Intermec ColorCoder V4 Service Manual

Page 1
ColorCoder V4
Color Label Printer
P/N 1-960470-00 Edition 1 August1999
Service Manual
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1
Chapter 0
0. Introduction
0.1 Contents
0. Introduction
0.1 Contents ..........................................................................................1
0.2 Notices and Approvals ....................................................................4
0.3 Preface ............................................................................................6
1. General Description
1.1 Features...........................................................................................7
1.2 Specifications ..................................................................................8
1.3 Parts of the Machine......................................................................10
A. Front View ..............................................................................10
B. Rear View ............................................................................... 10
C. Internal View ...........................................................................11
D. Control Panel........................................................................... 11
E. Cross Sectional View...............................................................12
1.4 Menu Hierarchy Diagrams ............................................................ 13
2. Operation and Timing
2.1 Basic Operation............................................................................. 17
A. Functional Construction...........................................................17
B. Outline of Electrical Circuit ..................................................... 18
C. Input from and Output to Formatter PCB .................................20
D. Input from and Output to Engine 1 PCB (1/2).......................... 21
E. Input from and Output to Engine 1 PCB (2/2).......................... 22
F. Input from and Output to Engine 2 PCB ..................................23
G. Input from and Output to Roll Holder PCB..............................24
H. Input from and Output to DC Power Supply Unit ....................25
I. Basic Sequence........................................................................26
J. Motor Control.......................................................................... 28
2.2 Image Formation System...............................................................32
A. Outline .................................................................................... 32
B. BubbleJet Line Head ...............................................................35
C. Recovery Unit .........................................................................37
2.3 Ink Supply System ........................................................................47
A. Outline .................................................................................... 47
B. Pump Unit ...............................................................................52
C. Ink Cartridge ........................................................................... 58
2.4 Pick Up/Feeder System ................................................................. 59
A. Outline .................................................................................... 59
B. Motor Control.......................................................................... 60
C. Pick Up Operation ...................................................................61
D. Feeding Operation ................................................................... 66
E. Checking for Paper Errors ....................................................... 68
2.5 Control/Interface System............................................................... 70
A. Outline .................................................................................... 70
B. Outline of Operation ................................................................ 71
C. Memory Card ..........................................................................72
D. Parallel Interface......................................................................73
2.6 Control Panel ................................................................................74
A. Outline .................................................................................... 74
B. Operation................................................................................. 75
2.7 Power Supply ................................................................................ 77
A. Power Supply .......................................................................... 77
Intermec ColorCoder V4 Service Manual Edition 1, August 1999 Part No. 1-960470-00
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2
Chapter 0 Introduction
0.1 Contents, cont'd.
3. Mechanical System
3.1 Externals ....................................................................................... 79
A. External Covers .......................................................................79
B. Control Panel ...........................................................................82
3.2 Image Formation System...............................................................83
A. BJ Head ................................................................................... 83
B. Recovery Unit .........................................................................93
C. Fan Unit ................................................................................100
D. Motor Unit ............................................................................ 104
3.3 Ink Supply System ......................................................................108
A. Upper Ink Room.................................................................... 108
B. Pump Unit .............................................................................109
3.4 Pick-Up/Feeder System ...............................................................122
A. Roll Unit................................................................................122
B. Feeder Unit ............................................................................131
C. Rowels and Rollers ................................................................141
3.5 PCBs........................................................................................... 144
A. Engine 1 PCB ........................................................................144
B. Formatter PCB ...................................................................... 145
C. Counter PCB ......................................................................... 146
D. Engine 2 PCB ........................................................................147
E. DC Power Supply Unit ..........................................................148
4. Installation
4.1 Installation Suggestions ............................................................... 150
4.2 Unpacking and Installation ..........................................................151
A. Unpacking .............................................................................151
B. Installation (roll type) ............................................................152
C. Installation (fan-fold type) ..................................................... 160
D. Check of Image and Operation .............................................. 166
E. Head Shading ........................................................................ 167
F. Relocation and Transportation ...............................................168
4.3 Daily Care by Customer ..............................................................172
A. Image Maintaining Functions ................................................173
B. Cleaning ................................................................................174
5. Maintenance and Servicing
5.1 Parts to be Replaced Periodically.................................................175
5.2 Consumable Parts........................................................................ 175
5.3 Maintenance................................................................................ 176
6. Troubleshooting
6.1 Preface ........................................................................................ 179
A. Initial Inspection ....................................................................179
B. Others ....................................................................................180
6.2 Specifications and Adjustments ................................................... 181
A. Electrical System ...................................................................181
6.3 Test Print..................................................................................... 183
A. Outline .................................................................................. 183
B. Test Patterns ..........................................................................184
C. Head Cleaning ....................................................................... 192
D. Cleaning of Head Face .......................................................... 193
6.4 Head Shading ..............................................................................195
A. Outline .................................................................................. 195
B. Procedure to Make HS Data ..................................................197
6.5 Service Mode .............................................................................. 211
A. Outline .................................................................................. 211
B. Operation of Service Mode .................................................... 211
C. Functions of Service Mode ....................................................212
D. List of Service Mode .............................................................213
E. Service Mode Menu Hierarchy Diagram ............................... 223
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Chapter 0 Introduction
0.1 Contents, cont'd.
Information in this manual is subject to change without prior notice and does not represent a commitment on the part of Intermec Printer AB. © Copyright Intermec Printer AB 1999. All rights reserved. Published in Sweden.
ColorCoder is a registered trademark of Intermec Technologies Corp. Centronics is a registered trademark of Centronics Data Computer Corp. Microsoft is a registered trademark of Microsoft Corporation. Swiss 721 is licensed from Bitstream Inc. Swiss is a trademark of Bitstream Inc. Courier/Script are licensed from Canon Inc.
6. Troubleshooting, cont'd.
6.6 Diagnosis .................................................................................... 229
A. Malfunction Indications .........................................................229
B. Warning Indications ..............................................................233
6.7 Image Troubleshooting ............................................................... 236
A. Measures to Take Against Faulty Images............................... 236
6.8 Function Troubleshooting ........................................................... 242
A. Measures to Take Against Malfunctions ................................ 242
6.9 Layout/Functions of Electrical Parts ............................................257
A. Sensors and Switches.............................................................257
B. Motors and Solenoids ............................................................258
C. Printed Circuit Boards ........................................................... 259
D. List of Variable Resistors (VR) and Check Pins by PCBs ...... 260
Appendix
A.1 Overall Circuit Diagram ..............................................................263
A.2 List of Packaging Parts ................................................................264
A.3 List of Special Purpose Tools ...................................................... 265
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Chapter 0 Introduction
FCC Notice United States of America
WARNING:
This equipment generates, uses, and can radiate radio frequency energy and if not installed and used in accordance with the instructions manual, may cause interference to radio communications. It has been tested and found to comply with the limits for a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interference in which case the user at his own expense will be required to take whatever measures may be required to correct the interference.
DOC Notice Canada
Canadian Dept. of Communication
REGULATIONS COMPLIANCE
(DOC-A)
This digital apparatus does not exceed the class A limits for radio noise emissions from a digital apparatus as set out in the radio interference regulations of the Canadian Department of Communication.
✳ ✳ ✳
Ministère des Communications du Canada
CONFORMITE DE REGLEMENTS
(DOC-A)
Le présent appareil numérique n´émet pas de bruits radio-électriques dépassant les limites applicables aux appareils numériques de classe A prescrites dans le règlement sur brouillage radioélectrique édicté par le Ministère des
Communications du Canada.
VDE Notice Germany
ALLGEMEINE VORSCHRIFT:
Reparaturen oder sonstige Eingriffe, die sich nicht auf normale Bedienung der Maschine beziehen, dürfen ausschließlich nur von einem ausgebildeten, zuständigen Fachmann vorgenommen werden.
0.2 Notices and Approvals
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Chapter 0 Introduction
DECLARATION OF CONFORMITY
We,
Intermec Printer AB
Idrottsvägen 10
Box 123
S-431 22 Mölndal
Sweden
declare under our sole responsibility1 that the product
ColorCoder V4
to which this declaration relates
is in conformity with the following standards
EMC:
EN 55022:1994/A2:1997 Class B
EN 61000-3-2;1995 EN 61000-3-3:1995
EN 50082-1;1997
EN 50204:1995 EN 61000-4-4:1995 EN 61000-4-5:1995 EN 61000-4-6:1996 EN 61000-4-8:1993
EN 61000-4-11:1994
Electrical Safety:
EN 60950:1992/A1/A2/A3
following the provisions of Directives
89/336/EEC and 73/23/EEC
Mölndal 1999-05-03
...................................................................
Mats Gunnarsson
President
1
/. Intermec assumes no responsibility as regards fulfilling the CE Directive if the printer is
handled, modified or installed in other manners than those described in the manuals.
0.2 Notices and Approvals, cont'd.
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Chapter 0 Introduction
This Service Manual contains the basic information for the carrying out of after-sales service to maintain product quality and perform­ance of the Intermec ColorCoder V4 printer.
The contents and make-up of the chapters are as follows. Chapter 1 General Description
Broad features, specifications, and parts of the ma­chine.
Chapter 2 Operation
Description of the principle of operation of the me­chanical and electrical systems, their functions, and timing of operations.
Chapter 3 Mechanical System
Description of the mechanical system, its disassembly, assembly, and adjustment.
Chapter 4 Installation
Location and installation procedure.
Chapter 5 Maintenance and Servicing
Parts requiring periodic replacement, consumable parts, and periodic servicing.
Chapter 6 Troubleshooting
Troubleshooting and service modes.
Appendix General circuit diagram.
List of packaging parts. List of special purpose tools.
Information in this manual is subject to change. Notification of such changes will be given in Printer Technical Bulletins.
The information contained in this Service Manual and the Printer Technical Bulletins is essential to proper maintenance of the ColorCoder V4 printer.
This Service Manual is supplemented by the following publica­tions, which the service technician also should keep easily avail­able:
• Intermec ColorCoder V4; User's Guide (multilingual)
• Intermec ColorCoder V4; Installation & Operation manual
• Intermec ColorCoder V4; Spare Parts Catalogue
• Intermec ColorCoder V4; Installation Instructions (for various options)
Please note that the operations described in this manual only should be carried out by skilled and authorized personnel with proper training and full understanding of written English. The printers contain wires and circuits with high voltage, which implies the risk of electrical shock. Moving parts may also cause harm, if incor­rectly manipulated.
It is assumed that the reader possesses reasonable skills in mechan­ics and electronics. It is also assumed that the reader has access to the standard tools of an electronics workshop.
0.3 Preface
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Chapter 1
1. General Description
1.1 Features
This product is the world's first 4 inch wide, high speed Color Label Printer employing the bubble jet printing process, and has the following features.
1. By using four 4-inch wide bubble jet (BJ) line heads (Y, M, C, K) in its printing head, it is able to produce full-colour printing at high speed (150 mm/sec.) and in fine detail (360 dpi).
2. Head shading utility software is developed to correct ejection error of each BJ head nozzle. Further high quality of full-colour image is realized.
3. Four types of English language fonts are available as built-in fonts. In addition to that, it has a function of font download from a host computer.
4. It has a bar code printing function, and is able to handle eight types of bar codes.
5. Is has a partial rewrite (overlay) function, which enables it to change part of the data with no need to stop printing.
6. Ink recycle system newly installed, taking waste ink generated through BJ head cleaning operation, and put it back into ink supply system to reuse it for printing. It saves both ink and running cost.
7. By employing high durable and reliable parts, the necessity to assign parts as periodic replacement or consumable parts has been minimized.
8. It has a handy cutter as standard equipment thus making label cutting work more efficient.
9. A roll unit is provided for the paper feeding. By setting a large roll of paper, consecutive mass-printing is possible. By remov­ing the roll unit drive system, fan-fold paper can also be used.
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Chapter 1 General Description
Model Desktop type Color Label Printer. Printing technology Bubble jet printing system. Printing head Four heads, Y, M, C, K.
Total number of nozzles: 1,360.
Number of effective printing nozzles: 1,344 (each colour). Resolution 360 dpi (14.1 dots/mm) verical and horizontal. Paper feed process By special paper roll feeder and fan-fold paper feeding. Ink cartridges Four independent, spearate colours (CMYK). Special ink cartridge
with ink capacity of 200 ml each. (Printer is delivered with 4 × 100
ml cartridges). Printing speed 150 mm/sec. ( 6"/sec.)
Printing speed may be reduced by cooling the increased head
temperature, or when waiting for variable printing data transfer.
Speed of 100 mm/sec. ( 4"/sec.) or 50 mm/sec. ( 2"/sec.) can be
selected on the operation panel. Max. printable paper size Width 94.8 mm (3.73"), Length 402 mm (15.82"). Paper type Special coated Collux paper (matt coated, glossy). Paper shape Special paper roll (tag, label) or fan-fold. Roll outside diameter Max. 180 mm (7.08"). Roll core diameter Paper tube 76.2 mm (3"). Types Labels with backing paper and gap between labels.
Labels/tickets with black mark.
Labels/Tickets with hole.
Tags/No TOF (not supported by printer drivers) Bar code types JAN/UPC/EAN series, Codabar (NW-7), Industrial 2 of 5, Inter-
leaved 2 of 5, MSI Code-39, Code-93, Code-128. Customer bar code edition function
Size 8.8 point, 9.4 point, 10.0 point, 10.6 point. Printing rotation 0°, 90°, 180°, 270°.
