Ioline FlexJet Series Quick start guide

14140 NE 200th St. Woodinville, WA. 98072 PH: [phone] FX: [phone]
FlexJet Carriage upgrade
Tools Required:
Philips screwdriver
9/64 (3.5mm) Allen wrench
5/16 (8mm) open end wrench
 Smallattippedscrewdriver
Notices:
Warning!EnsurethatallACpowercablesareremovedfromtheprinterbeforeattemptingtheseprocedures.
Attention!Thedischargeofstaticelectricitymaydamagethecarriageandlogicboardcomponents.Usetheincluded
groundstrapduringallprocedures.Keepplasticobjectsawayfromthecarriageandlogicboardassemblies.
Warning!TheFlexJetisheavyandcouldcauseseriousinjuryordeathifitfallsorrollsover.Makesurethataminimumof
twopeoplemoveit,especiallywhendetachedfromthestand.
Prepare the printer
a)TurntheFlexJetpoweroff.
b)Clearpaperfromaroundthecarriage.
c)Removeinkjetcartridges.DoNOTcoverthe
cartridgeheadswithanything.
d)RemovetheACpowercableandanyother
cablesconnectedtotherearoftheprinter.
Remove the end cover
a)Unplugtherollfeedmotorundertherightend
cover.
b)Removethe5screwsthatholdtheplasticend
coverontotherightendoftheprinter.There
aretwoontheatsurfaceoftheendplate,
onescrewintheback,and2screwsonthe
bottom.
Loosen the Carriage Belt
a)Findthebelttensionerontherightsideabove
thewhitecables.
b)Loosenthecarriagebelttensionerbyrotating
the9/64”HEXscrew4fullcounterclockwise
turns.
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Included with the upgrade kit
1)Screwsformountingthenewboard(3)
2)Newdaughterboard
3)Standoffs(2short,1long)
4)Flexcables(1short,4long)
5)Carriageassemblywithexcables
6)Belttensionerassembly
7)Tyraps(8)
8)Doublestickfoamtape
9)Groundingwriststrap
10) This procedure
RemoveCover
Loosenthisscrew
(9/64”)
P/N: 108384 R0

c)Findthewhiteexcableconnections.Gently
pullthelockingclipsontheconnectorshrouds
downtounlocktheexcableconnectors.
d)Removeallwhiteexcablesfromconnectors.
Remove the Logic Board Cover
Attention!Thecarriageandlogicboardcomponentsaresensi-
tivetothedischargeofstaticelectricity.Attachoneendofthe
groundstrap(included)toyourwristandtheotherendtoa
baremetalportionoftheprinterliketheframetheholdsthe
servicestation.Keepplasticobjectsawayfromthecarriageand
logicboardassemblies.Removethewriststraponlyafterthenew
carriageisattachedtothetraverse,thecoverisinstalled,andthe
metalcoverissecuredoverthemainlogicboard.
a)Removethe4screwsthatholdthesheetmetal
logicboardcoverplate.
Attention! Thecoverwillswingdownwhenthelastscrew
isremoved.Makesuretosupportitwithonehandandletit
slowlyrotate.
b)Unplugtherollfeedmotorpowerandencoder
cablesfromthelogicboardthensetthelogicboard
cover aside.
Remove the Old Flex Cables
a)Withthecarriagesecured,cliptheplasticties
thatholdthewhiteexcablesagainsttheright
sideoftheprinter.
b)Pullthebundleofcablesoutofthegreyclips
(ifpresent).
c) Pullthebundleawayfromtheendplateifit
securedwithfoamtape.Liftthecarriagebelt
tensioneroutofthewayifnecessary.
d)Fromthefrontofthemachine,pullthebundle
throughtheholeintheendplate.
e)Liftthecablebundleupandoffthetraverse
movingtowardtheleftsideofthemachine.
Don’tworryaboutthefoamtapestucktothe
traverse.
4
5
Remove screws
2-Front
2-Rear(Shown)
UnplugTake-upwires
fromthelogicboard
Unplugribboncables
RibbonCable
ShortScrew

