Fault Tree - ion/CAT

Fault tree – ion/CAT Rev 12 – revised 7/19/12

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FAULT TREE - CAT UV and Solara ion

This is a trouble-shooting guide for FSEs. Click on the link of the issue to bring you to

potential problems with associated solutions that may help diagnose and fix the issue at

hand. This covers the Cat firmware Rev C build 391 and Solara Ion firmware Rev J build

426.

CUSTOMER SYMPTOMS: Error message ........................................................................................... 3

Multiple boards not found............................................................................................ 4 Ballast board not found ................................................................................................ 7 Carriage board not found ............................................................................................ 8 Gantry board not found ............................................................................................... 8

Table board not found .................................................................................................. 9 Multiple inks empty ...................................................................................................... 9

Black empty ................................................................................................................... 9

Cyan empty .................................................................................................................... 9 Magenta empty ............................................................................................................ 10 Yellow empty ............................................................................................................... 10

Fill Error ...................................................................................................................... 10 Cyan Fill Error ............................................................................................................ 11

Magenta Fill Error ...................................................................................................... 11 Yellow Fill Error ......................................................................................................... 11 Black Fill Error ........................................................................................................... 11

Ink drawer error ......................................................................................................... 11 Print gap error ............................................................................................................ 11

Data link error or Data shift in image ...................................................................... 12 Vacuum pressure error .............................................................................................. 12

Waste tray error .......................................................................................................... 13 Ink pump error ........................................................................................................... 13 Ink solenoid error ....................................................................................................... 13

Ink overflow error....................................................................................................... 13 Lamp error .................................................................................................................. 14

Lamp fan error ............................................................................................................ 14 Cover fan error ........................................................................................................... 14 Hold down vacuum error ........................................................................................... 14

Job size error ............................................................................................................... 15 RIP error...................................................................................................................... 15

USB error ..................................................................................................................... 15 Print head connect error ............................................................................................ 16

Canceled by user ......................................................................................................... 16 Carriage Jam error ..................................................................................................... 16 Internal error – cycle power ...................................................................................... 17

Application question ................................................................................... 17

Ink leak ........................................................................................................ 17

Ink is leaking near the ink supply box ...................................................................... 17


2

Ink is dripping out of the head(s) .............................................................................. 17

Lock up ........................................................................................................ 18

Lock up with USB error(s) ......................................................................................... 18 Lock up with no error................................................................................................. 18

Machine won’t turn on ............................................................................... 18

No lights at the front panel ......................................................................................... 18 Machine is stuck on the “Gerber” screen ................................................................. 19 Machine is stuck on the “Check the shelf…” screen ............................................... 19

Material jam ................................................................................................ 19

Material jams carriage when printing on the table ................................................. 19

Material jams carriage when printing on roll-to-roll .............................................. 20

Other ............................................................................................................ 20

Alignment, Calibration, or Data startup test fails ................................................... 20

Table fans turn off immediately after turning on .................................................... 20

One side of gantry not moving up/down ................................................................... 20 Z-axis noise .................................................................................................................. 21

Winder does not roll up material .............................................................................. 21 Carriage is striking end of 10’ rigid material over roll-to-roll end ........................ 21 Printer is stuck on job “warming” screen ................................................................ 21

Gantry Board Has No Power ..................................................................................... 21 Motor issue .................................................................................................................. 22

Output durability ........................................................................................ 22

Image easily scratches off media (poor adhesion) .................................................... 22

Poor print quality ........................................................................................ 22

Banding in the print on the table ............................................................................... 22

Banding is inconsistent on roll-to-roll ....................................................................... 23 Missing or angled nozzles ........................................................................................... 23

Every 3rd

nozzle missing ............................................................................................. 25 One color drops out or fades away over short period of time ................................ 26 Color is bad at the start but gradually gets better as it prints ................................ 27

See Ink is dripping out of the head(s) ....................................................................... 27 Printed output is not the correct size ........................................................................ 28

Incorrect data coming out of print heads ................................................................. 28 Left edge of job is not consistently in the same location .......................................... 28 Print does not always start in the same location in x-axis ....................................... 28

Small text quality is poor ............................................................................................ 29 Ink mist on the printed image .................................................................................... 29

Uncured output ........................................................................................... 29

Entire output smudges when touched ....................................................................... 29 First few inches of job not curing .............................................................................. 30 Last few inches of job not curing ............................................................................... 30

One side of print not curing well ............................................................................... 31

Additional Error Codes shown on UI ......................................................... 4 System Health Decision Tree ..................................................................... 31


3

ERROR MESSAGE The following table includes all of the error messages that appear on the UI and the

related error code that would show in the printer log.

ERROR NAME ERROR NUMBERS IN GROUP

Multiple Boards Not Found 20

Ballast Board Not Found 21

Carriage Board Not Found 22

Gantry Board Not Found 24

Table Board Not Found 25

Multiple Inks Empty 705

Black Empty 706

Cyan Empty 707

Magenta Empty 708

Yellow Empty 709

Fill Error 730

Cyan Fill Error 731

Magenta Fill Error 732

Yellow Fill Error 733

Black Fill Error 734

Ink Drawer Error 284, 285, 721

Print Gap Error 290-292, 294, 295

Data Link Error 370, 374-377, 384-388, 606

Vacuum Pressure Error 711, 718, 910

Waste Tray Error 715

Ink Pump Error 717

Ink Solenoid Error 712, 719

Ink Overflow Error 722

Lamp Error 900, 971

Lamp Fan Error 901

Cover Fan Error 902

Hold Down Vacuum Error 922

Job Size Error 607, 608

RIP Error 500-504, 530, 535-537, 600, 601, 605

USB Error 26-30, 40-44, 60-69, 120-138, 300, 301, 304, 305

Printhead Connect Error 360, 911, 912, 970

Canceled By User 283, 293, 700

Carriage Jam Error 411


4

Internal Error – Cycle Power 1-6, 9, 11, 12, 14, 23, 51, 52, 58, 59, 70, 72-74, 80, 81,

92, 94-99, 102, 118, 119, 139-145, 200, 250, 257, 258,

260, 261, 270, 271, 282, 286, 296-298, 350-354, 356,

359, 380, 381, 383, 400-408, 414, 421, 430-433, 522,

523, 602-604, 701,703, 704, 710, 713, 714, 716, 723-

729, 750-765, 800-808, 903, 913-920, 921, 925, 926,

940, 942, 960-962, 15000, 15001

Additional Error Codes shown on UI The following table describes the error codes that will appear on the UI with the related

error description.

Error Code Description Recommended Action

13

The FPGA on the Master Board fails to load

during power up.

See message log for more details. Most

likely this error indicates that the Master

Board needs to be replaced.

15

Configuration related errors Generic error that covers a lot of

configuration issues.

31

FPGA power-up bus test failed on the

Master Board

Cycle power. If problem persists, replace

Master Board.

