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

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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

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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

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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

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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

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CONTENTS -11
Table
Table 1-1 List of required tools 1-2
Table 5-1 Booting Action List 5-43
Table 7-1 Maintenance part names (Cover) 7-4
Table 7-2 Maintenance parts names (Foot assembly) 7-4
Table 7-3 Maintenance parts names (Y drive unit) 7-5
Table 7-4 Maintenance parts names (X drive unit) 7-6
Table 7-5 Maintenance parts names (Power unit) 7-6
Table 7-6 Maintenance parts names (Carriage head unit) 7-7
Table 7-7 Maintenance parts names (Wiping unit) 7-7
Table 7-8 Maintenance parts names (Capping unit) 7-8
Table 7-9 Maintenance parts names (Ink cartridge unit) 7-8
Table 7-10 Maintenance parts names (Sub tank unit) 7-9
Table 7-11 Maintenance parts names (Winder unit) 7-9
Table 7-12 Maintenance parts names (cables) 7-9
Table 7-13 Maintenance parts names (Jigs) 7-10
Table 7-14 Maintenance parts (Dryer 64) 7-10

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CONTENTS -12
（Blank page）

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1-1
Section 1 Maintenance Procedure Overview
This section describes the primary maintenance procedure, necessary tools and the names
of parts of the printer.
1.1 Maintenance Procedure Overview
Maintenance is divided into periodic inspection and maintenance based on a maintenance
contract and non-periodic maintenance which is performed when a trouble occurs.
A flowchart of each type of maintenance is shown in Figure 1-1.
Figure 1-1 Maintenance work flowchart
Maintenance that is
performed when a
problem occurs
Start
Periodic inspection/When a
problem occurs
Periodic inspection
and maintenance
Check the state of the plotter (problem,
complaint, etc.).
Check or clean parts. => Section 2
Replace parts if necessary (=> Section 6),
or perform adjustment (=> Section 7).
Print a drawing to verify that there is no
problem.
End
Confirm the details of the problem and the
situation in which it occurred.
Perform troubleshooting.
- If the SCSI controller seems to be defective
=> Section 5
- General problem or defective print quality
=> Section 4
Replace defective parts. => Section 6
Replace parts or perform adjustment if
necessary. => Section 7
Verify that the problem has been eliminated.
End

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1-2
1.2 Required Tools
Table 1-1 lists the tools and measuring equipment required for maintenance.
Table 1-1 List of required tools (1/2)
Name Quanitity Remarks
Phillips screwdriver (2 bits) 1 Commercially available product
Phillips screwdriver (1 bit) 1 Encoder removal, commercially available product
Phillips torque driver (2 bits) 1 Head unit installation (5 kg), commercially available
product
Stabilized screwdriver (2 bits) 1 Commercially available product
Normal screwdriver 1 For removing E rings, commercially available
product
Normal precision screwdriver 1 For removing E rings, commercially available
product
Hexagonal bar spanner 1 Commercially available product
Spanner or long-nose pliers 1 For removing E rings, commercially available
product
Nippers 1 Commercially available product
Tester 1
For power supply voltage measurement,
commercially available product
Metal scale (JIS 1 class precision) 1 For head unit adjustment, 300 mm or more,
commercially available product
Tube cutter 1 Commercially available product
Cutter knife 1 Commercially available product
Cable binder 1 Commercially available product
Magnifier with scale (M830-S or equivalent) 1 Peak statt microscope x 100: No. 2008-100 (Scale:
standard)
Thermometer and hygrometer 1 For unit installation environment check,
commercially available product
Synchronous belt, deceleration belt grease 1 Tow cosing Asia EM-60L or equivalent (Silicon
grease can be substituted.)
IC card for rewriting engine F/W ROM 1 Fujitsu: MB98A81183-15 (U00045781700)
Fujisoku: JF4096A3-R06A (U00055389300)
Gloves or finger sack 1 set For ink stain protection
Commercially available product
Cleaning paper As
required For ink stain clraning, kim wipe or equivalent
Wipe stick As
required For cleaning front down surface of the carriage

