Tektronix Phaser 440 Service Manual

Service Manual

Phaser

™

440

Color Printer

Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in operating instructions unless you are qualified to do so.

This printing May 1995 070-9015-01

1995 by Tektronix, Inc., Wilsonville, Oregon. Printed in the United States of America. All rights

reserved. Contents of this publication may not be reproduced in any form without permission of Tektronix, Inc.

This instrument, in whole or in part, may be protected by one or more U.S. or foreign patents or patent applications. Information provided upon request from Tektronix, Inc., P.O. Box 1000, Wilsonville, Oregon 97070-1000.

If acquired subject to FAR or DFARS, the following shall apply:

■

Unpublished — rights reserved under the copyright laws of the United States.

■

Restricted Rights Legend — Use, duplication or disclosures by the government is subject to restrictions as set forth in subparagraph (c) (1) (ii) of the Rights in Technical Data and Computer Software at DFARS 252.227-7013, or in subparagraph (c) (2) of the Commercial Computer Software – Restricted Rights clause at FAR 52.227-19, as applicable. Tektronix, Inc., P.O. Box 1000, Wilsonville, Oregon 97070-1000.

Tektronix

is a registered trademark of Tektronix, Inc. TekColor™ and Photoﬁne™ are trademarks of Tektronix, Inc.

Phaser™ is a trademark of Tektronix, Inc. for color printers and related products.

Adobe™ and PostScript™ are trademarks of Adobe Systems, Incorporated which may be registered in certain jurisdictions.

Times™, Helvetica™, and Palatino™ are trademarks of Linotype-Hell AG and/or its subsidiaries.

Other marks are trademarks or registered trademarks of the companies with which they are associated.

PANTONE

* Colors generated by the Phaser 440 Color Printer are four-color process simulations and may not match PANTONE-identiﬁed solid color standards. Use current PANTONE Color Reference Manuals for accurate colors.

PANTONE Color simulations are only obtainable on these products when driven by qualiﬁed Pantone-licensed software packages. Contact Pantone, Inc. for a current list of qualiﬁed licensees. * Pantone, Inc.’s check-standard trademark for color reproduction and color reproduction materials. © Pantone. Inc., 1988.

Novell® and NetWare® are registered trademarks of Novell, Inc.

TCP/IP is a trademark of FTP Software. Copyright (c) 1986, 1987, 1988, 1989 by FTP Software, Inc. All rights reserved. PC/TCP for DOS is based on a set of programs originally designed and developed by the Massachusetts Institute of Technology. FTP Software has made extensive modiﬁcations and enhancements to the M.I.T. programs.

The X Window System™ is a trademark of Massachusetts Institute of Technology.

TE/JG

Users safety summary

Terms in manual:

Power source:

conductor and ground. Use only the speciﬁed power cord and connector. Refer to a qualiﬁed service technician for changes to the cord or connector.

Operation of product:

product. Do not operate without the covers and panels properly installed. Do not operate in an atmosphere of explosive gases.

Safety instructions: Terms on product:

may cover the hazardous area. Also applies to a hazard to property including the product itself.

Care of product:

power cord or plug is frayed or otherwise damaged, if you spill anything into the case, if product is exposed to any excess moisture, if product is dropped or damaged, if you suspect that the product needs servicing or repair, and whenever you clean the product.

Ground the product:

necessary, contact a licensed electrician to install a properly grounded outlet.

Symbols as marked on product:

CAUTION Conditions that can result in damage to the product. WARNING Conditions that can result in personal injury or loss of life.

Do not apply more than 250 volts RMS between the supply conductors or between either supply

Avoid electric shock by contacting a qualiﬁed service technician to replace fuses inside the

Read all installation instructions carefully before you plug the product into a power source.

CAUTION A personal injury hazard exists that may not be apparent. For example, a panel

DANGER A personal injury hazard exists in the area where you see the sign.

Disconnect the power plug by pulling the plug, not the cord. Disconnect the power plug if the

Plug the three-wire power cord (with grounding prong) into grounded AC outlets only. If

DANGER high voltage:

Protective ground (earth) terminal:

Use caution. Refer to the manual(s) for information:

WARNING:

cause an electrical shock. Electrical product may be hazardous if misused.

If the product loses the ground connection, usage of knobs and controls (and other conductive parts) can

Service safety summary

For qualiﬁed service personnel only: Do not service alone:

rendering ﬁrst aid or resuscitation is present.

Use care when servicing with power on:

personal injury, do not touch exposed connections and components while power is on.

Disconnect power before removing the power supply shield, soldering, or replacing components.

Do not wear jewelry:

contact with dangerous voltages and currents.

Power source:

between the supply conductors or between either supply conductor and ground. A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation.

