Xerox iiLINX Solid Inkjet 100 Service Manual

Chapter

General Information 1-1

Chapter 1

General Information

This chapter provides information and a general overview of the iiLINX
Solid Inkjet 100 Printer. Theory of operation, printer specifications and
components are presented in the following sections:

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LINX™ Solid Inkjet 100 Service Manual

General Information

The iiLINX Solid Inkjet 100 printer, shown in Figure 1-1, is a user­installable, low maintenance, environmentally friendly, High Quality
Referral Image PostScript printer.

0388-01

Figure 1-1. The iiLINX Solid Inkjet 100 Printer (shown with optional
Auxiliary Feeder Unit Assembly)

To ensure complete understanding of the Solid Inkjet 100 printer, we
recommend participation in Solid Inkjet 100 printer service training.

General Information 1-3

Solid Inkjet 100 Printer Overview

The Solid Inkjet 100 Printer is an Adobe PostScript Level 3 (Version

3010) grayscale, solid inkjet printer. It supports 409 x 409 dots-per­inch (dpi) resolution at draft mode, and 600 x 600 dpi at High
Resolution Medical mode. The speed of producing images is 4.8 pages­per-minute (ppm) in draft mode, and 2.5 ppm in High Resolution
Medical mode.

Base Solid Inkjet 100 printer

The base Solid Inkjet 100 printer features 136 built-in fonts, and is
equipped with 64 Mbytes of RAM. It can be upgraded to 128 Mbytes
of RAM by adding an optional 64 Mbyte RAM DIMM.

All printers support two available paper trays: A and A4 trays and an
optional 500-sheet high-capacity paper tray assembly give the printer
a two-tray capability. The high-capacity paper tray assembly is
usually referred to as an auxiliary feeder unit.

A 133-MHz PowerPC processor oversees print engine operations and
PostScript image processing. The printer features an integral
bidirectional parallel port (IEEE 1284C with ECP mode) and a
10baseT Ethernet port (with support for EtherTalk, TCP/IP, DHCP
and Windows Peer-to-Peer). A USB high-speed serial port is also
provided.

An optional Ethernet interface board offers a 10BaseT/100BaseT/
10Base2 Ethernet connection providing standard protocol support for
EtherTalk, TCP/IP and DHCP. When installed, this card disables the
standard 10baseT port.

A second rear panel slot accommodates an internal IDE hard drive for
DICOM support.

Solid inks

Solid inks, sometimes called phase-change inks, are solid at room
temperature and are liquid at the higher temperature used during
printing. The inks solidify almost instantly after being jetted onto the
printer’s drum. Each of the Solid Inkjet 100 printer inks is especially
formulated for this printer; the inks are not interchangeable with
other models of solid ink printers.

NOTE: Turning the printer off and allowing it to cool causes it to
perform a printhead cleaning and purge cycle upon power-up. The
printer’s purge cycle consumes a significant amount of ink. During
normal use and servicing, turn the printer off and allow it to cool only
when necessary.

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LINX™ Solid Inkjet 100 Service Manual

Memory Considerations

The printer dual frame buffer allows for printing one image while
processing a second image (which gives greater printing throughput).
With additional RAM memory, the printer’s capabilities increase as
detailed in Table 1-1:

Table 1-1. Installed RAM and Printer Capabilities

Feature Base Additional RAM Upgrade

Fast (draft) printing yes yes

High-Resolution
Medical Printing yes yes

Pipelining yes yes

DICOM Support no yes

(64 Mbytes) (128 Mbytes)

To verify what type of RAM is installed, print the 2-page
Configuration Page from the Front Panel menu and refer to “Installed
RAM.”

For example:

Installed RAM: 64 Mbytes
Memory Slot 1: SDRAM/Non-parity/32 Mbytes/

KMMe 665 403 CTL-GO

Memory Slot 2: SDRAM/Non-parity/32 Mbytes/

16LSDT 464AG-662C1

General Information 1-5

Print Engine Assemblies

Internal features of the print engine are illustrated in Figure 1-2.

