Text preview for : HP DeskJet 200-220 Service Manual.pdf part of HP DesignJet 200 HP DesignJet 200 and DesignJet 220 Plotters Service Manual
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Service Manual
HP DesignJet 220 and HP DesignJet 200 Plotters
For HP Internal Use Only E Copyright Hewlett Packard Company 1994 This document contains proprietary information that is protected by copyright. All rights are reserved. No part of this document may be photocopied, reproduced, or translated into another language without the prior written consent of Hewlett Packard Company. HP internal order number C3187 90000 Second edition, September 1994 Printed in France
Warranty The information contained in this document is subject to change without notice. Hewlett Packard makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. Hewlett Packard shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material.
WARNING The procedures described in this manual are to be performed by HP qualified service personnel only. Electrical Shock Hazard Serious shock hazard leading to death or injury may result if you do not take the following precautions: D Ensure that the ac power outlet (mains) has a protective earth (ground) terminal. D Disconnect the plotter from the power source prior to performing any maintenance. D Prevent water or other liquids from running onto electrical components or circuits, or through openings in the enclosure. Electrostatic Discharge Refer to the beginning of Chapter 6 of this manual, for precautions you should take to prevent damage to the plotter circuits from electrostatic discharge. Safety Symbols General definitions of safety symbols are given immediately after the table of contents.
Learning Products, Barcelona Division Hewlett Packard Española, S.A. Avda. Graells, 501 08190 Sant Cugat del Vallès Spain
Service Manual
HP DesignJet 220 and HP DesignJet 200 Plotters
Using this Manual
Purpose
This manual contains information necessary to test, calibrate and service D HP DesignJet 200 plotters (models C3180A and C3181A) D HP DesignJet 220 plotters (models C3187A and C3188A) For information about using these plotters, refer to the corresponding user guides.
Readership
The procedures described in this manual are to be performed by HP qualified service personnel only.
Training
The HP ongoing training course CEV2 TIJ provides training for HP Customer Engineers, on servicing the complete HP DesignJet series of large format, thermal inkjet plotters.
Part Numbers
Part numbers for plotter options, accessories and service parts are located in chapter 10.
Conventions
The term D/A1 size plotters refers generically to models C3180A and C3187A. The term E/A0 size 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 find information related to the topic you are consulting. The w symbol is used to indicate the name of a referenced paragraph.
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Using this Manual
C3187 90000
Contents
Using this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi 1 Product Information 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 4 4 4 4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Graphic Languages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Network Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plotting Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Legs and Media Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Margins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other Plotter Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upgrading a DesignJet 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Site Planning and Requirements
Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Choosing an Interface Cable (more ' User's Guide) . . . . . . . . . . . . . . . . . . . . . . . . . . . Choosing a Suitable Plotter Environment (more ' User's Guide) . . . . . . . . . . . . . . . Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plotter Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation and Configuration
2 2 2 2 2
2 2 3 3 3
Unpacking and Assembling the Plotter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspecting the Plotter for Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repacking the Plotter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembling the Legs and Bin (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Plotter (more ' User's Guide) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 3 3 3 3
2 3 3 4 6
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Contents iii
Using the Plotter (more ' User's Guide) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DesignJet 200 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DesignJet 220 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuring the Plotter (more ' User's Guide) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Verifying Plotter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Demonstration Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example of Setup Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Preventive Maintenance
3 3 3 3 3 3 3 3
6 6 6 7 7 7 7 8
Cleaning the Plotter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 General Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 Cleaning the Drive Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 5 Functional Overview 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 2 2 2 2 6 6 6 7 7 7 8 8 8 8 9 9 9 9 10 10 10 10 11 11 11 12 12 12 12
Loading the Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entry Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensing Media Presence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gripping the Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinch Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinch Arm Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Advancing the Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Drive Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Drive Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Providing a Force on top of the Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bail Lift Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bail Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stretching the Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overdrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moving the Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carriage Drive Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Detecting the Media Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Margins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Providing Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drop Growth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Important Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cartridge Chutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carriage PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Producing an Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Raster Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resolution (Dots Per Inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dot Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Too Much Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dot Depletion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draft Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enhanced Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Mode Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DesignJet 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DesignJet 220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aligning the Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing the Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling the Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Data Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swath Holding Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swath Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swath RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cartridge Interface ASIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carriage ASIC and Cartridge Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plotter Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Processor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Processor Support ASIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shuffler ASIC and Swath Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input/Output Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parallel Input/Output Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What is Bi Tronics ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial Input/Output Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power On Reset Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
