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HP DesignJet650C
User Guide
SERVICE MANUAL
HP C2858A/C2859A
DRAFTING PLOTTERS
SERIAL NUMBERS
This manual applies directly to HP C2858A and C2859A
plotters with serial numbers prefixed USA.
For additional information about serial numbers, see
SERIAL NUMBER INFORMATION in Chapter 1.
HEWLETT-PACKARD COMPANY 1993
16399 W. BERNARDO DRIVE
SAN DIEGO, CALIFORNIA 92127-1899
C2858-90000 Printed: March 1993
Using this Manual
This service manual contains information necessary to test, adjust, and service the
Hewlett-Packard Models C2858A and C2859A DesignJet 650C plotters. It is designed to
help you easily find the cause of a C2858A/C2859A hardware problem and to perform the
necessary repairs and adjustments to get the plotters into proper operating condition.
Service strategy for this manual is to support the products to the field replaceable unit.
For ease of reference, this manual is divided into ten chapters as follows:
Chapter1 Product Information
Chapter2 Site Planning and Requirements
Chapter3 Installation and Configuration
Chapter4 Preventive Maintenance
Chapter5 Functional Overview
Chapter6 Removal and Replacement
Chapter7 Adjustments/Calibrations
Chapter8 Troubleshooting
Chapter9 Product History
Chapter10 Parts and Diagrams
Chapter 1. Product Information
This chapter contains general information regarding the C2858A and
C2859A DesignJet 650C plotters. A description of the plotters features,
options and accessories, performance characteristics, and serial number
information, is included in this chapter.
Chapter 2. Site Planning and Requirements
Included in this chapter is pre-installation information regarding the
physical, environmental and electrical requirements for proper installation
and operation of the plotters.
Chapter 3. Installation and Configuration
In this chapter you will find installation, configuration and plotter
verification procedures. Included is information on ink cartridge and media
loading, accessing the front-panel menu structures for plotter configuration
and instructions on how to perform built-in demonstration plots to verify
proper plotter operation.
Using this Manual iii
Chapter 4. Preventive Maintenance
Chapter 4 contains information you will need to keep the plotters in their
best operating condition. Included are procedures that can be performed by
the user.
Chapter 5. Functional Overview
This chapter contains a simplified description of the plotter circuits and
mechanical functions.
Chapter 6. Removal and Replacement
Procedures for the removal and replacement of field replaceable units are
provided in this chapter along with electrostatic discharge information and
recommended tools to perform repairs.
Chapter 7. Adjustments
Here you will find descriptions of any adjustments and calibrations that may
be required to return the plotter to proper operating condition.
Chapter 8. Troubleshooting
Included in Chapter 8 are service tests, error codes and messages, and
diagnostic information to assist you in troubleshooting and solving plotter
symptoms and failures.
Chapter 9. Product History
Chapter 9 provides historical tracking of changes made to the plotters. The
differences between earlier versions of the plotters and the version
described in the main body of this manual are identified.
Chapter 10. Parts and Diagrams
In this chapter you will find drawings for purposes of identifying the various
field replaceable assemblies. Also in this chapter are associated parts lists
for ordering replacement parts shown on the drawings.
Glossary
The glossary contains a listing of terms used throughout the manual.
Index
Use the index to find references and locate subject matter in this manual.
Using this Manualiv
Contents
Chapter Page
1 Product Information
Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Options 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plug-in Memory 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROM Enhancement Modules 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modular Input/Output (MIO) PCAs 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performance Characteristics 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial Number Information 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Site Planning and Requirements
Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Specifications 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Requirements 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Cord Set 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environmental Specifications 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Physical Specifications 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable Restrictions 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RS-232-C Interface 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Centronics Interface 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HP-IB Interface 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Installation and Configuration
Introduction 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Instructions 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
User-Installable Modules 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connectivity 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Voltage and Fusing 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Cord Configurations 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
User Information and Operation 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media Guidelines 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media Type and Print Quality 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media Cutting and Stacking 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Usable Media Sizes 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Chapter Page
Loading Roll Media 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unloading Roll Media 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading Sheet Media 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unloading Sheet Media 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearing Media Jams 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pen Checking 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessing Pens 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Pens 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selectable Ink-Drying Times 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Controls 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Menus 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Languages 3-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Messages 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational Verification 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power-On Self-Test 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Demonstration Plot 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Preventive Maintenance
Introduction 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Effect on Product Reliability 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventive Maintenance Procedures 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Cleaning 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Roller Cleaning 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Functional Overview
Introduction 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Simplified Description of Circuits 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Overview 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printed Circuit Assembly (PCA) Overview 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main PCA 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carriage PCA 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interconnect PCA 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel PCA 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drop and Bail Sensors 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply PCA 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vi Contents
Chapter Page
6 Removal and Replacement
Introduction 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Considerations 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ESD Considerations 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Procedures 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRAM SIMM and ROM Module Removal 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
MIO Card Removal 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronics Enclosure Cover Removal 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interconnect PCA Removal 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main PCA Removal 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outer Electronics Enclosure Assembly Removal (C2858A Only) 6-11. . . . . . . . . .
Power Supply PCA Removal 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Removal 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Window Assembly Removal 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Endcovers (Left and Right) Removal 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primer Assembly and Sensor Removal 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinch Wheel Sensor Removal 6-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Window Sensor Removal 6-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media Sensor Removal 6-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailing Cable Removal 6-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back Panel Removal 6-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Removal 6-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carriage Motor Removal 6-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Motor Removal 6-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encoder Strip Removal 6-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rollfeed Cover Assembly Removal 6-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rollfeed Module Assemblies (Left and Right) Removal 6-31. . . . . . . . . . . . . . . . .
Cutter Assembly Removal 6-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailing Cable Guide Removal 6-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Y-Tensioner and Housing Removal 6-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pen Carriage Assembly and Main Drive Belt Removal 6-38. . . . . . . . . . . . . . . . . .
Drop Detect and Bail Sensors Removal 6-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starguard Assembly Removal 6-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bail Assembly Removal 6-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Station Assembly Removal 6-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overdrive Support Assembly Removal 6-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
viiContents
Chapter Page
Cutter Enclosure Assembly Removal 6-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Entry Platen Assembly Removal 6-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Roller Assembly Removal 6-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Bail Lift Mechanism Removal 6-55. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media Diverter Removal 6-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinch Arm and Lift Mechanism Removal 6-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Adjustments/Calibrations
Introduction 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calibrations 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sheet Length Calibration 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accuracy Calibration 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media Sensor Calibration 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drop Detect Calibration 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Edge Sensor Calibration 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bail Calibration 7-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Troubleshooting
Introduction 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostics 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power-On Self Tests 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power-On Self Test 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Initialization 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error Messages and Codes 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Worded Error Messages 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Error Codes 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Data Plot 8-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servo System Control Failures 8-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Tips 8-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROM Code Revision Level 8-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Tests 8-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration Plot 8-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Pattern Analysis 8-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading the EEROM Text Block 8-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analyzing the Pen Nozzle Test Block 8-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
viii Contents
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Page
9 Product History
Introduction 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
History of Assemblies by Serial Number 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
History of Printed Circuit Assemblies (PCAs) 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Parts and Diagrams
Introduction 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exchange Assemblies 10-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replaceable Parts 10-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Illustrated Parts Breakdown Drawings 10-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Labels and Cables 10-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
ix
General Definitions of Safety Symbols
International caution symbol (refer to manual): the product will be
marked with this symbol when it is necessary for the user to refer
to the instruction manual in order to protect against damage to the
instrument.
Indicates dangerous voltage (terminals fed from the interior by
voltage exceeding 1000 volts must also be marked).
Protective conductor terminal. For protection against electrical
shock in case of a fault. Used with field wiring terminals to indi–
cate the terminal which 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.
Frame or chassis terminal. A connection to the frame (chassis) of
the equipment which normally includes all exposed metal.
x
Alternating current
Direct current
Alternating or direct current
The WARNING sign denotes a hazard. It calls attention to a pro–
cedure, practice, or the like, which, if not correctly performed or
adhered to, could result in personal injury.
The CAUTION sign denotes a hazard. It calls attention to an op–
erating 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.
Safety
Chapter 1 Product Information
INTRODUCTION
This chapter contains a listing of documentation supplied with the HP C2858A and C2859A
DesignJet 650C plotters. Also provided are: descriptions of the plotters, information on the
plotter features, options and accessories, performance characteristics, and plotter serial
number information.
Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Options 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plug-in Memory 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROM Enhancement Modules 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modular Input/Output (MIO) PCAs 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performance Characteristics 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial Number Information 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1Product Information
DESCRIPTION
HP C2858A and C2859A DesignJet 650C plotters provide graphic displays of computer program output data. They operate with a number of computer systems and graphic terminals,
using either RS-232-C or Centronics external controllers. With one of several optional, modular input/output (MIO) cards installed, the plotter can operate: with an HP-IB external controller, within a Novell Ethernet or Token ring network, as a TCP/IP host workstation, with a
LAN Manager, with Ethertalk and with Apple LocalTalk.
The C2858/9A DesignJet 650C plotters will accept drawing data from Computer Aided Design (CAD) software programs supporting the HP-GL (vector), the HP-GL/2 (vector), HP
RTL (raster), and PJL languages. HP-GL/2 is available with Kanji character sets when the
Kanji ROM SIMM is installed. Postscript is also available when the PostScript ROM SIMM
upgrade is installed.
The HP C2858/9A DesignJet 650C plotters (see Figure 1-1) are large-format, color and
monochrome, ink-jet plotters designed to plot monochrome plots on commonly available
opaque bond paper, translucent (Japanese tracing) paper, vellum, or special inkjet-compatible drafting film. Quality color output is only supported when using HP special inkjet paper.
C2858/9A DesignJet 650C plotters can produce plots on single-sheet media or roll-feed media. Large format plots of high resolution and quality are generated for applications such as
computer aided design (CAD), computer aided manufacturing (CAM), mapping, mechanical and architectural drawings, and general drafting.
Five high-capacity ink cartridges are provided with the C2858/9A plotters. Selectable penwidth settings are modified to ISO standard pen widths. The cartridges simultaneously scan
across the media providing 300 dpi resolution in draft and final modes, 300 dpi addressable
resolution for color in enhanced mode and 600 dpi addressable resolution for monochrome in
enhanced mode.
C2858A plotters can plot on media sizes ranging from International Standards Organization
(ISO) sizes A1 through A4, American National Standards (ANSI) sizes A through D, and
architectural media sizes C and D. Model C2859A plotters can plot on media sizes ranging
from International Standards Organization (ISO) sizes A0 through A4, American National
Standards (ANSI) sizes A through E, and architectural media sizes C through E. Roll-feed
capability allows the plotters to perform long-axis plotting in lengths up to 50 feet.
1-2 Product Information
Figure 1-1.
The standard HP C2858/9A DesignJet 650C has four megabytes of on-board random access
memory (RAM). Memory expansion upgrades to 20 MB are available as well as various
ROM enhancement and modular I/O options. Other features that are standard include:
Automatic media edge sensing
Automatic pen alignment, testing and servicing
Automatic media stacking with adjustable media bin
An automatic, single-axis cutter
Queueing, nesting and expanded margin capabilities
Easy-to-read 2 row by 20 character vacuum fluorescent display (VFD)
Built-in diagnostic and demonstration plot routines
1-3Product Information
OPTIONS
PLUG-IN MEMORY
C2858/9A DesignJet 650C plotters have two memory expansion sockets. Each can hold either a four-megabyte or eight-megabyte, Single In-line Memory Module (SIMM). Therefore, memory can be expanded by 4, 8, 12 or 16 megabytes. The SIMM part numbers are:
Four Mbyte SIMM = P/N C2065A
Eight Mbyte SIMM = P/N C2066A
ROM ENHANCEMENT MODULES
Two ROM expansion sockets are also provided in the C2858/9A DesignJet 650C plotters.
Each will hold a single ROM enhancement SIMM. The ROM SIMMS could include firmware revision upgrades or language enhancements. A Kanji ROM SIMM is available for Japanese users who require the Kanji character sets. A PostScript upgrade is also available in
ROM SIMM. The part numbers for the kits are:
Kanji ROM Kit = P/N C2847-60031
PostScript ROM Kit = P/N C2882A
MODULAR INPUT/OUTPUT (MIO) PCAs
Interface circuitry is provided on the plotters which allows the user to install HP supported
modular I/O (MIO) cards for several interface applications. Although multiple protocols
may reside on an MIO, they are not simultaneously supported, only one protocol at at time
can be used. The MIO card part numbers are:
Multi-protocol Ethernet for Novell, TCP/IP, LAN Manager, Ethertalk
with RJ-45 (twisted pair) and BNC (ThinLAN) connectors) = P/N J2372A
with RJ-45 (twisted pair) connector only = P/N J2371A
Multi-protocol Token Ring for Novell, LAN Manager = P/N J2373A
HP-IB = P/N C1642A
Apple LocalTalk = P/N J2341A
1-4 Product Information
ACCESSORIES
The items listed in Table 1-1 are supplied with each plotter. Miscellaneous application notes,
flyers and driver disks are also provided. Depending upon the country of destination, the part
numbers of items listed as English or U.S. will differ. Accessories available for use with the
C2858/9A DesignJet 650C plotters are listed in the Supplies Catalog.