Remove the Old Carriage
a) RemovethePhillipsheadscrewattheright
sideofthecarriagecover.Thisscrewholdsthe
carriagecoveron.
b) Withonehandtoeachsideofthecarriage,
gentlypullthecarriagecovertabsoutthatare
locatednearwherethecarriagebeltsattachto
thecarriageandremovethecover.
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e) Holdthecarriageattherightandleftsideofthemetal
basewithbothhands.
Important: Donotholdthecarriagebytheinkjethead
stallsorthesensor.
f) Keepingthetoptwocarriagev-wheelsonthetra-
verse,gentlypushthecarriagedownandrotate
thebottomofthecarriagetowardsthefrontofthe
machineuntilthelowerv-wheelsslipoffofthelower
traverserail.
g) Liftthecarriageupandawayfromthemachine.The
longexcablebundleshouldfollowthecarriageas
youpullitoff.Setthewholeassemblyaside.
c) Unclipthecarriagebeltendsattheleftand
rightsidesofthecarriagebase.
d) Usinga5/16(8mm)openendwrenchloosenthe
#6-32hexnut½turnundertheRIGHTandLEFT
swingarmsuntilthewashersandroundspacerscan
movefreely.
Removecarriagecoverscrew
BeltClips
Right
Left
Loosenthisnut
Press down here
andontheotherside
Rotatebottom
towardsyou

7Attach the New Carriage to the Tra-
verse
Important: Pleasereadthenextstepsfullybefore
attemptingtoattachthecarriage.
a) Wipethetraverserailswithanisopropylalcohol
dampenedclothtoremovedust.Performthis
importantmaintenancestepoften,evenevery
weekdependingonmachineuse.
b) Whileholdingthecarriageandribboncable
bundle,inserttheendofthebundlethrough
theholeintheendplateattherightendof
thetraverse.Continuefeedingabout20”ofthe
bundlethroughthehole.
Attention! Donotholdthecarriagebythecartridgestalls
orthesilversensorassembly.
d) Feedthenewribboncablebundleintothechannel
inthetraversesothatthereisalooptotheleftof
thecarriage.Lightlypresstheloopintothegroove
atthebackofthetraversesothatitisinthecable
channel.
c) Movetothecenterofthemachineandholdthenew
carriageupnearthetraversewiththebluelever(s)
facingupandawayfromthemachine.
e) Ensurethattheblackdrivebeltisbetweenthetra-
verserailsandbehindthecarriagebase.Holdthecar-
riageattherightandleftsideofthemetalbasewith
bothhandsandslipthetoptwocarriagev-wheels
overthetoprailofthetraverse.
f) Keepingthetoptwocarriagev-wheelsonthetra-
verse,gentlypushthecarriagedownandrotate
thebottomofthecarriagetowardsthebackofthe
machineuntilthelowerv-wheelsslipontothelower
traverserail.
g) Gentlymovethecarriagerightthenlefttoensurethat
thewheelsmovesmoothly.
Pullriboncablethroughholeinrightside
RibbonCableloop
Carriage
RibbonCableloop
Carriage

