Barcelona Division Technical Marketing Department

CP

HP DesignJet Technical Training Advanced Training: Module 2.CP

HP DesignJet CP Series Printers

Diagnostics and Calibrations

HP Internal

This module last updated: 3- Dec-98

Diagnostics and Calibrations: Objectives This module: lists all the diagnostics and calibrations in Service Mode, explains the purpose and operation of each diagnostic and calibration routine, explains key user-accessible troubleshooting tools, explains the purpose and operation of the Tester PCA.

Diagnostics and Calibrations: Contents

CP

1. User-Accessible Tools (inc. Transport Mode) 2. Service Mode Introduction 3. Service Mode Diagnostics 4. Service Mode Calibrations 5. Tester PCA

2.cp.f Slide 2 3-Dec-98 HP Internal

Contents

1. User-Accessible Tools (1 of 4): Image Quality Print

Utilities Service Tests Image Quality Print

CP

Purpose To troubleshoot image-quality problems due to printheads or media. Operation To be printed in A3/B size, on the same media type that shows the image-quality problems in question. For details of how to use it, see User's Guide.

2.cp.f Slide 3 3-Dec- 98 HP Internal

Image Quality Print

1. User-Accessible Tools (2 of 4): Printhead Recovery

STATUS Recovering printheads .

CP

Prime printhead

Warm and spit the printhead while priming

This recovery is included in case of misdirected nozzles, weak nozzles or nozzles out, due to: l long periods of inactivity, l uncapping periods, l internal printhead problems (air, dust, fibers).
Capping Priming Wiping

Wipe printhead

Warm and spit all nozzles in all printheads

2.cp.f Slide 4 3-Dec- 98 HP Internal

End

Printhead Recovery

1. User-Accessible Tools (3 of 4): Accuracy Calibration

CP

Purpose To perform the media advance calibration recommended when there are banding problems due to mechanical accuracy. Operation l The media recommended for this calibration is HP Matte Film, to ensure a good dot placement control. l For details of how to run the calibration, see User's Guide. l The results of this calibration are stored in the user's area of the EEROM, and so you can always recover the factory default values.

2.cp.f Slide 5 3-Dec- 98 HP Internal

Accuracy Calibration

1. User-Accessible Tools (4 of 4): Transport Mode

Purpose To prepare the printer properly for removal or long-term storage, so that damage is avoided. Operation l The relevant front-panel option is under the Utilities menu. l For further information o the procedure, refer to the User's Guide, under Maintaining Your Printer.
2.cp.f Slide 6 3-Dec- 98 HP Internal Set transport YES-> mode NO->

CP
Open right door to access head cleaners

STATUS Accessing printheads Open window to access printheads

Close window to continue Remove all ink cartridge(s)

Remove all printheads

Close left door to continue

Open left door to access ink cartrg.

STATUS Checking ink system

Remove all head cleaner(s)

Switch power off

Transport Mode

2. Service Mode Introduction (1 of 3): Entering Service Mode

CP

1
Switch OFF

+
2.cp.f Slide 7 3-Dec- 98 HP Internal

Switch ON

Entering Service Mode

1. Switch off the printer using the rear switch. 2. Holding down the front-panel up-arrow and Enter keys simultaneously, switch the printer on. 3. Wait until the 'Initializing' message is displayed on the front panel before releasing the keys. 4. If you have successfully entered Service Mode, you will see letters at the bottom-right corner of the front-panel display changing. 5. When 'Ready' is displayed, go to Utilities > Service test.

2. Service Mode Introduction (2 of 3): Characteristics

CP

l Sensors disabled inside the calibrations and diagnostics

menus. This means that if carriage is moving and you open the window, the carriage will not stop.
l Diagnostics and calibrations menus visible. l The printer will re-initialize into Normal Mode after

five minutes without activity.

2.cp.f Slide 8 3-Dec- 98 HP Internal

Service Mode Characteristics

2. Service Mode Introduction (3 of 3): Navigation

CP

Previous: Exit current diagnostic/calibration (when finished). Up-arrow: Go to the next diagnostic/calibration. Down-arrow: Go to the previous diagnostic/calibration. Enter: Perform current diagnostic/calibration. Cancel: Move carriage to left (if required). Form Feed and Cut: Move carriage to right (if required).
C0X Diag. Name C0X00 OK C0X Diag. Name C0XYY Fail
2.cp.f Slide 9 3-Dec- 98 HP Internal

The calibration/diagnostic has been successful. The calibration/diagnostic has failed. Refer to the service manual for details of the failing part.