Table 1-1. Accessories Supplied
Description
C2858A/C2859A Manual Kit (English)
includes: Using Your Plotter’s Front Panel
Guide, Setting Up For Plotting Guide, and
Quick Reference Guide
Power Cord (U.S.) 1 8120–1378
Media Sampler Roll (CX Jet Series)
24ºx150’ C2858A
36ºx150’ C2859A
Pens: Black
Cyan
Magenta
Yellow
Hardware Kit 1 C2847–60061
Cable Management Hardware Kit 1 C2847-60030
Front Panel Overlay (English) 1 C2858–60026
Guide/Cutter Holder 1 C1633–40094
Manual Cutter 1 17291C
Supplies Catalog 1 5091–3485EUS
Supplies Catalog Update 1 5091–6787EUS
Unpackaging Instructions 1 C2858–90003
Spindle Assembly: C2858A
C2859A
Spindle Flange 1 07596-40076
Spindle Spacer 1 07596-40077
Qty HP Part Number
1 C2858–90051
1
1
2
1
1
1
1
1
51631D
51631E
51640A
51650C
51650M
51650Y
C2847-60033
07596-60060
1-5Product Information
PERFORMANCE CHARACTERISTICS
Table 1-2 lists the performance characteristics of the plotters.
Table 1-2. Performance Characteristics
Accuracy
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% RH, on HP film (monochrome mode only).
Throughput
D-sized loaded vertically: plain paper special paper special paper
monochrome monochrome color
Draft mode 1.8 min. 1.8 min. 3.4 min.
Final mode 3.2 min. 2.7 min. 4.3 min.
Enhanced mode 6.5 min. 6.5 min. 8.7 min.
Resolution
Draft Mode 300 dpi addressable
Final Mode 300 dpi addressable
Enhanced Mode 300 dpi addressable (color)
600 dpi addressable (monochrome)
Margins
Leading and Trailing 17 mm ( 2mm) (normal plot area),
10 mm (expanded plot area)
Sides 5 mm (normal or expanded plot area)
Media Dimensions
Sheet and Roll
Maximum Widths D (A1)-size 619 mm (24 in.)
E (A0)-size 917 mm (36 in.)
Roll
Maximum Media Length 150 feet (125 ft. for film)
SERIAL NUMBER INFORMATION
If the plotter serial number has a lower revision letter than the one shown on the title page,
information in the Product History chapter, Chapter 9, will adapt this manual to that plotter.
1-6 Product Information
Chapter 2 Site Planning and Requirements
INTRODUCTION
This chapter contains information concerning the electrical requirements for the installation
of HP C2858A and C2859A plotters. Also included is information on environmental operating conditions and physical specifications for the plotters.
Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Specifications 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Requirements 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Cord Set 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environmental Specifications 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Physical Specifications 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable Restrictions 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RS-232-C Interface 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Centronics Interface 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HP-IB Interface 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1Site Planning and Requirements
ELECTRICAL SPECIFICATIONS
POWER REQUIREMENTS
HP C2858A and C2859A DesignJet 650C plotters have self-adjusting power supplies and do
not require voltage selector or switch settings prior to use. Table 2-1 lists the power requirements for the plotters.
Table 2-1. Power Requirements
Voltage Requirements
Voltage Current (max)
100 Vac 1.4 A
120 Vac 1.2 A
220 Vac 650 mA
240 Vac 600 mA
Frequency
Consumption 140 Watts maximum
47-53 Hz and 57-63 Hz
Source
LINE CORD SET
W A R N I N G
The configuration of the ac line cord set required for use with the plotters is determined by the
country of destination for the plotters. Refer to Chapter 3 for a listing of the available ac line
cord connectors.
2-2 Site Planning and Requirements
ENVIRONMENTAL SPECIFICATIONS
Table 2-2 lists environmental specifications for the plotters.
Table 2-2. Environmental Specifications
Temperature
Storage
Operating
Optimal Operating
Relative Humidity (Operating) 20 to 80 % RH
–40 to +70 C (–40 to +158 F)
0 to +55 C (+32 to +131 F)
+15 to +30 C (+59 to +86 F)
PHYSICAL SPECIFICATIONS
The plotter physical specifications are listed in Table 2-3.
Table 2-3. Physical Specifications
C2858A C2859A
Length
Depth
Height
Weight
1092 mm (43 in) 1372 mm (54 in)
711 mm (28 in) 711 mm (28 in)
1169 mm (46 in) 1219 mm (48 in)
58 kg (128 lbs) 70 kg (155 lbs)
Packaging:
Plotter Body
Length
Width
Height
Weight
Leg Pack
Length
Width
Height
Weight
1270 mm (50 in) 1574 mm (62 in)
584 mm (23 in) 584 mm (23 in)
635 mm (25 in) 635 mm (25 in)
68 kg (150 lbs) 68 kg (150 lbs)
940 mm (37 in_ 1219 mm (48 in)
711 mm (28 in) 762 mm (30 in)
229 mm (9 in) 229 mm (9 in)
21 kg (45 lbs) 25 kg (55 lbs)
2-3Site Planning and Requirements
CABLE RESTRICTIONS
Cable restrictions for the plotter are determined by the type of interface being used. Recommendations for each interface are supplied in the following paragraphs.
RS-232-C INTERFACE
The use of short cables (each less than 15 metres or 50 feet) is recommended for the
RS-232-C Interface. Longer cables are permissible, provided the load capacitance does not
exceed 2500 picofarads.
CENTRONICS INTERFACE
The use of short cables (each less than 2 metres or 6.6 feet) is recommended for the Centronics Interface.
HP-IB INTERFACE
The HP-IB (Hewlett-Packard Interface Bus) allows up to 15 devices to be connected. The
maximum cable length is restricted to 2 metres (6.6 ft.) per device up to a total of 20 metres
(65.8 ft.). The devices may be connected in a star or linear bus network.
2-4 Site Planning and Requirements
Chapter 3 Installation and Configuration
INTRODUCTION
This chapter contains the information required to configure and verify proper operation of
the HP C2858A and C2859A DesignJet 650C plotters. Print cartridge and media loading procedures, as well as front panel menu structures, are also provided.
Introduction 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Instructions 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
User-Installable Modules 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connectivity 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Voltage and Fusing 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Cord Configurations 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
User Information and Operation 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media Guidelines 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media Type and Print Quality 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media Cutting and Stacking 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Usable Media Sizes 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading Roll Media 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unloading Roll Media 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading Sheet Media 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unloading Sheet Media 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearing Media Jams 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pen Checking 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessing Pens 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Pens 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selectable Ink-Drying Times 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Controls 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Menus 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Languages 3-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Messages 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational Verification 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power-On Self-Test 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Demonstration Plot 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1Installation and Configuration
INSTALLATION INSTRUCTIONS
USER-INSTALLABLE MODULES
Expansion sockets located behind a panel at the rear of the plotter allow the user to install
additional memory modules. These SIMMs (single in–-line memory modules) are available
in 4MB and 8MB sizes. Installation is accomplished by removing the access panel (4
screws), installing the module(s), and reattaching the access panel. ROM sockets are also
provided for use with ROM enhancements as developed. Installation instructions are provided with the modules and also provided in Chapter 6 of this manual. Information on ordering the memory expansion and ROM modules is provided in Chapter 1 of this manual.
An interface port on the back of the plotter allows the user to select one of several available
modular interfaces at a time. The modular I/O cards can be easily changed to match the desired application. Installation instructions are provided with the modules and also provided
in Chapter 6 of this manual. Information on ordering the modular I/Os is provided in Chapter
1 of this manual.
CONNECTIVITY
Depending upon the interface and hardware being used to drive the plotters, different cables
could be required. A listing of cables and other connectivity related issues is provided in the
DesignJet 650C documentation listed in Chapter 1 of this manual.
LINE VOLTAGE AND FUSING
The HP C2858/9A DesignJet 650C plotter ’s power supply automatically adjusts to the input
voltage. The plotter’s autoranging power supply accepts an input of 90 to 264 Vac.
POWER CORD CONFIGURATIONS
Power cord configurations shipped with the plotter depend upon the country of destination
for the plotter. See Figure 3-1 for information on the power cord configurations available for
use with the plotters. When connecting the plotter to the ac source, ensure that the appropriate
power cord is used.
3-2 Installation and Configuration
BS 1363A
Option No.
AS C112
CEE 7–VII
NEMA 5–15P
NEMA 6–15P
SEV 1011
250 Vac, 13 A, Single Phase plug rating.
For use in United Kingdom, Cypress,
Nigeria, Zimbabwe, Singapore.
250 Vac, 10 A, Single Phase plug rating.
For use in Australia, New Zealand.
250 Vac, 10/16 A, Single Phase plug rating.
For use in East and West Europe, Egypt.
125 Vac, 15 A, Single Phase plug rating.
For use in Canada, Mexico, Philippines,
Taiwan, Saudi Arabia, UL approved in the
United States
250 Vac, 15 A, Single Phase plug rating.
For use in Canada, UL approved in the
United States.
250 Vac, 10 A, Single Phase plug rating.
For use in Switzerland.
900
901
902
903
904
906
DHCK–107
MITI 41–9692
NOTE:
250 Vac, 10 A, Single Phase plug rating.
For use in Denmark.
250 Vac, 10 A, Single Phase plug rating.
For use in India, Republic of South Africa.
125 Vac, 12 A, Single Phase plug rating.
For use in Japan.
All plugs are viewed from the power outlet connector end.
L = Line or Active Conductor (also called ªliveº or ªhotº)
N = Neutral or Identified Conductor
E = Earth or Safety Ground
Figure 3-1.
912
917
918
3-3Installation and Configuration
USER INFORMATION AND OPERATION
MEDIA GUIDELINES
Guidelines on media handling are:
The leading edge must be straight and each side must be loaded evenly. If the
leading edge is jagged, trim it with the media knife (located in the manual holder at
the back of the plotter) using the track on top of the plotter as a guide.
If media is curled, load it with the curl up. The exception to this is film media,
which must always be loaded with the plotting side (matte side) down.
Roll media must be flush with the right edge of the core.
Film should be handled by the edges or when wearing cotton gloves. Load film
with the matte side down (shiny side up).
MEDIA TYPE AND PRINT QUALITY
DesignJet 650C plotters have several combinations of plotting modes. Each mode is dependent upon the color/monochrome setting, media type, and print quality settings input through
the front panel. Interaction between the settings produces the ten modes. Each mode has a
unique combination of print resolution, number of passes and resultant ink-drying time.
Media Type is set through the front panel when media is loaded into the plotter. The front
panel display prompts the user to select for sheet or roll loading and then to scroll through the
menu and select for one of the five media types listed below. The menu selection should be set
to match the media type being used.
Opaque bond (paper)
Film
Special paper
Vellum
Translucent
A front panel button allows you to plot in one of three Plot Quality modes. Continuous pressing of the button toggles through the modes and the associated LEDs are lit indicating the
current print quality mode selection. The Plot Quality modes are:
Draft
Final
Enhanced
3-4 Installation and Configuration
Real-time switching between plotting modes is not supported. If the user selects another
mode while plotting, the plotter waits until the current plot is finished and then switches to the
newly selected mode.
MEDIA CUTTING AND STACKING
Automatic and manual cutting of plots is available on the C2858/9A. In roll media operations, the user can choose between continuous plotting or cutting plots off the roll automatically as they are completed.
Automatic cutting When roll media is loaded, whether or not queueing is
ON, the plotter automatically cuts plots and drops them
into the media bin. When queueing and nesting are ON,
the plotter cuts each nest. The automatic cutter can be
programmatically disabled. When cutting is disabled, the
plotter draws tick marks at the plot margins to indicate
the end of a plot or nest. The automatic cutter can be
enabled programmatically or by cycling power.
Manual cutting The front panel Form Feed/Cut button can be used to
feed the media out and cut it after a plot is completed.
Media stacking Unattended stacking of cut sheets is provided by the
adjustable media bin. The user must adjust the movable
shelf of the bin according to the length of the cut sheets.
Bin capacity is 20 sheets.
Manual cutter A manual cutter is provided with the plotter for hand-
cutting of media and is stored in the manual holder on
the back of the plotter.
