Ioline FlexJet Service Manual

pany. Other product names, logos, designs, titles, words or phrases mentioned within this publication may be trademarks, service marks, or trade names of Ioline Corporation or other entities and may be registered in certain jurisdictions including internationally. Ioline Disclaimer IOLINE CORPORATION PROVIDES THIS MANUAL “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OR CONDITIONS OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL IOLINE, ITS DIRECTORS, OFFICERS, EMPLOYEES OR AGENTS BE LIABLE FOR ANY INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES (INCLUDING DAMAGES FOR LOSS OF PROFITS, LOSS OF BUSINESS, LOSS OF USE OR DATA, INTERRUPTION OF BUSINESS AND THE LIKE), EVEN IF IOLINE HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES ARISING FROM ANY DEFECT OR ERROR IN THIS MANUAL OR PRODUCT. Limit of Liability Statement This manual is provided for informational purposes only. The contents are subject to change without notice and Ioline Corporation assumes no responsibility for any errors that may be contained herein. Ioline has made every effort to make the FlexJet easy to operate, maintain, and repair. It is the responsi- bility of the operator of the printer to monitor the performance of the printer and maintain it in proper working condition by following the instructions in this manual and in the FlexJet User Guide and to follow all safety precautions and warnings that are described in these publications. Ioline Corporation is not responsible for injuries that may occur as a result of unsafe use. Ioline Corporation is not responsible for substandard operational performance as a result of failure to maintain the printer as described in this manual and in the FlexJet User Guide. © 2003-2005 Ioline Corporation. All rights reserved. This manual may not be copied, photocopied, repro- duced, translated, transmitted or converted to any electronic or machine-readable form in whole or in part without prior written approval of Ioline Corporation. Service and Support If you require assistance with an Ioline product, your local Ioline dealer or authorized service center is ready to help. Support information is also available 24/7 on the Ioline Web site—or you may contact Ioline directly: Ioline Corporation 14140 NE 200th Street Woodinville, Washington 98072 U.S.A. Ioline Customer Service Department Monday through Friday 7:00 A.M. - 5:00 P.M. U.S. Pacific Time Voice: 1.425.398.8282 Fax: 1.425.398.8383 [email protected] www.ioline.com User Notice Part Number: (File) 108675 Rev. 0

Figure 1. Proper lifting procedures for the FlexJet ............................................................ xiii Figure 2. The Ioline FlexJet Printer front view ................................................................... xvi Figure 3. The Ioline FlexJet Printer rear view ................................................................... xvii Figure 4. The Ioline FlexJet Printer front view close-up ................................................ xviii Figure 5. The Ioline Flexjet ...................................................................................................... 19 Figure 6. Paper direction .......................................................................................................... 21 Figure 7. Carriage movement .................................................................................................. 21 Figure 8. Workflow: output direct from CAD software (without FlexPlot) ................23 Figure 9. Workflow using FlexPlot for file conversion and output .............................23 Figure 10. FlexJet Control Center main menu .................................................................. 25 Figure 11. The Ioline Flexjet power supply ............................................................................ 29 Figure 12. Rear power panel assembly .................................................................................... 29 Figure 13. Service Station assembly ......................................................................................... 30 Figure 14. Pinchwheel assembly ................................................................................................ 30 Figure 15. Ink cartridges: HP 51645A ...................................................................................... 30 Figure 16. FlexJet logic board (Rev 1, above; Rev 2 below) ................................................31 Figure 17. Carriage assembly with cover on .......................................................................... 32 Figure 18. Carriage assembly with cover off .......................................................................... 32 Figure 19. LED lights on the keypad ..................................................................................... 36 Figure 20. Keypad LED error codes .................................................................................. 36 Figure 21. The correct paper feeding path on the Ioline FlexJet Printer ........................42 Figure 22. HP cartridges have an ink level indicator .................................................44 Figure 23. The ink cartridge is dirty, dry, or empty .............................................................. 44 Figure 24. The ink cartridge requires cleaning ...................................................................... 45 Figure 25. Damaged and dirty print cartridge ....................................................................... 45 Figure 26. Use a deliberate frame gap to help calibrate ......................................................46 Figure 27. The Cartridge Calibration window in the Control Center ..................47 Figure 28. The Cartridge Alignment dialog box .................................................................... 47 Figure 29. Increase the alignment value for cartridge #2 to improve line quality .........47 Figure 30. Decrease the alignment value for cartridge #2 to improve line quality .......47 Figure 31. The Motion Adjust window .................................................................................... 48 Figure 32. The heads are drawing the lines too late on this plot ......................................48 Figure 33. The Frame Gap window .......................................................................................... 48 Figure 34. Frame gaps on the plot ............................................................................................ 49 Figure 35. Frame gaps may indicate that the FlexJet platen or stand is not level ..........49 Figure 36. The height-adjusting spacer .................................................................................... 49 Figure 37. The ink stall can crack if the cartridge door is not closed and locked ........50

Figure 39. Replacing the fuse ..................................................................................................... 51 Figure 40. A good transitor on the left; the one on the right is blown ...........................52 Figure 41. Testing the Y-Axis motor ......................................................................................... 54 Figure 42. Mechanical, electrical and electronic diagnostics flow chart ...........................61 Figure 43. Removing the right end cover ............................................................................... 64 Figure 44. Loosen the belt tensioner ....................................................................................... 64 Figure 45. The carriage cover screw ........................................................................................ 65 Figure 46. Unclip the belt from both ends of the carriage .................................................65 Figure 47. Loosen the carriage wheel lock ............................................................................. 66 Figure 48. Gently press down on the carriage ...................................................................... 66 Figure 49. Rotate the v-wheels free of the traverse rail .....................................................66 Figure 50. Carriage installation .................................................................................................. 67 Figure 51. Use the spacer when attaching each swing arm ................................................67 Figure 52. The carriage belt tensioner .................................................................................... 68 Figure 53. Install the carriage cover ......................................................................................... 68 Figure 54. Remove the cover .................................................................................................... 69 Figure 55. Install the carriage cover ......................................................................................... 70 Figure 56. Remove the logic board cover plate .................................................................... 70 Figure 57. Unplug the feed motor and encoder cables from the logic board ................71 Figure 58. Unplug the ribbon cables ........................................................................................ 71 Figure 59. Make a loop in the ribbon cable to the left of the carriage ............................72 Figure 60. Carriage installation .................................................................................................. 73 Figure 61. The carriage belt tensioner .................................................................................... 73 Figure 62. Install the carriage cover ......................................................................................... 74 Figure 63. There should be a small gap in the ribbon cable loop ......................................75 Figure 64. The loop in the cable should not touch the left endplate ...............................75 Figure 65. Secure the sleeving with tape ................................................................................. 76 Figure 66. Remove the right end cover ................................................................................... 77 Figure 67. Remove the screws and let the keypad hang .....................................................77 Figure 68. Remove the carriage cover ..................................................................................... 77 Figure 69. Install the ink cartridges and turn the power on ...............................................78 Figure 70. Loosen the carriage catch bracket ........................................................................ 78 Figure 71. Cover the spit wells ................................................................................................. 78 Figure 72. Two lines in the spit well holes .............................................................................. 79 Figure 73. Use the plastic thumbscrew to adjust the lines if necessary ..........................79 Figure 74. Y Fine adjustment is performed within the Control Center ......................80 Figure 75. Watch the gap between the carriage and Service Station ..........................80 Figure 76. The Service Station stop screw ........................................................................ 81 Figure 77. Small gap between the screw and the Service Station ................................82 Figure 78. Tighten the nut to hold the stop bracket ............................................................ 82 Figure 79. Unplug the take-up motor ...................................................................................... 83 Figure 80. Remove the right cover ........................................................................................... 83 Figure 81. Unscrew the PCB cover .......................................................................................... 83

Figure 83. Carefully unplug connections to the board ........................................................84 Figure 84. Carefully remove the logic board ......................................................................... 84 Figure 85. Inspect the connections to the logic board ........................................................85 Figure 86. Remove the keypad screws and bracket. Unplug the keypad cable ..............87 Figure 87. Tighten the screws on the Y-Axis transmission .................................................88

Safety & Cautions Warranty Policy Ioline warranty policy  ......................................................................................   xiv How to use this manual Where to find information  .................................................................................................   xv What’s in this Service Manual  ............................................................................  xv Visual Reference Guide Chapter 1 Overview Product overview  ......................................................................................................................   19 Supported languages  .............................................................................................................   19 Specifications  ..........................................................................................................................   20 How the FlexJet works  ........................................................................................................   21 Paper movement  ...................................................................................................................   21 Carriage movement  ..............................................................................................................   21 Serial number identification  ................................................................................................   21 Glossary  ..................................................................................................................................   22 Software setup options  ........................................................................................................   22 Power on  .......................................................................................................................................   24 Installing FlexPlot and the Control Center  .................................................................   24 The FlexJet Control Center  ................................................................................................   25 Overview  .................................................................................................................................   25 Changing system settings  .....................................................................................................   25 Control Center menu bar features  ..................................................................................   26 File  ............................................................................................................................................   26 Communications  ...................................................................................................................   26 Tools  .........................................................................................................................................   26 Help  ..........................................................................................................................................   26 Control Center menu options  ............................................................................................   27 Software Version  ....................................................................................................................   27 Cartridge Count  ....................................................................................................................   27 Get Plotter Data  ...................................................................................................................   27 Plotter Data (check box)  .....................................................................................................   27 Line Width  ..............................................................................................................................   27 Scale  ..........................................................................................................................................   27 Frame Size  ...............................................................................................................................   27

Measurement Units  ...............................................................................................................   28 Chapter 2 Nomenclature Product components  ..............................................................................................................   29 General troubleshooting  .......................................................................................................   33 Error messages  ..........................................................................................................................   33 Chapter 3 Troubleshooting & Testing Control Center software errors  ........................................................................................   34 Keypad error codes  ..................................................................................................................   36 Legend  ......................................................................................................................................   36 Power problems  ........................................................................................................................   37 Communications  ......................................................................................................................   37 The FlexJet won’t respond to the computer  ..................................................................   37 Serial communication  ............................................................................................................   37 Common problems  .................................................................................................................   38 Paper problems  .........................................................................................................................   42 Regular or intermittent paper tearing  ..............................................................................   42 Media tracking  ........................................................................................................................   43 Print quality problems  ...........................................................................................................   44 Line quality  ..............................................................................................................................   44 Dirty or damaged cartridge  ................................................................................................   45 Cartridge calibration  ............................................................................................................   46 Calibration overview  ............................................................................................................   46 Cartridge alignment  ..............................................................................................................   46 Adjusting the cartridge alignment value  ...........................................................................   47 Motion adjustment  ................................................................................................................   48 Frame gap  ....................................................................................................................................   48 Unexplained frame gaps  .......................................................................................................   49 Ink cartridge stall problems  ................................................................................................   50 Noisy carriage movement  ....................................................................................................   50 Mechanical, electrical, and electronic diagnostics  .....................................................  51 No power to the FlexJet  .....................................................................................................   51 Electrical problems  ................................................................................................................   52 Troubleshooting sensors   ...................................................................................................   52 General mechanical / electrical issues  ..............................................................................   53 Simple electrical diagnostics test:  ............................................................................  54 Motor problems  ....................................................................................................................   54 Testing a motor  ......................................................................................................................   54 Logic board assembly troubleshooting  .............................................................................   55 Logic board troubleshooting steps (Revision 2)  ............................................................   56 Service & support  .....................................................................................................................   58 Getting help  ................................................................................................................................   58 Customer service  .....................................................................................................................   59 Chapter 4 Repair Procedures Maintenance procedures  .......................................................................................................   61 Repair procedures  ....................................................................................................................   61 Requesting service  ...................................................................................................................   62