Do not perform internal service or adjustment of this product unless another person capable of

Remove jewelry prior to servicing. Rings, necklaces, and other metallic objects could come into

This product is intended to operate from a power source that will not apply more than 250 volts rms

Refer also to the preceding Users Safety Summary.

Dangerous voltages may exist at several points in this product. To avoid

Contents

1 General Information

Phaser 440 overview 1-2 Dye sublimation printing 1-2 Print engine assemblies 1-3 Printer image processor board 1-5 Combination sensors and their meanings 1-6

Transfer roll type sensing 1-6

Media tray type sensing 1-7 Rear panel 1-8 Front panel 1-10

Front panel LED service mode error codes 1-11 Specifications 1-12

Regulatory specifications 1-16

Service Manual

2 Installing the Printer and Drivers

Pre-install questions for customers 2-2 Unpacking 2-5

Inventory for Phaser 440 printer 2-5 Setting up the printer 2-8 Cabling the printer 2-9

Connecting the printer to a Macintosh 2-9

LocalTalk connection to a Macintosh 2-9 Ethernet connection to a Macintosh 2-9

Connecting the printer to a PC 2-10

Direct connection to a PC 2-10 Networked connection to a PC using the printer’s Ethernet port 2-10

Connecting the printer to a workstation 2-10

Direct connection to a workstation 2-10 Networked connection to a workstation 2-10

Installing a SCSI hard disk drive on a Phaser 440 2-11 Turning on the printer 2-12

The startup page 2-12

The configuration page 2-13 Driver and communication setup 2-19

Installing the Macintosh driver 2-19

Installing the Tektronix driver for Windows 3.1 2-20

If you have other Tektronix printer drivers already installed 2-20

Configuring the Tektronix Windows printer driver 2-21 Updating the standard Microsoft Windows PostScript driver 2-23 Installing the printer driver for OS/2 Version 2 2-23 Configuring the printer's serial port for a PC 2-26 Using printcap to configure a Unix workstation for the printer's serial port 2-28 Configuring a Novell NetWare server for the printer 2-29 Configuring TCP/IP 2-30

Phaser 440 Color Printer

3 Verifying the Printer and Host Connections

Verifying printing from a Macintosh 3-1

Selecting the printer via the Chooser 3-1 Print the directory from Macintosh 3-2 Verifying that an application communicates to the printer 3-3 Using the Error Handler utility 3-3

Verifying printing from a PC 3-4

DOS connection verification 3-4 Windows 3.1 driver verification 3-4 OS/2 connection verification 3-5 Novell NetWare verification 3-6

Send a print file to the printer 3-6

Using the Error Handler utility 3-7

Verifying printing from a workstation 3-8

Verifying and printing using the TCP/IP protocols 3-8 Using the Error Handler utility 3-9

4 Key Operator Training

Printer controls and indicators 4-2 Loading media 4-3 Cleaning 4-3 Clearing paper jams 4-4 Warranty information 4-4 Supplies ordering 4-5 If you need help 4-5

HAL information system 4-5 Customer Support Hotline 4-6 Service support 4-6 Electronic bulletin board 4-6

Service Manual

vii

5 Theory of Operation

Print engine 5-2

Sublimation dye transfer — the engine's printing technology 5-2 The print process 5-2

Continuous-tone printing 5-3 Image data 5-4 Creating colors 5-4 Engine control board block description 5-5

CPU 5-6

Interface buffers 5-6

Data controller and line buffers 5-6

Heat controller (dot compensation) 5-6

Thermal head controller 5-7

Thermal head 5-7

Mechanical controller 5-7

Internal test pattern generator 5-7

Paper path in operation 5-8

Paper pick-up 5-8 Drum loading 5-10 Printing 5-12 Print unloading 5-13

Power supply 5-14 Image processor 5-16

Image rendering technology 5-16

6 Troubleshooting

System power-up sequence 6-1 Print engine troubleshooting 6-2

Verifying image processor operation by using the Test Pattern Generator 6-2 Verifying print engine operation by using its self-test print 6-3 Verifying power supply operation 6-3

Measuring power supply voltages 6-3 Inspecting the power supply fuses 6-5

Testing for a shorted motor 6-6

+24 VDC safety interlocks 6-6 Testing motor resistances 6-8

viii

Phaser 440 Color Printer

Media jams and the paper path 6-8

Media-based problems 6-8 Paper-pick errors 6-9 Paper-clamping errors 6-10 Print-eject jams 6-10 Checking the paper-feed motor and drive train 6-11 Media skews passing through the paper path 6-12 Transfer roll jam 6-12

Printing and print quality problems 6-13

Streaks or lines in the print parallel to the long axis of printing 6-13 Streaks or lines in the print parallel to the short axis of printing 6-13 White portion of print is colored 6-14 Color is uneven 6-14 Not printing 6-15 Printing too light or too dark 6-16 Image is offset or cut off 6-16 Wrinkling 6-17