Character Specifications Font Courier, Script, Swiss, OCR-B. Printing rotation 0°, 90°, 180°, 270°. Size 16 × 16 (Swiss), 48 × 48 (each type), 72 × 72 (Swiss). Magnification/reduction Normal (std), double width, double height, 4 times normal, half
normal, 1/4 normal, horizontal 4 times, vertical 4 or 16 times. Interface Parallel (conformed to Centronics, one-way communication. Power supply 100V – 240V, 50 or 60 Hz. Power consumption Max. 220 W. Acoustic noise When on stand by: 0 dB.
When printing: 60 dB (excluding peak period). Service life 1 year or 5,000,000 sheets, whichever comes first. Operating modes On line: Prints connected to host computer via Windows printer
driver or with ColorCoder LSW.
1.2 Specifications
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Chapter 1 General Description
Minimum margins Label paper Rear 1.4 mm
Front 1.5 mm
Leading edge 2.5 mm
Trailing edge 2 mm Tag paper Rear 3.4 mm
Front 3.4 mm
Leading edge 2.2 mm
Trailing edge 2.0 mm
Increasing of margins possible with menu key Scribed image buffer capacity 2 MB / colour Control panel LED display READY: Machine is ready to print
DATA: Data transmission/memory card access indication
ERROR: Indication of abnormality
ON LINE: Indication of ON LINE Selection keys PAUSE: Temporary cessation/restart of printing
STOP: Printing ended;
ON LINE: Switching On/Off Line
FEED: Feeding paper in OFF LINE state Menu key 1. Paper settings (No. of sheets to be printed, intervals, interval
sheets, paper size, margins, gap marker width between labels)
2. Maintenance (cleaning, test printing, adjusting position, setting
parameters, setting interface)
3. NVRAM save
Detecting functions Checks paper (no paper, paper jam), checks ink cartridges, checks
ink, serviceman call, door open, no paper fed Head cleaning function Operates automatically and manually Ink consumption 17,000 sheets/cartridge
(Conditions: 12.5% Duty/colour, paper size: 4" × 3" ) Memory card Can use card (SRAM 1MB ) conforming to JEIDA Ver 4.1. Manual cutter By rotating type cutter attached to paper delivery outlet. Partial rewrite function (overlay) Function available
(Exception: Printing speed slows depending on nature of rewrite Counter Provided. Counts only in printing for the 1-page length of 1019
lines (number of 3-inch long lines)
1. Total count (indicated on the operation panel in the service
mode)
2. Mechanical counter (positioned at the back of the main unit
inside) Options Cutter unit, Rewinder, Fan-fold kit
The above information is subject to change.
1.2 Specifications, cont'd.
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Chapter 1 General Description
1.3 Parts of the Machine
1.3:A Front View
1.3:B Rear View
1. Control panel
2. PHS (Printer Head Station) unit
3. Roll cover
4. Power switch
5. Front cover
1. Sub cover
2. Power cord connector
3. Parallel interface connector
4. Manual cutter
1 2
3
4
5
1
2
3
4
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Chapter 1 General Description
11
10
9
8
7
6
5
4
3
2
1
12
READY DATA
ERROR
MENU
PAUSE
ON LINE
FEED
STOP
ENTER
3
9
6
8
7
5
4
10
2
1
12
13
11
1.3:C Internal View
1.3.D Control Panel
1. Control panel 7. Roll retainer (inner)
2. Paper guide fixing screw 8. Roll retainer fixing screw
3. Paper guide (inner) 9. Roll retainer (front)
4. Paper guide (front) 10. Ink cartridges
5. Roll sensor lever 11. Memory card
6. Roll drive shaft 12. Front cover
1. Display 8. ENTER key
2. ON LINE key 9. Right cursor key
3. PAUSE key 10. READY lamp
4. STOP key 11. ON LINE lamp
5. FEED key 12. DATA lamp
6. MENU key 13. ERROR lamp
7. Left cursor key
1.3 Parts of the Machine, cont'd.
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Chapter 1 General Description
5
3
4
6
7
8
9
1
2
10
13
11
12
14
15
16
17
1.3:E Cross Sectional View
1. BJ head
2. Recovery unit
3. Roll sensor lever
4. Roll drive shaft
5. Follower roller
6. Pinch roller
7. TOF inlet sensor 1
8. TOF inlet sensor 2
9. Rowel units
10. Engine 2 PCB
11. Delivery roller
12. Drive roller
13. TOF outlet sensor 1
14. TOF outlet sensor 2
15. Engine 1 PCB
16. Formatter PCB
17. DC power supply unit
1.3 Parts of the Machine, cont'd.
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Chapter 1 General Description
1.4 Menu Hierachy Diagrams
INT. PAGE =01
INTERVAL SET.
INT.PAGE SET MARGIN SET
PRINT PAGES SET. PRINT PAGE =00001
TOP MARGIN =00
BOTTOM MARGIN=00
Next Page
CLEANING
PAPER SET
MEMORY CARD
NOZ. ADJ.PATTERN
SET.VALUE PRINT
TEST PRINTMAINTENANCE
POSITION ADJ. V-NOZZLE ADJ.
K-C GAP ADJ. C-M GAP ADJ.
M-Y GAP ADJ.
K-C GAP = 0 C-M GAP = 0
M-Y GAP = 0
STOP POS. ADJ. CUTTER POS. ADJ.
CUTTER POS. =0.0
DATE &TIME SET.
DATE SET.
TIME SET.
y-m-d 00-00-00 h:m:s 00:00:00
START-UP OPTION
OFF LINE START
*ON LINE START
OFF LINE
PAPER TYPE * TYPE 1 A:102X076
TYPE 2 C:102X076
TYPE 3 A:102X203 TYPE 4 C:102X203 TYPE 5 A:102X127
CLEANING (A) CLEANING (B)
INTERVAL =99999
CUT INTERVAL
CUT INT. =99999
TOP MARGIN SET.
BOT. MARGIN SET. LEFT MARGIN SET.
LEFT MARGIN =00
RIGHT MARGIN SET RIGHT MARGIN =00
MEM CARD PRINT MEM CARD FORMAT MEM CARD COPY
NOZ. CHK.PATTERN
H-NOZZLE ADJ.
C NOZZLE ADJ. M NOZZLE ADJ. Y NOZZLE ADJ. Y NOZZLE POS. =0
M NOZZLE POS. =0
C NOZZLE POS. =0
STOP POS. =0.0
PARAM. SET.
When cutter unit is not used. When cutter unit is used.
When cutter unit is not used.
(File name of print data)
When cutter unit is not used.
PRINT MODE SET.
MODE (A) AUTO. *MODE (B) 150 MODE (C) 100 MODE (D) 50
When cutter unit is used.
Font Name Indication
Upon insertion of font card.
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Chapter 1 General Description
1.4 Menu Hierachy Diagrams, cont'd.
Next Page
OUTPUT OPT.
*NOT USE
FRANCE
USE
DISPLAY MODE
*USA
JPN
CHAR. SET SEL.
*U.S.A
*CODE PAGE 437
GERMANY
DENMARK 1
U.K.
SPAIN 1
ITARY
SWEDEN
NORWAY
JAPAN
DENMARK 2
KOREA
LATIN AMERICA
SPAIN 2
LEGAL
I/F SET.
*PARALLEL *TYPE 1
TYPE 2 TYPE 3
CODE PAGE 850
CODE PAGE 850
CODE PAGE 850
CODE PAGE 850
CODE PAGE 850
CODE PAGE 850
CODE PAGE 850
CODE PAGE 850
CODE PAGE 850
CODE PAGE 850
CODE PAGE 850
CODE PAGE 850
CODE PAGE 850
CODE PAGE 850
*CODE PAGE 437
*CODE PAGE 437
*CODE PAGE 437
*CODE PAGE 437
*CODE PAGE 437
*CODE PAGE 437
*CODE PAGE 437
*CODE PAGE 437
*CODE PAGE 437
*CODE PAGE 437
*CODE PAGE 437
*CODE PAGE 437
*CODE PAGE 437
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Chapter 1 General Description
1.4 Menu Hierachy Diagrams, cont'd.
Next Page
PAPER TYPE SET.
TOP OF FORM SEL. *A:LABEL/GAP
B:LABEL/MARKER
C:TAG/MARKER D:TAG/HOLE
E:TAG/NO TOF
PAPER WIDTH SET.
PAPER LENGTH SET
MARK WIDTH SET.
PAPER WIDTH =102
PAPER LENGTH =076 LABEL GAP = 03
MARK WIDTH = 4
*TYPE 1 A:102X076
LABEL GAP SET.
TYPE 2 C:102X076
TYPE 3 A:102X203
TYPE 4 C:102X203
TOP OF FORM SEL. A:LABEL/GAP
B:LABEL/MARKER
*C:TAG/MARKER
D:TAG/HOLE E:TAG/NO TOF
PAPER WIDTH SET.
PAPER LENGTH SET
MARK WIDTH SET.
PAPER WIDTH =102 PAPER LENGTH =076 LABEL GAP = 03 MARK WIDTH = 4
LABEL GAP SET.
TOP OF FORM SEL. *A:LABEL/GAP
B:LABEL/MARKER C:TAG/MARKER
D:TAG/HOLE
E:TAG/NO TOF
PAPER WIDTH SET.
PAPER LENGTH SET
MARK WIDTH SET.
PAPER WIDTH =102 PAPER LENGTH =203 LABEL GAP = 03 MARK WIDTH = 4
LABEL GAP SET.
TOP OF FORM SEL. A:LABEL/GAP
B:LABEL/MARKER
*C:TAG/MARKER
D:TAG/HOLE
E:TAG/NO TOF
PAPER WIDTH SET.
PAPER LENGTH SET
MARK WIDTH SET.
PAPER WIDTH =102 PAPER LENGTH =203 LABEL GAP = 03 MARK WIDTH = 4
LABEL GAP SET.
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Chapter 1 General Description
1.4 Menu Hierachy Diagrams, cont'd.
TYPE 5 A:102X127
CLEANING MODE
*MODE (A)
MODE (B)
NVRAM
NVRAM RESET
NVRAM SAVENVRAM
PAPER WIDTH SET.
TOP OF FORM SEL.
PAPER LENGTH SET
LABEL GAP SET.
MARK WIDTH SET.
*A:LABEL/GAP
B:LABEL/MARKER C:TAG/MARKER
D:TAG/HOLE
E:TAG/NO TOF PAPER WIDTH =102 PAPER LENGTH =127 LABEL GAP = 06 MARK WIDTH = 4
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Chapter 2
2. Operation and Timing
2.1 Basic Operation
2.1:A Functional Construction
The printer can be divided into interface system, control system, image formation system, and pick up/feeder system in terms of its functions (see Figure 2-1).
The printer has the plural printing data acquiring routes, any of them being acquired through the system interface system.
The printing data are developed to an equivalent of one page of the image data in the image processing unit, and then printing operation starts.
When the printing operation starts, the BJ head is initialized, commencing paper pick up. The printing position of the paper is counted after the TOF inlet sensor detects the TOF mark on the paper (or the gap between the labels). Printing operation will take place after the image processing unit sends an equivalent of one line of the printing data to the image formation unit at the time when the printing position reaches the black head. Transmission and printing of an equivalent of one line of the printing data are repeated in synchronization with the feed of the paper to perform black printing. From now on, each time when the label reaches the cyan, magenta, and yellow heads, transmission and printing of an equiva­lent of one line of the printing data are repeated for each colour, completing an equivalent of one page of colour printing.
Image formation
system
Ink supply
system
Bubble jet
cleaning unit
Bubble jet
drive unit
Print system
Control
panel unit
Control system
Delivery unit
(Option)
Feeder unit
Roll paper
feeder unit
Engine control
unit
Image
processing
unit
Control
unit
Parallel
interface
Memory
card
Interface
system
Pick-up/feeder
system
Figure 2-1
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Chapter 2 Operation and Timing
2.1 Basic Operation, cont'd.
2.1:B Outline of Electrical Circuit
The printer consists primarily of a formatter PCB and engine 1 and 2 PCBs. Major functions of each PCB are as follows:
Formatter PCB
Each interface and image processing of the printing data are controlled by a microprocessor and a special gate array.
Controls the Parallel interface
Analyzes the command data emulation
Develops the printing data to image memory
Controls the control panel
Controls the roll holder unit
Controls the option (cutter unit)
Controls the output from the power supply unit
Interfaces with the engine control unit
Engine 1 PCB
The feeder system and the ink supply system are controlled by a microprocessor and a special gate array.
Controls the feeder system
Controls the ink supply system
Clock function
Backup memory function
Interfaces with the formatter PCB
Engine 2 PCB
All about the BJ heads and the PHS unit, such as cleaning, are controlled.
Controls the image data transmission of the heads
Controls the head drive and temperature
Controls the head motor
Controls the cap motor
Controls the fan motors
Figure 2-2 is a block diagram showing the printers major circuits. The electrical control of the printer is executed by two microproc-
essors each installed on the formatter PCB and the engine 1 PCB, respectively.
The printing data read by the memory card or Parallel interface from the host computer are image-processed on the formatter PCB, and sent to the BJ line heads via the engine 2 PCB at the time of printing.
Feeding of the paper and supply of the ink are controlled by the engine 1 PCB.