50

Invalid Bootloader in the Atmel AVR chip. Cycle power. If problem persists, replace

Satellite Board whose firmware is being

updated.

53

Satellite Board Flash memory compare

failure. After a firmware update to a

Satellite Board, the firmware in the Master

Board Flash memory is compared with the

firmware just loaded into the AVR Flash

memory. This error occurs if the

comparison fails.

Cycle power. See message log for more

details. If problem persists, replace

Satellite Board whose firmware is being

updated.

54

Unable to switch Satellite Board into SAFE

MODE since it isn’t running Satellite Board

firmware.

Cycle power. If problem persists, see

message log for more details.

55

Unable to switch Satellite Board into SAFE

MODE.



56

Unable to start Bootloader in Satellite

Board.



57

Failed to reboot the Satellite Board after a

firmware update.



93 Persistent Storage CRC error on MAC

Address section.

Verify that MAC Address is valid (and

NOT the default value of 00-52-C2-2D-

3E-FF). If it is not correct, then enter the

correct address through the Service web

page or replace the Master Board.

100 Download manager issue – No modules

found in tarball

Verify that the correct file is being loaded?

101 Download manager issue - HTTP data end

not found


103 Download manager issue – Module

programming error


104 Download manager issue – Module

validation failed



5

105 Download manager issue – Header

validation failed


106 Download manager issue – Flash failed to

erase


108 Download manager issue – Invalid S

Record checksum


109 Download manager issue – Invalid S record Verify that the correct file is being loaded?

110 Download manager issue – Invalid Hex

record checksum


111 Download manager issue – Invalid Hex

record


112 Download manager issue – Invalid S/Hex

record found


113 Download manager issue – Premature end

of record data


114

Download manager issue – Error rebooting

satellite board

Check logs to see which satellite board did

not reboot?

115 Download manager issues – ROM

Validation Failed

Checking the modules CRC.

117 Down load manager – ROM module not

present

255

Serial Flash busy on Satellite Board (this is

not an error). All Satellite Boards except

the Ballast Board has Serial Flash memory.


message log for more details. Also, see

Satellite Board logs for more details.

256 Serial Flash transfer error on Satellite

Board. All Satellite Boards except the

Ballast Board has Serial Flash memory.




Error occurs when the SPI port for the

Serial Flash can not be set up. Hardware

issue on board.

280 Generic motor error. Cycle power. If problem persists, see


Gantry and Table Board logs for more

details.

Error is set when axis is busy or it may be

turned off, uninitialized or excessive

position errors.

281 Motion timeout. See recommended action for error 280.

Problem with one of the motors. There is

an expected time that the motor motion

should be completed within This error

occurs when the the time out is exceeded.

Example- Gantry is given 2 seconds to go

home (Error would occur if after 2 seconds

the gantry was not home.)

302 Satellite Board power-up initialization

failure.




306 Satellite Board FPGA CRC failure. Cycle power. If problem persists, see


Satellite Board logs for more details. Re-

load system firmware.

307 Satellite Board FPGA load failure. Cycle power. If problem persists, see




6

Replace Satellite Board failing to load

FPGA.

308 Satellite Board FPGA load timeout. Cycle power. If problem persists, see



309 Satellite Board firmware CRC failure. Cycle power. If problem persists, see



310 Timeout occurred trying to place Satellite

Board in SAFE MODE.




311 CRC failure in Front Panel Serial Flash

memory.



Front Panel Board logs for more details.

312 Timeout during Front Panel Serial Flash

CRC verify.




355

Print head heater error found on power up.

(failed to turn On print head heaters.)

Potentially the error will be presented to the

user.

Review Carriage board logs?

357

Print Head temperature fault found when

trying to get ready to print.

Potentially the error will be presented to the

user.

Review Carriage board logs

358

Print head nominal voltage fault when

trying to get ready to print.

Error presented when the user types in

incorrect voltage values for the print heads

Review Carriage board logs. Is this a user

input error. Looks like the user/installer

can provide the nominal voltage for the

print heads.

382

X axis did not advance to expected location This error causes the printing to be stopped

and the print manger task to be stopped.

We check 100 times if the x axis has not

moved and is still too far from the end

point. Don’t know who has this issue to

help isolate the problem. ?

409

Servo chip I/O timeout. A Y-Axis move

did not complete before the timeout.

If problem persists, Check the message log

and Gantry Board log. There may be a

problem with the servo driver on the

Gantry Board.

410

Servo chip reset failed. If problem persists, Check the message log

and Gantry Board log. There may be a

problem with the servo driver on the

Gantry Board.

412

Axis over current error.

Error set when there are motion errors on

the axis.

Cycle power. Check Gantry log for more

information. If problem persists, check

stepper motor drivers on Gantry board.

Check X and/or Z motor connections and

wiring.

413

Axis over travel limits error. (The limit

sensor has been tripped).

This error occurs if the X or Y axis moves

too far at the end of travel. Check the Log

messages and Gantry log. For Y axis,

check for a clean encoder strip


7

416

Gantry voltage is out of range

This problem may occur if the interlock is

tripped before or during a move. If the

problem persists, check the Message log

and Gantry log to find out the conditions

leading up to the error. Check the voltage

regulators on the Gantry board. Check the

interlock relay on the table board.

702 In Ink Maintenance mode. Ink maintenance is currently being

performed.

Multiple boards not found Description: The master board cannot find more than one satellite board.

Problem Solution

More than one board is not

connected

Investigate the log file to determine which boards

are not connected to the system. Check the USB

connections to those satellite boards. Add RTV

to ensure the connections do not come free.

USB cable has failed If the connections to and from the boards appear

to be good, the USB cable may be damaged.

Replace the appropriate cable and add RTV to the

connections.

Board has failed If the connections and cables appear to be good,

look for red LEDs on the boards in question. If

the missing boards are the UI, ballast, and

carriage, the USB hub on the gantry board may

have failed. Replace the gantry board. If one of

those boards is missing, the USB connector on

the gantry board may be bad. Swap USB

connections on the gantry board and see if the

same board fails or if the new board is now

missing. If it follows the connector, replace the

gantry board. If the table board is missing, it

could be a USB connector issue on the master

board. Use the same gantry board logic here.

Ballast board not found Description: The master board cannot find the ballast board.

Problem Solution

Gantry board hub or connector

damaged

Swap the ballast board connection with another

board’s connection at the gantry board USB hub

and power back on. If the ballast board is still

missing, continue through this fault tree table. If

the other board is now missing, replace the gantry

board.

Ballast board is not connected Check the USB connection between the ballast

and gantry boards. Add RTV to ensure the


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connections do not come free.

USB cable has failed If the connections to and from the board appear to

be good, the USB cable may be damaged.

Replace the cable and add RTV to the

connections.

Ballast board has failed Replace the ballast board.

Carriage board not found Description: The master board cannot find the carriage board.

Problem Solution

Gantry board hub or connector

damaged

Swap the carriage board connection with another

board’s connection at the gantry board USB hub

and power back on. If the carriage board is still

missing, continue through this fault tree table. If

the other board is now missing, replace the gantry

board.

