Seiko I Infotech IP-6600 User manual

SIIT CONFIDENTIAL
IP-6600
Color Ink Jet Printer
Maintenance Manual
U00087443802
Seiko I Infotech Inc.

SIIT CONFIDENTIAL
U00087444000 February 2004
U00087444001 March 2004
U00087443802 April 2005
Copyright (c) by Seiko I Infotech Inc. 2005
All rights reserved
The information in this manual is subject to change without prior notice.

SIIT CONFIDENTIAL
CONTENTS-3
CONTENTS
Section 1 Maintenance Procedure Overview 1-1
1.1 Maintenance Procedure Overview 1-1
1.2 Required Tools 1-2
1.3 External Views and Names of Parts 1-4
1.4 Maintenance Space 1-6
Section 2 Inspection and Maintenance 2-1
Section 3 Maintenance Mode Menu Operations and Functions 3-1
3.1 Introduction 3-1
3.2 Entering Maintenance Mode 3-2
3.3 Basic Menu Operation 3-3
3.3.1 Menu tree 3-4
3.3.2 Basic operations and keys 3-11
3.4 Menu Operation: Maintenance Mode 3-15
3.4.1 MEC. ADJ Menu 3-15
3.4.2 H. ADJ. Menu 3-19
3.4.3 H. MNTE Menu 3-23
3.4.4 RESET Menu 3-36
3.4.5 TEST-PRN. Menu 3-37
3.4.6 SYSTEM Menu 3-40
3.4.7 FEED Menu 3-46
3.4.8 MONITOR Menu 3-47
3.4.9 DIAG Menu 3-50
3.4.10 SETUP Menu 3-54
3.4.11 ACTUATOR Menu 3-55
3.4.12 FUNCTION Menu 3-59
3.4.12.1 System information print 3-60
3.4.12.2 Error log print 3-60
3.4.12.3 Cleaning history print 3-64
3.4.13 COUNTER Menu 3-65
3.5 System Information Management 3-66
3.6 Heater Panel Maintenance Mode Menu Operations and Functions 3-69
3.6.1 Entering maintenance mode 3-69
3.6.2 Basic menu operation 3-69
3.6.3 Menu items 3-70
Section 4 Troubleshooting (General) 4-1

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CONTENTS -4
Section 5 Troubleshooting (Engine and SCSI Controllers) 5-1
5.1 Print Quality Defects 5-1
5.2 Error Message Types 5-4
5.3 Operator Call Errors 5-5
5.4 Warning 5-8
5.4.1 Communication errors 5-10
5.4.2 Winder timeout 5-10
5.5 Service Call Errors 5-11
5.5.1 Self-diagnostic errors at power on 5-11
5.5.1.1 Internal RAM (0001) 5-12
5.5.1.2 SRAM (0002) 5-12
5.5.1.3 Flash ROM (0004) 5-12
5.5.1.4 PIO (0008) 5-12
5.5.1.5 NVRAM 5-13
5.5.1.6 FPGA (IPB) (0020) 5-15
5.5.1.7 FPGA (ICB) (0040) 5-15
5.5.1.8 ASIC CONF (IPB1) (0080) 5-15
5.5.1.9 ASIC CONF (ICB1) (0100) 5-16
5.5.1.10 SCSI board (0200) 5-16
5.5.1.11 SCSI register (0400) 5-16
5.5.1.12 DRAM (0200) 5-17
5.5.1.13 POWER SUPPLY (+36, +24, +12 V) (800) 5-17
5.5.2 Engine error 5-19
5.5.2.1 Engine error 1110: GA_ATG block clear error 5-20
5.5.2.2 Engine error 1110: GA_ATG DMA error 5-20
5.5.2.3 Engine error 112X: Vacuum fan error 5-20
5.5.2.4 Engine error 1140: Flash ROM write error 5-21
5.5.2.5 Engine error 1150: Home position sensor error 5-21
5.5.2.6 Engine error 1160: Wiping error 5-22
5.5.2.7 Engine error 1170: Temperature sensor error 5-22
5.5.2.8 Engine error 1180: Capping motor error 5-23
5.5.2.9 Engine error 119X: VDD2 variable power supply error 5-24
5.5.2.10 Engine error 11AX: NVRAM error 5-25
5.5.2.11 Engine error 11C0: Cap position error 5-26
5.5.2.12 Engine error 11D0: Cooling fan error 5-26
5.5.2.13 Engine error 11E0: Long term strage error 5-26
5.5.2.14 Engine error 120X: Head drive IC error 5-27
5.5.2.15 Engine error 121X: Head temperature error 5-27
5.5.2.16 Engine error 1220: Edge sensor error 5-28
5.5.2.17 Engine error 123x: Sub-tank sensor error (Full or Half) 5-28
5.5.2.18 Engine error 124x: Ink supply sensor error 5-29
5.5.2.19 Engine error 125x: Sub-tank supply error 5-30
5.5.2.20 Engine error 126x: FFC cable connection error 5-31
5.5.2.21 Engine error 1700x: Servo error 5-31
5.5.3 System errors 5-33
5.6 Engine F/W composition and Version Up 5-34
5.6.1 Engine F/W Composition 5-34
5.6.2 Engine F/W Version UP 5-35
5.7 ASIC Program Composition and Version Up 5-37
5.7.1 ASIC Program Composition 5-37
5.7.2 ASIC Program Version Up 5-37

