SERVICE MANUAL HP C2858A/C2859A DRAFTING PLOTTERS SERIAL NUMBERS This manual applies directly to HP C2858A and C2859A plotters with serial numbers prefixed USA. For additional information about serial numbers, see SERIAL NUMBER INFORMATION in Chapter 1. HEWLETT-PACKARD COMPANY 1993 16399 W.
Using this Manual This service manual contains information necessary to test, adjust, and service the Hewlett-Packard Models C2858A and C2859A DesignJet 650C plotters. It is designed to help you easily find the cause of a C2858A/C2859A hardware problem and to perform the necessary repairs and adjustments to get the plotters into proper operating condition. Service strategy for this manual is to support the products to the field replaceable unit.
Chapter 4. Preventive Maintenance Chapter 4 contains information you will need to keep the plotters in their best operating condition. Included are procedures that can be performed by the user. Chapter 5. Functional Overview This chapter contains a simplified description of the plotter circuits and mechanical functions. Chapter 6.
Contents Chapter 1 Page Product Information Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug-in Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter Loading Roll Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unloading Roll Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loading Sheet Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unloading Sheet Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearing Media Jams . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 6 Page Removal and Replacement Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ESD Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter Cutter Enclosure Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entry Platen Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Roller Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Bail Lift Mechanism Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Media Diverter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 9 Page Product History Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 History of Assemblies by Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 History of Printed Circuit Assemblies (PCAs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 10 Parts and Diagrams Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Definitions of Safety Symbols International caution symbol (refer to manual): the product will be marked with this symbol when it is necessary for the user to refer to the instruction manual in order to protect against damage to the instrument. Indicates dangerous voltage (terminals fed from the interior by voltage exceeding 1000 volts must also be marked). Protective conductor terminal. For protection against electrical shock in case of a fault.
Chapter 1 Product Information INTRODUCTION This chapter contains a listing of documentation supplied with the HP C2858A and C2859A DesignJet 650C plotters. Also provided are: descriptions of the plotters, information on the plotter features, options and accessories, performance characteristics, and plotter serial number information. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . .
DESCRIPTION HP C2858A and C2859A DesignJet 650C plotters provide graphic displays of computer program output data. They operate with a number of computer systems and graphic terminals, using either RS-232-C or Centronics external controllers.
Figure 1-1. The standard HP C2858/9A DesignJet 650C has four megabytes of on-board random access memory (RAM). Memory expansion upgrades to 20 MB are available as well as various ROM enhancement and modular I/O options.
OPTIONS PLUG-IN MEMORY C2858/9A DesignJet 650C plotters have two memory expansion sockets. Each can hold either a four-megabyte or eight-megabyte, Single In-line Memory Module (SIMM). Therefore, memory can be expanded by 4, 8, 12 or 16 megabytes. The SIMM part numbers are: Four Mbyte SIMM = P/N C2065A Eight Mbyte SIMM = P/N C2066A ROM ENHANCEMENT MODULES Two ROM expansion sockets are also provided in the C2858/9A DesignJet 650C plotters. Each will hold a single ROM enhancement SIMM.
ACCESSORIES The items listed in Table 1-1 are supplied with each plotter. Miscellaneous application notes, flyers and driver disks are also provided. Depending upon the country of destination, the part numbers of items listed as English or U.S. will differ. Accessories available for use with the C2858/9A DesignJet 650C plotters are listed in the Supplies Catalog. Table 1-1.
PERFORMANCE CHARACTERISTICS Table 1-2 lists the performance characteristics of the plotters. Table 1-2. Performance Characteristics Accuracy 0.38 mm (0.015 in.) or 0.2% of the specified vector length, whichever is greater at 23 _C (73 _F) at 50-60% RH, on HP film (monochrome mode only). Throughput D-sized loaded vertically: plain paper monochrome Draft mode 1.8 min. Final mode 3.2 min. Enhanced mode 6.5 min.
Chapter 2 Site Planning and Requirements INTRODUCTION This chapter contains information concerning the electrical requirements for the installation of HP C2858A and C2859A plotters. Also included is information on environmental operating conditions and physical specifications for the plotters. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SPECIFICATIONS POWER REQUIREMENTS HP C2858A and C2859A DesignJet 650C plotters have self-adjusting power supplies and do not require voltage selector or switch settings prior to use. Table 2-1 lists the power requirements for the plotters. Table 2-1. Power Requirements Frequency Source Voltage Current (max) 100 Vac 1.4 A 120 Vac 1.
ENVIRONMENTAL SPECIFICATIONS Table 2-2 lists environmental specifications for the plotters. Table 2-2. Environmental Specifications Temperature Storage Operating Optimal Operating Relative Humidity (Operating) –40 to +70 _C (–40 to +158 _F) 0 to +55 _C (+32 to +131 _F) +15 to +30 _C (+59 to +86 _F) 20 to 80 % RH PHYSICAL SPECIFICATIONS The plotter physical specifications are listed in Table 2-3. Table 2-3.
CABLE RESTRICTIONS Cable restrictions for the plotter are determined by the type of interface being used. Recommendations for each interface are supplied in the following paragraphs. RS-232-C INTERFACE The use of short cables (each less than 15 metres or 50 feet) is recommended for the RS-232-C Interface. Longer cables are permissible, provided the load capacitance does not exceed 2500 picofarads. CENTRONICS INTERFACE The use of short cables (each less than 2 metres or 6.
Chapter 3 Installation and Configuration INTRODUCTION This chapter contains the information required to configure and verify proper operation of the HP C2858A and C2859A DesignJet 650C plotters. Print cartridge and media loading procedures, as well as front panel menu structures, are also provided. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION INSTRUCTIONS USER-INSTALLABLE MODULES Expansion sockets located behind a panel at the rear of the plotter allow the user to install additional memory modules. These SIMMs (single in–-line memory modules) are available in 4MB and 8MB sizes. Installation is accomplished by removing the access panel (4 screws), installing the module(s), and reattaching the access panel. ROM sockets are also provided for use with ROM enhancements as developed.
Option No. BS 1363A 250 Vac, 13 A, Single Phase plug rating. For use in United Kingdom, Cypress, Nigeria, Zimbabwe, Singapore. 900 250 Vac, 10 A, Single Phase plug rating. For use in Australia, New Zealand. 901 250 Vac, 10/16 A, Single Phase plug rating. For use in East and West Europe, Egypt. 902 125 Vac, 15 A, Single Phase plug rating. For use in Canada, Mexico, Philippines, Taiwan, Saudi Arabia, UL approved in the United States 903 250 Vac, 15 A, Single Phase plug rating.
USER INFORMATION AND OPERATION MEDIA GUIDELINES Guidelines on media handling are: The leading edge must be straight and each side must be loaded evenly. If the leading edge is jagged, trim it with the media knife (located in the manual holder at the back of the plotter) using the track on top of the plotter as a guide. If media is curled, load it with the curl up. The exception to this is film media, which must always be loaded with the plotting side (matte side) down.
Real-time switching between plotting modes is not supported. If the user selects another mode while plotting, the plotter waits until the current plot is finished and then switches to the newly selected mode. MEDIA CUTTING AND STACKING Automatic and manual cutting of plots is available on the C2858/9A. In roll media operations, the user can choose between continuous plotting or cutting plots off the roll automatically as they are completed.
USABLE MEDIA SIZES Media of different types and sizes can be used on the plotters. Refer to Table 3-1 for the media sizes usable on each plotter. Table 3-1. Media Sizes C2858A C2859A ISO A4 - A1 ISO A4 - A0 ANSI A - D ANSI A - E ARCH A - D ARCH A - E JIS B4 - B2 JIS B4 - B1 Oversize A2 Oversize A1 24 in. Wide Roll 24 in. Wide Roll 36 in.
(C) C2847-10(UM) Removing the Media Stop and Endcap Figure 3-2. (C) C2847-16(UM) Sliding the New Roll onto the Spindle Figure 3-3.
3. Open the roll cover and insert the spindle, with the endcap at the left and the media stop at the right. Firmly push on both ends. See Figure 3-4. Roll Cover Pinchwheel Lever (C) C2847-31(UM) Installing the Spindle Figure 3-4. 4. Once the roll is in place, push the media all the way to the right, so that it’s flush against the media stop. 5. Ensure that the pinchwheel lever at the right of the plotter is down. 6. Turn the plotter ON, if it is not already ON. 7.