Carriage board is not connected Check the USB connection between the carriage

and gantry boards. Add RTV to ensure the



be good, the USB cable may be damaged. Or the

cable is the old non-flexible version that has been

damaged. Replace the cable and add RTV to the

connections.

Carriage board has failed Replace the carriage board.

Gantry board not found Description: The master board cannot find the gantry board.

Problem Solution

Gantry board is not connected Check the USB connection between the gantry

and master boards. Add RTV to ensure the


Master board hub connector

damaged

Try plugging the gantry board USB cable into

another port of the master board hub.




connections.

Gantry board has failed Replace the gantry board.


9

Table board not found Description: The master board cannot find the table board.

Problem Solution

Table board is not connected Check the USB connection between the table and

master boards. Add RTV to ensure the


Master board hub connector

damaged

Try plugging the table board USB cable into

another port of the master board hub.

USB cable has failed

If the connections to and from the board appear to



connections.

Table board has failed Replace the table board.

Multiple inks empty Description: More than one color is reporting an empty pouch state.

Problem Solution

Ink pouch is empty Install a new ink pouch.

Printer falsely reporting an empty

pouch

Press Enter on the keypad to acknowledge the

message and Enter again to accept “No Change”

and allow the printer to continue with an

extended fill process.

Pouch was recently changed,

introducing air into the lines

If a pouch was recently changed, press Enter

twice as described above to continue with the

extended fill process.

Environment is too cold If the environment is too cold, the printer may

have problems pushing the ink. Press Enter twice

as described above to continue with the extended

fill process, and bring the environment within

specification.

Black empty Description: Printer is reporting an empty black pouch state.

See Multiple inks empty problems and solutions.

Cyan empty Description: Printer is reporting an empty cyan pouch state.



10

Magenta empty Description: Printer is reporting an empty magenta pouch state.


Yellow empty Description: Printer is reporting an empty yellow pouch state.


Fill Error Description: More than one color had trouble filling after the extended fill process.

Problem Solution

Ink pouch is empty Install a new ink pouch.

Environment is too cold If the environment is too cold, the printer may

have problems pushing the ink. Bring the

environment within specification and retry.

Ink pouch is not installed properly Open the ink drawers and ensure the pouch spout

is properly in the opening in the drawer and is

pushed all the way down.

Tubing kinked near ink supply pump Check for kinked/twisted Hubtron tubing on the

ink supply pump and the check valve. To fix,

disassemble at luer fittings and reassemble

without twisting tubing. Also, the supply tubing

should run straight through the drawer slides, not

at sharp bends to run down the back of the supply

box.

Check valve installed backwards Ensure that the check valve is installed in the

correct orientation.

Damaged solenoid If ink is coming out of the heads when the printer

is attempting to fill, the solenoid may be stuck

closed (perhaps from ink contamination).

Replace the solenoid and silicone tubing.

Ink supply pump is not working Ensure the pump is turning on properly by feeling

if it is running when asked. If it turns on, check

its functionality by running the ink pump flow

test (see P82904A).

Air leak in front of the ink pump (i.e.

at the needle o-ring or tubing

connection to ink pump or needle)

Check the tubing connection at the ink pump and

needle, and fix or replace parts as needed. If OK,

replace the needle so a new o-ring is in place.

Reservoir float is stuck or broken Check the float functionality by running the

reservoir float test. Replace reservoir assembly.

Also check for ink in clear silicone tubing and for

overflow fault. If so, replace overflow reservoir,

solenoid, and silicone tubing.

Cured ink in the supply line Normally only a problem with cyan 01GB ink. If

the machine was idle for a long period of time,


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there could be cured ink in the supply line. Open

the luer fitting between the ink supply and the

lower cable track and check for solid ink. If so,

replace the ink supply pump assembly, the 2

cable tracks, the proper reservoir assembly, and

the purge block assembly. You may also need to

replace the print heads.

Cyan Fill Error Description: Cyan had trouble filling after the extended fill process.

See Fill Error problems and solutions.

Magenta Fill Error Description: Magenta had trouble filling after the extended fill process.


Yellow Fill Error Description: Yellow had trouble filling after the extended fill process.


Black Fill Error Description: Black had trouble filling after the extended fill process.


Ink drawer error Description: There is a problem with the ink pouch drawer area.

Problem Solution

Ink drawer is open while gantry is

trying to move past it.

Close the ink drawers.

Ink drawer switch is damaged. Check the functionality of the ink drawer

switches and replace as necessary.

Print gap error Description: There is a problem with the print gap area.

Problem Solution

Trying to print on material that is

greater than 1” thick

Check the actual thickness of the material and

ensure it is less than 1” thick.

Gap solenoid is stuck Ensure the solenoid can move up and down freely

through the hole in the carriage plate. Adjust the

print gap solenoid assembly mounting if required.


12

Print gap sensor not working Check the functionality of the print gap sensor

using the web page and replace if necessary.

Flat flex cable not installed properly Check connection of flat flex cable between

carriage and gantry (bent pads, not installed

correctly, check for shorts/opens from one end to

the other).

Data link error or Data shift in image Description: There is a problem with the Print Data area.

Follow the System Health Decision Tree document on GerberNet.

Vacuum pressure error Description: There is a problem with the vacuum pressure area.

FOR PRESSURES THAT ARE TOO LOW (ERROR 729 IN LOG):

Problem Solution

Vacuum pump is not plugged in Check the connections for the vacuum pump.

Purge valve is open Ensure all the purge valves (setscrews) are

closed, including the overflow valve.

Silicone tubing is not plugged into

carriage board sensor

Ensure the tubing is properly connected on the

bottom port of the sensor on the carriage board.

Silicone tubing plugged into the

wrong vacuum pump port

Ensure the silicone tubing is plugged into the

vacuum port of the pump.

Reservoir(s) not full Ensure the reservoirs are full. If they will not fill,

see Multiple inks empty.

Vinyl cap on vacuum pump not

removed

Remove the vinyl cap that is on the unused port

of the ink vacuum pump.

Ink vacuum bleed orifice is missing The vacuum reservoir should contain a small

piece of tubing with a tiny bleed orifice inside. If

the orifice is missing or the tubing with it is

missing, it must be replaced.

Silicone tubing is damaged Check tubing for damage and replace if

necessary.

Vacuum pump is bad Replace vacuum pump.

FOR PRESSURES THAT ARE TOO HIGH (ERROR 728 IN LOG):

Problem Solution

Vacuum filter is clogged Replace the filter.

Bleed orifice is blocked Clean out the bleed orifice or replace if necessary.

Vacuum pump is bad Replace vacuum pump.


13

Waste tray error Description: There is a problem with the waste tray sensor area.

Problem Solution

Waste tray sensor and/or cable

damaged by ink contact

Clean excess ink near the waste tray sensor and

replace the waste tray sensor and cable assembly.