3-5Installation and Configuration
USABLE MEDIA SIZES
Media of different types and sizes can be used on the plotters. Refer to Table 3-1 for the media
sizes usable on each plotter.
Table 3-1. Media Sizes
C2858A
ISO A4 - A1 ISO A4 - A0
ANSI A - D ANSI A - E
ARCH A - D ARCH A - E
JIS B4 - B2 JIS B4 - B1
Oversize A2 Oversize A1
24 in. Wide Roll 24 in. Wide Roll
C2859A
36 in. Wide Roll
LOADING ROLL MEDIA
If the spindle is already loaded into the plotter, remove the spindle by opening the roll cover
and pulling on both ends of the spindle to remove it from the plotter. To load roll media into
the plotter, put a roll of media on the plotter spindle and insert the spindle in the plotter by
performing the following steps:
W A R N I N G
Be sure that the plotter wheels are locked to prevent
the plotter from moving while loading roll media. To
lock the wheels, press the locking levers on the wheels
to the down position.
1. Standing the spindle on the end opposite the large, scalloped media stop, pull the
scalloped media stop to release the spindle from the used roll. Set the spindle aside.
Turn the used roll over and slip the endcap out with your finger. See Figure 3-2.
2. Slide the roll onto the spindle with the leading edge winding clockwise. Push the
endcap into the media core, making sure the tabs are flush against the edge of the
roll. See Figure 3-3.
3-6 Installation and Configuration
(C) C2847-10(UM)
(C) C2847-16(UM)
Removing the Media Stop and Endcap
Figure 3-2.
Sliding the New Roll onto the Spindle
Figure 3-3.
3-7Installation and Configuration
3. Open the roll cover and insert the spindle, with the endcap at the left and the media
stop at the right. Firmly push on both ends. See Figure 3-4.
Roll Cover
Pinchwheel Lever
(C) C2847-31(UM)
Installing the Spindle
Figure 3-4.
4. Once the roll is in place, push the media all the way to the right, so that it’s flush
against the media stop.
5. Ensure that the pinchwheel lever at the right of the plotter is down.
6. Turn the plotter ON, if it is not already ON.
7. Grasp the leading edge of the media and pull about one foot (30 cm) of media out
from the roll. Check the leading edge of the media. If it appears uneven, or to ensure
a straight edge, the edge will need to be trimmed.
W A R N I N G
The cutter blade is very sharp. Use caution when using the
cutter to trim or cut media. Keep hands away from the blade
when cutting. Retract the blade into the cutter after use.
8. Trim the leading edge if it’s uneven. Pull it over the top of the plotter and lay it over
the cutting track. Using the cutter located in the holder at the back of the plotter, cut
off the first few inches of the media. See Figure 3-5. Return the cutter to the holder.
9. Load the leading edge, aligning the right edge with the perforated line on the entry
platen. Push the media in until it buckles slightly as it hits the stops inside the plotter.
Let go when the plotter begins to pull the media in. See Figure 3-6.
3-8 Installation and Configuration
Cutting Track
(C) C2847-15(UM)
(C) C2847-7(UM)
Trimming the Leading Edge of the Media
Figure 3-5.
Insert Media Until
it Buckles Evenly
Align Media with
Perforation Line
Loading the Leading Edge of the Media
Figure 3-6.
10. When the front panel displays ªSheet load/Roll load,º press the Down Arrow
button to select ªRoll load.º
11. When the front panel displays ªSELECT MEDIA,º press the Up or Down Arrow
button to scroll through and select the media choice. Press the Enter button to set the
plotter for the media type being used. The plotter will now load the roll of media.
12. When indicated on the front panel, raise the pinchwheel lever to the up position.
13. When ªPull
/ Align edges to rollº is displayed on the front panel, pull the left
and right edges of the roll toward you until taut. Then align the left and right edges of
3-9Installation and Configuration
the media so that they are flush with the left and right edges of the roll. See
Figure 3-7.
(C) C2847-97(UM)
(C) C2847-97a(UM)
Aligning the Left and Right Edges of the Media
Figure 3-7.
14. When the front panel instructs you, lower the pinchwheel lever. The plotter checks
to make sure the roll is properly aligned.
15. When ªClose roll cover/Continue
º is displayed, rewind the media stop to take up
any slack in the roll. Make sure the leading edge of the media is outside the roll cover, then close the roll cover. Press the Down Arrow button to continue. The plotter
trims off the first few inches of media. When roll loading is complete, the ªSTATUS
Ready to plotº message is displayed.
UNLOADING ROLL MEDIA
To unload roll media from the platen without removing the spindle from the plotter, do the
following steps:
1. Raise the pinchwheel lever to the up position.
2. Open the roll cover and turn the media stop to wind the media back onto the spindle.
3. Close the roll cover.
4. Lower the pinchwheel lever to the down position.
To remove the spindle with roll media, perform steps 1 and 2 above, then pull on both ends of
the spindle to remove it from the plotter.
3-10 Installation and Configuration
LOADING SHEET MEDIA
To load sheet media, perform the following steps:
1. Ensure that the pinchwheel lever is down and the roll cover is closed.
2. Load the leading edge of the sheet making sure to push the sheet in straight (not
skewed) while aligning the right edge of the sheet with the perforated line on the
entry platen. See Figure 3-8.
Insert Media Until
it Buckles Evenly
Align Media with
(C) C2847-15a(UM)
Perforation Line
3. Push the sheet in until it buckles slightly as it hits the stops inside the plotter. (The
buckling should be even across the width of the sheet.) Let go as soon as the plotter
begins to pull the media in.
4. When the front panel displays ªSheet load/Roll load,º press the Up Arrow button to
select ªSheet load.º
5. When the front panel displays ªSELECT MEDIA,º press the Up or Down Arrow
button to scroll through and select the media choice. Press the Enter button to set the
plotter for the media type being used. The plotter will now load the sheet of media.
6. The plotter moves the sheet in and out to check its size and alignment, then advances
it to the start of the page. When sheet loading is complete, the ªSTATUS Ready to
plotº message is displayed.
3-11Installation and Configuration
If difficulty in loading sheet media is experienced, an alternate method of loading is possible.
Do the following:
1. Ensure that the pinchwheel lever is down and the roll cover is closed.
2. Raise the window on the plotter.
3. Insert the sheet into the plotter until the leading edge hits the stops inside the platen
area. Align the right side of the sheet with the perforation line on the entry platen.
4. While holding the sheet against the stops and aligned with the perforation line, lower
the window on the plotter. Let go as soon as the plotter begins to pull the media in.
Perform steps 4 through 6 of the sheet loading procedure on the previous page to set the plotter for the media type being used.
UNLOADING SHEET MEDIA
To remove an unplotted sheet, press the Form Feed/Cut button and remove the sheet when
the plotter is finished feeding it out. Another way to remove unplotted sheet media is to raise
the pinchwheel lever at the right, remove the sheet, and lower the lever.
CLEARING MEDIA JAMS
To clear a media jam, first press the Form Feed/Cut button to see if the plotter will cut, and
advance the media out. Should the jam remain, turn the plotter OFF and raise the pinchwheel
lever and window to the up position.
W A R N I N G
If necessary, push the ink-cartridge carriage and the cutter carriage away from the jammed
media. Handle only the solid plastic part of the ink-cartridge carriage and the extension on the
left end of the cutter carriage. Carefully remove the jammed media from the plotter. When
finished, lower the window and pinchwheel lever before turning the plotter back ON.
3-12 Installation and Configuration
The steel encoder strip and automatic cutter blade inside the
plotter are very sharp. Use caution when inserting hands
into the plotter to clear media.
PEN CHECKING
Ink usage for cartridges may vary depending upon the ratio of color versus monochrome
plotting and the extent of each color used. Cartridge replacement is necessary only when any
of the following conditions occur:
Pen Checking is ON and you elect to replace the cartridges when the plotter
prompts you.
Poor plot quality indicates an out of ink condition or the cartridges appear clogged.
When Pen Checking is ON (default), the plotter checks the pens both before and after each
plot for proper electrical contact and nozzle function.
If either of the problems exist, the plotter displays the message ªService pens/Continueº,
You may elect to either ignore the message and continue by pressing the Down Arrow or
select ªService pensº by pressing the Up Arrow button. If you select ªService pens,º the
display tells you whether a pen needs to be replaced (nozzles aren’t working) or reseated
(poor electrical contact). The defective pen position is indicated by a flashing icon in the front
panel display.
When Pen-checking is OFF, the plotter does not check the pens for the above problems; the
only way you’ll be able to tell if you need to replace or reseat a pen is if your print quality is
poor. Use the ink level indicators on the cartridges to check ink levels.
Perform the following steps to change the current pen checking selection.
1. Press Enter button and use the arrow buttons to scroll to the Utilities menu.
2. Press Enter button and use the arrow buttons to scroll to ªMenu Modeº. Press
the Enter button.
3. Use the arrow buttons to toggle to ªFullº and press the Enter button.
4. Use the Previous button to return to the Status display.
5. Press Enter button and use the arrow buttons to scroll to the Plotter setup menu.
Press the Enter button.
6. Using the arrow buttons, scroll to ªPen checkº and press the Enter button.
7. Using the arrow buttons to toggle the options, select the option you want (ªOFFº or
ªONº) and press the Enter button.
3-13Installation and Configuration
Figure 3-9 shows you how to visually check the ink level in a cartridge.
Checking the Ink Level
Figure 3-9.
ACCESSING PENS
Press the Access Pens button to access the pen carriage when you need to replace, reseat, or
clean pens. The pen carriage will move into the platen area to allow easy access to the pens.
Each time the pen carriage moves out from its service station so that you can access the pens,
the pen nozzles are exposed to the air. If the pen nozzles are exposed to the air (except during
plotting) for more than a few minutes at a time, they are susceptible to clogging and drying.
Each time you remove a pen from its slot and then put it back, the plotter performs the pen
alignment procedure automatically.
REPLACING PENS
The pens should be replaced in response to a Pen Checking prompt or poor plot quality. Four
high-capacity ink cartridges are used in the plotter. Pen life expectancy is dependent on the
type of media and plotting mode used.
To replace the pens, perform the following steps:
Note
The four pens must be loaded in their designated pen slots in the carriage.
Use the color label on the cartridges and color dots on the carriage to match
positions. The plotter should be powered on when changing pens. If you selected ªService pensº from the display, skip step 1.
3-14 Installation and Configuration
1. Press the Access Pens button. The pen carriage moves out from the pen service sta-
tion at the left of the plotter and stops in front of the slot in the bail.
2. When the pen carriage stops and the display reads ªOpen window to access pens,º
open the window.
Note
If you don’t open the window within 30 seconds after the message is displayed, the pen carriage returns to the pen service station.
3. Refer to the plotter display. The display indicates, via flashing icon(s), which pen
position(s) is/are detected to be in need of servicing. The four icons represent the
following pen positions: outer left = Y (yellow), inner left = M (magenta), inner
right = C (cyan), outer right = K (black).
Note
In monochrome mode, only the black pen icon will appear solid, while the
remaining icons are outlined. In color mode, all pen icons will appear solid.
4. Place your hand on top of the pen you are replacing and press down slightly as you
pull the pen toward you. See Figure 3-10.
5. Lift the pen out of its slot.
3-15Installation and Configuration
6. Remove the protective tape from the new pen. Insert the pen into the empty pen slot.
7. Press down slightly and push the pen away from you until it snaps into the pen slot.
See Figure 3-11.
Installing a Pen
Figure 3-11.
8. Repeat steps 4 through 7 for each pen being replaced.
9. Close the plotter window. When ªLoad media to align pensº is displayed, load good
quality media into the plotter. Special paper must be used to properly align the color
pens. The pen alignment procedure takes about three minutes to complete.
Note
The plotter tests the pens to ensure proper operation. The test runs approximately one minute and the display indicates the pens being tested. After testing, the pen alignment procedure is automatically performed. Allow the
alignment procedure to complete before resuming normal plotter operation.
SELECTABLE INK-DRYING TIMES
User-selectable ink-drying times are available on the DesignJet 650C plotters through the
front panel menus. Dry time determines how long the plotter waits before cutting the plot.
Users should be cautioned that insufficient dry time can result in plot smearing as plots are
stacked in the media bin. Dry time choices are accessible through the Plotter setup menu.