Cutting Track (C) C2847-7(UM) Trimming the Leading Edge of the Media Figure 3-5. Insert Media Until it Buckles Evenly Align Media with Perforation Line (C) C2847-15(UM) Loading the Leading Edge of the Media Figure 3-6. 10. When the front panel displays “Sheet load/Roll load,” press the Down Arrow button to select “Roll load.” 11. When the front panel displays “SELECT MEDIA,” press the Up or Down Arrow button to scroll through and select the media choice.
the media so that they are flush with the left and right edges of the roll. See Figure 3-7. (C) C2847-97a(UM) (C) C2847-97(UM) Aligning the Left and Right Edges of the Media Figure 3-7. 14. When the front panel instructs you, lower the pinchwheel lever. The plotter checks to make sure the roll is properly aligned. 15. When “Close roll cover/Continue ” is displayed, rewind the media stop to take up any slack in the roll.
LOADING SHEET MEDIA To load sheet media, perform the following steps: 1. Ensure that the pinchwheel lever is down and the roll cover is closed. 2. Load the leading edge of the sheet making sure to push the sheet in straight (not skewed) while aligning the right edge of the sheet with the perforated line on the entry platen. See Figure 3-8. Insert Media Until it Buckles Evenly Align Media with Perforation Line (C) C2847-15a(UM) 3.
If difficulty in loading sheet media is experienced, an alternate method of loading is possible. Do the following: 1. Ensure that the pinchwheel lever is down and the roll cover is closed. 2. Raise the window on the plotter. 3. Insert the sheet into the plotter until the leading edge hits the stops inside the platen area. Align the right side of the sheet with the perforation line on the entry platen. 4.
PEN CHECKING Ink usage for cartridges may vary depending upon the ratio of color versus monochrome plotting and the extent of each color used. Cartridge replacement is necessary only when any of the following conditions occur: Pen Checking is ON and you elect to replace the cartridges when the plotter prompts you. Poor plot quality indicates an out of ink condition or the cartridges appear clogged.
Figure 3-9 shows you how to visually check the ink level in a cartridge. Label color indicates ink color. Green area will diminish as ink is dispensed. Replace pen when area is all black. Checking the Ink Level Figure 3-9. ACCESSING PENS Press the Access Pens button to access the pen carriage when you need to replace, reseat, or clean pens. The pen carriage will move into the platen area to allow easy access to the pens.
1. Press the Access Pens button. The pen carriage moves out from the pen service station at the left of the plotter and stops in front of the slot in the bail. 2. When the pen carriage stops and the display reads “Open window to access pens,” open the window. Note If you don’t open the window within 30 seconds after the message is displayed, the pen carriage returns to the pen service station. 3. Refer to the plotter display.
6. Remove the protective tape from the new pen. Insert the pen into the empty pen slot. 7. Press down slightly and push the pen away from you until it snaps into the pen slot. See Figure 3-11. Installing a Pen Figure 3-11. 8. Repeat steps 4 through 7 for each pen being replaced. 9. Close the plotter window. When “Load media to align pens” is displayed, load good quality media into the plotter. Special paper must be used to properly align the color pens.
CONFIGURATION FRONT PANEL CONTROLS Plotter set-up and plot management functions are input through the front panel. The front panel contains a 2-row by 20-character vacuum fluorescent display. Menu scrolling and implementation are accomplished through 4 menu buttons. Plotting modes are initiated through the color/monochrome select buttons and print quality buttons. User interaction is available through 3 pen/media action buttons.
Front panel controls and LEDs are described below. Menu buttons: Previous Use the Previous button to move to the next highest level and to return to the “Status” display. Use the up-arrow and down-arrow buttons to scroll through menu options or respond to action or error messages. Enter Use the Enter button to activate the current menu option, access additional submenus as indicated and to enter the first level of the menu structure from the “Status” display.
Action buttons: Cancel stops current operation (plotting, accuracy calibration, pen alignment and media loading). Cancel Form Feed/Cut Access Pens Pause Form Feed/Cut advances the page and, if roll media, cuts it. Access Pens brings the pen carriage out to the plotting area for pen access. (Plotter window must be closed). Pause stops plotter after plotting current drawing. Press again to continue. To select and confirm a menu option, do the following: 1.
FRONT PANEL MENUS There are seven main menus, each with an option or series of submenus. Pressing the Enter button from the “Status” display will access the menu structure. Both a short menu and a full menu are available in the plotter display. The short menu is the default menu and displays the more commonly used menus. Changing to the short or full menu (Menu mode submenu) is accessed through the “Utilities” main menu. A brief description of the main menus is given below.
FRONT PANEL LANGUAGES DesignJet 650C plotter menus and messages can be configured to display in English, French (“Francais”), German (“Deutsch”), Spanish (“Castell.”), Italian (“Italiano”), Portuguese (“Portuguese”) and Japanese (Katakana) characters. To change the display language, or if the display is in a language you cannot understand, use the following procedure to get to a language you do understand. 1. Turn the plotter OFF. 2. Press and hold down the Enter button while turning the plotter ON.
FRONT PANEL MESSAGES In addition to the menus that appear in the front panel display, three types of messages may also appear in the display. They are state messages, action messages, and error messages. State messages do not require any action and serve to notify the user of any current plotter actions occurring. State messages are listed in Table 3-2. Action messages do require user interaction. Typically the user is prompted to press a button, move a lever or load pens or media.
Table 3-2. State Messages (Continued) Message State Pen palette saved The pen source, pen number widths, and pen number shades you just entered have been saved as either Palette A or Palette B (whichever you specified). Returning pens The pen carriage is returning to its station at the left of the plotter. Roll feed Edge trim Machine is trimming the edge of roll media. RS-232 config loaded The RS-232-C configuration you just entered (Config A, Config B, or Factory) has been loaded.
Message Action Special Media Mono Media Press Up Arrow for Color plotting on Special (CX) paper. Press Down Arrow for Monochrome plotting. Calibrate done Continue Accuracy calibration is complete. Press Down Arrow to continue. Can’t replot Resend plot Replot buffer doesn’t have enough memory to hold the entire plot. Resend the plot. Close roll cover Continue Rewind the media to take up any slack in the roll, close the roll cover, then press Down Arrow to continue.
Table 3Ć3. Action Messages (Continued) Message Action Pull # / Align $ edges to roll Grasp the left and right free edges of the roll media and pull toward you until the media is taut. At the same time, align the left and right edges of the media so that they are flush with the left and right edges of the roll. Remove media Continue ! Ink is dry; you can remove the accuracy calibration plot the plotter just produced. Press Down Arrow to continue with accuracy calibration.
OPERATIONAL VERIFICATION DesignJet 650C plotters contain several types of internal operational checks and tests to ensure that the plotter is properly functioning and to help identify problems if any are detected. POWER-ON SELF-TEST Whenever the plotter is switched ON, it automatically performs a series of internal self-tests and initialization sequences which check the basic electrical and mechanical functions of the plotter. Among the items checked are the processors, motors and sensors.
Chapter 4 Preventive Maintenance INTRODUCTION This chapter contains information on keeping the HP C2858A and C2859A DesignJet 650C plotters in good operating condition. Included are general cleaning procedures to be performed by the user. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Effect on Product Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EFFECT ON PRODUCT RELIABILITY To maintain the plotter in good operating condition, keep it free of dust accumulation, ink, and other contamination. Cleaning intervals are determined by the local conditions under which the plotter is operated and by the types of plotter supplies used. As with any precision electronics equipment, proper maintenance will help to ensure reliability and prolong product life. PREVENTIVE MAINTENANCE PROCEDURES The following general cleaning procedure can be performed by the user.
DRIVE ROLLER CLEANING WARNING The drive roller cleaning procedure should be performed only by service-trained personnel; otherwise personal injury may occur. If ink is spilled on the drive roller, remove the ink. Due to the ink’s reflectance, ink on the roller can disrupt the plotter’s edge-sensing function. To remove any ink from the roller, perform the following procedure: 1. Connect the plotter to an ac power source. 2. Switch the plotter ON. 3. Press the Enter button on the front panel. 4.
Note The speed of the drive roller can be reduced or speeded up by pressing the appropriate arrow button. 11. Apply any common household cleaning solution (e.g. BonAmi aerosol, Simple Green) to a soft, lint-free rag and apply it to the drive roller surface while it is rotating. Thoroughly clean the roller surface. 12. Stop the roller by pressing the Enter button when through cleaning. 13. Press the Enter button to return to the SERVICE TESTS menu display. 14.