Cap/Wipe/Purge
assembly

Drum

Transfix
roller

Process
motor

Paper/
Drum
heater

Y-axis
motor

Printhead

Paper feed
motor

Ink load
assembly

X-axis drive
and motor

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LINX™ Solid Inkjet 100 Service Manual

Figure 1-2. Internal Features of the Print Engine

Seven circuit boards support the printer’s electronics. (Refer to
Figures 1-3 and 1-4). Two boards, called I/O boards, left and right,
support the front panel, solenoids and sensors. The main board
contains the printer’s CPU processor, RAM and ROM. The power
supply accepts the AC input voltage and distributes it or converts it
to various other levels of required DC voltages and distributes them.
The power control board distributes power supply voltages to the
other printer boards and drives many printer motors. The front panel
provides a user interface to the printer. The printhead drive board, a
part of the printhead, manages the signals and voltages of the
printhead’s printing elements and sensors. The optional Ethernet
interface card and internal hard drive could be considered the eighth
and ninth circuit boards.

Front
panel

I/O board
right

0388-03

Figure 1-3. Circuit Boards of the Print Engine (Right Front View)

General Information 1-7

Printhead drive
board

Optional
Internal hard
drive

Optional
Ethernet
Interface
card

Power
supply

I/O board

Main board

left

Figure 1-4. Circuit Boards of the Print Engine (Left Rear View)

Power
control
board

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LINX™ Solid Inkjet 100 Service Manual

An internal data bus, called the I2C bus, connects all I/O boards to the
main board. (Refer to Figure 1-5.) Through this single bus, the main
board can “poll” the I/O boards for the state of the printer’s sensors as
well as actuate the printer’s solenoids. This data bus greatly
simplifies the wiring that would otherwise be required for monitoring
numerous sensors and solenoids. The I2C bus also extends down to the
Auxiliary Feeder Unit.

Auxiliary
feeder unit
connection

Figure 1-5. The Printer’s I2C Bus

I2C bus

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General Information 1-9

Cap/Wipe/Purge
carriage drive

The printer features a printhead maintenance system used to clean
the printhead faceplate and clear clogs from the printhead nozzles.
(Refer to Figure 1-6.) The system consists of a vacuum pump
assembly, the cap/wipe/purge assembly, the cap/wipe/purge carriage
drive, the purge hose and tubing, and the purge filter.

Purge
Filter

Figure 1-6. Printhead Maintenance System

Purge hose
and tubing

Cap/Wipe/Purge
assembly

Vacuum
pump
assembly

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LINX™ Solid Inkjet 100 Service Manual

Sensors in the printer provide information to the main board to
determine the state of the printer. The printer monitors the positions
of some of the movable assemblies, such as the drum, as well as the
temperature of many other assemblies, such as the printhead, paper
preheater and the drum. Figure 1-7 shows the sensors and switches
on the right side of the print engine. Figure 1-8 illustrates the sensors
and switches on the left side of the printer.

Ink load
cover sensor

Top cover
switch

Front cover
switch

Preheater
entry/right
edge sensor

Hand-feed
sensor

Ink-stick­low sensor

Paper-pick
sensor

Ink-stick­out sensor

Tray type
sensors

Exit/tray-full
sensor

A4-size media
sensor

A-size media
sensor

Cap/Wipe/Purge
home sensor

Maintenance
blade position
sensor

Paper-empty
sensor

0388-07

Figure 1-7. Sensors and Switches on the Right Side of the Print Engine

General Information 1-11

Transfix exit
sensor

Drum
temperature
sensor

Duplex
paper sensor

Drum-home­position sensor

Drum encoder
sensor

Preheater
exit sensor

Process
gear position
sensor

Transfix
roller

Preheater
exit sensor
located on inside

Preheater

wall of drum/transfix
frame

Drum

Figure 1-8. Sensors and Switches on the Left Side of the Printer

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LINX™ Solid Inkjet 100 Service Manual

0388-34

Upper feed
roller clutch

The actual position of some printer assemblies, such as the
printhead or the cap/wipe/purge assembly, cannot be ascertained at
all times. The printer records, in NVRAM, where it last positioned
such assemblies each time it moves them. If, after power-down or a

CAUTION

power interruption, the assemblies are manually repositioned, the
printer erroneously assumes that the assemblies are in the position
it last left them. This assumption can result in damage to the printer
when it tries to position the assemblies. For example, the printhead
could be tilted forward and crash into the raised cap/wipe/purge
assembly.
Before turning on the printer, ensure the printhead is tilted forward,
centered in front of the drum and the cap/wipe/purge assembly is in
the retracted, home position. The tilt cam gear should be
disengaged from the gear drive train.