FlexJet carriage replacement  ..............................................................................................   63 FlexJet Cable replacement  ..................................................................................................   69 Service station procedures  ..................................................................................................   77 Y Fine adjustment for the Service Station  .......................................................................   77 Logic Board Procedures  ........................................................................................................   83 Logic board replacement  .....................................................................................................   83 Updating the firmware  .........................................................................................................   86 Keypad procedures  ..................................................................................................................   87 Keypad replacement  .............................................................................................................   87 Y-Axis procedures  .................................................................................................................   88 Y-Axis belt adjustment  .........................................................................................................   88 X-Axis procedures  ..............................................................................................................   89 Chapter 5 Parts & Drawings FlexJet BOM (Bill of Materials)  ..........................................................................................   91 Ioline FlexJet (Exploded view)  ............................................................................................   94 Ioline FlexJet (Electronics view)  ........................................................................................   95 Index

jury and prevent electrical shock, please read and follow these safety guidelines before attempting to service the printer: n Do not try to repair the machine without factory authoriza- tion. Only qualified service personnel should attempt any of the subsystem testing or replacement procedures that are de- scribed in this manual. If external mechanical adjustments are necessary, turn off the printer and disconnect it from all power sources (both the computer and the wall outlet). n Unless otherwise noted, all subsystem testing or replacement procedures must be performed with the FlexJet turned off and the power cord removed from the rear panel to avoid the pos- sibility of electrical shock. n Before beginning any subsystem testing or replacement proce- dure, make sure that the FlexJet is on a flat, stable, clean, and dry surface. n Keep fingers, hair, and clothing well clear of the FlexJet whenever moving parts are be- ing tested. n Be careful when moving or lifting the printer. Moving the printer requires at least 2 people. To avoid injury to your fingers, do not lift the printer by the end covers. Hold the gray bars on the printer to lift or move it. See Figure 1. Figure 1. Lift the printer head using the gray bars to avoid injury to your fingers. Safety & Cautions xiii

Ioline Corporation provides a 12 month parts and labor warranty on all new equipment and 90 days on repaired units, unless specifically noted otherwise. Every unit is recorded by serial number when it leaves the factory. The warranty period is based on the serial num- ber of the unit and extends from the date of manufacture up to 12 months, plus an extra 3 months for shelf life. Making the total war- ranty period 15 months from the date of manufacture. For warranty service, the end user must work through their dealer. Ioline Customer Service is available to assist Authorized Dealers with customer and equipment support.

maintaining and servicing the FlexJet: n FlexJet Quick Start Guide n FlexJet User Guide n FlexJet Service Manual n FlexPlot User Guide Where to find information The table below provides a quick directory of topics and resources: How to use this manual Topic Manual Assembly & setup FlexJet Quick Start Guide Paper loading FlexJet Quick Start Guide Removing markers FlexJet User Guide The Ioline Control Center (adjusting plot parameters) FlexJet User Guide Ioline FlexPlot software FlexPlot User Guide Design software set-up guides FlexPlot User Guide Maintenance FlexJet User Guide Basic troubleshooting FlexJet User Guide Advanced troubleshooting for qualified service personnel FlexPlot Service Manual Specifications, part names, drawings FlexPlot Service Manual What’s in this Service Manual The FlexJet Service Manual provides extensive product specifica- tions, testing and repair procedures. Chapter 1 Introductory information and general specifications. Chapter 2 Descriptive drawings listing part names for the FlexJet. This section is intended to supplement the FlexJet User’s Guide. Chapter 3 Troubleshooting and testing guide. Chapter 4 Details for repair and maintenance of the FlexJet. Chapter 5 Technical drawings and reference material.

B. Safety Cover C. Right End Cover D. Take-up Motor E. Stand Leveling Foot F. Feed Roll G. Take-up Shaft H. Paper Hub (2) I. Feed Shaft J. Support Block (2) KEY Figure 2. The Ioline FlexJet Printer front view. E A B C F D G xvi J I H

Figure 3. The Ioline FlexJet Printer rear view (head tilted in maintenance position.) K. Stand Leg (2) L. Take-up Motor Cable M. Take-up Motor Outlet N. Serial & USB Ports O. Power Switch and fuse P. Platen Leveling Foot Q. Cross-member (3) KEY L M N O xvii Q P K

R. Ink Cartridge Stall S. Cartridge Stall Latch T. Pinchwheel Lever U. Keypad V. Service Station (Beneath Cover) W. Take-up Sensor X. Platen Y. Pinchwheel Z. Drive Shaft Marker aa. Traverse ab. Carriage Assembly KEY R U Y X ab aa S V T W Z xviii

most commonly used in conjunc- tion with popular apparel software for printing marker patterns, used in the man- ufacture of cloth- ing. The FlexJet also comes with FlexPlot soft- ware that allows printing of the most popular formats such as AutoCad® (DXF), CorelDraw!® (PLT), Adobe® Illustrator® (DXF), Gerber® (STD, PLT or ASTM), Lectra® (ASTM), Investronica® (ASTM). The Ioline FlexJet can handle many different printing operations up to 72 inches wide and 600 yards long. Three industry standard printer languages (HPGL 7475, and DM/PL) are supported. The Ioline FlexJet also supports direct cable connection from many popular programs such as PAD®, Scanvec® Optitex®, Polytropon®, Ioline IPS software, and other applications. Supported languages Language Application HPGL Direct from software or Ioline FlexPlot. DM/PL Direct from software or Ioline FlexPlot. DXF Ioline FlexPlot only. STD Ioline FlexPlot only. ASTM 6959 FlexPlot only. Ioline syntax Direct special control characters for FlexJet. Figure 5. The Ioline Flexjet.

Specifications Metric Empirical Max. plotting width 1.83 m 72-in Media width min. max. .91-m 1.88-m 36-in 74-in Marker length 548.6-m (Unattended) 600 yds (Unattended) Floor space requirements Height Width Depth 2.4-m x .7-m 1.2-m 2.4-m .7-m 96-in x 26-in 46-in 89-in 26-in Weight Actual Dimensional (US) Dimensional (Int’l) 150 kg 190 kg 221 kg 330 lbs 417 lbs 487 lbs Paper type Recycled to bond Feed roll position Front floor loading Paper take-up roll position Ergonomic waist-level off-loading from front Line thickness Thin, normal or thick Resolution Best mode: Draft mode: 600 dpi 300 dpi Ink cartridges Off-the-shelf HP® 51645A cartridges PC interface USB / Serial (RS-232) Protocol HPGL / DM/PL Languages DM/PL, DXF, HP-GL, HP-GL/2, MicroJet STD, ASTM Compatibility Gerber® (Accumark®, MicroMark®, and Micro- dynamics®), Assyst®, AutoDesk® (AutoCAD®), Investronica®, IPS, Lectra®, Scanvec® (Optitex®), PAD®, Polygon®, Polytropon® (PolyPattern®), Veti- graph® and others Power requirements 85-260 VAC, 0.25 KVA, Single phase, 47-440 Hz Humidity Non-condensing Warranty 1-year parts and labor

How the FlexJet works The Ioline FlexJet combines paper and ink cartridge motion to create vector outputs in a wide 72-in format. The data are sent to the FlexJet via either a standard RS-232 serial or USB cable. When a file is sent to the printer, the electronic system translates the vectors into instruc- tions for the “X” (paper motion) and “Y” (Ink cartridge motion) mo- tors. At the same time instructions are sent to the carriage assembly to apply ink to the paper. Paper movement Paper motion is ac- complished by pull- ing paper through the machine with a trac- tion shaft. The shaft is connected to the X-axis motor with a timing belt transmisison assembly. The drive-shaft rotates in one direction. Carriage movement The Y-Axis transmission powers a timing belt that transports a V wheel carriage along the Y-Axis traverse extrusion. The ink cartridg- es are attached to the carriage and are made to apply ink to the paper by actuating the electronics of the ink cartridge. When not printing, the carriage assembly is stored in the FlexJet Service Station to keep the ink cartridges clean and capped so they don’t dry out. Serial number identification Identification of Ioline Corporation products is accomplished by use of a serial number located on the back of the right side cover on the print- er. You can determine the model and date of manufacture using the following guidelines: Figure 6. Paper direction. Figure 7. Carriage movement.

FJ 03 26 01 Number of machine manu- factured in that week Week of manufacture Year of manufacture Model number Glossary BOM Bill(s) of Material for Assembly Bottom Pan Metal housing protecting the underside of the printer. Carriage The component that holds the ink cartridges. It traveles along the Y-Axis on the traverse assembly. Keypad Where the user controls simple printer functions. Carriage and media motion is accessible from here during stop mode. Traverse Assembly The structure that supports and guides the carriage as- sembly. X-Axis The direction of the paper moving through the machine. Y-Axis The direction of the carriage moving back and forth. Software setup options Ioline recommends using FlexPlot for marker making on the FlexJet. FlexPlot offers the most robust and flexible workflow available for creating output. It’s especially useful when many file formats are used, a common situation for service bureaus. To set-up and learn how to use the software, see the FlexPlot User Guide. The FlexJet is designed to work in many different production envi- ronments. The type of marker printing you do will often determine your preferred communication method. Two typical methods for sending markers are: 1. Plot directly from the marker or design software to the FlexJet. (See Figure 8.) Unlike other marker printers, the FlexJet is capable of operating as a stand-alone device with no extra software running on the computer. This method works if your CAD software includes a driver for any Ioline product, such as the Ioline 600Ae or the Summit 2200. It will also work if the CAD software can create a compatible HPGL- or DM/PL- formatted file. { { { { An expanded Glossary is available in the FlexJet User Guide. Note i

Figure 9. Workflow using FlexPlot for file conversion and output. Figure 8. Workflow: output direct from CAD software (without FlexPlot). FlexJet FlexJet CAD Software FlexPlot [Network] HPGL DM/PL DXF ASTM 6959 STD CAD Software HPGL DM/PL (Alternate Configuration) CAD Software + FlexPlot 2. Use FlexPlot software to convert files before sending them to the FlexJet for output. The FlexJet includes the FlexPlot software which will convert many different files into a format that is compatible with the FlexJet. It also provides an advanced marker queue manage- ment system and other tools to optimize the performance of the printer.

Power on Turn on the computer and the printer to make sure they both work. The printer power switch is located next to the power cord on the back of the machine, behind the keypad. When the FlexJet is pow- ered up, the carriage will move toward the left side of the machine, then return to the opposite side to park in the Service Station. The OK light will turn red and the Square light will turn green on the front panel after the start-up process has finished. Installing FlexPlot and the Control Center The FlexJet includes two software interfaces: FlexPlot and the Control Center. FlexPlot will import and queue marker files from many design programs to optimize production operations. The Control Center is an interface for adjusting parameters to optimize printer performance. The printer comes with a CD-ROM which has Microsoft Windows® 98/2000/XP versions of the programs as well as PDF user guides and the required Adobe® Acrobat® reader. 1. Power on the computer and Windows®. 2. Insert the Ioline CD-ROM into the CD-ROM drive (usually D:). 3. The installation program should start automatically. If it does not: a. Select the Start button. b. Choose Run. c. Type D:\IOSETUP (substitute the correct letter if the CD- ROM drive letter is not D:) and Click OK. 4. Follow the instructions that appear on the screen. 5. The FlexPlot User Guide has details on using the FlexPlot soft- ware. In this manual, see the section The FlexJet Control Center for more details about the Control Center software. Keep hands and loose clothing away from all moving parts of the printer. Make sure the Service Station opening in the right end plate is not obstructed and that the stall latches are lowered. Caution

Figure 10. FlexJet Control Center main menu. To avoid communication port conflicts, do not simultaneously run more than one application that communicates with the printer. Note i The FlexJet Control Center Overview The FlexJet Control Center is a utility program that does two things: n Allows you to adjust settings to tailor output (e.g. scale, line width) from the computer. n Provides an interface to send completed files to the printer. Changing system settings A variety of settings are adjustable to fit specific needs: n Make sure the printer power is on and that the initialization process is complete. The carriage will park, the keypad OK light will turn red and the Square light will turn green. n The Screen Menu displays the primary settings that are adjust- able. The Menu Bar contains utilities for setting up the Control Center and calibrating the FlexJet. n Changes only take effect after one of the Send buttons is pushed.

Control Center menu bar features File Download Firmware Allows the user to download the lat- est firmware version for the FlexJet. See the FlexJet User Guide for more information. Send Plot File Print a PLT or PLX file. Exit Exit the Control Center. Communications Settings Select the COM port and baud rate to match the printer. Send Command Permits advanced users to manually enter commands. Tools Cartridge Calibration Displays tools to adjust print cartridge alignment. See the FlexJet User Guide for more details. Reset Machine ID Resets the machine serial number. A unique key code, only available from Ioline customer service, is re- quired. It is usually only necessary if the main logic board is changed. Size Calibration Allows adjustment of the size cali- bration settings. See the FlexJet User Guide for more details. Set Machine ID Stores the printer serial number in permanent memory. This step is required for upgrading the number of active print cartridges in machines pre-wired for expansion. Set Key Code Sets the license key code to enable inactive print heads in machines pre- wired for expansion. It requires that the serial number is stored in perma- nent memory with the Set Machine ID function described above. Help About Displays Control Center version information.