Inside the PHS unit are arranged two motors and one solenoid, which control the UP and DOWN motion of the head holder unit and capping and wipe evacuation operation of the recovery unit. These are controlled by the engine 2 PCB.
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Chapter 2 Operation and Timing
The feeder unit is provided with a motor and four paper detection sensors, and the pump unit is provided with a pump motor, solenoid, and three electromagnetic clutches.
The power supply consists of +12 V, +5 V, –12 V, and +24 V systems, and the power is supplied to the BJ head, motors, and solenoids in addition to each PCB.
2.1 Basic Operation, cont'd.
2.1:B Outline of Electrical Circuit, cont'd.
Image
processing
unit
Power control Circuit
Micro
computer
with ROM
Gate
Array
Gate
Array
Formatter PCB
Micro
computer
CG-ROM
Roll holder PCB
Memory
card holder
RAM
Motor driver
Engine 1 PCB
ROM
Feeder
motor
Pump motor
Motor driver
Engine 2 PCB
BJ head
(Black)
Head
motor
Cap
motor
Parallel interface
Control voltagecircuit
Q1
Q2
Q11
Q39 Q40 Q41
J109
Q301
Q302
PHS
control unit
Fan
motor
J102
Roll
motor
Option connector
J104
DC power supply unit
BJ head
(Cyan)
BJ head
(Magenta)
BJ head (Yellow)
Power switch
DRAM
Control panel
Head
control
Gate
Array
Counter
Counter
PCB
Figure 2-2
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Chapter 2 Operation and Timing
2.1 Basic Operation, cont'd.
2.1:C Input from and Output to Formatter PCB
J601
Formatter PCB
Control panel
Memory card
J109
External device
Cutter unit
(Option)
Engine 1
PCB
Roll holder
PCB
J32 J106
J102
J104
Parallel
J103
J307 J105
Figure 2-3
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Chapter 2 Operation and Timing
2.1 Basic Operation, cont'd.
2.1:D Input from and Output to Emgine 1 PCB (1/2)
TOF Inlet sensor 2
TOF Outlet sensor 2
TOF Inlet sensor 1
TOF Outlet sensor 1
Front door sensor
PHS lock solenoid
CL1
CL2
CL3
SL2
M2
Engine 1 PCB
PS1
PS2
PST1
PST2
PS3
SL1
M1
Pressure clutch
Suction clutch
Latch solenoid
Pump motor
Feeder motor
J1-1
-2
J2-1
-2
J3-1
-2
J4-1
-2
-3
J6-1
-2
J9-1
-3
-2
J8
J10-1
-3
-2
J11-3
-2
-1
J12-3
-2
-1
J13-3
-2
-1
J7-1
-2
-3
J302-1
-2
-3
-4
-5
-6
-7
-8
-9
-13
-14
J301
J305-A1
-A2
-A3
-A4
-A5
-A6
-A7
-A8
-A9
-A10
-A11
-A12
J305-B1
-B2
-B3
J309-1
-2
-3
When "H," drive movement is transmitted to pressure/release cam.
When "H," drive movement is transmitted to pressure pump.
When "H," drive movement is transmitted to suction pump.
When "H," pump motor rotates counterclockwise. When "H," pump motor rotates clockwise.
[HTOF IN]
[HTOF OUT]
[TTOF IN]
[TTOF OUT]
[PHS SLND1] [PHS SLND2]
[DOOR]
+5V
+5V
+5V
+5V
+5V
PS4
PS5
Pressure cam H. P sensor
Recovery pump H. P sensor
J14-3
-2
-1
J15-3
-2
-1
J305-B4
-B5
-B6
-B7
-B8
-B9
When "H," recovery pump is at home position.
+5V
+5V
PS12
Latch solenoid position sensor
J16-3
-2
-1
-B10
-B11
-B12
When "H," open/close latch is closed.
+5V
Cam pressure release clutch
When "L H," pressure/suction pump is at pressure position. When "H L," pressure/suction pump is at release position.
[PMP CR]
[PMP PRESSCR]
[PMP PULLCR]
When releasing sub-tank, set it to "H" to suck open/close solenoid. When closing sub-tank, set it to "H" to restore open/close solenoid.
[LT-SLND1] [LT-SLND2]
[PMP MA] [PMP MB]
[PMPSIT1] [PMPSIT2]
[PMSIT2]
[LTSLPSIT]
When TOF mark on paper passed sensor, "L."
When TOF mark on paper passed sensor, "L."
When TOF mark on paper passed sensor, "L."
When TOF mark on paper passed sensor, "L."
When front door is open, "L."
When "H," PHS unit is released. When "H," PHS unit is locked.
Figure 2-4
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Chapter 2 Operation and Timing
2.1 Basic Operation, cont'd.
2.1:E Input from and Output to Engine 1 PCB (2/2)
Figure 2-5
J303-1
J304-1
Formatter PCB
Engine 2 PCB
T1
T2
T3
T4
T5
T10
T11
T12
T13
J105
J406 J412
-2
-3
-4
-5
-6
-6
-7
-8
-9
J307
J308 J312
Ink remaining quantity sensor (K)
K
C
M
Y
INK
INK
INK
INK
CTRG
CTRG
CTRG
CTRG
K
C
M
Y
When resistance between each terminal and GND is measured with connector (J304) disconnected, if ink is full in ink cartridge, "several tens- several handreds (kΩ)."
When resistance between each terminal and GND is measured with connector (J304) disconnected, if ink is normal condition in ink cartridge, "infinity ()."
When resistance between each terminal and GND is measured with connector (J304) disconnected, if a new ink cartridge is set, "infinity ()."
Ink remaining quantity sensor (C)
Ink remaining quantity sensor (M)
Ink remaining quantity sensor (Y)
Overflow sensor
Ink cartridge sensor (K)
Ink cartridge sensor (C)
Ink cartridge sensor (M)
Ink cartridge sensor (Y)
CN2 CN4CN1CN3
Counter
Counter
PCB
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Chapter 2 Operation and Timing
Engine 2 PCB
PS6
PS7
PS8
PS9
MS1
Cap motor
Head motor
Fan motor
Fan motor
Fan motor
J401
J402
J403
J404
When recovery unit is at home position, "H."
When recovery unit is past home position, "H."
When head holder is at home position, "H."
HDPSIT1
When PHS unit is closed, "H."CAP
+24V
+5V
+5V
+5V
When "H," fan motor is turned ON.
BJ head (K)
BJ head (C)
BJ head (M)
BJ head (Y)
J308 J312
M4
M3
FM1
FM2
FM3
Engine 1 PCB
J406 J412
J407
J407
J409-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
J411-1
-2
J18
J19
J22-1
-2
J23-3
-2
-1
J24-3
-2
-1
J25-3
-2
-1
J26-3
-2
-1
Cap position sensor 1
Cap position sensor 2
Head position sensor 1
Head position sensor 2
PHS open/close detection switch
When "H," fan motor is turned ON.
FAN
When "H," fan motor is turned ON.
J27
J28
J29
J30
J408-1
-2
-3
-4
-5
-6
J20-1
-2
J21-1
-2
FAN
FAN
CPPSIT2
CPPSIT1
HDPSIT2
When head holder is past home position, "H."
+5V
2.1 Basic Operation, cont'd.
2.1:F Input from and Output to Engine 2 PCB
Figure 2-6
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Chapter 2 Operation and Timing
2.1 Basic Operation, cont'd.
2.1:G Input from and Output to Roll Holder PCB
Figure 2-7
Roll holder PCB
VIFF
PWDT
+5V
OPJLP 1
When roll guide plate is pressed to roll, "H."
When no slack in roll paper, "L."
OPIEND
When paper 4 inches wide is set, voltage is approx. 4V.
When paper 2 inches wide is set, voltage is approx. 0V.
Roll motor ON at "H."
+5V
+5V
Roll sensor
Paper width sensing slide rheostat
Roll motor
J61-3
-2
-1
J602-1
-2
-3
PS10
M5
-7
-8
J66-1
-2
J64-3
-2
-1
J603-3
-2
-1
J103
Formatter PCB
J601
J62-3
-2
-1
-5
-4
-6
PS11
VRU1
Roll paper end sensor
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Chapter 2 Operation and Timing
2.1 Basic Operation, cont'd.
2.1:H Input from and Output to DC Power Supply Unit
Figure 2-8
Power SW
SW SNS
Sleep
ON
Switching
Shut-down is going
J001
002
J002
J001-1
-2
-3
-4
-5
-6
314
J405
PC-SLP SW-SNS
VH-CONT VM-CONT
J108-1
-2
-3
-4
-5
-6
J306
Power supply Unit
Formatter PCB
Engine 1 PCB
Engine 2 PCB
While power is on, "H". While power is on, "L". From time when power SW is turned on to time when shutdown is completed, "H". See figure below. While power is on, "H". While power is on, "H".
J107 J002
+12V
+12V PC-SLP SW-SNS
VH-CONT VM-CONT GND
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Chapter 2 Operation and Timing
2.1 Basic Operation, cont'd.
2.1:I Basic Sequence
Figure 2-9
Power ON Initialization Sequence
The basic operation sequences for PHS holder release, pump unit initialization, and PHS unit initialization are shown below.
PHS lock solenoid Latch solenoid Pressure cam HP sensor Recovery pump HP sensor Pump motor Cam pressure release clutch
PHS holder lock
Pump unit initialization PHS unit initialization
Motor : Forward rotation/Solenoid: Lock Motor : Backward rotation/Solenoid: Release
Sequence
PHS holder lock
Pump unit initialization
Supply solenoid open Pump pressure release Recovery pump HP
Head position sensor 2 Head position sensor 1 Head motor Cap position sensor 1 Cap position sensor 2 Cap motor
Sequence
PHS unit initialization
86 pulse
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Chapter 2 Operation and Timing
2.1 Basic Operation, cont'd.
2.1:I Basic Sequence, cont'd.
Figure 2-10
Printing Sequence
The basic operation sequence of printing is shown below.
Sequence Operation
INIT Head/recovery system initialization operation HDCL Head cleaning processing MVPR Printing position movement operation HDPRT BJ head printing operation PD Delivery operation after printing MVCP BJ head/recovery system cap position movement SWBK Paper back feed operation
Sequence
Feeder motor TOF inlet sensor TOF outlet sensor Roll sensor Roll motor BJ head
INIT HDCL MVPR HDPRT PD
MVCP STBY
SWBK HDCL MVPR HDPRT
Initialization processing
POWER ON START
First printing
START
Second printing
Motor forward rotation Motor backward rotation
Cleaning processing
Head printing position movement
Head cap position movement
Cleaning processing
Head printing position movement
Table 2-1
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Chapter 2 Operation and Timing
2.1 Basic Operation, cont'd.
2.1:J Motor Control
Table 2-2
Outline
The printer has two 2 phase stepping motors in the PHS unit, a 5 phase stepping motor in the feeder unit, and a DC motor each in the ink supply system and the roll unit. See Figures 2-11 through 2-13. for the circuits that control each motor.
See Table 2-2 for the name of each motor and its function. The feeder motor and the pump motor are controlled by the motor
driver and the gate array (Q348) in the engine 1 PCB. The head motor and cap motor in the PHS are controlled by the motor driver and the gate array (Q401) in the engine 2 PCB. These main function is as follows.
Controls the motor ON and OFF
Controls the direction of motor rotation
Controls the speed of motor rotation
Three fan motors are started and stopped by Q401 via the transistor (Q421).
Start and stop, and rotating direction of the roll motor in the roll unit is controlled by the gate array (Q32) in the formatter PCB and the motor driver in the roll PCB.
The feed amount of the paper is detected by the roll sensor while the roll motor is on, and by feeding the output signal back to the motor driver via the detection circuit, the motor is controlled on and off so that a proper amount of the paper is always fed.
Motor Function
Feeder motor (M1) Drives feeder belt Head motor (M3) Moves head unit up and down Cap motor (M4) Drives recovery unit Pump motor (M2) Drives suction pump, pressure pump,
and recovery pump Roll motor (M5) Drives roll drive shaft Fan motors (FM1–3) Cools head while its temperature is in-
creasing
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Chapter 2 Operation and Timing
2.1 Basic Operation, cont'd.
2.1:J Motor Control, cont'd.
Figure 2-11
Engine 1 PCB
+24V
+12V
Q348 Q313 Q317
M1
Feeder motor
J301-1
-2
-3
-4
-5
FEEDMA
FEEDMB FEEDMC FEEDMD
FEEDME
Q318
Q338
+24V
PUMPMA
PUMPMB
J302-13
-14
Pump motor
M2
Driver
IC
Gate array
Driver
IC
Motor driver Control Circuit
Driver
IC
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Chapter 2 Operation and Timing
2.1 Basic Operation, cont'd.
2.1:J Motor Control, cont'd.
Figure 2-12
Motor driver
Gate array
Engine 2 PCB
Q401 Q404
J407-8
-6
-4
-9
-7
-5
M4
+24V
Cap motor
CAPMA
CAPMCOMA
CAPMA CAPMB
CAPMCOMB
CAPMB
Motor driver
Q402
J407-14
-12
-10
-15
-13
-11
M3
+24V
Head motor
HDMA
HDMCOMA
HDMA HDMB
HDMCOMB
HDMB
J408-2
-1
-4
-3
-6
-5
FM1
FM2
FM3
Fan motor 1
Fan motor 2
Fan motor 3
+24V
Q421
FAN
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Chapter 2 Operation and Timing
2.1 Basic Operation, cont'd.
2.1:J Motor Control, cont'd.
