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Océ
Océ XXXX xx-Chapter Title
Technical Service Manual
TSM Océ 5150
Preface
Contents
Contents
Preface
1 Copyright notations 2 2 Tsm information 3 3 General warnings 4 4 Notation conventions 4 5 Edition review 5 6 Modification bulletin survey 5 7 Safety data 5 8 Customer end test 5 9 Current status sheet 6 10 Document change request form 7
Preface
Edition 1.
Confidential © 1999 Océ-Technologies B.V.
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TSM Océ 5150
Preface
Copyright notations
Preface
1 Copyright notations
This publication is and remains the property of Océ-Technologies B.V. The information it contains is confidential and is solely intended as a personal aid for service personnel in carrying out service activities on the Océ equipment described in this publication. No part of this publication may be reproduced or be made public in any form or in any way whatsoever without the prior written permission of Océ-Technologies B.V. © 1999 Océ-Technologies B.V..
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Preface
Feedback
Tsm information
2 Tsm information
Why should you use the Technical Service Manual Océ 5150? The TSM Océ 5150 is one of the tools you will need for your work. It will enable you to meet customer requirements better, quicker and in a clearly structured and accessible way. The TSM provides you with information you will require for installing and carrying out corrective and preventive maintenance on this machine. At whom is the TSM Océ 5150 targeted? This TSM has certainly not been written as a teach-yourself manual. During the Océ 5150 service training course you will learn to use and interpret the TSM in such a way that you can work quickly and efficiently. The service training course also gives you an opportunity to broaden your knowledge on how the machine functions. The TSM and service training course are closely linked. Participating in a service training course without using the TSM is just as incomplete as using the TSM without having learnt how to use and interpret it in a service training course. The compilers of the TSM hope that you will find adequate information so that you can do your work quickly, correctly and with a continuing sense of satisfaction. Naturally, this TSM is always open to improvement. It is not unlikely that you may find imperfections and/or errors. Océ would be grateful if you would inform ITC (International Training Centre) in Venlo of any errors, imperfections or suggestions for improvement. You can do this as follows: This chapter contains a Document Change Request Form (DCRF). If you have any remarks about this manual, print this form and write them on the form or enter your remarks in the DCRF before printing. Send the DCRF to the Technical Co-ordination department. This department will inform the International Training Centre-Service. The address is: For the attention of: Océ-Technologies B.V. Manager I.T.C.- Service Postbus 101 5900 MA Venlo [email protected]
E-mail:
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Preface
General warnings
3 General warnings
We would like to draw your attention to the general warnings, summarised on this page. You will find specific warnings further on in the TSM in the descriptions of operations that have to be carried out in dangerous circumstances.
1 Avoid damaging PBA's via electrostatic discharges. You
4 Notation conventions
Wherever necessary, the following points for attention are indicated in this TSM. Note: A "Note" provides information that is essential for a correct functioning of the machine. It may also offer useful advice about its operation. Warning: A "Warning" provides information that can prevent the product (copy, original, the copier, etc.) from being damaged. Caution: A "Caution" provides information that prevents you from suffering personal injury. Approx.: Whenever a measurement is indicated with the expression approximately or approx., non calibrated measuring instruments can be used. For codenumbers of tools, jigs or measuring instruments please refer to the partslist.
2
3
4 5
6 7
8
should wear the wristband, code no. 7991.320 and use the antistatic mat, code no. 7991.322. Avoid electric shocks! Switch off the power supply to the machine and remove the mains plug from the wall socket if the machine does not need to be on when you are working on it. Avoid moving parts! When you remove the panels from the machine, make sure that you do not get your fingers caught between moving parts such as chains, cogs and gear belts. This equipment must be earthed. This equipment is not suitable for connecting to an IT-power system, often used in stand-alone power systems (for instance offshore, mining). When in doubt consult your Technical Coordinator. Always ensure that wall sockets and power switches are easily accessible. A blown fuse does not guarantee a powerless situation. Replace a blown fuse only with correct type and rating. Overrule never the safety of a clixon. When replacing a mains cable or mains plug, only use components which comply with local regulations.
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Preface
Edition review
5 Edition review
Edition Concept Edition Edition Edition Edition Edition Date October `99 Chapter All Section All -
7 Safety data
It is the responsibility of this manual to be informed about the latest edition Safety Data Sheets with safety and environmental information when working with Océ equipment and materials. For information about the latest safety data sheets we advise you to contact your local safety co-ordinator for a full set of safety data sheets. For the Océ 5150 the following Safety Data Sheets are available:
1 Product Safety Data Sheets: Océ 5150. 2 Material Safety Data Sheets: Océ 5150.
6 Modification bulletin survey
The following modification bulletins have been issued for the Océ 5150, at the moment of releasing this product. No. XXXX-X XXXX-X XXXX-X XXXX-X XXXX-X XXXX-X XXXX-X Description
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8 Customer end test
After every service visit a functional test must be done:
n n n
Make a copy of a typical original used by the customer. Show the copy to the customer. The customer must agree that the machine is performing according to his expectations and within the machine specifications laid down in this Technical Service Manual.
The overviews have been updated to include the most recent edition. Wherever possible, these bulletins have been integrated in the TSM.
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Preface
Current status sheet
9 Current status sheet
CHAPTER Preface SDS userinterface Faults SDS userinterface TOC Ed.1 Ed.1 Ed.1 Ed.1 TOC 04-Printing 12-Media loading 15-Media transport 20-Interface 22-Power and Control Partslist Ed.1 Ed.1 Ed.1 Ed.1 Ed.1 Ed.1 Ed.1 Ed.1 Ed.1 DIAG SDS SECTION Ed.1 Ed.1 Ed.1 Ed.1 ADJU DISA Ed.1 Ed.1 Ed.1 FUNC Ed.1 Ed.1 Ed.1 Ed.1 Ed.1 Ed.1 ELEC Ed.1 DIAGRAMS
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O ITC DOCUMENTATION CHANGE REQUEST FORM O
Requested by : Approved by : Document to be changed Manual: Chapter / Page Changes Country : Department : Tel : Edition Write brief decription of the changes requested.