Chapter 5 Functional Overview INTRODUCTION This chapter contains a simplified description of the HP C2858A and C2859A DesignJet 650C plotters circuits and mechanical functions. Mechanical and Printed Circuit Assembly (PCA) overviews present a functional description of how the plotter operates. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Simplified Description of Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIMPLIFIED DESCRIPTION OF CIRCUITS HP C2858A/59A DesignJet 650C circuits communicate with an external controller by way of either a Centronics or an RS-232-C interface. If an approved modular input/output (MIO) printed circuit assembly (PCA) is installed, the circuits can communicate by way of an HPIB interface or be connected to a network. The main processor reads Centronics, HP-IB, and Ethernet communications through the port it uses to read memories (ROM or DRAM).
The servo processor controls the servo motors, front panel, fan, electrically erasable read-only memory (EEROM), and the stepper drive. It sends configuration information to the carriage processor via its serial port. The EEROM stores plotter calibration and configuration information while power is OFF. The stepper drive moves the stepper motor. The stepper motor is used to raise the pen wiper for wiping pens or to operate the pen service station.
An internal cooling fan is supplied with +12 V. It is switched ON and OFF by the servo processor and is mounted in the electronics enclosure at the rear of the plotter. The fan is primarily used to cool the power supply PCA when plotting. When the plotter is not plotting, the fan is switched OFF. At high temperatures, the fan is switched ON. The window sensor is a switch mounted on the right sideplate at its top front edge.
PRINTED CIRCUIT ASSEMBLY (PCA) OVERVIEW MAIN PCA There are two clocks on the main PCA. The main clock provides a 31.85 MHz signal directly to the main processor. The 31.85 MHz is divided by the main processor, and the resulting signal is provided to the processor support ASIC. A separate clock provides a 12 MHz signal to the servo processor. In order to perform its functions, the main processor must have access to its memories (ROM and DRAM).
CARRIAGE PCA The carriage PCA contains an application-specific, integrated circuit (ASIC) that controls the operation of the pens and pen drivers that switch power pulses from the ASIC to fire the pens. It also provides feedback to the main PCA as to the current position of the carriage assembly. A line sensor module mounted on the carriage PCA monitors the lines produced by the pens and is used for pen alignment.
The dual-voltage, remote sense circuitry sends a + or – sense signal to the dual voltage regulators on the interconnect PCA when the voltage to the print heads deviates from the optimum pen voltages. The regulator will then adjust the voltage to bring it back to the optimum value. Pen voltages are ON when printing a swath and briefly at power-up, but OFF when idle or accessing pens.
DROP AND BAIL SENSORS The drop sensor is located in the drop detect assembly. Its purpose is to detect ink drops during pen testing. The drop sensor contains a detector system capable of detecting the presence of a drop shortly after one is fired into the detector. In order for the drop to be fired into the detector, the pen must be positioned over the sensor. An infrared LED sends a beam across an aperture. The beam is received at the other side by a photo-sensitive diode.
Chapter 6 Removal and Replacement INTRODUCTION This chapter contains repair information including safety and ESD precautions, a list of tools required for plotter repair and procedures for the removal and replacement of HP DesignJet 650C field replaceable assemblies. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Station Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overdrive Support Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutter Enclosure Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entry Platen Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Roller Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY CONSIDERATIONS The Safety Symbols used with Hewlett-Packard instruments are illustrated in the front matter of this manual. WARNING and CAUTION symbols and instructions must be reviewed before service work is performed. These warnings and cautions must be followed for your protection and to avoid damage to the plotter. WARNING The ac power outlet (mains) must have a protective earth (ground) terminal.
REQUIRED TOOLS Tools required to disassemble and repair the HP DesignJet 650C plotters are listed in Table 6-1. Item Size Torx Screwdriver with bits T8, T9, T10, T15, T20, T25, T30 Screwdriver, flat-blade Small Nut Drivers 1/4 in., 3/16 in., 5.5 mm (or 7/32 in.) Pliers, needle-nose Medium Wrenches, socket or open-end 3/8 in., 9/32 in. (or 7mm) REPAIR PROCEDURES Unless otherwise specified, reassembling should be performed in the reverse order of disassembly.
DRAM SIMM AND ROM MODULE REMOVAL To install or remove and replace a module, perform the following steps: 1. Using a small flat blade or Torx T10 screwdriver, remove the four screws that attach the cover plate to the back of the plotter and remove the cover plate. See Figure 6-1. Cover Plate (C)C2858-32 Figure 6-1. 2. After removing the cover plate, you will see four module slots: 2 larger ROM expansion slots above 2 smaller DRAM SIMM memory expansion slots. 3.
MIO CARD REMOVAL To install or remove and replace an MIO card, refer to Figure 6-2 and perform the following steps: 1. If an MIO card is not already installed, use a small flat blade or Torx T10 screwdriver to remove the two screws that attach the cover plate to the top back of the plotter. Remove the cover plate. 2. If an MIO card is already installed, loosen the MIO card thumbscrews. Carefully pull the MIO card straight up and remove the MIO card from the plotter. 3.
ELECTRONICS ENCLOSURE COVER REMOVAL To remove the electronics enclosure cover, perform the following procedure: 1. Switch the plotter OFF and disconnect the ac power cord and interface cable from the plotter. 2. If a modular input/output (MIO) card is installed, remove the MIO from the plotter. 3. Using a TORX T-15 screwdriver, remove the rear sideplate trim pieces and electronics enclosure cover shown in Figure 6-3. The C2858A has 10 cover screws and the C2859A has 12 cover screws.
INTERCONNECT PCA REMOVAL To remove the interconnect PCA, refer to Figure 6-4 and perform the following steps: 1. Remove the electronic enclosure cover. Note The cable connectors disconnected in the next step are labeled “P” for paper axis and “C” for carriage axis. Note the orientation of the cable connectors for assembly. 2. Disconnect the paper axis and carriage axis connectors from the interconnect PCA. 3.
MAIN PCA REMOVAL To remove the main PCA, perform the following procedure: 1. Remove the electronic enclosure cover. 2. Remove the interconnect PCA. 3. Using a 3/16” nut driver, remove the two screws on top of the electronics enclosure from the RS-232-C connector. 4. Using a TORX T-10 screwdriver, remove the two screws on top of the electronics enclosure from the parallel connector. 5. Disconnect all the cable connectors from the main PCA. 6.
Screws (12) Nuts (2) (C)C2858-44 EPROMs X-axis Encoder RS-232-C Fan Parallel Media Sensor Trailing Cable Pinch Wheel Sensor Front Panel Interconnect PCA Drop Sensor Main PCA Cable Connectors (L)C2858-3 Figure 6-5. 6-10 Removal and Replacement Power Dist.
OUTER ELECTRONICS ENCLOSURE ASSEMBLY REMOVAL (C2858A ONLY) To remove the outer electronics enclosure assembly, perform the following procedure: 1. Remove the electronics enclosure cover. 2. Disconnect all the cables from the PCAs shown in Figure 6-6. 3. Using a Torx T-15 screwdriver, remove the bottom three, and loosen the top three, electronics enclosure assembly screws shown in Figure 6-6. 4.
POWER SUPPLY PCA REMOVAL To remove the power supply PCA, perform the following procedure: 1. Remove the electronics enclosure cover. 2. For model C2858A plotters, remove the outer electronics enclosure assembly. 3. Remove the flexible, DANGER HIGH VOLTAGE, protective cover from the electronics enclosure. Carefully flex the cover and pull it out of the plotter. 4. Disconnect the ac connector and the dc power distribution connector at the power supply PCA. 5.
FAN REMOVAL To remove the fan, refer to Figure 6-8 and perform the following procedure: 1. Remove the electronic enclosure cover. 2. Disconnect the fan connector at the main PCA. 3. For model C2858A plotters, remove the outer electronics enclosure assembly. 4. Using a TORX T-10 screwdriver, remove the two screws that secure the fan to the electronics enclosure assembly. See Figure 6-8. 5. Lift the fan clear of the plotter. Fan Connector Fan Screws (2) (C)C2858-44 Figure 6-8.
WINDOW ASSEMBLY REMOVAL To remove the window assembly, perform the following steps: 1. Using a TORX T-15 screwdriver, remove the left and right rear trim pieces from the plotter. 2. Using a TORX T-15 screwdriver, remove the two screws that connect the window assembly to the back panel. See Figure 6-9. CAUTION 3.