Figure 2-13
motor driver
Gate array
I/O
controller
M5
+5V
+24V+5V
Formatter PCB Roll holder PCB
Roll sensor
output detection
circuit
Roll motor
J602-7
-8
Q1
Q18Q32
OPIMT1 OPIE/B
J601-6
-5
-2
J103-A8
-A9
J602-3
-2
-1
Roll sensor
+5V
J602-6
-5
-4
Roll paper end sensor
-A12
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Chapter 2 Operation and Timing
2.2 Image Formation System
2.2:A Outline
Construction
The image formation system causes the heads to eject ink to form images on paper based on the printing data read from the memory card or the host computer. The system consists primarily of a head holder unit and a recovery unit. See Figure 2-14 for the basic construction of the image formation system.
Head motor
Cap motor
BJ head
Recovery unit
Restoration tub unit
Absorber
Tube connector
Tube station
Figure 2-14
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Chapter 2 Operation and Timing
2.2 Image Formation System, cont'd.
2.2:A Outline, cont'd.
Outline of Operation
While the power is off or the printer is standby, the BJ head ejection face is covered by a Restoration tub to prevent clogging and sticking dust (capping position).
Figure 2-15 (Capping position)
During printing operation starts, the head holder moves upward to the evacuated position, the restoration tub unit moves to the evacuated position, and the head holder moves downward until the head ejection face reaches the printing position (printing position).
Figure 2-16 (Printing position)
After printing operation completes, the head is returned to the capping position by the opposite operation to the above.
The head holder unit is driven by the head motor (M3), and the capping position and the printing position are controlled by the number of pulses driving the motor signal from the reference position detected by the head home position sensor.
The restoration tub unit is driven by the cap motor (M4), and the capping position and the evacuated position are controlled by the cap home position sensor 1 and the cap position sensor 2.
BJ head
Absorber
Restoration tub
BJ head
Restoration tub
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Chapter 2 Operation and Timing
Outline of Operation, cont'd.
When the printing operation starts, the head moves to the printing position, and the pick up and feeder systems feed the paper. The printing position of the paper is counted after the TOF inlet sensor detects a TOF mark or hole or the gap between labels on the paper, and when the printing position on the paper has reached the BJ head (black), an equivalent of one line of the printing data is sent to the BJ head from the image processing unit to execute printing of an equivalent of one line.
The above-mentioned operation is repeated in synchronization with the feed of the paper to form images. Likewise, for cyan, magenta, and yellow, when the printing position of the paper reaches the respective BJ heads, the printing operation is repeated to form colour images on the paper.
Basic Operation Sequence of Image Formation System
The basic operation sequence of the image formation system is shown below.
2.2 Image Formation System, cont'd.
2.2:A Outline, cont'd.
Figure 2-17
Feeder motor
TOF inlet sensor
BJ line head (K)
BJ line head (C)
BJ line head (M)
BJ line head (Y)
TOF outlet sensor
Sequence
First paper Second paper Third paper Fourth paper Fifth paper
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Chapter 2 Operation and Timing
2.2 Image Formation System, cont'd.
2.2:B BJ Line Head
Figure 2-18
Ejectable nozzle 95.96mm (1360 nozzles)
Depiction area 94.83mm (1344 nozzles)
Block 1 Block 2 Block 3 Block 4 Block 5 Block 6 Block 7 Block 8 Block 9 Block 10Block 11
123 111
678
222
Construction
The BJ head of the printer is provided with 11 heater chips in which 128 pieces of small heater are arranged in a length of approximately 9 mm, each heater having an ejection nozzle on it. These heaters are driven by the driving signal from the engine 2 PCB to eject the ink out of the nozzle.
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Chapter 2 Operation and Timing
2.2 Image Formation System, cont'd.
2.2:B BJ Line Head, cont'd.
Figure 2-19
Principle of Ink Ejection
The BJ method takes advantage of the bubbles generated by the heater element. The generation of bubbles causes the pressure in the nozzle to change, causing the ink to be ejected.
2. Heaters are heated
The ink adjacent to the main heater is heated to form fine bubbles.
3. Boiling
The ink adjacent to the main heater vaporizes abruptly to have the bubbles grow.
4. Expansion of bubbles
When the bubbles grow to the maximum, the ink is ejected out of the ejection face.
5. Contraction of bubbles
The bubbles are cooled down with the ink to contract. The ink at the tip of the nozzle rushes out at the speed at which it is ejected.
6. Destruction of bubbles
The ink comes in contact with the heater surface to be abruptly cooled down.
7. Supply of ink
The ink is again supplied to the nozzle by the capillary tube phenomenon.
1. Normal condition
At the ejection face, the surface tension of the ink balances the outside pressure.
1
Ejection
face
Heater drive pulse (main heat section)
62 3 4 5 7
Main heater
Bubble volume (relative value)
Bubbles
1
2
3
4
5
6
7
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Chapter 2 Operation and Timing
2.2 Image Formation System, cont'd.
2.2:C Recovery Unit
Outline
The recovery unit is provided for the purposes of preventing the ink from clogging, eliminating the bubbles inside the nozzles, and eliminating the surplus ink adhered to the head nozzle surface.
The recovery unit takes the following conditions depending on the state and the purpose of the unit.
1. Capping state
2. Head cleaning operation
3. Printing state Each operation will be described below.
Outline of Operation
1. Capping State
While the power supply is off or the printer is standby state, the head is moved to the capping position, and covered by the restoration tub.
Figure 2-20
BJ head
Absorber
Cleaner blade
Restoration tub
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Chapter 2 Operation and Timing
2.2 Image Formation System, cont'd.
2.2:C Recovery Unit, cont'd.
Outline of Operation, cont'd.
2. Head Cleaning Operation
This operation consists of combinations of the following operations depending on the cleaning purpose.
Preliminary discharge
This ejection exhausts heavily viscous ink in the vicinity of the head nozzle outlet. To do this, the head is moved to the preliminary discharge position, and the ink is ejected on the absorber in the restoration tub.
Figure 2-21
Pressurization
When the head is in the capping position, closing the suction pump and the pressure pump feeds a trace of ink to the head to forcibly exhaust the in and bubbles inside the head nozzle.
(See III. INK SUPPLY SYSTEM, 1. Outline of Operation, C. Operation of the Pressure Mode.”)
Circulation
When the head is in the capping position, driving the pressure pump and the suction pump to feed ink from the sub-tank to the head.
(See III. INK SUPPLY SYSTEM, 1. Outline of Operation, B. Operation of the Circulation Mode.”)
Head nozzle face
Cleaner blade
Restration tub
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Chapter 2 Operation and Timing
Outline of Operation, cont'd.
Head wiping
The head is moved to the wipe position, and the surplus ink adhered to the head nozzle face is removed with a cleaner blade.
Figure 2-22
3. Printing Operation
The restoration tub evacuates to the printing position, the head nozzle face moves downward to about 2.9 mm above the platen (about 1.5 mm from the paper), and then printing operation starts.
Figure 2-23
2.2 Image Formation System, cont'd.
2.2:C Recovery Unit, cont'd.
Head nozzle face
Cleaner blade
Restration tub
BJ head
Restration tub
Platen
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Chapter 2 Operation and Timing
2.2 Image Formation System, cont'd.
2.2:C Recovery Unit, cont'd.
Outline of Operation, cont'd.
Operation of Head Holder Unit
The head holder unit is driven by the head motor. The position of the head holder unit is detected by the head position sensor 1 whether or not it is in the reference position (wipe position), and the movement of the unit from that position to the predetermined position is controlled by the number of pulses driving the head motor. However the evacuated position is detected by the head position sensor 2.
Evacuation position to which the head evacuates when the restoration tub is moved.
Wipe position
Position of head wipe operation
Preliminary discharge position
Position of preliminary discharge
Capping position
Position of capping and pressurizing
Printing position
Position of printing
Operation of Restoration Tub Unit
The restoration tub unit is driven by the cap motor. The capping position and the evacuated position of the restoration tub unit are sensed by the cap position sensor 1 and the cap position sensor 2.
Capping position
Position of preliminary discharge, capping, and pressurizing
Evacuated position
Position of printing
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Chapter 2 Operation and Timing
2.2 Image Formation System, cont'd.
2.2:C Recovery Unit, cont'd.
Basic Operation Sequence
The basic operation sequence of the rcovery unit is shown below.
1. Preliminary discharge
2. Head wipe
Head position sensor 2 (PS9) Head position sensor 1 (PS8) Head motor (M3) BJ head
Sequence MVPF PF MVCP
86 pulse59 pulse
MVPF PF MVCP
: Preliminary discharge position movement : Preliminary discharge : Cap position movement
Figure 2-24
Figure 2-25
Head position sensor 2 (PS9) Head position sensor 1 (PS8) Head motor (M3) Cap position sensor 1 (PS6) Cap position sensor 2 (PS7) Cap motor (M4)
Sequence MVWP WP MVCP
86 pulse
21 pulse20 pulse
MVWP WP MVCP
: Wipe position movement : Wipe : Cap position movement
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Chapter 2 Operation and Timing
2.2 Image Formation System, cont'd.
2.2:C Recovery Unit, cont'd.
Head cleaning procedure
Head cleaning is automatically set up when the power switch is turned ON, printing is started, or when required during the printing process. Cleaning type can be selected on the operation panel or by service mode. Nine head cleaning modes are available as listed below.
Cleaning when power switch is turned ON
When the machine power switch is turned ON, the cleaning process takes place as follows depending on the time after the previous cleaning 4.
When more than 12 hours have elapsed after the previous
cleaning 4: ink supply cleaning 4
When less than 12 hours have elapsed after the previous cleaning
4: Cleaning 3
Cleaning type Procedure Operation mode
Cleaning 1 Preliminary discharge Service mode Cleaning 2 Pressurizing head wiping preliminary discharge Auto cleaning
(After the head wiping, waste ink is sucked.) Service mode
Cleaning 3 Suction of waste ink started.
Pressurizing head wiping preliminary discharge
Cleaning 4 Suction of waste ink started.
Ink circulation head wiping preliminary discharge
(Cleaning 2) x 4 Suction of waste ink pressurizing head wiping Service mode
preliminary discharge
Cleaning (A) Suction of waste ink started. Operation of the control
Pressurizing head wiping preliminary discharge panel (same as in the cleaning 3) Service mode
Claening (B) Suction of waste ink started Operation of the control
(Ink circulation pressurizing head wiping) process panel repeated twice. preliminary discharge Service mode
Recovery before printing Pressurizing head wiping Auto cleaning
(After the head wiping process, waste ink is sucked.)
Recovery before printing Preliminary discharge • Auto cleaning
Table 2-3
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Chapter 2 Operation and Timing
Head cleaning procedure, cont'd.
Cleaning when printing is started
When printing is started, the cleaning process takes place as follows depending on the time after the previous cleaning 4.
When more than 12 hours have elapsed after the previous
cleaning 4...
When the interval between the cleaning 4 and start of printing
is more than 30 minutes: Recovery before printing recovery before printing, before the printing process is started
When the interval between the cleaning 4 and start of printing
is less than 30 minutes: Recovery before printing, before the printing process is started.
When less than 12 hours have elapsed after the previous cleaning
4....
When the interval between the recovery ➀ before printing and
start of printing is more than 30 minutes: Recovery before printing recovery before printing, before the printing process is started.
When the interval between the recovery ➀ before printing and
start of printing is less than 30 minutes: Recovery before printing, before the printing process is started.
Cleaning when printing is interrupted
When the printing process is interrupted, the cleaning process takes place as follows.
When the PHS lock is released (“CHK. PAPER: MID is
indicated)
When the interval between the cleaning 3 and restart of
printing is more than 20 seconds: Recovery before printing recovery before printing ➁, before the printing process is started.
When the interval between the cleaning 3 and restart of
printing is less than 20 seconds: No cleaning process takes place before printing is restarted.
When the PHS lock is not released...
When the interval to restart of printing is more than 20 seconds:
Recovery before printing recovery before printing ➁, before the printing process is restarted.
When the interval to restart of printing is less than 20 seconds:
No cleaning process takes place before the printing process is restarted.
2.2 Image Formation System, cont'd.
2.2:C Recovery Unit, cont'd.
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Chapter 2 Operation and Timing
Head cleaning procedure, cont'd.
Cleaning during printing process (1)
After the previous cleaning 2 or 4, when the following or ➁, whichever earlier, is reached, cleaning 2 takes place.
Printing on paper equivalent to 600 sheets of standard paper (4"
× 3") with standard image (printing density 12.5%).
When mode A is selected in the “Cleaning setup menu: 1
minute. When mode B is selected in the Cleaning setup menu: 3 minutes.
Cleaning during printing process (2)
After the previous cleaning 4, when printing on paper equivalent to 2,500 sheets of standard paper (4" × 3") with standard image (printing density 12.5%) is completed, cleaning 4 takes place. However, if paper has exhausted during the printing process, and printing on paper equivalent to 2,000 sheets has already completed, cleaning 4 takes place.
2.2 Image Formation System, cont'd.
2.2:C Recovery Unit, cont'd.
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Chapter 2 Operation and Timing
2.2 Image Formation System, cont'd.
2.2:C Recovery Unit, cont'd.