Please use print-script to fill-out this form for error free handling Please attach extra pages if necessary Technicians send this request form to: Technical Coordination please send this request form to: SIGNED: DATE:
Technical Coordination Department Océ Technologies B.V. Attention of: Manager International Training Centre-Service P.O. Box 101 5900 MA Venlo The Netherlands
TSM Océ 5150
Cas-C
Contents
Contents
Cas-C Océ 5150
04 Printing 2 12 Media loading 2 15 Media transport 2 20 Interface 3 22 Power & Control 3 25 Customer/Environment/Installation 4 Fill out instruction 5
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04 Printing
Cas-C Océ 5150
04 Printing
001 002 003 004 005 007 008 010 011 012 013 014 015 017 018 023 025 026 027 038 039 040 Printhead Inktank Carriage unit Short flexible cables Carriage PBA Carriage drive belt Ink tank detection sensor PS4 Linear scale Linear encoder assy. PS8 Wiper blade Remaining ink detection sensor PS3 Waste ink tank Long flexible cable Purge unit Y-motor M2 Carriage home position sensor PS2 Purge motor M3 Wiper solenoid SL1 Purge cam home pos. sensor PS1 Mechanical connection Electrical connection Other
12 Media loading
445 446 450 465 478 479 480 Media sensor PS9 Suction fan FM1 Cutter unit Leading/trailing edge sensor PS6 Mechanical connection Electrical connection Other
15 Media transport
561 562 563 564 566 598 599 600 Transport roller X-motor M1 Pinch roller Pinch roller unit Platen Mechanical connection Electrical connection Other
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20 Interface
20 Interface
Controller 700 Image controller PBA 701 Engine controller PBA 703 Boot firmware 706 Boot flash memory 710 Main firmware 711 Flash memory 720 Memory modules Data/emulation 730 Incorrect data 735 Unknown command 736 Unsupported command Cable 737 Incorrect data cable 798 799 800 Mechanical connection Electrical connection Other
22 Power & Control
854 855 856 857 858 878 879 880 Power switch SW1 Power supply PBA Cover switch SW2 Control panel Cooling fan FM2 Mechanical connection Electrical connection Other
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25 Customer/Environment/Installation
25 Customer/Environment/Installation
Customer/operator 961 No fault on arrival 962 Incorrect operation 963 Exaggerated demands 964 Customer application 965 Océ drivers / software 966 Océ host hardware interface 967 Océ device hardware interface 968 Océ device software interface Environment 970 Mains supply 971 Temperature 972 Humidity 973 Static charges Supplies 981 982 Media Ink
Installation 991 Packing damaged 992 Cover(s) 993 Frame / stand 994 Painting 998 Other 999 Machine OK.
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Fill out instruction
Fill out instruction
Symptoms 1 Print quality 2 Image position / original / recognition 3 Print quality: spots stripes deformation 4 --5 Paper / original jam 6 No print scan from digital env. 7 Total stop 8 Display message (permanent error) 9 Noise, odour, damage others Codes Actions 1 Replace (life time) 2. Replace (detective) 3 Install (missing part) 4 Adjust, correct 5. Repair / fix 6 Clean / dismount / lubricate 7 Replenish / drain 8 Instruct / install 0. -----
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SDS description
Contents
Contents
SDS description
1 Service Menus 2 2 Test prints 5 3 Firmware upgrade 6 4 Calibration menus 7 5 Auto tests 9
SDS description
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SDS description
Service Menus
SDS description
1 Service Menus
The service function tree is accessible through the control panel with the password: Left, Right, Up, Down, Right then Left. (<>^V ><) The tree menu is described below: SERVICE
G G G G G G G G G G G G G
Service print The service print is always printed with the following settings:
G G
Current quality and color mode Need a roll or cut sheet greater or equal to A1
This print allows to check the correct printing quality (head skew, heads, calibration and colors registration) Print count reset This sub-tree allows to reset to zero all the print count values (A0, A1, A2, A3, and A4). The current value of these parameters can be displayed under the statistics menu. Cutter count reset This sub-tree allows to reset to zero the value of the cutter count. The current value of this function can be displayed under the statistics menu. Power on time reset This sub-tree allows to reset to zero power on time value. The current value of this parameter can be displayed under the statistics menu. Media length reset This sub-tree allows to reset to zero the value of the media length. The current parameter of this value can be displayed under the statistics menu.
SERVICE PRINT PRINT COUNT RESET CUTTER COUNT RESET POWER ON TIME RESET MEDIA LENGTH RESET SERIAL NUMBER VALUE LOG FILE RESET CTRL SETUP RESET BOOT UPGRADE WASTE INK TANK RESET CARRIAGE TIME RESET ENGINE SETUP BACKUP RESTORE
Every service menus and messages are only displayed on the LCD screen in English, whatever the chosen language
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SDS description
Service Menus
Serial number This sub-tree contains the serial number of the machine and allows to set it to the correct number when replacing the Image controller PBA. Log file reset This sub-tree allows clearing to zero the value of all the parameters stored in the machine log file. A confirmation is requested through RESET sub-menu. Cntrl setup reset This sub-tree allows resetting to their default value of several configurations parameters stored in the non-volatile area (ZPRAM). Refer to appendix for storage parameters list. A confirmation is performed through RESET sub-menu.
Boot upgrade This function allows to upgrade the boot Firmware of the Image controller (e.g., the code implemented on the boot flash only). It will use the same core function as the functional test UPBC. This service accepts to download s-record data format file.see appendix). The usage is the following:
1 When this function has been validated, the controller
switches in download mode. It is ready to receive data through the Centronics interface. The following message is displayed on the two LCD lines: BOOT DOWNLOAD WAITING DATA
2 Send new boot firmware through Centronics interface.
If no data is received on the Centronics interface within a timeout of 30 seconds, the firmware switches back to the normal mode else the following message is displayed on the two LCD lines: BOOT DOWNLOAD IN PROGRESS The received data are stored in the controller, end of file will be detected using either file footer recognition or Timeout value of 30 seconds.
3 A check is performed in the controller on data integrity
(header, checksum and footer information) compared to the defined format.
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SDS description
Service Menus
In case of wrong result, the following message is displayed on the two LCD lines: BOOT DOWNLOAD WRONG FILE, POWER OFF/ON ( turning message) In case of good result, the following message is displayed on the two LCD lines: BOOT UPGRADE IN PROGRESS
Waste ink tank reset This sub-tree allows to reset the waste ink tank ratio. A reset is necessary after each exchange of the waste tank by an empty one. Carriage time reset This service allow to reset the carriage time of use to. A reset is necessary after a change of the engine PCB. Engine setup This service allows to save and restore some engine parameters when the engine board must be changed. Two functions are provided in this sub-menu:
G
4) Controller firmware then replaces current boot with the updated one in the boot flash device. The result is displayed on the second LCD line:
G
UPGRADE DONE POWER OFF/ON ...( turning message) UPGRADE FAILED POWER OFF/ON ...( turning message)
BACKUP which allows to save into the Image controller non-volative area (ZPRAM), the following engine parameters : carriage time, waste ink tank values and scale adjustment values. RESTORE which allows to restore into the Engine controller non-volative memory, the following engine parameters : carriage time, waste ink tank value and scale adjustment values.
If the second message appears, it indicates that probably the boot flash component is out of order. Note: In case of power down of the machine during the last phase of BOOT UPGRADE function, no warranty is given on boot integrity.
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SDS description
Test prints
2 Test prints
Demo print No demo print is available for the user in the menu of the Océ 5150. The technician can use the Service print and palatte print as demo prints. see "Service print" Dump config The dump configuration allows printing the current configuration of the machine.