3-16 Installation and Configuration
CONFIGURATION
FRONT PANEL CONTROLS
Plotter set-up and plot management functions are input through the front panel. The front
panel contains a 2-row by 20-character vacuum fluorescent display. Menu scrolling and implementation are accomplished through 4 menu buttons. Plotting modes are initiated through
the color/monochrome select buttons and print quality buttons. User interaction is available
through 3 pen/media action buttons. LEDs associated with various buttons are used to indicate whether the function is enabled or disabled. The front panel is shown in Figure 3-12.
message display
Cancel Form Feed/Cut Access Pens
action buttons
(L)C2858-1
Pause
Previous
Enter
Color
Mono
menu buttons
Busy
Enhanced
Final
Draft
plot mode buttons
The front panel display is used for plotter set-up and management messages including menu
selections and operator interaction messages. It also provides various plotter status messages
and error messages. The Busy LED is lit whenever the plotter is processing information.
3-17Installation and Configuration
Front panel controls and LEDs are described below.
Menu buttons:
Previous
Use the Previous button to move to the
next highest level and to return to the
ªStatusº display.
Use the up-arrow and down-arrow buttons
to scroll through menu options or respond
to action or error messages.
Enter
Use the Enter button to activate the
current menu option, access additional
submenus as indicated and to enter
(L) C2847-1a
the first level of the menu structure
from the ªStatusº display.
Plot Mode (Color/Mono and print quality) buttons:
Plotter set to plot in Enhanced, Final or Draft
modes. LED will be lit for mode selected. Sets the
resolution quality parameter for the media type
being used.
Select Color mode or Mono (black and white) mode.
Color
Mono
Enhanced
Final
Draft
Plot Type Media Type Print Quality Resolution (dpi) #Passes Pass Density
Mono Paper Draft
Final
Enhanced
Mono Trans/Vel Draft
Final
Enhanced
Mono Film Draft
Final
Enhanced
Color Special Draft
Final
Enhanced
300 addressable
300 addressable
600 addressable
300 addressable
300 addressable
600 addressable
300 addressable
300 addressable
600 addressable
300 addressable
300 addressable
600 addressable
1 50%
1 100%
2 50%
1 50%
2 50%
4 25%
2 50%
2 50%
4 25%
1 50%
1 100%
2 50%
3-18 Installation and Configuration
Action buttons:
Cancel stops current
operation (plotting,
accuracy calibration,
pen alignment and
media loading).
Form Feed/Cut advances the page and,
if roll media, cuts it.
Cancel Form Feed/Cut Access Pens
Pause
Access Pens brings the pen carriage out to the
plotting area for pen access. (Plotter window
must be closed).
Pause stops plotter after
plotting current drawing.
Press again to continue.
To select and confirm a menu option, do the following:
1. Press the Enter button to move from the ªStatusº display to the menu structure.
2. Press either the up ( = ) or down ( Ο) arrow button to review the options at the current
menu level.
3. When the menu or option you want is displayed, press the Enter button.
4. Repeat from step 2 to reach the next level or sublevel of options you want to set.
Note
Many menus contain subgroups of plotter options. Pressing Enter then dis-
plays the next level of options. When you have reached the final level of
your option, pressing Enter confirms your menu selection or value. In many
instances, your choice is saved in the plotter’s continuous memory. This
means it is not erased or reset when you turn OFF the plotter.
To exit to a previous menu, press the Previous button. Continuous pressing of the Previous
button will move you to higher levels of the menu structure until you reach the ªStatus’ display. If you are in a menu that has variables, pressing Previous returns you to the previous
menu without changing any values or without saving any menu changes. You can confirm
menu changes only by pressing Enter.
3-19Installation and Configuration
FRONT PANEL MENUS
There are seven main menus, each with an option or series of submenus. Pressing the Enter
button from the ªStatusº display will access the menu structure. Both a short menu and a full
menu are available in the plotter display. The short menu is the default menu and displays the
more commonly used menus. Changing to the short or full menu (Menu mode submenu) is
accessed through the ªUtilitiesº main menu.
A brief description of the main menus is given below.
Plot Management Controls plot file management in the queue including queueing,
nesting and number of copy specifications.
Page Format Specifies the size, orientation and margins for the plots.
Pen Settings Defines the pen attributes including the palette which contains
individual pen width and shading/color settings. Two custom
palettes of 16 pens each can be defined and stored by the user.
Plotter Setup Defines basic operating setup including graphics language, dry
time, pen checking and media bypass conditions.
I/O Setup Controls plotter I/O configuration and interaction with the
controller. For configuring the RS-232 and MIO interfaces and
parameters. Two user customized RS-232 configurations can be
stored in memory.
Demo Plot Accesses the internal demonstration plot routine.
Utilities Accesses accuracy calibration procedures. Also contains front
panel menu configuration information, plotter statistic information
(plot size, memory size, firmware revision level, ROM SIMMs
present) and default menu options.
Complete information on using the various menu and submenu options is contained in the HP
C2858A and C2859A DesignJet 650C Using Your Plotter’s Front Panel Guide. Additional
setup information is available in the DesignJet 650C Setting Up For Plotting Guide. Refer to
Chapter 1 in this manual for more information regarding these guides.
Figure 3-12, located at the end of this chapter, provides a diagram of the menu tree showing
the various menus and submenus of the DesignJet 650C plotters. Both the short and full menu
structures are presented on the diagram.
3-20 Installation and Configuration
FRONT PANEL LANGUAGES
DesignJet 650C plotter menus and messages can be configured to display in English, French
(ªFrancaisº), German (ªDeutschº), Spanish (ªCastell.º), Italian (ªItalianoº), Portuguese
(ªPortugueseº) and Japanese (Katakana) characters.
To change the display language, or if the display is in a language you cannot understand, use
the following procedure to get to a language you do understand.
1. Turn the plotter OFF.
2. Press and hold down the Enter button while turning the plotter ON. Release the
Enter button.
3. Using the arrow buttons, scroll to the desired language to be displayed and press the
Enter button.
3-21Installation and Configuration
FRONT PANEL MESSAGES
In addition to the menus that appear in the front panel display, three types of messages may
also appear in the display. They are state messages, action messages, and error messages.
State messages do not require any action and serve to notify the user of any current plotter
actions occurring. State messages are listed in Table 3-2. Action messages do require user
interaction. Typically the user is prompted to press a button, move a lever or load pens or
media. Action messages are listed in Table 3-3. Error messages indicate that either a user error or internal plotter error has occurred. Some error messages require user action to clear and
others are only displayed until the next operation is performed by the plotter. Error messages
and their recommended actions are a part of the troubleshooting information presented in
Chapter 8 of this manual.
Table 3-2. State Messages
Message
Accessing pens You have pressed the Access Pens button. The pen carriage is moving out
Aligning pens Machine is aligning pens.
Cancelling You have pressed the Cancel button and the plotter is in the process of
Checking media Machine is checking to see if media is properly positioned with respect
Creating
calibration plot
Ink drying
(xxx seconds)
Loading roll Machine is loading roll media.
Loading sheet Machine is loading sheet media.
Measuring plot Machine is measuring the accuracy calibration plot you just loaded.
Pen palette
loaded
State
so you can access it.
cancelling the procedure. You may continue when this message is no
longer displayed.
to the perforated line of the entry platen.
Machine is performing accuracy calibration.
The ink on your plot is drying. Wait the indicated number of seconds before removing the plot. If you need to remove it before the indicated time
has passed, use caution to avoid smearing the ink.
The pen palette you just entered (Palette A, Palette B, or Factory) has
been loaded.
3-22 Installation and Configuration
Message State
Table 3-2. State Messages (Continued)
Pen palette
saved
The pen source, pen number widths, and pen number shades you just entered have been saved as either Palette A or Palette B (whichever you
specified).
Returning pens The pen carriage is returning to its station at the left of the plotter.
Roll feed
Machine is trimming the edge of roll media.
Edge trim
RS-232 config
loaded
RS-232 config
saved
The RS-232-C configuration you just entered (Config A, Config B, or
Factory) has been loaded.
The baud, handshake, and parity settings you just entered for your
RS-232-C configuration have been saved as either Config A or Config B
(whichever you specified).
STATUS
Machine is doing internal checking upon power-up.
Initializing
STATUS
Out of media
STATUS
The plotter has detected that the roll is empty (you must be in Roll mode
for this to happen). If desired, remove the old roll and insert a new one.
Machine is plotting.
Plotting
STATUS
Machine is ready for you to load media.
Ready for media
STATUS
Machine is ready to plot.
Ready to plot
STATUS
Machine has received plot data.
Receiving
Testing pens The machine is testing the pens for problems, i.e., clogged pen or bad
electrical connection (improper seating).
3-23Installation and Configuration
Message Action
Special Media
Mono Media
Calibrate done
Press Up Arrow for Color plotting on Special (CX) paper.
Press Down Arrow for Monochrome plotting.
Accuracy calibration is complete. Press Down Arrow to continue.
Continue
Can’t replot
Resend plot
Close roll cover
Continue
Create plot
Measure plot
Replot buffer doesn’t have enough memory to hold the entire plot. Resend the plot.
Rewind the media to take up any slack in the roll, close the roll cover,
then press Down Arrow to continue.
Press Up Arrow to create a calibration plot.
Press Down Arrow to measure a calibration plot.
Lift lever Lift the media lever at the right of the plotter.
Load arrow edge
print side down
Load cancelled
Remove media
Load media
Remove accuracy calibration plot, turn it so that the edge with arrows
printed on it is print side down, then load that edge into the plotter.
You pressed the Cancel button while media loading was in progress.
Remove media.
Load media to proceed with pen alignment.
to align pens
Lower lever
after aligning
Lower window
to continue
Open window to
When you’ve finished aligning the roll media as instructed, lower the
media lever at the right of the plotter.
You have lifted the window while the processor is busy. Close the win-
dow to continue.
Lift the window to access the pens.
access pens
Pen alignment
Close the window to proceed with pen alignment.
Close window
Power OFF
Y-Axis servo shutdown. Troubleshoot and repair.
Check Pen Path
Power OFF
X-Axis servo shutdown. Troubleshoot and repair.
Check Paper Path
3-24 Installation and Configuration
Message Action
Pull / Align
edges to roll
Remove media
Continue
Replace
Y, C, M, K pen
Reseat
Y, C, M, K pen
Sheet load
Roll load
Sheet / Roll?
Reload media
Grasp the left and right free edges of the roll media and pull toward
you until the media is taut. At the same time, align the left and right
edges of the media so that they are flush with the left and right edges of
the roll.
Ink is dry; you can remove the accuracy calibration plot the plotter just
produced. Press Down Arrow to continue with accuracy calibration.
Y, C, M, or K pen has a clogged nozzle. You must replace the defective
pen to continue. Defective pen position is indicated by a flashing icon
in the display.
Y, C, M, or K pen has not made proper contact in the pen slot. Remove
the appropriate pen and reseat it in the slot. Defective pen position is
indicated by a flashing icon in the display.
Press Up Arrow to load sheet media.
Press Down Arrow to load roll media.
You have chosen Sheet mode while loading roll media. Reload media.
You have loaded a sheet more than 51 inches (130 cm) long. Trim
sheet and reload.
3-25Installation and Configuration
OPERATIONAL VERIFICATION
DesignJet 650C 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-TEST
Whenever the plotter is switched ON, it automatically performs a series of internal self-tests
and initialization sequences which check the basic electrical and mechanical functions of the
plotter. Among the items checked are the processors, motors and sensors. If an error is detected, a message or system error code will be visible in the front panel display. Error codes
and messages are presented in Chapter 8 of this manual. Self tests are listed in Chapter 8.
DEMONSTRATION PLOT
Two demonstration plot samples are resident in the HP DesignJet 650C plotters. Proper plotter operation can be checked through use of the demo plots. The demo plots show different
plotter capabilities including pen line widths and shading. The demo plot can be set to plot in
any of the available front panel languages.
To plot a demo plot, perform the following steps:
1. Turn the plotter ON and load a sheet of media.
2. From the ªStatusº display, press the Enter button.
3. Using the arrow buttons, scroll to the ªDemo plotº main menu display.
4. Press the Enter button.
5. Using the arrow buttons, scroll to select either the Sample or Palette demo plot.
6. Press the Enter button.
7. The ªBusyº LED will light indicating that the demo plot is being accessed.
8. The demonstration plot will be plotted.
3-26 Installation and Configuration
Chapter 4 Preventive Maintenance
INTRODUCTION
This chapter contains information on keeping the HP C2858A and C2859A DesignJet 650C
plotters in good operating condition. Included are general cleaning procedures to be performed by the user.
Introduction 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Effect on Product Reliability 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventive Maintenance Procedures 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Cleaning 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Roller Cleaning 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1Preventive Maintenance
EFFECT ON PRODUCT RELIABILITY
To maintain the plotter in good operating condition, keep it free of dust accumulation, ink,
and other contamination. Cleaning intervals are determined by the local conditions under
which the plotter is operated 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.
PREVENTIVE MAINTENANCE PROCEDURES
The following general cleaning procedure can be performed by the user. Follow normal
safety precautions and prevent water or other cleaning materials from entering the electronics enclosure of the plotter.