Electric clutches and solenoids are used by the printer to engage
rollers as needed to move paper through the printer as well as start
some print processes. Refer to Figure 1-9.

Drum maintenance
cam clutch

Cap/Wipe/Purge
clutch

Pick
clutch

Figure 1-9. Solenoids and Clutches on the Print Engine

Air valve
solenoid

Transfix
solenoid

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General Information 1-13

The Main Board

The main board features the printer’s PowerPC processor that
controls the engine and the PostScript processing. Refer to Figure 1-

10. Prominent on the main board is the code ROM DIMM and the
RAM DIMM plug-in modules. The code ROM DIMM also contains the
printer’s on-board fonts. Variations of the code ROM DIMM contain
alternate language fonts such as Kanji or Hangul.

Network connection is provided through a built-in 10baseT port.
The printer stores unique printer status and PostScript values in its

NVRAM module. The printer’s Ethernet address, unique to each
printer, is stored in Boot ROM/Printer ID chip, an 8-pin socketed IC
in location U390. All these socketed components should be transferred
to a replacement main board to maintain customer-unique settings.

Boot ROM/
Printer ID

Figure 1-10. Features of the Main Board

RAM DIMMs

NV RAM/
Real Time Clock

Code ROM
DIMM

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LINX™ Solid Inkjet 100 Service Manual

Media Tray Type Sensing

The combinations of the three tray sensors inform the print engine
what type of media tray (A or A4) is installed. These combinations are
shown in Table 1-2. The print engine does not detect the type of media
installed in the tray; it only detects the particular tray being used by
the presence of sensor flags on the side of the tray. The tray sensors
are located on the right-side interior of the paper tray slot, mounted
on I/O board right. There are two tray types:

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

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

Table 1-2. Tray Switch Sensor Combinations

Tray type

A Paper A4 Paper

Top switch Closed Open
Middle switch Open Closed

Bottom switch Open Open

Front Panel

These front panel features (shown in Figure 1-11) are found on the
printer:

• 128 x 64 pixel backlit LCD graphic display

• Two push buttons and four navigation arrow buttons

• Two LEDs (Power and Error)

LCD. The backlit LCD serves two purposes: displaying current image
processor and print engine status information and displaying an
interactive menu. Status information includes image processor status
such as Ready to Print, Receiving Data and Printing. Print engine
status includes messages such as Out of Paper, Paper Jam and Add
Ink as well as error messages.

Customers can review and modify certain NVRAM, I/O ports and
peripheral parameters. Using the front panel to review and change
parameters is discussed in the topic, “Adjustments”.

Buttons. Four of the six buttons are arranged as a diamond-shaped
keypad. The other two buttons are used as Select and Help.

In the Service Support menu, pressing and holding the Left arrow
button , and then pressing the Select button enters the hidden
service support menu.

Pressing and holding the Right arrow button and then pressing the
Select button proceeds immediately to the language selection menu.

General Information 1-15

Pressing and holding the Left arrow while turning off the printer
will confirm the printhead is correctly parked by flashing both front
panel LEDs.

Turning the printer on with the rear panel DIP switch 2 in the
“down” position, allows access to the front panel during the warm-up
cycle.

The topic “Resetting NVRAM” explains how to use the front panel
buttons to reset the NVRAM to its factory-default values.

Navigation
buttons

Power

READY TO PRINT

Error

LCD
Display

Figure 1-11. Printer Front Panel

Help
button

Select
button

0388-10

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LINX™ Solid Inkjet 100 Service Manual

Rear Panel

Connectors

The rear panel (Figure 1-12) of the printer features the host interface
connectors to the printer; it includes the following connectors:

• Standard parallel (high-density connector), IEEE 1284C

• Twisted Pair (10BaseT) Ethernet connector

• Universal Serial Bus port

• A special 5-pin connector accommodates a service RS-232 cable
from a PC running PC-based diagnostics.