13 13 13 14 14 14 14 14 14 14 15 15 15 16 17 17 17 18 18 18 18 19 19 19 19 20 20 20 20 20 20 20 21 22 23 23 23 24 24 24 24 24 25 25 25 25
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Contents
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Servo Processor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servo Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Processor Support ASIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Panel Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stepper Motor Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carriage Processor Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EEROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carriage and Media Motor Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Cartridge Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carriage PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carriage Processor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carriage Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle Timing ASIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servo Processor Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A/D Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Panel PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removal and Replacement
5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
26 26 26 27 27 27 27 27 28 28 28 28 29 29 29 30 30 30 30 30 31 31 31 32
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ESD Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Electronics Enclosure Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Memory Module (DRAM SIMM) . . . . . . . . . . . . . . . . . . . . . . . . Removing the Main PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Power Supply PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Center Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Left Endcover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Right Endcover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 6 6 6 6 6 6 6 6 6 6 6 6 6
2 2 2 3 5 5 7 9 12 14 15 16 18 19
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Removing the Automatic Cartridge Adjust Linkage . . . . . . . . . . . . . . . . . . . . Removing the Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Pinch Arm Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Window Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Media Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Media Sensor Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Trailing Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Front Panel PCA and LED Assembly . . . . . . . . . . . . . . . . . . . . Removing the Carriage (Y Axis) Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Media (X Axis) Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing The Encoder Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstalling the Encoder Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Trailing Cable Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Y Tensioner and Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Cartridge Carriage and Main Drive Belt . . . . . . . . . . . . . . . . . Removing the Bail Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing The Bail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Service Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Overdrive Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Overdrive Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Re installing the Overdrive Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Entry Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Re installing the Entry Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Drive Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Automatic Bail Lift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Pinch Arm Lift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Calibrations
6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6
20 21 23 24 26 28 29 32 34 35 37 39 41 43 45 48 55 56 57 60 62 63 65 67 69 71 72
When to Calibrate the Plotter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entering Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Panel Keys in Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Performing Tests and Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cartridge Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accuracy Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bail Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Sheet Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 7 7 7 7 7 7 7 7 7
2 2 2 3 3 4 6 8 9 10
C3187 90000
Contents vii
8
Troubleshooting 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 2 2 3 3 4 5 5 5 5 6 6 7 7 8 9 10 11 11 11 11 11 11 12 12 12 12 12 12 12 13 13 13 13 14 14 14 14 15 15 15 15 16 16 16
Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extended Power On Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What You Should See and Hear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Errors Indicated by LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . User Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Error and Cartridges flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Error and Ready flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Error and Busy flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Error and Load Media flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Error and Busy lit and steady: Input/output errors . . . . . . . . . . . . . . . . . . Error and Ready lit and steady: Memory errors . . . . . . . . . . . . . . . . . . . . . Error and Load Media lit and steady: Media path/servo errors . . . . . . . . Error and Cartridge lit and steady: Miscellaneous errors . . . . . . . . . . . . . Firmware Code Revision Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair + Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnosing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servo Control System Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Axis (X Axis) Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carriage Axis (Y Axis) Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequent Cartridge Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove Tape and Align Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Damaged Encoder Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Incompatibility between Carriage and Firmware . . . . . . . . . . . . . . . . . . . . . . . Misaligned Cartridge Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function of the Cartridge Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What can Cause Cap Misalignment? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Cartridge Cap Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bail Lift Mechanism Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal Bail Lift Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Teflon Washers versus Cam Gear Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cartridge Carriage Rubbing against Encoder Strip . . . . . . . . . . . . . . . . . . . . . . . . Premature Wearing of Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor does not Correctly Find Media Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Last Swath is Clipped when Replotting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ink Smearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Add Starwheel Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Change Carriage Rear Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Plots Joined or Not Plotted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HP GL Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Incompatibility between Trailing Cable and Main PCA . . . . . . . . . . . . . . . . . Incorrect Line Widths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plotter won't Read Setup Sheet; Plots Solid Black Area Fill . . . . . . . . . . . . . . . . Problems in Loading Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Long Media doesn't Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Translucent Media doesn't Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Binding, or Missing Sensor Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Skews Badly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description Bail Cycle Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bail Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input/Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinch Arm Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Configuration Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Monitor (Data Display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servo/Encoder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stepper Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Window Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Which Service Test to Perform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Performing the Service Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bail Cycle Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bail Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input/Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinch Arm Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Configuration Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Monitor (Data Display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servo/Encoder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stepper Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Window Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interpreting the Service Configuration Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analyzing the Bar Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First Four Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fifth and Sixth Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seventh Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parameters Printed Below EEROM Text Block . . . . . . . . . . . . . . . . . . . . . . . . Reading the EEROM Text Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearing the EEROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8
16 16 16 16 17 17 17 17 17 17 18 18 18 18 18 19 19 19 19 19 20 20 21 22 22 22 22 23 23 23 23 24 24 24 24 25 25 25 25 25 26 26 29
C3187 90000
Contents ix
9
Product History 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 2 2 3 3 3 3 4 7 8 9 10 11 13 14 14
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial Number Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identifying a Printed Circuit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision Letter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Firmware Revision Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Potential Ink Smearing Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problems Corrected by Firmware Release A.01.01 . . . . . . . . . . . . . . . . . . . . . . . . . Problems that will be Corrected by Firmware Release A.01.02 . . . . . . . . . . . . . . EPROMs and Masked ROMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Re installing Teflon Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . New Bail Lift Mechanism Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Change in Trailing Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Change in Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Change in Bail and Overdrive Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Parts and Diagrams Exchange Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part Lists and Exploded View Diagrams: Legs and Media Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Window, Center and Bottom Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronics Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Endcover and Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Endcover and Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carriage Axis Drive (Left End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carriage Axis Drive (Right End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Drive Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bail and Overdrive Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinch Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line Cord Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interface Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 2 10 3 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
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Contents
C3187 90000
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).
OR
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. 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.
OR
Frame or chassis terminal. A connection to the frame (chassis) of the equipment, which normally includes all exposed metal. Alternating current Direct current Alternating or direct current
WARNING
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.
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.
CAUTION
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Safety
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Notes
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Safety
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Product Information
11
Description
Applications
HP DesignJet 200 and HP DesignJet 220 plotters are large format, monochrome, ink jet plotters that provide hardcopy output of computer program data. Large format plots of high resolution and quality are generated for applications such as D D D D D Computer aided design (CAD) Computer aided manufacturing (CAM) Mapping Mechanical and architectural drawings General drafting
Graphic Languages
The plotters accept drawing data from CAD software programs supporting the following languages: D D D D Hewlett Packard Graphics Language (HP GL), a vector language HP GL/2, an enhanced version of HP GL Hewlett Packard Raster Transfer Language (HP RTL), a raster language Printer Job Language (PJL)
The plotters support HP GL/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 RS 232 C or Centronics/Bi Tronics 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 D D D Novell Netware (Ethernet and Token Ring networks) LAN Manager (Ethernet and Token Ring networks) TCP/IP (Ethernet networks only) Apple Ethertalk (Ethernet networks only)
Memory
The plotters have a standard 2 megabytes of on board random access memory (RAM). They also have one RAM expansion socket, which can hold an optional 2 megabyte, 4 megabyte or 8 megabyte, single in line memory module (SIMM). The maximum RAM is therefore 10 MB.