Ink pump error Description: There is a problem with the ink supply pump area.

Problem Solution

An ink supply pump is not working

properly or connected properly.

Check the functionality and connections of the

ink supply pumps by conducting the ink flow test

(see P82904A), and replace as necessary.

Ink solenoid error Description: There is a problem with the ink solenoid area.

Problem Solution

Solenoid valve is not working

correctly (cannot open due to ink

contamination)

Run solenoid test: do inspect nozzles, turn

off vacuum pressure, open solenoids, ink

should be dripping out of the heads within a

couple of minutes, if not then that color's

solenoid is bad

Replace ink solenoid valve and any silicone

tubing that had ink inside of it.

Run ink reservoir test: solenoid could be

damaged because a reservoir float was not

working correctly. Check functionality of the

float and replace the reservoir assembly if

necessary.

Ink overflow error Description: Ink has overflowed into the vacuum reservoir chamber.

Problem Solution

Ink has filled the vacuum reservoir

chamber.

Determine which color(s) has overflowed the

reservoir past the solenoid and drain the vacuum

reservoir by opening the overflow purge valve

screw. Remember to close the purge valve screw

when the ink stops dripping. If unit has plunger

style solenoid replace with pinch style type. Also

replace the silicone tubing, ink reservoir (of the

color that overflowed), and vacuum reservoir. If

the unit has pinch style solenoid have customer

clear per service note and if problem repeats with

that color, replace the ink reservoir (of the color

that overflowed), and vacuum reservoir.


14

Float in vacuum reservoir chamber is

not plugged in to carriage board.

Check the connections of the vacuum reservoir

chamber float at the carriage board.

Float in vacuum reservoir chamber is

not working properly or stuck.

If there is no ink in the vacuum chamber and the

connections to the vacuum chamber float are

good, replace the vacuum reservoir chamber

assembly.

Lamp error Description: There is a problem with the lamp or ballast area.

Problem Solution

Lamp thermistors are damaged or

disconnected.

Use the Lamp Statistics web page to determine

which lamp assembly has a problem. Check the

connections to the thermistors. Check that the

thermistors are properly connected to the lamps.

Replace the lamp assembly as necessary.

Lamp is not turning on. Ensure that both lamps are turning on properly.

Check all lamp connections and ballast

connections. If only one lamp turns on, swap

which lamp is connected to which ballast to

determine if the lamp is bad or the ballast is bad.

Replace the lamp assembly or ballast as

necessary.

Lamp fan error Description: Unable to turn a lamp fan on.

Problem Solution

Lamp fan(s) is not working properly. Check the functionality and connections of the

lamp fans. Replace as necessary.

Cover fan error Description: Unable to turn a cover fan on.

Problem Solution

Top cover fan(s) is not working

properly.


top cover fans. Replace as necessary.

Hold down vacuum error Description: One or more hold down vacuums failed.

Problem Solution

Table vacuum blower(s) not working

properly.


table vacuum blowers. Replace as necessary.

Roll-to-roll vacuum fan(s) not

working properly.


roll-to-roll vacuum fans. Replace as necessary.


15

Job size error Problem Solution

Job size is not within the valid range

for the printer

Check the design of the job at the RIP and ensure

it is within the valid range for the printer.

RIP error Problem Solution

Issue with the RIP file Check the job file from the RIP. Re-RIP and

resend the job.

Computer issue Reboot the RIP computer and retry.

USB error Description: There is a problem with the USB communication between boards.

Problem Solution

Bad USB cable connection Check all USB connections on all boards

Gantry board J48 connection is not

secure

Lock USB connector on gantry board with RTV

Satellite boards have old revision of

AVR chip

Upgrade satellite boards to AVR chip rev 3 (see

SNote 2008-Ion-012 USB errors and lockups.pdf

for info on identifying chip revs)

Gantry board not properly grounded Improve gantry board grounding by removing

paint on mounts

Electrical box not properly grounded Ensure there are star washers holding the

electrical box to the machine skirt, and that the

electrical box cover is on and has star washers

holding the cover on the electrical box.

Wires coming out of USB connector

to UI board

Gently tug on wires and ensure they stay in place;

if not, bend “ear” up to lock in place, or replace

cable.

Contamination on master board

DIMM socket

Touch DIMM, if printer locks up, replace master

board

Old USB cable in gantry cable track

damaged

Install the new high-flex USB cable between the

gantry and carriage boards.

5V out of spec at the gantry board Measure the 5V test point on the gantry board.

Place the ground probe of meter into any black

test point, and place other probe at test point 19.

If it is below 4.85V, measure 5V at the table

board (between a black ground test point and test

point 7). If it is above 5.15V, then the cable

between the table board and the gantry board is

bad. If it is less than 5.15V, then replace the

power supply NOTE: If you are slightly less than

5.15V at the supply, perhaps the calibration of

your meter is slightly off, which would not

necessarily justify changing the power supply.


16

Bad board (no heartbeat) Check the heartbeat LED status on all boards. If

one is not beating correctly, replace that board.

Master board failure Replace the master board.

Master board USB phy issue Check if all 4 USB LEDs on the gantry board and

both USB LEDs on the master board (that have

cables connected to them) are red. If so, one

satellite board is causing the master board USB

phy to lock up. Recheck all USB connections to

the boards, ensure everything in the fault tree

above this item has been checked, and potentially

replace each satellite board one at a time to

determine the cause (even if the AVR chip rev is

correct).

Print head connect error Description: There is a problem with the area surrounding the connection of the

print heads.

Problem Solution

Print head flat flex cable not

connected

Use the Print Head Statistics web page to

determine which head has a problem. Check the

connections of the print head flat flex cables at

the carriage board and at the print head interface

board. Ensure the interface board is properly

connected to the head.

Print head flat flex cable damaged Inspect the ends of the flat flex cable for damaged

or bent pin pads. Replace the print head interface

board and cable assembly as necessary.

Canceled by user Description: The user just canceled an operation. This is not an error.

Problem Solution

The printer is stuck on this screen Cycle power to clear the error. If this problem

persists, examine the log for more details.

Carriage Jam error Description: The carriage has stopped unexpectedly, as if it jammed into

something.

Problem Solution

Carriage jammed into material See Material Jam section


17

Internal error – cycle power Description: Unexpected error internally with printer logic.

Problem Solution

Internal error with the printer Press Enter to clear the error and retry what you

were doing. If the problem continues, try cycling

power or examine the log for more details.

APPLICATION QUESTION See Applications Notes on GerberNET and/or the Material Applications Web Site

INK LEAK

Ink is leaking near the ink supply box Problem Solution

Ink pouch is not installed properly. Open the ink drawers and ensure the pouch spout

is properly in the opening in the drawer and is

pushed all the way down.

Ink pouch valve is broken If ink comes out of the ink pouch when it is

removed from the printer, replace the pouch.

O-ring on pouch “needle” is missing

or worn out.

Replace pouch needle assembly (do not try to

replace just the O-ring).