W A R N I N G
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. Wipe the plotter dry after cleaning.
Note
Do not use abrasive cleaners on the plastic carriage cover. Clean the cover
with a mild solution of soap and water and wipe it dry with a soft lint-free
cloth to prevent scratching.
4-2 Preventive Maintenance
DRIVE ROLLER CLEANING
W A R N I N G
The drive roller cleaning procedure should be
performed only by service-trained personnel;
otherwise personal injury may occur.
If ink is spilled on the drive roller, remove the ink. Due to the ink’s reflectance, ink 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 an ac power source.
2. Switch the plotter ON.
3. Press the Enter button on the front panel.
4. Using the arrow buttons, scroll to the utilities menu display, then press the
Enter button.
5. Using the arrow buttons, scroll to the statistics submenu display.
6. Simultaneously press the Enter and the Up Arrow buttons to access the service tests
menu.
7. Using the Up Arrow button, scroll to reach the following display:
SERVICE TESTS
X motion control
8. Press the Enter button, and the following display will appear:
REMOVE MEDIA
PRESS ENTER
9. Remove any media from the plotter.
10. Raise the window. Holding the window sensor down with a pen, pencil or small
screwdriver, press the Enter button. The display will show that the arrow buttons
can be used to control the roller speed for cleaning. Press the Up Arrow button sev-
eral times until the drive roller reaches a convenient speed for cleaning.
4-3Preventive Maintenance
Note
The speed of the drive roller can be reduced or speeded up by pressing the
appropriate arrow button.
11. Apply any common household cleaning solution (e.g. BonAmi aerosol, Simple
Green) to a soft, lint-free rag and apply it to the drive roller surface while it is rotating. Thoroughly clean the roller surface.
12. Stop the roller by pressing the Enter button when through cleaning.
13. Press the Enter button to return to the SERVICE TESTS menu display.
14. Using the Previous button, scroll to the ªSTATUS Ready for Mediaº display.
15. Allow the drive roller to dry before inserting media in the plotter.
4-4 Preventive Maintenance
Chapter 5 Functional Overview
INTRODUCTION
This chapter contains a simplified description of the HP C2858A and C2859A DesignJet
650C plotters circuits and mechanical functions. Mechanical and Printed Circuit Assembly
(PCA) overviews present a functional description of how the plotter operates.
Introduction 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Simplified Description of Circuits 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Overview 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printed Circuit Assembly (PCA) Overview 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main PCA 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carriage PCA 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interconnect PCA 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel PCA 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drop and Bail Sensors 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply PCA 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1Functional Overview
SIMPLIFIED DESCRIPTION OF CIRCUITS
HP C2858A/59A DesignJet 650C circuits communicate with an external controller by way
of either a Centronics or an RS-232-C interface. If an approved modular input/output (MIO)
printed circuit assembly (PCA) is installed, the circuits can communicate by way of an HPIB interface or be connected to a network. The main processor reads Centronics, HP-IB, and
Ethernet communications through the port it uses to read memories (ROM or DRAM).
RS-232-C communications are handled by a universal, asynchronous, receiver-transmitter
(UART) and baud rate generator built into the processor support application-specific integrated circuit (ASIC).
HP DesignJet 650C plotters accept plots in Hewlett-Packard Graphics Language (HP-GL),
Hewlett-Packard Graphics Language 2 (HP-GL/2) or Hewlett-Packard Raster Transfer Language (HP RTL) form. The main processor converts the plot into an internal format and
stores the entire plot in its dynamic random-access memory (DRAM). Then it transfers the
plot a swath at a time into the swath RAM by way of the processor support ASIC.
On the main PCA, the processor support ASIC is designed to manipulate swath data into the
actual firing order for the pen nozzles on the four pen cartridges that are mounted on the carriage assembly. The processor support ASIC receives pixels from the physical swath RAM
and sends them serially to the carriage ASIC.
A main processor on the main PCA controls all plotter operations with the help of the processor support ASIC and the servo processor. Communications between the servo processor and
the main processor take place through registers in the processor support ASIC.
The processor support ASIC provides pulse-width-modulated signals to the Y-axis motor
driver and the X-axis motor driver to drive the Y-axis (carriage) motor and the X-axis (paper)
motor. The linear encoder connected to the carriage PCA gives the processor support ASIC
feedback about the position of the carriage. The X-axis motor encoder on the X-axis motor
gives the processor support ASIC feedback about the position of the X-axis motor.
In addition, the processor support ASIC contains a DRAM controller that generates multiplexor control and enable strobes for the DRAM row and column addresses during a memory
access. The DRAM controller also arbitrates between a memory request and a refresh request, and it performs the refresh operation.
The servo processor communicates with the main processor through registers in the processor support ASIC. The servo processor writes information into the registers and sends an interrupt to the main processor. The main processor then reads the registers and the interrupt is
automatically cleared. Using this procedure, the servo processor provides the main processor
with information from the plotter sensors. The sensors give the main processor the ability to
check status conditions.
5-2 Functional Overview
The servo processor controls the servo motors, front panel, fan, electrically erasable read-only memory (EEROM), and the stepper drive. It sends configuration information to the carriage processor via its serial port. The EEROM stores plotter calibration and configuration
information while power is OFF. The stepper drive moves the stepper motor. The stepper motor is used to raise the pen wiper for wiping pens or to operate the pen service station.
A line sensor on the carriage PCA provides the servo processor with information used to
align the pens. It also provides a media edge sensing capability to the plotter (for width measurement).
The carriage ASIC controls the firing of the pens. It receives pixel data from the processor
support ASIC over a synchronous serial channel. It contains a 100-bit shift register (one bit
per pen nozzle), which performs a serial-to-parallel conversion on the data. It contains timing, sequencing, and delay circuitry to ensure that pen nozzles are fired in the correct sequence and at the correct time. It also contains fire waveform generators to create the firepulse waveforms used to fire the pens. Pen drivers provide the power necessary to fire the
pens under the control of the carriage ASIC.
During pen testing, the processor support ASIC provides a means to generate a fire position
pulse when the carriage is docked in the service station. The carriage ASIC will receive this
signal and fire selected nozzles. If a drop is sensed by the drop detector each time a nozzle is
fired, the nozzle is working properly. The independently generated fire position pulse is also
used for warm-up pulse generation and for firing to clear clogged nozzles.
MECHANICAL OVERVIEW
The Y-axis (carriage) motor is mounted under the plotter’s right endcover. It is electrically
connected to the interconnect PCA, which contains a Y-axis motor driver. Its drive shaft is
mechanically connected to the carriage by way of a small drive belt, double pulley, and main
drive belt. When the carriage motor rotates, it moves the carriage assembly. An optical encoder, located on the carriage assembly, provides position feedback for Y-axis servo control.
The line sensor, also mounted on the carriage assembly, is used to detect and measure lines
when performing pen alignment and the accuracy calibration. The line sensor is also used to
detect media width and skew during media loading.
The X-axis (paper) motor is also mounted under the right endcover and is electrically connected to the interconnect PCA which contains an X-axis motor driver. It has a worm-style
pinion gear which meshes with a gear at the right end of the drive roller. When the paper motor rotates, it moves the drive roller and, consequently, the media. The encoder mounted on
the motor sends feedback about the X-axis motor position to the main PCA.
5-3Functional Overview
An internal cooling fan is supplied with +12 V. It is switched ON and OFF by the servo processor and is mounted in the electronics enclosure at the rear of the plotter. The fan is primarily used to cool the power supply PCA when plotting. When the plotter is not plotting, the fan
is switched OFF. At high temperatures, the fan is switched ON.
The window sensor is a switch mounted on the right sideplate at its top front edge. Feedback
about the window’s position (up or down) is sent to the main PCA through the front panel.
An optical pinch wheel sensor is mounted on the lower rear portion of the plotter’s right sideplate and is electrically connected to the main PCA. When the pinch arms are raised, a cam in
the pincharm lift mechanism interrupts the beam of the optical sensor, and, when the pincharms are lowered, the beam is not interrupted. Thus, the position of the pincharms can be
determined from the electrical state of the sensor.
The media sensor is also an optical sensor and is mounted toward the right end of the entry
platen. A reflective label, located under the cutter enclosure, provides a reflective surface for
the sensor. A base intensity level for reflected light is determined for the sensor in the absence
of media. This intensity level is stored in the EEROM. It is calculated when a new main PCA
with a blank EEROM is first powered-up, or after the EEROM has been cleared. When media
is loaded, a difference between the new intensity level and the base intensity level indicates
that media is present. This sensor 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.
The drop sensor is an infrared detector mounted in the service station. It is used to test that the
nozzles in the pen cartridge are operating properly. It is part of a drop-detection system that
measures the time from the firing of a nozzle to the sensing of a drop (typically < 900
sec).
The operation of the sensor system depends upon an illuminated infrared optical path, in
which the received power is modulated a small amount by a drop passing through an aperture
on the way to the waste containment system. The illumination is provided by an infrared LED
which is regulated by an automatic power control to provide a fixed operating point in the
optical receiver photo-diode. The automatic power control compensates for contamination,
device aging, and environmental effects.
An optical sensor mounted on the primer assembly is used to determine the initial position of
the primer assembly cam. When the stepper motor that drives the primer assembly rotates in
one direction, it obtains the values for selecting each pen for priming. When rotated in the
opposite direction, a clutch engages a diaphragm to provide the vacuum for priming.
An optical sensor on the service station housing is used to determine the position of the bail.
When the bail is in the ªdownº position, the photo beam is interrupted by a small plastic flag
actuated by the bail. When it is up, the photo beam path is clear. The resulting BAIL logic
level is sent to the main PCA by way of the service station cable. The service station cable
assembly consists of the drop detect and bail sensors, the stepper motor and the primer sensor.
5-4 Functional Overview
PRINTED CIRCUIT ASSEMBLY (PCA) OVERVIEW
MAIN PCA
There are two clocks on the main PCA. The main clock provides a 31.85 MHz signal directly
to the main processor. The 31.85 MHz is divided by the main processor, and the resulting
signal is provided to the processor support ASIC. A separate clock provides a 12 MHz signal
to the servo processor.
In order to perform its functions, the main processor must have access to its memories (ROM
and DRAM). To create plots at the direction of an external controller, it must be able to communicate with the controller by way of its interfaces (MIO, Centronics, and RS-232-C). To
address the ROM or DRAM interface, the main processor places the appropriate address on
the address bus and reads or writes the data directly. Data is passed to the main processor by a
transceiver in the case of ROM or DRAM SIMM data. MIO or Centronics input and output
data pass through another transceiver on its way to the main processor.
The main PCA ROM contains the following types of information:
Programs
Program constants
Character sets
Demonstration plot
The main PCA DRAM is used to store the following types of information:
Variables
Temporary constants
Plots
As a plot is received from an external controller by way of one of the plotter interfaces, it is
stored in DRAM. When the complete plot is in DRAM, the main processor converts it, one
swath at a time, to a format suitable for storage and sends it to swath RAM by way of the
processor support ASIC. A swath is 96 dots high and extends from border to border across the
width of the plot. The processor support ASIC extracts the plot data from the swath RAM,
converts it to pixels, and sends the pixels serially by way of the trailing cable to the carriage
ASIC on the carriage PCA.
5-5Functional Overview
CARRIAGE PCA
The carriage PCA contains an application-specific, integrated circuit (ASIC) that controls
the operation of the pens and pen drivers that switch power pulses from the ASIC to fire the
pens. It also provides feedback to the main PCA as to the current position of the carriage assembly. A line sensor module mounted on the carriage PCA monitors the lines produced by
the pens and is used for pen alignment. The line sensor also provides an edge sensing capability used to identify the media loaded in the plotter. Voltage sense circuitry senses deviations
in the pen voltages supplied to the print heads and sends signals to the voltage regulators on
the interconnect PCA.
The carriage processor and the print control ASIC on the carriage PCA are driven by a 12.288
MHz, on-board clock. At power-on time, the main PCA reset circuit delays the operation of
the print control ASIC until the +5 V reaches a steady state.
The line sensor module is used to calibrate the writing system for mechanical tolerances as
well as to sense the left and right edges of the media. It consists of a photo-diode device
whose photo-current is amplified by a transimpedance amplifier connected to the PCA
through a ZIF connector. The resulting voltages are coupled and then measured by an eightbit, analog–to–digital (A/D) converter whose bits are sent serially to the carriage microprocessor. Illumination of the surface being read by the line sensor is provided by two green,
high-intensity LEDs. A dual lens, unity conjugate ratio system directs the light from the illuminated surface to the sensor-phase plate combination.
