Fault tree – ion/CAT Rev 12 – revised 7/19/12
1
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
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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.
Cycle power. If problem persists, see
message log for more details.
56
Unable to start Bootloader in Satellite
Board.
Cycle power. If problem persists, see
message log for more details.
57
Failed to reboot the Satellite Board after a
firmware update.
Cycle power. If problem persists, see
message log for more details.
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
Verify that the correct file is being loaded?
103 Download manager issue – Module
programming error
Verify that the correct file is being loaded?
104 Download manager issue – Module
validation failed
Verify that the correct file is being loaded?
Fault tree – ion/CAT Rev 12 – revised 7/19/12
5
105 Download manager issue – Header
validation failed
Verify that the correct file is being loaded?
106 Download manager issue – Flash failed to
erase
Verify that the correct file is being loaded?
108 Download manager issue – Invalid S
Record checksum
Verify that the correct file is being loaded?
109 Download manager issue – Invalid S record Verify that the correct file is being loaded?
110 Download manager issue – Invalid Hex
record checksum
Verify that the correct file is being loaded?
111 Download manager issue – Invalid Hex
record
Verify that the correct file is being loaded?
112 Download manager issue – Invalid S/Hex
record found
Verify that the correct file is being loaded?
113 Download manager issue – Premature end
of record data
Verify that the correct file is being loaded?
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.
Cycle power. If problem persists, see
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.
Cycle power. If problem persists, see
message log for more details. Also, see
Satellite Board logs for more details.
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
message log for more details. Also, 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.
Cycle power. If problem persists, see
message log for more details. Also, see
Satellite Board logs for more details.
306 Satellite Board FPGA CRC failure. Cycle power. If problem persists, see
message log for more details. Also, see
Satellite Board logs for more details. Re-
load system firmware.
307 Satellite Board FPGA load failure. Cycle power. If problem persists, see
message log for more details. Also, see
Satellite Board logs for more details.
Fault tree – ion/CAT Rev 12 – revised 7/19/12
6
Replace Satellite Board failing to load
FPGA.
308 Satellite Board FPGA load timeout. Cycle power. If problem persists, see
message log for more details. Also, see
Satellite Board logs for more details.
309 Satellite Board firmware CRC failure. Cycle power. If problem persists, see
message log for more details. Also, see
Satellite Board logs for more details.
310 Timeout occurred trying to place Satellite
Board in SAFE MODE.
Cycle power. If problem persists, see
message log for more details. Also, see
Satellite Board logs for more details.
311 CRC failure in Front Panel Serial Flash
memory.
Cycle power. If problem persists, see
message log for more details. Also, see
Front Panel Board logs for more details.
312 Timeout during Front Panel Serial Flash
CRC verify.
Cycle power. If problem persists, see
message log for more details. Also, see
Satellite Board logs for more details.
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
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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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
Fault tree – ion/CAT Rev 12 – revised 7/19/12
8
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
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. 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
connections do not come free.
Master board hub connector
damaged
Try plugging the gantry 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
be good, the USB cable may be damaged.
Replace the cable and add RTV to the
connections.
Gantry board has failed Replace the gantry board.
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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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
connections do not come free.
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
be good, the USB cable may be damaged.
Replace the cable and add RTV to the
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.
See Multiple inks empty problems and solutions.
Fault tree – ion/CAT Rev 12 – revised 7/19/12
10
Magenta empty Description: Printer is reporting an empty magenta pouch state.
See Multiple inks empty problems and solutions.
Yellow empty Description: Printer is reporting an empty yellow pouch state.
See Multiple inks empty problems and solutions.
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,
Fault tree – ion/CAT Rev 12 – revised 7/19/12
11
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.
See Fill Error problems and solutions.
Yellow Fill Error Description: Yellow had trouble filling after the extended fill process.
See Fill Error problems and solutions.
Black Fill Error Description: Black had trouble filling after the extended fill process.
See Fill Error problems and solutions.
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.
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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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.
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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.
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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.
Check the functionality and connections of the
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.
Check the functionality and connections of the
table vacuum blowers. Replace as necessary.
Roll-to-roll vacuum fan(s) not
working properly.
Check the functionality and connections of the
roll-to-roll vacuum fans. Replace as necessary.
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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.
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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.
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
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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.
Shield on bottom of carriage is
hanging down too low
Ensure the shield on the bottom of the carriage is
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.
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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.
Shield on bottom of carriage is
hanging down too low
Ensure the shield on the bottom of the carriage is
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
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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.
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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
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.
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
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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.
Excessive UV to print heads from
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
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.
Fault tree – ion/CAT Rev 12 – revised 7/19/12
25
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.
Excessive UV to print heads from
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
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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.
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
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
Too much daily maintenance
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)
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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.
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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 is not a Gerber qualified
material
Check the Material Applications Web Site and
use a Gerber qualified material.
Material not properly
cleaned/handled
Wipe the material surface with 99% IPA or IP
Surface Cleaner using a lint-free cloth. Vinyl
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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
Too much daily maintenance
solution used during head clean
Use only the specified amount of DMS when
cleaning.
Environment is marginally within
spec
Try running in High lamp spec mode.
Material is not a Gerber qualified
material
Check the Material Applications Web Site and
use a Gerber qualified 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
Environment is marginally within
spec
Try running in High lamp spec mode.
Material is not a Gerber qualified
material
Check the Material Applications Web Site and
use a Gerber qualified 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
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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.
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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?
Verify Motion/Encoder
Health
EndYes
No
Is Motion/
Encoder Health
good?
Verify Motion/Encoder
Health
End
No
Yes
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
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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
Verify Print Data Health
Verify Print Data Health
Verify Print Data Health
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
Fault tree – ion/CAT Rev 12 – revised 7/19/12
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
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