Print engine self-diagnostics 6-18

Starting service mode (self-diagnostics) 6-18 Displaying error codes on the front panel 6-18

Problems and solutions 6-19

Print engine error codes and their causes 6-19 Power problems 6-24 Front panel indicators 6-24 Macintosh printing problems 6-25 PC DOS printing problems 6-26 Windows printing problems 6-28 Workstation printing problems 6-29

Phaser 440 image processor 6-30

Image processor normal operation indicators 6-30 Image processor hard and soft error indicators 6-30 Verifying the image processor's operation 6-30

Image processor self-diagnostics 6-31

Image processor rear panel switches for self-testing 6-31

Printing the configuration page 6-32

Resetting NVRAM 6-32

Service Manual

7 Cleaning and Maintenance

Cleaning 7-1 Lubrication 7-2 Inspecting 7-3 Replacements 7-4

8 FRU Disassembly/Assembly

Required tools 8-1 Lower tray assembly 8-2 Printer cabinet panels 8-4 Paper-feed module 8-6

Accessing the pick roller, aligning roller, and the lower feed roller 8-7 Paper-pick roller, clutch, and paper-empty flag 8-10 Lower aligning roller, clutch, and paper-pass sensor Removing the upper aligning roller 8-14 Removing the feed Removing the exit

Bail roller assembly 8-17 Thermal head 8-18 Drum 8-20 Motors 8-25

Paper-feed motor 8-25 Drum motor 8-26 Transfer roll take-up Thermal head lift motor 8-30

Sensors and switches 8-31

Paper-pass sensor Paper clamp sensor 2 8-31 Thermal head position sensors 8-31 Transfer roll mark sensors 8-31 Tray sensor circuit board 8-32 Paper-pass sensor Paper clamp sensor 1 8-35

Card cage and power supply 8-36

roller 8-15

rollers 8-16

motor 8-28

1 and paper-empty sensor 8-31

2 8-33

flag 8-12

Phaser 440 Color Printer

Circuit boards 8-38

Power supply circuit board 8-38 Engine control board 8-40 Paper-feed circuit Card cage interconnect board 8-42 I/O board 8-43 Image processor board 8-44 RAM SIMM 8-45 Ethernet card 8-46

board 8-41

9 Checks and Adjustments

Required tools summary 9-1 Printing test patterns 9-2 Printer self-checks 9-4

Thermal head motor check 9-5 Power supply thermal head voltage (VH) check 9-5 Lower Tray Assembly connection test 9-6 Paper-path check 9-7 Top loss adjustment 9-8 Leading edge (top) margin adjustment 9-10 Switch and interrupt sensor checks 9-12 Tray select 9-14 Calibrating the reflective sensors 9-15 Pick roller cleaning 9-15

Adjusting for best print quality 9-16

Thermal head temperature adjustment 9-16 Thermal head skew (to correct speckle and wrinkle) 9-18 VH current compensation adjustment 9-20 Drum belt tension adjustment 9-22 Head lift motor belt tension adjustment 9-23

A Field Replaceable Units List

B Test Patterns

C Wiring Diagrams

D Test Pattern Generator

Index

Service Manual

Figures

Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 1-5 Figure 1-6

Figure 2-1 Figure 2-2 Figure 2-3

Figure 5-1 Figure 5-2 Figure 5-3 Figure 5-4 Figure 5-5 Figure 5-6 Figure 5-7 Figure 5-8 Figure 5-9 Figure 5-10 Figure 5-11