Control Center menu options Software Version Displays the current firmware version installed in the FlexJet. Cartridge Count Displays how many cartridges are in active use by the printer. Get Plotter Data Reads and displays the current settings stored in the FlexJet in the input boxes. Plotter Data (check box) Indicates when the displayed settings were successfully downloaded from the printer. If this box is unchecked, the Control Center was unable to connect with the FlexJet and cannot display current settings. Check the connections, baud rate and COM port. Press the Get Plotter Data button to attempt to download settings if the process failed during startup. Line Width Controls the weight of the plotted line using line width. Three levels are available; Thin, Normal, and Thick. Thin lines use less ink and make fine details like Asian text and small pieces easier to see. Thick lines use more ink to produce higher contrast lines. Used in conjunction with the Quality Setting (see below), the FlexJet provides six options for output quality, to enable you to produce clearly visible lines using the least possible amount of ink. Scale The printer scale ranges from 1% to 999%. The factory default Scale is 100%. A scale set to 50% prints at half size. Changes do not take effect until the Set Scale button is pressed. Note: Both X- and Y-Axes are set independently. Frame Size Most design software sends long plots to printers by breaking them into smaller pieces called frames. In general, design software does this automatically and adjusts the Frame Size in the printer to match. The Frame Size setting establishes clipping limits for each data frame. If the printed size of a plot frame exceeds the frame size set in the FlexJet, the excess is clipped or thrown away. (If the plot is clipped, try increasing the Frame Size manually.) The factory-set X-axis (paper direction) frame size is 46-in (116.8-cm), maximum is 21600-in (54,864-cm). Default and maximum Y-axis (carriage direc- tion) frame size is 72-in (182.9-cm).

Quality Setting Choose Draft or Best to control line density. Draft mode uses 300 DPI. Best mode uses 600 DPI. A lower DPI setting uses less ink by creating a fainter line. Higher DPI uses more ink but makes a darker line. Use this setting in conjunction with the Line Width (see above) to find a bal- ance between saving ink and making clearly visible lines. Measurement Units Choose between English or Metric units for settings display.

Figure 12. Rear power panel assembly. Power cord plugin Power switch Product components

Figure 15. Ink cartridges: HP 51645A. Figure 13. Service Station assembly. Servo motor Carriage stop adjustment screw Cartridge wipers Cartridge caps Cartridge “spit wells” Figure 14. Pinchwheel assembly. Wheels (Replaceable)

Figure 16. FlexJet logic board (Rev 1, above; Rev 2 below). Y-Axis motor power X-Axis motor power Take-Up motor power Service Station motor power Main power Fans: 1,2 & 3 Y axis encoder X-Axis encoder Take-up encoder Service station encoder Serial port Ribbon cable socket Y-Axis motor power X-Axis motor power Take-Up motor power Service Station motor power Main power Fans: 1,2 & 3 Y axis encoder X-Axis encoder Take-up encoder Service station encoder Serial port Keypad Secondary sensor Ribbon Cable Socket USB port USB port Take-up Sensor Keypad Secondary sensor Take-up Sensor

Figure 17. Carriage assembly with cover on. Carriage cover Figure 18. Carriage assembly with cover off. Ink cartridges Cartridge catch bracket Red Light alignment indicator Base Carriage stall Carriage latch V-notch

basic operatioinal difficulties and diagnosing mechanical, electri- cal and electronic processes. Chapter 4 also contains related repair procedures. If the system isn’t functioning correctly, first determine which com- ponent is causing the problem. Likely difficulties may involve: } The computer } The power cord or communication cables } The apparel/marker design software } The FlexJet printer Changes to the computer operating system or the installation of new peripherals or software can cause conflicts. If the problem appears to be with the computer or apparel design software, consult the appro- priate documentation or an Ioline dealer. If the problem is with the FlexJet, begin by making sure power is on and that the cable between the machines and the PC is connected correctly. The information in this chapter begins with the simplest and most common issues, and progresses to more complex and invasive trou- bleshooting. If you are unable to resolve a problem after consulting this manual, fill out the Diagnostic Record at the end of this chapter then contact Ioline Customer Service. Error messages Error messages that are specific to the Ioline FlexJet are divided into two catagories: Control Center software errors and LED codes. Software errors present themselves on the computer screen and usu- ally indicate a communication problem. LED codes are visible on the keypad and can be a green light, a red light or a combination of both. The keypad LED code table (Figure 19) is helpful for isolating the cause of obvious external or communication problems. Comprehen- sive information later in the chapter can help troubleshoot mechani- cal and electrical difficulties. Errors caused by the operating system or the plotting software should be resolved with the software author.

Control Center software errors The FlexJet did not respond. Do you wish to continue anyway? The Control Center did not get a response from a FlexJet on the COM port it is currently configured to use. If the FlexJet is connected and the power is on, click ‘Yes’. Follow the directions in the FlexJet User Guide for configuring the COM port and baud rate. Unable to open communication port. You may need to select a differ- ent COM port. Do you wish to continue? The Control Center did not get a response from a FlexJet on the COM port it is currently configured to use. If the FlexJet is connected and the power is on, click ‘Yes’. Follow the directions in the FlexJet User Guide for configuring the COM port and baud rate. Incorrect plotter model. Do you wish to continue? The Control Center did not recognize the printer model connected to the COM port. Upgrade the Control Center to the latest version. If that does not resolve the problem, confirm that ‘FlexJet Control Center’ is displayed in the menu bar of the program. If it is not, obtain the correct version from Ioline. Fatal Error: COM port pointer is NULL Unable to recover. A serious internal failure in the program or Windows® has occurred. Close all programs, restart Windows® then start the Control Center program. Unable to change FlexJet baud rate Do you wish to change baud rate in Control Center? The Control Center did not get a response from a FlexJet on the COM port it is currently configured to use. If the FlexJet is connected and the power is on, click ‘Yes’. Follow the directions in the FlexJet User Guide for configuring the COM port and baud rate. Warning: Unable to open log file; Status messages will not be saved. This error occurrs if the Control Center is unable to write the firmware up- grade process log in the same folder where the firmware source file is stored on the PC. It is typical if installing firmware from a CD-ROM or if the user does not have ‘Modify’ or ‘Full’ permissions to the PC file system. Copy the firmware to the hard disk and make sure permissions are correct before installing.

FlexJet is not responding. Please check your cables and baud rate. The Control Center did not get a response from a FlexJet on the COM port it is currently configured to use. If the FlexJet is connected and the power is on, click ‘Yes’. Follow the directions in the FlexJet User Guide for configuring the COM port and baud rate. NOTICE: Your firmware is out of date. It is recommended that you update it as soon as possible, but it is not required. This program will work with new and old firmware. Firmware upgrades are available from Ioline Customer Service at (425) 398-8282 PST-USA. The firmware in the FlexJet is obsolete. An upgrade is highly recommended. Contact Ioline Customer Service to obtain the software and instructions. The identification numbers for this board have already been set. You must use the ‘Reset Machine ID’ dialog to change them now. The user is attempting to overwrite an internal license that is already set. Contact Ioline customer service for assistance.

OK n l p Problem/Status G OFF OFF OFF Ready to Print, Origin Set R OFF OFF OFF Paused / Offline, Keypad Active R G OFF OFF Power on reset finished. R Y-Blink OFF OFF Cover open (obsolete) R OFF Y-Blink OFF Paper Feed Out / Jammed Y-Blink R R OFF X- (paper) axis jam Y-Blink G R OFF Y- (carriage) axis jam Y-Blink G G OFF TU (take-up) jam Y-Blink R G OFF SS (Service Station) jam OFF R Y-Blink OFF Buffer Overflow Y-Blink OFF R OFF Init from EPROM failed OFF R R OFF File syntax error Y-Blink Y-Blink Y-Blink OFF Printer ready to receive firmware Y-Blink OFF OFF OFF Motors off / System Stop Legend G = Green light R = Red light Y = Yellow light Y-Blink = Blinking yellow light* OFF = Unlit Figure 20. Keypad LED error codes. Keypad error codes Figure 19. LED lights on the keypad. If keypad errors are not shown on the chart to the left, update the firmware. For more information, please contact Ioline Customer Service. Note i * First generation FlexJet keypad lights do not blink.

Power problems If the FlexJet won’t power on or initialize—or if the fan does not spin—follow these initial diagnostic steps: 1. Check the power cord. Make sure that it is firmly plugged into the wall and into the back of the printer. 2. Check the voltage at the wall outlet and verifiy that it is within the operating limits as specified in Chapter 1, Specifications. If there are no obvious power problems, proceed to the Mechanical, Electrical, and Electronic Diagnostics later in this chapter. Communications The FlexJet won’t respond to the computer If the FlexJet doesn’t accept commands from the computer, try the following: 1. Verifiy that the communication cable is correctly connected to the printer and to the proper communications port on the computer. 2. Change the computer COM port settings to match the FlexJet’s serial communications settings. (See Serial Communication, below.) Serial communication The serial port on the FlexJet has an adjustable baud rate. Available speeds are 9600, 19200, 38400, 57600, and 115200. It is critical that the FlexJet Control Center, FlexPlot or design software use the same baud rate that the FlexJet is using. If there is ever any doubt about what baud rate the printer is using, Ioline recommends resetting it to the default of 38400. To reset the baud rate: 1. Turn off the power to the FlexJet. 2. Press and hold the Page Advance key (the key below Set Origin) while turning power on. 3. Continue holding the Page Advance key until the OK light turns red and the Square light turns green. If using a terminal program like TeraTerm™ to communicate with the FlexJet, make sure to use 8 Data Bits, No Parity, 1 Stop Bit, and Xon/Xoff (software) Flow Control.

Common problems Good print quality is dependant upon several factors. The type of paper, environmental conditions, and operator habits are only a few of the variables that can affect the quality of the plot. It is important to load paper in the FlexJet—and maintain it—ac- cording to the guidelines in the FlexJet User Guide. The table below summarizes the some of the most common difficulties users encounter. The sections following the table examine each issue in greater depth. A marker plot doesn’t start at the correct point on the paper Cause: The origin is not set correctly. Solution: Position the V-notch where the plot should start. Press the Set Origin key. Poor line quality. Cause: 1. Ink cartridge is improperly installed. 2. Frame Gap setting is incorrect. 3. Carriage electronics or cables are damaged. 4. Ink cartridge is dry. Solution: 1. Remove and reinstall ink car- tridge. 2. Use the Control Center to adjust frame gap as shown in the Routine Maintenance chapter of the FlexJet User Guide. 3. Contact Ioline customer service. 4. Clean or replace cartridge. The printer does not complete the marker. Cause: 1. Outdated software. 2. The frame/panel size is mis- matched between the printer and the design software. Solution: 1. For updated firmware, please contact Ioline Customer Service. 2. Check the panel size in the software. It should be equal to the printer panel size. When a marker plot file is sent, nothing happens. Cause: A communication problem has oc- curred or the printer is in STOP (red light) mode. Solution: Make certain the communication port is connected and configured properly. Position the V-notch where the plot should start and press the Set Origin key to put the printer in START (green light) mode.

Regular or intermittent paper tearing. Cause: 1. Front or rear dancer bar is not installed. 2. Paper gets “yanked” by the machine during take up. 3. Paper buckles when plotting to floor. 4. Paper roll damaged. 5. Paper not loaded correctly. 6. Platen not level. 7. Outdated firmware does not advance paper at startup. 8. Pinchwheels press on a drive shaft bearing. Solution: 1. Install front or rear dancer bar. 2. Make sure the front dancer bar is below the Take-up Sensor, then press Set Origin. 3. Clear paper path. Refer to the FlexJet User Guide for proper loading procedures. 4. Inspect the feed paper roll. Dropping the paper roll on an end can wrinkle the edge which can catch the carriage and cause a tear. 5. Correct paper loading is vital. Follow the steps in the Opera- tion chapter of the FlexJet User Guide to reset paper align- ment. Make sure the front silver dancer bar is BELOW the front optical sensor before plotting. 6. Make sure the distance between the print heads and platen surface is the same at the right, center and left side of the printer. Adjust the platen levelers as described in the FlexJet Quick Start Guide if necessary. 7. Use the Control Center to check the firmware version and ensure it is 324 or greater. 8. With power off, raise the pinchwheels and align them with the white driveshaft markers on the traverse. Jagged scan alignment. Cause: 1. Cartridge alignment is incorrect. 2. Motion alignment is incorrect. 3. Platen or stand is not level. 4. Loose carriage pulley causing ran- dom/uneven gaps between scans. Solution: 1. Use the Control Center to adjust cartridge alignment as shown later in this chapter. 2. Use the Control Center to ad- just motion alignment as shown later in this chapter. 3. Follow the directions in the FlexJet Quick Start Guide to level the stand and platen. 4. Contact Ioline customer service.