Ink pouch spacers not

assembled/missing

Check for the ink pouch spacers on the needle

inside the ink box. The spacers could be plastic

washers or retaining rings. Install spacers if

missing.

More than one ink pouch spacer

installed

Ensure only one ink pouch spacer is installed on

each needle inside the ink box.

Ink is dripping out of the head(s) Problem Solution

Ink vacuum is not working correctly See Vacuum pressure error.

Bad connection or other leak Run leak test: run clean heads completely, do

inspect nozzles, use web page to close solenoids,

use web to set vacuum, wait 30 seconds, open all

solenoids, wait 30 seconds, close all solenoids,

wait 30 minutes, ensure there is no ink dripping

out of the heads, if so there is a leak at a

connection somewhere.



contamination)






18

solenoid is bad

If unit has plunger style solenoid replace with

pinch style type. Also replace the silicone

tubing, ink reservoir (of the color that

overflowed), and vacuum reservoir. If the

unit has pinch style solenoid have customer

clear per service note and if problem repeats

with that color, replace the ink reservoir (of

the color that overflowed), and vacuum

reservoir.

Clogged ink line, constantly trying

to purge/clean etc.

If ink has partially cured (from sitting idle for too

long) in the ink line, or if another type of clog has

occurred, the build-up of pressure in the line from

the purge/clean procedures between the check

valve at the ink supply and the clog can slowly

push ink through the clogged area causing ink to

drip from the imbalance of pressure in the

reservoir.

Too much daily maintenance

solution used on swab/anticon when

swabbing heads

Use only recommended amount of DMS per

swab/anticon.

LOCK UP

Lock up with USB error(s) Description: Printer does not respond to key presses or any action, but a USB error

is on the screen.

See USB error problems and solutions.

Lock up with no error Description: Printer does not respond to key presses or any action.

See USB error problems and solutions.

MACHINE WON’T TURN ON

No lights at the front panel Description: LEDs on the front panel (Flat, Roll, Clean Heads, etc.) are not on at

power up.

Problem Solution

Power cord not connected Ensure the power cord is properly connected to

the wall outlet.

Front panel board not connected Check the cabling between the gantry board and


19

the UI board.

Machine is stuck on the “Gerber” screen Description: Front panel will not move past “Gerber” screen at powerup.

Problem Solution

Printer could be loading front panel

firmware

Check the log to see if the front panel firmware is

loading to the board.

USB cables on master board not

plugged in

Ensure both USB cables are plugged in to the left

and right ports on the master board.

Master board damaged If no USB LEDs are on when USB cables are

plugged in correctly at both ends, replace board.

Communication error from new

firmware download

If you were just trying to upgrade the firmware

and the machine gets stuck, try to reboot the

printer again.

Machine is stuck on the “Check the shelf…” screen Description: Printer displays “Check the shelf…” screen at powerup or regardless

of any key press.

Problem Solution

Interlock is open Ensure the maintenance shelf is up, the access

door is in, and the e-stops are both up. Press

Enter.

Flat flex cables not plugged in

correctly

Ensure flat flex cables are connected properly

between the master board and gantry board.

Cables should be fully inserted, square with the

board with the conductive side facing the

contacts.

Flat flex cable ends damaged Check all the ends of the flat flex cables between

the master board and gantry board for even

spacing. Replace if needed.

Pin loose on e-stop connector Check for a loose pin on the 2-pin connector for

the e-stops (on the left side of the printer that you

unplug to remove the top cover). Replace

appropriate cable if necessary.

Table board damaged Replace board.

Gantry board damaged Replace board.

Master board damaged Replace board.

MATERIAL JAM

Material jams carriage when printing on the table Problem Solution


20

Material edges are raised/curled Ensure the entire piece of material is held down

flat. If edges are raised, tape them down.

Table map is not within spec Check the table map and ensure it is within spec.

If not, rerun the Z Axis Home procedure.

Shield on bottom of carriage is

hanging down too low

Ensure the shield on the bottom of the carriage is

mounted properly.

Material jams carriage when printing on roll-to-roll Problem Solution

Edge hold downs not used Properly locate the edge hold downs on both

sides of the material.

Vacuum is not in correct state For most materials, ensure the roll vacuum is set

to “on” when printing the job. However, heavier

materials like banner may work better with the

roll vacuum off.




mounted properly.

OTHER

Alignment, Calibration, or Data startup test fails See Data link error or Data Shift in image.

Table fans turn off immediately after turning on Problem Solution

Print gap solenoid error not allowing

system to function.

Check the print gap solenoid functionality and see

Print gap error.

One side of gantry not moving up/down Problem Solution

Z-axis motors plugged in incorrectly

or swapped

Ensure each z-axis motor is plugged into the

correct connector on the gantry board.

Loose set screw on motor coupling Check that the setscrews are tight on the coupling

between the z-axis motor and drive shaft. If any

of the 4 setscrews are loose, ensure the setscrew

is above the flat surface of the shaft before

tightening.


21

Z-axis noise Problem Solution

Lack of lubrication Grease Z-axis gears and lubricate shafts

Bent gantry housing Attempt to bend it back in place. If extreme,

replace gantry assembly.

Winder does not roll up material Problem Solution

Winder is not set to automatically

wind material

Briefly press the winder switch in either direction

to activate automatic winding mode.

Carriage is striking end of 10’ rigid material over roll-to-roll end Problem Solution

Edge of rigid material is raised up Tape the end of the material down to the roll-to-

roll platen. For some thinner material, can try

turning the vacuum fans on using the pull-down

selection on the System Settings web page. For

the item “Roll to Roll Vacuum”, select “On

During Flat Jobs”.

Roll-to-roll platen mounting screws

loose causing platen to be higher

than the rigid table surface

Ensure screws that mount the roll-to-roll are

tightened.




mounted properly.

Roll-to-roll platen mounting is at

incorrect height causing platen to be

higher than rigid table surface

Determine how much higher the platen is (using

table and R2R mapping on the webpage)

compared to the table surface and add shims

under the table to raise it to the platen height.

Printer is stuck on job “warming” screen Problem Solution

Printhead voltage problem Check the Printhead Statistics web page for print

head voltage faults. If so, replace carriage board.

USB error See USB error.

Gantry Board Has No Power Description: The gantry board has no LEDs on, indicating no power to the board.

Problem Solution

Waste tray sensor and cable Wires that were damaged by ink may have


22

damaged by ink insulation removed, where the wires short against

each other, maybe even when the waste tray or

access door is installed/moved. Check for this,

clean up any ink, and replace the waste tray

sensor and cable.

Gantry board damaged Replace gantry board.

Note: In general, any board showing no power could be caused by a sensor or actuator

attached to that board being shorted to ground.

Motor issue Problem Solution

Smoke from the gantry board and

axis motor(s) not working

Short in the motor cable can damage motor(s)

and/or gantry board driver chip(s). Replace as

needed.