CURRENT CONFIGURATION ----------------------------------------COMMERCIAL ID: 5150 SERIAL NUMBER: 20201 LOGIC VERSION: CC 1.4.0 [PK_11.x.x] BOOT VERSION: BC 0.9 ENGINE VERSION: EC 1.9 MEMORY SIZE: 16384 KB LANGUAGE: ENGLISH COLOR MODE: COLOR AUTOCUT: ENABLE MEDIA TYPE: ROLL = COATED PAPER CUT SHEET = OTHER PRINT QUALITY: NORMAL
Banner print The banner print is a message printed at the end of the current print in case of error detection (mainly memory allocation failure in the interpretation or rasterization/rendering process). The message banner length is limited to 100 characters. These errors occur during the rasterization/rendering process:
1 If a memory allocation fails at the rasterizing initialization
in normal processing, the following banner is printed: initRaster Allocation Failure on normal processing In that case, the current print is discarded and nothing is printed. 2 If a memory allocation fails at the rasterizing initialization in on the fly processing, the following banner is printed: initRaster Allocation Failure on the fly mode In that case, the current print is discarded and nothing is printed.
3 If a memory allocation fails during the polygon rasteriza-
tion process, the following banner is printed: not enough memory for rasterization in polygon buffer In that case, the print is printed until the error occurrence.
4 If a memory allocation fails to rasterize vectors in on the fly
ALIGN PRIORITY : X ALIGNMENT X ALIGNMENT MONO : 0 X ALIGNMENT COLOR : 0 X ACCURACY MONO : 0 X ACCURACY COLOR : 0 MEDIA SIZE: E END OF PRINT TIME OUT: PEN WIDTH 01 0.21 mm 02 0.21 mm 03 0.21 mm COLOR 01 02 03
rasterization process, the following banner is printed: too many vectors : Not enough memory In that case, the print is printed until the error occurrence.
180 PEN WIDTH 09 0.21 mm 10 0.21 mm 11 0.21 mm COLOR 09 10 11
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SDS description
Firmware upgrade
Print recovery The basic principle is to recover the print under printing every time it is possible when a problem occur. Two types of recovery mechanism have been developed:
G G
3 Firmware upgrade
The printer will switch in download mode (firmware upgrade for engine and controller) when the user presses two keys ( Left and Right) simultaneously during the power on of the machine The exact behavior is described in the Auto Tests paragraph see "Automatic download mode switch" .
Print continuation (cover open, ...) Print again from the beginning (out of paper, ...)
However, in some cases, recovery is not possible:
G G
Upon an error which requests a power off/on sequence With files which do not fit completely into the DL memory size
Palette print The palette print menu is only visible on the LUI when color mode is set to full color. The colors printed depends on the setting of the HPGL2 pen priority parameter:
G
G
Pen priority set to Language: color palette is printed with the full range of standard HPGL2 colors, including RGB information. Pen priority set to Setup: color palette is printed with the colors that have been set for each pen. Text is always printed with pen number 1 and so with the color assigned to this pen.
The palette print is always printed in the current quality mode.
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SDS description
Calibration menus
4 Calibration menus
The calibration prints are available into the calibration menu. The calibration menu is accessible in the Utilities menu.
CALIBRATION PRINT REGISTRATION X ALIGNMENT X ACCURACY VALUE X ALIGNMENT X ACCURACY X PRIORITY
X alignment print The default parameters to draw this print are:
G G G
Printing mode forced to one-pass mono-directional 360 dpi
These parameters are reset to their setup values at the end of the print. This print is composed by a series of nine vertical bands filled with a particular pattern to analyze the effects of changing the media feed length value. Each band is printed with a different media feed length value, from 84 µm to +µ84 mm per step of 70/3 µm around the calibrated value retrieved from the engine.
Registration print This feature performs automatic adjustment of the different head position between them (in X, Y direction, forward and backward). This adjustment is managed directly by the engine but is requested by the Image controller. The head registration adjustment must be done by operator after each print head change (but not in case of ink tank change). It starts after validation of the registration menu. No recovery is assumed during this adjustment. In case of error during the process, the adjustment is cancelled. The registration print can work with cut sheet or roll mode but needs at least an A3 media size. The following messages are displayed during the autoregistration adjustment:
Color x-alignment
Océ 5150
The user then selects the number of the band (from -4 to +4) that minimizes the jointing effect. The values may be different depending on the machine color mode. The operator has to perform the adjustment in both color and monochrome mode and enter the corresponding X alignment value.
AUTO-ADJUSTMENT PLEASE WAIT ... ( turning message)
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X accuracy print The X accuracy print is always printed with:
G G G G
SDS description
Calibration menus
Printing mode forced to one-pass mono-directional 360 dpi Needs a roll or cut sheet greater or equal to A1
Note: Normally, this print is not needed since the engine is calibrated by manufacturing. In case of power off during the X accuracy print, the operator should re-start the operation to re-calibrate the X accuracy value. Error Log file Each time that an error occurs on the machine, the error is stored in the Log file. The Error Log File is a storage of the last 50 errors and significant events recorded during the printer life. The last ten errors of the error log file are printed at the end of the dump config under the following form : CURRENT ERROR LOG FILE CODE POWER ON TIME (hours) Error code time Error code time Where "Error code" is a numerical value identifying the event and "time" the value of the power-on-time counter when the event was detected. The Log file is also accessible through the functional test with the command ERLO. The list of all the possible errors is available in the appendices.
In this print a 500 by 500 mm square is printed. User has to measure the X side of the printed square to see how many mm is off.
X Accuracy plot
500mm
Océ 5150
The user then enters the number of mm to add/subtract to the measured length to have 500 mm, a negative value if the X value is greater than 500 mm else a positive value. The range is between -1 mm and +1 mm per step of 0.1mm (-25 to 25 by step of 1 on the LUI menu) Apart from the adjustment, the accuracy is 0.2 %. For instance, if you have measured 499.6mm, you should enter a value of +4.
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500mm
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SDS description
Auto tests
5 Auto tests
General The general behaviour of Océ 5150 controller auto-tests is to unitary test every exchangeable part of the product:
G G G G G
Boot Flash SDRAM module tests SIMM Flash module Controller Board Printer Board
The tests, up to the SIMM Flash one, will be located in the Boot Flash of the controller. The following tests will be located in the SIMM Flash module. Each test will be sequentially executed until auto-test phase completion - if no problem occurs. In case an error is found, firmware will enter into a blocked mode where two means will allow to resume:
G G
Power OFF/ON the machine Press together the keys: Left, Down and Enter (BypassMode)
Bypass mode should only be used by field engineer to get access to specific services of the machine. They can have a more accurate diagnostic of the problem found in the auto-tests. No bypass is available prior to SIMM flash tests. In the bypass mode, no limits on machine features will be set by the firmware but no warranty is given on machine behavior. The complete execution time for a successful auto-tests phase must be below 1 minute.