Poor paper tracking. Cause: 1. Paper is improperly loaded. 2. Bad paper roll or paper quality. 3. Pinchwheels not in correct location. 4 Feed paper roll isn’t centered on feed shaft. 5. Loose paper hubs. Solution: 1. Reload and align paper. 2. Replace the paper roll. 3. With power off, raise the pinchwheels and align them with the white driveshaft markers on the traverse. 4. Center the paper roll on feed shaft. Make sure screws are tight on both paper hubs. 5. Tighten screws on the paper hubs. Rear heavy bar goes to the top or bottom of the channel and the key- pad shows an error. Cause: 1. Out of paper. 2. Paper path is obstructed. 3. Dirty feed roll support blocks. 4. Paper is not aligned properly. 5. Paper runs under rear cross- member. Solution: 1. Change the paper roll. 2. Make sure nothing is touching the feed roll and that the rear top bar rotates freely. 3. Clean then lubricate the feed shaft block. Use the included white lithium grease. 4. Load paper straight as described in the Operation chapter. of the FlexJet User Guide. 5. Adjust paper to go between the front and rear cross-members. Gap between each scan. Cause: 1. Frame Gap setting is incorrect. 2. Ink cartridge is out of ink, dirty or the print head is plugged. Solution: 1. Use the Control Center to adjust frame gap as shown in the Routine Maintenance chapter of the FlexJet User Guide. 2. Check ink level indicator. Replace cartridge if indicator is black. If cartridge is not empty, see Cartridge Maintenance and Handling under the Rou- tine Maintenance chapter in the FlexJet User Guide. When changing paper rolls make sure you let the paper rest out- side the packaging overnight first. Note i

No power when printer is turned on; Keypad lights stay dark. Cause: 1. The power cord is damaged or disconnected. 2. Check power supply voltage. 3. The printer is damaged and needs professional service. Solution: 1. Check the power connection. 2. See Repair Procedures later in chapter 4. 3. Contact an Ioline distributor or Ioline Customer Service. Pauses during printing. Cause: 1. Vector density is very high due to fine detail or the design soft- ware is not using fonts embed- ded in the printer. 2. Communication baud rate is set very low. 3. Frame length is too big. Solution: 1. Reduce vector density, use em- bedded printer fonts, or increase communication baud rate. 2. Increase baud rate from the minimum of 9600 baud to the default of 38,400 or higher. Make sure the FlexJet and the soft- ware are set to the same baud rate. 3. Reduce frame length. Set be- tween 5-in and 35-in.

Rear Top Bar Figure 21. The correct paper feeding path on the Ioline FlexJet Printer. Platen Take-up Shaft Feed Roll Proper Paper Path After Loading Front Top Bar Pinchwheel Lever Paper Path when Ready to Plot and Dancer Bars installed Front Dancer Bar Rear (Heavy) Dancer Bar Paper problems Regular or intermittent paper tearing Common situations that cause paper tearing while the FlexJet is operat- ing include: n The paper was incorrectly loaded in the machine. n The rear, heavy dancer bar was not loaded in the FlexJet after the paper was loaded. Figure 21 represents the proper paper path. The diagram on the left shows the paper after it is inserted properly and taped to the take-up shaft. The illustration on the right shows the result after the dancer bars are inserted. The paper path and instructions for printing to the floor is illus- trated in the FlexJet User Guide, Figure 25. Note i

Media tracking Tracking is the process that controls media motion over the platen and assures accurate lines. If the paper slips under the pinchwheels or is out of alignment, printing quality will degrade. To resolve tracking difficulties try the following suggestions: n Install paper correctly. See the Operation chapter in the FlexJet User Guide for more details. n Make sure the paper path and dancer bars are set correctly (as shown in Figure 21 (and in the FlexJet User Guide.) n Inspect the paper for wrinkles or folds. Never use paper that is folded, wrinkled, or torn in any way. It may cause paper jams. n Make sure the pinchwheels are spaced across the paper as out- lined in the FlexJet User Guide. n The pinchwheels should never be positioned over bearings on the drive shaft as paper tearing and bunching will occur. Verify that the pinchwheels are positioned over treads (e.g. under the white markers affixed to the traverse.) n Check to make sure that the printer is level. See the FlexJet Quick Start Guide for more information. n The paper may slip when debris accumulates on the drive shaft. Inspect and clean the drive shaft. Refer to the Routine Mainte- nance chapter in the FlexJet User Guide for more information. n Contact an Ioline distributor or Ioline Customer Service if you are unable to resolve the problem or if the FlexJet is damaged.

Print quality problems Line quality In most cases, poor line quality is caused by one of several things: n The ink cartridge is empty, dirty, damaged or dried up. n The Motion Factor or Carriage Calibration needs adjustment. n The platen is not level If line quality is uneven, try the following: 1. Press Start/Stop then the Clean keys on the keypad to automatically clean the cartridges. 2. Inspect the ink level window on car- tridge. If it is black, then the cartridge is empty. Replace it with a new one. 3. Remove the cartridge(s) and manu- ally clean the print head with a (de- ionized) water-moistened, lint-free cloth. (See Cartridge Maintenance and Handling in the FlexJet User Guide.) 4. Plot on higher quality or undamaged (free of wrinkles and bubbles) paper. 5. Use genuine HP 45 cartridges as recommended by Ioline. 6. Recalibrate cartridges as described below. 7. Level the platen as outlined in the FlexJet Quick Start Guide. 8. Contact an Ioline distributor or Ioline Customer Service if you need further help. Figure 23. The ink cartridge is dirty, dry, or empty. Figure 22. HP cartridges have an ink level indicator.

Figure 24. The ink cartridge requires cleaning. Figure 25. Damaged and dirty print cartridge. Dirty or damaged cartridge Sometimes a cartridge will go bad for no apparent reason. The cartridge may look perfect and be full of ink, but it will not plot. If this occurs first try pressing the Clean button on the keypad. Install a new cartridge and the tests to see if this fixes the problem. If this has no effect remove, clean, inspect for damage, then test. If the cartridge fails again replace it. Broken circuit from mishandling

Cartridge calibration The Cartridge Calibration window is located in the Control Center and can be accessed in the Tools menu. Step-by-step instructions on the calibration process are provided in the FlexJet User Guide. The examples below show different results and settings of the cartridge calibration window. If the FlexJet is printing poorly, check some of the examples here for a possible fix. Calibration overview Cartridge Calibration: Aligns the ink cartridges with each other. On 1-head machines, cartridge calibration is not neccessary. Motion Adjustment: Aligns (side to side) each pass of the car- riage with the next pass. Frame Gap: Aligns (from top to bottom) each pass of the carriage. Cartridge alignment Cartridge alignment will align the ink cartridges with each other. This adjustment is only good for 2 or more heads. A one-head FlexJet does not need ink cartridge alignment. Figure 26 shows a plot from a two head machine with a frame gap of -30 and all cartridges set to zero in the Cartridge Alignment win- dow. As you can see, the heads don’t quite line up with each other. Cartridge #1 Cartridge #2 Frame gap: -30 Figure 26. When calibrating, set a deliberate frame gap to help you see how the heads line up.

Adjusting the cartridge alignment value To align the cartridges on a two- head FlexJet, run the plot file 70x8.plt for 72-in wide paper, or 40x8.plt for 63-in wide paper. Compare the plot to Figures 29 & 30. Adjust the alignment values for the second cartridge, as indicated, in the Calibration Alignment window to bring the two lines into alignment. It is not necessary to adjust cartridge #1. Figure 27. The Cartridge Calibration window in the Control Center. Figure 29. Increase the alignment value for cartridge #2 to improve line quality. Figure 30. Decrease the alignment value for cartridge #2 to improve line quality. Figure 28. The Cartridge Alignment dialog box. Start with a frame gap of -30, and all cartridges set to zero so you can see a separation between the heads. This will make it easier to line the heads up with each other. Note i

Motion adjustment To understand Motion Adjustment, think of each reversal in carriage direc- tion as a “pass”. With every pass, each head draws a line 1/2 -in long. If the FlexJet has 2 heads, it draws a 1-in line for each pass. A four-head machine will draw a 2-in line. If the Motion Factor is too low, the FlexJet will draw the line too late. Visu- ally, this appears as if the line drifts to the right, as shown in Figure 32. Mo- tion Factor set too high results in drift to the left. Frame gap The frame gap is defined as the space between each pass. Use the Frame Gap window to make adjustments and elimi- nate the gap. Figure 32. The heads are drawing the lines too late on this plot. Scan Scan Poor motion adjustment = Direction of carriage travel Figure 31. The Motion Adjust window. Figure 33. The Frame Gap window. You must align the ink cartridges before performing motion adjustment. Note i

Unexplained frame gaps If your plots exhibit occasional frame gaps, like Figure 35 for in- stance, may indicate that the FlexJet body is not be level. Notice how the right and left lines are right on, but the middle line mis-aligned. Figure 34. Frame gaps on the plot. One Scan Frame Gap Try releveling the FlexJet to see if this corrects the problem. The FlexJet Quick Start Guide provides detailed instructions. You’ll need to locate the height-adjusting spacer in the Acces- sory Kit for this task. If the leveling procedure does not cor- rect the problem, see Ink cartridge stall problems later in this chapter. Figure 35. Occasional frame gaps may indicate that the FlexJet platen or stand is not level. Figure 36. The height-adjusting spacer.

Ink cartridge stall problems Always remember to close and lock the cartridge doors after remov- ing or replacing an ink cartridge. Failure to do so can cause cracks in the bottom of the ink cartridge stall. When the carriage tries to cap in the service station, the doors hit the service station end plate. A cracked stall can cause print mis-alignment that is difficult to calibrate. Noisy carriage movement If you notice unusual noise coming from the carriage, the wheel on the carriage assembly may need cleaning or replacement. Remove the carriage assembly from the traverse and clean the wheel. Also wipe the traverse rails before re-installing the carriage assembly. If cleaning does not resolve the noise, contact Ioline Customer Service. Figure 37. The ink stall can crack if the cartridge door is not closed and locked. Figure 38. If the carriage makes noise, you may need to clean or replace the wheel.