Basic Operation Sequence of the Head Cleaning
The basic operation sequence at the time of head cleaning is shown below.
Basic operation sequence of cleaning 1
Basic operation sequence of cleaning 2
Basic operation sequence of cleaning 3
Sequence
Head position sensor (PS9) Head position sensor (PS8)
Head motor (M3)
BJ head
Preliminary discharge
position movement
Preliminary discharge Cap position movement
86Pulse
59Pulse
Motor running forward, sensor light blocking, clutch ON Motor running backward
Figure 2-26
Motor running forward, sensor light blocking, clutch ON Motor running backward
Sequence
Pressure cam position sensor (PS4) Recovery pump position sensor (PS5) Pump motor (M2)
Cam pressure release clutch (CL1) Pressure clutch (CL2) Head position sensor (PS9) Head position sensor (PS8)
0.4sec
20
pulse
21
pulse
Cam press­urized
Cam pressure released
Preliminary discharge
position movement
Cap position
movement
Ink
pressurized
Wait
Preliminary
discharge
Waste ink suction / wiping
Wiping position
movement
Cap position
movement
8.5sec 6.0sec
0.4sec
Head motor (M3) Cap position sensor (PS6) Cap position sensor (PS7) Cap motor (M4)
BJ head
86
pulse
86
pulse
59
pulse
Figure 2-27
Sequence
Pressure cam position sensor (PS4)
Recovery pump position sensor (PS5)
Pump motor (M2) Cam pressure release clutch (CL1) Pressure clutch (CL2)
30sec
3.0sec 1.6sec
1.6sec
Motor running forward, sensor light blocking, clutch ON Motor running backward
Waste ink
suction
Waste ink
suction started
Ink
pressure
Wait
Wiping
Preliminary
discharge
Waste ink suction
completed
Cam
pressure
release
Cam
pressure
40sec
15sec
Figure 2-28
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Chapter 2 Operation and Timing
2.2 Image Formation System, cont'd.
2.2:C Recovery Unit, cont'd.
Basic Operation Sequence of the Head Cleaning, cont'd.
Basic operation sequence of cleaning 4
Sequence
Motor running forward, sensor light blocking, clutch ON Motor running backward
Pressure cam position sensor (PS4) Recovery pump position sensor (PS5)
Pump motor (M2) Cam pressure release clutch (CL1) Pressure clutch (CL2) Suction clutch (CL3)
30sec
7.0sec
7.0sec
0.6sec
7.0sec 15sec
0.6sec
Waste ink
suction
Cam
pressure
Preliminary
discharge
WipingWait
Waste ink suction started /
ink circulation
Waste ink
suction completed
Cam
pressure
release
40sec
Pressurizing/suction
Post-
pressurizing
Figure 2-29
Basic operation sequence of cleaning 4
Sequence
Pressure cam position sensor (PS4) Recovery pump position sensor (PS5)
Pump motor (M2)
Cam pressure release clutch (CL1) Pressure clutch (CL2)
Latch solenoid (SL2)
Motor running forward, sensor light blocking, clutch ON Motor running backward
Sub-tank
closed
Sub-tank
opened
Ink supplied
Figure 2-30
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Chapter 2 Operation and Timing
2.3 Ink Supply System
2.3:A Outline
The ink supply system executes replenishment of the ink from the ink cartridge, supply of the ink to the BJ head, circulation of the ink inside the BJ head, and collection of the waste ink accumulated in the restoration tub. The basic construction of the ink supply system is shown below.
BJ Head
Restoration tub unit
Tube station
Filter unit
Ink remaining quantity detection sensor
Sub tank
Needle block
Cartridge detection contact
Ink cartridge
Ink room (lower)
Pressure release
cam
Suction pump
Recovery pump
Pressure pump
Open/close
lutch
Breather unit
Pump retainer
Figure 2-31
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Chapter 2 Operation and Timing
2.3 Ink Supply System, cont'd.
2.3:A Outline, cont'd.
Outline of Operation
The ink supply system operates in any one of four types of modes depending on the conditions of the printer.
Ink supply mode Supplies the ink from the ink cartridge to the sub-tank.
Circulation mode Circulates the ink between the sub-tank and the BJ head.
Pressure mode Pressurizes the ink and supplies it from the sub­tank to the BJ head.
Printing mode Supplies the ink from the sub-tank to the BJ head.
Operation of Ink Supply Mode
The printer stores the ink in the sub-tank in order to establish a proper surface tension at the ejection outlet of the head and supplies the ink to the BJ head from the sub-tank. The rest of the ink in the sub tank is detected during printing operation or at the start of cleaning operation. When the ink supply sensor detects no ink in the sub-tank, the ink supply operation takes place.
In the ink supply mode, the open/close latch of the sub-tank is closed. Under this condition, the pressure pump executes the ink supply operation to supply the ink to the sub-tank from the cartridge. The inside pressure of the sub-tank limits the amount of the ink to be supplied to the sub-tank. When the ink exceeds a certain amount, it is forced to flow back to the ink cartridge. The ink circulation operation between the sub-tank and ink cartridge enables to mix the ink with new one in the sub tank, so that it enables to prevent ink from getting gummy.
Recovery pump home position sensor
Recovery pump
Sub tank
One way
clutch
Pressure
pump
Air buffer
M
Pump motor
Pressure cam home position
sensor
Cam
pressure
release
clutch
C.W.
Pump
retainer
Suction
clutch
Pressure
clutch
SL
Filter unit
Outlet Release value
Breather
unit
Pump retainer
Inlet
Latch solenoid (Release)
Latch lever (Up)
BJ Head
Restoration tub unit
Tube station
Needle block
Ink cartridge
Suction
pump
Ink tank
Figure 2-32
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Chapter 2 Operation and Timing
2.3 Ink Supply System, cont'd.
2.3:A Outline, cont'd.
Outline of Operation, cont'd.
Operation of Circulation Mode
This operation will be executed during Cleaning 4. This mode circulates the ink between the sub-tank and the BJ head
to refresh the ink inside the head. This will eliminate the bubbles in the BJ head and prevent the ink from becoming gummy(sticky).
During this circulation mode, the open/close latch of the sub-tank is opened and the pressure pump and the suction pump are driven by pressurizing the pressure/release cam. Then, the pressure pump executes the pressure operation and the suction pump executes the suction operation. The ink supply pressure of the pressure pump is slightly higher than the return pressure (ink circulation pressure) of the suction pump, so that this pressure difference creates an inside pressure in the BJ head.
The recovery pump executes the suction operation in order to return the ink exhausted to the restoration tub into the sub tank.
Figure 2-33
Recovery pump home position sensor
Recovery pump
SL
Outlet Release value
Breather
unit
Inlet
Latch solenoid (Pull)
Latch lever (Down)
Sub tank
One way
clutch
Pressure
pump
Air buffer
M
Pump motor
Pressure cam home position
sensor
Cam
pressure
release
clutch
C.C.W.
Pump
retainer
Suction
clutch
Pressure
clutch
Pump retainer
Filter unit
BJ Head
Restoration tub unit
T
ube
station
Needle block
Ink cartridge
Suction
pump
Ink tank
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Chapter 2 Operation and Timing
2.3 Ink Supply System, cont'd.
2.3:A Outline, cont'd.
Figure 2-34
Outline of Operation, cont'd.
Operation of Pressure Mode
This operation will be executed during Cleaning 3 or Cleaning 4. During the pressure mode, the open/close latch of the sub-tank is
opened, the pressure/release cam is pressurized with the suction pump stopped, so that the suction pump is closed. When the pressure pump executes pressure operation under this condition, the ink is forcibly fed to the BJ head from the sub-tank and exhausted out of the nozzle. The recovery pump executes the suction operation to return the ink exhausted to the restoration tub into the sub tank.
Recovery pump home position sensor
Recovery pump
SL
Outlet Release value
Breather
unit
Inlet
Latch solenoid (Pull)
Latch lever (Down)
Sub tank
One way
clutch
Pressure
pump
Air buffer
M
Pump motor
Pressure cam home position
sensor
Cam
pressure
release
clutch
C.C.W.
Pump
retainer
Suction
clutch
Pressure
clutch
Pump retainer
Filter unit
BJ Head
Restoration tub unit
Tube station
Needle block
Ink cartridge
Suction
pump
Ink tank
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Chapter 2 Operation and Timing
2.3 Ink Supply System, cont'd.
2.3:A Outline, cont'd.
Figure 2-35
Outline of Operation, cont'd.
Operation of Printing Mode
During printing, the open/close latch of the sub-tank is opened and the pressure/release cam is released, so that the suction pump and pressure pump are stopped and released. When the pressure of the ink inside the BJ head and the tubing slightly goes down because of ink ejection, the ink is replenished to the BJ head from the sub-tank by means of a capillary tube phenomenon of the BJ head nozzles.
Error Detection
In the ink supply system. the following types of errors are detected.
No ink cartridge error: The presence or absence of the ink car-
tridge is checked for the ink room. “CHECK CART.” takes place, when no ink-cartridge in the ink room.
Empty ink error : The amount of the ink remained is checked
for the sub-tank. The error is detected at the time when the ink supply operation is completed. “Empty ink error” takes place when the ink-remaining-quantity-detec­tion sensor attached to the sub-tank does sense no ink at the time when the ink supply operation is completed.
Ink overflow error: 26 SERVICEMAN CALL” takes place,
when the ink leaks inside the printer and reaches the ink leak sensor.
Recovery pump home position sensor
Recovery pump
SL
Outlet Release value
Breather
unit
Inlet
Latch solenoid (Pull)
Latch lever (Down)
Sub tank
One way
clutch
Pressure
pump
Air buffer
M
Pump motor
Pressure cam
home position
sensor
Cam
pressure
release
clutch
Pump
retainer
Suction
clutch
Pressure
clutch
Pump retainer
Filter unit
BJ Head
Restoration tub unit
Tube station
Needle block
Ink cartridge
Suction
pump
Ink tank
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Chapter 2 Operation and Timing
2.3 Ink Supply System, cont'd.
2.3:B Pump Unit
Outline
The pump unit contains three pump systems, three electromagnetic clutches, and one DC motor. Each pump is driven by the DC motor, and ON/OFF of the pressure and suction pumps is controlled by the two clutches. The pressure/release cam is driven by the cam clutch to press and release the tubing of the suction and pressure pumps through the pump retainer. These are controlled by the engine 1 PCB.
Figure 2-36
Suction clutch
Pressure clutch
Pump motor
Recovery pump
Recovery pump home position sensor
Cam
pressure
release
clutch
Suction pump
Pressure pump
Pressure release cam
Pressure cam home
position sensor
Pump retainers
Pressure pump
The pressure pump is driven by engaging the pressure clutch while the pump retainer presses the tubing of the pump. By switching the rotating direction of the pump motor, ink is supplied either from the cartridge to the sub-tank or from the sub-tank to the BJ head.
Suction pump
The suction pump is driven by engaging the suction clutch while the pump retainer presses the tubing of the pump. Only sucking operation is excuted.
Recovery pump
The recovery pump is connected to the pump motor via the one-way clutch, and the pump is driven only when the motor runs in the counter-clockwise direction. With the recovery pump home posi­tion sensor, the pump always stops at the position of the released condition without no roller.
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Chapter 2 Operation and Timing
2.3 Ink Supply System, cont'd.
2.3:B Pump Unit, cont'd.
Figure 2-37
Outline of Operation
Ink supply mode
1. The pump motor is driven in the clockwise direction by engag­ing the cam pressure release clutch, to place the pressure/release cam in the press position.
2. The pump motor is driven in the clockwise direction by engag­ing the pressure clutch.
CW
CCW
Suction clutch
Pressure clutch
Pump motor
Recovery pump
Recovery pump home position sensor
Cam
pressure
release
clutch
Suction pump
Pressure pump
Pressure release cam
Pressure cam home
position sensor
Pump retainers
CCW
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Chapter 2 Operation and Timing
Outline of Operation, cont'd.
Circulation mode
1. The pump motor is driven in the clockwise direction by engag­ing the cam pressure release clutch, to place the pressure/release cam in the pressure position.
2. The pump motor is driven in the counterclockwise direction by engaging the pressure clutch and the suction clutch.
2.3 Ink Supply System, cont'd.
2.3:B Pump Unit, cont'd.
Figure 2-38
CCW
CW
CW
Suction clutch
Pressure clutch
Pump motor
Recovery pump Recovery pump home position sensor
Cam
pressure
release
clutch
Suction pump
Pressure pump
Pressure release cam
Pressure cam home
position sensor
Pump retainers
CW
CW
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Chapter 2 Operation and Timing
Outline of Operation, cont'd.
Pressure mode
1. The pump motor is driven in the clockwise direction by engag­ing the cam pressure release clutch, to place the pressure/release cam in the pressure position.
2. The pump motor is driven in the counterclockwise direction by engaging the pressure clutch.
2.3 Ink Supply System, cont'd.
2.3:B Pump Unit, cont'd.
Figure 2-39
CCW
CW
Suction clutch
Pressure clutch
Pump motor
Recovery pump
Recovery pump home position sensor
Cam
pressure
release
clutch
Suction pump
Pressure pump
Pressure release cam
Pressure cam home
position sensor
Pump retainers
CW
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Chapter 2 Operation and Timing
Outline of Operation, cont'd.