ENDCOVERS (LEFT AND RIGHT) REMOVAL To remove the endcovers, perform the following procedure: 1. Raise the plotter window to the open position. 2. Remove the window assembly. 3. Lower the rollfeed cover to the open position. 4. Using a TORX T-15 screwdriver, remove the two front screws that connect each endcover and front sideplate trim to the plotter. See Figure 6-10. 5. Using a TORX T-15 screwdriver, remove the bottom rear screw (hidden) that connects each endcover to the sideplate.
Left Front Trim Right Front Trim Screw Screw Screw Screw (C)C2858-37 (C)C2858-38 (C)C2858-33 (C)C2858-34 Bottom Right Screw (hidden) Bottom Left Screw (hidden) Figure 6-10.
PRIMER ASSEMBLY AND SENSOR REMOVAL To remove the primer assembly and sensor, perform the following steps: 1. Remove the window assembly. 2. Remove the left endcover. 3. Disconnect the primer assembly and sensor cable connector. 4. Disconnect the four rubber tubes from the primer assembly. 5. Using a TORX T-20 and extension bit, remove the two bottom screws and loosen the top screw, that attach the primer assembly to the left sideplate. See Figure 6-11. 6. Slide the primer assembly out from the plotter. 7.
PINCH WHEEL SENSOR REMOVAL To remove the pinch wheel sensor, perform the following procedure: 1. Remove the electronic enclosure cover. 2. Remove the right endcover. 3. Disconnect the pinch wheel sensor cable connector from the main PCA. 4. Pull the pinch wheel sensor cable clear of any clamps. 5. Using a Torx T-10 screwdriver, remove the two screws that attach the toroid to the bracket. See Figure 6-12. 6.
WINDOW SENSOR REMOVAL To remove the window sensor, perform the following procedure: 1. Remove the right endcover. 2. Disconnect the window sensor cable connector from the front panel PCA. 3. Using a TORX T-8 screwdriver, remove the two screws that attach the window sensor to the right sideplate and lift the sensor clear of the plotter. See Figure 6-13. Don’t cross-thread or over-tighten the screws when installing. Window Sensor Cable Window Sensor (C)C2858-49b Figure 6-13.
MEDIA SENSOR REMOVAL To remove the media sensor, perform the following steps: 1. Remove the electronics enclosure cover. 2. Disconnect the media sensor cable connector from the main PCA. 3. Remove the right endcover. 4. Using a TORX T-10 screwdriver, remove the screw that attaches the media sensor to the entry platen. The screw is accessible from underneath the entry platen. 5. Remove the sensor through the access hole in the right sideplate. See Figure 6-14.
TRAILING CABLE REMOVAL While removing the trailing cable, see Figure 6-15. To remove the trailing cable, perform the following procedure: 1. Remove the window assembly. 2. For models C2858A, remove the main PCA. For models C2859A, remove the outer electronics enclosure assembly. 3. Using a TORX T-10 screwdriver, remove the two screws that attach the toroid to the rear of the electronics enclosure assembly. 4. Separate the two endcaps of the toroid and remove the toroid from the trailing cable. 5.
Toroid Toroid Endcaps Trailing Cable (C)C2858-62 Trailing Cable Rear Tray Screws (5) (C)C2858-42 Carriage PCA Trailing Cable Connector Bracket Screw (C)C2858-77 Figure 6-15.
BACK PANEL REMOVAL To remove the back panel, perform the following procedure: 1. Remove the window assembly. 2. Using a TORX T-15 screwdriver, remove the 5 screws that attach the trailing cable rear tray to the back panel. 3. Using a TORX T-15 screwdriver, remove the screws that attach the back panel to the electronics enclosure assembly. The C2858A has three screws and the C2859A has four screws. Lift the back panel clear of the plotter.
FRONT PANEL ASSEMBLY REMOVAL To remove the front panel assembly, perform the following procedure: 1. Remove the right endcover. 2. Disconnect the window sensor connector and the front panel cable connector from the front panel assembly. See Figure 6-17. 3. Release the front panel cable from the clamp on the front panel assembly. 4. Using a TORX T-20 screwdriver, loosen the three screws that connect the front panel assembly to the right sideplate and slide the front panel assembly clear of the plotter.
CARRIAGE MOTOR REMOVAL To remove the carriage motor, perform the following steps: 1. Remove the right endcover. 2. Remove the electronics enclosure cover. 3. Disconnect the carriage motor cable connector (labeled C) from the interconnect PCA. 4. Press the small drive belt against the tensioner wheel in the belt tensioner to loosen the belt and slide the belt off of the motor gear. See Figure 6-18. 5. Carefully release the tensioner wheel. 6.
PAPER MOTOR REMOVAL Note The drive roller gear and paper motor must be replaced at the same time. To remove the paper motor and drive roller gear, perform the following procedure: 1. Remove the right endcover. 2. Remove the electronics enclosure cover. 3. Remove the carriage motor. 4. Remove the front panel assembly. 5. Disconnect the paper motor cable connector (labeled P) from the interconnect PCA. 6. Disconnect the encoder cable connector from the paper motor. See Figure 6-19.
Mark must face toward front of plotter when paper motor is fully installed Paper Motor Encoder Connector Drive Roller Gear Paper Motor Worm Gear (C)C2858-47a Front View (C)C2858-66 Motor Screws (2) Figure 6-19.
ENCODER STRIP REMOVAL To remove the encoder strip, refer to Figure 6-20 and perform the following steps: 1. Remove the window assembly. 2. Remove the left and right endcovers. WARNING 3. Using a 5.5 mm nut driver, remove the nut and washer that secure the encoder strip to the right side encoder spring-bracket. See Figure 6-20. 4. Using a 5.
Nut and Washer Ground Strap Service Station Left Side (C)C2858-76 Nut and Washer Encoder Spring Encoder Spring Bracket Encoder Strip Right Side (C)C2858-47a Figure 6-20.
ROLLFEED COVER ASSEMBLY REMOVAL To remove the rollfeed cover assembly, perform the following procedure: 1. Lower and hold the rollfeed cover about halfway open. WARNING 2. Using a TORX T-10 screwdriver, remove the screws and washers that attach the left and right springs to the pivot spring anchor pins. See Figure 6-21. 3.
ROLLFEED MODULE ASSEMBLIES (LEFT AND RIGHT) REMOVAL To remove the left or right rollfeed module assembly, perform the following procedure: 1. Remove the appropriate left or right endcover as required. 2. Remove the rollfeed cover assembly. 3. Using a TORX T-20 screwdriver, remove the three screws that secure the rollfeed module assembly to the sideplate. See Figure 6-22.
CUTTER ASSEMBLY REMOVAL To remove the cutter assembly, refer to Figure 6-23 and perform the following steps: 1. Remove the right endcover. 2. Using a 5.5 mm nut driver, remove the nut and washer that hold the right end of the encoder strip to the encoder strip spring-bracket. 3. Press the encoder strip spring-bracket inward and release the encoder strip from the spring-bracket. 4. Using a TORX T-15 screwdriver, remove the encoder spring bracket. Note The cutter carriage preload arms are spring-loaded.
Bottom Finger of Cutter Assembly Slider Rod Bushing Starguard Upper Wheels Cutter Blade Linear Blade Lower Wheels Side View Overdrive Support Assembly (C)C2858-55 Starguard Cutter Blade Cutter Assembly Right Pre-load Arm Overdrive Support Assembly (C)C2858-66 Linear Cutter Blade Front View Figure 6-23.
TRAILING CABLE GUIDE REMOVAL To remove the trailing cable guide, perform the following steps: 1. Remove the left and right endcovers. 2. Using a TORX T-15 screwdriver, remove the screw that attaches the ground strap and trailing cable guide to the tensioner housing. See Figure 6-24. CAUTION 3. Using a TORX T-15 screwdriver, remove the screw inside the ferrite ring that attaches the trailing cable guide to the Y-drive bracket. 4.
Trailing Cable Guide Front Guide Screw Tensioner Housing (C)C2858-53 Left Side Ferrite Ring Screw (Inside Ring) Trailing Cable Guide Y-drive bracket (C)C2858-73 Right Side Figure 6-24.