The rear panel also includes two option slots. With the addition of an
optional Ethernet Interface network card in the lower slot, the printer
can support 10Base2 or 100BaseT Ethernet connectors.

NOTE: When an optional Ethernet Interface card is installed, the
printer’s built-in 10BaseT Ethernet port is disabled.

The second slot accommodates an internal IDE hard drive for print
DICOM support.

Health LEDs

Two health LEDs indicate the status of the printer’s CPU functions:
PostScript (PS) processing and Print Engine (PE) control.

• Blinking: The printer is operating normally. Both LEDs blink
irregularly during diagnostics. To indicate the printer passes
the POST tests and is operating normally, the left (PS) LED
flashes in a “heartbeat” rhythm (on 0.5 seconds, off 0.5
seconds). The right (PE) LED pattern is two quick flashes on,
then off for a count of two for a total cycle time of just over two
seconds.

If a soft error occurs, image processing occurs, but in a reduced
capacity. Soft errors include failure of expansion memory
DIMMs or of any of the interface ports. When a soft error
occurs, the printer automatically prints a startup page listing
the error.

• On or Off, or blinking a coded error indication: A hard error
condition has occurred that would keep the image processor
board from operating. Refer to the topic “Error Codes and
Messages” for the meaning of a coded indication.

General Information 1-17

Ethernet Card

Switches

Four DIP switches allow you to reset the printer or place the printer
in different operating modes. Figure 1-12 illustrates the rear panel of
the printer and location of the DIP switches.

Table 1-3. Rear Panel DIP Switch Settings

Function Switch 1 Switch 2 Switch 3 Switch 4

Normal operating mode UP UP UP UP
Service mode DOWN UP UP UP
Reset printer UP UP UP DOWN
Manufacturing mode UP DOWN UP UP

(Bypass mode)
Development mode DOWN DOWN DOWN UP

(engineering use only)
Recovery mode DOWN UP DOWN UP

(engineering use only)

IDE hard drive

Optional Ethernet
Interface card

PostScript
health
light

100
Mbs

TX
RX

TP
LINK

10/100Base-TX

10Base2

Print
Engine
health
light

Service

RS-232

Ethernet
10BaseT

Figure 1-12. Rear Panel

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LINX™ Solid Inkjet 100 Service Manual

Parallel USB DIP

switches

0388-11

Bypass Mode (Manufacturing Mode)

Bypass mode allows you to access the front panel menus (bypassing
the engine and PostScript initializing processes) without having to
wait for the printhead to warm up. This way, you can observe or
change some of the printer settings without waiting for the printer to
complete the normal warm up sequence. Meanwhile, the printer
continues to warm-up and initialize “in the background.”

1. At the rear of the printer, set DIP Switch 2 in the down
position. Ensure Switches 1, 3 and 4 are up. (Normal
operation is all switches up.)

2. Turn on the printer.

The printer will not print a Cleaning Page or a Startup Page when
placed in Bypass Mode.

Cool Down Mode

The printer features a menu item that accelerates the cooling down of
the printhead. When the printer is turned off, it automatically gives
the option of performing a quick cool down.

1. Turn off the printer.

2. Scroll to the menu item Quick Cool to Move and press the
Select button.

3. Open printer doors to help speed the cooling process.

The printer turns off all the engine heaters and runs the fans on high
until the ink in the printhead has solidified. Then the printer shuts
itself off.

General Information 1-19

Preparation for Moving the Solid Inkjet 100 Printer and
Accessories

It is very important that you follow the correct repacking procedure
before shipping the Solid Inkjet 100 printer. Complete repacking is
required. Failure to properly repack the printer can damage the
printer’s internal components. You are responsible for any shipping
damage to the printer that results from improper or inadequate
packing.

