Ioline FlexJet User manual

Service Manual
Ioline FlexJet™

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

Service Manual
Ioline FlexJet™

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

Figure 38. Carriage noise may indicate a dirty or faulty wheel ........................................ 50
Figure 39. Replacing the fuse .................................................................................................... 51
Figure 40. A good transitor on the left; the one on the right is blown .......................... 52
Figure 41. Testing the Y-Axis motor ........................................................................................ 54
Figure 42. Mechanical, electrical and electronic diagnostics ow chart .......................... 61
Figure 43. Removing the right end cover ............................................................................... 64
Figure 44. Loosen the belt tensioner ...................................................................................... 64
Figure 45. The carriage cover screw ....................................................................................... 65
Figure 46. Unclip the belt from both ends of the carriage ................................................ 65
Figure 47. Loosen the carriage wheel lock ............................................................................ 66
Figure 48. Gently press down on the carriage ..................................................................... 66
Figure 49. Rotate the v-wheels free of the traverse rail .................................................... 66
Figure 50. Carriage installation ................................................................................................. 67
Figure 51. Use the spacer when attaching each swing arm ............................................... 67
Figure 52. The carriage belt tensioner ................................................................................... 68
Figure 53. Install the carriage cover ........................................................................................ 68
Figure 54. Remove the cover .................................................................................................... 69
Figure 55. Install the carriage cover ........................................................................................ 70
Figure 56. Remove the logic board cover plate .................................................................... 70
Figure 57. Unplug the feed motor and encoder cables from the logic board ...............71
Figure 58. Unplug the ribbon cables ....................................................................................... 71
Figure 59. Make a loop in the ribbon cable to the left of the carriage ........................... 72
Figure 60. Carriage installation ................................................................................................. 73
Figure 61. The carriage belt tensioner ................................................................................... 73
Figure 62. Install the carriage cover ........................................................................................ 74
Figure 63. There should be a small gap in the ribbon cable loop ..................................... 75
Figure 64. The loop in the cable should not touch the left endplate .............................. 75
Figure 65. Secure the sleeving with tape ................................................................................ 76
Figure 66. Remove the right end cover .................................................................................. 77
Figure 67. Remove the screws and let the keypad hang ..................................................... 77
Figure 68. Remove the carriage cover .................................................................................... 77
Figure 69. Install the ink cartridges and turn the power on .............................................. 78
Figure 70. Loosen the carriage catch bracket ....................................................................... 78
Figure 71. Cover the spit wells ................................................................................................ 78
Figure 72. Two lines in the spit well holes ............................................................................. 79
Figure 73. Use the plastic thumbscrew to adjust the lines if necessary ......................... 79
Figure 74. Y Fine adjustment is performed within the Control Center ..................... 80
Figure 75. Watch the gap between the carriage and Service Station ......................... 80
Figure 76. The Service Station stop screw ....................................................................... 81
Figure 77. Small gap between the screw and the Service Station ............................... 82
Figure 78. Tighten the nut to hold the stop bracket ........................................................... 82
Figure 79. Unplug the take-up motor ..................................................................................... 83
Figure 80. Remove the right cover .......................................................................................... 83
Figure 81. Unscrew the PCB cover ......................................................................................... 83

Figure 82. Remove the logic board cover ............................................................................. 83
Figure 83. Carefully unplug connections to the board ....................................................... 84
Figure 84. Carefully remove the logic board ........................................................................ 84
Figure 85. Inspect the connections to the logic board ....................................................... 85
Figure 86. Remove the keypad screws and bracket. Unplug the keypad cable ............. 87
Figure 87. Tighten the screws on the Y-Axis transmission ................................................ 88

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

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

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

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

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

Four publications are available to assist you in setting up, operating
maintaining and servicing the FlexJet:
nFlexJet Quick Start Guide
nFlexJet User Guide
nFlexJet Service Manual
nFlexPlot User Guide
Where to nd information
The table below provides a quick directory of topics and resources:
How to use
this manual
Topic Manual
Assembly & setup FlexJet Quick Start Guide
Paper loading FlexJet Quick Start Guide
Removing markers FlexJet User Guide
The Ioline Control Center (adjusting plot
parameters)
FlexJet User Guide
Ioline FlexPlot software FlexPlot User Guide
Design software set-up guides FlexPlot User Guide
Maintenance FlexJet User Guide
Basic troubleshooting FlexJet User Guide
Advanced troubleshooting for qualied service
personnel
FlexPlot Service Manual
Specications, part names, drawings FlexPlot Service Manual
What’s in this Service Manual
The FlexJet Service Manual provides extensive product specica-
tions, testing and repair procedures.
Chapter 1 Introductory information and general specications.
Chapter 2 Descriptive drawings listing part names for the
FlexJet. This section is intended to supplement the
FlexJet User’s Guide.
Chapter 3 Troubleshooting and testing guide.
Chapter 4 Details for repair and maintenance of the FlexJet.
Chapter 5 Technical drawings and reference material.

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

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

Figure 4. The Ioline FlexJet Printer front view close-up (safety cover lifted for clarity.)
R. Ink Cartridge Stall
S. Cartridge Stall Latch
T. Pinchwheel Lever
U. Keypad
V. Service Station
(Beneath Cover)
W. Take-up Sensor
X. Platen
Y. Pinchwheel
Z. Drive Shaft Marker
aa. Traverse
ab. Carriage Assembly
KEY
R
U
Y X
ab aa
S
V
T
W
Z
xviii

Chapter 1
Overview
Product overview
The FlexJet is
most commonly
used in conjunc-
tion with popular
apparel software
for printing
marker patterns,
used in the man-
ufacture of cloth-
ing. The FlexJet
also comes with
FlexPlot soft-
ware that allows
printing of the
most popular
formats such as
AutoCad®(DXF),
CorelDraw!®(PLT),
Adobe®Illustrator®(DXF), Gerber®(STD, PLT or ASTM), Lectra®
(ASTM), Investronica®(ASTM).
The Ioline FlexJet can handle many different printing operations
up to 72 inches wide and 600 yards long. Three industry standard
printer languages (HPGL 7475, and DM/PL) are supported.
The Ioline FlexJet also supports direct cable connection from many
popular programs such as PAD®, Scanvec®Optitex®, Polytropon®,
Ioline IPS software, and other applications.
Supported languages
Language Application
HPGL Direct from software or Ioline FlexPlot.
DM/PL Direct from software or Ioline FlexPlot.
DXF Ioline FlexPlot only.
STD Ioline FlexPlot only.
ASTM 6959 FlexPlot only.
Ioline syntax Direct special control characters for FlexJet.
Figure 5. The Ioline Flexjet.

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