Tighten the Carriage Swing Arms
a) Gentlyholdthespacerupagainstthe
bottomofoneoftheupperv-wheelswing-
arms.Thespacercanbeheldupwitha
ngerorasmallscrewdriverinsertedfrom
therightsideofthecarriage.
b) Whilekeepinggentleupwardpressureon
thespacer,securelytightenthenylocknut
usinga5/16(or8mm)openendwrench.
c) Repeatthisprocessfortheotherswingarm
onthecarriage.
8
Replace tensioner and Attach the carriage
belt.
a) Guidetheribboncablebundleunderthecar-
riagebelttensioner.
b) Placethenewbelttensionernexttotheold
one.Counttheexposedscrewthreadsonthe
oldtensionerthenrotatethescrewinthe
newonetomatchtheoldone.
c) Insertthebeltthroughthenewtensionerso
thatthebeltteethfacethepulley.
d) Guidebothendsofthebeltthroughthehole
intheendplateandinfrontofthetraverse.
e) Holdthenewcarriagebelttensionersothat
the2tabsandscrewtiprestintheholesand
detentintherightendplate.Totheleftofthe
ServiceStationarea,holdbothwebsofthe
carriagebelttomaintainslightbelttensionso
thatthecarriagebelttensionerdoesn’tmove
outofplace.
f) Whilemaintainingtensiononthecarriage
belt.Attachthecarriagebeltclipstoeach
sideofthecarriagebase.
Important:Makesurethebeltisnottwistedbefore
attachingtheclips.
g) Tightenthecarriagebelttensionerbyrotat-
ingthe9/64”(3.5mm)screw4fullclockwise
turns.
9
Install the Carriage Cover
a) Installthecarriagecoverbyaligningitwith
thebaseandpushingbackuntilthetabs
bythebeltendsgrabontothecarriage
base.
b) Pressagainstthecovertabstoensurethat
they‘snap’intotheslotsinthecarriage
base.
c) Installthe#6-32screwattherightsideof
10
Tightenthisnut
Flathead
Screwdriver
5/16”boxwrench
Push up on
Cylinder
Makesuretensionerisinholes
Lockingtab

Secure and Arrange the Ribbon Cable Bundle
- Part 1
Note:Thewristgroundstrapcanberemoved
now,butwillneedtobewornagainlaterinthis
procedure.
Important: Thisprocessisimportantforproperoperationof
theFlexJet.Thesleevedribboncablesrequirearmconnection
tothetraverseatthemiddleoftheprinterandattherightendof
thetraverse.Leaveexistingfoamtapeifthepiecesarestillsticky
andnotbunchedup.Applytheincludedfoamadhesivetapeto
theexistingfoamtapeifnecessary.
a) Holdtheribboncablebundleoutofthe
wayandattacha10cmpieceofthesup-
plieddoublesidedfoamtapetothetraverse
channeltotherightoftheexistingtape
(ifpresent)atthemiddleofthemachine.
Removethetapebackingsothattheside
facingupisexposed.
b) Repeatthisprocessneartherightendplate
butplacethetapetotheleftoftheexisting
tape(ifpresent).Removethetapebacking
sothatthesidefacingupisexposed.
c) Slidethecarriageovertotheleftendplate
andholditinplace.Astheleftsideofthe
carriagejusttouchesthesmallroundbum-
pers,lookattheribboncablebundleloop.
Itshouldleaveasmallgapbetweenthe
sleevingandtheleftendplate(nofurther
than.08”(2mm)away)asthecarriagebase
touchesthebumpers.
11
Secure and Arrange the Ribbon Cable Bundle-
Part 2
a) Continuetosmooththeribboncablebundle
towardtherightendplatetostretchthe
blacksheathingsothatitlaysrelativelyat
andtaut.
b) Firmlypushthesleevingintothetapeat
therightendofthetraverse.Ifitdoesnot
stick,applythefoambackedtapeoverthe
foamtapeandrepeattheprocess.
d) Totherightofthecarriage,holdtheribboncable
bundledownrmlyinthetraversechannelwiththe
lefthand.
e) Withtherighthand,smooththeribboncable
bundlebeyondthetapeatthemiddleofthetra-
versesothattheblacksleevingisstretchedand
laysrelativelyatandtaut.
f) Firmlypushtheblacksleevingintothetapeatthe
middleofthetraverse.Ifitdoesnotstick,applythe
suppliednon-foambackedtapeoverthefoamtape
andrepeattheprocess.
g) Movethecarriagetotheright10”thenslideitback
totheleftendplateandensurethattheloopinthe
cablebundleisstillnottouchingtheleftendplate.
12
RibbonCableloop
Gap
RibbonCable
Placetapehere