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CONTENTS -5
5.8 Upgrading Heater F/W 5-38
5.8.1 Heater F/W Composition 5-38
5.8.2 How to Upgrade Heater F/W 5-38
5.9 Setting During Engine Board (IPB1) Replacement 5-39
5.10 Special Power-On Procedure 5-44
5.11 Countermeasures for No Error Message 5-45
5.12 System Information Setting Operation After Head Replacement 5-46
5.13 Heater Errors 5-47
5.13.1 Heater error H01: System error 5-48
5.13.2 Heater error H02: Relay board error 5-48
5.13.3 Heater error H03: F heater temperature error. 5-48
5.13.4 Heater error H04: R heater temperature error 5-49
5.13.5 Heater error H05: P heater temperature error 5-49
5.13.6 Heater error H06: F heater time out error 5-49
5.13.7 Heater error H07: 7 R heater time out error 5-51
5.13.8 Heater error H08: P heater time out error 5-52
5.13.9 Heater error H09: Operation panel switch error 5-54
5.13.10 Heater error H10: Zero cross error 5-54
Section 6 Troubleshooting (Dryer 64) 6-1
6.1 Error Indication 6-1
6.2 Error Types and Counteractions 6-2
6.2.1 Power supply 6-2
6.2.2 Fan 6-3
6.2.3 Heater 6-7
6.2.4 Timer 6-13
6.3 Appendix 6-15
6.3.1 IP6600 Error Code - Replacement Association Table 6-15
6.3.2 Dryer unit 64 Failure Description - Replacement Association Table 6-18