Y-TENSIONER AND HOUSING REMOVAL To remove the Y-tensioner and housing, perform the following procedure: 1. Remove the left endcover. 2. Slide the pen carriage a few inches towards the center of the plotter in order to access the tensioner. 3. Remove the trailing cable guide screw which attaches the guide to the tensioner housing. 4. Using a TORX T-15 screwdriver, remove the tensioner plate screw. See Figure 6-25.
Main Idler Trailing Cable Guide Guide Screw Y-Tensioner Housing Y-Tensioner Spring Y-Tensioner Housing Screw Y-Tensioner Bracket Tensioner Plate Screw (C)C2858-53 Y-Tensioner Tensioner Plate Figure 6-25.
PEN CARRIAGE ASSEMBLY AND MAIN DRIVE BELT REMOVAL To remove the pen carriage assembly, see Figure 6-26 and perform the following procedure: 1. Remove the window assembly. 2. Remove the left and right endcovers. 3. Disconnect the trailing cable from the carriage PCA. 4. Using a TORX T-15 screwdriver, remove the screw that secures the trailing cable bracket to the pen carriage assembly and lift the trailing cable assembly clear of the pen carriage assembly. 5. Remove the trailing cable guide. 6.
Carriage PCA Trailing Cable Bracket Trailing Cable Connector (C)C2858-77 Encoder Strip Nut & Washer Encoder Strip Spring Encoder Strip Encoder Strip Bracket Small Drive Belt Cutter Assembly Y-Drive Bracket (C)C2858-47a Figure 6-26.
DROP DETECT AND BAIL SENSORS REMOVAL To remove the drop detect or bail sensor, refer to Figure 6-27 and perform the following procedure: 1. Remove the window assembly. 2. Remove the left endcover. 3. Move the pen carriage to the middle of the platen. 4. Disconnect the drop detect sensor cable connector from the wire harness. Release the drop detect sensor cable from the Y-tensioner bracket and let the cable hang down. 5.
Service Station Cover Sled Drop Detect Sensor (C)C2858-78 Bail Sensor Screws (4) Service Station Housing Figure 6-27.
STARGUARD ASSEMBLY REMOVAL To remove the starguard assembly, perform the following procedure: 1. Remove the window assembly. 2. Remove the left and right endcovers. 3. Remove the cutter assembly. 4. Remove the front panel assembly. 5. Using a TORX T-20 screwdriver, loosen the upper of the two screws that attach the the starguard assembly to the left and right sideplates until the ends of the screws are flush with the inner surfaces of the sideplates. See Figure 6-28. 6.
BAIL ASSEMBLY REMOVAL To remove the bail assembly, perform the following procedure: 1. Raise the window and move the pen carriage assembly to the extreme left. 2. Slide the cutter assembly to the extreme right. 3. Using a TORX T-15 screwdriver, remove the three screws at the left and right ends of the bail that attach the bail to the left and right bail brackets. See Figure 6-29. 4. Lift the bail up and clear of the plotter. (C)C2858-11 Bail Screws (3 Each End) (C)C2858-11 Figure 6-29.
SERVICE STATION ASSEMBLY REMOVAL To remove the service station assembly, see Figure 6-30 and perform the following procedure: 1. Remove the window assembly. 2. Remove the left endcover. 3. Move the pen carriage to the center of its travel. 4. Using a 5.5 mm nut driver, remove the nut and washer that attach the ground strap and encoder strip to the service station housing. 5. Remove the encoder strip from the service station assembly. 6. Disconnect the four rubber tubes from the primer assembly. 7.
To install the sled during reassembly, see Figure 6-30 and do the following: 1. Set the sled springs to their full upright position with the curved part of the springs resting against the stops inside the service station housing. 2. Feed the rubber tubes through the slot in the bottom of the service station housing while lowering the sled into position. Ensure that the outer two tubes go on the outside of the springs while the inner two tubes go through the gap between the springs. 3.
Wiper Cap Sled (C)C2858-79 Sled Rubber Tubes Through Sled Springs: (middle tubes between springs, outer tubes outside of springs) Tubes Through Slot In Bottom Of Service Station Housing (C)C2858-80 Stops Sled Springs Drop Detect Sensor Bail Sensor (C)C2858-81 Figure 6-30.
OVERDRIVE SUPPORT ASSEMBLY REMOVAL To remove the overdrive support assembly, perform the following procedure: 1. Remove the window assembly. 2. Remove the left and right endcovers. 3. Remove the encoder strip. 4. Remove the front panel assembly. 5. Remove the cutter assembly. 6. Remove the bail assembly. 7. Remove the service station assembly. 8. Using a TORX T-15 screwdriver, remove the gear shoulder screw that secures the overdrive cluster gear to the left sideplate. See Figure 6-31. 9.
Overdrive Assembly Shaft Overdrive Assembly Clutch Shoulder Screw Overdrive Cluster Gear (C)C2858-10 Clutch Retainer Left Side Overdrive Support Mount Screw (C)C2858-14 Overdrive Support Mount Right Side Screw (C)C2858-12 Figure 6-31.
CUTTER ENCLOSURE ASSEMBLY REMOVAL To remove the cutter enclosure assembly, perform the following procedure: 1. Using a TORX T-15 screwdriver, remove the screws that attach the front trim pieces to the left and right sideplates. Remove the front trim pieces. 2. Remove the overdrive support assembly. 3. Using a TORX T-15 screwdriver, remove the upper of the two screws that attach the left and right ends of the cutter enclosure assembly to the left and right sideplates. See Figure 6-32. 4.
(C)C2858-71 Media Guides C2858A (3) C2859A (4) Cutter Enclosure Assembly Upper Screw Left Side Wedge Screw (C)C2858-31b Upper Screw Right Side Wedge Screw (C)C2858-3 Figure 6-32.
ENTRY PLATEN ASSEMBLY REMOVAL To remove the entry platen assembly, perform the following procedure: 1. Remove the window assembly. 2. Remove the left and right endcovers. 3. Remove the electronics enclosure cover. 4. Disconnect the media sensor cable from the main PCA. 5. Disengage the media sensor cable from all clamps and remove the media sensor from the entry platen. 6. Lower the rollfeed cover to the open position. 7.
5. When correctly installed, the right side of the entry platen will be against the right sideplate and the top of the platen should be against the top reference pins in the left and right sideplates. Wedge Screw Left Side Top Screw (C)C2858-31b Pinch Arm Lift Lever Screw Rear Locating Pins (Outside View) Front Locating Pin (Outside View) Top Screw Wedge Screw Right Side (C)C2858-30b Figure 6-33.
DRIVE ROLLER ASSEMBLY REMOVAL While removing the drive roller assembly, see Figure 6-34. To remove the platen roller assembly, perform the following procedure: 1. Remove the window assembly. 2. Remove the left and right endcovers. 3. Remove the encoder strip. 4. Remove the bail assembly. 5. Remove the overdrive support assembly. 6. Remove the carriage drive motor assembly. 7. Remove the paper drive motor assembly. 8.
Drive Roller Assembly Drive Roller Gear Left Side (C)C2858-10 Screws (2) Right Side Paper Drive Motor Drive Roller Worm Gear (C)C2858-49c Paper Motor Screws (3) Drive Roller Collar Screws (2) (C)C2858-3 Drive Roller Bearing Axial Bias Plate (C)C2858-27 Figure 6-34.
AUTOMATIC BAIL LIFT MECHANISM REMOVAL To remove the bail lift mechanism, perform the following steps: 1. Remove the window assembly. 2. Remove the left and right endcovers. 3. Remove the encoder strip. 4. Remove the bail assembly. 5. Remove the overdrive support assembly. 6. Remove the drive roller assembly. 7. Using needle-nose pliers, remove the engagement lever spring. See Figure 6-35. 8. Using a TORX T-10 screwdriver, remove the engagement lever screw from inside the left sideplate.
MEDIA DIVERTER REMOVAL To remove the media diverters, perform the following procedure: 1. Remove the window assembly. 2. Remove the left and right endcovers. 3. Remove the encoder strip. 4. Remove the bail assembly. 5. Remove the overdrive support assembly. 6. Remove the drive roller assembly. The media diverters are made of a clear plastic. Observe that the long tab on each of the media diverters is oriented vertically and toward the left side of the plotter before performing the next step. 7.