OUTPUT DURABILITY

Image easily scratches off media (poor adhesion) Problem Solution

Material was not properly cleaned

before printing

Clean the material surface with IP Surface

Cleaner or 99% IPA and wipe off with a lint-free

cloth. Vinyl materials should be cleaned with

distilled water.

Humidity in environment is too high Lower the relative humidity of the room and/or

try high lamp spec mode.

Material is not a Gerber qualified

material

Check the Material Applications Web Site and

use a Gerber qualified material.

POOR PRINT QUALITY

Banding in the print on the table Problem Solution

Missing or angled nozzles in one or

more colors

Run nozzle test and determine which colors have

missing nozzles. Run the angled nozzle test and

evaluate for angle nozzles. Tests printed on

glossy chipboard can be sent back to Gerber to

scan and evaluate for angled nozzles. If there is a

problem, see Missing or angled nozzles.

Gantry step not properly calibrated Increase or decrease gantry step adjust based on

print tests and procedures.

Step Blending mode is off Try to set Step Blending to “on”.

X-axis steel belt not tensioned

properly

If belt seems loose, replace belt and properly

tension the new belt on both sides.


23

X-axis rubber/drive belt not

tensioned properly

Ensure rubber/drive belts are tensioned properly.

Motor pinion is loose on x-axis

motor shaft

Check if motor pinion on x-axis motors are

properly secured to the motor shaft. If not,

replace motor assembly and re-tension belts.

Heads are not aligned mechanically Check the mechanical alignment of the heads,

including the gantry square and carriage angle.

Banding is inconsistent on roll-to-roll Problem Solution

Roll-to-roll has not been upgraded Upgrade roll-to-roll assembly.

Specific media is showing an issue Try turning the vacuum fans off, or paying out

the material, to reduce media drag.

Media feed adjust needs adjustment

in the RIP software

Change the media feed adjust value in the RIP

software based on the media.

Roll-to-roll support legs are not

square

Square/plumb the table legs under the roll-to-roll

platen and ensure the supply roll can rotate freely.

Roller, Idler RT is worn Replace the roller, idler RT.

Angled nozzles Problem Solution

Customer not performing routine

daily maintenance

Ensure the Clean Heads process is being

performed whenever the Clean Heads LED is

blinking and you are ready to print. Ensure the

End of Day Clean is performed at the end of

every day of printing.

Customer not performing the “as

needed” maintenance procedure

Perform the “as needed” maintenance procedure

as needed (perhaps weekly or about every 40

hours of printing).

Cured ink buildup on head from not

using the sliding UV shield correctly

Always place the sliding UV shield next to the

material when the printer asks you to, as

explained in the User’s Manual.

Using incorrect swabs/anticon wipes Always use the proper Fisher Scientific swabs

and Anticon wipes from Gerber.

Using too much daily maintenance

solution on the swab/anticon.

Only use the specified amount of DMS when

cleaning. Should clear up after printing

Using too much force when

swabbing.

Apply very light pressure when swabbing heads.

Only hold the swab with 2 fingers.

Material being printed on has static

electricity on surface causing angled

nozzles or overspray




distilled water.

Head voltage values in memory do

not match what is on the heads

Check the head voltage values in memory and

compare to the voltage values on the stickers that


24

are mounted on the actual print heads.

Excessive UV to print heads from

placing spaces in between material

blanks

No space is allowed between material blanks. If

you must space the material (or are using

irregular shaped material), you must use masking

material of the same height as the material you

are printing on. See appropriate Application

Note.


user adding to the print gap

You are not permitted to place an additional

thickness of material over the media to be printed

in order to “trick” the printer to think that the

material is thicker than it actually is in order to

attempt to prevent carriage strikes. This causes

excessive UV light to reflect to the print heads.

The print gap must be properly maintained.

Head flatness and/or carriage shield

flatness is out of spec

Run the procedures to measure and correct the

head flatness and carriage shield flatness to

eliminate the excessive reflected UV light to the

print heads.

Front maintenance shelf is too low

relative to the table

Adjust the height of the maintenance shelf to

ensure it is aligned with the table surface. This

will prevent excessive UV light to reflect back to

the print heads.

Heads are scratched and damaged Replace the print head.

Missing nozzles Problem Solution

Air in the lines or printhead Perform purge on the proper color. You can tell

if a purge is required if there are large

groups/banks of nozzles missing. Purging is done

on an as needed basis. If working on an Ion and

purging does not help, you may try a “power

purge” (purge while leaving purge valve screws

closed). Do not power purge on a CAT UV.

Customer not performing routine

daily maintenance

Ensure the Clean Heads process is being

performed whenever the Clean Heads LED is

blinking and you are ready to print. Ensure the

End of Day Clean is performed at the end of

every day of printing.

Cured ink buildup on head from not

using the sliding UV shield correctly

Always place the sliding UV shield next to the

material when the printer asks you to, as

explained in the User’s Manual.

Material being printed on is dirty

and has contaminated the heads




distilled water.


25


placing spaces in between material

blanks

No space is allowed between material blanks. If

you must space the material (or are using

irregular shaped material), you must use masking

material of the same height as the material you

are printing on. See appropriate Application

Note.


user adding to the print gap

You are not permitted to place an additional

thickness of material over the media to be printed

in order to “trick” the printer to think that the

material is thicker than it actually is in order to

attempt to prevent carriage strikes. This causes

excessive UV light to reflect to the print heads.

The print gap must be properly maintained.

Head flatness and/or carriage shield

flatness is out of spec

Run the procedures to measure and correct the

head flatness and carriage shield flatness to

eliminate the excessive reflected UV light to the

print heads.

Front maintenance shelf is too low

relative to the table

Adjust the height of the maintenance shelf to

ensure it is aligned with the table surface. This

will prevent excessive UV light to reflect back to

the print heads.

Heads are scratched and damaged Replace the print head.

Every 3rd nozzle missing Description: When running nozzle test, check if every 3

rd nozzle is missing as shown

in example images below.

Nozzle Out Test


26

Angled Nozzle Test

Same problems and solutions apply to something that looks like the following image,

where the lines are dotted rather than solid:

Angled Nozzle Test

Problem Solution

Bad connection between the

printhead and carriage board

Check the connection of the printhead flat flex

cable at the carriage board and the connection of

the interface board to the printhead.

Damaged printhead interface board

and cable assembly

Replace the printhead interface board and cable

assembly.

One color drops out or fades away over short period of time Problem Solution

Air in the lines that is trapped Perform purge to the proper color. You can tell if

a purge is required if there are large groups/banks

of nozzles missing. If the customer is purging

more than once per week, then there is likely

another issue. If working on an Ion and purging


27

does not help, you may try a “power purge”

(purge while leaving purge valve screws closed).

Do not power purge on a CAT UV.

If a purge does not seem to fix the

issue, check the log for recent fills of

that color…

If the last fill failed, check to ensure the

pouch is not empty. Then check the ink

supply pump functionality by running the ink

pump flow test (see P82904A).