A temperature sensor IC is used to measure ambient temperature near the print heads. Energy
used to fire the pens is based on temperature. This temperature reading is also used to determine when to switch the fan ON. Normally, the fan only runs when plotting. At high temperatures, it is left ON.
A linear encoder detects pen carriage position as the carriage assembly moves along the encoder strip. The linear encoder IC is connected to the carriage PCA via a 5-pin ZIF connector.
The carriage processor operates at 12.288 MHz. The clock signal is generated by a crystaloscillator circuit internal to the ASIC. The primary task of the processor is to configure the
print control ASIC and read data to control pen energy and pen calibration. It communicates
with the servo processor on the main PCA using a serial port.
The print control (carriage) ASIC receives pixel data from the processor support ASIC on the
main PCA via a synchronous serial channel and on–board line driver. Signals from the print
control ASIC fire the nozzles in the print heads. Whenever a print head nozzle is fired, a comparator outputs a pulse to a counter in the carriage microprocessor.
5-6 Functional Overview
The dual-voltage, remote sense circuitry sends a + or – sense signal to the dual voltage regulators on the interconnect PCA when the voltage to the print heads deviates from the optimum pen voltages. The regulator will then adjust the voltage to bring it back to the optimum
value. Pen voltages are ON when printing a swath and briefly at power-up, but OFF when idle
or accessing pens.
INTERCONNECT PCA
The interconnect PCA contains an X-axis (paper) motor drive, a Y-axis (carriage) motor
drive, a switching pre-regulator, two linear regulators for the black and color pen voltages,
and direct paths for the MIO lines to the main PCA. The drivers and the voltage regulator
receive +24 Vdc via the main PCA. The pre-regulator steps down the +24V to +19.5V for the
two linear regulators. The two linear regulators output voltages from +9 to +15V and receive
+ and – sense signals that originate at the carriage PCA and then routed through the main
PCA on their way to the interconnect PCA. When the pen voltages delivered to the pen cartridges deviate above or below their respective values, the sense signals will cause the voltage regulator outputs to move to counter the deviation.
Part of the pen shutdown circuitry resides on the interconnect PCA. The pens are shutdown
when the +5V falls below a certain value (during power-up/down), when the carriage ASIC
asserts shutdown during an access pens command, between swath printing or when idle.
The interconnect PCA receives PA and PB drive signals for the paper motor driver and the
carriage motor driver from the processor support ASIC on the main PCA. PA and PB are pulse-width-modulated (PWM) signals. The PA signal to the paper motor driver causes the paper motor to drive the paper up and out of the front of the plotter. The PB signal to the paper
motor driver causes the paper motor to drive the paper down, over the entry platen and out of
the the plotter. The PA signal to the carriage motor driver causes the carriage motor to drive
the carriage toward the right side of the plotter. The PB signal to the carriage motor driver
causes the carriage motor to drive the carriage toward the left side of the plotter.
FRONT PANEL PCA
The front panel consists of a 2-row by 20-character, vacuum-fluorescent display (VFD),
seven LED indicators, and a 10-button key pad. The servo processor on the main PCA writes
serially to the VFD and the LEDs and reads the key pad on its input/output lines. It provides
for local control, configuration and testing of the plotter and serves to display various plotter
conditions.
5-7Functional Overview
DROP AND BAIL SENSORS
The drop sensor is located in the drop detect assembly. Its purpose is to detect ink drops during pen testing. The drop sensor contains a detector system capable of detecting the presence
of a drop shortly after one is fired into the detector. In order for the drop to be fired into the
detector, the pen must be positioned over the sensor. An infrared LED sends a beam across an
aperture. The beam is received at the other side by a photo-sensitive diode. When a drop
passes through the beam, it causes a disturbance in the reception. The slight modulation in
power output by the receiving diode is amplified by the pre-amplifier, further amplified by
the amplifier, and sent to the processor support ASIC on the main PCA. The processor support ASIC can measure the time between the firing of a print head nozzle and reception of the
amplified, drop-detect signal, typically less than 900 microseconds.
The bail sensor consists of a photo-emitting diode and a collector. When the bail is down, the
path between the diode and the collector is interrupted by a small plastic flag, and the BAIL
signal is 0 V. When the bail is lifted, the path between the diode and the collector is clear, and
the BAIL signal is +5 V. The bail signal is sent to the servo processor on the main PCA.
POWER SUPPLY PCA
An auto-ranging power supply for the DesignJet 650C plotter is located in the electronics
enclosure assembly. It accepts and automatically adjusts to an ac input of 90 V through 264 V
and produces regulated voltages of +5 V, +12 V, and –12 V and an unregulated +24 V. These
voltages produced by the power supply are used as follows:
+24 V Motor drivers and voltage regulator on the interconnect PCA.
(Regulated +9 to +15 V for pen circuits on the carriage PCA).
+12 V Fan power, MIO and RS-232 driver.
–12 V RS-232 driver.
+5 V IC power and sensors, drop sense PCA.
In the primary portion of the supply are contained fusing and input protection circuitry, line
filters, and a rectifier. The primary output is converted to a pulse-width-modulated (PWM),
unidirectional current by a flyback dc-to-dc converter.
The secondary portion of the power supply contains the four secondary windings of the transformer that convert the PWM current in the primary to four ac voltages which are rectified to
the +5 V, +12 V, –12 V and +24 V dc voltages required by the plotter. Standard +12 V and –12
V regulators are included in the secondary portion of the power supply.
5-8 Functional Overview
Chapter 6 Removal and Replacement
INTRODUCTION
This chapter contains repair information including safety and ESD precautions, a list of tools
required for plotter repair and procedures for the removal and replacement of HP DesignJet
650C field replaceable assemblies.
Introduction 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Considerations 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ESD Considerations 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Procedures 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRAM SIMM and ROM Module Removal 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
MIO Card Removal 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronics Enclosure Cover Removal 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interconnect PCA Removal 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main PCA Removal 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outer Electronics Enclosure Assembly Removal (C2858A Only) 6-11. . . . . . . . . .
Power Supply PCA Removal 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Removal 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Window Assembly Removal 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Endcovers (Left and Right) Removal 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primer Assembly and Sensor Removal 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinch Wheel Sensor Removal 6-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Window Sensor Removal 6-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media Sensor Removal 6-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailing Cable Removal 6-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back Panel Removal 6-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Removal 6-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carriage Motor Removal 6-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Motor Removal 6-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encoder Strip Removal 6-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rollfeed Cover Assembly Removal 6-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rollfeed Module Assemblies (Left and Right) Removal 6-31. . . . . . . . . . . . . . . . .
Cutter Assembly Removal 6-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailing Cable Guide Removal 6-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Y-Tensioner and Housing Removal 6-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pen Carriage Assembly and Main Drive Belt Removal 6-38. . . . . . . . . . . . . . . . . .
Drop Detect and Bail Sensors Removal 6-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starguard Assembly Removal 6-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bail Assembly Removal 6-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1Removal and Replacement
Service Station Assembly Removal 6-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overdrive Support Assembly Removal 6-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cutter Enclosure Assembly Removal 6-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Entry Platen Assembly Removal 6-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Roller Assembly Removal 6-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Bail Lift Mechanism Removal 6-55. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media Diverter Removal 6-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinch Arm and Lift Mechanism Removal 6-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2 Removal and Replacement
SAFETY CONSIDERATIONS
The Safety Symbols used with Hewlett-Packard instruments are illustrated in the front matter of this manual. WARNING and CAUTION symbols and instructions must be reviewed
before service work is performed. These warnings and cautions must be followed for your
protection and to avoid damage to the plotter.
W A R N I N G
!
!
ESD CONSIDERATIONS
Integrated circuits can be damaged by electrostatic discharge. To prevent damage to the plotter circuits from high voltage electrostatic discharge, take the following precautions:
1. Do not wear clothing that is subject to static build-up.
2. Do not handle integrated circuits (ICs) in carpeted areas.
3. Do not remove an IC or a PCA from its conductive foam pad or conductive packaging until you are ready to install it.
4. Ground your body while disassembling and working on the plotter.
5. After removing a cover from the plotter, attach a clip lead between the PCA common
and earth ground. Touch all tools to earth ground to remove static charges before
using them on the plotter.
6. After removing any PCA from the plotter, place it on a conductive foam pad or into
its conductive packaging to prevent ESD damage to any ICs on the PCA.
6-3Removal and Replacement
REQUIRED TOOLS
Tools required to disassemble and repair the HP DesignJet 650C plotters are listed in
Table 6-1.
Item Size
Torx Screwdriver with bits T8, T9, T10, T15, T20, T25, T30
Screwdriver, flat-blade Small
Nut Drivers 1/4 in., 3/16 in., 5.5 mm (or 7/32 in.)
Pliers, needle-nose Medium
Wrenches, socket or open-end 3/8 in., 9/32 in. (or 7mm)
REPAIR PROCEDURES
Unless otherwise specified, reassembling should be performed in the reverse order of disassembly. Be sure to read and perform any precautions given in the procedures.
Certain repairs will require you to perform calibration procedures to return the plotter to certain performance parameters or ensure proper operation after repairs are completed. Refer to
the table of calibration requirements in Chapter 7 and perform the calibrations listed after the
appropriate repairs are made.
Many repair procedures require other assemblies to be removed to perform the desired repair.
Assemblies to be removed will be referenced in the procedure. To remove those assemblies,
refer to the appropriate removal procedures in this chapter.
W A R N I N G
6-4 Removal and Replacement
DRAM SIMM AND ROM MODULE REMOVAL
To install or remove and replace a module, perform the following steps:
1. Using a small flat blade or Torx T10 screwdriver, remove the four screws that attach
the cover plate to the back of the plotter and remove the cover plate. See Figure 6-1.
Cover Plate
(C)C2858-32
2. After removing the cover plate, you will see four module slots: 2 larger ROM expansion slots above 2 smaller DRAM SIMM memory expansion slots.
3. Attach a conductive wristband (if available) to yourself and a good chassis ground
on the plotter or touch the outer metal surface of the plotter.
Figure 6-1.
4. To remove a module, press the two retaining clips outward, grasp the module by its
edges and carefully pull it out of the slot.
Note
When only one DRAM SIMM is to be installed, it must be inserted into the
lower SIMM slot. When only one ROM module is to be installed, it must be
inserted into the upper ROM slot.
5. To install a module, hold the module by its edges with the non–metallic edge toward
you and the notch to your right.
6. Tilt the non-metallic edge down about 45 and firmly push the module into the slot.
Gradually tilt the module up and push it in until it clicks into place.
7. Install the cover plate with its four screws.
6-5Removal and Replacement
MIO CARD REMOVAL
To install or remove and replace an MIO card, refer to Figure 6-2 and perform the following
steps:
1. If an MIO card is not already installed, use a small flat blade or Torx T10 screwdriver
to remove the two screws that attach the cover plate to the top back of the plotter.
Remove the cover plate.
2. If an MIO card is already installed, loosen the MIO card thumbscrews. Carefully
pull the MIO card straight up and remove the MIO card from the plotter.
3. To install an MIO card, insert the card into the MIO slot and push the card firmly in
until fully seated in the slot.
4. Tighten the MIO
MIO Slot
(C)C2858-32
6-6 Removal and Replacement
Figure 6-2.
ELECTRONICS ENCLOSURE COVER REMOVAL
To remove the electronics enclosure cover, perform the following procedure:
1. Switch the plotter OFF and disconnect the ac power cord and interface cable from the
plotter.
2. If a modular input/output (MIO) card is installed, remove the MIO from the plotter.
3. Using a TORX T-15 screwdriver, remove the rear sideplate trim pieces and electronics enclosure cover shown in Figure 6-3. The C2858A has 10 cover screws and the
C2859A has 12 cover screws. The trim pieces have two screws each.
4. Gently pull the trim pieces and then the cover off of the plotter.
Rear Trim
(C)C2858-32a
Rear Trim
Electronics Enclosure Cover
Figure 6-3.
6-7Removal and Replacement
INTERCONNECT PCA REMOVAL
To remove the interconnect PCA, refer to Figure 6-4 and perform the following steps:
1. Remove the electronic enclosure cover.
Note
The cable connectors disconnected in the next step are labeled ªPº for paper
axis and ªCº for carriage axis. Note the orientation of the cable connectors
for assembly.
2. Disconnect the paper axis and carriage axis connectors from the interconnect PCA.
3. Using a TORX T-10 screwdriver, remove the two screws that secure the interconnect
PCA to the electronics enclosure assembly.
4. Gently pull the interconnect PCA clear of its main PCA connection and lift the PCA
clear of the plotter.
Screw
Locating Pin
(C)C2858-46
Paper Axis Connector
Carriage Axis Connector
When installing the Interconnect PCA, ensure the locating hole in the upper
left corner of the PCA engages the locating pin on the electronics enclosure.