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SDS description
Auto tests
Auto-tests list At power on, the boot code is launched and the first initialization of the hardware is done. Then the following message is displayed on LCD: DRAM TEST Only the slot 0, always equipped with 32 Mbytes, is tested in a first time. The result of the test is displayed on the second LCD line : OK or FAILED Then the following message is displayed on LCD : BOOT FLASH TEST The checksum of the boot flash is computed. This checksum is compared with the value stored into the ZPRAM area of this flash boot. The result of the test is displayed on the second LCD line: OK or FAILED Then the following message is displayed on LCD:
The result of the test is displayed on the second LCD line: OK or FAILED or UNSUPPORTED
Then the following message is displayed on LCD: CONTROLLER TEST The firmware tests the various parts embedded in the controller firmware:
G G G
Interruptions Engine command interface (not tested today) Engine data interface
The result of the test is displayed on the second LCD line: OK or FAILED Then the following message is displayed on LCD: Printer test In this state, the Image controller auto-tests have succeeded. The application firmware is launched which first performs initialization (Operating System, Memory allocation, ..) and engine synchronization. The printer test phase result will be OK if the Engine controller synchronization has been performed without troubles. The result of the test is displayed on the second LCD line: OK or FAILED Then the following message is displayed on LCD: READY The Image controller and Engine controller firmware are initialized and ready to operate.
FLASH TEST
The checksum of the main flash module is computed and-
compared with the value stored into the ZPRAM area of the flash boot. The result of the test is displayed on the second LCD line: OK or FAILED
Then the following message is displayed on LCD :
DRAM CONFIG TEST
The slots are tested to ensure a supported configuration is
installed and correctly mounted in the machine.
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SDS description
F/W UPDATE IN PROGRESS
Auto tests
Note: If the printer test is FAILED and the result is bypassed,the final message will be INIT instead of
READY.
Automatic download mode switch During auto-tests, if the checksum of the Image or Engine controller application firmware is bad, the controller switches automatically in download mode. In this case, operator will have the following messages on LCD: F/WARE DOWNLOAD WAITING DATA User must send the firmware package (see User Manual appendix) through the Centronics interface. This message remains until data will be received on this interface. When the Image controller receives data, the message will be: F/WARE DOWNLOAD IN PROGRESS The received data are stored in the Image controller, the end of file will be detected using suppressed recognition of file footer. A check is performed in the controller on data integrity (header, checksum and footer information) compared to the defined format (see appendix). In case of wrong result, the following message is displayed on the two LCD lines: F/WARE FAILED ERROR #101: WRONG FILE, POWER OFF/ON ( turning message) In case of good result, the following message is displayed on the two LCD lines:
Then, the Image controller firmware replaces current firmware with the updated one in the SIMM flash module, or downloads the Engine controller firmware onto the Engine controller. The result is displayed on the second LCD line: UPDATE DONE POWER OFF/ON ... ( turning message) UPDATE FAILED ERROR #102: CALL SERVICE... ( turning message) If the second message appears, it indicates that probably the SIMM flash module is out of order or the Engine controller board is broken.
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Faults
Contents
Contents
Error messages
1 Temporary Warning (TW) 2 2 Permanent Warning (PW) 2 3 Operator Recoverable Error (ORE) 3 4 Machine Recoverable Error (MRE) 7 5 Error code number summary 10
Faults
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Faults
Error messages
Error messages
1 Temporary Warning (TW)
Interface relative errors: G Framing Error: The machine serial line setting does not match with host serial line setting. G Parity Error: The parity set for serial line setting does not match with host serial line setting. G Overrun Error: Indicates that data have been lost during transfer. Processing file errors: G Print Clipped: The expected print is bigger than the loaded media. G Syntax Error: Indicates that errors have been found in the file currently processed. The resulting print may be corrupted. G Data Loss: Indicates that data have been lost with the file currently processed. The resulting print will be corrupted. G Print Aborted: Indicates that the processed file can't be processed (bad language, bad format of the file). No print will be done in this case.
2 Permanent Warning (PW)
Engine relative errors: G INK LOW [K C M Y]: The ink remaining in the mentioned tank (K=black, C=Cyan, M=Magenta, Y=Yellow) is under the threshold value. The message is only displayed on the first line. No special recovery is required to continue. INK LOW: K, C, M, Y /Normal message/
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Faults
Error messages
Cover open error The following message is displayed on the control panel: COVER OPEN CLOSE COVER ......... ( turning message) If the printer is in printing mode, the printer will finish the current printed band and Stop. When the operator closes the cover, the machine will resume the printing.
3 Operator Recoverable Error (ORE)
G G
G G
G
G
G
G G
G G
G
G
Out of ink: One or several tanks are empty. No media: No media is present in the selected media path. Cover open: The dust cover is open. Head missing: One or several heads aren't installed in the machine. Tank missing: One or several tanks aren't installed in the machine. Head error: The mentioned head K, C, Y and/or M is out of order. Illegal head: The mentioned head K, C, Y and/or M can't be identified or is not in the right location. Cutter error: The cutter unit has failed to cut media. Media error: There are troubles to detect correctly the size of the loaded media. End of media: The media is finished. Media misaligned: Media skew has been detected which required a media alignment from the user. Media too small: Loaded media is too small (minimum A3 size required) to execute Auto adjustment feature. Carriage error: Engine carriage troubles.
Note: To achieve a better print quality, it is not advised to open the cover during printing. Head missing error The following message is displayed on the control panel:
HEAD MISSING ERROR #60: PLEASE PRESS ENTER INSTALL HEAD... (turning message)
Operator must install head(s).
After to press ENTER key, the carriage goes to the change position. Displayed messages are:
HEAD MISSING ERROR #60: PLEASE INSTALL HEAD ... ( turning message)
When the cover is closed, the carriage goes back to the home-station and checks the head and the tank. Other error messages can be displayed after the check of the configuration.
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Faults
Error messages
Tank missing error The following message is displayed on the control panel
:
HEAD ERROR ERROR#nr: PLEASE PRESS ENTER TO REPLACE HEAD... ( turning message) The way of recovery is (for error 18 or 19): After pressing the ENTER key, the carriage goes to the change position. The following message is displayed: HEAD ERROR ERROR#nr: PLEASE PRESS ENTER TO REPLACE ( turning message)
G G G
TANK MISSING ERROR #61: PLEASE PRESS ENTER TO INSTALL TANK ( turning message) Operator must install tank(s). After pressing the ENTER key, the carriage goes to the change position. Displayed messages are: TANK MISSING
ERROR #61: PLEASE INSTALL TANK
( turning message)
G G
Open the cover Operator must install tank(s).
Open the cover Change head X Close the cover, and then the carriage moves back to the home station
When the cover is closed, the carriage goes back to the home-station and checks the head and the tank. Other error messages can be displayed after the check of the configuration. Head error There are two types of head errors. The first type is a change of a head. So the following messages are displayed on the control panel with number equal to 18 or 19:
The second type, the messages are displayed just to inform the operator that a head error occurs. In this case, the displayed messages are (number equal to 24 or 36): HEAD ERROR ERROR #nr: PLEASE PRESS ENTER TO CONTINUE (turning message) The way of recovery is (for error 24 or 36):
G
Press ENTER key to recover this error
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Illegal head error
ILLEGAL HEAD ERROR #20: PLEASE PRESS ENTER TO REPLACE HEAD...(turning message)
Faults
Error messages
Media error This group is composed with 23 errors. They survey the detection, the cut, the skew, the size, and the end of the media. Here are the messages and the way of recovery
The way of recovery is: After pressing the ENTER key, the carriage goes to the change position. The following message is displayed:
ILLEGAL HEAD ERROR #20: PLEASE REPLACE HEAD (turning message)
G G G
.