Service Mode Navigation

3. Service Mode Diagnostics (1 of 17): Checklist

D01 D02 D03 D04 D05 D06 D07 D08 D09
2.cp.f Slide 10 3-Dec- 98 HP Internal

CP

Electronics Line Sensor Carriage Axis Media Axis Service Station Refill mechanism Front Panel Sensors MIO presence

D10 D11 D12 D13 D14 D15 D16 D17 D18

Cutter Bail Image Quality Printhead ID Printhead Continuity Clean roller Erase EEROM Reset counters HDD revision

Service Mode Diagnostics

3. Service Mode Diagnostics (2 of 17): D01 Electronics

Purpose To check operation of: l Electronics module l Trailing cable l Carriage electronics l Line sensor presence l Hard disk
D01 Electronics D0100 OK

CP

Code Description
D0101 D0102 D0103 D0104 D0105 D0106 Swath RAM failure Printhead control ASIC failure EEROM failure Hard disk failure Line Sensor failure Printheads / trailing cable / carriage failure

or
2.cp.f Slide 11 3-Dec- 98 HP Internal

D01 Electronics D010X Fail

Service Mode Diagnostics

3. Service Mode Diagnostics (3 of 17): D02 Line Sensor

Purpose To check correct behavior of line sensor. (This tests the overall behavior; the LEDs electronics are tested by D01.)
Load white media if necessary. M0004 7200 Move carriage

CP

Move carriage by pressing Cancel and Form Feed and Cut. When at correct location, press Enter.

GREEN OK V: 7.50 BLUE OK V: 11.00 To exit, press Previous.

2.cp.f Slide 12 3-Dec- 98 HP Internal

or

GREEN Fail V: 11.00 BLUE Fail V: 13.50

Line Sensor D0200 Done

Service Mode Diagnostics

3. Service Mode Diagnostics (4 of 17): D03 Carriage Axis

Purpose To check correct behavior of carriage-axis assembly.
D03 Carriage Axis D0300 OK 117C

CP

Assembly working correctly.

Maximum measured PWM and position where it has been found (R/C/L)

or
D03 Carriage Axis D030X Fail 160L

Code Description
D0301 D0302 D0303 Static friction test failure PWM too low (<0) PWM too high (>140) Encoder incorrect

2.cp.f Slide 13 3-Dec- 98 HP Internal

D0304

Service Mode Diagnostics

3. Service Mode Diagnostics (5 of 17): D04 Media Axis

Purpose To check correct behavior of media-axis assembly.

CP

D04 Media Axis D0400 OK 117

Assembly working correctly.

Measured PWM

or
D04 Media Axis D040X Fail XXX

Code Description
D0401 D0402 D0403 Accuracy test failure PWM too low (<50) PWM too high (>170) Mark not found

2.cp.f Slide 14 3-Dec- 98 HP Internal

D0404

Service Mode Diagnostics

3. Service Mode Diagnostics (6 of 17): D05 Service Station

Purpose To test service station and primer assemblies.
D05 Service Station D0500 OK

CP

Assemblies working correctly. Primer assembly failure. Service station assembly failure.

or
D05 Service Station D0501 Fail

or
D05 Service Station D0502 Fail
2.cp.f Slide 15 3-Dec- 98 HP Internal

Service Mode Diagnostics

3. Service Mode Diagnostics (7 of 17): D06 Refill Mechanism

Purpose To test refill and elevator assemblies.
D06 Refill D0600 OK

CP

Assemblies working correctly. Refill assembly failure. Elevator assembly failure.

or
D06 Refill D0601 Fail

or
D06 Refill D0602 Fail
2.cp.f Slide 16 3-Dec- 98 HP Internal

Service Mode Diagnostics

3. Service Mode Diagnostics (8 of 17): D07 Front Panel

Purpose To test front-panel keys and LEDs.
M0012 8 Press Enter Key D07 Front Panel D0700 OK D07 Front Panel D0701 Fail
2.cp.f Slide 17 3-Dec- 98 HP Internal

CP

At the start of this test all front-panel LEDs are should be lit. Check them visually.
Second counter

Press key indicated within 10 seconds. Front-panel keys working correctly. One key timed out.