SIIT CONFIDENTIAL
CONTENTS -6
Section 7 Parts Replacement (Disassembly/Reassembly) 7-1
7.1 Reading This Section 7-1
7.1.1 Disassembly/Reassembly Procedure 7-1
7.2 Names of Parts 7-2
7.2.1 Names of parts and layout 7-2
7.3 Maintenance Parts Disassembly and Reassembly 7-11
7.3.1 Covers and foot assembly 7-13
7.3.1.1 Ink cartridge cover (right) switch assembly
(Ink cassette cover (front right)) 7-13
7.3.1.2 Ink cartridge cover (left) switch assembly
(Ink cassette cover (front left)) 7-13
7.3.1.3 Interlock microswitch 7-14
7.3.1.4 Photo sensor assembly 7-15
7.3.1.5 Operation panel assembly, panel cable 7-15
7.3.1.6 Heater panel assembly 7-16
7.3.1.7 Waste ink bottle sensor 7-16
7.3.1.8 Supply pump end sensor 7-17
7.3.2 Y drive unit 7-18
7.3.2.1 Photo sensor assembly 7-18
7.3.2.2 Carriage motor assembly, Bearing (DE-46562) 7-18
7.3.2.3 Two-step pulley assembly, synchronizing belt 7-19
7.3.2.4 Steel belt (64) 7-20
7.3.2.5 Driven pulley assembly 7-21
7.3.2.6 Pressure bracket assembly 7-22
7.3.2.7 Pressure roller 7-23
7.3.2.8 T fence 7-24
7.3.2.9 Carriage cable 64 7-25
7.3.3 X drive unit 7-27
7.3.3.1 Media feed motor assembly and deceleration belt 7-27
7.3.3.2 Adsorption fan assembly 7-28
7.3.3.3 Paper sensor assembly (front) 7-28
7.3.3.4 Paper sensor assembly (rear) 7-29
7.3.3.5 Grit roller 7-30
7.3.4 Electrical unit 7-34
7.3.4.1 Cooling fan assembly 7-34
7.3.4.2 Power supply unit 7-34
7.3.4.3 Board (PCB-ASSY-IPB1, PCB-ASSY-WIM1,
PCB-ASSY-VDD2) 7-34
7.3.4.4 Board (PCB-ASSY-RLY) 7-35
7.3.5 Carriage assembly, head unit 7-36
7.3.5.1 Head cable 64 7-38
7.3.5.2 Edge sensor assembly 7-39
7.3.5.3 PCB-ASSY-ICB1 7-40
7.3.5.4 Head ASSY, Cooling Fan 7-41
7.3.5.5 Linear encoder assembly 7-46

SIIT CONFIDENTIAL
CONTENTS -7
7.3.6 Wiping unit 7-49
7.3.6.1 Wiping unit (64) 7-49
7.3.6.2 Cleaner (wiper 64) unit 7-50
7.3.6.3 Blade (Wiper rubber 64) 7-51
7.3.6.4 Motor (wiper) assembly 7-52
7.3.6.5 Switch (wiper) assembly 7-53
7.3.6.6 Belt (wiper) 7-53
7.3.7 Capping unit 7-56
7.3.7.1 Capping unit (64) 7-56
7.3.7.2 Motor (cap) assembly 7-58
7.3.7.3 Timing belt 7-58
7.3.7.4 Solenoid 7-59
7.3.7.5 Cap assembly 7-60
7.3.7.6 Tray (ink) assembly 7-61
7.3.7.7 Torque limiter 7-62
7.3.7.8 Pump assembly 7-63
7.3.7.9 Joint (CAP Sa) 7-64
7.3.8 Ink cartridge unit 7-65
7.3.8.1 Ink box (left/right) assembly, filter assembly (Sa),
and pump tube 7-65
7.3.8.2 PCB-ASSY-INK 2 7-68
7.3.9 Sub tank unit 7-69
7.3.9.1 Sub tank unit, full sensor ASSY, half full sensor ASSY. 7-69
7.3.10 Heater unit 7-71
7.3.10.1 Paper guide F (with heater) 7-71
7.3.10.2 Paper guide R (with heater) 7-71
7.3.10.3 Platen assembly 7-72
7.3.11 Winder Unit 7-73
7.3.11.1 Flange 7-73
7.3.12 Dryer 64 7-74
7.3.12.1 Circuit breaker 7-74
7.3.12.2 Relay 7-74
7.3.12.3 SSR 7-75
7.3.12.4 Power supply unit 7-75
7.3.12.5 Timer 7-76
7.3.12.6 Thermostat 7-77
7.3.12.7 THRM-CBL-ASSY 7-77
7.3.12.8 VOLSW-CBL-ASSY 7-78
7.3.12.9 FAN-ASSY 7-78
7.3.12.10 FAN (EL-BOX) 7-79
7.3.12.11 PCB-ASSY-DRY 7-79
7.3.12.12 Flange insulator 7-80
7.3.12.13 Terminal protecting insulator set 7-82