Printing mode
The pump motor is driven by engaging the cam pressure release clutch, to place the pressure release cam in the release position. All the pumps without the recovery pump are stationary.
2.3 Ink Supply System, cont'd.
2.3:B Pump Unit, cont'd.
Figure 2-40
Suction clutch
Pressure clutch
Pump motor
Recovery pump
Recovery pump home position sensor
Cam
pressure
release
clutch
Suction pump
Pressure pump
Pressure release cam
Pressure cam home
position sensor
Pump retainers
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Chapter 2 Operation and Timing
Outline of Operation, cont'd.
Recovery pump
Recovery pump is driven by transmitting power through the one­way clutch, when the pump motor runs in the direction of counterclockwise. In the ink circulation and pressure modes, the recovery pump is, therefore, in the driving operation and in the ink supply mode stationary. The recovery pump starts running to suc the waste ink accumulated in the restoration tub and push it back to the sub-tank. The recovery pump starts running at the same time when cleaning operation starts and keeps running during stand-by time after the cleaning, printing operation and a required time to suck the waste ink in the restoration tub unit. Since the recovery pump home position sensor detects the location at which the recovery pump stops, the recovery pump always stops in the open condition with no roller on the tube.
Filter unit
In the printer, ink recycle system is installed to recycle the ink taking waste ink appeared through the head cleaning and putting it back to the ink supply system to re-use. Fine grains and foreign matters contained in the waste ink need to be removed in order to re-use the waste ink. The waste ink collected through the recovery pump is designed to run through the filter unit before running back to the sub tank, thus, the fine grains and foreign matters are filtered and the waste ink is reinstated for re-use for printing.
Breather unit
It is very difficult to avoid ink viscosity caused by evaporation, even if the ink is reinstated through the ink recycle system. The ink supply system in the printer is air tight structure in order to minimize viscosity of the ink in the sub-tank. The breather unit is connected to the sub-tank and has open/close valves (breath valves) and release valves. The open/close valve is the valve to release the sub­tank from closed condition and is controlled with the latch solenoid.
The release valve is the valve to balance inside pressure of the subtank with outside air pressure, when inside pressure is changed in the subtank, environmental temperature is changed where the machine is installed and air pressure is changed while the machine is being transported by air.
2.3 Ink Supply System, cont'd.
2.3:B Pump Unit, cont'd.
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Chapter 2 Operation and Timing
2.3 Ink Supply System, cont'd.
2.3:C Ink Cartridge
The outside view of the ink cartridge is shown in Figure 2-41 below.
The following outlines the function of each part.
Ink tank Stores ink to be used for printing.
Cartridge detection contacts Contacts for being detected the pres-
ence or absence of the cartridge by printer.
Slots to prevent misinsert Slots to ensure that the ink cartridge
is inserted into the fixed position for each colour. The cartridge can not be inserted into wrong position.
Figure 2-41
Cartridge detection contact
Slots to prevent misinsert
Ink tank
Ink supply joint
Ink returning joint
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Chapter 2 Operation and Timing
2.4 Pick Up/Feeder System
2.4:A Outline
The pick up and feeder of the printer consists of a roll unit and a feeder unit.
The roll unit can supply both the roll paper and fan fold paper. The roll drive shaft rotates to hold and feed the paper. The roll drive shaft is driven by rotations of the roll motor. Quantity of paper supplied is detected with the roll sensor to ensure that the required paper feeding is kept. In case of the fan fold paper, the paper can be supplied by removing the roll unit drive system and setting the dip switch on the roll holder PCB. The paper supplied is fed on the feeder belt of the feeder unit. The feeder belt is driven by the rotations of the feeder motor in the feeder unit.
The start position of printing is sensed by the TOF inlet sensor 1 or 2, and poor feeding of the paper is sensed by the TOF inlet sensor 1or 2, and the TOF outlet sensor 1 or 2.
Figure 2-42
TOF outlet sensor 2
Feeder motor
TOF inlet sensor 1
Roll paper
Roll paper end sensor
Roll sensor
Roll motor
Slide rheostat unit
Feed belt
TOF outlet sensor 1
Roll drive shaft
TOF inlet sensor 2
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Chapter 2 Operation and Timing
2.4 Pick Up/Feeder System, cont'd.
2.4:B Motor Control
Roll Motor
The roll motor drives the roll drive shaft. When a control signal is output from the formatter PCB, a motor drive signal is output from the roller holder PCB, and the rotation of the motor is controlled so that the paper is supplied by a necessary length.
See Chapter 2.1 Basic Operation, I Motor Control for the drive and control of the roll motor.
Feeder Motor
The feeder motor drives the feeder belt. The paper to be fed is controlled by the motor drive signal issued from the engine 1 PCB.
The normal feed speed is 150 mm/sec; however, the speed will decrease for the following cases.
1. While the head temperature is increasing, the printing operation is executed at a speed of 50 mm/sec.
2. The partial rewriting including variable data spend some time in developing data. A printing speed is selectable in PRINT MODE SET in MAINTENANCE MODE on the control panel. The default is 150 mm/sec.
If it does not catch up with a given speed for developing image data, the feeding of paper pauses every print of 1 page.
See Chapter 2.1 Basic Operation, I Motor Control for the drive and control of the feeder motor.
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Chapter 2 Operation and Timing
2.4 Pick Up/Feeder System, cont'd.
2.4:C Pick Up Operation
Outline
Pick up operation of this machine indicates the procedure that required quantity of paper is supplied to the feeder unit from the roll paper and fan fold paper.
Figure 2-43
Figure 2-44
Slide rheostat unit
Roll paper end sensor
Roll sensor lever
Roll sensor
Roll drive shaft
Roll paper
Roll holder PCB
Slide rheostat unit
Roll holder PCB
Fan fold paper
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Chapter 2 Operation and Timing
2.4 Pick Up/Feeder System, cont'd.
2.4:C Pick Up Operation, cont'd.
Summary of operation
Paper feeding procedure
Since the fan fold paper is picked up and fed with the feed unit, its feeding procedure is not referred to here.
The paper pick-up operation indicates the procedure that the roll paper is rotated by the rotations of the roll drive shaft holding the roll paper so that required quantity of paper for the feeding and printing is sent.
When the printing operation is started, the roll unit starts to feed the paper.
If the paper is slackened, light for the roll sensor is blocked with the roll sensor lever and the roll drive shaft stops rotating.
Figure 2-45
When printing is started and paper is fed, the slackness is eliminated and the paper pushes the roll sensor lever. Then the roll sensor is unblocked and the roll sensor ON signal is sent to the roll holder PCB. The roll holder PCB detects the roll sensor ON signal, issues a roll motor drive signal, rotates the roll drive shaft and sends the paper.
When the paper is sent, the roll sensor lever is released and blocks the light to the roll sensor.
When the roll holder PCB detects the roll sensor OFF, the roll motor drive signal is stopped and the roll drive shaft stops rotating.
Above procedure is repeated so that the roll unit feeds required quantity of paper.
Roll paper Roll drive shaft
Roll paper
[Roll paper slackened]
[Roll paper not slackened]
Roll sensor lever
Roll sensor
Figure 2-46
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Chapter 2 Operation and Timing
2.4 Pick Up/Feeder System, cont'd.
2.4:C Pick Up Operation, cont'd.
Summary of operation, cont'd.
Paper width detection
By setting the paper guide (front) to match the paper, the slide lever of the slide rheostat unit movement is linked with the paper guide (front) to convert the position of the paper guide (front) to voltage signal. The voltage signal is transmitted to the engine 1 PCB through the roll holder PCB and formatter PCB and A/D converted. The paper guide (front) setting position is detected based on the converted value to recognize the width of the paper.
Figure 2-47
Slide rheostat unit
Paper guide
Feedback operation
When a printing operation is completed and the next printing process is started, or when the printing process is interrupted with the PAUSE key and then restarted, unprinted paper in the feed unit or paper being printed is returned to the printing start position to avoid waste. This process is called feedback process.
Figure 2-48
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Chapter 2 Operation and Timing
2.4 Pick Up/Feeder System, cont'd.
2.4:C Pick Up Operation, cont'd.
Summary of operation, cont'd.
After completion of printing (or when printing is interrupted), the last printed paper is delivered out of the outlet.
When printing is started (resumed) next, the feed belt and roll unit roll drive shaft is reversed (only when roll paper is used) to return the top of the paper next to the printed paper to the position of the TOF inlet sensor 1 or 2.
Figure 2-49
Roll drive shaft
When the top of the next paper returns to the position of the TOF inlet sensor 1 or 2, paper pick up and feeding operation is started.
Figure 2-50
Feed belt
TOF inlet sensor
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Chapter 2 Operation and Timing
2.4 Pick Up/Feeder System, cont'd.
2.4:C Pick Up Operation, cont'd.
Figure 2-51
Summary of operation, cont'd.
Roll paper end detection
When paper has exhausted and paper slackness is eliminated, the roll sensor lever is fully pushed. Then, light to the roll paper end sensor is blocked and the roll paper end detection signal is sent to the roll holder PCB. When the roll holder PCB detects the roll paper end detection signal, it stops rotation of the roll drive shaft. At the same time, the roll paper end detection signal is sent to the formatter PCB through the roll holder PCB and NO PAPER is indicated on the operation panel.
Roll drive shaft
Roll sensor lever
Roll sensor
Roll paper end sensor
Roll paper
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Chapter 2 Operation and Timing
2.4 Pick Up/Feeder System, cont'd.
2.4:D Feeding Operation
Outline
The paper supplied to the feeder unit is fed by means of the pinch roller, the feed belt, and the delivery roller.
These are driven by the feeder motor. Five rowels provided along the feeder path prevent the paper from being off-contact. The feeder motor is of a 5 phase type. During the printing operation, every 70.5 mm (an equivalent of one line of 360 dpi) paper fed, an equivalent of one line of the ink of the BJ head is ejected.
Delivery rowel
Rowels
Feeder motor
Pinch roller
Roll paper
Feed belt
Roll drive shaft
Figure 2-52
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Chapter 2 Operation and Timing
2.4 Pick Up/Feeder System, cont'd.
2.4:D Feeding Operation, cont'd.
Outline of Operation
The following is an outline of how the paper is picked up and fed.
Figure 2-53
Sequence
Feeder motor TOF inlet sensor TOF outlet sensor Roll sensor *1 Roll motor *1 BJ head
INIT HDCL MVPR HDPRT PD
MVCP STBY
SWBK HDCL MVPR HDPRT
Initialization processing
POWER ON START
First printing
START
Second printing
Motor forward rotation Motor backward rotation
Cleaning processing
Head printing position movement
Head cap position movement
Cleaning processing
Head printing position movement
*1. Only when roll paper is used
Sequence Operation
INIT Head/recovery system initialization operation HDCL Head cleaning processing MVPR Printing position movement operation HDPRT BJ head printing operation PD Delivery operation after printing MVCP BJ head/recovery system cap position movement SWBK Paper back feed operation
Table 2-4
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Chapter 2 Operation and Timing
2.4 Pick Up/Feeder System, cont'd.
2.4:E Checking for Paper Errors
Outline
To check if the paper is moving normally, signals from the sensors are read at such times as instructed by the microprocessor.
When the microprocessor identifies a jam, the ongoing printing operation is suspended immediately and the printer is stopped.
After the printer stops, [CHK. PAPER: MID] or [NO PAPER FED] message is indicated on the operation panel and the error lamp lights up.
The microprocessor identifies the following conditions as paper error.
Basic Operation Sequence of Checking for Paper Error
The basic operation sequence of checking for paper error is shown below.
Paper feed error
When the paper is not fed to the TOF sensor within a specified time after print starting.
1. Paper feed error at the pick up assembly: When the TOF mark of the paper does not reach the TOF inlet sensor within a specified time after print starting. [CHK. PAPER: MID] : When first sheet of paper is at the TOF inlet sensor. [NO PAPER FED] : When the first sheet of paper is not at the TOF inlet sensor.
2. Paper feed error at the delivery assembly: When the TOF mark of the paper does not reach the TOF outlet sensor within a specified time after the TOF inlet sensor detect the TOF mark.
PRINTWAIT
Normal condition
PWR ON PRINT START
Paper feed motor
Inlet TOF sensor
1.6sec
PRINTWAIT
Abnormal condition
PWR ON PRINT START
1.6sec
ERROR
Abnormal
PRINTWAIT
Normal condition
PWR ON PRINT START
Paper feed motor
Inlet TOF sensor
1.3sec
PRINTWAIT
Abnormal condition
PWR ON PRINT START
ERROR
1.3sec
Abnormal
TOF outlet sensor or cutter TOF sensor
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Chapter 2 Operation and Timing
2.4 Pick Up/Feeder System, cont'd.
2.4:E Checking for Paper Errors, cont'd.
Basic Operation Sequence of Checking for Paper Error, cont'd.
3. Paper feed error: When detection of the TOF mark by the TOF inlet sensor or the TOF outlet sensor continues more than a specified time while the paper is being fed.
4. Paper feed error: After the TOF mark is detected by the TOF inlet sensor, the TOF inlet sensor detects the next TOF mark earlier than a specified time.
5. Paper feed error: After the TOF mark is detected by the TOF inlet sensor, the TOF inlet sensor cannot detect next TOF mark while a specified time.
