
converters,
documentation, user,
part numbers, 10Ć28
analogĆtoĆdigital, 5Ć30
vectorĆtoĆraster, 5Ć20
rasterĆtoĆraster, 5Ć20
dot
depletion, 5Ć14
size, 5Ć14
cooling the electronics, 5Ć18
covers,
dots per inch, 1Ć3, 5Ć13, 5Ć15
double pulley, part number, 10Ć18
dpi. See dots per inch
part numbers,
bottom, 10Ć6
center, 10Ć6
electronics enclosure, 10Ć8
left end, 10Ć10
right end, 10Ć12
Draft mode, 1Ć3, 5Ć14, 5Ć15
DRAM, GĆ2. See memory, random access
drive belt,
CRC, GĆ2
premature wearing, 8Ć15
main,
current, maximum, 2Ć2
part number, 10Ć14
small,
part number, 10Ć18
D
drive roller, 5Ć7, GĆ2
distance to cartridges, 9Ć4
part number, 10Ć22
removing, 6Ć69
D/A1Ćsize plotters, GĆ2
damage, inspecting the plotter for, 3Ć3
data flow, 5Ć19
drive tensioner, part number, 10Ć18
dc, GĆ2
drivers, GĆ2
delay, swath, 5Ć15
fan, 5Ć28
demonstration plot, 3Ć7
density ofpasses, 5Ć15
depth ofplotter, 2Ć3
motor, 5Ć28
software,
part numbers, 10Ć28
stepperĆmotor, 5Ć27
description ofplotters, 1Ć2
drop growth, 5Ć11
DTR, GĆ2
DesignJet 200,
upgrading to DesignJet 220, 1Ć4
detecting the media edges, 5Ć10
diagrams, chapter 10
E
dimensions,
media, 1Ć4
plotter, 2Ć3
E/A0Ćsize plotters, GĆ2
edges, media,
detecting, 5Ć2, 5Ć10
not found, 8Ć15
DIP, GĆ2
display data. See service monitor
display list, 5Ć19
EEROM, 5Ć27, GĆ2
clearing, 8Ć29
text block, 8Ć26
distance between cartridges and roller, 9Ć4
(EEROM ꢀ EPROM)
IndexĆ4
C3187Ć90000
electrical specifications, 2Ć2
Error and Cartridge LEDs
flashing, 8Ć5
electrical test
lit and steady, 8Ć10
description, 8Ć18
performing, 8Ć22
Error and Load Media LEDs
flashing, 8Ć6
electronics enclosure,
part numbers, 10Ć8
cover, removing, 6Ć5
lit and steady, 8Ć9
Error and Ready LEDs
flashing, 8Ć5
electronics overview, chapter 5
lit and steady, 8Ć8
electrostatic discharge, precautions, 6Ć2
errors,
encoder,
indicated by LEDs, 8Ć5
input/output, 8Ć7
media path, 8Ć9
memory, 8Ć8
media motor, 5Ć7
strip, 5Ć9, 10Ć14, 10Ć18
carriagerubbing against, 8Ć15
damaged, 8Ć12
miscellaneous, 8Ć10
servo, 8Ć9
installing, 6Ć41
removing, 6Ć39
system, 8Ć7
spring, 10Ć18
user, 8Ć5
test, 8Ć19, 8Ć24
ESD, GĆ2
endĆpoint accuracy. See accuracy
precautions, 6Ć2
endcovers,
Ethernet, 1Ć2
left,
Ethertalk, 1Ć2
part number, 10Ć10
removing, 6Ć18
right,
exchange assemblies, part numbers, 10Ć2
expanding memory. See memory, random
part number, 10Ć12
removing, 6Ć19
access
exploded views, chapter 10
engaging lever, part number, 10Ć24a
Enhanced mode, 1Ć3, 5Ć13, 5Ć14, 5Ć15
entering service mode, 7Ć2
extended powerĆon selfĆtest, 8Ć3
F
entry platen, 5Ć2
installing, 6Ć67
part number, 10Ć22
removing, 6Ć65
fan, 5Ć18
driver, 5Ć28
part number, 10Ć8
removing, 6Ć14
environmental specifications, 2Ć3
EPROMs, 5Ć23, 9Ć9, GĆ2
installing, 6Ć11
ferrite, part numbers,
on sideplate, 10Ć19
on trailing cable, 10Ć8
ring, 10Ć18
part numbers, 10Ć8
(EPROM ꢀ EEROM)
Error and Busy LEDs
flashing, 8Ć6
FET, GĆ2