PINCH ARM AND LIFT MECHANISM REMOVAL To remove the pinch arm lift mechanism, perform the following procedure: 1. Remove the window assembly. 2. Remove the left and right endcovers. 3. Remove the encoder strip. 4. Remove the bail assembly. 5. Remove the overdrive support assembly. 6. Remove the drive roller assembly. 7. Place the manual lift lever in the “down” position. 8. Disconnect the rocker plate tension spring to relieve any remaining tension on the pinch arm lift mechanism. See Figure 6-37. 9.
To install, place the pinch arm assembly spring into its bushing. Insert the front end of the spring into the hole in the pinch arm assembly with the pinch arm 90 degrees from its normal position. Press the pinch arm assembly back and rotate it to the vertical position. Then slide the cam bar to the right until the pinch arm assembly is captured in the chassis. The cam bar must be positioned between the left and right sideplates or the lift mechanism will not work.
Chapter 7 Adjustments/Calibrations INTRODUCTION This chapter describes any adjustments and/or calibration procedures to be performed on Models C2858A and C2859A DesignJet 650C plotters. Also provided is a listing of when each procedure is required. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibrations . .
ADJUSTMENTS There are no electrical or mechanical adjustments required on the HP C2858A and C2859A DesignJet 650C plotters. CALIBRATIONS DesignJet 650C plotters have several calibration procedures that must be performed under certain conditions. Refer to Table 7-1 to determine when calibrations are required. Table 7-1.
All calibration procedures are accessible through the front panel menu structure. Procedures accessed by users are available through the “Utilities” main menu. These procedures include Pen Alignment and Accuracy submenus. The Accuracy submenu contains two lower submenus, Restore Factory settings and Recalibrate procedures. The Config Plot function, also located in the “Utilities” menu, is used in conjunction with the Accuracy procedures for comparison purposes.
ACCURACY CALIBRATION Performance of these accuracy procedures allow you to either restore the plotter to the factory accuracy settings or to recalibrate the plotter to the current environment. Accuracy calibration constants are stored in the plotter EEROM. When performing the accuracy calibration from the “Service Test” menu, the factory correction value will be recalculated. This will be the new factory default calibration value.
3. Press Enter at the “Status” display. 4. Use the arrow buttons to scroll to the “Utilities” main menu. Press Enter. If not already set to Full menu mode, scroll to Full and press Enter. 5. User accuracy: Service accuracy: Scroll to the “Accuracy” submenu. Press Enter. Simultaneously press the Enter and Up Arrow buttons. 6. User accuracy: Service accuracy: Scroll to the “Recalibrate” submenu. Press Enter. Scroll to the “Accuracy Calib” submenu. Press Enter.
MEDIA SENSOR CALIBRATION This procedure calibrates the optical media sensor threshold value stored in the EEROM. The value represents what the sensor should detect without media present. Perform the media sensor calibration whenever the: Media Sensor Calibration is accessible through the “Service Tests” menu.
DROP DETECT CALIBRATION In this procedure, the position of the drop detect sensor relative to the four print cartridges is calibrated. Four values are calculated and stored in the plotter EEROM. Perform the drop detect calibration whenever the: the EEROM is cleared or replaced drop detect sensor is removed or replaced pen checking algorithm continues to reject pens service station is removed or replaced Drop Detect Calibration is accessible through the “Service Tests” menu.
EDGE SENSE CALIBRATION The edge sense calibration is used to calibrate the intensity of the line sensor in the carriage PCA. A flag is cleared and set in the EEROM after the calibration and is used until recalibrated. An improper calibration can result in edge detection failures during media loading. The pen alignment procedure is also performed as a part of this calibration.
BAIL CALIBRATION In this procedure, the ‘up’ position of the bail assembly is calibrated. A value is stored in the EEROM when the procedure is completed. Perform the bail calibration whenever the: Bail Calibration is accessible through the “Service Tests” menu. To perform the bail calibration, do the following: 1. Press Enter at the “Status” display. 2. Use the arrow buttons to scroll to the “Utilities” main menu. Press Enter. 3.
Notes 7-10 Adjustments/Calibrations
Chapter 8 Troubleshooting INTRODUCTION This chapter contains diagnostic instructions, error codes and messages, service tests, and troubleshooting information for use as an aid in solving Model C2858A and C2859A DesignJet 650C plotter symptoms and failures. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTICS Several types of built-in diagnostic and service tests reside in the DesignJet 650C plotters. These troubleshooting aids include power-on self tests and mechanical initialization routines. In addition, worded error messages; system error codes; and internal service menu tests are provided. POWER-ON SELF TESTS HP C2858A/9A DesignJet 650C plotters will automatically perform a series of internal self tests, as well as certain initialization sequences, whenever the plotter is switched ON.
a. The EEROM checksum is tested. If this portion of the test fails, clear or reĆ place the EEROM and run the calibration adjustments described in chapter 7. If replacing the EEROM and running the adjustments does not fix the problem, replace the main PCA. b. The servo processor transfer buffer and interrupt tracking abilities are tested. If this test fails, replace the main PCA. c. Another communication test between the processors is performed. Check the trailing cable and connect or replace it.
ERROR MESSAGES AND CODES Two types of error messages can be viewed in the front panel display: WORDED ERROR MESSAGES Worded error messages indicate that a user error or an internal error has occurred. Some error messages require action to clear, and others are only displayed until the next operation is performed by the plotter. See Table 8-1. Table 8-1.
Table 8-1. Worded Error Messages (Continued) Message Error/Action Media too small Media loaded for accuracy calibration or pen alignment is too small. Reload appropriate media. Mispositioned Reload roll Roll is mispositioned. Unload roll media. Open the roll cover and push the media roll all the way to the right so that it is flush against the media stop on the roll core. Reload media with the right edge no more than 0.2 inches (0.5 cm) from the perforated line on the entry platen.
Table 8-1. Worded Error Messages (Continued) Message Error/Action Roll misaligned Reload roll Roll media is skewed. Unload roll media. Open the roll cover and push the media roll all the way to the right so that it is flush against the media stop on the roll core. Reload, making sure that the left/right media edges are even with the left/right roll core edges. RS-232 error Baud, parity The RS-232-C interface is configured incorrectly.
SYSTEM ERROR CODES System error codes are hexadecimal-based numbers generally caused by internal system errors. See Table 8-2 for a list of system error codes and their respective descriptions and recommended corrective actions. Table 8-2. System Error Codes Error Code Problem Description Corrective Actions 010001 Window sensor circuitry not operating correctly. Check window sensor switch. Check that the sensor cable is connected to the front panel PCA.
Table 8-2. System Error Codes (Continued) Error Code 8-8 Problem Description Corrective Actions 010024 Pen interface ASIC test failure. Replace main PCA. 010025 Communication failure between the main and servo processors. Communication occurs through the processor support ASIC. Replace main PCA. 010026 Replace main PCA. Servo interrupts not occurring or not reaching the main processor through the processor support ASIC. 010027 Error in servo drive calculations. Replace main PCA.
Table 8-2. System Error Codes (Continued) Error Code Problem Description Corrective Actions 010041 Error detected in Y-axis servo feedback loop. Check encoder strip, carriage assembly, trailing cable, main PCA. 010050 Uppermost SIMM indicates a failure. Replace uppermost SIMM. 010051 Next to uppermost SIMM indicates a failure. Replace next to uppermost SIMM. 010052 Both upper and lower SIMMs indicate a failure. Replace both upper and lower SIMMs. 010080 RS-232-C data overflow.
Table 8-2. System Error Codes (Continued) Error Code 8-10 Problem Description Corrective Actions 05xxxx Plotter system errors found. MIO problem is indicated. The most likely cause is the main PCA or the interconnect PCA. Replace the interconnect PCA. Replace the main PCA. 060111 Line sensor LED not bright enough. The optical sensor on the carriage has failed to locate lines drawn during the pen calibration routine. Reduce the ambient light.
DISPLAY DATA PLOT Display data is a plot feature, located under the “Utilities Menu’, that allows you to plot the first and last 1000 bytes of graphic instructions of a plot file sent. This feature can be used to ensure proper data reception. The instructions will be plotted in ASCII. format. To use the Display Data feature, do the following: 1. Remove any media from the plotter and make sure the plot queue is empty. 2. Enter the “Utilities” menu and select “Display Data”.
TROUBLESHOOTING TIPS Certain failures, such as the media sensor and pinchwheel sensor, will not allow access to the service menu after the normal initialization process occurs. The front panel will be locked at this point. To alleviate this situation, perform the following steps: 1. Unload media (if present). 2. Switch OFF the plotter. 3. Simultaneously press the ENTER and UP ARROW buttons while switching ON the plotter.