Mechanical, electrical, and electronic diagnostics No power to the FlexJet If you should power the machine up and nothing happens, check the fuse in the power entry module (Figure 39a) on the back of the right side cover. 1. To check or replace the fuse start by flipping the fuse door down (Figure 39b). 2. Pull out the red fuse holder. (Figure 39c & d). 3. Check or replace fuses as needed. (Figure 39e). 4. Use only 5A, 250V, 5x20mm slow blow fuses for replacement. Figure 39. Replacing the fuse. a b c d e The fuse holder is universal. so it doesn’t matter which way it goes back in. Make sure the flat end is facing out. Note i

Electrical problems If, during power on, the FlexJet experiences one or all of the follow- ing, it may have a blown transistor: n Smoke coming from inside the machine. n The carriage won’t move. n The carriage hits the right or left side hard. n The carriage moves in only one direction. n Motors only move in one direction n A motor on the machine will try to keep turning after it stops. The most common reason for a transistor to fail is a bad or old mo- tor. As motors age, their bearings start to break down due to insuf- ficient lubrication. As this break-down happens the transistors have to work harder to move the motor, causing them to heat up and eventually fail. (Figure 40). In most cases, both the transistor and motor will need replacement. Contact Ioline Tech Support for more detailed instructions on testing a transistor. Troubleshooting sensors The FlexJet uses the same sensor in multiple places for tracking pa- per path status. The sensors are industrial-grade and will withstand many years of use. If a sensor ever fails, the following conditions might occur: 1. The paper take up motor will not stop rotating and will pull the paper tight against the platen. This might result in an X motor jam and a ‘popping’ noise during printing. 2. The Paper Out sensors will not detect that the paper feed roll is empty and printing may continue with no paper in the printer. Figure 40. A good transitor on the left; the one on the right is blown. The presence of solder bubbling out of the chip indicates it overheated. Solder

To replace a defective sensor: IMPORTANT: Never disconnect or connect sensors when power is on to the machine or electronics. This will permanently dam- age the sensor and might affect the logic board. 1. Power off the printer. 2. Disconnect the plug from the sensor. 3. Note the orientation of the old sensor, specifically where the optical ‘eye’ is pointing. 4. Remove the old sensor by removing the hardware or adhesive. 5. Mount the new sensor in exactly the same orientation as the old one. 6. Connect the plug to the sensor, it is keyed to only connect one- way. 7. Power on and test the installation. General mechanical / electrical issues If you encounter any of the following problems, try the diagnostics test outlined below: n The FlexJet didn’t initialize (No LEDs, fans not running, car- riage didn’t move, small jerking motion during power up) n The FlexJet has been working but did not initialize after being reset by turning the power off them back on. n Jam messages occur without media or other objects obstructing normal operation. n The carriage is making loud or unusual sounds. Required tools n Multimeter capable of reading AC voltage n Phillips head screwdriver n Allen wrenches: 1/16 and 5/64 n Nut driver or socket wrench with extension: 11/32

Simple electrical diagnostics test: 1. Turn the power to the machine off. 2. Inspect the FlexJet for any obvious damage or signs of mechani- cal malfunction. 3. Measure the voltage at the wall socket. Verify that the AC volt- age is between 85 and 250 VAC. 4. Clear all paper from the machine and make sure that nothing is obstructing movement of the front take-up roll. 5. Move the carriage from side to side by hand. If the carriage resists easy movement, the motor may be bad or there could be a short on the main board. (See Motor Problems and Testing the Logic Board later in this chapter.) Motor problems Perform the following simple test to determine if a motor problem exists. The following are possible motor problems: 1. Bad or burned motor components. 2. The motor brushes are worn down. 3. A transistor has blown on the logic board. 4. The motor is unplugged. 5. The encoder is dirty, damaged or unreadable. Testing a motor Test the motors on the FlexJet by following this procedure. The Y-Axis motor (Figure 41a, on the left side of the machine) is shown below. 1. Power the machine off and remove the left side cover. 2. Unplug the motor power wires. (Figure 41b). a b c d Figure 41. Testing the Y-Axis motor. This test applies to all the motors on the FlexJet. Note i

3. Straighten out a paperclip so it looks like Figure 41c. 4. Attach the paperclip to the power lugs as shown in Figure 41d. 5. Now, move the carriage back and forth by hand. 6. Now remove the paperclip and move the carriage back and forth by hand again. This test is designed to put resistance on the motor. By connecting the two power lugs, the motor should get a lot harder to turn. If you noticed a difference in resistance between Steps 5 and 6, the motor is still good. If there is no difference in resistance, most likely the motor is bad and needs to be replaced before powering the ma- chine back on. Logic board assembly troubleshooting The electronic logic board is constructed of many advanced electron- ic components with fine pitch connections. Very few of the compo- nents are user serviceable. The table below explains indicator lights and test points on the logic board and some troubleshooting steps to resolve user serviceable issues. Ensure that the FlexJet is unplugged from the wall outlet and that all AC power cables are removed from the printer before replacing the cable. The discharge of static electric- ity may damage the carriage and logic board components. Use the included ground strap throughout the procedure. Attach one end of the ground strap (included in the Upgrade Kit) to your wrist and the other end to a bare metal portion of the printer (like the frame the holds the service sta- tion.) Keep plastic objects away from the carriage and logic board assemblies. Remove the wrist strap only after the new carriage is attached to the traverse, the cover is installed, and the metal cover is secured over the main logic board. Caution

LED/Test Point ID Normal Indicates Error TP6 30 VDC 30 volt main power supply is functioning Erratic machine performance. TP7 3.3 VDC 3.3 volt regulated power supply is functioning Erratic machine performance. TP8 5 VDC 5 volt regulated power supply is functioning Erratic machine performance. D14 Dark light Y motor fault Solid red D15 Dark light X motor fault Solid red D16 Dark light Take up motor fault Solid red D17 Dark light Service station motor fault Solid red D18 Dark light Carriage power fault Solid red D20 Solid red USB connection to PC active Dark light D21-D24 Blinking red pattern Motor control system functioning Solid lights or no lights D25 Solid red Serial connection to PC active Dark light Logic board troubleshooting steps (Revision 2)

Causes Troubleshooting Steps A short on the PCB. Main power supply voltage is not adjusted properly. Main power supply has failed. DC voltage measurement between TP9 (ground) and TP6 should read 30 volts +/- 1%. If voltage is out of specifica- tion, check power supply connections and main power supply output. Contact Ioline Customer Service for more information if the voltages are out of specification. On-board regulator failed. Main power supply failed. DC voltage measurement between TP9 (ground) and TP7 should read 3.3 volts +/- 5%. Return logic board to Ioline for service. On-board regulator failed. Main power supply failed. DC voltage measurement between TP9 (ground) and TP8 should read 5 volts +/- 5%. Return logic board to Ioline for service. Over-current condi- tion on circuit due to a short or high heat. Check the motor connections and motor to ensure there are no shorts to ground. A hardware problem with the motor drive circuit. Return the board to Ioline for service. Over-current condi- tion on circuit due to a short or high heat. Check the motor connections and motor to ensure there are no shorts. A hardware problem has occurred with the motor drive circuit. Return the board to Ioline for service. Over-current condi- tion on circuit due to a short or high heat. Check the motor connections and motor to ensure there are no shorts. A hardware problem has occurred with the motor drive circuit. Return the board to Ioline for service. Over-current condi- tion on circuit due to a short or high heat. Check the motor connections and motor to ensure there are no shorts. A hardware problem has occurred with the motor drive circuit. Return the board to Ioline for service. Over-current condition on circuit due to a short or high heat. Check the carriage cables and the carriage logic board to ensure there are no shorts to ground. A hardware prob- lem has occurred with the power switch for the carriage printhead power. Return the board to Ioline for service. USB cable is not connected to a PC. Connect to the PC USB port. The serial port does not function when the USB connection is active. Test the USB cable and connections to ensure proper working order. Motor jam. Software error. Remove issue causing motor jam. Cycle power on ma- chine. Update to latest firmware. USB cable is con- nected to a PC rather than a serial cable. Disconnect the USB cable. Connect the serial cable to the PC. Test the serial cable and connections to ensure proper working order.

Service & support Ioline has many years of experience working with designers, graders and marker makers. Feel free to contact us if you have questions—or to share information. Getting help Ioline is committed to providing the highest quality service and sup- port to its customers. If you need assistance with an Ioline FlexJet, a number of resources are available: 1. First, refer to this FlexJet User Guide and FlexJet Quick Start Guide for answers to your specific questions. 2. Many detailed troubleshooting and repair issues are listed in the FlexJet Service Manual, available upon request from Ioline Customer Service. 3. Consult the support section of the Ioline Web site: www.ioline. com. FlexJet users must have a User Name and Password to log into the site. Please contact Ioline customer service to set up your free account. 4. For additional assistance, contact your local dealer or Ioline Customer Service. Contact information is listed under Customer Service in this chapter. Any warranty servicing of this product not specifically described in this manual must be authorized in writing by Ioline Customer Service. You may obtain service by calling or faxing Ioline Customer Service. The technicians will help you determine the nature of the problem. If factory repair is necessary, you will receive a RMA (Re- turn Material Authorization). Please gather the information indicat- ed on the next page before contacting Ioline or your dealer. 1. When returning a machine, carefully package the equipment in its original container or packaging equivalent. You may purchase shipping containers from Ioline by contacting Ioline Customer Service. Ioline is not responsible for any damage due to inadequate or improper packaging. 2. Carefully wrap and secure all items in the shipping container to prevent damage. Seal the container and note the RMA number near the address block. 3. Ship the container using FED-EX or another approved carrier. COD shipments ARE NOT ACCEPTED. An Ioline representa- tive will contact you prior to the start of work with an estimate of repair cost. All repairs are warranted for 90 days.

Customer service Ioline Corporation is committed to providing quality service and support to our customers. If you need assistance with an Ioline prod- uct, contact your local dealer or Ioline authorized service center. You may also contact: Ioline Customer Service Department Monday through Friday 7:00 A.M. - 5:00 P.M. U.S. Pacific Time Voice: 1.425.398.8282 Fax: 1.425.398.8383 [email protected] www.ioline.com

and storing inkjet cartridges. Repair procedures The diagnostic processes that follow are detailed and invasive. Do not attempt to service the FlexJet until it you determine that simpler solutions fail to resolve the problem (see Troubleshooting). Follow the recommended sequence in Figure 42 when troubleshoot- ing repair issues with the FlexJet and record the results of your diag- nostic examination on the Diagnostic Record (see below). Computer Software Resolution LED Codes Communication Problem Computer Software Resolution Begin recording diganostic information Examine the external components Disassemble, check cabling and connections Examine power supplies Examine logic board Examine motors Contact Ioline Customer Service (if required) Power On Test Power On Test Power On Test Power On Test Begin recording diagnostic information Figure 42. Mechanical, electrical and electronic diagnostics flow chart.

Requesting service If the suggestions and guidelines in this manual don’t fix the prob- lem, fill out the form below and contact Ioline Customer Service. Diagnostic Record n What is the serial number for this unit? ______________ n What is the logic board revision #? ______________ n Name of dealer who sold the machine to you? ______________ n What is the logic board revision #? ______________ n Any lights on the logic board associated with this problem? Y / N n Any lights on the keypad associated with this problem? Y / N n Has the unit worked properly up to the point of this recent failure? Y / N If yes, please describe them: _________________________________ n Any communications or software problems? Y / N If yes, please describe them: _________________________________ n When the printer is first turned on— } Does the carriage move smoothly? Y / N } Does the fan come on? Y / N n With power off, slide the carriage from side to side. } Does the carriage slide easily to each side? Y / N } Is there more resistance to move the carriage: Left / Right / Equal n Were all cable connections securely fastened to the logic board? Y / N n Was the power voltage within the tolerance? Y / N n Record the power supply voltage readings here: TP6 (+30V) ____________ TP7 (+3.3V) ____________ TP8 (+5.0V) ____________ n Were any encoders bad? If yes, which ones? Y / N X motor ____ Y motor ____ Roll Feed motor ____ n Please list any other problems. (Be specific about the nature of the problem and the symptoms associated with it. ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________

Step 1:  Prepare the printer 1. Turn power off to the FlexJet. 2. Clear paper from around the carriage. 3. Remove inkjet cartridges. There is no need to store or cover the cartridge heads. 4. Remove the AC power cable and any other cables connected to the rear of the printer. Step 2:  Remove the end cover 1. Unplug the roll feed motor under the right end cover. 2. Remove the five screws that hold the plastic end cover on the right end of the printer. There are two screws on the flat surface of the end plate, one screw in the back, and two screws on the bottom. (Figure 42.) n Phillips screwdriver n 9/64-in (3.5mm) Allen wrench n 5/16-in (8mm) open-end wrench n Small, flat-tipped screwdriver Parts/tools included with the upgrade kit: n Replacement carriage assem- bly n Tyraps (8) n Grounding wrist strap Required tools Carriage procedures FlexJet carriage replacement Tools Required Observe caution when handling electrostatic- sensitive devices. The discharge of static electric- ity may damage the carriage and logic board components. Use the included ground strap during all procedures. Keep plastic objects away from the carriage and logic board assemblies. Ensure that all AC power cables are removed from the printer before attempting these procedures. Caution The FlexJet is heavy and could cause injury if it falls. A minimum of two people are required to safely unpack the printer and attach it to the stand. Caution

Figure 43. Removing the right end cover. Step 3:  Loosen the carriage belt 1. Find the belt tensioner on the right side above the white cables. 2. Loosen the carriage belt tensioner by rotating the 9/64-in HEX screw 4 full counterclockwise turns. (Figure 44.) Step 4:  Remove the old carriage 1. Remove the Phillips head screw (on the right side of the car- riage cover) that holds the carriage cover on. 2. With one hand to each side of the carriage, gently pull the carriage cover tabs out. The tabs are located near where the car- riage belts attach to the carriage. Remove the carriage cover. Remove cover Figure 44. Loosen the belt tensioner. Loosen this 9/64-in screw

