AstroNova TrojanLabel T3-OPX User manual

SERVICE GUIDE

Confidential, Not for Redistribution
T3-OPX Service Guide
Part Number 22834700-EN-E
Revision 1.0
6/2020
TrojanLabel®, An AstroNova®Company
World Headquarters
600 East Greenwich Ave., West Warwick, RI 02893
Tel: [phone]
E-mail: [e-mail]
www.trojanlabel.com

Confidential, Not for Redistribution
Copyright © 2020 AstroNova ®, Inc.
This manual is copyrighted with all rights reserved. No part of this manual may be reproduced,
transmitted, transcribed, stored in a retrieval system, or translated into any language in any
form by any means without written permission of AstroNova.
Trademarks
TrojanLabel® is a registered trademark of AstroNova, Inc.

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Contents
Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety When Working with Electricity . . . . . . . . . . . . . . . . . . . . . . . . . . 6
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 2: Diagnostic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
External Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 3: Common Service Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removing External Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installing External Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 4: Print Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Original Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
New Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Shipping the Original Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Chapter 5: PCB Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Replacing the Internal PC (T3OPX-ECM) . . . . . . . . . . . . . . . . . . . . . . . . 19
Replacing the Webpath PCB (T1030) . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Replacing the HP MPCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Replacing the HP Ink Short PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Chapter 6: Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Replacing the Print Unit Fan (FAN4001) . . . . . . . . . . . . . . . . . . . . . . . . . 28
Chapter 7: Actuator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Replacing the Actuator (33360230) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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Introduction
Intended Audience
This service guide describes how to service and repair the T3-OPX. This guide is intended for
use by qualified service and maintenance personnel. For operation and configuration
information, refer to the T3-OPX User Guide.
Note: This service guide is for use by authorized service and maintenance personnel. Do not
distribute it to others.
General Safety Precautions
Workplace and Work Methods
• Keep the area around the device clean during and after maintenance.
• Work in a safety-conscious manner.
• Store dismantled device parts in a safe place while maintenance is being performed.
• Ensure tools do not become trip hazards.
Clothing
Danger: Moving parts can draw in clothing and lead to injuries.
• If possible, do not wear clothing which could be caught by moving device parts.
• Button or roll up shirt or jacket sleeves.
• Tie or pin up long hair.
• Tuck the ends of scarves, ties and shawls into your clothing or secure them with
non-conductive clips.
Danger: Risk of death from increased flow of current via metal parts which come into contact
with the device.
• Do not wear clothing with metal parts.
• Do not wear jewelry.
• Do not wear glasses with a metal frame.
Protective Clothing
If a possible danger to your eyes is present, wear protective goggles, especially in the following
cases:
• when knocking in or knocking out pins and similar parts with a hammer
• when using spring hooks
• when loosening or inserting springs, snap rings and gripping rings

Introduction
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• when soldering
• when using solvents, cleaning agents or other chemicals
Protective Equipment
Danger: Risk of injury in case of missing or faulty protective equipment.
• After performing maintenance work, attach all safety equipment (covers, safety precau-
tions, ground cables, etc.).
• Replace faulty parts and those which have become unusable.
Safety When Working with Electricity
Qualifications of Personnel
The following work may only be performed by instructed and trained electricians:
• work on the electrical assemblies
• work on the device while it is open and connected to the power supply
Maintenance Precautions
• Locate the emergency-stop or power switch so that it can be actuated in case of an emer-
gency.
• Unplug the device from the electrical outlet before performing the following work:
– removing or installing power supply units
– working in the immediate vicinity of exposed power supply parts
– mechanical inspection of power supply parts
– modifying the device circuits
• Ensure that the device is de-energized.
• Check the workplace for possible sources of danger, e.g. moist floors, defective exten-
sion cables, faulty protective conduction connections.
Additional Precautions for Devices with Exposed Energized Parts
• Give another person the task of remaining near the workplace. This person must be
familiar with the location and operation of the emergency-stop and power switches and
switch off the power if danger arises.
• Use only one hand while working on electrical circuits when a device is switched on. Hold
the other hand behind your back or put it in your jacket pocket. This prevents the elec-
tricity from flowing through your body.
Tools
• Do not use worn or damaged tools.
• Use only tools and testing equipment that is suitable for the respective task.

Introduction
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If an Accident Occurs
• Proceed in a very cautions and calm manner.
• Avoid endangering yourself.
• Switch the power off.
• Request medical help (emergency physician).
• Call for first aid if necessary.
System Overview
General Description
The machine consists of a metal cabinet, ink delivery system, service door, print engine,
embedded PC, touchscreen, media sensor, printhead and four ink cartridges.
If any changes or alterations are made to the machine, these changes or alterations must be
reflected in these instructions as necessary.
Machine Purpose and Intended Use
The machine is only to be used to print on materials which meet the material specification
requirements. The machine must not be used for any other purpose than the purpose
mentioned above.