SIIT CONFIDENTIAL
CONTENTS -8
Section 8 Adjustment 8-1
8.1 Steel Belt Tension Adjustment 8-2
8.2 Head Cover Plate Adjustment 8-3
8.3 Synchronizing Belt (Y Drive Motor Belt) Tension Adjustment 8-4
8.4 Deceleration Belt (X Drive Motor Belt) Tension Adjustment 8-4
8.5 Wiping Unit Height Adjustment 8-5
8.6 Blade Height and Levelness Adjustment 8-6
8.7 Wiping Position Correction 8-6
8.8 Wiping Unit Belt Adjustment 8-9
8.9 Cap Position Correction 8-10
8.10 Cap Unit Height Adjustment 8-12
8.11 Shield HB Height Adjustment 8-14
8.12 Initial Ink Charge/Ink Extraction 8-15
8.13 Nozzle Check 8-17
8.13.1 Manual cleaning (the same function as the cleaning in the user mode) 8-17
8.13.2 Manual Cleaning 8-18
8.13.3 Fill Cap 8-18
8.13.4 Discharging ink 8-19
8.13.5 Cleaning with maintenance liquid cartridge 8-19
8.14 Head Drive Voltage Setting 8-20
8.15 Ink Head Adjustment Procedure 8-21
8.16 Head Position Correction (L and R) 8-31
8.17 Head Position Correction (Main) 8-34
8.18 Bi-directional Print Position (L) Correction 8-37
8.19 Bi-directional Print Position (R) Correction 8-40
8.20 Paper Feed Amount Correction 8-41
8.20.1 Adjustment using “FEED PATTERN” 8-42
8.21 Head Position Correction (Main scanning direction) 8-45
8.22 Side Margin Position Correction (SENSOR (SIDE) ADJ) 8-48
8.23 Top Margin Position Correction (SENSOR (TOP) ADJ) 8-50
8.24 Appendix 8-52

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CONTENTS -9
Section 9 Operations 9-1
9.1 System Operation Overview 9-1
9.2 Paper Transport System 9-2
9.3 Carriage Transport System 9-5
9.4 Ink System 9-7
9.5 Print Functions 9-11
9.6 Principle of Head Drive 9-15
9.7 Print Mode 9-16
9.8 IPB1 (Engine Control) Board 9-20
9.8.1 Basic configuration 9-20
9.8.2 Engine Unit Operation 9-21
9.9 Engine Control Firmware 9-27
9.9.1 Function blocks 9-27
9.9.2 Operation description 9-26
9.10 Power Supply Unit 9-28
9.10.1 Electrical specifications 9-29
9.10.2 Connector specifications 9-29
9.10.3 ON/OFF sequence 9-31
9.10.4 Others 9-31
9.11 Heater Unit 9-32
9.11.1 Block Diagram of Heater Unit 9-32
9.11.2 Heater System Electric Unit Operations 9-33
9.11.3 Heater Firmware 9-34
9.11.4 Heater wiring diagram 9-34
9.11.5 Wiring Diagram of Heater Unit 9-34
9.11.6 Heater Operations 9-35
9.12 Dryer 64 Operation Outline 9-38
9.13 Electric Configuration of Dryer 64 9-39
9.13.1 Electric Unit Operations 9-40
Appendix Appendix-1

SIIT CONFIDENTIAL
CONTENTS -10
Figure
Figure 1-1 Maintenance work flowchart 1-1
Figure 1-2 External views and names of parts (Front) 1-4
Figure 1-3 External views and names of parts (Rear) 1-5
Figure 1-4 Maintenance space 1-6
Figure 7-1 Cover Names and Layout 7-2
Figure 7-2 Cover names and layout (Dryer 64) 7-3
Figure 9-1 Outline of operation 9-1
Figure 9-2 Transport system mechanism (X axis) 9-2
Figure 9-3 Transport system mechanism (Y axis) 9-2
Figure 9-4 Ink system overview 9-7
Figure 9-5 Ink system concept 9-7
Figure 9-6 Head drive principle 9-15
Figure 9-7 Basic hardware configuration 9-20
Figure 9-8 SCSI/Engine F/W function block 9-27
Figure 9-9 Power ON/OFF state transition 9-31
Figure 9-10 Principal of dryer 64 operation 9-38
Figure 9-11 Block diagram of dryer 64 electric unit 9-39