The Phaser 440 printer (shown with the Lower Tray Assembly) 1-1

Internal features of the Phaser 440 print engine 1-3

Sensors and switches on the Phaser 440 print engine 1-4

Features of the Phaser 440 image processor board 1-5

Phaser 440 rear panel 1-9

Phaser 440 front panel 1-10

The Phaser 440 packaging 2-6

The drum shipping blocks 2-7

Connecting a SCSI hard disk drive to a Phaser 440 2-11

The dye sublimation print process 5-3

Print engine board block diagram 5-5

The paper pick process 5-9

Paper clamp opening to receive a sheet of paper 5-10

Clamping the paper 5-11

Positioning the paper for printing 5-11

Printing on the paper 5-12

Raising the thermal head between passes 5-13

Ejecting the print 5-13

Power supply block diagram 5-15

The image processor graphics pipeline 5-17

Figure 6-1 Figure 6-2 Figure 6-3

Figure 7-1

Figure 8-1 Figure 8-2 Figure 8-3 Figure 8-4

xii

Measuring the DC voltages (test points) 6-4

Locating the fuses 6-5

24 VDC safety interlocks (top and front covers) 6-7

Lubricating the clutches 7-3

Removing the Lower Tray Assembly 8-3

Removing the cabinet panels 8-5

Removing the paper-feed module 8-6

Removing the paper-feed circuit board 8-7

Phaser 440 Color Printer

Figure 8-5 Figure 8-6 Figure 8-7 Figure 8-8 Figure 8-9 Figure 8-10 Figure 8-11 Figure 8-12 Figure 8-13 Figure 8-14 Figure 8-15 Figure 8-16 Figure 8-17 Figure 8-18 Figure 8-19 Figure 8-20 Figure 8-21 Figure 8-22 Figure 8-23 Figure 8-24 Figure 8-25 Figure 8-26 Figure 8-27 Figure 8-28 Figure 8-29 Figure 8-30 Figure 8-31 Figure 8-32 Figure 8-33 Figure 8-34 Figure 8-35 Figure 8-36 Figure 8-37 Figure 8-38

Removing the paper-feed unit screws 8-8 Separating the paper-feed Removing the pick roller and Removing the paper-empty flag 8-11 Removing the lower aligning Removing the paper-pass sensor 1 flag 8-13 Removing the upper aligning roller 8-14 Removing the feed roller 8-15 Removing the exit rollers 8-16 Removing the bail roller assembly 8-17 Removing the thermal head 8-18 Removing the drum belt and pulley 8-21 Removing the front idler Removing the drum's right end bushing 8-23 Removing the drum 8-24 Removing the paper-feed Removing the drum motor 8-27 Removing the transfer roll take-up gear 8-28 Removing the transfer roll take-up motor 8-29 Removing the thermal head lift Removing the tray sensor circuit board 8-32 Removing the paper-feed circuit board 8-33 Removing the paper-pass Removing the paper clamp sensor 8-35 Disconnecting the wiring harnesses and removing the card cage 8-36 Removing the card cage and power supply 8-37 Removing the power supply circuit board 8-39 Disconnecting the wiring harnesses 8-40 Removing the engine control board 8-41 Removing the interconnect Removing the I/O board 8-43 Removing the image processor board 8-44 Installing the RAM SIMM on the image processor board 8-45 Installing the Ethernet card on the image processor board 8-46

unit 8-9

clutch 8-10

roller 8-12

roller 8-22

motor 8-25

motor 8-30

sensor 2 8-34

board 8-42

Service Manual

xiii

Figure 9-1 Figure 9-2 Figure 9-3 Figure 9-4 Figure 9-5 Figure 9-6

Figure A-1 Figure A-2

Figure B-1 Figure B-2 Figure B-3

Figure C-1 Figure C-2

Figure D-1

Engine control board DIP switches 9-2

Paper top loss adjustment at the paper clamp 9-11

Adjusting for thermal head skew 9-19

VH current compensation adjustment 9-21

Tensioning the drum belt 9-22

Tensioning the head lift motor belt 9-23

The printer exterior FRUs A-3

The internal printer A-5

Inspection /check pattern B-1

Saturation dither pattern B-2

Wrinkle pattern B-3

Print engine control board connector diagram C-4

Print engine wiring diagram C-5

Plugging the Test Pattern Generator into the printer's parallel port D-2

xiv

Phaser 440 Color Printer

Tables

Table 1-1 Table 1-2 Table 1-3 Table 1-4 Table 1-5 Table 1-6 Table 1-7 Table 1-8 Table 1-9 Table 1-10

Table 2-1 Table 2-2

Table 6-1 Table 6-2 Table 6-3 Table 6-4 Table 6-5 Table 6-6 Table 6-7 Table 6-8 Table 6-9

Transfer roll core sensor combinations 1-6 Tray switch sensor combinations (main engine feeder) 1-7 Tray switch sensor combinations (Lower Tray Assembly) 1-7 Phaser 440 rear panel DIP Switches 1-9 Service mode error code summary 1-11 Physical dimensions 1-12 Printer clearances 1-12 Functional specifications 1-13 Electrical specifications 1-14 Environmental specifications 1-15

Configuration page settings 2-13 Values for modifying the DEVPARAMS.PS file 2-27

Motor and solenoid resistances 6-8 Decoding the front panel display 6-18 Print engine error codes and their meanings 6-19 Power problems 6-24 Front panel indicators and their meanings 6-24 Macintosh printing problems 6-25 PC DOS printing problems 6-26 Windows printing problems 6-28 Workstation printing problems 6-29

Table 9-1 Table 9-2 Table 9-3 Table 9-4 Table 9-5 Table 9-6

Table A-1 Table A-2

Selecting self-test print patterns 9-3 Self-check mode summary 9-4 Top loss adjust settings 9-8 Top margin adjust settings 9-10 Mechanical and interrupt switch check summary 9-13 Setting thermal head temperature (based on thermal head resistance) 9-17