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Product Information
C3187 90000
Accuracy
The accuracy of the plotters in drawing a vector is"0.38 mm (0.015 in) or "0.2% of the specified vector length, whichever is greater, at 23 _C (73 _F) at 50 60% relative humidity, on HP special polyester film.
Resolution
The resolution of the plotter output is measured in dots per inch (dpi). (Explanation ' chapter 5.) The plotter resolutions for different plot quality settings are as follows:
Plot/Print Quality Draft Final Enhanced HP DesignJet 200 300 x 300 dpi, dot depleted True 300 x 300 dpi HP DesignJet 220 300 x 300 dpi, dot depleted True 300 x 300 dpi Addressable 600 x 600 dpi.
Plotting Time
The plotting time for one plot on paper is as follows:
Plot/Print-Quality HP DesignJet 200 D/A1-size plot Draft Final Enhanced approx 3.8 min approx 5.0 min E/A0-size plot approx 7.5 min approx 10.0 min HP DesignJet 220 D/A1-size plot approx 2.3 min approx 3.1 min approx 6.5 min E/A0-size plot approx 3.9 min approx 5.3 min approx 10.6 min
Legs and Media Bin
The plotter legs and media bin are optional.
Media Types
Media type Plotter paper Translucent bond Vellum Single-matte inkjet polyester film Characteristics Smooth surface, good for everyday use. Good for diazo reproductions and preliminary drawings. Diazo-reproducible, archivable, translucent. Diazo-reproducible, archivable, very stable, pencil-writable on the matte side. Cost Low Low Moderate High
(Further advice ' User's Guide, chapter 2, w Choosing and using media.)
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Product Information 1 3
Media Sizes
The plotters handle only sheet media, not roll media. Supported standard sizes are as follows:
D/A1-size plotters (C3180A and C3187A) ANSI ISO Metric Oversize Architectural JIS A, B, C, D A4, A3, A2, A1 A2, A1 C, D A4, A3, A2, A1 B4, B3, B2 E/A0-size plotters (C3181A and C3188A) A, B, C, D, E A4, A3, A2, A1, A0 A2, A1, A0 C, D, E, E1 A4, A3, A2, A1, A0 B4, B3, B2, B1, B0
210 1625 mm 8.3 64 in
The plotters handle media that does not exceed the following maxima and minima:
210 1625 mm 8.3 64 in
C3180A C3187A plotters
C3181A C3188A plotters
210 625 mm 8.3 24.6 in
210 917 mm 8.3 36.1 in
17 mm
Media Margins
The media margins define the real available plotting area on the media:
5 mm portrait 5 mm 5 mm
17 mm
landscape
5 mm
17 mm = 0.67 in 5 mm = 0.2 in All measurements +/ 2mm (0.08 in)
Other Plotter Features
D Automatic media edge sensing D Automatic cartridge alignment, testing and servicing D Built in diagnostic and demonstration plots
Upgrading a DesignJet 200
Users can order an upgrade kit to upgrade a DesignJet 200 to a DesignJet 220. The kit should be installed by HP qualified service personnel only.
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Product Information
17 mm
17 mm
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Site Planning and Requirements
21
Power Requirements
HP C3180A and C3181A DesignJet 200 and HP C3187A and C3188A DesignJet 220 plotters have self adjusting power supplies and do not require a voltage selector or switch settings prior to use. The table below lists the power requirements for the plotters. Power Requirements
Source Voltage Requirements: Voltage 100 V ac 120 V ac 220 V ac 240 V ac Frequency: Consumption: Max current (rms) 1.4 A 1.2 A 650 mA 600 mA
47-53 Hz and 57-63 Hz 140 watts maximum
WARNING
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.
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 ' chapter 10.)
Choosing an Interface Cable
(Instructions ' User's Guide, chapter 1, w Choosing an interface cable.)