Service Mode Diagnostics

3. Service Mode Diagnostics (9 of 17): D08 Sensors

Purpose To test all sensors by activating them.
Code Description
M0026 8 Remove Black Valve Second counter
D0801 D0802 D0803 D0804 D0805 D0806

CP

Windows sensor failure Left door sensor failure Right door sensor failure K valve sensor failure M valve sensor failure C valve sensor failure Y valve sensor failure Standby button failure Media sensor failure Pinch-arm sensor failure

Follow instructions within 10 seconds. Sensors working correctly. Sensor timed out.

D08 Sensors D0800 OK D08 Sensors D08XX Fail

2.cp.f Slide 18 3-Dec- 98 HP Internal

D0807 D0808 D0809 D0810

Service Mode Diagnostics

3. Service Mode Diagnostics (10 of 17): D09 MIO Presence

Purpose To test communication between main PCA and MIO PCA (not the MIO itself).
D09 MIO Presence D0900 OK

CP

Communication correct. MIO failure or not present or incorrectly inserted.

or
D09 MIO Presence D0901 Fail

2.cp.f Slide 19 3-Dec- 98 HP Internal

Service Mode Diagnostics

3. Service Mode Diagnostics (11 of 17): D10 and D11 Cutter & Bail
Purpose To check correct behavior of cutter (D10) and bail (D11).

CP

Assess whether the assemblies are working correctly or not by visual inspection.
D10 Cutter D1000 Done
2.cp.f Slide 20 3-Dec- 98 HP Internal

D11 Bail D1100 Done

Service Mode Diagnostics

3. Service Mode Diagnostics (12 of 17): D12 Image Quality

Purpose To check if various image quality attributes have been calibrated correctly.
Status Aligning printhead SAD CYAN: SAD MAGENTA: SAD YELLOW: SAD BLACK: 0.2 0.0 0.1 0.9

CP
Scan Axis Directionality values X-Axis Color-toColor alignment values Y-Axis Color-toColor alignment values

C2C X CYAN: 0.1 C2C X MAGENTA: 0.0 C2C X YELLOW: C2C X BLACK: 0.4 0.0

Output l Units: nozzles l Limits: 1 < value < 1

2.cp.f Slide 21 3-Dec- 98 HP Internal

C2C Y CYAN: -0.4 C2C Y MAGENTA: 0.0 C2C Y YELLOW: C2C Y BLACK: BIDIR 20: BIDIR 28: -0.5 0.0 0.2 0.3

D12 Image Quality D1200 Done

Bi-directional error values

Service Mode Diagnostics

3. Service Mode Diagnostics (13 of 17): D13 Printhead ID

Purpose To display printhead identifiers.
C:200000 M:200000 Y:200000 B:200000

CP

Printheads with imaging ink.

C:220000 M:220000 Y:220000 B:220000

Printheads with UV ink.

D13 Printhead ID D1300 Done

2.cp.f Slide 22 3-Dec- 98 HP Internal

Diagnostic finished.

Service Mode Diagnostics

3. Service Mode Diagnostics (14 of 17): D14 Printhead Continuity

Purpose To test electrical continuity between printhead and electrical carriage connections
PH addr: Cyan ps: PH addr: Magenta ps: PH addr: Yellow ps: PH addr: Black ps: 0 0 0 0 0 0 3fffff 3fff

CP

All contacts correct.

No contact detected (no printhead loaded). Diagnostic finished.

2.cp.f Slide 23 3-Dec- 98 HP Internal

Printhead Cont. D1400 Done

Service Mode Diagnostics

3. Service Mode Diagnostics (15 of 17): D15 Clean Roller

Purpose To help with removal of ink spilled on right side of drive roller.
M0005 Move Roller 0

CP

Excessive ink reflectance can cause either media rejection (due to edge-sensing failure) media shifting effect.

Use up- and down-arrow keys to move drive roller. Operation finished.

D15 Clean Roller D1500 Done

2.cp.f Slide 24 3-Dec- 98 HP Internal

Service Mode Diagnostics

3. Service Mode Diagnostics (16 of 17): D16 Erase EEROM

Purpose To reset EEROM and recalculate checksum (calibrations not included).
D16 Erase EEROM D1600 Done M0100 0 Yes=ENTER No=PREV D16 Erase EEROM D1601 Fail D16 Erase EEROM D1600 Cancelled

CP

Diagnostic successfully completed. Diagnostic failed.

2.cp.f Slide 25 3-Dec- 98 HP Internal

Diagnostic canceled.

Service Mode Diagnostics

3. Service Mode Diagnostics (17 of 17): D17 Reset Counters

Purpose To reset internal counters after preventative maintenance.
D17 Reset Counters D1700 Done M0100 0 Yes=ENTER No=PREV D17 Reset Counters D1701 Fail D16 Reset Counters D1700 Cancelled

CP

Diagnostic successfully completed. Diagnostic failed.