If the last fill was OK, then you know the

pump is OK so move on in the fault tree to

look for other issues.

Purge block is clogged not allowing

air in lines to escape

Replace purge block assembly and purge all

heads.



contamination)





solenoid is bad

If unit has plunger style solenoid replace with

pinch style type. Also replace the silicone

tubing, ink reservoir (of the color that

overflowed), and vacuum reservoir. If the

unit has pinch style solenoid have customer

clear per service note and if problem repeats

with that color, replace the ink reservoir (of

the color that overflowed), and vacuum

reservoir.

Vacuum pump is not working

properly.

See Vacuum pressure error.

Air is being ingested between the

reservoir and the head

This could occur if a head was ever replaced.

Perhaps the connections from the reservoir to the

head were not sealed properly. Attempt to reseal

the connections at the head using a heat gun. If

no successful then replace the tubing to the head

by replacing the reservoir assembly.

Tubing between reservoir and head

is kinked or contains obstruction.

Replace the tubing to the head by replacing the

reservoir assembly. Assure tubing from reservoir

is angled downwards to the print head.

Color is bad at the start but gradually gets better as it prints Problem Solution


solution was used when cleaning

Only use the specified amount of DMS when

cleaning.

Partially clogged reservoir vent

causes nozzle plate to wet during See Ink is dripping out of the head(s)


28

filling and slowly dry up while

printing

Printed output is not the correct size Problem Solution

If the table jobs are not the correct

size in the x-axis direction…

Adjust the gantry step size until there is no

banding, then redesign the job to increase the size

based on how the output prints.

If the roll-to-roll jobs are not the

correct size in the x-axis direction…

Change the media feed adjust setting in the RIP

software based on the media.

If the y-axis direction size is

incorrect… Check that the latest y-axis encoder strip is

installed.

Check Motion/Encoder health is good if not

see System Health Decision Tree

Incorrect data coming out of print heads Problem Solution

Corrupt carriage board FPGA state Cycle power to reset FPGA and retry printing.

Bad interface board and cable

assembly (or connection)

Check the connection of the interface board and

cable assembly at both ends. Replace the

assembly if necessary.

Problem Print Data Path See System Health Decision Tree

Carriage board failed Replace carriage board.

Left edge of job is not consistently in the same location Problem Solution

Y-axis motor pinion is slipping on

the motor shaft

Replace the y-axis motor assembly with a pinned

motor.

Y-axis steel belt slipping excessively Adjust the tension of the y-axis steel belt, or

replace it to properly tension it.

Y-axis motor drive belt is not

tensioned

Adjust the tension of the y-axis motor drive

(rubber) belt.

Print does not always start in the same location in x-axis Problem Solution

X-axis steel belt not tensioned

properly

If belt seems loose, replace belt and properly

tension the new belt on both sides.

X-axis rubber/drive belt not

tensioned properly

Ensure rubber/drive belts are tensioned properly.

Motor pinion is loose on x-axis

motor shaft

Check if motor pinion on x-axis motors are

properly secured to the motor shaft. If not,

replace motor assembly with pinned motor and

retention belts.


29

Small text quality is poor Problem Solution

Printer has Large Field mode turned

on

Turn off the Large Field mode.

Printer has Step Blending mode

turned on

Turn off the Step Blending mode.

Printer has poor alignment Run the mechanical and electrical alignment jobs

and correctly align the printer.

Ink mist on the printed image Problem Solution

Static issue Address all static concerns – raise the humidity,

ensure the printer operator is not on carpet, clean

the media with 99% IPA or IP Surface Cleaner

(do not clean the media with anything dry).

Vinyl should be cleaned with distilled water.

Angled nozzles See Missing or angled nozzles.

No sponge in waste tray (CAT only) Ensure the sponge is properly placed in the waste

tray.

Print head voltages are incorrectly

set in the printer

Verify the voltages between the web page and the

actual marking on each head to ensure they are

correct.

Print gap setting is out of calibration Recalibrate the z-axis and print gap, then rerun

the table map.

UNCURED OUTPUT

Entire output smudges when touched Problem Solution

Voltage from the wall is out of spec Measure voltage at the wall and increase to

230VAC±10%. Use the site requirements

document to ensure everything is correct.

Environment out of spec Bring the relative humidity and the room

temperature into spec.

Environment is marginally within

spec

Try running with High lamp spec mode.


material



Material not properly

cleaned/handled

Wipe the material surface with 99% IPA or IP

Surface Cleaner using a lint-free cloth. Vinyl


30

materials should be cleaned with distilled water.

If the material has a removable liner, most

manufacturers recommend waiting to print on the

material for 24 hours after removing the liner.

Lamp thermistors in wrong

orientation

Ensure the lamp thermistors are on the underside

of the lamps, closest to the table.

Lamp has fallen out of the lamp clip

Ensure the lamps are properly held in place by the

lamp clips.

Lamp temperature issue

Check functionality of lamp fans and lamp

thermistors. Replace fan or lamp assembly as

necessary.

Print is over saturated with ink Verify the correct profile

If the curing issue is on heavy black areas, try to

substitute single color black for the 4-color black

to lay less ink down.

Lamp is aged or damaged Look for black discoloration on the bulb surface.

Replace if necessary.

First few inches of job not curing Note: The first and last few swipes of a job may appear slightly different than the middle

of the job due to the lamps being turned off/on.

Problem Solution


solution used during head clean

Use only the specified amount of DMS when

cleaning.


spec

Try running in High lamp spec mode.


material



Last few inches of job not curing Note: The first and last few swipes of a job may appear slightly different than the middle

of the job due to the lamps being turned off/on.

Problem Solution


spec

Try running in High lamp spec mode.


material



Lamp turns off from over

temperature condition

Check for lamp temperature going over 140 deg F

error, check UV Lamp statistics, verify cooling

fans, lamp, and ballast operation

Front Lamp did not restrike after

warm up and starting the print

Check printer information web page for proper

lamp operation


31

One side of print not curing well Description: The left or right side of the print is not cured.

Problem Solution

Something is blocking the UV light

from getting to the print on one side

Ensure there is nothing blocking how the UV

light shines down on the print, like jammed

material or tape stuck to the bulb or reflector.

Material has residue on part of it Wipe the material surface with 99% IPA or IP

Surface Cleaner using a lint-free cloth. Vinyl

materials should be cleaned with distilled water.

Lamp has fallen out of the lamp clip Ensure the lamps are properly held in place by the

lamp clips.

Lamp fans and/or thermistors are not

working properly

Check the lamp temperatures while printing and

ensure they are between 80 and 140˚C and are all

relatively close to each other. Check fan

operation. Replace fan or bulb assembly as

necessary.

Table map is out of spec Run the table map and ensure it is within spec.

Lamp is aged or damaged Look for black discoloration on the bulb surface.

Replace if necessary.