Film, 5Ć15
lit and steady, 8Ć7
C3187Ć90000
IndexĆ5
Final mode, 1Ć3, 5Ć14, 5Ć15
I
firmwareĆcode revision, 8Ć11, 9Ć3
revision A.01.00, 9Ć7
revision A.01.01, 9Ć7
revision A.01.02, 9Ć8
See also EPROMs
IC, GĆ3
idler,
driveĆpulley,
part number, 10Ć18
main,
flow of data, 5Ć19
frequency, 2Ć2
part number, 10Ć14
IEEE, GĆ3
front panel, 3Ć6
initialization, 8Ć2
mechanical, 8Ć3
errors indicated on, 8Ć5
interface, 5Ć27
part numbers, 10Ć12
PCA, 5Ć31
ink,
cartridges. See cartridges
smearing, 8Ć16, 9Ć4
too much, 5Ć14
PCA and LED assembly, removing, 6Ć34
removing, 6Ć32
service mode, 7Ć3
input/output interfaces, 2Ć2, 5Ć19, 5Ć24
cables,
technical information, 5Ć31
functional overview, chapter 5
choosing, 2Ć2
part numbers, 10Ć32
errors, 8Ć6, 8Ć7
G
networks, 1Ć2
part numbers, 10Ć29
switching ports, 3Ć7
test,
graphiclanguages, 1Ć2
gripping the media, 5Ć6
growth of drops, 5Ć11
description, 8Ć18
performing, 8Ć23
installing
encoder strip, 6Ć41
entry platen, 6Ć67
EPROMs, 6Ć11
H
hardĆclip limits. See media, margins
height of plotter, 2Ć3
legs and bin, 3Ć4
masked ROMs, 6Ć11
mediaĆsensor flags, 6Ć28
memory module, 6Ć8
overdrive enclosure, 6Ć63
plotter, 3Ć2, 3Ć6
help cards, part numbers, 10Ć12
history of product, chapter 9
HP JetDirect EX, 1Ć2
part numbers, 10Ć29
teflon washers, 9Ć10
HPĆGL, 1Ć2
insulator, power supply,
part number, 10Ć8
timeout, 3Ć7, 8Ć16
HPĆGL/2, 1Ć2, GĆ2
interconnections, PCA and sensor, 5Ć22
HPĆRTL, 1Ć2, GĆ2
bug fixed, 9Ć8
interface,
carriageĆprocessor, 5Ć27
frontĆpanel, 5Ć27
humidity, 2Ć3
IndexĆ6
C3187Ć90000
interface (cont.),
legs and bin, GĆ3
input/output. See input/output interfaces
servo processor, 5Ć30
assembly instructions, 3Ć4
part numbers, 10Ć4
I/O. See input/output interfaces
length of plotter, 2Ć3
ISO, GĆ3
liftĆmechanism, bail. See bail, lift
mechanism
lights, front panel. See LEDs, front panel
J
line
merging, 3Ć7
jam, media, 8Ć12
sensor, 5Ć10, 5Ć29, 5Ć30, GĆ3
widths incorrect, 8Ć16, 9Ć7
JetDirect EX, HP, 1Ć2
part numbers, 10Ć29
line cord, part numbers, 10Ć30
joined plots, 8Ć16
linkage, cartridge adjust,
part number, 10Ć14
removing, 6Ć20
K
Load Media and Error LEDs
flashing, 8Ć6
Kanji, GĆ3
lit and steady, 8Ć9
keys, front panel, 3Ć6
loading media
assembly part number, 10Ć12
service mode, 7Ć3
functional overview, 5Ć2
problems, 8Ć6, 8Ć17
long media, 9Ć7
technical information, 5Ć31
LSB, GĆ3
L
label,
M
media load, part number, 10Ć12
serial number, part number, 10Ć10
main drive belt,
part number, 10Ć14
removing, 6Ć48
LAN manager, 1Ć2
language
main PCA, 5Ć22
demonstration plot, 3Ć7
graphics, 1Ć2, 3Ć7
setup sheet, 3Ć7
part numbers, 10Ć2, 10Ć8
removing, 6Ć9
main processor system, 5Ć23
LEDs, GĆ3
carriage, 5Ć10
manual, user's,
front panel, 3Ć6
part numbers, 10Ć28
assembly part number, 10Ć12
errors indicated by, 8Ć5
technical information, 5Ć31
margins, media, 1Ć4
masked ROMs, 5Ć23, 9Ć9
installing, 6Ć11
left endcover,
part numbers, 10Ć8