FRU exterior parts list A-2 FRU interior parts list A-4

Service Manual

Table C-1

Connector CN1 C-1

Table C-2 Table C-3 Table C-4 Table C-5 Table C-6 Table C-7

Table D-1

Connector CN2 C-1

Connector CN3 C-1

Connector CN5 C-2

Connector CN6 C-2

Connector CN7 C-3

Connector CN8 C-3

Test Pattern Generator DIP Switch settings for Phaser 440 D-3

xvi

Phaser 440 Color Printer

Chapter

General Information

This service manual contains information useful to verify operation, troubleshoot, repair, adjust, and maintain the Tektronix Phaser™ 440 Color Printer. The ﬁrst half of this manual familiarizes you with the printer and provides information on installing and verifying the printer and training printer users as a part of the Option S0 printer installation procedure. The latter half of the manual includes troubleshooting guides, adjustment procedures, assembly/disassembly procedures and an FRU list.

To ensure complete understanding of the product, we recommend participation in Phaser 440 service training, if available.

Figure 1-1 The Phaser 440 printer (shown with the Lower Tray Assembly)

Phaser 200i

Service Manual

8699-01

1-1

General Information

Phaser 440 overview

The Phaser 440 Color Printer is an Adobe PostScript Level 2 (version 1.3) color, dye sublimation printer with Tektronix color matching extensions (TekColor 3.0). Printing at an addressability of 300 dots-per-inch, the printer features a single paper tray (Universal size) that holds A, A4, and Letter Extra media with an optional Lower Tray Assembly (A or A4 only) which gives the printer a dual-tray capability. (The Lower Tray Assembly is sometimes referred to as the second feeder.) The printer prints images on A- and A4-size paper and transparency ﬁlm with 5 mm (0.2 in.) margins as well as Letter Extra paper which allows for full-size A and A4-size bleeds. The Phaser 440’s image processor is powered by a 24-MHz RISC processor and features integral EtherTalk. The EtherTalk port supports 10Base5, 10Base2 and 10BaseT external line units. Also standard are 16 Mbytes of RAM (expandable to 64 Mbytes), 39 standard fonts, and support for an external SCSI disk for additional font storage. For host image input, the image processor also features a standard parallel port, an RS-232 serial port and a LocalTalk port. The Phaser 440 optionally includes support for Novell NetWare and TCP/IP networks (with the Ethernet card installed).

Dye sublimation printing

Dye sublimation printing is an extension of thermal wax transfer printing. Many of Tektronix’ current and older printers are based on thermal-wax transfer technology. During the dye sublimation printing process, transfer roll dye, in contact with a sheet of special paper, is vaporized (sublimed) into the surface of the paper by an electronically controlled thermal head. The thermal head features individually controllable heating elements at 300 elements per inch that span the width of the printing paper and the transfer roll. The temperature of each element can be controlled so that a speciﬁc amount of dye is vaporized into the paper. This allows the printer to produce a remarkably wide range of colors and shades with detailed precision.

The printer, using the subtractive color method, transfers sequential layers of yellow, magenta, cyan and black dye into the paper to create its full gamut of color.

The printing paper is an ultra-smooth coated paper. Since the transferred dye penetrates and bonds into the surface of the paper, the prints are durable and do not scratch, rub off, or retransfer to other materials.

1-2

Phaser 440 Color Printer

Print engine assemblies

I/O board

Card cage

Image processor board

Engine control board

Interior fans

Thermal head lift motor

Thermal head fan

Torque limiter

Thermal head

General Information

Drum

Upper exit roller

Exit roller belt

Interconnect board

Drum motor

Drum belt

Power supply

Paper-feed motor

Transfer roll take-up motor

Print-feed circuit board

Figure 1-2 Internal features of the Phaser 440 print engine

Lower exit roller Paper-feed module

Feed roller

Pick roller

9015-11

Service Manual

1-3

General Information

TEST button

Transfer roll core sensor (left)

Transfer roll mark sensor

Top-cover- open sensor

DIP Switch 1

DIP Switch 2

Paper clamp sensor 1

Paper clamp sensor 2

Transfer roll  core sensor (right)

Thermal head position sensors (2)

-- mounted on top cover Transfer roll 

core sensor (front)

Drum-home- position senso

Paper-pass  sensor (2)

Tray sensors (3)

Paper-exit sensor Front-cover-open sensor

Aligning roller solenoid

Paper-pass sensor (1)

Paper-pick solenoid

Figure 1-3 Sensors and switches on the Phaser 440 print engine

Paper-empty sensor

9015-01

1-4

Phaser 440 Color Printer

Printer image processor board

ROM

00-3

00-2

16-3

00-1

16-2

00-0

16-1

16-0

µp

Ethernet card

General Information

RAM SIMM

J7

J8

J9

I/O interconnect cables

Figure 1-4 Features of the Phaser 440 image processor board

9015-03

Service Manual

1-5

General Information

Combination sensors and their meanings

Combinations of sensors are used by the Phaser 440 print engine to determine the type of transfer roll and the type of media tray installed in the printer.