MEDIA ERROR
ERROR #nr: PLEASE REMOVE MEDIA AND PRESS ENTER... (turning message)
Number can be 1 to 10, 13 to 16, 31 and 32. The way of recovery is:
G G G G
Open the cover Change head X Close the cover, and then the carriage moves back to the home station
Open the cover Re-install the media Close the cover Press ENTER key to re-start media loading operation
Cutter error
CUTTER ERROR ERROR #11: PLEASE REMOVE MEDIA AND PRESS ENTER... ( turning message)
End of media error The following messages are displayed on the control panel with number equal to 25 or 26 END OF MEDIA ERROR #number: PLEASE INSTALL MEDIA... ( turning message) The way of recovery is:
G G G G
The way of recovery is: G Open the cover G Pull out the media G Close the cover G Press ENTER key to re-start media loading operation
Open the cover Install new media Close the cover Press ENTER key to start media loading operation
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Faults
Carriage error
Error messages
Media misaligned error The following message is displayed on the control panel
:
MEDIA MISALIGNED
ERROR #42: PLEASE REALIGN MEDIA AND PRESS
CARRIAGE ERROR ERROR #: PLEASE PRESS ENTER TO CONTINUE ... ( turning message) The way of recovery is:
G
ENTER... ( turning message) The way of recovery is:
G G G G G
Press ENTER key to recover this error
Open the cover Re-align the media Close the cover Press ENTER key Restart media loading operation
Media too small error The following message is displayed on the control panel with number equal to 38, 43 or 44 MEDIA TOO SMALL
ERROR #nr: PLEASE REMOVE MEDIA AND PRESS ENTER.. ( turning message)
The way of recovery is:
G G G G G
Open the cover Pull out the media Close the cover Press ENTER key Restart media loading operation
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Faults
Error messages
Comm error The following messages are displayed on the control panel COMM ERROR ERROR #103: POWER OFF/ON ... ( turning message) The way of recovery is:
G G
4 Machine Recoverable Error (MRE)
G
G G
G
G G
G G
Comm error: The communication between engine and controller has failed. Carriage error: Engine carriage troubles. F/W update failed: The update of the controller or the engine firmware has failed. AUTO-REGI failed: The auto-registration feature has failed or the cover has been opened during auto-registration. Waste ink tank full: The waste ink tank is full. Printer error: The checksum of the engine firmware is corrupted or the engine non-volatile memory is corrupted or the communication between the engine processor and the engine micro-controller has failed. Fan error: The fan is out of order. Purge error: The purge is out of order.
Power OFF and ON the machine If still unsuccessful, the operator must call the service people.
Carriage error The following message is displayed on the control panel with a number equal to 12 and 17: CARRIAGE ERROR ERROR #: POWER OFF/ON ... ( turning message) The way of recovery is:
G G
Power OFF and ON the machine If still unsuccessful, the operator must call the service people.
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Faults
Error messages
Auto-regi failed error The following message is displayed on the control panel with number equal to 39 or 41: AUTO-REGI FAILED ERROR #number: POWER OFF/ON ... ( turning message) The way of recovery is:
F/W update failed error The following message is displayed on the control panel with number equal to 47, 48 or 49 (engine part) or 102 (controller part): F/W UPDATE FAILED ERROR #number: POWER OFF/ON ... ( turning message) If the received file is corrupted: F/W DOWNLOAD FAILED ERROR #101: WRONG FILE, POWER OFF/ON (turning message) The way of recovery is:
G G G
G G G
Power OFF and ON the machine Retry operation. If still unsuccessful, the operator must call the service people.
Waste ink tank full error The following message is displayed on the control panel: WASTE TANK FULL ERROR #40: CALL SERVICE ... ( turning message) The way of recovery is:
G
Power OFF and ON the machine Retry operation. If still unsuccessful, the operator must call the service people.
Call the service people
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Faults
Error messages
Purge error The following message is displayed on the control panel:
Printer error The following message is displayed on the control panel with number equal to 30, 33, 34, 35, 45 or 46: PRINTER ERROR ERROR #number: CALL SERVICE ... ( turning message) The way of recovery is:
PURGE ERROR ERROR #27: CALL SERVICE ... (turning message) The way of recovery is:
G
G G
Power OFF and ON the machine If it is still unsuccessful, the operator must call the service people
G
Power OFF and ON the machine If it is still unsuccessful, the operator must call the service people.
Fan error The following message is displayed on the control panel: FAN ERROR ERROR #28: CALL SERVICE ... ( turning message) The way of recovery is:
G G
Power OFF and ON the machine If it is still unsuccessful, the operator must call the service people
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Faults
Error messages
5 Error code number summary
An error code number is displayed on the control panel with each error message. It is also stored in the log file in the same way. If the error number is less than 100, the error is related to the engine. If the error number is greater than 100, the error is related to the controller. Engine related errors Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Description Media detection regi sensor (standard value) Media detection regi sensor (range) Media tail edge detected during regi sensor adjustment Regi sensor for regi scan adjustment error Left edge cannot be detected Right edge cannot be detected Right edge cannot be detected at slant detection Top edge cannot be detected (roll) Tail edge cannot be detected (cut sheet) Top edge cannot be detected (cut sheet) Failed to cut paper Carriage motor stepped out Failed to detect top edge at media width detection Media lost when detecting the top edge Media lost during the regi sensor adjustment Media lost during media width detection Carriage failed to stop at the exact position Head temperature abnormaly high Head temperature adjustement time over Display yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes Logfile yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes
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Number 20 21 22 23 24 25 26 27 28 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 Description Illegal head Head removed without cover opened Head moved near the cutter Head moved near the purge station Head DI correction failed Media ran out during roll print
Faults
Display yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes
Error messages
Logfile yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes
Unexpected media out when printing cut sheet Failed to detect home position of the purge station Detected lock detection of the power supply cooling fan Slave CPU communication error Exeeded media feed limit (forward feed) Exeeded media feed limit (backfeed) Failed to write backup memory Failed to read backup memory Failed to initialize backup memory Head cooling timeout Failed to detect head position Media too small for autoregi Illegal autoregi value Waste ink tank full Failed to read autoregi pattern Skew amount over the limit Media width less than 250mm Media length less than 80 mmm EEPROM checksum error EEPROM data is broken FLASH ROM erase error
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Number 48 49 60 61 Description FLASH ROM write error FLASH ROM verify error One or severals heads are missing One or severals tanks are missing
Faults
Display yes yes yes yes
Error messages
Logfile yes yes yes yes
Controller related errors Number 101 102 103 106 107 108 109 Description FW UPDATE FAILED Package file corrupted FW UPDATE FAILED SIMM FLASH update has failed Communication between controller and engine has failed INIT RASTER ALLOCATION FAILED Software error ACTIVE BUFFER OVERFLOW Software error TASK SUSPEND Software error ASSERT FAILED Software erro Display yes yes yes yes yes yes yes Logfile yes yes yes yes yes yes yes
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Contents
Contents
Dis-/assembly
1 Carriage 400
1.1 Removal of the carriage unit 400 1.2 Removal of the short flexible cable/print head holder 403 1.3 Removal of the head relay PBA. 405 1.4 Removal of the linear sensor 406 1.5 Removal of the media sensor (PS9) 407 1.6 Replacing the long flexible cable 409