part number, 10Ć10
removing, 6Ć18
C3187Ć90000
IndexĆ7
mechanical initialization, 8Ć3
mechanical overview, chapter 5
memory (cont.),
errors, 8Ć5, 8Ć8
expansion module. See memory, random
access
media,
axis, GĆ3. See media drive
bin, part numbers, 10Ć4
director, part number, 10Ć26
diverter, part number, 10Ć26
drive,
random access (RAM), 1Ć2, 5Ć25
installing, 6Ć8
part numbers, 10Ć8
removing, 6Ć7
swath, 5Ć20, 5Ć24
calibration. See accuracy, calibration
mechanics, 5Ć7
merging lines, 3Ć7
mirror, 3Ć7
part numbers, 10Ć22
shutdown, 8Ć12
monitor, service,
accessing, 8Ć24
description, 8Ć19
edges,
detecting, 5Ć2, 5Ć10
not found, 8Ć15
motor,
guide, 10Ć24b
carriage, 5Ć9
jam, 8Ć12
part number, 10Ć18
removing, 6Ć35
media, 5Ć7
lever, part number, 10Ć26
length calibration. See media, sensor,
calibration
mount, problems, 9Ć4
part number, 10Ć22
removing, 6Ć37
stepper, 5Ć16
test, 8Ć20
loading
functional overview, 5Ć2
problems, 8Ć6, 8Ć17
long media, 9Ć7
margins, 1Ć4
drivers, 5Ć28
motor, 5Ć7
mount problems, 9Ć4
part number, 10Ć22
removing, 6Ć37
moving the carriage, 5Ć9
MSB, GĆ3
path errors, 8Ć9
sensor, 5Ć2, 5Ć27, 10Ć22
calibration, 7Ć9, GĆ3
flags, installing, 6Ć28
removing, 6Ć26
N
nameplate, part number, 10Ć10
test
network interface, 1Ć2
part numbers, 10Ć29
description, 8Ć19
performing, 8Ć23
sizes, 1Ć4
Novell Netware, 1Ć2
nozzle problems, analyzing, 8Ć25
nozzle timing ASIC, 5Ć30
types, 1Ć3, 5Ć15
memory,
EEROM, 5Ć27, GĆ2
clearing, 8Ć29
number, serial,
format, 9Ć2
text block, 8Ć26
EPROMs, 5Ć23, 9Ć9, GĆ2
installing, 6Ć11
part numbers, 10Ć8
label, part number, 10Ć10
number of passes, 5Ć15
NVRAM, GĆ3
IndexĆ8
C3187Ć90000
pen, GĆ3. See cartridges
O
pen palette, 3Ć7
operation, verifying plotter, 3Ć7
options, part numbers, 10Ć28
orientation, plot, 3Ć7
pinch arms, 5Ć6
lift mechanism, removing, 6Ć72
part numbers, 10Ć26
sensor, 5Ć6, 5Ć27, GĆ3
removing, 6Ć23
overdrive, 5Ć9
change in, 9Ć14
enclosure,
test
description, 8Ć19
performing, 8Ć23
installing, 6Ć63
removing, 6Ć62
part numbers, 10Ć24a
roller, removing, 6Ć60
PJL, 1Ć2, GĆ3
bug fixed, 9Ć8
planning, site, 2Ć1
overlay, frontĆpanel,
part numbers, 10Ć12
service mode, 7Ć3
platen roller. See drive roller
plot,
See also front panel
clipped when replotting, 8Ć15
files not plotted, 8Ć16
joined, 8Ć16
P
orientation, 3Ć7
quality, 1Ć3, 5Ć14, 5Ć15, 8Ć11, 8Ć25, 9Ć4
P/N, GĆ3
plotter architecture, 5Ć21
plotting time, 1Ć3
PAL, GĆ3
palette, GĆ3
PNP, GĆ3
Paper, 5Ć15
ports, switching interface, 3Ć7
paper axis. See media drive
power,
parallel interface, 2Ć2, 5Ć24
components, 5Ć28
cord, part numbers, 10Ć30
requirements, 2Ć2
supply, 5Ć32
See also input/output interfaces
parity, 3Ć7, GĆ3
parser, 5Ć19
part number, 10Ć8
PCA, removing, 6Ć12
parts and diagrams, chapter 10
passes,
power on,
density, 5Ć15
number of, 5Ć15
reset signals, 5Ć25
selfĆtests, 8Ć2, 8Ć3
PC, GĆ3
preventive maintenance, 4Ć1
PCA, GĆ3
print
carriage, 5Ć12, 5Ć29