Prepare the Daughter Card
Attention! Attachoneendofthegroundstrap(included)toyour
wristandtheotherendtoabaremetalportionoftheprinterlike
theframetheholdstheservicestation.Keepplasticobjectsaway
fromthecarriageandlogicboardassemblies.
a) Removethethreescrewsindicated.
b) Installtheincludedlongspacerintheholein
thecornerofthelowerlogicboardasshown.
13
c) Installthetwoshortspacersintheholesin
theupperlogicboardasshown.
d) Installthelongribboncablesinthedaughter
card
e) Liftthelockingcollarsupfromthewhite
ribboncableconnectorsonthebottomofthe
daughtercard
f) Inserttheribboncablesintotheconnector
andpressdownonthecollartothe“closed”
position.
g) Insertthefourlongerexcablesintothedaughter
cardconnectors.
NOTE: Itisveryimportantthattheconductivesideof
thecablesalignwiththeconductivepadsinthe
connector.
h) Pressthelockingcollarbackdownaftereachcable
isinserted.
i) Inserttheshorterexcableintothewhiteconnector
onthebottomofthedaughtercardasshown.Itis
veryimportantthattheconductivesideofthecable
alignswiththeconductivepadsintheconnector.
Attach the Daughter Card
a) Liftthelockingcollarsupfromthewhite
ribbon cableconnectorsonthemotorcon-
trollogicboardasshown.(longcables
only).
b) Aligntheholesinthesmalldaughtercard
withtheholesinthespacersasshown.
14
Removethe3
screws Replacewithstandoffs
Long
Short
Short
Collaropen
CollarClosed
Notch
Long
Short
Pluginthelongribboncablesrst
Note: Theblackorblueendsattheendofthelongcables
shouldfacethemiddleofthemachine.

c) Insertallveribboncablesintotheircorresponding
whitesocketsonthemainlogicboard.
d) Pressthelockingcollarsbackdownaftereachcable
isinserted(longcablesonly).
e) Gentlyfoldthecablestowardthecenterofthe
machinethenpresstheboarddowntowardthemain
logicboards.
f) Insertandtightenthescrewsremovedinstep1
abovetosecurethedaughterboard.Extrascrewsare
includedintheupgradekit.
c) Make90degreefoldsinthecableendsasshown
thenconnectthemtothedaughtercard.
d) Topmost(longest)cable-plugintoconnectorJ9
(PWR/SENS)withthebluecableedgefacingthe
centeroftheprinter.
Important: Makesurethecableplugsintotheconnector
correctlyandarenotshiftedbyaroworcolumn
ofpins.
e) Nextcableinthebundle-plugintoconnectorJ1
(PRT1)withthebluecableedgefacingawayfrom
theprinter.
f) Continueattachingcablesintheorderthattheyare
stackedmakingsurethattheconnectorsarefolded
as shown.
Attach the Ribbon Cables
Attention!Theribboncableconnectorsaresmall.
Makesurethattheconnectoriscorrectlyaligned
withtheheaderpinsbeforeinserting.
a) Pulltheribboncablesoutstraightfromthe
rightendplateandpullthemtowardthe
bottomedgeoftheboard.
b) Theconnectornumberscanbeseennext
totheconnectorbylookingupatthelogic
board(withyourheadunderthemachine).
g) Attachtheribboncablebundletotheendplatewith
cabletiesasshown.Asmallfoldinthebundleis
requiredtotakeupslackinthecables.Slidethe
blackferritebeadsalongthecabletopositionthem
as needed.
h) Checkallofthecableconnectionsandhardwareto
ensurethatthemachineisreadytotest.
15
Daughterboardinstalled
Open
Closed
Head4
Head3
Head2
Head1
Sensor
Connecttheribboncableendswithfolds
Tyraps

Attach the Logic Board Cover and Tighten the
Carriage Belt
a) Hangthemetallogicboardcoveroverthe
endoftheservicestationframe.NOTE:Make
surethelogicboardcoveredgesareOUT-
SIDEoftheservicestationframeonthefront
andback.
b) Makesuretheribboncablebundlets
throughtheslotattheendofthecover
andinthedaughtercard.Ifneededshiftthe
cablestothesidetoavoidpinchingthem.
c) Connectthetakeupmotorpowerand
encodercablesasshownin.
16
PluginTake-upwires