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Diagnostic Setup
External Cable Connections
TeamViewer
TeamViewer is a free application available online. To connect to the printer via TeamViewer,
enter the TV ID of the unit located in the Settings tab in the Trojan UI. Password will be
displayed on the Trojan touchscreen when attempting to connect. Alternatively, the “master
password” may be used - “Tr0C0n68”.
External PC to MPCA
An external USB AB cable is needed for connection between a PC and the MPCA. The USB A
side will connect to a standard PC USB slot. The USB B side should be inserted (after removing
installed cable) to the MCPA USB A connector. The standard program for communication with
the MPCA is FlexScript. This is available free online.

Diagnostic Setup
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External PC to Webpath
An external USB A-miniB cable is needed for connection between a PC and the T1030 PCB.
The USB B side will connect to a standard PC USB slot. The USB miniB side should be inserted
into the T1030 open miniB USB connector. The standard program for communication with the
MPCA is Terra Term. This is available free online.

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Common Service Procedures
Removing External Covers
Most procedures in this guide require access to internal printer components such as printed
circuit boards (PCBs), fans, etc. Use the following instructions to remove external cover panels
and access internal components. Before starting work, review the instructions and perform the
minimum amount of disassembly required.
1. To remove the top cover, remove the six hex screws (DIN7991-M4X8-A2) and carefully
slide the top cover off the printer. Use caution and avoid catching any harnesses during
cover removal.

Common Service Procedures
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2. To remove the right side cover, remove the ten hex screws (ISO7380-M4x6-A2) and
carefully remove the cover from the printer.
3. To remove the left side cover, remove the ten hex screws (ISO7380-M4x6-A2) and
carefully remove the cover from the printer.

Common Service Procedures
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Installing External Covers
After performing service work, use the following instructions to install the external cover panels.
1. To install the top cover, position the cover on the printer and secure it with six hex screws
(DIN7991-M4X8-A2). Use caution and avoid catching any harnesses during cover
installation.
2. To install the right side cover, position the cover on the printer and secure it with ten hex
screws (ISO7380-M4x6-A2).

Common Service Procedures
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3. To install the left side cover, position the cover on the printer and secure it with ten hex
screws (ISO7380-M4x6-A2).

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Print Engine Replacement
Original Engine Removal
1. Ensure all inks have been removed from the system. Install the orange ink cavity filler for
shipping. This will be included in the replacement engine packaging.
2. Remove the printer top cover and right side cover. See “Removing External Covers” on
page 10.
3. Disconnect the three flat flex cables from the print engine.
4. Open the front plate by fully loosening the four captive hand screws.
5. Install the orange left and right inserts behind the maintenance tray. These will be
included in the replacement engine packaging.
6. Remove the three screws (DIN912-M4x8-A2) securing the print engine in the printer.
7. Carefully remove the print engine, ensuring the flat flex cables do not get tangled and
damaged during removal.
8. Place the original print engine to the side for repackaging in the new print engine shipping
pack.
New Engine Installation
1. Unpack the print module.
2. Remove the three strips of blue tape.
3. Keep the orange shipping inserts in place.

Print Engine Replacement
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4. Swing open the flat flex cable bracket and tape cables as shown.
5. Insert 15141120 print module and secure using three hex screws (DIN912-M4x8-A2).
6. Remove the tape from the flat flex cables.
7. Snap the flat flex cable bracket back into place.
8. Connect the three flat flex cables from 15141120 print module to ATA15141300 Main
PCA board assembly.
9. Power on the unit in MFG mode using the T1030 with Tera Term. The baud rate is
921600.
10. Open Flexscript.
While in MFG mode, run the following scripts located on the OPX Sharepoint \HP Callisto
- Documents\Production\T3OPX_Remanufacturing_Scripts_Version_4.0TL:
a. 0_OOBE_BYPASS - This will prevent the bar from purging when powered on.
Expected output:
DSID_IDS_FIRST_CHARGE_REQUIRED = 0->0
DSID_INK_SUPPLY_OOBE_COMPLETE = 0->1
DSID_FM_PEN_STARTUP_STEP = 0->999
DSID_IDS_STARTUP_ALLOWED = 0->1
DSID_PEN_PRINTER_STARTUP_BITS = 0->0
DSID_OOBE_STATE = 1->255
DSID_CAL_OOBE_STATE = 0->2
DSID_CAL_OOBE_PROGRESS = 0->0
DSID_BDD_FAIL_MASK = 16->16
DSID_MACHINE_STATE = 2->2
DSID_MECH_DIRTY_FLAG = 1->1
b. 3_SET_SERIAL_NUMBER - This will allow you to set the serial number of the unit.
The serial number MUST be 10 digits in length. Use the SN shown on the side of
the printer.

Print Engine Replacement
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c. 4_MECH_INIT - This will move the print bar and sled and set some states. This
also sets the PPS to 2500. Depending on OEM strategy, this distance might
change. Note that during this, you will likely see the following message.
This indicates that the engine has not been purged, so the user should not attempt
to print. This will go away after the printer is purged and can sense that ink is there.
d. 5_CHECK_SLED - This will exercise the service tray and ensure it is moving
normally. This script will output details about the movements that could be logged
as a control.
e. 6_CHECK_PRINTBAR - This will exercise the print bar elevator and ensure it is
moving normally. This script will output details about the movements that could be
logged as a control.
f. 7_SPIT_ON_WEB – This will uncap the print bar and spit a small number of drops
on the wiper to validate printing. This enables the testers to verify that the system
has been integrated and is able to fire the pen.
Caution: Do not run this more than three times on any one unit.
g. Move the print unit all the way up.