frontĆpanel, 5Ć31
main, 5Ć22
cartridges. See cartridges
quality, 1Ć3, 5Ć14, 5Ć15, 8Ć11, 8Ć25, 9Ć4
printĆengine controller, 5Ć20
identifying a, 9Ć3
part numbers, 10Ć2, 10Ć8
printĆmode characteristics, 5Ć15
C3187Ć90000
IndexĆ9
printed circuit assembly. See PCA
removing (cont.),
frontĆpanel assembly, 6Ć32
frontĆpanel PCA and LED assembly, 6Ć34
left endcover, 6Ć18
problem solving, chapter 8
processor,
carriage, 5Ć29
main, 5Ć23
servo, 5Ć26
main drive belt, 6Ć48
main PCA, 6Ć9
media motor, 6Ć37
media sensor, 6Ć26
processor support ASIC, 5Ć24, 5Ć26
product history, chapter 9
memory module (DRAM SIMM), 6Ć7
overdrive enclosure, 6Ć62
overdrive roller, 6Ć60
pinchĆarm lift mechanism, 6Ć72
pinchĆarm sensor, 6Ć23
powerĆsupply PCA, 6Ć12
service station, 6Ć57
pulley, double,
part number, 10Ć18
PWM, GĆ3
stepper motor, 6Ć21
Q
trailing cable, 6Ć29
trailingĆcable guide, 6Ć43
window, 6Ć15
quality, print. See print quality
window sensor, 6Ć24
YĆtensioner and housing, 6Ć45
R
repacking,
kit, part number, 10Ć28
instructions, 3Ć3
part number, 10Ć28
RAM. See memory, random access
random access memory. See memory,
random access
replot clips plots, bug fixed, 9Ć8
requirements, power, 2Ć2
raster technology, 5Ć13, GĆ3
rasterĆtoĆraster converter, 5Ć20
reset signals, powerĆon, 5Ć25
resolution, 1Ć3, 5Ć13, 5Ć15, GĆ3
Ready and Error LEDs
flashing, 8Ć5
lit and steady, 8Ć8
revision,
firmware. See firmwareĆcode revision
reassembly, 6Ć2. See also installing
PCA, 9Ć3
removing
right endcover,
part number, 10Ć12
removing, 6Ć19
bail, 6Ć56
bailĆlift mechanism, 6Ć71
bail sensor, 6Ć55
carriage, 6Ć48
rms, GĆ3
carriage motor, 6Ć35
cartridgeĆadjust linkage, 6Ć20
center cover, 6Ć16
drive roller, 6Ć69
electronicsĆenclosure cover, 6Ć5
encoder strip, 6Ć39
entry platen, 6Ć65
fan, 6Ć14
rocker plate, part number, 10Ć26
roller, drive, 5Ć7
distance to cartridges, 9Ć4
part number, 10Ć22
removing, 6Ć69
ROM, GĆ3. See EEROM and EPROMs
IndexĆ10
C3187Ć90000
rotate, 3Ć7
service station, 5Ć17
caps, misaligned, 8Ć13
part numbers, 10Ć16
removing, 6Ć57
RSĆ232ĆC, GĆ4. See input/output interfaces
RTL, 1Ć2, GĆ4
bug fixed, 9Ć8
servicing cartridges. See service station
RTS, GĆ4
servo
errors/failures, 8Ć9, 8Ć12
processor, 5Ć26
interface, 5Ć30
test,
S
safety
description, 8Ć19
performing, 8Ć24
precautions, 6Ć2
symbols, xi
setting up the plotter, 3Ć6
self test, powerĆon, 8Ć2, 8Ć3
setup sheet
sensors, 5Ć27
calibration, 7Ć10
error, 8Ć5
bail, 5Ć8
part number, 10Ć24a
line, 5Ć10, 5Ć29, 5Ć30
does not find media edge, 8Ć15
media, 5Ć2
example of, 3Ć8
not read, 8Ć17
shuffler ASIC, 5Ć24
calibration, 7Ć9
SIMM, GĆ4. See memory, random access
site planning, chapter 2
part numbers, 10Ć22
PCA connections, 5Ć22
pinchĆarms, 5Ć6
size
part number, 10Ć26
window, 10Ć12
of dots, 5Ć14
of media, 1Ć4
serial interface, 2Ć2, 5Ć25, 8Ć6. See also
small drive belt, part number, 10Ć18
smearing of ink, 8Ć16
SMT, GĆ4
input/output interfaces