System Health Decision Tree The next 4 pages are a fault tree for repair of the most common faults that the customer

reports as a small data shift in the image or a reported datalink error on Ion or CAT

printers.

The “Phone Support” page is used for first customer contact and possible customer

resolution and ends with setting up parts and focus for the FSE visit.

The “Motion/Encoder Health” page resolves issues with carriage motion or distorted

encoder signal form the sensor. The log entry from a print pass at level 5 will show the

low level errors that drive the health rating like the Number of Trigger Periods above

Max value, Maximum Trigger Period, Number of Trigger Periods faster than the

waveform (ignored), Trigger Count difference from expected, Number of Encoder Errors,

and Encoder Tic Count difference from expected marked with an “*”.

The “Print Data Health” page resolves the electrical side of the of the data transfer from

the master board to the carriage board. The log entry from a print pass at level 5 will

show the low level errors that drive the health rating parity, framing, packet count and tile

count errors marked with an “*”.

The “USB Health” page resolves USB electrical network issues.


32

Customer reports a shift in the image, poor System

Health, data link error, failed encoder test

(1- alignment, 2- calibration, or 3- data)

See note below about health ratings

PHONE SUPPORT

Yes

No

The Customer can check for

carriage interference with ink

build up on side plates, or

with sliding UV shield

Yes

Is the Lowest

Overall System

Health good?

Boot printer and

run until Lowest

System Health is

fair to poor

Is Carriage Motion

smooth across the full

gantry travel?

No

Send Motion/

Encoder parts to

site and go to

FSE-1

Send Print Data

parts and go to

FSE-2

Send Motion/

Encoder parts to

site and instruct

FSE to start with

FSE-1

Verify System Health

end

Is Motion/Encoder

Health good?No

Yes

Which Health is

fair or poor? Follow

all that apply

Motion/Encoder USB

Print Data or

Link Timing

Go to FSE-3

Note:

1- Lowest System Health ratings are reset at power up only

2- Material Jams, Canceling a job, pushing the Estop can result in false

indication of fair to poor System health

Encoder/Motion Health Parts

42pl System

P82838A 1 EA BEARING, PILLOW BLOCK, SET OF 2

P82881C-PKG 1 EA (S) PKG'D MOTOR, Y-AXIS DRIVE W/PIN

P82876C 1 EA ASSEMBLY, PULLEY & SHAFT, Y-AXIS IDLER

P82875C 1 EA ASSEMBLY, PULLEY & SHAFT, Y AXIS DRIVE

P82508B-PKG 1 EA 42PL, (S) PKG'D ENCODER,LNR Y-AXIS,360LP

P83268C 1 EA 42PL, CABLE, SENSOR, LINEAR ENCODER

14pl System

P82838A 1 EA BEARING, PILLOW BLOCK, SET OF 2

P82881C-PKG 1 EA (S) PKG'D MOTOR, Y-AXIS DRIVE W/PINP82876C 1 EA ASSEMBLY, PULLEY & SHAFT, Y-AXIS IDLERP82875C 1 EA ASSEMBLY, PULLEY & SHAFT, Y AXIS DRIVE

P83098C 1 EA 14PL, CABLE, MAGNETIC ENCODER

Print Data Health Parts

42pl System

P81840D-OMB 1 EA 42PL, (R) PCA-CARRIAGE CONTROLLER

P81891D-OMB 1 EA (R) PCA-MASTER CONTROLLER

P82587D-OMB 1 EA (R) PCA-GANTRY CONTROLLER

P82239A 1 EA (S) PKG'D CABLE CARRIAGE DATA

P82240A 2 EA (S) PKG'D CABLE CARRIAGE POWER

P81160C 2 EA CABLE, GANTRY FLEX CHAIN, LVDS

P81974C 2 EA TABLE, PKG’D BLOWER ASSY

14pl System

P83126D-OMB 1 EA 14PL, (R) PCA-CARRIAGE CONTROLLER

P81891D-OMB 1 EA (R) PCA-MASTER CONTROLLER

P82587D-OMB 1 EA (R) PCA-GANTRY CONTROLLER

P82239A 1 EA (S) PKG'D CABLE CARRIAGE DATA

P82240A 2 EA (S) PKG'D CABLE CARRIAGE POWER

P81160C 2 EA CABLE, GANTRY FLEX CHAIN, LVDS

P81974C 2 EA TABLE, PKG’D BLOWER ASSY

SYSTEM HEALTH DECISION

TREE REV 2, 7/10/2012

(For ion rev J or CAT rev C)

To verify System Health 1- Go to Printer Information Web Page

2- Boot the printer and observe the System Health and UI for error messages

3- Print a typical job and observe the System Health


33

Ensure encoder strip is

clean and sensor is

aligned properly

Ensure encoder strip

spring is creating

tension on the far end

of the strip. Adjust

spring and clips if

necessary.

Verify y-axis motor is

pinned and replace if

necessary

FSE-1MOTION/ENCODER HEALTH

Ensure encoder clamp

is installed and read

head gap is correct

Ion or CAT?Ion CAT

Clean rails and apply

grease to y-axis linear

bearings

Replace Encoder Strip

and Optical Sensor

Check y-axis pulley

bearings and replace if

necessary

Check y-axis linear rail

bearings and replace if

necessary

Check for cable track

interference, carriage

interference with ink

build up on side plates,

or carriage interference

with sliding UV shield,

and adjust if necessary.

Is Carriage Motion

smooth across the full

gantry travel?

Replace Encoder Read

head

Replace Magnetic

Encoder Strip

Ion or CAT?Ion CAT

No Yes

End

Verify Motion/Encoder

Health

Is Motion/

Encoder Health

good?


Health

EndYes

No

Is Motion/

Encoder Health

good?


Health

End

No

Yes





34

Is Print Data

Health good?

Is Print Data

Health good?

No

No

end

Is Print Data

Health good?No

Yes

Yes

Yes

Replace carriage, master,

gantry board one at a time

PRINT DATA HEALTH FSE-2

Check and reseat flat flex

cable connections on all

boards. While doing this,

look for bent traces on

connector ends.

Replace any table blower

that doesn’t sound normal

(noisier or slower than the

other)

Is Print Data

health good?NoYes

Replace all 5 flat flex

cables

Verify Print Data Health








35

Is USB Health

Good?

Is USB Health

Good?

No

No

end

Is USB Health

Good?No

Yes

Yes

Yes

Verify the 5 volt supply is above 4.85V at the

gantry board and above 5.15V at the Table

brd. Repair as nesscessary.

USB HEALTH FSE-3

Check the heartbeat LED status and AVR

Rev Level on all boards. Replace boards if

needed.

Check for new high-flex USB cable between

the gantry and carriage boards. Replace if

needed

Is USB Health

Good?NoYes

Check, reseat, and RTV the USB cable

connections on all boards. Including the

checking for loose pins in the flat connector

between the Gantry and the UI

Verify USB Health

Verify USB Health

Verify USB Health

Verify USB Health




Documents

Fault Tree - ion/CAT