3. Unclip the carriage belt ends at the left and right sides of the carriage base. (Figure 46.) 4. Using a 5/16-in (8-mm) open-end wrench, loosen the #6-32 hex nut one-half turn under the right and left swing arms until the washers and round spacers move freely. (Figure 47.) Figure 45. The carriage cover screw. 5. Hold the carriage at the right and left side of the metal base with both hands. 6. Keeping the top two carriage v-wheels on the traverse, gently push the carriage down (Figure 48) and rotate the bottom of the carriage towards the front of the machine until the lower v-wheels slip off of the lower traverse rail. (Figure 49.) 7. Lift the carriage up and away from the machine. The long flex cable bundle should follow the carriage as you pull it off. 8. Cut the tyraps and disconnect the ribbon cable ends from the back of the carriage. The cables are staggered so there is only one way they can be installed on the new carriage assembly. Figure 46. Unclip the belt from both ends of the carriage. Remove the carriage cover screw Left belt clip Right belt clip Do not hold the carriage by the inkjet head stalls or the sensor. Improper removal or installation of the carriage can damage the carriage wheels. Caution

Step 5:  Install the new carriage 1. Connect the ribbon cable ends to the new carriage and secure with tyraps. Verify that each connector is plugged into all the pins and that the 2 spacers and washers are loose so that the upper wheels are not locked. 2. Ensure that the black drive belt is between the traverse rails and behind the carriage base. Hold the carriage at the right and left side of the metal base with both hands and slip the top two carriage v-wheels over the top rail of the traverse. 3. With the top two carriage v-wheels on the traverse, gently push the carriage down and rotate the bottom of the carriage towards the back of the machine until the lower v-wheels slip onto the lower traverse rail. 4. Gently move the carriage right then left to ensure that the wheels move smoothly. Figure 47. Loosen the carriage wheel lock. Figure 48. Gently press down on the car- riage. Figure 49. Rotate the v-wheels free of the traverse rail. Loosen this nut Press down here on both sides Rotate bottom toward you Do not hold the carriage by the inkjet head stalls or the sensor. Improper removal or installation of the carriage can damage the carriage wheels. Caution

Step 6:  Tighten the carriage swing arms 1. Gently hold the spacer up against the bottom of one of the upper v-wheel swing-arms. The spacer can be held up with a finger or a small screwdriver inserted from the right side of the carriage. 2. While keeping gentle upward pressure on the spacer, securely tighten the nylock nut using a 5/16-in (or 8-mm) open-end wrench. 3. Repeat this process for the other swing arm on the carriage. Figure 50. Carriage installation. Step 7:  Replace tensioner and attach the carriage belt. 1. Attach the belt ends to the right and left side of the carriage. 2. Hold the carriage belt tensioner so that the two tabs and screw tip rest in the holes and detent in the right endplate. (Figure 52.) To the left of the Service Station area, hold both webs of Figure 51. Use the spacer when attaching each swing arm. Tighten nut 5/16-in box wrench Flathead screw driver Push up on cylinder

the carriage belt to maintain slight belt tension so that the car- riage belt tensioner doesn’t move out of place. 3. While maintaining tension on the carriage belt, attach the car- riage belt clips to each side of the carriage base. 4. Tighten the carriage belt tensioner by rotating the 9/64-in (3.5- mm) screw four full clockwise turns. Figure 52. The carriage belt tensioner. Make sure tensioner is in holes Figure 53. Install the carriage cover. Locking tab Make sure the belt is not twisted before attaching the clips. Note i

Step 8:  Install the carriage cover 1. Install the carriage cover by aligning it with the base and pushing back until the tabs by the belt ends grab onto the carriage base. (Figure 53.) 2. Press against the cover tabs to ensure that they ‘snap’ into the slots in the carriage base. 3. Install the #6-32 screw at the right side of the carriage. Tools Required n Philips screwdriver n 9/64-in (3.5-mm) Allen wrench n 5/16-in (8-mm) open-end wrench n Small flat-tipped screwdriver Step 1:  Prepare the printer 1. Turn the FlexJet power off. Remove the AC power cable and any other cables connected to the rear of the printer. 2. Clear paper from around the carriage. 3. Remove inkjet cartridges. Do NOT cover the cartridge heads. Step 2:  Remove the end cover 1. Unplug the roll feed motor under the right end cover. 2. Remove the five screws that hold the plastic end cover on to the right end of the printer. There are two on the flat surface of the endplate, one screw in the back, and two screws on the bottom. Step 3:  Loosen the carriage belt 1. Find the belt tensioner on the right side above the white cables. 2. Loosen the carriage belt tensioner by rotating the 9/64-in hex screw four full, counterclockwise turns. (Figure 55.) Figure 54. Remove the cover. FlexJet Cable replacement Ensure that the FlexJet is unplugged from the wall outlet and that all AC power cables are removed from the printer before replacing the cable. The discharge of static electric- ity may damage the carriage and logic board components. Use the included ground strap throughout the procedure. Attach one end of the ground strap (included in the Upgrade Kit) to your wrist and the other end to a bare metal portion of the printer (like the frame the holds the service sta- tion.) Keep plastic objects away from the carriage and logic board assemblies. Remove the wrist strap only after the new carriage is attached to the traverse, the cover is installed, and the metal cover is secured over the main logic board. Caution The FlexJet is heavy and could cause injury if it falls. A minimum of two people are required to safely unpack the printer and attach it to the stand. Caution

Step 4:  Remove the logic board cover 1. Remove the four screws that hold the sheet metal logic board cover plate. (Figure 56.) 2. Put static strap on. (See Caution in margin on page 69.) Loosen this 9/64-in screw Figure 55. Install the carriage cover. Figure 56. Remove the logic board cover plate. Short screw Remove screws 2 - Front 2 - Rear (Shown) The logic board cover will swing down when the last screw is removed. Make sure to support it with one hand and let it slowly rotate. Caution

3. Unplug the roll feed motor power and encoder cables from the logic board. Set the logic board cover aside. (Figure 57.) 4. Find the white flex cable connections. Gently pull the locking clips on the connector shrouds down to unlock the flex cable connectors. 5. Remove all white flex cables from connectors. (Figure 58.) Figure 57. Unplug the feed motor and encoder cables from the logic board. Unplug take-up wires from the logic board Figure 58. Unplug the ribbon cables. Unplug ribbon cables

Step 5:  Remove the old flex cables 1. With the carriage secured, clip the plastic ties that hold the white flex cables against the right side of the printer. 2. Pull the bundle of cables out of the grey clips (if present). 3. Pull the bundle away from the end plate if it secured with foam tape. Lift the carriage belt tensioner out of the way if necessary. 4. From the front of the machine, pull the bundle through the hole in the end plate. 5. Lift the cable bundle up and off the traverse moving toward the left side of the machine. Don’t worry about the foam tape stuck to the traverse. Step 6:  Attach the new carriage to the traverse Important: Read these steps fully before attempting to attach the carriage. 1. Feed the new ribbon cable bundle into the channel in the tra- verse so that there is a loop to the left of the carriage. (Figure 59.) Lightly press the loop into the groove at the back of the traverse so that it is in the cable channel. 2. Ensure that the black drive belt is between the traverse rails and behind the carriage base. Hold the carriage at the right and left side of the metal base with both hands and slip the top two carriage v-wheels over the top rail of the traverse. 3. Keeping the top two carriage v-wheels on the traverse, gently push the carriage down and rotate the bottom of the carriage towards the back of the machine until the lower v-wheels slip onto the lower traverse rail. Figure 59. Make a loop in the ribbon cable to the left of the carriage. Ribbon cable Do not hold the carriage by the inkjet head stalls or the sensor. Caution

4. Gently move the carriage right then left to ensure that the wheels move smoothly. Figure 60. Carriage installation. Step 7:  Replace tensioner and attach the carriage belt. 1. Guide the ribbon cable bundle under the carriage belt tensioner. 2. Place the new belt tensioner next to the old one. Count the ex- posed screw threads on the old tensioner then rotate the screw in the new one to match the old one. 3. Insert the belt through the new tensioner so that the belt teeth face the pulley. 4. Guide both ends of the belt through the hole in the endplate and in front of the traverse. 5. Hold the new carriage belt tensioner so that the two tabs and screw tip rest in the holes and detent in the right endplate. (Figure 61.) To the left of the Service Station area, hold both webs of the carriage belt to maintain slight belt tension so that the carriage belt tensioner doesn’t move out of place. Figure 61. The carriage belt tensioner. Make sure tensioner is in holes Make sure the belt is not twisted before attaching the clips. Caution

6. While maintaining tension on the carriage belt, attach the car- riage belt clips to each side of the carriage base. 7. Tighten the carriage belt tensioner by rotating the 9/64-in (3.5-mm) screw four, full clockwise turns. Step 8:  Install the carriage cover 1. Install the carriage cover by aligning it with the base and pushing back until the tabs by the belt ends grab onto the carriage base. 2. Press against the cover tabs to ensure that they ‘snap’ into the slots in the carriage base. (Figure 62.) 3. Install the #6-32 screw at the right side of the carriage cover. Figure 62. Install the carriage cover. Locking tab Step 9:  Secure and arrange the ribbon cable bundle - Part 1 1. Hold the ribbon cable bundle out of the way and attach a 10-cm piece of the supplied double sided foam tape to the traverse channel to the right of the existing tape (if present) at the middle of the machine. Remove the tape backing so that the side facing up is exposed. 2. Repeat this process near the right end plate, but place the tape to the left of the existing tape (if present). Remove the tape backing so that the side facing up is exposed. 3. Slide the carriage over to the left endplate and hold it in place. As the left side of the carriage just touches the small round bumpers, look at the ribbon cable bundle loop. It should leave a small gap of no more than .08-in (2-mm) between the sleeving and the left end- plate where the carriage base touches the bumpers. (Figure 59.) 4. To the right of the carriage, hold the ribbon cable bundle down firmly in the traverse channel with the left hand. The wrist ground strap can be removed now, but will need to be worn again later in this procedure. Note i This process is important for proper operation of the FlexJet. The sleeved ribbon cables require a firm connection to the traverse at the middle of the printer and at the right end of the traverse. Leave existing foam tape if the pieces are still sticky and not bunched up. Apply the included foam adhesive tape to the existing foam tape if necessary. Note i

5. With the right hand, smooth the ribbon cable bundle beyond the tape at the middle of the traverse so that the black sleeving is stretched and lays relatively flat and taut. 6. Firmly push the black sleeving into the tape at the middle of he traverse. If it does not stick, apply the supplied non-foam backed tape over the foam tape and repeat the process. 7. Move the carriage to the right 10 inches, then slide it back to the left end plate and ensure that the loop in the cable bundle is still not touching the left endplate. (Figure 64.) Figure 63. There should be a small gap in the ribbon cable loop. Gap Ribbon Cable Lop Ribbon cable Figure 64. The loop in the cable should not touch the left endplate.

Step 10:  Secure and Arrange the ribbon cable bundle—Part 2 1. Continue to smooth the ribbon cable bundle toward the right end plate to stretch the black sheathing so that it lays relatively flat and taut. 2. Firmly push the sleeving into the tape at the right end of the traverse. If it does not stick, apply the foam backed tape over the foam tape and repeat the process. Place tape here Figure 65. Secure the sleeving with tape. Step 11:  Connect the ribbon cables to the logic board 1. Plug the ribbon cables into the logic board in the correct order. 2. Tyrap the cables to the right end plate. 3. Verify that all connectors are properly plugged in. (See Figure 85.) 4. Install the board cover, making sure to plug in the take-up wire connections to the board first. Make sure there are no wires or cables pinched between the cover and the body. 5. Install the right side plastic cover. 6. Connect the power and communication cables. 7. Test the machine for proper functioning. Press the arrows on the keypad to make sure all directions are working. 8. If problems arise call Ioline Customer Service.

