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Service Manual
HP DesignJet 430 HP DesignJet 450C HP DesignJet 455CA Printers
For HP Internal Use Only E Copyright HewlettPackard Company 1997 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 HewlettPackard Company.
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 Printer 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 8 of this manual, for precautions you should take to prevent damage to the Printer circuits from electrostatic discharge. Safety Symbols General definitions of safety symbols are given immediately after the table of contents.
First edition, September 1997
Product Support, Barcelona Division Hewlett-Packard Española, S.A. Avda. Graells, 501 08190 Sant Cugat del Vallès Spain
Service Manual
HP DesignJet 430 HP DesignJet 450C HP DesignJet 455CA Printers
Using this Manual
Purpose This manual contains information necessary to test, calibrate and service:
D D D
HP DesignJet 430 printers (models C4713A and 4714A). HP DesignJet 450C printers (models C4715A and 4716A). HP DesignJet 455CA printers (models C6080A and C6081A).
For information about using these printers, refer to the corresponding user and quick reference guides. Readership The procedures described in this manual are to be performed by HP certified service personnel only. Part Numbers Part numbers for plotter options, accessories and service parts are located in chapter 7. Conventions This manual contains information for the color HP DesignJet 430, 450C and 455CA printers. 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.
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Using this Manual
HP DesignJet 430, 450C and 455CA Printers
Contents
Using this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x 1 Troubleshooting 12 12 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 3 3 4 4 4 4 5 6 6 7 7 8 8
Is the Printer Using the Latest Firmware Revision? . . . . . . . . . . . . . . . . . . . . . . . Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What Can I do when a System Error Code Appears on the Front Panel Display? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Have you performed a Service Test on the Failed Component/Assembly? . . . . . . . Have you Performed the Accuracy Calibration? . . . . . . . . . . . . . . . . . . . . . . . . . . . What can I do to Solve Print Quality Problems? . . . . . . . . . . . . . . . . . . . . . . . . . . . What can I do if the Line Sensor has Problems Detecting Media? . . . . . . . . . . . What can I do if the Carriage is Noisy? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What can I do if the Cover Sensor isn't Working? . . . . . . . . . . . . . . . . . . . . . . . . . . What can I do if the Carriage Assembly has problems parking in the Service Station? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What can I do if the Printer continuously rejects Cartridges? . . . . . . . . . . . . . . . What can I do if the Media continuously crashes? . . . . . . . . . . . . . . . . . . . . . . . . . What can I do if the Printer does not Power ON? . . . . . . . . . . . . . . . . . . . . . . . . . . What can I do if the Printer has problems with Media Loading? . . . . . . . . . . . . . What can I do if the Printer has problems with the Cutter? . . . . . . . . . . . . . . . . . What can I do if the Bail Mechanism Fails? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What is an EEROM error? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 System Error Codes
Important Information on Troubleshooting Error Codes . . . . . . . . . . . . . . . . . . . 2 2 System Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4 3 User Messages
User Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2
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Service Tests 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 2 2 3 3 4 6 6 6 7 8 9 10 12 15 16 18 19 21 22 22 22 23 24 25 26 27 29 30 30 32
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self Test and Normal Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Which Service Test to Perform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Tests (Diagnostics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Mode 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping a Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entering Service Mode 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Viewing Test Output via the Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bail Cycle Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carriage Axis (Y axis) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carriage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensors Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Axis (X Axis) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bench Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modular Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronics Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Mode 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping a Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entering Service Mode 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bail Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servo/Encoder Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Monitor (Data Display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EEROM Model ID Configuration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Configuration Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printing the Service Configuration Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interpreting the Service Configuration Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearing the EEROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Service Calibrations
Accuracy Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What is the End Point Accuracy Specification ? . . . . . . . . . . . . . . . . . . . . . . . . What can Affect the End Point Accuracy ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Before Performing the Accuracy Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . Performing the Accuracy Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the Carriage to Media Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . To check the carriage to media distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . To adjust the carriage to media distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Image Quality 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 2 3 3 3 3 5 5 5 7 9 11 12 15 15 16 16 16 16 17 17 18
Print Quality Troubleshooting Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Quality Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the Print Quality Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printing the Print Quality Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analyzing the Print Quality Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Pattern 1: Cartridge Warm up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Pattern 2: Nozzle Print Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Pattern 3: Vertical Line Straightness Test . . . . . . . . . . . . . . . . . . . . . . . . Test Pattern 4: Color Alignment Quality Test . . . . . . . . . . . . . . . . . . . . . . . . . . Test Pattern 5: Color Variation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Pattern 6: Banding Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No Printing Defects Found in the Print Quality Plot . . . . . . . . . . . . . . . . . . . Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Quality Defects Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starwheel Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Uneven Fill Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bleeding, Blooming and Wicking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ink Smearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hue Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Parts List
Exchange Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1 General View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2 Printer Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3 Rollfeed Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5 Front Panel, Spittoon and Electronics Module . . . . . . . . . . . . . . . . Figure 6 X and Y axis Motors and Encoder Strip . . . . . . . . . . . . . . . . . . . . . . Figure 7 Primer Assembly and Service Station Assembly . . . . . . . . . . . . . . Figure 8 Carriage Assembly and Trailing Cable . . . . . . . . . . . . . . . . . . . . . . . Figure 9 Bail and Overdrive Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 10 Pincharm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11 Entry Platen, Drive Roller, Bail and Overdrive Assembly . . . . . Printer Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Users Guide and Quick Reference Guide Bundle . . . . . . . . . . . . . . . . . . . . . . . Front Panel Overlays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compatible Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug in memory (RAM SIMM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Print Servers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Removal and Installation 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 3 3 3 4 5 6 7 8 9 10 11 12 13 15 17 18 20 21 22 23 24 25 26 28 32 34 36 37 41 42 44 45 47