2.cp.f Slide 26 3-Dec- 98 HP Internal

Diagnostic canceled.

Service Mode Diagnostics

4. Service Mode Calibrations (1 of 17): Checklist

C01 C02 C03 C05 C06 C07 C08 C09 C10
2.cp.f Slide 27 3-Dec- 98 HP Internal

CP

Carriage Refill Line Sensor Printhead Alignment Printhead Check Color Calibration (DJ2500 and DJ3500) Media Advance accuracy Maintenance counters HDD Font Type (DJ2500 and DJ3500)

Service Mode Calibrations

4. Service Mode Calibrations (2 of 17): Context

CP

2.cp.f Slide 28 3-Dec- 98 HP Internal

Service Mode Calibrations

4. Service Mode Calibrations (3 of 17): C01 Carriage

Purpose To calibrate and set printheads working temperature.

CP

C01 Carriage C0100 OK C01 Carriage C01XX Fail

Assembly calibrated. Assembly not calibrated.

2.cp.f Slide 29 3-Dec- 98 HP Internal

Service Mode Calibrations

4. Service Mode Calibrations (4 of 17): C02 Refill Calibration (1 of 5)

Purpose To ensure correct position of carriage assembly with respect to refill assembly. Tools l All these tools are part of the carriage assembly and refill assembly replacement kit, which also includes instructions.
l Items 1 and 2 are also included
2.cp.f Slide 30 3-Dec- 98 HP Internal

CP

1. Digitizing sight

2. Calibration printhead

3. Spanner

4. Gauge 2000CP Series: 2-level gauge 3000CP Series: 3-level gauge

in the electronics module replacement kit.

Max

Min

Max Min Nominal

Service Mode Calibrations

4. Service Mode Calibrations (5 of 17): C02 Refill Calibration (2 of 5)

Setting the Printhead Height This calibration is most accurate with the left cover on, so some models have a small round hole on the left side of the left cover, enabling you to perform the procedure without having to remove the cover. If there is no hole, remove the left cover.
2.cp.f Slide 31 3-Dec- 98 HP Internal

CP

1. Loosen the two back screws on the carriage.

2. Tighten or loosen the back top screw in order to calibrate the printhead height. Use the correct gauge. l 2000CP Series: minimum height. l 3000CP Series: nominal height.

Service Mode Calibrations

4. Service Mode Calibrations (6 of 17): C02 Refill Calibration (3 of 5)

Setting the correct refill position Align both dots in the center.

CP

To calibrate on the Z-axis See next slide.

Z-axis refill position

To calibrate on the Y-axis Use the two front-panel keys Cancel or Form Feed and Cut.

2.cp.f Slide 32 3-Dec- 98 HP Internal

Y-axis refill position

Cancel=L Form Feed=R Continue------------------>

Service Mode Calibrations

4. Service Mode Calibrations (7 of 17): C02 Refill Calibration (4 of 5)

To calibrate on the Z-axis 1. Loosen the refill slide rods screw. 2. Holding the screwdriver in place, turn the spanner to move the refill up and down. 3. Holding the spanner in place, tighten the screw to secure the position.

CP

2.cp.f Slide 33 3-Dec- 98 HP Internal

Service Mode Calibrations

4. Service Mode Calibrations (8 of 17): C02 Refill Calibration (5 of 5)

Replacing the electronics module When the electronics module is replaced, you adjust the refill position on the Y-axis, as stored on the EEROM, but change neither the printhead height nor the refill position on the Z-axis (mechanical positions).
2.cp.f Slide 34 3-Dec- 98 HP Internal

CP

Y-axis refill position For instructions, see previous slide.

Service Mode Calibrations

4. Service Mode Calibrations (9 of 17): C03 Line Sensor

Purpose To calibrate the current range of the internal green and blue LEDs with respect to the light reflected over the media. (Sensor is used to detect media edges and read calibration patterns.)
C03 Line sensor C0300 OK C03 Line sensor C0301 Fail

CP

Assembly calibrated. Assembly not calibrated.