Service station procedures Y Fine adjustment for the Service Station This procedure must always be done after replacing or upgrading the carriage assembly. Tools Required n Scotch tape n Phillips screwdriver Step 1:  Service station centering 1. Remove power and communications cables and the right side cover. (Figure 66.) 2. Remove the four Phillips screws that hold the keypad on. Let the keypad hang. Make sure both ends are still plugged in. (Figure 67.) 3. Remove the carriage cover. (One screw on the right side, un- clip the back right and left sides. Figure 68.) Figure 66. Remove the right end cover. Figure 67. Remove the screws and let the keypad hang. Figure 68. Remove the carriage cover. Screw Pull out on the tabs to remove the cover The discharge of static electricity may damage the keypad and components. Use the included ground strap during all procedures. Keep plastic objects away from the keypad and logic board assemblies. Caution

4. Make sure the ink cartridges are installed. Power the FlexJet on. 5. Loosen (do not remove) the car- riage catch bracket. Figure 69. Install the ink cartridges and turn the power on. 6. Place a piece of (clear) scotch tape on the service station spit wells. Figure 71. Cover the spit wells. Figure 70. Loosen the carriage catch bracket. Carriage catch bracket Loosen nut Tape covering the holes in the spit wells

7. Press the “Clean” button on the keypad. You should see two lines in the middle of the spit well holes. 8. If the lines don’t appear in the middle of the holes, turn the plastic thumbscrew on the side of the service station (clock- wise to move them left; Counter-clockwise to move the lines to the right.) Figure 72. After you press the clean button, you should see two lines in the spit well holes. Figure 73. Use the plastic thumbscrew to adjust the lines if necessary. Spit well- centering thumbscrew Lines on the tape 9. Turn the power off, remove the ink cartridges and close the stall latches. After removing the ink car- tridges, lower the blue ink doors before continuing. Caution

Step 2:  Y Fine adjustment The purpose of the Y Fine axis adjustment is to get the bottom of the carriage as close as possible to the ink wells without pressing too hard or leaving a gap. Also, proper adjustment assures the inkjet heads will be capped so they don’t dry out. 1. Turn on the FlexJet and let it initialize. 2. Open the FlexJet Control Center software. 3. When the window opens press Ctrl-Alt-B. You should see the following window. 4. Look at the gap between the bottom of the carriage and the Service Station. With the Y Fine Adjust set, there will be a large gap between the top of the grey ink wells and the bottom of the carriage. Figure 74. Y Fine adjustment is performed within the Control Center. Figure 75. Watch the gap between the carriage and Service Station.

5. Click the Move carriage out from SS button. The carriage will move out of the Service Station. 6. Change the Y Fine Adjust number to -800 and click the Set fine adjust button. 7. Click on the Return carriage to SS button. The carriage will move back into the Service Station. 8. Follow steps 4 thru 6 again adding 100 to the Y Fine Adjust number each time until the bottom of the carriage is just close to touching the grey ink wells. 9. Reduce the gap further by adding smaller numbers. 10. Press and hold the UP Arrow on the keypad of the printer. While holding the button, turn the machine back on. When the carriage starts to move, let go of the button. 11. Once the carriage is back in the Service Station, check the gap one more time to make sure they are touching. Step 3:  Final screw adjustment 1. If you are happy with the spacing between the carriage and the Service Station, turn the service station stop screw on the side of the machine until it just touches the Service Station. 2. Back the screw off one-half turn until you can see a little bit of light between the screw and the service station. Apply Loctite® or Super Glue® to the screw so it won’t back out while the ma- chine is running. (Figure 77.) 3. Move the carriage catch bracket until it hits the magnet. Tight- en the nut to hold the stop bracket. (Figure 78.) Figure 76. The Service Station stop screw. Service Station stop screw A Y Fine Adjust change of 25 mils results in a gap change that is equivalent to the thickness of a piece of paper. A Y Fine Adjust change of 100 mils results in a gap change of 18 mils. Note i

Figure 78. Tighten the nut to hold the stop bracket. Figure 77. You should see a small gap between the screw and the Service Station. 4. If you are happy with the adjustments, turn FlexJet power off. 5. Let the machine sit for 5 seconds, then turn the power back on. 6. When the carriage initializes into the service station check all the gaps and stop brackets to make sure the adjustments are still right. 7. Re-install the keypad. Run a test plot to the machine before put- ting the covers back on. 8. If problems arise contact Ioline Customer Service. Very small gap Magnet w/ rubber bumpers Carriage catch bracket In Step 3, it’s best to use a nut driver that can reach the nut while the carriage is in the service station. Otherwise tighten the nut enough to hold the bracket and move the carriage out of the service station to ??? Note i

Logic Board Procedures Logic board replacement Tools Required: n Phillips head screwdriver n 5/32-in Allen wrench 1. Unplug the take-up motor cable from the bottom of the ma- chine. Unplug the power and serial cable. (Figure 79.) 2. Remove the right side cover of the machine. (Figure 80.) 3. Remove the four Phillips screws that hold the logic board cover on. (Figure 81.) 4. Make sure you are grounded with a static grounding strap. For now, leave the new logic board in its packaging. Remove the logic board cover on the FlexJet. Carefully unplug the take-up connector from the logic board before completelly removing the cover. (Figure 82.) Figure 79. Unplug the take-up motor. Take-up motor cable Figure 80. Remove the right cover. Figure 81. Unscrew the PCB cover. Figure 82. Remove the logic board cover. Cover screws (rear) 5. Label the cables to make it easy to rematch during re-assembly. Carefully unplug the connections from the board. Remove the six silver phillips screws holding the board in the machine.

Support the logic board hand when removing the last screw to prevent it from falling onto the floor. (Figure 83.) Figure 84. Carefully remove the logic board. 6. Pull the edge opposite the serial port out first. (Do NOT force it.) Then pull the PCB away from the rear so the serial port con- nection is not damaged. Figure 83. Carefully unplug connections to the board. Logic board screws 7. Remove the new logic board from it’s packaging. When removing the new logic board from the packaging make sure you have the static grounding strap on correctly. If there is a static discharge to the new board it may not function properly. The strap is included in the replacement kit. Caution

8. Install the new logic board into the machine. Carefully insert the serial port end into the holes in the metal bracket first. Tighten the six phillips screws that hold the board in making sure not to overtighten them. 9. Plug in all the wire connections to the board. Make sure the connectors are not off by a pin. (Figure 85.) 10. Install the board cover, making sure to plug in the take-up wire connections to the board first. Make sure there are no wires or cables pinched between the cover and the body. 11. Install the right side plastic cover. 12. Connect the power and communication cables. 13. Test the machine for proper functioning. Press the arrows on the keypad to make sure all directions are working. 14. If problems arise call Ioline Customer Service. Figure 85. It’s easy to miss a pin when plugging in the logic board. Inspect the con- nections to make certain the board is properly connected. Right Wrong

Updating the firmware Step 1:  Determine your firmware version number 1. Power on the PC and FlexJet. 2. Ensure that the serial cable connects the PC to the FlexJet. 3. Make sure there is a Green light on the keypad of the FlexJet and open the Control Center. 4. The main screen shows the current firmware version in the up- per right corner. 5. If the firmware version is not shown, please check connections to the printer. Call Ioline Customer Service for help resolving communication issues. Step 2:  Manually set the initial Y Fine adjustment number 1. Turn on the FlexJet and let it initialize. 2. Open the Control Center software. 3. When the window opens press Ctrl-Alt-B. You should see the Service Station window. 4. Click the Move carriage out from SS button. The carriage will move out of the Service Station. 5. Change the Y Fine adjust number to -1000 and click the Set fine adjust button. 6. Click on the Return carriage to SS button. The carriage will move back into the Service Station. Step 3:  Auto updating firmware version 253.2 or higher 1. Make sure the firmware file has been saved in the Ioline folder. Choose File>Download Firmware from the menu. 2. Press the Select Firmware button. 3. Follow the on-screen directions that explain how to restart the printer so that it will accept new firmware. Press OK when the printer is ready (four yellow lights on the keypad). 4. Use the window to browse to the location where the firmware file is stored (usually xxxxx.mot, where xxxxx is the version number). 5. A window will appear that shows the transfer progress. 6. The printer will go through the initialization process when the firmware is finished. When finished, the OK light will turn red and the Square light will turn green. 7. Press the Done button when the process is complete. 8. Follow steps for Y Fine Adjustment for the Service Station under the Service Station Procedures section of this chapter. If firmware is a lower number than version 253.2, use the Manu- al firmware update procedure Note i

Keypad procedures Keypad replacement 1. Remove the right end cover. 2. Remove the four screws holding the logic board cover. Unplug the connector from the logic board and set the cover aside. 3. Remove the four Phillips screws holding the keypad to the bracket. Also remove the keypad bracket from the machine. Tools Required n Phillips head screwdriver 4. Unplug the keypad cable from the keypad and the logic board 5. Screw the new keypad and bracket to the machine and connect the keypad cable to the logic board. (Hold the keypad cable straight out from the keypad. The bottom lead in the cable should go to Pin 1.) 6. Test the machine to make sure the new keypad works. 7. Remove the old take-up connector from the bottom of the old logic board cover, and install it on the new cover. 8. Install the new board cover making sure to plug in the take- up wire connections to the board first. Make sure there are no wires or cables pinched between the cover and the body. 9. Re-install the right side cover if everything works. Figure 86. Remove the keypad screws and bracket. Unplug the keypad cable. Keypad bracket Keypad screws Keypad cable

Y-Axis procedures Y-Axis transmission adjustment This procedure covers tightening the setscrews on the Y-Axis trans- mission. If you are experiencing size or skipping problems while printing, follow this procedure as one possible fix. Tools Required n 5/64-in Hex wrench Tighten the setscrews shown on the Y-Axis transmission. Figure 87. Try tightening the screws on the Y-Axis transmission if you see evidence of skipping problems on your plots. 5/64-in Screws 5/64-in Screws Y-Axis belt adjustment A y-belt that is too loose can cause belt tooth skip resulting in inac- curate plots. A y-belt that is too tight can generate excessive noise. Follow these steps to adjust the Y-axis belt tension. 1. Send a plot to the printer. 2. Hold the motor with one hand and using a screwdriver loosen the 3 screws that attach the motor to the transmission bracket. 3. Pull the motor to tension the belt. Excessive tension will create a loud whining noise. Tension the belt so that the transmis- sion sounds quiet, does not whine, and the belt teeth smoothly engage the pulley teeth. 4. Securely tighten the 3 motor screws. The following steps in- volve machine adjustment during printer operation. Keep fingers and loose clothing away from the y-motor transmis- sion. Caution

X-Axis procedures If you are experiencing variable frame gap or shifting of the paper in the Y direction this may indicate that the motor or driveshaft pulley setscrews have loosened or that the belt tension is too low. Using a 1/16-in Hex wrench, tighten the 2 setscrews per pulley. Make sure that the motor pulley has one setscrew tightened onto the flat area of the motor shaft. The belt tension can be adjusted by loosening the 3x motor screws, pushing the motor pulley to adjust belt tension and then retightening the screws.

FlexJet BOM (Bill of Materials) Part Number Description SEQN QTY 107758 SERVICE STATION ASSY, FJ 1 1 107215 PINCHWHEEL ASSY, 6 LB, 1:1, PLASTIC 2 8 108495 KEYPAD ASSY, FJ 3 1 108270 CARRIAGE ASSY, FJ, FRAME-UP 4 1 108227 ASSY, Y TRANS, GT 5 1 107588 TOP BAR ASSY, 600/28AE 6 1 107700 SUPPORT ASSY, TOP BAR, LEFT 7 1 107701 SUPPORT ASSY, TOP BAR, RIGHT 8 1 107590 SHAFT, TOP BAR, 600/28AE 9 1 107698 SPACER, C-SHAPE, 10 OD, .25ID 10 1 106708 TENSIONER ASSY, SC98 11 1 107699 DRIVE SHAFT ASSY, INK-JET 12 1 106684 LEVER ASSY, PINCHWHEEL, REAR 13 1 108225 Y BELT ASSY, GT, 3MM PITCH 14 1 107830 COVER ASSY, BOTTOM, LEFT 15 1 107833 COVER ASSY, BOTTOM, RIGHT 16 1 108305 TAKE-UP ASSY, RIGHT, FJ 17 1 107697 PLATEN, FLEX JET 18 1 107828 TRAVERSE, FLEXJET 19 1 108264 DUST COVER, FJ 20 1 108201 SPACER, DRIVESHAFT, PL, 8.6LG 21 1 108202 SPACER, DRIVESHAFT, PL, 9.3LG 22 1 107774 PLATE, END, RIGHT, FJ 23 1 107775 PLATE, END, LEFT, FJ 24 1 107886 BRACKET, POWER SUPPLY, 5X9 25 1 108252 CHANNEL, TOP, RIGHT, FRONT 26 2 108251 CHANNEL, TOP, LEFT, FRONT 27 2 108349 COVER, LOGIC BOARD, FJ 28 1 106845 SHAFT, CAM, I/S 600 31 1 106550 BELT, .080 X 1/4 X 100T 32 1 100279 CONN, CABLE CLIP 33 10 103026 CONN, CABLE CLIP, .18 DIA 34 3