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrostatic Discharge (ESD) Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing a RAM or ROM SIMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Bail Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Rollfeed Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Left End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Right End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Electronics Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Encoder Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Right Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Carriage Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Spittoon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Cutter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Drive Roller Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Media Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Pinch Arm Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Primer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Service Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Bail Lift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Engaging Lever Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Trailing Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Trailing Cable Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Drive Belt Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Drive Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstalling the Drive Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Pinch Arm Lift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Overdrive Assembly (including the Overdrive Roller, Media Separator, Media Deflectors and Media Sensor) . . . . . . . . . . . . . . . . . . . . . Removing the Entry Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Preventive Maintenance
8 50 8 52
Moisture on Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Level of Printer Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Friction on Slider Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Noisy Carriage Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ink Spilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt Swelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the Drive Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Contents
HP DesignJet 430, 450C and 455CA Printers
10 Functional Overview Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roll Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Static Charge from the Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gripping the Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinch Arm Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Providing a Force on Top of the Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bail Lift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Detecting the Lines and Media Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moving the Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carriage Drive Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor, Belt and Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carriage Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Positional Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carriage PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Providing Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distance between Carriage and Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Producing an Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Mode Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing the Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spittoon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronics Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EEROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input/Output Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bi Tronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS 232 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Memory Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plot Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Raster Image Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 2 2 2 3 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 6 6 6 6 7 7 7 7 7 8 8 8 8 8 9 9 9
HP DesignJet 430, 450C and 455CA Printers
Contents vii
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
viii
Contents
HP DesignJet 430, 450C and 455CA Printers
1
Troubleshooting
HP DesignJet 430, 450C and 455CA Printers
1-1
Introduction
This chapter will guide you through the relevant steps to take when troubleshooting the printer. Is the Printer Using the Latest Firmware Revision? Before spending time troubleshooting the problem by doing the various tests or replacing parts (which may not need replacing), check which firmware revision the printer is using. To check which firmware revision the printer is using, Print the Service Configuration Plot ' page 4 29. Some problems which occurred in earlier firmware releases may have been solved in later revisions. So if there is a new firmware revision then replace the Firmware SIMM before replacing any parts. Important Information The Printer firmware is contained either on a flash ROM SIMM at the back of the Printer or on a masked ROM inside the electronics module. The firmware revision level, for example A.01.03, is printed by the Printer on the setup sheet and on the service configuration plot. The revision level is also printed on a label on any flash ROM SIMM. Do not open the electronics module. Important: When replacing the electronics module, always remember to check the firmware revision level of the new electronics module. The revision level will be printed on the top surface of the module. Also, check the firmware revision level of the ROM SIMM installed in the old electronics module. With this information you must do the following: 1. If the firmware revision level of the ROM SIMM in the old electronics module is lower than the firmware revision level of the new electronics module, then you must not install the ROM SIMM into the module. 2. If the firmware revision level of the ROM SIMM in the old electronics module is higher than the firmware revision level of the new electronics module, then you must install the ROM SIMM into the module. Example 1: The ROM SIMM firmware revision level is A.01.03 and the firmware revision level of the electronics module is A.01.04. You would use the electronics module without the ROM SIMM installed. Example 2: The ROM SIMM firmware revision level is A.01.05 and the firmware revision level of the electronics module is A.01.04. You would use the electronics module with the ROM SIMM installed.
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HP DesignJet 430, 450C and 455CA Printers
Troubleshooting
What Can I do when a System Error Code Appears on the Front Panel Display? Chapter 2 contains a list of system error codes and their respective descriptions and recommended corrective actions. Only try one recommended action at a time and check if the error code has disappeared. If you have an error code which is not documented in this Service Manual or you have an error which you cannot resolve, then report the error to the HP Response Center or the nearest HP Support Office. When reporting the error, have the following information ready:
D D D D D D D D
Model and Serial Number of the printer. Which firmware revision the printer is using. The complete error code. The Service Configuration Plot. The Current configuration sheet. Which software application the customer is using (name, version, etc.). Is the problem reproducible by you? Additional comments about the usage, the setting, etc..
Have you performed a Service Test on the Failed Component/Assembly? If possible, always perform a Service Test on the component/assembly that you are about to replace, just to make sure that is the component/assembly that has failed. If the test on that component/assembly passes, you should NOT replace it. For information on the Service Tests and how to use them ' Chapter 4. Have you Performed the Accuracy Calibration? Is the printer calibrated correctly after replacing a component? Refer to Chapter 5 to check when the Accuracy Calibration is required. What can I do to Solve Print Quality Problems? Whenever an Print Quality problem appears, it is advisable to print the Print Quality Plot to help diagnose the problem. The Print Quality Print will help you differentiate between possible Cartridge errors and other problems such as incorrect front panel selection, driver or RIP configuration or mechanical problems. For information on solving Print Quality problems ' Chapter 6.