6-8 Removal and Replacement
Screw
Main PCA Connector
Figure 6-4.
Note
MAIN PCA REMOVAL
To remove the main PCA, perform the following procedure:
1. Remove the electronic enclosure cover.
2. Remove the interconnect PCA.
3. Using a 3/16º nut driver, remove the two screws on top of the electronics enclosure
from the RS-232-C connector.
4. Using a TORX T-10 screwdriver, remove the two screws on top of the electronics
enclosure from the parallel connector.
5. Disconnect all the cable connectors from the main PCA.
6. Using a TORX T-10 screwdriver, remove the 12 screws securing the main PCA to
the electronics enclosure assembly. See Figure 6-5.
7. Using a 7mm socket or open-end wrench, remove the two nuts that secure the main
PCA to the electronics enclosure assembly.
8. Lift the main PCA clear of the plotter.
If installing a new PCA, do the following:
1. Remove the original EEROM (8-pin IC) from the socket and install it on the replacement PCA.
2. Remove the original EPROMs from their sockets, and install them on the replacement PCA.
3. Remove any SIMMs that were installed on the original PCA.
4. Remove the plastic SIMM guard from the original PCA and install it on the replacement PCA. Install any SIMMs removed from the original PCA.
Note
When installing the main PCA, temporarily leave the screws and nuts that
attach the main PCA and the interconnect PCA loose. Tighten the I/O connectors first, then tighten the PCA screws and nuts.
6-9Removal and Replacement
Screws
(12)
(C)C2858-44
X-axis Encoder
Media Sensor
Pinch Wheel Sensor
Front
Panel
(L)C2858-3
RS-232-C Parallel
Interconnect PCA
Main PCA Cable Connectors
Trailing
Cable
Figure 6-5.
Nuts
(2)
Sensor
Drop
EPROMs
Fan
Power Dist.
6-10 Removal and Replacement
OUTER ELECTRONICS ENCLOSURE ASSEMBLY REMOVAL
(C2858A ONLY)
To remove the outer electronics enclosure assembly, perform the following procedure:
1. Remove the electronics enclosure cover.
2. Disconnect all the cables from the PCAs shown in Figure 6-6.
3. Using a Torx T-15 screwdriver, remove the bottom three, and loosen the top three,
electronics enclosure assembly screws shown in Figure 6-6.
4. Carefully lift up and pull the electronics enclosure assembly from the plotter making
sure to ease the cables through the slots in the assembly.
Loosen Screws
(Screw accessed
through hole)
(L)C2858-32c
Remove screws
Figure 6-6.
6-11Removal and Replacement
POWER SUPPLY PCA REMOVAL
To remove the power supply PCA, perform the following procedure:
1. Remove the electronics enclosure cover.
2. For model C2858A plotters, remove the outer electronics enclosure assembly.
3. Remove the flexible, DANGER HIGH VOLTAGE, protective cover from the electronics enclosure. Carefully flex the cover and pull it out of the plotter.
4. Disconnect the ac connector and the dc power distribution connector at the power
supply PCA.
5. Using a TORX T-10 screwdriver, remove the six screws that secure the power supply
PCA to the electronics enclosure assembly. See Figure 6-7.
Screws (6)
(C)C2858-43
Connector (To Main PCA) Connector (To ac Power)
Figure 6-7.
6-12 Removal and Replacement
FAN REMOVAL
To remove the fan, refer to Figure 6-8 and perform the following procedure:
1. Remove the electronic enclosure cover.
2. Disconnect the fan connector at the main PCA.
3. For model C2858A plotters, remove the outer electronics enclosure assembly.
4. Using a TORX T-10 screwdriver, remove the two screws that secure the fan to the
electronics enclosure assembly. See Figure 6-8.
5. Lift the fan clear of the plotter.
Fan Connector
(C)C2858-44
Fan Screws (2)
Figure 6-8.
6-13Removal and Replacement
WINDOW ASSEMBLY REMOVAL
To remove the window assembly, perform the following steps:
1. Using a TORX T-15 screwdriver, remove the left and right rear trim pieces from the
plotter.
2. Using a TORX T-15 screwdriver, remove the two screws that connect the window
assembly to the back panel. See Figure 6-9.
C A U T I O N
3. Raise the rear portion of the assembly until the front portion drops down slightly and
slide the assembly slightly toward the front of the plotter. Then lift the assembly
clear of the plotter.
Window Assembly
Screw
(L)C2858-32d
Screw
Back Panel
Figure 6-9.
6-14 Removal and Replacement
ENDCOVERS (LEFT AND RIGHT) REMOVAL
To remove the endcovers, perform the following procedure:
1. Raise the plotter window to the open position.
2. Remove the window assembly.
3. Lower the rollfeed cover to the open position.
4. Using a TORX T-15 screwdriver, remove the two front screws that connect each
endcover and front sideplate trim to the plotter. See Figure 6-10.
5. Using a TORX T-15 screwdriver, remove the bottom rear screw (hidden) that connects each endcover to the sideplate.
Note
When removing the left endcover, pull the endcover out until you can reach
under the cover and disconnect the internal ac power cord from the internal
ac receptacle. Reconnect the cord during reassembly.
When removing the right endcover, do not stress or apply pressure to the
front panel assembly. Note the upper and lower grooves the endcover engages on the front panel for reassembly.
6. Maintaining an even pressure on the top and bottom of the endcover, pull it away
from the plotter.
6-15Removal and Replacement
Left Front Trim
Right Front Trim
Screw
(C)C2858-37
Screw
Screw
Screw
(C)C2858-38
(C)C2858-34
Bottom Right Screw (hidden)
6-16 Removal and Replacement
(C)C2858-33
Bottom Left Screw (hidden)
Figure 6-10.
PRIMER ASSEMBLY AND SENSOR REMOVAL
To remove the primer assembly and sensor, perform the following steps:
1. Remove the window assembly.
2. Remove the left endcover.
3. Disconnect the primer assembly and sensor cable connector.
4. Disconnect the four rubber tubes from the primer assembly.
5. Using a TORX T-20 and extension bit, remove the two bottom screws and loosen the
top screw, that attach the primer assembly to the left sideplate. See Figure 6-11.
6. Slide the primer assembly out from the plotter.
7. To remove the optical sensor from the primer assembly, use a TORX T-10 screwdriver and remove the two screws that attach the sensor to the primer assembly.
Screw
Optical Sensor
Cable
Connectors
Primer
Assembly
Screws (2)
(C)C2858-76
Tubes (4)
Figure 6-11.
6-17Removal and Replacement
PINCH WHEEL SENSOR REMOVAL
To remove the pinch wheel sensor, perform the following procedure:
1. Remove the electronic enclosure cover.
2. Remove the right endcover.
3. Disconnect the pinch wheel sensor cable connector from the main PCA.
4. Pull the pinch wheel sensor cable clear of any clamps.
5. Using a Torx T-10 screwdriver, remove the two screws that attach the toroid to the
bracket. See Figure 6-12.
6. Using a Torx T-20 screwdriver, remove the two screws that attach the toroid bracket
to the right sideplate. Don’t cross-thread or over-tighten the screws when installing.
7. Using a TORX T-10 screwdriver, remove the screws that attach the pinch wheel sensor to the right sideplate and lift the pinch wheel sensor clear of the plotter.
Toroid
Toroid Bracket
(L)C2858-48
6-18 Removal and Replacement
Pinch Wheel Sensor
Pinch Wheel
Sensor Cable
Figure 6-12.
WINDOW SENSOR REMOVAL
To remove the window sensor, perform the following procedure:
1. Remove the right endcover.
2. Disconnect the window sensor cable connector from the front panel PCA.
3. Using a TORX T-8 screwdriver, remove the two screws that attach the window sensor to the right sideplate and lift the sensor clear of the plotter. See Figure 6-13.
Don’t cross-thread or over-tighten the screws when installing.
Window Sensor Cable
(C)C2858-49b
Figure 6-13.
Window Sensor
6-19Removal and Replacement
MEDIA SENSOR REMOVAL
To remove the media sensor, perform the following steps:
1. Remove the electronics enclosure cover.
2. Disconnect the media sensor cable connector from the main PCA.
3. Remove the right endcover.
4. Using a TORX T-10 screwdriver, remove the screw that attaches the media sensor to
the entry platen. The screw is accessible from underneath the entry platen.
5. Remove the sensor through the access hole in the right sideplate. See Figure 6-14.
Note
During installation ensure that the sensor is properly aligned to its mounting
hole in the entry platen before screwing it down. Perform the sensor calibration procedure when completed.
(C)C2858-3
Access Hole
6-20 Removal and Replacement
Media Sensor Cable
Figure 6-14.
TRAILING CABLE REMOVAL
While removing the trailing cable, see Figure 6-15.
To remove the trailing cable, perform the following procedure:
1. Remove the window assembly.
2. For models C2858A, remove the main PCA.
For models C2859A, remove the outer electronics enclosure assembly.
3. Using a TORX T-10 screwdriver, remove the two screws that attach the toroid to the
rear of the electronics enclosure assembly.
4. Separate the two endcaps of the toroid and remove the toroid from the trailing cable.
5. Using a TORX T-15 screwdriver, remove the five screws that attach the trailing
cable rear tray to the back panel. See Figure 6-15.
Note
For models C2859A, remove the trailing cable tray center bracket screw to
release the tray from the bracket.
6. Cut the tie wrap and free the trailing cable from the trailing cable rear tray.
7. Disconnect the trailing cable connector from the pen carriage PCA.
8. Using a TORX T-15 screwdriver, remove the trailing cable bracket screw from the
pen carriage assembly.
9. Pull the trailing cable up through the slot at the top of the electronics enclosure assembly and lift the trailing cable brackets with trailing cable from the plotter.
If installing a new trailing cable, use the old trailing cable as a template to bend and crease the
new trailing cable to exactly match the creases in the old trailing cable. Make sure that the
cable is properly aligned in the front trailing cable tray and does not bind or scrape the tray.
6-21Removal and Replacement
(C)C2858-42
Toroid
Toroid Endcaps
Trailing Cable
(C)C2858-62
Trailing Cable Rear Tray Screws (5)
Carriage PCA
Trailing Cable Connector
(C)C2858-77
6-22 Removal and Replacement
Bracket
Screw
Figure 6-15.
BACK PANEL REMOVAL
To remove the back panel, perform the following procedure:
1. Remove the window assembly.
2. Using a TORX T-15 screwdriver, remove the 5 screws that attach the trailing cable
rear tray to the back panel.
3. Using a TORX T-15 screwdriver, remove the screws that attach the back panel to the
electronics enclosure assembly. The C2858A has three screws and the C2859A has
four screws. Lift the back panel clear of the plotter.
Trailing Cable Rear Tray Screws (5)
(C)C2858-42
(C)C2858-2
Back Panel Screws
C2858A (3) C2859A (4)
Figure 6-16.
6-23Removal and Replacement
FRONT PANEL ASSEMBLY REMOVAL
To remove the front panel assembly, perform the following procedure:
1. Remove the right endcover.
2. Disconnect the window sensor connector and the front panel cable connector from
the front panel assembly. See Figure 6-17.
3. Release the front panel cable from the clamp on the front panel assembly.
4. Using a TORX T-20 screwdriver, loosen the three screws that connect the front panel
assembly to the right sideplate and slide the front panel assembly clear of the plotter.
Window Sensor Connector
Front Panel Cable
Connector
Screws (3)
(C)C2858-49b
6-24 Removal and Replacement
Figure 6-17.
CARRIAGE MOTOR REMOVAL
To remove the carriage motor, perform the following steps:
1. Remove the right endcover.
2. Remove the electronics enclosure cover.
3. Disconnect the carriage motor cable connector (labeled C) from the interconnect
PCA.
4. Press the small drive belt against the tensioner wheel in the belt tensioner to loosen
the belt and slide the belt off of the motor gear. See Figure 6-18.
5. Carefully release the tensioner wheel.
6. Using a TORX T-15 screwdriver, loosen the two carriage motor screws about 1/4
inch and rotate the motor until the motor can be pulled down clear of its bracket.
7. Retain the two screws for use with the replacement motor.
Drive Belt (Small)
Belt Tensioner
(C)C2858-47b
Screws (2)
Carriage Motor
Figure 6-18.
6-25Removal and Replacement
PAPER MOTOR REMOVAL
Note
The drive roller gear and paper motor must be replaced at the same time.
To remove the paper motor and drive roller gear, perform the following procedure:
1. Remove the right endcover.
2. Remove the electronics enclosure cover.
3. Remove the carriage motor.
4. Remove the front panel assembly.
5. Disconnect the paper motor cable connector (labeled P) from the interconnect PCA.
6. Disconnect the encoder cable connector from the paper motor. See Figure 6-19.
Note
Note the orientation of the mark (9 0’clock position) on one side of the drive
roller gear for installation purposes.