SERVICE TESTS HP DesignJet 650C plotters have numerous internal service tests that can be used in troubleshooting. To access the service tests menu, perform the following steps: 1. Switch the plotter ON. Note Certain plotter failures that can occur will prevent the plotter from reaching the “STATUS Ready for Media” state. If one of these problems occurs, switch the plotter OFF. Press and hold down the ENTER and the UP ARROW buttons while switching the plotter ON. This will allow access to the service tests.
Table 8-3. Service Tests Test Description Assemblies Tested EEROM (Clear) Allows you to either clear or test the EEROM. Clearing defaults all set-up values, clears calibration values and calculates a new EEROM checksum. The EEROM should only be cleared in event of a checksum failure. After clearing, cycle power without media, and do the following calibrations in the order listed: bail calibration, media sensor calibration, drop detect sensor calibration, edge sensor calibration and accuracy calibration.
Table 8-3. Service Tests (Continued) Test Description Assemblies Tested Parallel I/O The data and status registers of the Centronics PAL are read. A successful test completes very quickly (<1 s). “PASS TEST PRESS ENTER” will be indicated. If the test fails, the system will hang up. A system error error code will NOT be displayed, and power to the plotter must be recycled. This tests only a small portion of the Centronics I/O functionality. To EXIT, press ENTER button.
Table 8-3. Service Tests (Continued) Test Description Assemblies Tested Primer Verifies the ability of the primer to select individual pens and run the pump for testing priming capability. Also tests the optical sensor’s ability to initialize the primer cam. Pens Primer Assembly Optical Sensor Pen Continuity Checks for proper interconnection between all four pens and the carriage. Uses a matrix of primitives (PS) and addresses (Addr Sel) to select nozzles to fire and determine pen ID.
Table 8-3. Service Tests (Continued) Test Description Assemblies Tested Cover Sensor Verifies the operation of the window interlock microswitch. After the test is selected, manually raise and lower the window The display should change as the window is raised and lowered. Stop the test by pressing the DOWN ARROW button. Window Sensor Switch Sensor Switch Path to Main PCA Edge Detect Verifies operation of the optical sensor in the pen carriage.
Table 8-3. Service Tests (Continued) Test Description Assemblies Tested Cutter Verifies operation of the cutter. Allows either single or continuous cut operation. An offset value can be entered to determine how much margin the cutter system has. Cutter Assembly Pen Carriage/ Cutter Assembly Operation Rotary Blade Overdrive Support Assembly Button Test The display indicates which button the servo processor interprets as being pressed. Button code is matched against a look-up table.
CONFIGURATION PLOT The configuration plot aids in the analysis of plotter problems by providing: a hardclip border around the plot so the margins can be measured. unique patterns for use in detecting pen nozzle problems, penĆtoĆpen alignĆ ment problems, ink flow problems and vertical line straightness. four, XĆshaped marks (crosshairs) for measuring plotter penĆtoĆpen accuracy (The centers of the crosshairs should be 500 mm apart) . pen/palette set up information.
10. The “busy” LED on the front panel will light to show that a configuration plot is being generated, the pens will be tested at the service station, and the configuration plot will automatically run to completion. BAR PATTERN ANALYSIS The configuration plot has several special diagnostic features built in. The four sets of color bars printed along the top represent the four specific pen locations being checked.
READING THE EEROM TEXT BLOCK Contents of the EEROM IC are printed during the configuration plot in hexadecimal form. Sample portions of the EEROM contents block and the pen nozzle test block are presented in the following pages of this chapter to assist you in interpreting the configuration plot results. To read the EEROM contents block, perform the following steps. 1. Examine the sample EEROM memory map (Table 8-4) to find the memory address of the data you want to read. 2.
Table 8-4.
Table 8-4.
Table 8-4.
A sample portion of the memory location key is provided in Table 8-5. Use it as a key to the EEROM memory text block on the configuration plot. The first column depicts the block of text shown on the plot and in Table 8-6, but the remaining blocks show the memory location number instead of the contents at each position on the text block. Table 8-5.
The block of text on the configuration plot that shows the contents of the EEROM appears in the form shown in Table 8-6. This table is a sample portion of the text block from a configuration plot. The contents of the EEROM that you are testing may differ from this sample. Table 8-6.
Chapter 9 Product History INTRODUCTION This chapter describes the differences between earlier versions of the HP C2858A/C2859A DesignJet 650C plotters and the latest version documented in this manual. Versions are identified by their serial number and the date codes on their printed-circuit assemblies (PCAs). Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 History of Assemblies by Serial Number . . . . . . . . . . . . . . . . .
HISTORY OF ASSEMBLIES BY SERIAL NUMBER C2858A and C2859A plotters use a serial number format as follows: USAxxyyyyy where; US indicates country of manufacture, A indicates the plotter revision level, xx indicates the month (1-9, A, B, C) and week (1-4) of manufacture, and the remaining digits (y-y) are the individual sequential numbers of the plotters as they are manufactured.
HISTORY OF PRINTED-CIRCUIT ASSEMBLIES Hewlett-Packard’s PCAs have three major identification features: Part Number. PCAs having the same part number are directly interchangeable. If a PCA is revised in any way that makes it non-interchangeable with previously issued PCAs of a particular part number, a new part number is assigned to the revised PCA. Revision Letter. This letter identifies the most recent revision to the etched circuit pattern. The original issue is identified with the letter A.
Notes 9-4 Product History
Chapter 10 Parts and Diagrams INTRODUCTION This chapter contains information for locating, identifying and ordering replacement parts for the HP C2858A and C2859A plotters. Parts lists with associated illustrated parts breakdown drawings are provided. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exchange Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . .
EXCHANGE ASSEMBLIES Factory rebuilt assemblies that can be exchanged are listed in the following Table. Exchange, factory repaired and tested, assemblies are available only on a trade-in basis; therefore, the defective assemblies must be returned for credit. Exchange Assemblies HP Part Number CD Qty C2858-69104 0 1 Description PCA, MAIN (REBUILT) REPLACEMENT PARTS Parts shown on the illustrated parts breakdown drawings in this chapter are listed in the associated parts listings for the drawings.
Left Endcover and Trim See Page 10-13. C2858A Electronics Enclosure Assembly See Page 10-11. Right Endcover and Trim See Page 10-15. Carriage Axis Drive (Left End) See Page 10-19. C2859A Electronics Enclosure Assembly See Page 10-9. Primer and Service Station See Page 10-21. Window and Back Cover Assemblies See Page 10-7. Carriage Axis Drive (Right End) See Page 10-23. Paper Drive Assemblies See Page 10-27. Rollfeed Components See Page 10-17. Bail and Overdrive Support Assemblies See Page 10-29.
Parts List, Stand Assemblies Ref. Des.
1 2 3 3 4 1 8 3 5 3 9 9 3 3 7 6 3 (C)C2858–1–1 5 Stand Assemblies, Illustrated Parts Breakdown Parts and Diagrams 10-5
Parts List, Window and Back Cover Assemblies Ref. Des. HP Part Number C D Qty 1 2 3 4 5 C2858-60024 0620-0520 07575-40012 07575-40111 C2847-60008 C1633-60053 C2847-00009 C1633-00030 0624-0744 C2847-40003 C1633-40075 C2858-00011 C2859-00002 0515-0380 0515-0390 0515-2304 C2858-00005 5 3 2 2 2 7 7 4 3 5 1 4 3 2 4 9 6 1 1 2 2 1 1 1 1 4 1 1 1 1 2 5 6 1 6 7 8 9 10 11 12 13 10-6 Parts and Diagrams Description CABLE ASSEMBLY, TRAILING SCREW, 6-19 0.
4 3 5 6 4 3 To Main PCA 1 8 10 7 13 2 9 11 To Pen Carriage 7 Electronics Enclosure C2858A See Page 10-9. C2859A See Page 10-11.
Parts List, C2859A Electronics Enclosure Ref. Des.
(C)C2858-3-1 C2859A Electronics Enclosure, Illustrated Parts Breakdown Parts and Diagrams 10-9
Parts List, C2858A Electronics Enclosure Ref. Des.
(C)C2858-4-1 C2858A Electronics Enclosure, Illustrated Parts Breakdown Parts and Diagrams 10-11
Parts List, Left Endcover and Trim Ref. Des.