Print Engine Replacement
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h. 7_1 PRINT HEIGHT TEST AND SET - Test the print height of the print.
Run script: 7_1 Print height test and set.bas
Test different heights. Start with 5250 and move from there. The target is to touch
the crash plate, but not push it down.
i. Update the “settings.ini” file with the new print height and time out distance.
Use TeamViewer to remotely log into the internal PC. Open the “settings.ini” file.
This file is located in the following folder:
C:\TrojanOne-data\settings\t3x
In the General section, insert values for the following:
PPS=<print height> (for example, PPS=5160)
TimeoutInches=2000
Save settings.
j. 7_2 Set GPIOS
Run script: 7_2 Set GPIOS.bas
This will set the page ready communication between the print engine and T1030.
Note: The FI-1000 Bar-In-Box is filled with shipping fluid that allows it to be stored
and to go through dynamic events. Prior to using the engine in production, it must
go through a startup process. This process will spit the shipping fluid out and
replace it with ink.
k. Install a spittoon/absorber tray below the print bar.
l. Run 8_PREP_FOR_SHIP - This will prepare the unit to start a purge cycle on the
next power up.
SET PURGE HEIGHT - Insert the purge height in the pop-up, which should be the
same has the print height determined in the previous steps in the pop up.
The script should return a success value.
m. Power the unit off. (Hard Power off through Trojan Control)
11. Power on the unit.
12. Open the service menu.

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13. Select “Start purge on next power on”.
14. Confirm the process initiation.
Purge will deplete 300-350 ml of shipping fluid. It will require the spittoon placed under
the print head. After pressing OK, the print unit will be moved to the purge height and
purge will start on next power on. The operation can not be undone once accepted.
15. Confirm the process success.
Purge process initialized successfully. Place spittoon under the print head, then power
off the printer unit by switching off the main PSU. Purge will automatically start on next
power on.
If the unit failed to move to the print height, check if the height control has been initialized
in the handling menu.
The process will use the “purge height” in the settings menu.
Shipping the Original Engine
1. Place the original print engine in the replacement print engine packaging.
2. Return the original print engine to AstroNova via the return merchandise authorization
(RMA) process.

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PCB Replacement
After replacing any internal PCB, perform a firmware update via the Trojan Control Updater. All
removed boards should be packaged in the replacement part packaging and returned to
AstroNova via the return merchandise authorization (RMA) process.
Replacing the Internal PC (T3OPX-ECM)
1. If possible, use TeamViewer to remotely log into the internal PC. Copy the “settings.ini”
file from the internal PC to your local PC. This file is located in the following folder:
C:\TrojanOne-data\settings\t3x
You will use information from this file to restore settings after replacing the T3OPX-ECM.
2. Disconnect all power from the printer.
3. Remove the top cover from the printer. See “Removing External Covers” on page 10.
4. Disconnect all cables from the T3OPX-ECM. Connections are illustrated below for
reference.
5. Remove the four hex cap screws and lock washers from the T3OPX-ECM. Remove the
T3OPX-ECM from the printer.
6. Install the new T3OPX-ECM on the PCB holder stack using the four hex cap screws and
lock washers.
7. Connect all cables to the new T3OPX-ECM.
8. Install the top cover on the printer. See “Installing External Covers” on page 12.

PCB Replacement
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9. Turn the printer power on.
10. Use TeamViewer to remotely log into the new internal PC. Edit the “settings.ini” file to
mirror the settings from the original “settings.ini” file.
11. If the print height (PPS) could not be recovered from the original ECM, the print height
test and set will need to be re-run to find the applicable print height setting. See “New
Engine Installation” on page 14.
Replacing the Webpath PCB (T1030)
1. Disconnect all power from the printer.
2. Remove the top cover from the printer. See “Removing External Covers” on page 10.
3. Disconnect all cables from the T1030.
4. Remove the micro disk from the T1030 and set aside carefully. The micro disk is
illustrated below for reference.
5. Remove the four hex cap screws (DIN912-M3x6-A2) and lock washers
(DIN6798J-M3-A2) from the PCB. Remove the PCB from the printer.
6. Install the new T1030 on the PCB holder stack using the four hex cap screws
(DIN912-M3x6-A2) and lock washers (DIN6798J-M3-A2).
7. Replace the new micro disk with the original that was set aside previously. Retain the new
micro disk in case it is needed.
8. Connect all cables to the new T1030.
9. Install the top cover on the printer. See “Installing External Covers” on page 12.
10. Power on the printer to verify function.
• If the printer operates as expected, no further action is needed.
• If the printer does not operate as expected, you will need to install the new micro
disk and configure it. See “Installing and Configuring the Micro Disk” on page 21.