Transfer roll type sensing

The combinations of the three transfer roll core sensors “tell” the print engine what type of transfer roll is installed. The length of the cores (long or short) actuate the switches. Long cores close the switches, turning them on.

Table 1-1 Transfer roll core sensor combinations

Right front transfer roll core sensor

Closed Closed Open 4-Color Transfer Roll (with true

Closed Open Closed 3-Color Transfer Roll (with

Closed Closed Closed Black Transfer Roll (monochrome)

Right rear transfer roll core sensor

Left transfer roll core sensor

Transfer roll type

black)

composite black)

1-6

Phaser 440 Color Printer

Media tray type sensing

The combinations of the three tray sensors “tell” the Phaser 440 print engine what type of paper tray is installed. (The print engine does not detect the type of media installed in the tray; it only detects the particular tray being used.) The tray sensors are located on the right-side interior of the paper tray slot. There are three tray types:

■

Letter (A-size). This tray is sized for 8.5 x 11-inch paper and

transparency ﬁlm. A slide switch on the side of the media tray lets you select either paper or transparency ﬁlm.

Metric Letter (A4-size). This tray is used for 210 x 297 mm paper and

■

transparency ﬁlm. A slide switch on the side of the media tray lets you select either paper or transparency ﬁlm.

■

Universal. This tray is used for A, A4, and Letter Extra paper and A

and A4 transparency ﬁlm. The extra-long and wide Letter Extra paper allows users to print full-page bleeds. After cutting the print down to either 8.5 x 11 inches or 210 x 297 mm, the result is an A- or A4-size print in which the image bleeds off all four of the paper’s edges with no unprinted margins. A slide switch on the side of the media tray lets you select either A, A4 or Letter Extra as well as paper or transparency ﬁlm. The Universal tray can only be used in the printer’s main tray feeder; the Lower Tray Assembly accepts only the Letter (A-size) and Metric Letter (A4-size) trays.

General Information

Table 1-2 Tray switch sensor combinations (main engine feeder)

Top switch Middle switch Bottom switch Tray type

Closed Closed Open Letter Extra paper Open Closed Open Closed Open Closed Letter (A-size) paper Open Open Closed Letter (A-size) transparency ﬁlm Closed Closed Closed Metric Letter (A4-size) paper Open Closed Closed Metric Letter (A4)-size transparency ﬁlm

not used

Lower Tray Assembly. A different switch combination scheme is used to

determine the type of tray (referred to as the lower tray) installed in the Lower Tray Assembly. (The Lower Tray Assembly is sometimes referred to as the

feeder

Table 1-3 Tray switch sensor combinations (Lower Tray Assembly)

Top switch Middle switch Bottom switch Tray type

Open Closed Open Letter (A-size) paper Closed Open Open Letter (A-size) transparency ﬁlm Open Closed Closed Metric Letter (A4-size) paper

second

Closed Open Closed Metric Letter (A4-size) transparency ﬁlm

Service Manual

1-7

General Information

Rear panel

Connectors

The rear panel of the Phaser 440 printer features the host interface connectors to the printer. It includes the following connectors:

Standard parallel

■

RS-232 serial

LocalTalk

■

SCSI (font hard disk drive only)

Ethernet

■

The Phaser 440 rear panel also features DIP switches to control certain aspects of the printer’s imaging. You can also use the DIP switches for controlling the self-tests of the printer’s image processor board. Refer to the Section 6 topic “Image processor self-diagnostics” on page 6-31.

Health LED

A health LED indicates the status of the printer.

Blinking (at a steady rate): The printer is operating normally. The LED

■

blinks irregularly during diagnostics.

If a soft error occurs, the image processor board will operate, but in a reduced capacity. Soft failures include failure of expansion memory SIMMs or any of the interface ports. When a soft error occurs, the printer automatically prints a startup page listing the error.

■

or Off : A hard error condition has occurred that would keep the

image processor board from operating.

TEST button

The TEST button, located at the bottom right rear corner of the printer, has two functions:

■

Following normal power-up, pressing the TEST button for 2 to 3 seconds prints a composite test pattern. Refer to Figure B-1 in Appendix B,

Pressing and holding the TEST button while you turn on the printer

■

places the printer in Service mode.

1-8

Phaser 440 Color Printer

Test Patterns for a sample of the composite test pattern.