1 2 16 9 9 10 14 13 3 4 13 15 5 12 11 10 6 7 8 5 (C)C2858-5-1 Left Endcover and Trim, Illustrated Parts Breakdown Parts and Diagrams 10-13
Parts List, Right Endcover and Trim Ref. Des.
2 2 4 3 1 6 9 5 7 19 20 8 10 14 13 12 15 21 16 11 13 12 17 18 15 (C)C2858-6-1 Right Endcover and Trim, Illustrated Parts Breakdown Parts and Diagrams 10-15
Parts List, Rollfeed Components Ref. Des.
8 5 2 7 4 3 12 6 8 9 5 4 2 3 1 10 11 (C)C2858-7-1 Rollfeed Components, Illustrated Parts Breakdown Parts and Diagrams 10-17
Parts List, Carriage Axis Drive (Left End) Ref. Des.
7 6 6 8 5 6 4 9 3 1 2 11 15 16 10 17 21 14 18 13 9 12 9 Service Station See Page 10-21.
Parts List, Service Station Assembly Ref. Des.
9 6 8 5 7 10 12 11 4 1 2 3 (C)C2858-9-1 Service Station Assembly, Illustrated Parts Breakdown Parts and Diagrams 10-21
Parts List, Carriage Axis Drive (Right End) Ref. Des.
9 10 11 Pen Carriage Assembly See Page 10-25.
Parts List, Pen Carriage Assembly Ref. Des. HP Part Number C D Qty 1 2 3 4 5 6 7 8 9 10 C2858-60023 C2858-40016 C1633-80014 C2858-40017 0624-0737 C2858-60010 C2858-60014 07575-40013 07575-40014 C2847-00029 1500-0856 4 3 2 4 4 9 3 3 4 1 4 1 2 1 1 4 1 1 1 1 1 1 10-24 Parts and Diagrams Description PEN CARRIAGE ASSEMBLY BUSHING, FRONT SPRING, PRELOAD BUSHING, REAR SCREW, 2-28 X .
4 3 5 6 2 1 2 7 8 9 5 10 (C)C2858-11-1 Pen Carriage Assembly, Illustrated Parts Breakdown Parts and Diagrams 10-25
Parts List, Paper Drive Assemblies Ref. Des.
(C)C2858-12-1 Paper Drive Assemblies, Illustrated Parts Breakdown Parts and Diagrams 10-27
Parts List, Bail and Overdrive Support Assemblies Ref. Des.
(C)C2858-13-1 Bail and Overdrive Support Assemblies, Illustrated Parts Breakdown Parts and Diagrams 10-29
Parts List, Pincharm Assembly Ref. Des.
2 1 3 7 5 6 4 8 9 4 24 24 3 21 23 22 2 1 10 20 19 18 11 12 17 16 15 13 14 (C)C2858-14-1 Pincharm Assembly, Illustrated Parts Breakdown Parts and Diagrams 10-31
Parts List, Starwheel, Starguard and Chassis Assemblies Ref. Des.
(C)C2858-15-1 Starwheel, Starguard and Chassis Assemblies, Illustrated Parts Breakdown Parts and Diagrams 10-33
Labels Label Name Part Number Media Bin Front C2847-00036 Serial Number C2858-00018 Name Plate C2858-00017 Roll Loading C1633-00084 Carriage Warning C1633-00104 Power Supply Insulator C1633-00105 Carriage Stripes C1633-00107 Media Loading C1633-00131 Pen Alignment C1633-90009 Pen Color Code C2858-00019 Carriage PCA Media Sensor Trailing Cable C2858-60024 C2847-60019 Encoder Paper Motor C2847-60021 C2847-60003 Pinch Wheel Sensor C2847-60022 Main PCA 3160-0814 Fan C2847-60005
Glossary address The address specifies the plotter’s location on the HP-IB (IEEE-488) interface cable (bus). ASCII American Standard Code for Information Interchange. An 8-bit code that uses 7 bits to represent character data such as letters, punctuation, symbols, and control characters. Bit 8 can be used for parity. baud rate For an RS-232-C interface, the data transmission rate between a computer and a peripheral (bits per second).
IEEE 488-1978 interface A parallel interface standardized by Electronic Industries Association Standard 488-1978. initialize To set plotter conditions to known default values. interface Anything (a cable, for example) used to join components of a computer system so they function in a compatible and coordinated fashion. Also, standards which allow systems to connect with each other (e.g., HP-IB, RS-232-C). I/O error A data transmission error between a computer and a peripheral.
Index Accessories, 1Ć5 Back Panel, Removal, 6Ć23 Adjustments, 7Ć2 Bail, Automatic Lift Mechanism, Removal, 6Ć55 Analysis, Bar Pattern, 8Ć20 ASIC (Application Specific Integrated Circuit) Carriage, 5Ć2 Pen Interface, 5Ć2 Data, 5Ć3 Print Control, 5Ć6 Data, 5Ć6 Processor Support, 5Ć2 Assemblies, History of, 9Ć2 Assembly Bail, Removal, 6Ć43 Cutter, Removal, 6Ć32 Cutter Enclosure, Removal, 6Ć49 Drive Roller, Removal, 6Ć53 Entry Platen, Removal, 6Ć51 Front Panel, Removal, 6Ć24 Left Rollfeed Module, Remo
Configuration Plot, Description, 8Ć19 confirming a menu option, 3Ć19 Controller, DRAM, 5Ć2 Controllers, HPĆIB.
Handling Media, 1Ć3 Media Guidelines, 3Ć4 Housing, YĆTensioner, Removal, 6Ć36 Left Rollfeed Module Assembly, Removal, 6Ć31 Line Cord Set, 2Ć2 Required, 2Ć2 Line Sensor, 5Ć3 Description, 5Ć6 Linear Encoder, 5Ć2 Identification Procedures, 9Ć3 Indicators, LED, 5Ć7 Initialization, Mechanical, 8Ć3 Ink Cartridges, 1Ć2 Input/Output.
Media Diverter, Removal, 6Ć56 Media Sensor, Removal, 6Ć20 Memory Expansion Sockets, 1Ć4 Main PCA RAM, Information, 5Ć5 Main PCA ROM, Information, 5Ć5 PlugĆin, 1Ć4 RAM, 1Ć3 Single InĆline, 1Ć4 Menus, Front Panel, 3Ć20 Messages Error, 8Ć4 Front Panel, 3Ć22 MIO Ethertalk, 1Ć2 HPĆIB, 1Ć2 LAN Manager, 1Ć2 LocalTalk, 1Ć2 Novell ethernet. Input/Output TCP/IP. Input/Output Token Ring, 1Ć2 MIO Cards.
Pinch Arm and Lift Mechanism, Removal, 6Ć57 Pinch Wheel Sensor, Removal, 6Ć18 RAM (Random Access Memory), 1Ć3 Plot Configuration Description, 8Ć19 Steps, 8Ć19 Conversion, 5Ć5 Demonstration, Running, 3Ć26 Transfer, 5Ć2 Registers, 5Ć2 Processor Support ASIC, 5Ć2 Plotter Color, 1Ć2 Description, 1Ć2 Features, 1Ć3 InkĆjet, 1Ć2 Installing, 3Ć2 Languages, 5Ć2 HP/GL2, 5Ć2 RTL, 5Ć2 LargeĆformat, 1Ć2 Monochrome, 1Ć2 Sensors, 5Ć2 Plotting Modes Color, 3Ć18 Monochrome, 3Ć18 Power, 2Ć2 Power Supply Autoranging,
YĆaxis Motor, 6Ć25 YĆTensioner Housing, 6Ć36 Restrictions, Cable, 2Ć4 Centronics Interface, 2Ć4 HPĆIB Interface, 2Ć4 RSĆ232ĆC Interface, 2Ć4 Rollfeed, Plotting, 1Ć2 Rollfeed Cover Assembly, Removal, 6Ć30 ROM, Main PCA, Information, 5Ć5 Safety Considerations, 6Ć3 Strip, Encoder, Removal, 6Ć28 Swath, 5Ć5 Tensioner, Y, Housing, Removal, 6Ć36 Tests, Service, 8Ć13 Tools, Required, 6Ć4 Trailing Cable, Removal, 6Ć21 Trailing Cable Front Tray, Removal, 6Ć34 Tray, Trailing Cable Front, Removal, 6Ć34 Troublesh