Repacking for shipment consists of four basic tasks. Each of these
tasks is explained in detail. If you have questions regarding any of
the repacking procedures, call Sterling for assistance:

Sterling Diagnostic Imaging, Customer Care Center at (800) 252-

9099. Outside the U.S. and Canada, contact your local Sterling
Diagnostic Imaging service organization.

Overview

After reviewing this section, follow the more detailed processes which
follow to complete this task.

CAUTION

1. Turn off the printer using the On/Off switch and then selecting
Shut Down For Moving Printer at the front panel.

2. Remove the maintenance drawer, seal it in a plastic bag, and
store the tray on a flat surface.

NOTE: A used maintenance drawer leaks drum fluid if tipped.

3. Make sure that the printer has completed its shut down before
moving the printer (after approximately 15 minutes, the front
panel goes blank). This allows the ink to solidify.

4. Repack the printer and its accessories using the original
packing materials.

Turning off the Printer

To avoid damaging the printer’s internal components, always turn
the printer power off using the On/Off switch (this places the
printhead in the proper position for safe shipment). Failure to do so
may result in damage to the printer.

pulling the power cord.

Never turn off the printer by

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LINX™ Solid Inkjet 100 Service Manual

CAUTION

CAUTION

1. Use the rear-panel On/Off switch to turn off the printer.

2. At the front panel, immediately select Quick Cool to Move
Printer (you have 4 seconds before the display goes blank).

The printer reports the shut down status and takes approximately 15
minutes to cool down. While it is cooling, it is recommended that you
remove the maintenance drawer (see the next topic).

If you do not select Quick Cool to Move Printer, you must wait 30
minutes for the ink to solidify. Before moving the printer, always
wait for the ink to solidify or you may damage the printer.

Removing the Maintenance Drawer

To avoid damaging the printer, always remove the maintenance
drawer before moving or shipping the printer. Never ship a partially
used maintenance drawer.

1. Open the printer’s front cover.

1239-58

General Information 1-21

WARNING

2. Remove the maintenance drawer from the printer. Once you’ve
removed the maintenance drawer, keep it level.

1239-59

A used maintenance drawer leaks drum fluid if tipped. Keep the
maintenance drawer level to prevent spills. Contact with
maintenance drawer fluid poses no health risk, however, do not
leave the used maintenance tray where it could spill and create a
slipping hazard.

3. Place the used maintenance drawer in a plastic bag and seal
the bag. Store the used maintenance drawer for future use. Do

not ship a partially used maintenance drawer.

Disconnecting the Cables

Once the printer completes its shut down process, the front panel goes
blank. Once this happens, disconnect the power cord and all other
cables from the printer.

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LINX™ Solid Inkjet 100 Service Manual

WARNING

Repacking the Printer and its Accessories

The printer weighs about 36 kg (79 lb.). Do not attempt to lift it
without the assistance of another person.

1. Repack the media tray. Remove the media trays and remove all
media from the trays. Position the cardboard tray insert into
the media tray to prepare it for shipping. Reinsert the media
tray into the printer.

1239-38b

2. Repack the printer. Position the lower cushion insert in the
shipping tray as shown in the illustration. Lower the printer
onto the cushion inserts. Place the plastic bag provided over
the printer. Place the cushion inserts on each side of the
printer.

3. Repack the printer’s accessories. Place the power cord, cleaning
kit, and all printer documentation in the area provided in the
accessories box. Do not ship a partially used maintenance
drawer.

General Information 1-23

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LINX™ Solid Inkjet 100 Service Manual

1239-35b

Figure 1-13. Repacking the Printer

WARNING

The printer is not permanently attached to the Auxiliary Feeder unit.
When moving the printer or auxiliary feeder unit, move each unit
separately to avoid damage or personal injury. The printer weighs
about 36 kg (79 lb.). Do not attempt to lift it without the assistance
of another person.

Repacking the Auxiliary Feeder Unit

If you have an Auxiliary Feeder unit, repack for shipment using the
original packaging.

Remove the media tray from the Auxiliary Feeder unit and remove all
media from the tray. Slide the media tray into the Auxiliary Feeder
unit and place the assembly inside the plastic shipping bag. Place the
front and rear cushions on the Auxiliary Feeder unit. Place the entire
assembly into the cardboard box.