04 - Printing
2 Y motor control 503
2.1 Outline 503 2.2 Operation: 504
3 Linear encoder 505
3.1 Outline 505 3.2 Structure 505 3.3 Output signal. 505 3.4 Control 507 3.5 Automatic adjustment of the head 508
4 Detection of the presence of the ink tank
4.1 Outline 511 4.2 Method of detecting the presence of the ink tank.
2 Purge unit 412
2.1 Removal of the purge unit 412 2.2 Removal of the purge motor (M3) 414 2.3 Removal of the wiper solenoid (SL1) 414 2.4 Removal of the purge unit home position sensor (PS1) 415 2.5 Removal of the carriage home position sensor (PS2) 415 2.6 Removal of the remaining ink detection sensor (PS3) and ink tank detection sensor (PS4) 416 2.7 Removal of the waste ink tank 416
5 Detection of remaining ink 512
5.1 Outline 512 5.2 Method of detecting residual ink 512
6 INK JET UNIT 514
6.1 Ink jet print head/ink tank 514 6.2 Ink jet head 516 6.3 Ink discharge mechanism 517 6.4 Nozzle arrangement 518
7 Purge unit 519
7.1 Outline 519 7.2 Head cleaning 522
3 Removal of the Y motor (M2) 418 4 Removal of the carriage drive belt 419 5 Installing the carriage drive belt 420
8 Waste ink tank 528
Functional description
1 Carriage unit 500
1.1 Outline 500
Electrical description
1 Head driving 600
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Dis-/assembly
3 Remove the dust cover and upper cover. (See "1.2 Re-
Dis-/assembly
1 Carriage
1.1 Removal of the carriage unit
Caution: Before disassembling or reassembling the carriage unit, remove the ink jet print heads and cutter unit.
1 Remove the right cover and left cover.
moval of the upper cover and the dust cover" ).
4 Pull out the carriage to the loading position, and remove
the print heads.
5 Remove 2 connectors [3] (J501, J502) of the long flexible
cables on the head relay PBA and suspend the long flexible cables to the left side.
[3]
(See "1.1 Removal of the right cover" ).
2 Unhook the 4 hooks [1] and remove the carriage cover [2].
[2]
Figure 3-202
Caution: The long flexible cables are fixed by the ferrite core. When removing the long flexible cables, be careful not to damage the long flexible cables.
[1]
[1]
Figure 3-201
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Dis-/assembly
6 Remove the tension spring [4] of the pulley and remove
7 Unscrew 2 screws [7] and remove the stopper [8].
the pulley [5] and pulley stand [6].
[8]
[4]
[7]
[6]
Figure 3-204
[5]
Figure 3-203
8 Unscrew 7 screws [9] and remove the left frame [10].
[10]
[9]
[9]
Figure 3-205
[9]
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Dis-/assembly
Caution: When removing the carriage unit, be careful not to damage or stain the carriage drive belt and linear scale.
9 Remove the carriage unit [11] from the left side of the
Caution: When reassembling the carriage unit, check that the linear scale is inserted correctly between the carriage unit and linear sensor.
machine.
[11]
O.K.
Not O.K.
Not O.K.
Figure 3-206
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Dis-/assembly
1.2 Removal of the short flexible cable/print head holder
1 Remove the right cover and left cover.
[3]
(See "1.1 Removal of the right cover" )..
2 Unhook the 4 hooks [1] and remove the carriage cover [2].
[2]
[4]
[1] [1]
Figure 3-208
Figure 3-207
Caution: When removing the print head holder, keep the print head height adjustment lever at the highest position.
3 Remove the dust cover and upper cover. (See "1.2 Re-
moval of the upper cover and the dust cover" ).
4 Pull out the carriage to the loading position and remove
the print heads.
5 Remove the cutter 6 Remove the 4 connectors [3] (J503, J504, J505, J506) of
the short flexible cables on the head relay PBA and remove the 4 short flexible cables [4] from the hook (take care not to damage).
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Dis-/assembly
7 Shift the print headprint head holder [5] upward and re-
move it from the carriage.
[5]
Figure 3-209
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Dis-/assembly
1.3 Removal of the head relay PBA.
1 Remove the right cover.
3 Remove all of the 8 connectors [3] on the head connector
PBA. Caution: When removing the head relay PBA, be careful not to damage or stain the short flexible cables.
4 Unscrew 2 screws [4] and remove the head relay board
(See "1.1 Removal of the right cover" ). 2 Unhook the 4 hooks [1] and remove the carriage cover [2].
[5].
[4]
[3]
[4]
[2]
[1]
[1]
[3]
Figure 3-210
[3]
Figure 3-211
[5]
Note: The connectors of the flexible cables are of two different types: For the long flexible cables: the cables are just shifted into the connectors (no securing clamps). The other connectors have securing clamps which should be first lifted before you remove the cable
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Dis-/assembly
1.4 Removal of the linear sensor
1 Remove the carriage unit.
(See "1.1 Removal of the carriage unit" )..
2 Remove the linear sensor connector and 5 connectors [1]
of the short flexible cables on the head relay PBA.
3 Remove the 4 short flexible cables [2]
(take care not to damage).
[1]
[3]
Figure 3-213
6 Unscrew 2 screws [4] and remove the linear sensor [5].
[2]
Figure 3-212
4 Remove the cutter
[4]
Caution: When removing the print head holder, keep the print head height adjustment lever at the highest position.
5 Shift the print head holder [3] upward and remove it from
the carriage.
[5]
Figure 3-214
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Dis-/assembly
1.5 Removal of the media sensor (PS9)
1 Remove the right cover.
[3]
(See "1.1 Removal of the right cover" )..
2 Unhook the 4 hooks [1] and remove the carriage cover [2].
[2]
Figure 3-216
4 Open the dust cover and pull out the carriage to the load-
[1]
[1]
ing position. Caution: When removing the media sensor, be careful not to damage or stain the linear scale.
Figure 3-215
3 Remove the 1 connector [3] (J509) of the media sensor
flexible cable on the head relay PBA.
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Dis-/assembly
5 Unscrew 2 screws [4] and remove the media sensor [5].
[4] [5]
[4]
Figure 3-219
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Dis-/assembly
1.6 Replacing the long flexible cable
1 Remove the image controller PBA.
[3]
(See "4.1 Replacing the image controller PBA" ).
2 Remove the engine controller PBA.
(See "4.2 Replacing the engine controller PBA" ).
3 Remove the right cover and left cover.
(See "1.1 Removal of the right cover" ).
4 Remove the dust cover and upper cover.(See "1.2 Remov-
al of the upper cover and the dust cover" ).