Troubleshooting
HP DesignJet 430, 450C and 455CA Printers
1-3
What can I do if the Line Sensor has Problems Detecting Media? 1 Excessive ink deposits on the drive roller surface can fool the sensor by reflecting the light. Clean the drive roller ' Chapter 9. 2 Line sensor incorrectly calibrated: The accuracy calibration includes calibration of the line sensor on the carriage. You must use HP Matte film when performing the accuracy calibration (Details ' Chapter 5). Otherwise the line sensor will have problems loading some types of media. 3 The Line Sensor is faulty. Replace the Carriage Assembly ' page 8 37. What can I do if the Carriage is Noisy? 1 Dirty Carriage bushings. Remove dust particles from the Carriage bushings and from the slider rod along which the Carriage moves. If necessary, apply lubricant to the slider rod. 2 Make sure that the belt is correctly positioned on the Y axis motor. 3 Remove dust particles from the Back Beam and, if necessary, apply grease. 4 Check for a faulty Carriage. Perform the Carriage Axis Test ' page 4 10. What can I do if the Cover Sensor isn't Working? The cover sensor is part of the front panel assembly. 1 Before troubleshooting, make sure that you are not in Service Mode 1 because the Cover sensor is disabled and Printer will think that the cover is always closed. Power OFF the Printer and switch it back ON again and check if the Cover sensor works. 2 Check if the cable for the front panel assembly is connected correctly to the electronics module. 3 Replace the front panel assembly ' page 8 12. What can I do if the Carriage Assembly has problems parking in the Service Station? 1 Mispositioned trailing cable: The trailing cable may be preventing the carriage from reaching the left hand stop. Make sure that the trailing cable is positioned under the plastic tabs at the back of the carriage cover, and not above them. 2 The Carriage is not at the correct height. Check and, if necessary, adjust the Carriage height (Details ' chapter 5). 3 The Belt is not correctly positioned over the idler pulley. 4 Check for a faulty bail lever mechanism because the Carriage may have trouble passing over it.
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HP DesignJet 430, 450C and 455CA Printers
Troubleshooting
What can I do if the Printer continuously rejects Cartridges? If you are in Service Mode 1, the cover sensor is disabled. In order to test a new Cartridge set, the Printer must be powered OF and and ON again. 1 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. 2 Dirty pads: The connection between the carriage PCA and the cartridge flex connector is made by means of a gold bubble on the flex connector that touches a gold pad on the PCA. The Carriage Test (details ' page 4 12) includes a test of this connection. When nozzle failures occur, clean the flex contacts on the cartridge and in the Carriage. 3 Continuity Problem: Remove all the cartridges from the Carriage and try installing just the rejected cartridge. If the cartridge is still rejected then replace the cartridge with a new one. If the new cartridge is not rejected then check, one by one, if the other cartridges are rejected or not. 4 Faulty cartridge: Some black cartridges (51640A) with USE BEFORE dates of April '96 and earlier may have thin film damage. This means that the material used for channeling ink behind the nozzles can crack with aging. When this happens, ink seepage may cause many nozzles to fail (eight or more). Replace the black cartridge with one with USE BEFORE date of May '96 or later. 5 If the Cartridges are not inserted correctly into the Carriage, the Cartridges will be rejected. Make sure that the springs that hold the Cartridges in the Carriage are not broken or misplaced. 6 Perform the Carriage Test ' page 4 12. 7 Replace the Trailing Cable ' page 8 8. 8 Replace the Carriage Assembly ' page 8 37.
Troubleshooting
HP DesignJet 430, 450C and 455CA Printers
1-5
What can I do if the Media continuously crashes? 1 Check if the media loaded is HP approved. If the media is not HP approved, advise the customer to use HP media and check to see if the problem is now solved. 2 Anti static brush: If this brush (located under the entry platen) is damaged or removed, static charge can build up on the media. A charge can cause the media to stick to itself and jam the Printer. 3 The Carriage is at the incorrect height in relation to the Drive Roller. Check and if necessary adjust the carriage to media distance ' page 5 5 and try to load the media again. 4 The Drive Roller is installed incorrectly. Remove the Drive Roller and install in the correct position ' page 8 44 and try to load the media again. 5 The overdrive wheels turn free in both directions, creating bubbles in the media. Make sure that the Clutch assembly is installed correctly and is not faulty. 6 Missing or damaged starwheels. Make sure that all the starwheels on the bail assembly are correctly installed and turn properly. 7 Missing Media Deflectors. Make sure that all the Media deflectors are installed on the Printer, otherwise there could be media crashes. What can I do if the Printer does not Power ON? 1 Check that the power cord is connected correctly. 2 Check that the ROM SIMM (firmware) is installed correctly in the correct slot (the slot furthest from you) at the back of the Printer. 3 Try to disconnect all the cables, apart from the Front Panel Cable, from the Electronics Module and then try to power ON the Printer again. If nothing appears on the front panel display, then replace the Electronics Module ' page 8 13. If the Printer does Power On with the cables disconnected, then the problem must be with another component of the Printer. To find the faulty component, power OFF the Printer and connect one of the cables and power ON again. Once the faulty component is connected, it will not allow the Printer to power ON. This component should then be replaced.