Part Number Description SEQN QTY 103027 TYRAP, .1 IN X 5 3/4 LG 35 30 106816 MOTOR, SERVO, 24V 36 1 103740 TAPE, FOAM, .5 IN, .025 THICK 37 1 100705 PAD, PEN CAP, 1/4 DIA 38 6 106649 LABEL, DRIVE AREA 39 12 106652 RIVET, PLASTIC, .2 GR X .169 OD 40 8 106693 BUSHING, NYLON,.52ID, .62OD, .75FL 41 2 105933 PULLEY, 16T X .080 X 1/4 43 1 104180 SCREW, #8, .50 LG, SLF TAP, PHP, SE 45 18 105514 SCREW 1/4-20, 1.75 LG, BTM HD SOCK 48 2 104590 SCREW #8, .50 LG, ST, FHP 49 10 102726 SETSCREW #10-32, .75 LG, STEEL 50 15 104013 NUT, #8-32, KEP 51 10 107211 COTTER PIN, 1/8 X .75 53 2 102281 SCREW #10-32, 1.0 LG, PHP 54 1 107850 CABLE ASSY, MOTOR, X, IJ02 55 1 107852 CABLE ASSY, MOTOR, Y, IJ02 56 1 107853 CABLE ASSY, ENCODER, LONG, IJ02 57 2 107854 CABLE ASSY, MTR/ENC, TU, IJ02 58 1 107856 CABLE ASSY, MOTOR, SS, IJ02 59 1 107857 CABLE ASSY, ENCODER, SS, IJ02 60 1 107859 CABLE ASSY, TU SENSOR, IJ02 62 1 108328 PROC, INST, FJ PCB ASSYS 63 1 107861 CABLE ASSY, FAN, SHORT, IJ02 64 1 107862 CABLE ASSY, FAN, LONG, IJ02 65 1 107864 CABLE ASSY, POWER, DC, IJ02 66 1 106951 SPRING, TORSION, .53 ID, .045 WIRE 67 1 108496 POWER SUPPLY, CALIBRATED, 30V 69 1 108177 FAN ASSY, 24-48 V, W/CONN 70 2 104717 NUT, #10-32, HEX, NYLOCK 71 8 108192 POWER ENTRY ASSY, AC, FJ 72 1 107849 CAP, VINYL, .437”D X 1.5”L 73 1 108350 RAMP, STATION, FJ 74 1 108242 MAGNET, NEO, .5 OD, .375 LG 75 1 108074 COVER, WIRE, FJ 78 1 106750 CAP, VINYL, .093 ID, BLK 79 2 103260 SCREW #4-40, .75 LG, PHP 80 4 108314 FERRITE, MOTOR ENCODER, FLEXJET 82 4 105930 LABEL, WARNING, CRUSH HAZARD 83 1 108316 FERRITE, MOTOR POWER, FLEXJET 84 4 107502 WSHR, .500 OD, .145 ID,.031 T, PTFE 85 2 106532 NUT, #6-32, HEX, NYLOCK 86 2 100020 SCREW #6-32, .187 LG, PHP 87 4 100046 SCREW #8-32, 1.25 LG, SHC, FULL THD 88 2 107738 SENSOR, OPTICAL 90 2

Part Number Description SEQN QTY 101601 NUT, #4-40, HEX, THIN NYLOCK 91 6 102219 LEVELER, 1.5 PAD, 3 IN ADJUST 92 2 108271 SHIELD, LOGIC BOARD, FJ 94 1 104471 TAPE, UHMW, .43 WIDE 96 2 103726 TYRAP, .1 IN X 3 IN, BLACK 97 4 104726 GROMMET STRIP, CONTINUOUS 7/64 98 9 108453 CAP, ETHERNET PORT 100 1 106528 TAPE, DOUBLE COATED, 1.25 W 101 1 102220 NUT, #3/8-16, HEX 102 2

2 8X 4 12 8 14 19 20 22 21 69 SEE DETAIL D 70 2X 78 92 2X 15 16 40 8X 49 10X 45 2X 4X 9X 41 39 12X 6 80 2X 90 27 91 2X 25 87 4X 31 13 67 73 2X 72 51 2X 71 2X 41 2X 2X 80 2X 90 26 91 2X 53 2X 79 7 REF 32 51 4X 5 91 2X 1 23 2X 93 9 18 50 15X 26 54 71 2X 24 27 45 43 36 90 48 79 88 79 2X 38 2X 71 2X 98 7 10 38 2X A A B C C B 2x REF 5X 71 2X 3 45 17 51 85 51 83 86 11 48 99 37 30 75 38 74 14 45 100 94 88 Ioline FlexJet (Exploded view) Ioline FlexJet (P/N: 107772)

GRN/YEL BLK GRN COM V1 NEUTRAL LINE WHT BLK 56 55 57 57 58 59 60 62 63 64 65 66 84 4X 82 4X 34 3X 35 2X 63 REF 55 REF 56 REF 35 20X 33 9X 56 REF 57 REF POWER SUPPLY WIRING GND 35 10X 33 VIEW A-A VIEW B-B VIEW C-C DETAIL D 3 KEYPAD Ioline FlexJet (Electronics view) Ioline FlexJet (P/N: 107772)

Adobe® Illustrator® 19 Assembly xv Lifting technique xiii ASTM 19, 23 AutoCad® 19 B Baud rate 26, 27, 34, 37, 41 Belt tensioner 64, 67, 68, 69, 72, 73, 74 Best mode 20, 28 Bill of Materials 22, 91–93 BOM—See Bill of Materials Bottom Pan 22 C Cable Replacement 69–76 Cables Power cord 24, 41 Calibration 25, 26, 46–48 Cartridge alignment 46, 47 Frame gap 46 Motion adjustment 46, 48 Size 26 Carriage xviii, 21, 22, 24, 25, 27, 30, 32, 36, 38, 39, 44, 61, 63, 64, 66, 67, 69, 72, 73, 74, 78, 82 Assembly 32 Close-up view xviii Latch 32 Magnetic stop plate 32 Notched ‘V’—See Set origin Red light alignment indicator 32 Replacement 63–68 Stall xviii Carriage latch 32 Carriage rail—See Traverse Carriage stall 32 Carriage stop adjustment screw 30 Carriage swing arms 67 Cartridge “Spit” wells 30 Cartridge Caps 30 Cartridges—See Ink cartridges Cartridge wipers 30 Clean 40, 44 Clipping 27 Communications Baud rate 26, 27, 37, 41 Data bits 37 Flow control 37 Parity 37 Conflicts 25 Errors 34–35 Get plotter data 27 Ports—See Serial port, USB RS-232 20, 21 Send Command 26 Settings 26 COM port 26, 27, 37—See also Communications Consumables Paper Proper paper path 42 Control Center xv, 24, 25, 26, 27, 37, 38, 39, 40, 46, 47, 80, 86 Cartridge calibration 26

98 Cartridge count 27 Download firmware 26 Error messages 34–35 Exit 26 Frame size 27 Get plotter data 27 Help about 26 Installation 24 Line width 27 Main Menu 25 Measurement units 28 Menu Bar 26 Menu Options 27 Quality setting 28 Reset machine ID 26 Scale 27 Screen Menu 25 Send command 26 Send plot file 26 Set key code 26 Set machine ID 26 Settings 26 Size calibration 26 Software version 27 Control panel—See Keypad Conversion 23 CorelDraw!® 19 Covers xvi Cross-member xvii Customer service 59 Contact information 59 D Dancer bar Front dancer bar 42 Insertion 19, 21, 29, 30, 31, 32 Rear (heavy) dancer bar 42 Data bits 37 Design software 22, 27, 37, 38, 41 DM/PL 19, 20, 22, 23 Draft mode 20, 28 Drive shaft 39, 43 Drive shaft marker xviii Location xviii DXF 19, 20, 23 E End covers xvi Error codes Firmware update 36 Keypad errors 36 Error messages 33 F Feed roll xvi, 42 Feed shaft xvi, 40 File formats 22, 23 Files Conversion 23 Download firmware 26 File name extensions EPS 26 PLT 26 PLX 26 Plot file adjustments—See Control Center Send plot file 26 Firmware 26, 34, 86 Software version 27 Updating 26, 35 FlexJet Connections 37 Front close-up xviii Front View xvi Pre-wiring for expansion 26 Rear view xvii Settings 27 Start-up process 24 FlexJet Control Center—See Control Center FlexJet Quick Start Guide xv, 39, 43 FlexJet User Guide xiv, 42, xv, 38, 43, 44, 46, 49 FlexPlot xv, 19, 22, 23, 24, 37 Installation 24 Workflow using CAD software 23 Workflow with FlexPlot 23 FlexPlot User Guide xv, 22, 24 Flow control 37 Foot Platen leveling foot close-up xvii Stand leveling foot close-up xvi Frame gap 38, 40, 46, 48, 49

Frame size 27 Front dancer bar 42 Front top bar 42 Fuse holder 51 G Gerber® 19, 20 Get Plotter Data 27 Gray bars xiii Lifting by gray bars xiii Grease 40 Green light mode—See also START Mode H Help 58–60 HPGL 19, 20, 22, 23 I Ink cartridge motion 21 Ink cartridges—See Ink cartridges Active 27 Calibration 26, 46–48 Calibration & alignment 26 Cartridge count 27 Cartridges in stalls xviii Cartridge stall latch xviii Cartridge stall problems 50 Ink level indicator 40, 44 Empty cartridge 44 Maintenance and handling 44 Stalls xviii Upgrading number of stalls 26 Investronica® 19, 20 Ioline Corporation 59 IPS software 19 J K Keypad 24, 25, 36, 40, 44 Clean 40, 44 Error codes 36 Lights LED lights 36 OK light 24, 25, 37 Square light 24, 25, 37 Page advance 37 Set origin 38, 39 Start/Stop 44 L Lectra® 19, 20 LED error codes 36 Left end cover xvi Leveling foot xvi, xvii Leveling pads—See Leveling foot License key code 26 Limit of liability statement xiv Line quality—See Printing Quality Line width 20, 25, 27, 28—See also Printing Quality Logic board 26, 31, 53, 54, 55, 61, 62, 63, 69, 70, 71, 77, 83, 84, 85, 87 Changing 26 Fans 31 Rev 1 31 Rev 2 31 Ribbon cable socket 31 Troubleshooting 55–57 logic board 76 Loss of registration between frames 38 M Machine ID 26 Main Power 31 Maintenance xv, 38, 40, 43, 44 Markers Length 20 Removing xv Scale—See Control Center

100 Measurement Units 28 Media 43 Paper type 20 Tracking 43 Width 20 Media tracking 40 Menu Control Center 26 Motor xvi, 21, 31, 52, 54, 55, 63, 69, 71, 83 N O OK light 24, 25, 37 Operating system 24 Optical sensor—See Sensor Optitex® 19, 20 Origin 36, 38, 39 P PAD® 19, 20 Page advance 37 Paper hub xvi Paper jams—See Troubleshooting Paper loading xv Paper motion 21 Paper Out Sensor 52 Paper path 39, 42 Correct feeding path 42, 44, 45, 46, 47, 48, 49, 50, 51, 52, 54, 61, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 87, 88 Paper sensor 39 Parity 37 Pinchwheel Assembly 30 Location of xviii Pinchwheel lever xviii, 42 View from front xviii Platen xvii, xviii, 39, 42 Platen leveling foot xvii Plot 22, 28, 39, 40, 43 Adjustments with Control Center 25–27 Frame 27, 38, 40 Frame size 27 Line width 25, 27, 28 Scale 25, 27 Sending to printer 25 Send Plot File 26 Setup 22–23 X-axis 27 Y-axis 27 Plotter Data 27 Plotting pens—See Ink cartridges Plotting quality—See Printing quality PLT 19, 26 Polytropon® 19, 20 Power cord 24, 41 Power panel assembly 29 Power requirements 20 Power supply 29 Power switch xvii, 24 Pre-wiring for expansion 26 Printer settings 24, 25, 26, 27, 37, 38, 39, 40 Max. plotting width 20 Resolution 20 Printing Page advance 37 Quality 28 Queue management 23 Recommended software 22 Removal—See Unroll Send plot files to printer 26 Workflow 22–23 Using CAD software 23 Using FlexPlot 23 Q Quality—See Printing quality Queue management 23 R Rear dancer bar 42