PRINT
Normal condition
Paper feed motor
Inlet TOF sensor
Outlet TOF sensor
Approx. 0.06 sec
PRINT
Abnormal condition
ERROR
Abnormal
Approx. 0.06 sec
Approx. 0.06 sec
PRINT
Normal condition
Paper feed motor
Inlet TOF sensor
Approx. 0.05 sec
PRINT
Abnormal condition
ERROR
Abnormal
Approx. 0.5 sec
(When the 3 inch length paper is used)
(When the 3 inch length paper is used)
PRINT
Normal condition
Paper feed motor
Inlet TOF sensor
Approx. 2 sec
PRINT
Abnormal condition
ERROR
Abnormal
Approx. 2 sec (When the 3 inch length paper is used)
(When the 3 inch length paper is used)
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Chapter 2 Operation and Timing
2.5 Control/Interface System
2.5:A Outline
The control/interface system which controls overall operation of the printer and interface system consists primarily of a formatter PCB.
Figure 2-54
Host computer
Engine 2 PCB
Engine 1 PCB
Formatter PCB
Control system
Parallel interface
Y M C K BJ head
Memory card
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Chapter 2 Operation and Timing
2.5 Control/Interface System, cont'd.
2.5:B Outline of Operation
The printer has the following two printing data access routes.
1. The printing data stored in the memory card are directly printed.
2. The printing data are transmitted from a host computer through parallel interface.
In any case of the above, the printing operation will start after an equivalent of one page of the image data are developed in the bit map RAM inside the formatter PCB.
When the development of the image data are completed, the formatter PCB will send a print start signal to the engine unit, where the initialization of the head, the paper feed operation, and the counting operation of the print start position are executed.
When the paper reaches the print start position, an equivalent of one black line of the printing data are sent from the image data of the bit map RAM inside the formatter PCB to the black head via the engine 1 and 2 PCBs. At the head, these data are once stored and printed. Each time when an equivalent of one line of the paper is fed, an equivalent of one line of the printing data is repeatedly transmitted and printed in this manner to form continuous images.
Likewise, when the printing position reaches each head position of cyan, magenta, and yellow, printing data of each colour are printed to form color images.
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Chapter 2 Operation and Timing
2.5 Control/Interface System, cont'd.
2.5:C Memory Card
A memory card is a media which the printing data are read from and written into. The printer can print the data by using the memory card.
Note: Although the printer is capable of using memory cards, Intermec does not support this facility. Neither does Intermec provide any means for programming memory cards.
Figure 2-55
When the printing operation starts with the memory card installed in which the printing data are stored, the gate array in the formatter PCB starts to identify whether the printing data are the image data or the code data. If the printing data are image data, the data are transmitted to the bit map RAM inside the formatter PCB, and after transmission of the data completes, the printing operation will start. On the other hand, the printing data are the code data, the gate array develops the image data in the bit map RAM in accordance with the information of the data ( printing position, direction, character size, and character code). Character font data are stored in the CG ROM inside the formatter PCB.
When the development of the image data to the bit map RAM completes, the printing operation starts.
CPU
Gate array
Bit map
RAM
CG ROM
Formatter PCB
J109
Memory card
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Chapter 2 Operation and Timing
2.5 Control/Interface System, cont'd.
2.5:D Parallel Interface
The printer is equipped with the Centronics-conformed Parallel interface as standard. This makes an on-line control connected with a host computer possible. The host computer can execute the following controls.
Transmission of control code, special commands
Transmission of printing data
Start/stop of printing operation
Transmission of variable data commands
Figure 2-56
When the printing data are transmitted from the host computer via the parallel interface, the signal is received by the CPU inside the formatter PCB. If the printing data are image data, the data are transmitted to the bit map RAM , and after transmission of the data completes, the printing operation will start. On the other hand, the printing data are the code data, the gate array develops the image data in the bit map RAM in accordance with the information of the data ( printing position, direction, character size, and character code). When the development of the image data to the bit map RAM completes, the printing operation starts.
Host computer
CPU
Gate array
Bit map RAM
CG ROM
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Chapter 2 Operation and Timing
2.6 Control Panel
2.6:A Outline
The control panel of the printer is provided with four LEDs, one LCD (liquid crystal display), and eight switches.
The control panel is connected to the formatter PCB, and has the following functions.
LCD displays status, errors of the printer.
LEDs displays operating conditions of the printer.
Eight switches control printing conditions of the printer, such as
start, stop and pause.
Figure 2-57
READY DATA ERROR
MENU
PAUSE
ON LINE
FEED
STOP
ENTER
Ready lamp
Data lamp
Display panel
Error lamp
Menu key
Right cursor key
Enter key
Left cursor key
On-line key
Pause key
Stop key
Feed key
On-line lamp
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Chapter 2 Operation and Timing
2.6 Control Panel, cont'd.
2.6:B Operation
LEDs and LCD on the control panel are controlled by the signal output from the formatter PCB. All of the signals generated by the switches on the control panel are input to the formatter PCB.
The meaning of each signal is shown below. D8 ~ D15: Data bus lines used for transmitting the data displayed
with LCD, outputting the ON/OFF signals of LEDs, and inputting the output signals of the key switches.
CSLED: Indicates that the signal on the data bus lines is the ON/
OFF signal of LEDs.
CSKEY: Requests the output signal of the key switch to the data
bus line.
LCDECK: Indicates clock signals on which written-in signal is
about to be sent to LCD controler and read-out signal is about to be sent from LCD controler.
WR: Indicates that the signal on the data bus line is the write-
in signal to LCD.
A1: Indicates that whether the signal on the data bus line is
the display data or the control signal.
Figure 2-58
READY DATA
ERROR
MENU
PAUSE
ON LINE
FEED
STOP
ENTER
Formatter PCB
LCDECK WR A1
DC+5V GND D8~D15 CSLED
CSKEY
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Chapter 2 Operation and Timing
2.6 Control Panel, cont'd.
2.6:B Operation, cont'd.
Write-in of operation keys
The following show the period during which the key is effective, when a key on the control panel is pressed.
On-line lamp On-line key Feed key Pause key Stop key Right cursor key Left cursor key Enter key Menu key
Note 1 Note 2
ON LINE OFF LINE ON LINE
INIT
STBY
PRINT
STBY
Normal mode
Set-up mode
Power switch
ON
StandbyPRINT
Press the
on-line key
Press the
menu key.
Press the
on-line key.
Note 3
Figure 2-59
Note
1. If the on-line key is pressed during this period, the on-line display flashes, and the printer will be the off-line state immediately after the printing operation completes.
2. If the on-line key is pressed during this period, the printer will immediately reset to the on-line during the printer is set up. During the operation in the menu mode, the on-line display flashes, and the printer will be the on-line state immediately after the operation completes.
3. If the feed key is pressed during this period, the printer feeds one sheet of the paper. If the feed key is pressed instantaneously during this term, the printer feeds one sheet of the paper for about 10mm. (The key can be used even while an operation call error has occurred.) If the feed key and right cursor key are pressed at the same time during this period, the printer feeds the paper forward during they are pressed. If the feed key and left cursor key are pressed at the same time during this period, the printer feeds the paper backward during they are pressed.
As obviously from the above, the periods during which the keys on the control panel of the printer are effective can be divided into the following four groups.
1. On-line and during standby The on-line key is effective.
2. On-line and during printing operation The on-line, pause, and stop keys are effective.
3. Off-line and in normal mode The on-line and feed keys are effective.
4. Off-line and in setup mode The on-line, right cursor, left cursor, menu, and enter keys are effective.
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Chapter 2 Operation and Timing
2.7 Power Supply
2.7:A Power Supply
Figure 2-60 is a block diagram showing how the power is distrib­uted within the printer.
DC power supply unit
Formatter PCB
Engine 1 PCB Engine 2 PCB
BJ head
(Yellow)
+5V
+24V
BJ head
(Magenta)
+5V
+24V
BJ head
(Cyan)
+5V
+24V
BJ head
(Black)
+5V
+24V
+24V
+12V
+5V
+5V
+12V
+24V
-12V
+24V
+24V
+24V
+5V
Sensor
Motor
Clutch
Solenoid
Battery BH301
AC
+5V
+24V
+24V
VM-CONT
VH-CONT
SW-SNS
SLEEP
Counter PCB
+5V
Roll holder
PCB
+24V
+12V
+5V
Control panel
+5V
+5V
+5V
+24V
Motor
Counter
Sensor
+24V
+24V
+24V
+5V
Sensor
Motor
Solenoid
Fan
motor
Figure 2-60
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Chapter 2 Operation and Timing
2.7 Power Supply, cont'd.
2.7:A Power Supply, cont'd.
DC Power Supply Unit
The accuracy and the destination of each power supply output from the DC power supply circuit are as follows:
Power Supply Accuracy Destination
+24V DC ±0.5V Motors, solenoids, fans, and
BJ heads.
+12V DC ±5% Analog control circuit +5V DC +6%/-3% PCBs, sensors, and BJ heads
-12V DC ±5% Analog control circuit
(Values at the output terminals of PCBs).
Table 2-4
Connecting the power cord between the printer and an output receptacle will allow the AC power supply to be supplied to the DC power supply unit.
The DC power supply unit of the printer controls each power supply to be output and be stopped by means of the power switch and the control signal from the formatter PCB by means of the control circuit in the DC power supply unit. The following are the descrip­tion on the operation.
1. When the power switch is turned ON Turning the power switch on causes +5 VDC, +12 VDC, –12 VDC, and +24VDC to each PCBs to be output by means of the function of the control circuit in the DC power supply unit.
2. When the power supply is turned OFF By turning the power switch off, the DC power supply unit outputs the SW-SNS signal to the formatter PCB. When the formatter PCB receives the signal, shut-down operation is carried out by placing the BJ head in the capping position. After completion of the shutdown operation, the formatter PCB turns the SLEEP signal off. Then, the DC power supply unit stops supplying all the DC power.
Battery
The engine 1 PCB is provided with a battery (BH301). The printer has a clock function, by which timing of the cleaning operation and others are controlled. Even while the power is off, the power has to be supplied to maintain this function. The battery supplies the power to the clock IC.
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Chapter 3
3. Mechanical System
3.1 Externals
3.1:A External Covers
General Instructions
1. Disconnect the power cord for safety before disassembly or reassembly work.
2. Group the screws by type (length and diameter) and location.
3. The fixing screw for the grounding wire and varistors is fitted with a washer to ensure electric continuity; be sure to use the washer for reassembly.
4. As a rule, avoid operating the machine with any of its parts removed.
5. Unless otherwise noted, re-assembly is the reverse of disassembly.
Figure 3-1 Figure 3-2
1
3
8
2
7
9
6
5
4
1. Control panel (2)
2. PHS cover (2)
3. Front cover
4. Left cover (2)
5. Rear cover (3)
6. Sub cover
7. Roll cover
8. Inner cover (2)
9. Manual cutter [tightened together with the (2) left cover]
Note: The number in parentheses indicates the number of mounting screws used.
Detach the covers as necessary to clean, inspect, or repair the inside of the printer. Those that can be detached by mere removal of the mounting screws without detaching any others in advance are omit­ted from the discussions.
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Chapter 3 Mechanical System
3.1 Externals, cont'd.
3.1:A External Covers, cont'd.
Detaching the External Covers
1. Remove the two mounting screws (2) from the PHS cover (1), and detach the PHS cover.
Figure 3-3
See Chapter 3.1:B Control Panel as to how to detach the control panel.
2. Remove the two mounting screws (3) from the left cover (1) and manual cutter (2).
Figure 3-4
2
1
1
2
3
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Chapter 3 Mechanical System
3.1 Externals, cont'd.
3.1:A External Covers, cont'd.
Detaching the External Covers, cont'd.
3. Remove the three mounting screws (2) from the rear cover (1), and detach the rear cover.
Figure 3-5
4. Open the front cover.
5. Remove the two mounting screws (2) from the inner cover (1), and then slide the inner cover in the left direction to detach.
Figure 3-6
1
2
2
1
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Chapter 3 Mechanical System
3.1 Externals, cont'd.
3.1:B Control Panel
Detaching the Control Panel
1. Remove the left and right mounting screws (2) from the control panel (1), and remove the control panel from the lowest claw (3) while sliding the panel downward.
2. Disconnect connector J32 rand remove the screw and the tooth washer of the grounding wire (4) from the control panel.
Figure 3-7
3. Remove the eight mounting screws (2) on the control panel PCB (1).
Figure 3-8
1. Control panel PCB
2. Screws (8 pieces)
3. Conductive rubber sheet
4. Key top A
5. Key top B
6. Key top C
7. LED lens (3 pieces)
8. Housing
1
2
2
5
4
3
8
4
5
6
3
2
1
7
Precautions in disassembling and re­assembling
1.Always remove the control panel PCB with the housing face down, because the key tops and the conductive rubber sheet can come off together with the panel when re-moving it.
2.Before re-assembling, clean the conductive rubber sheet and the contacts of the pattern of the control panel PCB with an air brush to remove chips and dust .
3.Before re-assembling, clean the rear sides of the LCD display of the housing and the LED lens to remove chips and dust. (When a housing of the supply parts is used, peel off the protective sheet from the rear side of the LCD display.)
4.In re-assembling, install the key top B first, and then the key top A.
5.When re-assembling the control panel to PHS unit, put it back to PHS unit with parallel to the inner cover and the clearance of 2 mm between the control panel and the inner cover.