serial number,
format, 9Ć2
label, part number, 10Ć10
software/hardware guide, part number,
10Ć29
service
solving problems, chapter 8
sound power, 2Ć3
configuration plot,
description, 8Ć19
interpreting, 8Ć25
plotting, 8Ć23
mode, 7Ć2
sound pressure, 2Ć3
specifications,
accuracy, 1Ć3
monitor,
accessing, 8Ć24
description, 8Ć19
notes, chapter 9
tests, 8Ć18
electrical, 2Ć2
environmental, 2Ć3
resolution, 1Ć3
speed of carriage, 5Ć15
spitting, 5Ć18
performing, 8Ć22
stand. See legs and bin
C3187Ć90000
IndexĆ11
starwheel mounts,
Token Ring, 1Ć2
tools, 6Ć3
change in number of, 9Ć14
part number, 10Ć24a
trailing cable,
change in, 9Ć13
guide,
stepper motor, 5Ć16
driver, 5Ć27
part number, 10Ć14
removing, 6Ć21
test,
part number, 10Ć14
removing, 6Ć43
part number, 10Ć6
removing, 6Ć29
description, 8Ć20
performing, 8Ć24
Transl. See Translucent
Translucent, 5Ć15
storage environment, 2Ć3
stretching the media, 5Ć9
troubleshooting, chapter 8
true dpi, 5Ć13
supplies source, part number, 10Ć29
swath, 5Ć15
delay, 5Ć15
holding area, 5Ć20
manager, 5Ć20
memory, 5Ć20, 5Ć24
U
UART, GĆ4
switches, 5Ć27
unpacking instructions, 3Ć2
part number, 10Ć28
switching interface ports, 3Ć7
symbols, safety, xi
updates, firmware. See firmwareĆcode
revision
system
data flow, 5Ć19
errors, 8Ć7
upgrading a Designjet 200, 1Ć4
kit part number, 10Ć29
user errors, 8Ć5
user's guide, part numbers, 10Ć28
T
using
TCP/IP, 1Ć2, GĆ4
the plotter, 3Ć6
this manual, ii
teflon washers, reĆinstalling, 9Ć10
temperature, operating, 2Ć3
tensioner, main,
V
part number, 10Ć14
vectorĆtoĆraster converter, 5Ć20
tests, service, 8Ć18
Vellum, 5Ć15
time, plotting, 1Ć3
voltage, 5Ć32
timeout, HPĆGL, 3Ć7, 8Ć16
regulator, 5Ć28
requirements, 2Ć2
IndexĆ12
C3187Ć90000
wiper, part number, 10Ć14
wiping cartridges, 5Ć17
W
warning symbols, xi
washers, reinstalling teflon, 9Ć10
weight of plotter, 2Ć3
X
XĆaxis. See media drive
width of lines, incorrect, 8Ć16, 9Ć7
window,
part number, 10Ć6
removing, 6Ć15
sensor, 5Ć27
Y
YĆaxis. See carriage drive
part number, 10Ć12
removing, 6Ć24
test
YĆtensioner and housing,
bracket, part number, 10Ć14
removing, 6Ć45
description, 8Ć20
performing, 8Ć24
C3187Ć90000
IndexĆ13
Notes
IndexĆ14
C3187Ć90000
About This Edition
This is the second edition
of this service manual. It
updates information in
respect to the
HP DesignJet 200 and
introduces the
HP DesignJet 220.
1st edition, titled
HP C3180A/C3181A
DesignJet 200 Service
Manual, August 1993
2nd edition, titled
HP DesignJet 220 and
HP DesignJet 200 Plotters
Service Manual,
September1994
R
What's in This Book
This manual contains information
necessary totest, 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.
The procedures described in this
manual are tobe performed by
HPĆqualified service personnel only.
Recycled paper
Printed in France 9/94
HP Internal Order Number
C3187Ć90000.
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