1-6
HP DesignJet 430, 450C and 455CA Printers
Troubleshooting
What can I do if the Printer has problems with Media Loading? 1 Check that the Media Sensor is installed correctly. 2 Check if the cable for the Media Sensor is connected correctly. 3 Check if the Pincharms are down (the Pincharm lever should be up). 4 If the media is continuously rejected during the media edge check, then make sure that the Line Sensor is installed correctly. If necessary, perform the Carriage Test ' page 4 12. 5 Make sure the line sensor is calibrated. Perform the Accuracy Calibration ' page 5 2. 6 Replace the Media Sensor (part of the overdrive assembly) ' page 8 50. 7 Replace the Carriage Assembly ' page 8 37. Only replace one component at a time and check if the problem has been solved before replacing another component. Using this procedure you will be able to determine exactly which component failed. What can I do if the Printer has problems with the Cutter? 1 If the Carriage Assembly has problems picking up the Cutter:
D
D
Check that the cable for the Front Panel Assembly is is not loose and is routed correctly in the cover clips. A loose cable can be trapped by the Cutter, preventing the Cutter from moving. Make sure that the Spittoon Assembly is correctly installed and is aligned with the Overdrive Assembly. If the Spittoon is loose or mispositioned, the cutter will have problems parking in the right cover. Make sure that there is no media trapped inside the Cutter mechanism. Remove the Cutter to inspect it correctly. Remove the Cutter and make sure that both rotary blades are touching each other by the flat sides and not the sloping sides. If the rotary blades are touching each other by the sloping sides, you must reseat them. If the Printer is placed on a table, it must be placed as close to the edge as possible to make sure that the media that is coming out falls correctly. If the Printer is in the middle of the table, the media that is coming out will be lifted up causing the cutter to crash into it.
2 If the media crashes when moving the Cutter:
D D
D
Troubleshooting
HP DesignJet 430, 450C and 455CA Printers
1-7
What can I do if the Bail Mechanism Fails? 1 Obstructions: Check that there are no obstructions in the way of the Bail Assembly. 2 Wearing of parts: The cam gear and engaging gear may not make correct contact with the left drive roller gear even though the carriage is actuating the engaging lever. This can happen due to excessive wearing of parts. Another problem may be that the bail cable has broken. 3 Carriage motor control: The carriage may not properly locate the engagement lever, preventing the gears from engaging. Any problems with the carriage motor 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. 4 Bail cam: The bail may fall from the up position. This can happen if the cam is over or under rotated. The notch on the cam, used to engage the left bail bracket, is not properly located for the bail up" condition, and the bail falls abruptly. Perform a bail cycle test. 5 Adjust carriage: If the carriage moves over the engaging lever without raising it, you may need to adjust the carriage angle on the slider rod. (Details ' page 5 5.) However, be careful not to jeopardize the print quality, which is very sensitive to the carriage angle.
EEROM Errors
What is an EEROM error? An EEROM error means that some of the internal tests that the firmware performs have detected that, when re reading information from the EEROM, it doesn't correspond to the information that had previously been written there, or that the checksum of all the information is incorrect. This failure has five possible causes:
D D D D D
Faulty electronics module. Contact problems with the trailing cable connections. Faulty trailing cable. Faulty carriage. The Printer was turned off while a test was writing to the EEROM, thus leaving corrupt information (or a communication cable was disconnected while sending information to the EEROM using software diagnostic tools).
It is generally not easy to discover the cause, due to the intermittent character of the failure modes.
1-8
HP DesignJet 430, 450C and 455CA Printers
Troubleshooting
If you are sure that the failure occurred just after an electricity power cut, or after turning off the Printer during the bench run or other service tests, then the Printer is not faulty. You just need to reset the EEROM. In other cases, you need to find the cause: There is always an EEROM error when you switch on the Printer: D If it is easy to reproduce a Steady EKL error, then try one or all of the following steps for a possible solution: 1 Configure the EEROM with the correct model ID (instructions ' page 4 27).
D
2 If you cannot configure the EEROM with the correct model ID after several attempts and you continue getting the same error code, replace the electronics module ' page 8 13. There is sometimes an EEROM error when you switch on the Printer (normally shows up as a Steady EK error): 1 Switch on the Printer, allow it to initialize until it has completed the power on LED sequence, and switch off the Printer. (You are now sure that the EEROM has not been corrupted. If a Steady EK error appeared, it also corrects the EEROM contents, and the next time you switch the Printer ON, the error should not occur in good units.)
D
2 Leave the unit off for 15 minutes to detect if the EEROM is losing its information. Then turn it on again and allow it to initialize. If a Steady EK error appears during the initialization sequence, and the carriage does not begin to move, then the EEROM is probably faulty. Replace the electronics module.