Serial (RS 232 C) Interface A short cable (less than 15 meters or 50 feet) is recommended
for the RS 232 C interface. A longer cable is permissible, provided the load capacitance does not exceed 2500 picofarads.
Parallel (Bi Tronics/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.)
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Site Planning and Requirements
C3187 90000
Choosing a Suitable Plotter Environment
(Instructions ' User's Guide, chapter 1, w Positioning the plotter.) Environmental Specifications
Hardware: Operating environment: Plotter With cartridges and media: Optimal print quality and media handling: Storage environment: Plotter/media Cartridges Environmental Class B2 Temperature 0 to 55_C (32 to 131_F) 10 to 40_C (50 to 104_F) 15 to 30_C (59 to 86_F) Temperature 40 to +70_C (40 to +158_F) 40 to +60_C (40 to +140_F) Sound Pressure 54 dB (Acoustic) < 20 dB (A) Sound Power 6.5 bels (A) < 3.6 bels (A) Relative Humidity 20-80% 20-80% 20-80% Relative Humidity 5-95%
Acoustics:* Operating Idle assumes fan is off.
*These specifications are typical sound pressures at a one meter bystander position. Idle specification
Plotter Dimensions and Weight
Plotter Model: Length Depth Height (window closed) Height (window open) Weight C3180A/C3187A 1076 mm (42.36 in) 380 mm (14.96 in) 355 mm (13.97 in) 505 mm (19.88 in) 39.1 kg (86.2 lbs) C3181A/C3188A 1375 mm (54.13 in) 380 mm (14.96 in) 355 mm (13.97 in) 505 mm (19.88 in) 46.7 kg (103.0 lbs)
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Site Planning and Requirements
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Notes
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Site Planning and Requirements
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Installation and Configuration
31
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
2
3
4
5
6
7
8
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Installation and Configuration
C3187 90000
9
10
1
2
11
1 2
12
2
A
2
A B 1 2 13
2
A
1 1 1
B
14
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.)
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Installation and Configuration
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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)
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Installation and Configuration
C3187 90000
4
1
2
6 mm (0.25 in)
3
4
5
5
A
1 A B B
2 A
B
3
A+B
4
5
X X
X
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Installation and Configuration
35
Installing the Plotter
(Instructions ' User's Guide, chapter 1, Setting up the plotter.)
Line Cord 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
DesignJet 200 Front Panel
(Instructions ' User's Guide, chapter 2, Using the plotter.)
Setup
Access Cartridges
Align Cartridges
Replot
Error Final Draft
Cartridges Paper Transl Vellum Film
Load Media Ready Busy
Form Feed
Plot Quality
Media Type
Cancel
DesignJet 220 Front Panel
Setup
Access Cartridges
Align Cartridges
Replot
Error Draft Final
Both ON = Enhanced
Cartridges Paper Transl Vellum
Both ON = Film
Load Media Ready Busy
Form Feed
Print Quality
Media Type
Cancel
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Installation and Configuration
C3187 90000
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 HP GL timeout period Plot orientation (rotate and mirror) Line merging Pen palette settings (width and density)
An example of a setup sheet is given on the following page.
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.
Power On Self Tests
Whenever you switch the plotter on, it automatically performs a series of internal self tests and mechanical initialization sequences. If a failure occurs, an error is indicated on the front panel LEDs. You can perform a failure analysis by interpreting the LED error code. (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.)
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Installation and Configuration
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Example of Setup Sheet
The following is a scaled version of a DesignJet 200 setup sheet:
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Installation and Configuration
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Preventive Maintenance
41
Cleaning the Plotter
To maintain the plotter in good operating condition, keep it free of dust accumulation, ink, and other contamination. Cleaning intervals are determined by the plotter environment and by the types of plotter supplies used. As with any precision electronics equipment, proper maintenance will help to ensure reliability and prolong product life. WARNING Disconnect the plotter from the power source prior to performing any maintenance. DO NOT allow water to run on to 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 should include 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 lint free cloth.