1239-01

General Information 1-25

Configuration Page

The configuration page, shown on pages 1-27 and 1-28, lists the
values the printer stores in its NVRAM. These values can be
informative when troubleshooting the printer, particularly networked
operations. The configuration page gives information such as:

• General information about the printer, such as page count, the

• Printhead information such as serial number, calibration and

• Parallel port settings

• USB setting

• Hard drive

• Network information

• EtherTalk settings

• Novell NetWare settings

programmed name, Ethernet address, time-outs, number of
fonts and total memory

adjust values

• TCP/IP settings

Configuration page settings are provided in Table 1-4.

Printing the Configuration Page

1. Turn on the printer .

2. Allow the printer to complete its power-up self-tests. The front
panel displays:

READY TO PRINT

3. Scroll to Menu and press the Select button.

4. Scroll to the menu item Demo and Test Pages and press the
Select button.

5. Scroll to the menu item Print Configuration Page and press
the Select button.

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General Information 1-27

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LINX™ Solid Inkjet 100 Service Manual

Table 1-4. Configuration Page Settings

Parameter Description Saved in

NVRAM

Printer name The current name of the printer

Page count;
upper and lower
tray counts

Startup page
enabled

Serial number Unique number representing the

Product

Printer ID A unique number for each

PostScript version Firmware level of the

as seen on a network

Total number of print jobs
processed through the image
processor.

Indicates if the printer prints a
startup page upon power-up.

printer serial number

Ethernet-capable printer.

PostScript interpreter code.

yes

yes 0

yes Yes No

yes

yes Hardware-

N/A 3016.106

Default Limits or alternate choices

Ii

LINX

SIJ100

Ii

LINX Solid

Inkjet 100

dependent.

Any name defined by the customer
up to 32 characters in length.

Legal values have the form
xx:xx:xx:xx:xx:xx

Firmware version Firmware levels of the main

Flash Installed Yes
Installed RAM Total amount, type, and size of

ROM fonts
available

Sys/Job Start Indicates if the printer is to

Job Timeout Amount of time a job can take

board operating system code
version, printer engine’s
operating system code,
PostScript code, engine code,
and networking code.

RAM on the main board in each
DIMM slot.

Number of fonts stored in the
printers ROM memory.

execute a Sys/Start job file
found on an attached hard
drive at power-up

to process.

N/A a.aa/b.bb/c.cc/d.dd, where a.aa is

64 Mbytes 64, 96,128

136

yes yes no

yes 0 seconds Any value denoted in seconds. 0

the Sterling version of VxWorks,
b.bb is the PostScript version
number, c.cc is the engine code
version, and d.dd is the network
code firmware version

means unlimited amount of time

General Information 1-29

Table 1-4. Configuration Page Settings (continued)

Parameter Description Saved in

NVRAM

Wait Timeout Amount of time the image

Energy Star time­out

Intelligent Ready Indicates if the automatic

Media Source Indicates the default tray the

Upper Tray Indicates the size and type

Lower Tray Indicates the size and type

processor waits for additional
data from a host.

Amount of idle time allowed
before the printer switches to
a low energy power down mode.

standby/wake up feature is
enabled.

printer uses for self-prints

of tray installed

of tray installed

yes 40 seconds Any value greater than 14 denoted

yes 67 hours Any integer from 1 to 999 denoting

yes on off

yes Upper Tray Upper Tray, Lower Tray

no Letter, A4

no Letter, A4

Default Limits or alternate choices

in seconds; 0 means unlimited
amount of time

hours.

Print Quality Indicates the combined

Parallel Port
Enabled

Language Indicates the language

Encoding Indicates the type of data

Job pipelining Indicates if multiple printfile

Output Device Device used for standard

setting of the HW Resolution.

Indicates if the parallel port is
enabled

interpreter in use at the port

encoding at the parallel port

processing is allowed

output and standard error

yes High

Resolution
Medical

yes Enabled Disabled

yes PostScript

yes Binary ACSII (normal), Raw, TBCP

yes Off 0n

yes Parallel any communication device

High Resolution Medical, Draft

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