2.cp.f Slide 35 3-Dec- 98 HP Internal

Service Mode Calibrations

4. Service Mode Calibrations (10 of 17): C05/6/7 Writing System Calibrations

CP

These calibrations are exactly the same as the equivalent automatic calibrations, as explained in the Writing System module (2.CP.e). C05 Printhead Alignment C06 Printhead Check

C07 Color Calibration

2.cp.f Slide 36 3-Dec- 98 HP Internal

Service Mode Calibrations

4. Service Mode Calibrations (11 of 17): C08 Accuracy Calibration (1 of 4)

Purpose To perform the media advance calibration, recommended for banding problems due to mechanical accuracy.
l Use HP Matte Film to ensure good
Create pattern-----> Measure pattern---->

CP

control of dot placement.

l Results stored directly in Factory

Area of EEROM, overwriting default values.

2.cp.f Slide 37 3-Dec- 98 HP Internal

Service Mode Calibrations

4. Service Mode Calibrations (12 of 17): C08 Accuracy Calibration (2 of 4)

CP

The accuracy calibration calibrates just those mechanical parts of the printer related to media advance, in order to avoid advance error.
Mark encoder Helical gear Disk encoder and sensor

Drive roller
2.cp.f Slide 38 3-Dec- 98 HP Internal

Worm gear

X-motor

Service Mode Calibrations

4. Service Mode Calibrations (13 of 17): C08 Accuracy Calibration (3 of 4)

Advance position (inches)

CP

Roller position (degrees) Nominal position Roller diameter error

2.cp.f Slide 39 3-Dec- 98 HP Internal

Roller eccentricity Worm gear eccentricity

Service Mode Calibrations

4. Service Mode Calibrations (14 of 17): C08 Accuracy Calibration (4 of 4)

CP

2.cp.f Slide 40 3-Dec- 98 HP Internal

Heating Areas (usually with image quality problems, e.g. banding, nozzles out, etc)

Service Mode Calibrations

4. Service Mode Calibrations (15 of 17): C09 Maintenance Counter

Purpose To view and/or set the internal preventive maintenance counter (number of swaths).
l The message Preventive
Swaths: 2722 Set new number---->

CP
Current value

Press the up-arrow.

New swath counter 00002722

maintenance advised appears after:

7 million cycles DJ2X00CP 6 million cycles DJ3X00CP

l To ensure the validity of the

this counter, you must reset it when replacing the electronics module. 2.cp.f
Slide 41 3-Dec- 98 HP Internal

Use the up- and down-arrows to change each digit (or leave it at zero), and then press Enter to move to the next digit.

Service Mode Calibrations

4. Service Mode Calibrations (16 of 17): C10 Font Type Set (1 of 2)

Purpose To view the current font type and, if necessary, select the correct Asian font from the hard disk (for example, after replacing the electronics module).

CP

2.cp.f Slide 42 3-Dec- 98 HP Internal

Service Mode Calibrations

4. Service Mode Calibrations (17 of 17): C10 Font Type Set (2 of 2)

CP

l The hard disk fonts license ID is saved in the main PCA EEROM.

Therefore, when replacing electronics module, set the license ID to the correct Asian font. Font types on hard disk l When a new electronics module is R: Roman being installed, the print counter is J2: Japanese zero, enabling the correct C10 CS: Chinese Simplified calibration. If it isnt, then perform CT: Chinese Traditional Diagnostic D17 (Reset Counters). CB: Chinese Both l Available since firmware release K: Korean A.02.14.
2.cp.f Slide 43 3-Dec- 98 HP Internal

Service Mode Calibrations

5. Tester PCA (1 of 3)

CP

Purpose To be attached to the electronics module in order to detect burnt motors. Access To enable the Tester PCA, press Form Feed and Cut on the front-panel while powering up. Distribution l HP DesignJet 2000CP Series: supported since firmware release A.02.14. l HP DesignJet 3000 Series: all.
2.cp.f Slide 44 3-Dec- 98 HP Internal

Tester PCA

5. Tester PCA (2 of 3): How Does it Work?

Media motor encoder Standby button

CP

l The electronics module has the Test PCA

Refill station

Service station

plugged into the service station and refill connectors (the large, black connectors) l When the electronics module is installed in the printer, the connectors indicated below be connected to the Test PCA.

Media motor
2.cp.f Slide 45 3-Dec- 98 HP Internal

Media sensor

Pinch-wheel sensor

Tester PCA: How Does it Work?

5. Tester PCA (3 of 3): Operation

CP

Operation l The Test PCA detects if there is a short in either the DC motors (carriage and media axis) or stepper motors, or a defective connection (short to the printer chassis). l If the test fails, either check the connections or replace the defective motor or cable, along with the electronics module.

2.cp.f Slide 46 3-Dec- 98 HP Internal

Tester PCA: Operation