Cleaning the Drive Roller
Due to the ink's reflectance, ink spilled on the roller can disrupt the plotter's edge sensing 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 and wait for it to finish initialization. 3 With the window closed and no media loaded, press Form Feed repeatedly until the stained area of the drive roller is positioned at the top where it can be cleaned. 4 Turn the plotter OFF, disconnect it from the ac power source and raise the window. 5 Apply any common household cleaning solution to a soft, lint free rag and apply it to the drive roller surface. 6 Thoroughly clean the roller surface. 7 If other areas of the roller have been stained by 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.
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Preventive Maintenance
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Functional Overview
51
Loading the Media
Entry Platen
The media load path begins with the entry platen, which provides a loading surface. (Illustration ' page 10 23.) When you assemble the plotter, it is important to correctly position the entry platen to ensure that the dashed lines exactly indicate the permitted right edge loading area. The left side of the entry platen should be pressed up against the left side plate. (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 10 23). 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 double lever system provides a leading and trailing edge sensing capability (for media length measurement) to the plotter. The media sensor is electrically connected to the main PCA. 1. Media Not Loaded Drive roller stopped
Secondary flag Photo sensor area (cross-section) Primary flag Sensor housing
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Functional Overview
C3187 90000
The media not loaded state can be summarized as follows: D D D D D D Media: not inserted or has not yet reached the primary flag Primary flag: vertical position (idle) Secondary flag: resting on plastic detector housing (idle) Optical sensor: optical path closed by both flags Drive roller: stopped Front panel: Load Media LED on
2. Media Inserted (Beginning) Drive roller stopped
Primary flag Secondary flag D D D D D D Photo sensor window
Media inserted
Media: inserted but has not yet reached the secondary flag Primary flag: rotated 90° counter clockwise (active) Secondary flag: resting on plastic detector housing (idle) Optical sensor: optical path blocked by secondary flag Drive roller: stopped Front panel: Load Media LED on
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Functional Overview
53
3. Front Edge Reaches Secondary Flag
Drive roller full speed inwards
Secondary flag D D D D D D D
Primary flag Photo sensor window
Media inserted
Media: reaches the secondary flag Primary flag: rotated 90° counter clockwise (active) Secondary flag: rotated 35° counter clockwise (active) Optical sensor: optical path cleared by both flags Drive roller: full speed inwards, engaging media Front Panel: Load Media LED off, Busy LED on 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
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Functional Overview
C3187 90000
4. Rear Edge Clears Primary Flag
Drive roller slow speed inwards
Media inserted
Leading edge of media Secondary flag D D D D D D D Primary flag Photo sensor window Media: clears the primary flag Primary flag: rotates 90° clockwise (original position active) Secondary flag: still in previous position (active) Optical sensor: optical path blocked by falling edge of primary flag Driver roller: slows down but still rotating inwards... Front Panel: Load Media LED off, Busy LED on Media Length Measurement: rear edge detected
As soon as the optical sensor detects that the primary flag is back in it's original position, the roller motion slows down but needs some time to overcome the system's inertia before being able to reverse the direction of rotation.
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Functional Overview
55
5. Rear Edge Measured
Drive roller slow speed outwards
Media inserted
Secondary flag
Leading edge of media Primary flag Photo sensor window
D D D D D D D
Media: pushes the primary flag Primary flag: rotates 90° clockwise (active) Secondary flag: still in previous position (active) Optical sensor: optical path cleared by primary flag Driver roller: rotates slowly outwards... Front Panel: Load Media LED off, Busy LED on 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.
CAUTION
If you pull the media parallel to the plotter length, while attempting to clear a media jam, you could break the flags.