5 Unhook the 4 hooks [1] and remove the carriage cover [2].
Figure 3-221
[2]
Caution: The long flexible cables are fixed by the ferrite core. When removing the long flexible cables, be careful not to damage the long flexible cables.
6 Pull out the carriage to the centre and remove the 2 con-
[1]
[1]
nectors [3] (J501, J502) of the long flexible cable on the head relay PBA.
Figure 3-220
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Dis-/assembly
7 Remove the fixing sheet [4] of the ferrite core and remove
9 Unscrew 5 screws [9] from the flexible cable shield [8].
the ferrite core.
[8]
[4]
[9]
[5]
Figure 3-222
Figure 3-224
10 Remove the long flexible cables [11] from the flexible
8 Unscrew 4 screws [6] and remove the flexible middle
guide and remove the ferrite core [10].
guide [7].
[6]
[7]
[10] [11]
Figure 3-225
Figure 3-223
Caution: Remove the double-sided tape completely, leaving no residual on the flexible guide [11].
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Dis-/assembly
11 Fold the new long flexible cable as shown in the figure be-
12 Stick double-sided tape over the flexible guide and attach
low, stick double-sided tape to the position [A] and check if the new long flexible cable matches with the connectors.
[A]
the new long flexible cable aligned with the mark [B] to the flexible guide edge [12].
[B]
[12]
Figure 3-226
Figure 3-227
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Dis-/assembly
4 Cap the joint [2] of the waste in tube at 2 positions using
2 Purge unit
Caution: Do not touch the cleaner blade and head cap.
the waste ink tube cap [3].
2.1 Removal of the purge unit
1 Remove the right cover.
(See "1.1 Removal of the right cover" ).
2 Open the dust cover and pull out the carriage to the load-
ing position. Caution: Be careful: do not allow the waste ink dropping on the floor, etc.
3 Remove the tube retainer [1] and remove the joint [2] of
[2] [3]
Figure 3-302
the waste in tube.
[2]
[1]
[2]
Figure 3-301
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Dis-/assembly
5 Remove 4 connectors [4] and remove the wiring harness
from the wiring harness guide.
Caution: Since waste ink sticks to the bottom of the purge unit, hold only the sides of the purge unit when disassembling or reassembling it. Be careful not to stain the floor, etc. with the ink attached to the purge unit.
6 Unscrew 3 screws [5] and remove the purge unit [6].
[5]
[4]
Figure 3-303a
[6]
Figure 3-304
[4]
Figure 3-303b
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Dis-/assembly
2.2 Removal of the purge motor (M3)
1 Remove the right cover.
2.3 Removal of the wiper solenoid (SL1)
1 Remove the purge unit.
(See "1.1 Removal of the right cover" ). 2 Unscrew 2 screws [1] and remove the purge motor [2].
(See "2.1 Removal of the purge unit" ).
2 Remove 1 connector [1] and unscrew 2 screws [2]. 3 Remove the wiper solenoid [3].
[1] [2]
Figure 3-305
[2]
[1]
Figure 3-306
[3]
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Dis-/assembly
2.4 Removal of the purge unit home position sensor (PS1)
1 Remove the purge unit.
2.5 Removal of the carriage home position sensor (PS2)
1 1) Remove the purge unit.
(See "2.1 Removal of the purge unit" ). 2 Remove the connector [1]. 3 Unhook the 2 hooks [2] and remove the purge unit home position sensor [3]
(See "2.1 Removal of the purge unit" ).
2 Remove the connector [1]. 3 Unhook the 4 hooks [2] and remove the carriage home po-
sition sensor [3].
[2]
[3]
[3]
[1] [2]
[1]
Figure 3-308 Figure 3-307
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Dis-/assembly
2.6 Removal of the remaining ink detection sensor (PS3) and ink tank detection sensor (PS4)
1 Remove the right cover.
2.7 Removal of the waste ink tank
1 Remove the right cover.
(See "1.1 Removal of the right cover" ).
2 Remove the front cover.
(See "1.1 Removal of the right cover" ). 2 Open the dust cover and pull out the carriage to the loading position. 3 Remove the 2 connectors [1], unscrew 1 screw [2] and remove the remaining ink detection sensor[3] and the ink tank detection sensor [4].
(See "1.3 Removal of the front cover" ).
3 Remove the tube retainer [1] and remove the joint (2) of
the waste ink tube. Caution: Be careful not to drop the waste ink on the floor, etc.
[2] [3]
[1]
[2]
Figure 3-310
[1]
Figure 3-309
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Dis-/assembly
4 Cap the joint [2] at 2 positions of the waste ink tube with
6 Unscrew 2 screws [5] and remove the waste ink tank [6].
the waste ink tube cap [3].
[6] [2] [3]
Figure 3-311
[2]
[5]
Figure 3-313
5 Unscrew the 2 screws [4].
[4]
Figure 3-312
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Dis-/assembly
4 Unscrew 4 screws [4] and remove the Y motor [5].
3 Removal of the Y motor (M2)
1 Remove the right cover and left cover.
(See "1.1 Removal of the right cover" ).
2 Remove the tension spring [1] of the pulley, remove the
pulley [2] and pulley stand [3] and remove the carriage drive belt.
[4]
[1]
[4] [5]
Figure 3-502
[3] [2]
Figure 3-501
Caution: When re-assembling, face the Y motor connector upward.
3 Remove the PBA box.
(See "4.3 Removing the PBA box" )..
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Dis-/assembly
4 Removal of the carriage drive belt
1 Remove the carriage unit.
(See "1.1 Removal of the carriage unit" ).
2 Remove the 2 belt stoppers [1] at the rear side of the
carriage (e.g. by using a flat screwdriver) and remove the drive belt [2].
[1] [1] [2]
Figure 3-505
[2]
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Dis-/assembly
1 Match the belt stopper [1] and the drive belt [2] as shown
5 Installing the carriage drive belt
Caution: Install the carriage drive belt so that the belt stopper and the drive belt joint surfaces are as shown in the figure below.
in figure 3-506 and insert them into the hole at the rear side of the carriage. 2 Pull the drive belt in the direction as shown in the figure below and check that the belt stopper has been correctly installed.
NG
OK NG
[2]
[1]
Figure 3-507
OK
Figure 3-506
NG
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Functional description
Functional description
1 Carriage unit
1.1 Outline
Figure 2-201 shows the composition of the carriage and its driving components. The Y motor (M2) drives the carriage through the carriage drive belt to the left and to the right (y-axis direction) over the paper. The distance is controlled by counting the number of pulses of the linear encoder. The engine controller PBA transmits the print signal to the print head through the head relay PBA.