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Section 1 Maintenance Procedure Overview
1-3
Table 1-1 List of required tools (2/2)
Name Quanitity Remarks
Cleaning Liquid As
required Ethanol
200 g (1.96 N) push/pull spring scale 1 - SUS belt tension adjustment (push)
10 kg (98 N) push/pull spring scale 1 - X motor belt tension adjustment (pull)
-Y motor belt tension adjustment (pull)
1 kg (9.8 N) push/pull spring scale 1 - Pressure roller grip power measurement (pull)
Clearance gauge 1 0.2～0.5mm
Platen squareness/height adjustment jig 1 - Platen squareness adjustment
-Platen height (level) adjustment
-Wiping unit height adjustment
Carriage (head base) height adjustment jig 1 - Carriage height adjustment
- Carriage parallelism adjustment
Head position adjustment jig 1 set Head incliration and position adjustment
Head positioning pin (short) 1 -
Head positioning pin (long) 1 -
Head positioning reference plate 1 -
Head positioning reference jig 1 1 -
Head positioning reference jig 2 1 -
- screw driver (short) 1 -
+ screw driver (long) 1 -
Offset latchet screwdriver 1 set Y rail cover mounting screw removal
Cap cleaning liquid 1 set Daily maintenance kit
Wiper cleaning liquid 1 set Daily maintenance kit
Cleaning swab 1 set Daily maintenance kit
Syringes 1 set Daily maintenance kit
Maintenance liquid cartridge 6 -
Dammy cartridge 6 -
Cleaning liquid cartridge 6 -

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1-4
1.3 External Views and Names of Parts
The externals and names of parts of the printer are shown in Figures 1-2 and 1-3.
①Operation panel
The lamps and LCD, which indicate the printer status, and keys for setting
functions are located on the operation panel.
②Heater control panel The keys for setting heater temperature are located on the heater control
panel.
③Ink holder Holds the ink cartridge.
④Flange Sets paper roll.
⑤Caster Unlocks the caster to move the printer, and lock it to secure the printer.
⑥Paper pressure alternation lever Alternates paper pressure depending on the paper thickness.
⑦Pressure roller up/down lever Presses down the paper after inserting the paper into the paper supplying
part and releases the pressing down of the paper.
⑧Paper-out release lever (ME lever)
Releases paper-out detection sensor.
Figure 1-2 External views and names of parts (Front)
③
<Front of the printer>
Ink cartridge
Roll paper
Lock Unlock

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Section 1 Maintenance Procedure Overview
1-5
<Rear of the printer>
Figure 1-3 External views and names of parts (Rear)
⑨Power receptacle
⑩Printer switch Printer power supply ⑰Power receptacle ⑱Heater switch Heater power
⑪Rear cover ⑲100 V/200 V alternation switch supply
⑫SCSI connector ⑳Cap cover
⑬ID switch SCSI controller Wiper cover
⑭Terminator switch Print stop/restart, cancel keys
⑮Paper outlet FAN guard slide lever
⑯Waste ink bottle Head up/down lever
22
21
23
24
Winding roll
SCSI controller Network controller

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1-6
1.4 Maintenance Space
The space required for maintaining the plotter is shown in Figure 1-4.
Height direction: 1700
(Unit: mm)
Figure 1-4 Maintenance space
(Front)
400400
10001000

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2-1
Section 2 Inspection and Maintenance
We recommend that maintenance and inspection should be performed to keep the printer
performance in the best condition.
The maintenance mode is used to carry out maintenance and inspection.
Parts should be adjusted and checked as required during inspection and maintenance.
The following inspection and maintenance procedures must be followed:
・Maintenance mode menu operations and functions : Section 3
・Troubleshooting: Sections 4, 5 and 6
・Replacement parts information and disassembly/reassembly procedures: Section 7
・Adjustment: Section 8
Details of inspection and maintenance are described in the subsequent pages.

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2-2
■Daily inspection and maintenance
The wiper sponge needs to be dampened periodically. Keep it damp by replenishing a
dropping pipet full of wiper cleaning fluid.
1Capping Unit Cleaning
Enter to the SERVICE menu and select “CAP CLEANING” on the operation panel.
The head carriage will move to the wiper side and you can access easily to the capping unit.
Open the rear cover and cap cover. Wipe up the edge and periphery of the upper surface of
all (six) caps with the cotton swab.
Close the cap cover and rear cover. The head carriage will return to the capping unit
position (home position) automatically.
#CAP CLEANING
>
- Do not leave the printer for long time in the condition that the head carriage is
not on the capping unit.
NOTE
Carriage cover
Rear cover
Clean he edge and
periphery of the upper
surface of the cap.