Procedure: Firmware update for the Ioline FlexJet
Prepare the FlexJet to Update the Firmware
Updating the rmware
1
Determine what version of rmware you have
1.PoweronthePCandFlexJet.
2.EnsurethattheserialcableconnectsthePCtothe
FlexJet.
3.Makesurethereisagreenlightonthekeypadofthe
FlexJetandopentheFlexJetControlCenter.
4.Themainscreenshowsthecurrentrmwareversionin
theupperrightcorner.
5.Ifthermwareversionisnotshown,pleasecheck
connectionstotheprinter.CallIolineCustomerService
forhelpresolvingcommunicationissues.
6.Ifrmwareisalowernumberthanversion253.2,use
the“Manualrmwareupdate”procedure
Auto Updating the Firmware
Note: Follow this procedure if your current rmware version is
253.2 or higher.
1.Makesurethermwarelehasbeensavedinthe
Iolinefolder.ChooseFile>DownloadFirmwarefromthe
menu.
2.PresstheSelectFirmwarebutton.
3.Followtheonscreendirectionsthatexplainhowto
restarttheprintersothatitwillacceptnewrmware.
PressOKwhentheprinterisready(fouryellowlights
onthekeypad.)
4.Usethewindowtobrowsetothelocationwherethe
rmwareleisstored(usuallyxxxxx.mot,wherexxxxx
istheversionnumber).
5.Awindowwillappearthatshowsthetransferprogress.
6.Theprinterwillgothroughtheinitializationprocess
whenthermwareisnished.Whennished,theOK
lightwillturnredandtheSquarelightwillturngreen.
7. PresstheDonebuttonwhentheprocessiscomplete.
8.Followstepsforthenextprocedure“Yneadjustment
fortheservicestation”.
Manually Updating the rmware
Note: Usethisprocedureifyourcurrentrmwareislowerthan
version253.2
Prepare to Update the Firmware
1. PoweronthePCandFlexJet.
2. EnsurethattheserialcableconnectsthePCtothe
FlexJet.
3. Copythermwareletoafolderlikec:\Ioline\
Firmwareoranotherlocationthatiseasytoremem-
ber.IfitisaZIParchive,makesureitisdecompressed
beforesendingittotheFlexJet.
Setup TeraTerm
1. StartTeraTerm.PleasecontactIolineifyouneeda
copy.ItisincludedontheFlexJetCDROMinthe
X:\tools(whereXistheCDROMdriveletter)folder.
2. Whenthe“NewConnection”windowappears,clickon
thecirclenextto‘Serial’thenselecttheCOMportthat
connectstheprintertothePC.
3. InthemainTeraTermwindowmenu,clickon
Setup>SerialPort.
4. Changethe‘Baudrate’to38400.Makesuretheother
settingsmatchthefollowing:
a. Data:8bit
b. Parity:None
c. Stop:1bit
d. FlowControl:Xon/Xoff
e. TransmitDelay:0/0
5. Press‘OK’.
IMPORTANTNOTE:FlexPlotversion1requiresrevision1
oftheFlexJetrmware(229.0)orlater.Pleasecontact
customerserviceforafreermwareupgrade.
Set the initial Y Fine Adjustment number
1)TurnontheFlexJetandletitinitialize.
2)Openthe“FlexJetControlCenter”software.
3)WhenthewindowopenspressCtrl-Alt-B.Youshould
seethe“ServiceStation”window.
4)Clickthe“MovecarriageoutfromSS”button.The
carriagewillmoveoutoftheServiceStation.
5)Changethe“Yneadjust”numberto-1000andclick
the“Setneadjust”button.
6)Clickonthe“ReturncarriagetoSS”button.Thecar-
riagewillmovebackintotheServiceStation.
2a
2b