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Functional description
[2] [1] [3] [11] [4]
[10] [5]
[6]
[9] [8]
[7]
Figure 2-201
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No. 1 2 3 4 5 6 7 8 9 10 11 Name Linear encoder Y Motor (M2) Carriage home position sensor (PS2) * Remaining ink detection sensor (PS3) * Ink tank detection sensor (PS4) * Carriage Print head height adjuster lever Y Cutter Media Sensor (PS9) Carriage drive belt Head relay PBA
04-Printing
Function
Functional description
Forms rectangular pulses according to the movement of the carriage Moves the carriage to the left or to the right Detects the carriage home position. Detects the ink level remaining in the ink tank Detects presence of the ink tank The assembly of the four ink jet print heads driven by the Y motor (M2). Adjusts 3 distances between the head and platen. (1.1 - 1.5 - 2.4 mm) Cuts the roll paper. Detects the paper edges for width and skew and the position of the ink dots when automatically adjusting the head. Transmits the driving force of the Y motor (M2) to the carriage. Relays the print signal from the engine controller PBA to the print head. Conducts serial communication with the engine controller PBA with the 4 bit slave CPU and sends the room temperature, head temperature and head ink information to the engine controller PBA.
* These sensors compose the purge unit.
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Functional description
2 Y motor control
2.1 Outline
The Y motor (M2) of the printer is a 2-phase stepping motor. It controls the movement to the left and to the right of the carriage. The Y motor (M2) is controlled on the engine controller PBA mainly for the functions as shown below.
1 2 3 4 5
Y motor ON/OFF control Y motor rotating direction control Y motor rotating speed control Y motor supply current control Detection of a rotation error
Engine controller Engine controllerboard board
26V
D/A 1 MTP 9 Current MTP 10 control
CPU
Vref 1
YMA
Vref 2
Motor Y Ydriver motor
MTP 11 MTP 12 MTP 13 MTP 14 MTP 15
circuit
YMAN driver YMB YMBN
M2 M2 Y Motor Y motor
CPU
Figure 2-202
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Functional description
2.2 Operation:
1 ON/OFF control.
Y motor ON/OFF is controlled by Y motor driver control signal (MTP12-15) from the CPU to the Y motor driver. When MTP12 - 15 is "0", the Y motor driver generates motor drive pulses (YMA, YMAN, YMB, YMBN) and the Y motor (M2) is rotated by those pulses. When MTP12-15 is "1", no motor drive pulse is generated and the Y motor (M2) stops rotating.
2 Control of rotating direction.
The output timing of the motor drive pulses (YMA, YMAN, YMB, YMBN) controls the rotating direction of the Y motor (M2).
3 Rotating speed control.
The frequency of the Y motor current control signal (MTP9-11) and the Y motor driver control signal (MTP1215) issued control the rotating speed of the Y motor (M2).
4 Supply current control.
By changing the combination of 2 signals (Vref 1, Vref 2) output from the motor drive control signal (D/A 0), the current output to the Y motor (M2) is set up for stopping, holding, low speed rotation and high speed rotation. The Y motor supply current is changed according to the rotating condition of the Y motor (M2) for smooth rotation of the Y motor (M2).
5 Detection of a rotation error.
If a heavy load is given to the carriage for some reason, the pulse signal output from the linear encoder cannot be detected within the specified time. The engine controller PBA judges it as a trouble in the Y motor and stops rotation of the Y motor (M2).
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TSM Océ 5150
04-Printing
Functional description
3 Linear encoder
3.1 Outline
The printer has a linear encoder to control the carriage position and to adjust the Y position of the ink drops discharged on the paper. The home position of the carriage is 12mm to the right after the carriage home position sensor (PS2) is turned ON.
3.3 Output signal.
When the linear sensor moves along the linear scale, the photo diode detects the light and darkness from the slit patterns and outputs 4 signals (A, A, B, B) to the signal processing circuit. Two comparators make rectangular waves (LSA, LSB) with phase difference of 90° from these signals.
3.2 Structure
LSA/LSB
Head relay PBA
1/360 inch
Linear sensor
Linear Scale Figure 2-203
1 Linear scale.
Slits are printed at an interval of 1/360 inch on a polyethylene telephthalate sheet. 2 Linear sensor. Composed of a light emitting diode and a photo diode. Reads the slit patterns of the linear scale and outputs a 2phase rectangular wave.
Edition 1.
Confidential © 1999 Océ-Technologies B.V.
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TSM Océ 5150
04-Printing
Functional description
Light emitting unit
Linear sensor (PS8)
Head relay PBA
Engine controller PBA
J502
-3
Photo diode
A A B B
+5V J214 -8 -9
Comparator
LED
+
LSA LSB
-4 -2
Signal processing circuit
+
Gate array
-
Lens
-1
LSA LSB
Position When the carriage is moving to the left
LSA LSB
Position When the carriage is moving to the right
Figure 2-204
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Confidential © 1999 Océ-Technologies B.V.
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TSM Océ 5150
04-Printing
Functional description
3.4 Control
The engine controller board controls or checks as follows, based on the A and B-phase pulse signals (LSA, LSB) input.
1 Control of ink discharging timing 2 Check of carriage operation 3 Check of carriage position 1 Ink discharging timing.
The LTCLK signal is generated synchronously with the rising edge of the LSA pulse when the carriage moves to the left or with the falling edge of the LSA pulse when the carriage moves to the right. So the ink dot position can be adjusted on the paper.
2 Carriage operation.
The LSA signal has a phase difference of -90° to the LSB signal when the carriage is moving to the left and at a phase difference of +90° when the carriage is moving to the right. The engine controller PBA checks herewith the carriage operating condition and moving direction.
3 Carriage position.
The carriage position is checked by counting the number of pulses at the LSA pulse rising edge when the carriage is moving to the left and at the LSA pulse falling edge when the carriage is moving to the right.
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Confidential © 1999 Océ-Technologies B.V.
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TSM Océ 5150
04-Printing
Functional description
The tolerance of the carriage driving components causes the positions where ink is discharged onto the media to be shifted.
3.5 Automatic adjustment of the head
When the print heads are installed to the carriage, the nozzle positions of the different colour print heads are displaced to each other, causing displacement of dots of different colours on the paper. The automatic adjustment of the head is a function to compensate this displacement automatically. The head can be automatically adjusted, vertically (in the x axis direction) and horizontally (in the y axis direction) following the steps below. A. Vertical adjustment (X axis). First the line patterns of 1 band in the y axis direction (horizontal direction) are printed in the order of: cyan, magenta, yellow and black, respectively when the carriage moves to the right and moves to the left. Second the black lines of 1 band are printed when the carriage moves to the right. This process is repeated for 15 sets. The distance between the centre value of the black line patterns printed on the second time and the centre value of the colour patterns, is measured for these15 sets. The average value is calculated and the calibration value for is determined. B. Adjustment in horizontal direction (Y axis). Line patterns of 30 vertical line pairs are printed. The 30 distances between the centre values of the black line and the colour line are measured, and the average value is calculated to determine the compensation value. In horizontal direction the adjustment is in steps of 1/270 inch (theoretical value). The adjustment is carried out for 7 different events:
1 When the carriage moves to the right, the printer detects
2
3
4
5
6
7
the shifted value on the line pattern with medium black drops printed with the frequency of 7,2 KHz and corrects the standard position where ink is discharged. When the carriage moves to the left, divergence between the black line pattern when printed in black small drops with the printing frequency of 7.2KHz and the colour line pat