Gripping the Media
Pinch Arms
When you load media, it is gripped by the pinch arms. (Illustration ' page 10 27.) Pinch Arm Sensor The pinch arm sensor is an optical sensor that is attached to the right side plate. It is used to detect the position of the pinch arm lever. Linkage, attaching the lever to a sensor flag, causes the flag to block and unblock the sensor as the pinch arms are raised and lowered. The pinch arm sensor is electrically connected to the main PCA.
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Functional Overview
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Advancing the Media
Media Drive Mechanics
The media is advanced by the media drive (X drive) system. Components include: D Media motor (X axis motor) D Worm pinion and helical drive roller gear D Drive roller (Illustration ' page 10 23.) The main component of the drive system is a full width, 6.4 cm (2.5 inch) diameter roller with an elastomer skin. This roller directly drives the media and provides the surface that references the media to the print head. The media motor 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.
Media Drive 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 media drive accuracy (end point accuracy, or X axis accuracy) specifies how accurately a plotter can draw a line of a given length. (Specifications ' chapter 1.) The configuration plot draws cross hairs 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 media drive accuracy. The following also contribute: D Radius variations produced by the way the media wraps around the drive roller, and the way the pinch wheels and star wheels maintain this radius D Errors in the media motor's optical encoder feedback system (this system gives feedback to the motor control 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 media drive accuracy specification. Polyester film is the only media that maintains dimensional stability to within the plotter specification ranges.
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Functional Overview
57
Providing a Force on Top of the Media
Bail
The bail provides a normal force on top of the media. (Illustration ' page 10 25.) When the pinch wheels grip the media and the drive roller advances it, the plotter raises the bail. This enables the leading edge of the media to pass below the bail. 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.
Bail Lift 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 10 25) 1 The cartridge carriage presses down on the engaging lever. 2 The engaging lever gear and cam gear (which are always in contact) engage the drive roller gear on the left end of the drive roller. 3 The media drive system drives the drive roller, and also the cam and engaging lever gears. The auto cam, which is attached to the cam gear, turns with the gear. 4 The auto cam contacts the left bail bracket and pushes up on the bracket. As the bracket is pushed, the bail lifts. 5 The bail sensor switch opens and the resulting bail logic level is sent to the main PCA. 6 The media drive rotates the auto cam to a detent position. The detent position allows the bail bracket to rest on the auto cam after the carriage moves away from the engaging lever. 7 The media drive drives the media through the media path. 8 Once the media has passed the bail, the carriage again engages the bail lift 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 side plate. (Illustration ' page 10 25)
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Functional Overview
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Stretching the Media
Overdrive
The overdrive roller stretches the media slightly as it is moved through the plotter. It thus reduces bubbling and media cockle caused by media expansion due to the absorption of water based ink into the media. Even though the geometry chosen for the plotters minimizes the occurrence of this phenomena, it still could occur on very dense plots. Operation (Part illustrations ' page 10 25) The overdrive roller is geared to the media drive system and has a surface speed 10% greater than that of the 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 pinch wheels and the overdrive roller (the print zone). The overdrive roller is segmented into small rollers made of polyurethane. A clutch (overdrive gear assembly) is geared to the speed ratio gear (overdrive gear cluster) and drives the overdrive roller in the forward direction only.
Moving the Carriage
Carriage Drive Mechanics
The Carriage (Y axis) drive consists of a DC motor driving the carriage by means of a dual, kevlar belt system incorporating three pulleys and two tensioner assemblies. Operation (Part illustrations ' pages 10 19 and 10 21) 1 A gear pinion, pressed onto the carriage motor shaft, drives a small belt tensioned with a self compensating, spring loaded 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 friction fit belt clamps. It is tensioned using a self compensating, spring loaded tensioner wedge and main idler. (Illustration ' page 10 15.) The belt moves the carriage along slider rods, which are part of the chassis assembly. The carriage bearing system consists of three bushings. 4 Positional feedback is obtained using a 150 line per inch linear encoder strip that is spring loaded and passes t