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Chapter 3 Mechanical System
3.2 Image Formation System
3.2:A BJ Head
Caution:
As the components of the image formation unit (BJ head, recovery unit, etc.) are removed, the PHS unit becomes lighter in weight and may jump up suddenly; care should be paid.
Detaching the BJ Head
Caution:
Installing the head requires the operation of service mode. The control panel and other electrical components and connectors must all be connected so that when the power switch is turned on, the machine is ready for normal operation.
Note:
Always make sure efficiency of head shading, when you have replaced the heads of C, M & Y or adjusted horizontal registration. If it is necessary, make a new data of the head shading. See Chapter 6.4. Head Shading.
1. Detach the PHS cover (see Chapter 3.1. Externals).
2. Loosen the one mounting screw (2) on the head upper plate (1), and slide the head upper plate in the right direction to disengage the claw (3).
Figure 3-9
2
1
3
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Chapter 3 Mechanical System
2
1
Detaching the BJ Head, cont'd.
3. Open the ferrite core (1), disconnect the connector (2) from the upper part of the BJ head and the connector of the engine 2 PCB, and detach the flexible cable.
Figure 3-10
4. Release the tube release lever (1).
Figure 3-11
Caution:
Never open the tube release lever, if it’s not necessary. If opened, carry out the procedure for initial ink fill after re-assembling in compliance with Chapter
3.3:B Punp Unit, Precautions in assembling (last page).
3.2 Image Formation System, cont'd.
3.2:A BJ Head, cont'd.
1
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Chapter 3 Mechanical System
3.2 Image Formation System, cont'd.
3.2:A BJ Head, cont'd.
Detaching the BJ Head, cont'd.
5. Disconnect all the four tube connector (1). Attach the connector packing (1-901808-00) to each tube connector and then close the connector cap (2).
Figure 3-12
6. Connect the transportation connector for bypass (1-901809-00) to all the four tube station, and close the tube release lever.
Caution:
1.Remove the ink or mark cling to the tube station (joints with the tube station) with the lint-free sponge (1-901800-00).
2.Connector packing (1-901808-00) must be cleaned with the lint-free sponge (1-901800-00) before installed, in order to prevent for foreign substance, dust or ink from coming in the tubes.
3.Move the BJ head with the tube connector being parallel and place on the dust free sheet (1-901807-00).
7. Hold the heat sink (1) of the BJ head by both hands, and holding the head holder (2), detach the BJ head from the head holder (2) upward.
Figure 3-13
2
1
2
1
1
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Chapter 3 Mechanical System
3.2 Image Formation System, cont'd.
3.2:A BJ Head, cont'd.
Precautions in handling the BJ head
1. Never touch the surface of the BJ heads (ejection face) with your fingers, a cloth, tissue, lint-free towel or with any materials.
2. Never breathe out on the BJ head, especially the face and keep off from water, oil and solvent.
3. Never allow the BJ head to dry nor expose it to dust. Put it back to the capping position as soon as possible, when it is removed from the machine.
4. If the situation requires cleaning of the BJ head, always use the new lint-free sponge (1-901800-00) and clear ink (1-901805-00). Wipe off the face at a stroke slightly with the lint-free sponge moistlned with a trace of the clear ink.
Figure 3-14
Head face
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Chapter 3 Mechanical System
3.2 Image Formation System, cont'd.
3.2:A BJ Head, cont'd.
Assembling the BJ Head Unit
When replacing the BJ head or tube connector with a new one, assemble the head unit in following procedure, and then put it to the head holder.
Caution:
When assembling a new BJ head of the service part, leave a protective tape on the head face during the work, and peel it off just before to assembling the head to the printer.
1. Install the heat sink (3) to the head main body (1) with the four screws (2). Fasten the screws in the order of A (temporary tightening) B C → D A.
Figure 3-15
2. Affix the absorbtion sheet (2) to the back side of the connector cap (1).
Figure 3-16
3. Select the tube connector, matching with the colour of the BJ head to be used.
Colour P/N of Tube Connector
Black 1-901216-00 Cyan 1-901221-00 Magenta 1-901214-00 Yellow 1-901220-00
1
3
2
B
C
D
A
1
2
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Chapter 3 Mechanical System
3.2 Image Formation System, cont'd.
3.2:A BJ Head, cont'd.
Assembling the BJ Head Unit, cont'd.
Joints of the tube connectors are cut out as shown on the Figure 3-17 in order to comply with the colors used and prevent from connection errors.
(The figure is the top view, cut the shadow part.)
Figure 3-17
4. Put the connector cap (3) on the tube connector (1), and connect the tube connector (1) to the head connector (2) of the BJ head. Ensure that the rubber packing (4) is fixed in the correct direction.
Figure 3-18
Caution:
1.Since the foreign substance in the BJ head connector causes ink leakage, clean it with the lint-free sponge (1-901800-00) before connecting.
2.When the rubber packing comes off from the connector, re-fix it in the proper position and clean it with the lint-free sponge (1-901800-00). Projecting surface is the outside.
Black Cyan Magenta Yellow
UP
DOWN
2
3
1
4
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Chapter 3 Mechanical System
3.2 Image Formation System, cont'd.
3.2:A BJ Head, cont'd.
Installing the BJ head
Caution:
Installing the BJ head requires the operation of service mode. The control panel and other electrical components and connectors must all be connected so that when the power switch is turned on, the machine is ready for normal operation.
1. Open the PHS unit (1). Place some lint-free towels (2) on the feed unit, bring its rear side to the TOF inlet and outlet sensors 1.
Figure 3-19
2. Close the PHS unit.
3. Peel off the protective tape on the head face. Temporarily place the BJ head (1) on the head holder unit by putting on it along the guides naturally. In so doing, never force the BJ head in.
Figure 3-20
2
1
1
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Chapter 3 Mechanical System
Installing the BJ head, cont'd.
4. Connect the flexible connector (1) to the BJ head which was temporarily placed in Step 3 and to the engine 2 PCB and close the ferrite core. In so doing, be careful not to force the BJ head in and be sure to connect the connector (1) positively.
Figure 3-21
5. Connect the power cord to a wall outlet, and turn the power on in service mode (see Chapter 6.5 Service Mode).
6. Move the head to the printing position in the maintenance mode [Head Print/Cap] menu.
7. Push into the temporarily placed BJ head, and bring the both sides of the BJ head (1) to the bottom face (2) of the head holder.
Figure 3-22
3.2 Image Formation System, cont'd.
3.2:A BJ Head, cont'd.
Magenta(M)
Cyan(C)
Black(K)
Yellow(Y)
1
2
1 1
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Chapter 3 Mechanical System
Installing the BJ head, cont'd.
8. Install the head upper plate (1), and fasten the one screw (2). (If
the BJ head is not brought to head holder unit, the head upper plate can not be installed.)
Figure 3-23
9. Move the BJ head to the cap position in the maintenance mode
[Head Print/Cap] menu.
10. Open the PHS unit. Remove the head mount sheet placed on the
feed unit.
11. Close the PHS unit.
12. Release the tube release lever, and remove the transportation
connectors (1-901806-00) from the tube stations.
13. Remove the connector packing (1-901808-00) from the tube
connectors (1), and connect the tube connectors to the tube stations.
Figure 3-24
14. Close the tube release lever. Attach the PHS cover.
15. Execute SETUP CLEANING”.
16. Finish the service mode, and transfer to the normal mode (see
Chapter 6.5 Service Mode).
3.2 Image Formation System, cont'd.
3.2:A BJ Head, cont'd.
2
1
1
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Chapter 3 Mechanical System
Installing the BJ head, cont'd.
17. Execute Cleaning (B).
18. Execute Cleaning (A).
19. Check the image quality with [NOZ ADJ. PAT-TERN] and
[NOZ CHK. PATTERN]. Execute adjustment of the registra­tion, if necessary (see Chapter 6.3 Test Print/Test Pattern).
3.2 Image Formation System, cont'd.
3.2:A BJ Head, cont'd.
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Chapter 3 Mechanical System
3.2 Image Formation System, cont'd.
3.2:B Recovery Unit
Removing the Recovery Unit
1. Detach the external cover (see Chapter 3.1. Externals).
2. Detach the BJ head (see Chapter 3.2:A. Detaching the BJ head).
3. Open the PHS unit.
4. Remove the two mounting screws (2) from the operation panel support plate (1), and detach the plate.
Figure 3-25
5. Remove the three screws (2) from the PHS right under cover (1), and detach the cover. Remove the mounting screw (4) and disconnect the connector (5) from the right fan unit (3), and detach the fan unit.
Figure 3-26
2
2
1
2
4
3
5
2
1
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Chapter 3 Mechanical System
Removing the Recovery Unit, cont'd.
6. After making a mark for the mounting position of the pinch roller unit, remove two screws (2) from the pinch roller unit (1), and detach the unit.
Figure 3-27
7. Disconnect the connectors of the cap position sensors 1 and 2 (1). Remove the mounting screw (2) and toothed washer from the grounding wire, and remove the grounding wire.
Figure 3-28
8. Detach the recovery tubing (1) from the recovery pump.
Figure 3-29
3.2 Image Formation System, cont'd.
3.2:B Recovery Unit, cont'd.
Marking
2
1
Do not remove the painted screw.
1
2
1
Caution:
When the recovery tubing is removed, suck the waste ink in the tubing with the paper towel and, if leaving the recovery tubing removed, put paper towel around the edge of the tubing.
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Chapter 3 Mechanical System
3.2 Image Formation System, cont'd.
3.2:B Recovery Unit, cont'd.
Removing the Recovery Unit, cont'd.
9. Lift up the head holder unit by rotating the gear of motor unit.
Remove the two mounting screws (2), from the recovery unit (1), and detach the recovery unit while pulling it downward.
Figure 3-30
10. Remove the two mounting screws (2) from the blade cleaner
(1), unhold the claws (3) and (4), and detach the blade cleaner from the restration tub unit.
Figure 3-31
11. Remove the two mounting screws (2), and pull up and detach
the blade assembly (1) by holding the aluminum plate fixed to the blade assembly with tweezers.
Figure 3-33
2
1
3
4
1
2
Caution:
Since the recovery unit and the head holder unit are precisely adjusted in mounting position of BJ heads and recovery system before shipment, follow the precaution below:
1.The whole recovery unit is not replaceable as a unit except some of its components. The height of the blade can not be ajusted to the ejection face. If the height is not appropriated, the ink may splash out or non-fire. When the blade needs to be replaced, you should replace the hole unit of the PHS unit.
2.Do not remove the head holder unit in the service. In particular, do not touch the adjustment screws (1).
Figure 3-32
3.Do not touch the mounting screws of the front support plate (2) in Figure 3-38 and also those of the recovery support plate (2) in Figure 3-37.
1
1
1
2
Caution:
1. Use tweezers to hold the aluminum plate fixed to the blade assembly. Never touch the blade with your fingers. Care should be taken not to damage the blade nor to allow dust and oil to adhere to the blade.
2.To clean the blade, use a new lint free sponge (1-901800-00) moistened with traces of clear ink (1-901805-00).
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Chapter 3 Mechanical System
3.2 Image Formation System, cont'd.
3.2:B Recovery Unit, cont'd.
Installing the Recover Unit
Caution in assembling
When assembling the recovery unit, the following must be observed to prevent the BJ head from being damaged.
1.The BJ heads are removed beforehand.
2.After installation of the recovery unit has been completed, BJ head must be installed in accordance with Chapter 3.2:A BJ Head/Installing the BJ head to protect the head face.
1. Install the restoration tub plate (1) to the restoration tub unit (2), and fit the claws (3) and (4) in it, and then fix the unit with two screws (5).
Figure 3-34
2. Run the recovery tubes (2) of the recovery unit (1) to the rear side through between the PHS unit and the feeder unit, and connect it to the recovery pump (3).
Figure 3-35
4
3
2
1
5
3
2
2
1
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Chapter 3 Mechanical System
Installing the Recover Unit, cont'd.
3. Install the connectors J21 & J22 (2) to the cap position sensors 1 & 2 (1), and fix the grounding wire (3) with the screw.
Figure 3-36
4. Insert the claws (1) of the further side of the recovery unit in the holes (2) of the recovery support plate and push it to the bottom.
Figure 3-37
3.2 Image Formation System, cont'd.
3.2:B Recovery Unit, cont'd.
2
3
1
2
1
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Chapter 3 Mechanical System
Installing the Recover Unit, cont'd.
5. Push the fore side of the recovery unit (1) to the plate (2), and fix the unit with two screws (3).
Figure 3-38
Caution in assembling
Since the recovery unit positioning stopper (2) and the recovery support plate [(1) of Figure 3-37] are precisely adjusted in mounting position screws.
6. Insert the recovery tube into the recovery pump completely and connect with recovery pump.
7. Install the pinch roller unit (1) to the position marked, and fix with the two screws (2).
Figure 3-39
3.2 Image Formation System, cont'd.
3.2:B Recovery Unit, cont'd.
1
2
2
3
Marking
2
1
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Chapter 3 Mechanical System
3.2 Image Formation System, cont'd.
3.2:B Recovery Unit, cont'd.
Installing the Recover Unit, cont'd.
8. Install the right fan unit (1), and fix with one screw (2). Connect with the connector (3). Install the lower-right PHS cover (4) with three screws (5).
Figure 3-40
9. Install the BJ head (see Chapter 3.2:A Installing the BJ head ).
4
1
3
5
2
5
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