General Information

The following ﬁgures illustrate the rear panel of the Phaser 440.

Parallel

SCSI Disk

2 3 4

1 6

Reset

Diagnostics

Run

*See User Manual

LocalTalk

Start Job

Status

Skip Run

Serial

(RS-232)

1200

Baud Rate

Variable

PHASER 440 MODEL 4685

Figure 1-5 Phaser 440 rear panel

8 9

Color Correction

Ethernet

Not Installed

9015-02

Table 1-4 Phaser 440 rear panel DIP Switches

Switches 440i

2 through 4 Diagnostic modes, conﬁguration page, demo pages

6 not used 7

8 through 9 Color corrections, NVRAM reset

Normal operation

↓

Reset

↑

2 3 4

↓

Normal power-up self tests; default

↑

↓

↑

↓

↓ ↑

↑

↓

↑

Check for

↓ ↑

Bypass

Serial communication baud rate is variable

↓ ↑

Baud rate fixed

8 9

↓ ↓

↑ ↑

↓ ↑

Sys/Start

Veriﬁcation mode

↓ ↓

No self tests

↓

Service mode Conﬁguration page

↑

not used

↑

not used not used

↑

Sys/Start

file on attached SCSI disk

file

No color corrections; factory default Simulate Press; Speciﬁcation for Web Offset Publications

(SWOP)/NVRAM reset

Vivid Blue

Use NVRAM-stored setting (default is Euroscale Press)

Service Manual

1-9

General Information

Front panel

The front panel consists of seven LEDs indicating the printer's normal operating status.

POWER: Illuminates to indicate that the power supply is generating +5 VDC.

READY: On indicates the printer is idle. Blinking indicates the printer is

receiving and processing data (or completing its power up self-test).

COVER: On indicates either the front or top cover is open.

TRANSFER ROLL (RIBBON): On indicates the transfer roll is empty and

needs to be replaced.

MEDIA: On indicates the paper tray is empty or the tray is not installed

JAM: On indicates a jam has occurred inside the printer. Blinking indicates a

paper-pick error has occurred.

ERROR: On indicates a hardware engine error has occurred. Blinking indicates a data processing error has occurred with the image processor board.

ERROR JAM RIBBON COVER

Figure 1-6 Phaser 440 front panel

READY

POWERMEDIA

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Phaser 440 Color Printer

Front panel LED service mode error codes

Detected error conditions in the print engine are displayed on the front panel as LED patterns. The following table lists the service mode error codes which are displayed while the printer is in service mode. (Service mode is explained in Chapter 9, “Checks and Adjustments.”) These codes are more speciﬁc than the error codes displayed during normal operation (see the previous topic “Rear panel”). If an error occurs during normal operation, pressing the rear panel TEST button causes the more speciﬁc service mode error code to be displayed on the front panel. The error codes listed below are explained in greater detail in the Chapter 6 topic “Print engine error codes and their causes” on page 6-19.

Table 1-5 Service mode error code summary

Front panel LEDs Hex code Error

o o o o o o ● 00 No error. o o o o o ✺ ● 01 Drum position error. o o o o ✺ o ● 02 Thermal head temperature error. o o o ✺ o o ● 04 Top or front cover open error. o o o ✺ ✺ o ● 06 Thermal head strobe (too long) error. o o o ✺ ✺ ✺ ● 07 Engine control board RAM read/write error. o o ✺ o o o ● 08 Engine control board ROM checksum error. o o ✺ o ✺ o ● 0A Interface error with image processor board. o o ✺ o ✺✺ ● 0B Tray conﬁguration changed. o o ✺ ✺ o ✺ ● 0D Engine thermistor failure (open or short) o o ✺ ✺ ✺ o ● 0E Thermal head lift error. o o ✺ ✺ ✺✺ ● 0F Thermal head thermistor failure (open or short). o ✺ o o o o ● 10 Transfer roll empty. o ✺ o o ✺ o ● 12 Transfer roll jam. o ✺ o o ✺✺ ● 13 No transfer roll installed. o ✺ o ✺ o o ● 14 Transfer roll encoding read failure. o ✺ ✺ o o o ● 18 Transfer roll feed timer error. o ✺ ✺ ✺ ✺✺ ● 1F Selected media tray type unknown.

✺ o o o o o ● 20 Out of tray media. ✺ o o o o ✺ ● 21 Tray not installed. ✺ o o o ✺ o ● 22 Paper eject sensor failed to turn on.

o o o ✺✺●23 Paper-pass error / lower tray.

✺

o o ✺ o o ● 24 Paper-pass error / upper tray.