Troubleshooting
HP DesignJet 430, 450C and 455CA Printers
1-9
2
System Error Codes
HP DesignJet 430, 450C and 455CA Printers
2-1
System Error Codes
If you have an error code which is not documented in this Service Manual or you have an error which you cannot resolve, then report the error to the HP Response Center or the nearest HP Support Office. When reporting the error, have the following information ready:
D D D D D D D D
Model and Serial Number of the printer. Which firmware revision the printer is using. The complete error number. The Service Print (Utilities / Service Tests). The Current configuration sheet. Which software application the customer is using (name, version, etc.). Is the problem reproducible by you? Additional comments about the usage, the setting, etc..
Important Information on Troubleshooting Error Codes Before spending time troubleshooting the problem by doing the various tests or replacing parts (which may not need replacing), check which firmware revision the printer is using or check if a service note deals with this particular problem. Some problems which occurred in earlier firmware releases may have been solved in later revisions. So if there is a new firmware revision then update the ROM SIMM before replacing any parts. Refer to Chapter 7 for the part number of the ROM SIMM.
2-2
HP DesignJet 430, 450C and 455CA Printers
System Error Codes
1
SETUP
2
FORM FEED
3
REPRINT
4
CANCEL
STATUS GROUP
D E F
READY ALIGN MEDIA LOAD MEDIA
ERROR GROUP
K L M N O
CARTRIDGES DATA MEDIA
A B C
FAST NORMAL BEST
G H I J
PAPER FILM COATED GLOSSY
ROLL SHEET
5
PRINT QUALITY
6
MEDIA TYPE
7
MEDIA SOURCE
LED Symbols:
Off On (Steady) Flashing
LED Letters:
D E F A B C G H I J K L M N O
LED Code Examples:
Flashing KLM LEDs K, L and M are flashing. Steady DEL
LEDs D, E and L are on.
System Error codes The following pages contain the possible error codes and the instructions necessary to solve the problem.
System Error Codes
HP DesignJet 430, 450C and 455CA Printers
2-3
Error Codes for the HP DesignJet 430, 450C and 455CA Printers
D E F A B C G H I J K L M N O
Cartridges + Data + Media: An error which the customer could probably solve, like a paper jam, minor cartridge problem etc. In order to get more information on the error, the CANCEL key must be pressed which will display a Subcode. Use the error codes below to find information on the subcode. Cartridges + Data + Media: This error code indicates a severe problem which will require a Service Engineer to troubleshoot. In order to get more information on the error, the CANCEL key must be pressed which will display a Subcode. Use the error codes below to find information on the subcode. Ready + Cartridges: The RAM SIMM test failed. Possible causes: D D D D RAM SIMM installed is not an original HP supported part. RAM SIMM badly connected. Faulty RAM SIMM. Faulty electronics module.
Steady KLM
D E F A B C G H I J
K L M N O
Flashing KLM
D E F A B C G H I J
K L M N O
Steady DK
D E F A B C G H I J
K L M N O
Ready + Data: Cartridge Continuity Test Failure. Possible causes: D D D D D Cartridges faulty or badly seated. Faulty or badly connected trailing cable. Dirty carriage flex circuit. Faulty carriage. Faulty electronics module.
Steady DL
2-4
HP DesignJet 430, 450C and 455CA Printers
System Error Codes
D E F A B C G H I J
K L M N O
Ready + Media: X axis Shutdown. Possible causes: D D D D Obstacle or friction in X axis. Faulty or badly connected X axis Encoder Cable. Faulty media motor, or motor cable pinched. Faulty electronics module.
Steady DM
D E F A B C G H I J
K L M N O
Ready + Align Media + Load Media + Cartridges: Memory or Accuracy Calibration Problems. Possible causes: D Not enough memory for the current plot. Add extra memory by installing a bigger RAM SIMM. Refer to Chapter 7 for the correct part numbers of the RAM SIMMs. If this error code appeared while performing the Accuracy Calibration: D Check that the quality of the Accuracy Calibration print is good. If the quality is bad, try to clean the black cartridge or replace it. D Make sure that you load the Accuracy Calibration print in the correct position and orientation, and make sure that you select the correct media type. D Make sure that the line sensor on the carriage is clean. If the Line sensor is dirty or not functioning correctly, it will have problems reading the accuracy calibration print. D Faulty Trailing Cable. D Faulty Carriage Assembly. D Faulty Electronics Module. Ready + Load Media + Cartridges: Mechanical Problem. Possible causes: D Check the Bail Assembly. D Check the Capping Position in the Service Station.
Steady DEFK
D E F A B C G H I J
K L M N O
Steady DFK
System Error Codes
HP DesignJet 430, 450C and 455CA Printers
2-5
D E F A B C G H I J
K L M N O
Ready + Align Media + Load Media + Media: Error in bail lift mechanism. The bail lift system is unable to raise or lower the bail. (It is the carriage that tests to see whether the bail is in the correct position by trying to knock against it.) Possible causes: D Check the bail lift system to see if it is working correctly. D Use the bail cycle test to help troubleshoot.
Steady DEFM
D E F A B C G H I J
K L M N O
Ready + Data + Media: Error in X axis calibration. Possible causes: D Is X axis calibration done? (details ' Chapter 5) D Did you load media in correct orientation? D Are the marks visible on the plot? If not, check cartridges. D Are cartridges correctly aligned? If so, the problem may be in the electronics module, media motor or drive roller gear; if alignment is incorrect, the problem may be in the carriage. Load Media + Data: Firmware has a problem interacting with some of the characteristics of the print. The Printer is using an old Firmware revision Install the latest firmware revision. D If this error remains, report the problem to your HP Response Center. Note conditions and actions before error occurred. Include setup sheet and service configuration plot in report.
Steady DLM
D E F A B C G H I J
K L M N O
Steady FL
D E F A B C G H I J
K L M N O
Ready + Align Media + Load Media + Data: This is a generic System Error that covers about 600 error codes. D Report the problem to your HP Response Center. Note conditions and actions before error occurred. Include setup sheet and service configuration plot in report.
Steady DEFL
2-6
HP DesignJet 430, 450C and 455CA Printers
System Error Codes
D E F A B C G H I J
K L M N O
Ready + Align Media + Data: Communication problem with RS 232 (Serial Port). Possible causes: D Incorrect configuration in communications speed/protocol. D Incorrect communications cable. D Error in host computer. Ready + Load Media + Data: There is a communication problem between the Main PCA and the internal microprocessors. The Main PCA is faulty Replace the Electronics Module.
Steady DEL
D E F A B C G H I J
K L M N O
Steady DFL
D E F A B C G H I J
K L M N O
Ready + Cartridges + Data: Mark Encoder not detected. Possible causes: D D D D D D D D D The line on the mark encoder is dirty or missing. Faulty or badly connected trailing cable. Faulty or badly connected carriage sensor. Faulty or badly connected X axis Encoder Cable. The drive roller has shifted slightly from the expected position (mechanics). Check that the carriage sensor lights just over the white mark on the drive roller when starting. Faulty carriage PCA. Faulty X motor. Faulty Y motor. Faulty electronics module.
Steady DKL
D E F A B C G H I J
K L M N O
Align Media + Load Media + Data: Error reading Centronics I/O Problems in the Centronics Communications. Probably due to the bad contacts of the connector. D If this error remains, report the problem to your HP Response Center. Note conditions and actions before error occurred. Include setup sheet and service configuration plot in report.
Steady EFL
System Error Codes
HP DesignJet 430, 450C and 455CA Printers
2-7
D E F A B C G H I J
K L M N O
Load Media + Cartridges + Data: Problems when initializing the carriage. Possible causes: D D D D Carriage assembly is not present. Faulty or badly connected trailing cable. Faulty carriage PCA. Faulty electronics module.
Steady FKL
D E F A B C G H I J
K L M N O
Align Media + Cartridges + Data: Model ID not configured. D After replacing a new electronics module, it must be configured either as a DesignJet 430, 450C or 455CA. If a new module does not show this error, it means that it has been installed previously and was probably calibrated with other parameters. After configuring the module Error code Steady DLM will appear which means the accuracy calibration must be done. After the accuracy calibration is done, all other calibrations must be done. If configuring the module does not remove the error, even after switching the Printer OFF and ON, then the EEROM in the main PCA is probably defective. Before trying to replace the electronics module try clearing the EEROM and perform all the calibrations again and see if that solves the problem. Refer to page 4 27 in order to configure the correct model ID. For more information ' page 1 8.
Steady EKL
D E F A B C G H I J
K L M N O
Align Media + Cartridges: EEROM test error. Possible causes: D Switch the Printer OFF and ON again and see if the error remains. If the error appears continuously, replace the Electronics Module. D The Calibrations in the EEROM have been lost. Perform the Accuracy Calibration (refer to Chapter 5).
Steady EK
2-8
HP DesignJet 430, 450C and 455CA Printers
System Error Codes
D E F A B C G H I J
K L M N O
Load Media + Cartridges: Electronics Module Failure. Possible causes: D D D D Fan faulty or badly connected. Faulty ROM SIMM. Faulty RAM SIMM. Faulty Electronics Module.
Steady FK
D E F A B C G H I J
K L M N O
Align Media + Media: Y axis Shutdown. Possible causes: D Problems with the Cutter Assembly. D Clear any binding due to a media jam. D Turn the Printer off. Manually move the carriage along the carriage axis. Check for any areas where the carriage may be binding. D Ensure that the belt and belt pulley are in correct working order. Remove dirt from the pulley that could cause the belt to slip. D Perform the carriage axis test and the servo/encoder test to check for problems with the carriage motor, encoder strip, and electronics module. D Remove dirt from the slider rod and chassis beam. Apply oil (Anderol 4068, HP part number: 6040 0858) to the carriage bushings. D At high temperatures, and if the fan is not working correctly, the internal resistance of the motor driver may increase, causing a decrease in the voltage between the motor contacts, and a shutdown of the motor. D Ensure that the encoder strip is not inverted, damaged or absent. D Reconnect or replace the trailing cable ' page 8 8. D Replace the carriage assembly ' page 8 37. Ready + Align Media + Media: Y axis Movement Error. Possible causes: D Something is causing excessive friction in the Y axis (carriage axis). D The carriage touches the bail as it moves.
Steady EM
D E F A B C G H I J
K L M N O
Steady DEM
System Error Codes
HP DesignJet 430, 450C and 455CA Printers
2-9
D E F A B C G H I J
K L M N O
Ready + Load Media + Media: Error in X axis encoder quadrature. Possible causes: D D D D Incorrect routing of the motor cables. Electrical noise in motors. Faulty motor encoder. Motor received an electrostatic discharge while operating.
Steady DFM
D E F A B C G H I J
K L M N O
Align Media + Load Media + Media: Error in Y axis encoder quadrature. Possible causes: D D D D D D Damaged or broken encoder strip. Faulty or badly connected trailing cable. Incorrect routing of the motor cables. Electrical noise in motors. Faulty motor encoder. Trailing Cable received an electrostatic discharge while the Printer was operating. Replace the Trailing Cable ' page 8 8.
Steady EFM
D E F A B C G H I J
K L M N O
Align Media + Data: Cartridge Alignment Error. Possible causes: D D D D D Faulty Cartridges. Dirty or incorrect media. Faulty Line Sensor. Faulty Carriage Assembly. Faulty Electronics Module.
Steady EL
2-10
HP DesignJet 430, 450C and 455CA Printers
System Error Codes
3
User Messages
HP DesignJet 430, 450C and 455CA Printers
3-1
User Messages
The lights on the front panel provide the means for your day to day communication" with the printer. They tell you the printer's current status and, if there is an error, the nature of the error. In order to understand the meaning of each combination of lights, you should check the table in this chapter to help you to understand the meaning. You will therefore find this table useful in troubleshooting.
Key to table starting below This graphic ... means ... The fifteen lights on the printer's front panel. The sequence of explanations in the table is:
1: Status group 3: Print quality group 4: Media type group 2: Error group 5: Media source group
This light is ON and STEADY. This light is ON and FLASHING. This light is OFF or this is the relevant light. The state of this light is not relevant.
Lights No lights All lights off
Explanation and Action If no lights are on, you may have a power problem, or the printer may be switched off.
3-2
HP DesignJet 430, 450C and 455CA Printers
User Messages
Lights Status group
READY light off
Explanation and Action The printer is not ready to print.
Check the state of the other lights and look them up in this table.
READY
The printer is ready to print.
Send your print from your computer or, for a special internal print, press the appropriate key combination.
READY
PAPER
The printer is busy with a task or is receiving a file. Wait. If combined with one of the four media type group lights flashing. The printer is waiting for the media to dry. This can be terminated by pressing Form Feed. You are loading media and need to realign it, even if it seems perfectly aligned.
ALIGN MEDIA
Lower the media lever, realign the media, and raise the media lever.
The printer is ready, but you need to load media.
LOAD MEDIA
When you are ready to print, load media.
The printer has a file in memory, which it is waiting to print, but no media is loaded.
LOAD MEDIA
Load media.
User Messages
HP DesignJet 430, 450C and 455CA Printers
3-3
Lights
CARTRIDGES
Explanation and Action Either: one of the color or black print cartridges is faulty, misplaced or missing. Reseat or replace the cartridge. Or: you have loaded a print cartridge of the wrong type for this printer. For the correct part numbers of the cartridges supported by this printer, see Chapter 7.
DATA
Error Group
Either: the current print is too large for the printer's memory. Look on your computer screen for any error message: some drivers, for example the Microsoft Windows driver supplied with your printer, allow you to choose a different printing mode and try to send the file again. In the case of the Microsoft Windows 95 driver shipped with the printer, the relevant field is called "Process document" in the Options dialog box.
Otherwise, you may need to install more memory to print this print. For information on available memory expansion modules, see Chapter 7.
Or: there is a problem with the serial interface. The printer's settings for baud rate and parity must be the same as those of the computer sending the data. Either: the sheet you loaded is misaligned. Realign it again. See the Users Guide for a short tutorial on loading media. Or: it is an invalid size. For supported media sizes, refer to the Users Guide. Or: the media lever is lowered. Raise the lever. Or: the cover is open when the printer is initializing. Lower the cover.
MEDIA
3-4
HP DesignJet 430, 450C and 455CA Printers
User Messages
4
Service Tests
HP DesignJet 430, 450C and 455CA Printers
4-1
Introduction
This chapter explains how to use the built in Service Tests (Diagnostics) and what to do if the tests fail. If possible, always perform a Service Test on the component that you are about to replace, just to make sure that is the component that has failed. If the test on that component passes, there is no need to replace it.
Power On
The Printers automatically perform a series of internal self tests and mechanical initialization sequences whenever the user switches the Printer on. 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 2.) Self Test and Normal Initialization The power on self test and initialization procedure 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 EEROM checksum. 5 Tests the servo processor transfer buffer and interrupt tracking. 6 Tests the ROM checksum. 7 Causes the main processor to initialize certain firmware modules. 8 Performs a subset of the electrical service test. 9 Checks the cover sensor. If the cover is open, nothing further happens until you close it. 10 Initializes the carriage axis (Y axis). 11 Uses the mark encoder to check the start of the drive roller. 12 Ejects any loaded sheet. Does not eject roll media if loaded. 13 Checks the media sensor. 14 Sets the Printer to accept media.
4-2
HP DesignJet 430, 450C and 455CA Printers
Service Tests
Service Tests
Which Service Test to Perform
Use the following table as a rough guide:
Assembly/Feature Bail system Carriage Carriage motor and drive system (including belt, pulley and slider rod) Cartridge identification Cartridge nozzles Communication between computer and Printer Cover sensor DRAM SIMM EEROM Electronics module Tested by ... Bail cycle test, Bench run, Modular Test Carriage test, Electrical test, Modular test Carriage-axis test, Bail cycle test, Modular test, Bench run Carriage test, Modular test Carriage test, Modular test Service monitor Sensors test, Modular test Electrical test, Power-on tests, Bench run Electrical test, Power-on tests, Bench run Electrical test, Power-on tests, Servo/Encoder test, Sensors test, Bail cycle test, Front-panel test, Media-axis test, Carriage test, Carriage-axis test, Bench run, Modular test Carriage-axis test, Servo/Encoder test, Modular test, Bench run Front-panel test, Modular test Servo/Encoder test, Media-axis test, Modular test, Bench run Media-axis test, Modular test, Bench run Sensors test, Modular test Sensors test, Modular test Carriage test, Modular test Electrical test, Power-on tests, Bench run Bail cycle test Electrical test, Power-on tests, Bench run
Encoder strip Front-panel keys and LEDs Media-axis encoder and cable Media motor and drive system (including drive roller and overdrive) Media sensor Pinch-arm sensor Optical sensor (on carriage) ROM Service station Trailing cable
Service Tests
HP DesignJet 430, 450C and 455CA Printers
4-3
Service Tests (Diagnostics)
The following is a list of all internal service tests available in the Printers. Instructions for entering service mode 1 are given on page 4 6. Instructions for entering service mode 2 are given on page 4 22. 1 Bail Cycle Test ' page 4 8 This tests the operation of the bail system, Service Station and the Y axis by engaging and disengaging the bail lift mechanism and capping/uncapping the cartridges to ensure a correct lifting action. 2 Front Panel Test ' page 4 9 The purpose of this test is to verify the operation of the front panel keys and LEDs. 3 Carriage Axis (Y axis) Test ' page 4 10 The purpose of this test is to verify the operation of the components of the Carriage Axis. 4 Carriage Test ' page 4 12 The purpose of this test is to verify the operation of the Carriage subsystems, like the Line Sensor and analog multiplexer. This test also checks the connection between the carriage flex circuit and the cartridges. 5 Sensors Test ' page 4 15 This tests the operation of the cover sensor, pincharm sensor and media sensor. 6 Media Axis (X Axis) Test ' page 4 16 The purpose of this test is to verify the operation of the components of the Media Axis. 7 Bench Run ' page 4 18 This test has been designed to be used during the manufacturing stage and not in the field. do not at anytime enter this test when troubleshooting the Printer. 8 Modular Test ' page 4 19 This test has been created to check the interaction between various components of the Printer. It combines the following tests:
D D D D D
Carriage axis test. Carriage test. Media axis test. Front panel test. Sensors test.
HP DesignJet 430, 450C and 455CA Printers
4-4
Service Tests
9 Electronics Test ' page 4 21 The purpose of this test is to verify the operation of the FIBIS Column address and the shuffler. 10 Bail Test ' page 4 23 This tests the operation of the bail system, Service Station and the Y axis by engaging and disengaging the bail lift mechanism and capping/uncapping the cartridges. 11 Electrical Test ' page 4 24 This tests the operation of some of the electrical components of the electronics module. 12 Servo/Encoder Test ' page 4 25 The servo/encoder test performs the following:
D D D
Media axis encoder test: Verifies the operation of the servo loop (media axis feedback). Carriage axis encoder test: Verifies the operation of the servo loop (carriage axis feedback). Records the maximum friction detected in the EEROM. You can view this information on the service configuration plot.
13 Service Monitor ' page 4 26 The service monitor is useful to find out why the Printer is not plotting what you expect it to plot. It enables you to read the graphics language instructions that the Printer is receiving from the computer. Instead of plotting the drawing that you send, the Printer prints the beginning and end of the code that would otherwise have been used to plot the drawing. 14 EEROM Model ID Configuration Procedure ' page 4 27 This procedure is necessary if the Printer needs to be reconfigured as a DesignJet 430, 450C or 455CA. 15 Service Configuration Plot ' page 4 29 Gives a service report of the Printer. 16 Clearing the EEROM ' page 4 32 Instructions on how to clear the EEROM.
Service Tests
HP DesignJet 430, 450C and 455CA Printers
4-5
Service Mode 1
Service Mode 1 contains tests that do not need a complete initialization of the Printer. This means if there is a system error in normal mode, it is still possible to enter into Service Mode