7. Using a TORX T-10 screwdriver, remove the two screws that secure the drive roller
gear to the drive roller shaft and remove the gear.
8. Using a TORX T-20 screwdriver, remove the two screws that secure the ink drop
well and remove the well.
9. Using a TORX T-15 screwdriver, remove the two screws that secure the paper motor
to its bracket.
10. Pull the paper motor toward the rear of the plotter until the motor can be removed
from the plotter.
If installing a new motor, apply grease (supplied with the motor) to the motor worm gear.
Note
Ensure that the mark on the drive roller gear faces to the front of the plotter
(9 0’clock position) when the motor worm gear is fully engaged with the
drive roller gear.
6-26 Removal and Replacement
Mark must face
toward front of
plotter when
paper motor is
fully installed
Drive Roller Gear
Worm Gear
(C)C2858-47a
Paper Motor
Encoder
Connector
Paper Motor
(C)C2858-66
Front View
Motor Screws (2)
Figure 6-19.
6-27Removal and Replacement
ENCODER STRIP REMOVAL
To remove the encoder strip, refer to Figure 6-20 and perform the following steps:
1. Remove the window assembly.
2. Remove the left and right endcovers.
W A R N I N G
3. Using a 5.5 mm nut driver, remove the nut and washer that secure the encoder strip to
the right side encoder spring-bracket. See Figure 6-20.
4. Using a 5.5 mm nut driver, remove the nut and washer that secure the ground strap
and encoder strip to the service station.
5. Compress the encoder spring-bracket to release tension on the encoder strip.
6. Carefully release the encoder strip from the encoder spring-bracket.
7. Carefully pull the encoder strip through and out of the carriage assembly.
When installing the encoder strip, do the following:
1. Ensure that the encoder strip is oriented with the transparent area down. Thread the
strip through the apertures in the pen carriage assembly.
2. Using a 5.5 mm nut driver, install the ground strap, washer and nut that secure the
encoder strip to the service station. Make sure the encoder strip engages the two
small tabs adjacent to the threaded post on the service station.
3. Press the forward end of the encoder spring-bracket slightly inward and place the
encoder strip between the tabs of the encoder spring-bracket and over the threaded
post on the encoder spring-bracket.
4. Using a 5.5 mm nut driver, install the washer and nut that secure the encoder strip to
the encoder spring-bracket.
5. Slide the carriage back and forth the length of its travel to ensure free movement. The
encoder strip should not bind or rub on the carriage. To adjust the encoder strip, loosen the spring-bracket screws and move the bracket up or down as necessary. Center
the encoder strip in the pen carriage apertures and tighten the spring-bracket screws.
6-28 Removal and Replacement
Nut and Washer
Left Side
Ground Strap
Service Station
(C)C2858-76
Nut and Washer
Encoder Strip
Right Side
Encoder Spring
Encoder Spring Bracket
(C)C2858-47a
Figure 6-20.
6-29Removal and Replacement
ROLLFEED COVER ASSEMBLY REMOVAL
To remove the rollfeed cover assembly, perform the following procedure:
1. Lower and hold the rollfeed cover about halfway open.
W A R N I N G
2. Using a TORX T-10 screwdriver, remove the screws and washers that attach the left
and right springs to the pivot spring anchor pins. See Figure 6-21.
3. Using a 7 mm wrench, loosen the two nuts that secure each end of the rollfeed cover
to the pivots.
4. Pull the rollfeed cover clear of the plotter.
(C)C2858-37
Left Pivot Spring
Anchor Pin Screw
6-30 Removal and Replacement
(C)C2858-38
Nuts
(2 each side)
Right Pivot Spring
Anchor Pin Screw
Figure 6-21.
ROLLFEED MODULE ASSEMBLIES (LEFT AND RIGHT) REMOVAL
To remove the left or right rollfeed module assembly, perform the following procedure:
1. Remove the appropriate left or right endcover as required.
2. Remove the rollfeed cover assembly.
3. Using a TORX T-20 screwdriver, remove the three screws that secure the rollfeed
module assembly to the sideplate. See Figure 6-22.
Left Rollfeed
Module Assembly
(C)C2858-52 (C)C2858-37
Rollfeed Cover
Module Assembly Screws
(3) Each Side
Right Rollfeed
(C)C2858-52a
(C)C2858-38
Module Assembly
Rollfeed Cover
Figure 6-22.
6-31Removal and Replacement
CUTTER ASSEMBLY REMOVAL
To remove the cutter assembly, refer to Figure 6-23 and perform the following steps:
1. Remove the right endcover.
2. Using a 5.5 mm nut driver, remove the nut and washer that hold the right end of the
encoder strip to the encoder strip spring-bracket.
3. Press the encoder strip spring-bracket inward and release the encoder strip from the
spring-bracket.
4. Using a TORX T-15 screwdriver, remove the encoder spring bracket.
Note
The cutter carriage preload arms are spring-loaded. Hold the cutter wheels
toward the center of the cutter carriage assembly while performing step 5.
5. Holding the cutter wheels in toward the center of the cutter carriage assembly, move
the cutter assembly to the right and off of the front slider bar.
6. Slowly release the wheels to relax the spring tension on the wheel arms and lift the
cutter assembly clear of the plotter.
To install the cutter assembly, do the following:
1. Rotate the wheel preload arms against the spring tension to the center of the cutter
carriage and hold them in position while performing the next step.
2. Move the cutter assembly’s lower wheels onto the overdrive support assembly.
3. Slide the cutter assembly along the overdrive support assembly and guide the upper
wheels into the starguard groove.
4. Guide the cutter blade in front of the linear blade. See Figure 6-23.
5. Slide the bushing into the cutter assembly and move the cutter so that the bushing
slides onto the front slider rod.
6. Verify correct installation by sliding the cutter assembly along its travel path.
7. Verify the cutter assembly pick-up function works by sliding the pen carriage into
the cutter assembly so that the pen carriage will engage the cutter assembly.
6-32 Removal and Replacement
Bottom Finger of
Cutter Assembly
Starguard
Upper Wheels
Cutter Blade
Linear Blade
Slider Rod
Bushing
(C)C2858-55
(C)C2858-66
Side View
Cutter Blade
Front View
Lower Wheels
Overdrive Support Assembly
Cutter AssemblyStarguard
Right Pre-load Arm
Overdrive Support
Assembly
Linear Cutter Blade
Figure 6-23.
6-33Removal and Replacement
TRAILING CABLE GUIDE REMOVAL
To remove the trailing cable guide, perform the following steps:
1. Remove the left and right endcovers.
2. Using a TORX T-15 screwdriver, remove the screw that attaches the ground strap
and trailing cable guide to the tensioner housing. See Figure 6-24.
C A U T I O N
3. Using a TORX T-15 screwdriver, remove the screw inside the ferrite ring that attaches the trailing cable guide to the Y-drive bracket.
4. Lift up the guide and carefully remove the ferrite ring.
6-34 Removal and Replacement
Trailing Cable Guide
(C)C2858-53
Front Guide Screw
Tensioner Housing
Left Side
Ferrite Ring
Screw (Inside Ring)
Y-drive bracket
(C)C2858-73
Trailing Cable Guide
Right Side
Figure 6-24.
6-35Removal and Replacement
Y-TENSIONER AND HOUSING REMOVAL
To remove the Y-tensioner and housing, perform the following procedure:
1. Remove the left endcover.
2. Slide the pen carriage a few inches towards the center of the plotter in order to access
the tensioner.
3. Remove the trailing cable guide screw which attaches the guide to the tensioner
housing.
4. Using a TORX T-15 screwdriver, remove the tensioner plate screw. See Figure 6-25.
C A U T I O N
(viewed from the rear) of the tensioner plate to keep the
tensioner spring compressed. Move the plate to the right
until it clears the slot in the housing.
5. Carefully move right end of the tensioner plate up and clear of the retaining tab.
6. Decompress the tensioner spring by allowing the tensioner plate to move toward the
rear of the plotter.
7. Remove the Y-tensioner spring and Y-tensioner from the housing.
8. Using a TORX T-15 screwdriver, loosen the Y-tensioner housing screw.
9. Remove the Y-tensioner housing from the Y-tensioner bracket.
10. Release the main idler from the pen carriage belt.
11. Lift the Y-tensioner housing clear of the plotter.
Hold the right end
6-36 Removal and Replacement
Trailing Cable Guide
Y-Tensioner Spring
Y-Tensioner Housing Screw
Main Idler
Guide Screw
Y-Tensioner Housing
(C)C2858-53
Y-Tensioner Bracket
Y-Tensioner
Tensioner Plate Screw
Tensioner Plate
Figure 6-25.
6-37Removal and Replacement
PEN CARRIAGE ASSEMBLY AND MAIN DRIVE BELT REMOVAL
To remove the pen carriage assembly, see Figure 6-26 and perform the following procedure:
1. Remove the window assembly.
2. Remove the left and right endcovers.
3. Disconnect the trailing cable from the carriage PCA.
4. Using a TORX T-15 screwdriver, remove the screw that secures the trailing cable
bracket to the pen carriage assembly and lift the trailing cable assembly clear of the
pen carriage assembly.
5. Remove the trailing cable guide.
6. Remove the encoder strip.
7. Remove the Y-tensioner and housing.
8. Slide the main idler out of the housing.
9. Remove the encoder spring-bracket.
10. Remove the double pulley from the Y-drive bracket. While doing this keep the palm
of one hand beneath the double pulley to catch the double-pulley bushing.
11. Using a TORX T-20 screwdriver, remove the three screws that attach the Y-drive
bracket to the sideplate. Position the Y-drive bracket assembly out of the way, so that
the pen carriage assembly can be removed.
12. Remove the cutter assembly making sure to hold the rear cutter bushing and spring
in place while removing the cutter.
13. Remove the pen carriage assembly with main drive belt from the plotter.
14. Set the pen carriage assembly top side down on a flat surface.
15. Using a small, standard screwdriver, remove the left and right belt clamps from the
pen carriage assembly.
16. Remove the main drive belt from the pen carriage assembly.
When reinstalling the encoder strip, remember to properly adjust the strip so that it does not
touch the pen carriage assembly. To adjust, loosen the encoder spring-bracket screws and
move the bracket up or down as necessary to center the strip in the pen carriage apertures.
6-38 Removal and Replacement
Carriage PCA
Trailing Cable
Connector
(C)C2858-77
Trailing Cable
Bracket
Encoder Strip
Nut & Washer
Encoder Strip
Cutter Assembly
Y-Drive Bracket
(C)C2858-47a
Encoder Strip Spring
Encoder Strip Bracket
Small Drive Belt
Figure 6-26.
6-39Removal and Replacement
DROP DETECT AND BAIL SENSORS REMOVAL
To remove the drop detect or bail sensor, refer to Figure 6-27 and perform the following
procedure:
1. Remove the window assembly.
2. Remove the left endcover.
3. Move the pen carriage to the middle of the platen.
4. Disconnect the drop detect sensor cable connector from the wire harness. Release the
drop detect sensor cable from the Y-tensioner bracket and let the cable hang down.
5. Using a TORX T-9 screwdriver, remove the four screws that secure the service station cover to the service station housing.
6. While holding the sled in position with one hand, lift the service station cover up.
Slowly release the sled and lift the cover clear of the service station housing.
7. To remove the drop detect sensor, pull the drop detect sensor up and out of the service
station housing.
8. To remove the bail sensor, use a small flat-blade screwdriver to carefully pry up on
the bail sensor and lift the sensor out of the service station housing.
When installing, be sure the small bail flag properly actuates by manually
raising and lowering the bail.
6-40 Removal and Replacement
Note
SledService Station Cover
Drop Detect
Sensor
(C)C2858-78
Screws (4)
Bail Sensor
Service Station Housing
Figure 6-27.
6-41Removal and Replacement
STARGUARD ASSEMBLY REMOVAL
To remove the starguard assembly, perform the following procedure:
1. Remove the window assembly.
2. Remove the left and right endcovers.
3. Remove the cutter assembly.
4. Remove the front panel assembly.
5. Using a TORX T-20 screwdriver, loosen the upper of the two screws that attach the
the starguard assembly to the left and right sideplates until the ends of the screws are
flush with the inner surfaces of the sideplates. See Figure 6-28.
6. Rotate the top of the starguard assembly toward the rear of the plotter so that it clears
the sideplate.
7. Slide the starguard assembly to the left and out of the plotter.
Right Starguard
Screws (2)
Left Starguard
Screws (2)
(C)C2858-64
(C)C2858-71
Star Wheels
C2858A (9)
C2859A (13)
6-42 Removal and Replacement
(C)C2858-51a
Starguard Assembly
Figure 6-28.
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