✺ ✺ o o ✺ o ✺ ● 25 Paper-pass sensor 2 error. ✺ o o ✺ ✺ o ● 26 Paper clamp error, media not detected in clamp. ✺ o o ✺ ✺✺ ● 27 Media size error – media too long or too short. ✺ o ✺ o o o ● 28 Paper eject sensor failed to turn off. ✺ o ✺ o o ✺ ● 29 Paper-pass sensor 1 failed to turn off after eject. ✺ o ✺ o ✺ o ● 2A Paper-pass sensor 2 failed to turn off after eject. ✺ o ✺ o ✺✺ ● 2B Paper clamp timer error, sensor failed to turn off.

General Information

o means LED off

● means the POWER LED which is always on

✺ means LED on

Service Manual

1-11

General Information

Speciﬁcations

These speciﬁcations apply to the Phaser 440 printer.

Table 1-6 Physical dimensions

Dimensions Value

Height: 28 cm. (11 ins.)

Width: 342 cm (13.4 ins.) Depth: 42.5 cm (16.7 ins.) Weight: Approximately 18 kgs (40 lbs). Print engine weight only; add

37 cm (14.5 ins.) with Lower Tray Assembly

26.4 kgs (12 lbs.) for Lower Tray Assembly.

Table 1-7 Printer clearances

Clearances Value

Top: 45.7 cm (18 ins.) Left: 10.2 cm (4 ins.) Right: 10.2 cm (4 ins.) Front: Unrestricted to replace trays and transfer rolls Rear: 10.2 cm (4 ins.) Bottom: No obstruction under printer that could block its cooling

Mounting surface ﬂatness:

vents. Within 5 degrees of horizontal with all four feet in contact with

the surface.

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Phaser 440 Color Printer

General Information

Table 1-8 Functional speciﬁcations

Characteristic Speciﬁcation

Printing process Sequential dye sublimation transfer printing.

Transfer rolls Dye-impregnated transfer rolls. The printer automatically

Addressability 300 dots-per-inch (horizontal and vertical). Engine printing speed The time it takes from paper loading to paper ejecting a print:

senses the transfer roll type by the combination of lengths (short or long) on the transfer roll cores. 3-Color Transfer Roll features sequential bands of yellow, magenta, and cyan; 100 prints per roll. 4-Color Transfer Roll features sequential bands yellow, magenta, cyan and black; 100 prints per roll. Black Transfer Roll features all black panels; 200 prints per roll.

3-Color transfer roll: on A-size: about 110 seconds per print.

on A4-size: 115 seconds per print on Letter Extra: 126 seconds per print

4-Color transfer roll:

on A-size: about 145 seconds per print. on A4-size: 151 seconds per print on Letter Extra: 167 seconds per print

Black transfer roll:

on A-size: about 64 seconds per print. on A4-size: 67 seconds per print

on Letter Extra: 74 seconds per print Print times do not include image processing time by the image processor, which varies, due to image complexity. Print times more than double when printing on transparency ﬁlm.

Minimum printing margins (± 2 mm)

Maximum print area A-size: 8.27 x 10.4 in.

Left and right sides: 3 mm (0.12 in.) Top side (clamped end): 11.5 mm (0.43 in.) Bottom edge: 2.5 mm (0.1 in.)

210 x 265 mm

2480 x 3136 pixels A4-size: 8.03 x 11.1 in.

204 x 282 mm

2416 x 3344 pixels Letter Extra: 9.33 x 12.72 in.

237 x 323 mm

2800 x 3816 pixels

Service Manual

1-13

General Information

Table 1-9 Electrical specifications

Characteristic Speciﬁcation

Primary line voltages 87 to 128 VAC (110 VAC nominal)

Primary voltage frequency range

Power consumption 460 watts at idle. (1700 BTUs/hour) with image processor

Current rating 115 VAC conﬁguration – 5.7 amp max./1 amp min.

Primary voltage fusing 115 VAC conﬁguration – 8 amp

Secondary voltages +5

RF emissions Both 115 and 220 VAC-conﬁgured instruments pass these

174 to 264 VAC (220 VAC nominal) Input voltage range is switch-selectable.

47 to 63 Hz

and all options installed – maximum power consumption 500 watts.

220 VAC conﬁguration – 3.6 amp max./1 amp min.

220 VAC conﬁguration – 5 amp Fuses are not user-accessible.

V (4.95 ~ 5.05 V) — 8 A maximum

+12 V (11.4 ~ 12.6 V)

-12 V (115.4 ~ 12.4V) +24 V (24.4 ~ 24.7V) VH – thermal head voltage (9.5 V to 18.5 V variable)

standards: FCC Part 15 Class A EN55022 (CISPR 22) Class B VCCI (CISPR 22) Class B

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Phaser 440 Color Printer

+ 193 hidden pages

Tektronix Phaser 440 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual