HP Scitex FB500 / FB700 Service Repair Manual

HP Scitex FB500 / FB700 Service Manual *CQ114-90048* Document part number: CQ114-90035, Rev. B

Part No. CQ114-90035 Rev B HP Scitex FB500 / FB700 Service Manual Page 1 of 510 Table of Contents Printer orientation ................................................................................................12 Required tools ......................................................................................................13 Parts List for Field Replaceable Modules .................................................. 14 Exploded Views ...................................................................................... 31 Exploded views: Off-head supply assemblies .......................................................31 OHS part numbers .......................................................................................................................... 31 Ink pumps, Exploded view ............................................................................................................... 32 Vacuum pump assembly exploded view............................................................................................. 33 Vacuum reservoir, Exploded view ..................................................................................................... 34 Ink homogenizer, Exploded view ...................................................................................................... 35 Exploded views: Carriage assemblies ...................................................................36 Trolley assembly (upper and lower) exploded view ............................................................................. 36 Carriage assembly, exploded views .................................................................................................. 37 Carriage assembly brackets, exploded view....................................................................................... 37 Carriage pen plate, exploded view ................................................................................................... 38 Carriage reservoirs, exploded views ................................................................................................. 39 Printhead interface plate’s alignment pin, exploded view ..................................................................... 39 Carriage back plate, exploded view ................................................................................................. 40 Carriage side attachments, exploded views........................................................................................ 41 Exploded views: Carriage-drive assemblies ..........................................................48 Exploded views: Service station assemblies ..........................................................49 Exploded views: Track assemblies ........................................................................52 Track attachment at carriage ............................................................................................................ 52 Exploded views: Media-drive assemblies ..............................................................54 Media-drive assemblies exploded views ............................................................................................ 54 Media-drive assemblies part numbers ................................................................................................ 57 Exploded views: Media-drive actuator assemblies ................................................58 Media-drive actuator assemblies exploded views ................................................................................ 58 Theory of operation and component identification................................... 65 Off-Head Supply Assemblies ................................................................................65 About the OHS (off-head supply)....................................................................................................... 65 About the vacuum assembly ............................................................................................................. 65 Vacuum assembly diagram .............................................................................................................. 66 Vacuum assembly air flow diagram................................................................................................... 67 About the vacuum pump .................................................................................................................. 68 About the vacuum regulator ............................................................................................................. 68 About the vacuum air-inlet filter ......................................................................................................... 68 About the vacuum accumulator ......................................................................................................... 68 About the vacuum restrictor .............................................................................................................. 69 About the vacuum sensor ................................................................................................................. 69 About the vacuum assembly power supply ......................................................................................... 69 About the pressure pump ................................................................................................................. 70 About the pressure sensor ................................................................................................................ 70 About the ink pumps........................................................................................................................ 71 About the ink-pump check valve ........................................................................................................ 72 About the permanent ink filters ......................................................................................................... 72 About the ink .................................................................................................................................. 73 About the tubes............................................................................................................................... 73 About the ink boxes ........................................................................................................................ 73 About the profilers .......................................................................................................................... 74 About the white ink option ............................................................................................................... 74 About the ink homogenizer (shaker) .................................................................................................. 75 About the ink-box filters ................................................................................................................... 75 About the OHS controller ................................................................................................................. 76 Carriage ...............................................................................................................76 Wiring diagram for FB500 Carriage Assembly .................................................................................. 77 Wiring diagram for FB700 Carriage Assembly .................................................................................. 78 About the carriage head height ........................................................................................................ 79 About the lamps.............................................................................................................................. 79 About the lamp bulbs ...................................................................................................................... 80 About the camera ........................................................................................................................... 80 About the air manifold ..................................................................................................................... 81 About the carriage ink filters............................................................................................................. 81 About the printhead reservoirs .......................................................................................................... 82 About the thermistors ....................................................................................................................... 83

Part No. CQ114-90035 Rev B HP Scitex FB500 / FB700 Service Manual Page 2 of 510 About the vacuum tubes ................................................................................................................... 84 About the vacuum tubes, split ........................................................................................................... 84 About the printheads ....................................................................................................................... 85 About the printhead interface plate ................................................................................................... 86 About printhead serial numbers ........................................................................................................ 87 About printhead y-axis and x-axis positioning ..................................................................................... 87 About printhead saber angle ............................................................................................................ 87 About carriage (gross) saber angle ................................................................................................... 87 About the carriage headboard ......................................................................................................... 87 About the carriage headboard lights ................................................................................................. 88 About the encoder reader ................................................................................................................ 89 About the carriage home sensor ....................................................................................................... 89 About the carriage trolley assembly................................................................................................... 90 About the upper carriage trolley assembly ......................................................................................... 90 About the lower carriage trolley assembly .......................................................................................... 90 Service station ......................................................................................................91 About the service station .................................................................................................................. 91 About ink purges ............................................................................................................................ 91 About the Shop-Vac ........................................................................................................................ 91 About the float Sensor ..................................................................................................................... 92 About the service station wipers ........................................................................................................ 93 About the wiper-carriage home sensor ............................................................................................... 93 About the gap sensor ...................................................................................................................... 94 About the service station access sensor .............................................................................................. 94 About the service station actuator (up-down motor) .............................................................................. 94 About the service station encoder...................................................................................................... 94 About the service station encoder reader ........................................................................................... 95 About the waste-ink jug.................................................................................................................... 96 Carriage-drive ......................................................................................................97 About the carriage-drive assembly .................................................................................................... 97 About the carriage-drive smooth pulley .............................................................................................. 97 About the carriage-drive shaft ........................................................................................................... 97 About the carriage-drive timing belt ................................................................................................... 97 About the carriage-drive motor ......................................................................................................... 98 About the Carriage Idler .................................................................................................................. 98 About the carriage-drive belt ............................................................................................................ 98 About the carriage-drive belt length and tension ................................................................................. 99 About the rail strips ......................................................................................................................... 99 About the carriage encoder strip..................................................................................................... 100 Track assemblies ................................................................................................101 About the track assembly ............................................................................................................... 101 About the ink tubes ....................................................................................................................... 101 About the LVDS cable .................................................................................................................... 102 About the headboard power cables ................................................................................................ 102 About the H-block clamp ................................................................................................................ 102 Media drive........................................................................................................104 About the media-drive motor .......................................................................................................... 104 About the media-drive motor coupling ............................................................................................. 104 About the media-drive motor encoder .............................................................................................. 105 About the high-resolution encoder ring............................................................................................. 105 About the high-resolution belt encoder reader ................................................................................... 105 About the media-drive belt ............................................................................................................. 108 About the media-drive roller ........................................................................................................... 108 About the idler roller ..................................................................................................................... 109 About the adjustment bearing block assembly .................................................................................. 109 About the vacuum trays ................................................................................................................. 110 About the airflow plate .................................................................................................................. 111 About the ionizer .......................................................................................................................... 111 About the N-up pins ...................................................................................................................... 111 About the actuator motors .............................................................................................................. 112 About the media alignment bar ...................................................................................................... 113 About the input roller ..................................................................................................................... 113 About the output roller ................................................................................................................... 114 About the media thickness sensor .................................................................................................... 114 About the media detection sensor ................................................................................................... 114 Roll-to-roll ............................................................................................ 115 About the roll-to-roll assembly ...........................................................................115 Lift and press foam rollers .............................................................................................................. 115 About the supply assemblies ........................................................................................................... 115

Part No. CQ114-90035 Rev B HP Scitex FB500 / FB700 Service Manual Page 3 of 510 Mid-spool support for heavy media rolls .......................................................................................... 116 About the takeup assemblies .......................................................................................................... 117 About the limit switches ................................................................................................................. 118 Electronics ..........................................................................................................119 Wiring diagram for the FB500 printer ............................................................................................. 119 Wiring diagram for FB500 main electronics ..................................................................................... 120 Wiring diagram for the FB700 printer ............................................................................................. 121 Wiring diagram for FB700 main electronics ..................................................................................... 122 About the main electronics box ....................................................................................................... 123 Electronics box components identified ............................................................................................. 123 About the motor control board ........................................................................................................ 124 About the 38v/24v power supply ................................................................................................... 125 About the AC power distribution board ........................................................................................... 125 About the AC filter ........................................................................................................................ 125 About the AC relay ....................................................................................................................... 126 About the ATX power supply .......................................................................................................... 126 About the hard disk ....................................................................................................................... 126 About the motherboard.................................................................................................................. 126 About the UV power supply............................................................................................................ 126 About the I/O board ..................................................................................................................... 128 About the main power cable .......................................................................................................... 129 Uninterrupted power supply ........................................................................................................... 130 Cable Pinouts .....................................................................................................131 Troubleshooting printer components ..................................................... 142 Troubleshooting carriage-drive assemblies .........................................................142 Carriage motion failures ................................................................................................................ 142 Troubleshooting carriage motion failures .......................................................................................... 142 Troubleshooting the carriage-drive smooth pulley .............................................................................. 144 Troubleshooting the carriage-drive shaft ........................................................................................... 144 Troubleshooting the carriage-drive timing belt ................................................................................... 144 Troubleshooting the carriage-drive motor ......................................................................................... 144 Troubleshooting the carriage-drive belt ............................................................................................ 145 Troubleshooting the rail strips ......................................................................................................... 145 Troubleshooting the carriage encoder strip ....................................................................................... 145 Troubleshooting Carriage Assemblies .................................................................146 Troubleshooting carriage head height ............................................................................................. 146 Troubleshooting the lamps .............................................................................................................. 146 Troubleshooting the camera ........................................................................................................... 146 Troubleshooting the air manifold ..................................................................................................... 146 Troubleshooting the carriage ink filters ............................................................................................. 147 Troubleshooting printhead reservoirs ............................................................................................... 147 Troubleshooting thermistors ............................................................................................................ 147 Troubleshooting the vacuum tube .................................................................................................... 147 Troubleshooting split vacuum tubes.................................................................................................. 147 Troubleshooting printheads ............................................................................................................ 147 Troubleshooting the printhead interface plate ................................................................................... 148 Troubleshooting the carriage headboard ......................................................................................... 148 Troubleshooting the carriage encoder reader ................................................................................... 148 Troubleshooting the home sensor .................................................................................................... 149 Troubleshooting the upper trolley .................................................................................................... 149 Troubleshooting the lower trolley..................................................................................................... 149 Troubleshooting the OHS assemblies ..................................................................150 Troubleshooting the vacuum assembly ............................................................................................. 150 Troubleshooting the vacuum pump .................................................................................................. 150 Troubleshooting the vacuum regulator.............................................................................................. 150 Troubleshooting the vacuum accumulator ......................................................................................... 150 Troubleshooting the vacuum restrictor .............................................................................................. 151 Troubleshooting the vacuum sensor ................................................................................................. 151 Troubleshooting vacuum power supply ............................................................................................ 151 Troubleshooting the pressure pump ................................................................................................. 151 Troubleshooting the ink pumps ........................................................................................................ 151 Troubleshooting the ink-line check valve ........................................................................................... 151 Troubleshooting profilers ................................................................................................................ 152 Troubleshooting the ink shaker ........................................................................................................ 152 Troubleshooting ink-box filters ......................................................................................................... 152 Troubleshooting the OHS controller ................................................................................................. 152 Troubleshooting maintenance system .................................................................153 Troubleshooting the service station .................................................................................................. 153 Troubleshooting the printhead wipers .............................................................................................. 153

Part No. CQ114-90035 Rev B HP Scitex FB500 / FB700 Service Manual Page 4 of 510 Troubleshooting the service station encoder and encoder reader......................................................... 153 Troubleshooting the waste ink jug ................................................................................................... 154 Troubleshooting the track assemblies ................................................................ 155 Troubleshooting the track assembly ................................................................................................. 155 Troubleshooting the LVDS cable and LVDS error ............................................................................... 155 Detecting a damaged LVDS chip..................................................................................................... 156 Troubleshooting error: Failed to Program FPGA ................................................................................ 157 Troubleshooting the media-drive assemblies.......................................................159 Troubleshooting the media-drive motor coupling ............................................................................... 159 Troubleshooting the media-drive motor encoder ................................................................................ 159 Troubleshooting the high-resolution media-drive encoder .................................................................... 159 Troubleshooting the media-drive belt ............................................................................................... 160 Troubleshooting the ionizer ............................................................................................................ 160 Troubleshooting the media alignment bar......................................................................................... 160 Troubleshooting the rail actuator motor ............................................................................................ 160 Troubleshooting the media thickness sensor ...................................................................................... 160 Troubleshooting the media detection sensor...................................................................................... 160 Troubleshooting the supply spool .................................................................................................... 161 Troubleshooting the electronic assemblies ...........................................................162 Troubleshooting the motor control board .......................................................................................... 162 Troubleshooting the I/O board ....................................................................................................... 162 Troubleshooting the 38/24v power supply....................................................................................... 162 Printer’s Service Menus ......................................................................... 163 TOOLS > USER CLEANING AND MAINTENANCE ....................................................163 Menu: Maintenance reminders ....................................................................................................... 163 Menu: Replace UV lamp bulb or bulbs............................................................................................. 163 Menu: Clean rail encoder strip ....................................................................................................... 163 Menu: Clean ionizer needles .......................................................................................................... 163 Menu: Clean and lube rail strips ..................................................................................................... 163 Menu: Clean print head orifice plates .............................................................................................. 163 Menu: Clean/lube service station rails ............................................................................................. 163 Menu: Clean service station wiper .................................................................................................. 163 Menu: Clean carriage wheels......................................................................................................... 164 Menu: Vacuum bottom of carriage .................................................................................................. 164 Menu: Clean carriage home sensor................................................................................................. 164 Menu: Replace UV lamp filters ........................................................................................................ 164 Menu: Clean electronics box filters .................................................................................................. 164 Menu: Replace service station wiper................................................................................................ 164 Menu: Drain waste from service station............................................................................................ 164 Menu: Clean media thickness sensor roller ....................................................................................... 164 TOOLS > USER DIAGNOSTICS ..............................................................................165 Menu: Carriage motion ................................................................................................................. 165 Menu: Rail motion ......................................................................................................................... 165 Menu: Calibration......................................................................................................................... 165 Menu: Verify H2H Y Alignment ....................................................................................................... 165 Menu: Print quality ........................................................................................................................ 165 Menu: Service station .................................................................................................................... 165 Vacuum pressure .......................................................................................................................... 165 Menu: Hard drive ......................................................................................................................... 165 Menu: LVDS ................................................................................................................................. 165 Menu: Print diagnostic plot ............................................................................................................. 165 Menu: Print jet statistics .................................................................................................................. 166 Menu: Warnings and actions list .................................................................................................... 166 Menu: Error history ....................................................................................................................... 166 Menu: Log error history.................................................................................................................. 166 Menu: Log system info ................................................................................................................... 166 TOOLS > SERVICE PRINTER > DEVICE TESTS...........................................................167 Menu: Device test wizard............................................................................................................... 167 Menu: Vacuum fan test .................................................................................................................. 167 Menu: Media thickness sensor test .................................................................................................. 167 Menu: Rail-height motor test ........................................................................................................... 168 Menu: Roller, alignment bar, sensor and switch test .......................................................................... 168 Menu: Carriage home sensor test .................................................................................................... 168 Menu: Profiler test ......................................................................................................................... 168 Menu: Service station tests ............................................................................................................. 169 Menu: Cabinet fans test ................................................................................................................. 169 Menu: Carriage cooling fan test ..................................................................................................... 169 Menu: Ionizer relay test ................................................................................................................. 170 Menu: UV lamp test ....................................................................................................................... 170

Part No. CQ114-90035 Rev B HP Scitex FB500 / FB700 Service Manual Page 5 of 510 Menu: Media motion velocity test .................................................................................................... 170 Menu: Test media drive control system............................................................................................. 171 TOOLS > SERVICE PRINTER > DEVICE TESTS > IMAGE SENSOR TESTS ......................172 Menu: Visually examine LEDs ......................................................................................................... 172 Menu: Whitepoint ......................................................................................................................... 172 Menu: Take picture of white paper .................................................................................................. 172 Menu: Take raw picture of dots ...................................................................................................... 173 Menu: Take enhanced picture of dots .............................................................................................. 173 TOOLS > SERVICE PRINTER > DEVICE TESTS...........................................................174 Menu: Open loop actuator test ....................................................................................................... 174 Menu: Open loop service station test ............................................................................................... 174 Menu: Pod test.............................................................................................................................. 174 Menu: Hard drive file system check ................................................................................................. 174 TOOLS > SERVICE PRINTER > PRINT TESTS ............................................................175 Menu: Print prime bars .................................................................................................................. 175 Menu: Print test ............................................................................................................................. 175 Menu: Belt & rail parallel test ......................................................................................................... 175 Menu: Media feed accuracy test, one.............................................................................................. 175 Menu: Media feed accuracy test, all ............................................................................................... 176 Menu: Horizontal dot accuracy....................................................................................................... 176 Menu: Vertical dot accuracy........................................................................................................... 176 Menu: Print test page..................................................................................................................... 176 Menu: Print faux 662 .................................................................................................................... 176 Menu: Comb banding ramps.......................................................................................................... 176 TOOLS > SERVICE PRINTER > INK SYSTEM TESTS...................................................176 Menu: Air valves........................................................................................................................... 176 Menu: Prime ink pumps ................................................................................................................. 176 Menu: Ink pumps .......................................................................................................................... 177 Menu: Ink / air thermistors ............................................................................................................. 177 Menu: Pressure pump .................................................................................................................... 177 Menu: Vacuum pump .................................................................................................................... 177 Menu: Turn ON / OFF white ink shaker .......................................................................................... 178 Menu: Initial ink fill........................................................................................................................ 178 Menu: Prep for shipping ................................................................................................................ 178 Menu: Disable on-head system ....................................................................................................... 178 TOOLS > SERVICE PRINTER > SERVICE CALIBRATIONS ...........................................179 Menu: Calibration wizard .............................................................................................................. 179 TOOLS > SERVICE PRINTER > SERVICE CALIBRATIONS > INDIVIDUAL CALIBRATIONS180 Menu: LCD touchscreen calibration ................................................................................................. 180 Menu: Head height calibration ....................................................................................................... 180 Menu: Media thickness sensor calibration ........................................................................................ 180 Menu: Service station calibration .................................................................................................... 181 Menu: Input roller home calibration ................................................................................................. 181 Menu: Output roller home calibration .............................................................................................. 182 Menu: Alignment bar home calibration ............................................................................................ 182 Menu: UV lamps shutter calibration ................................................................................................. 182 Menu: Image sensor height & position ............................................................................................. 183 Menu: Printhead Y calibration ........................................................................................................ 183 Menu: Media feed calibration ........................................................................................................ 184 Menu: Manual bidi calibration ....................................................................................................... 184 Menu: Auto head X calibration ....................................................................................................... 185 Menu: Pin & alignment bar position ................................................................................................ 185 Menu: Media sensor position calibration ......................................................................................... 185 Menu: Media alignment bar alignment ............................................................................................ 185 TOOLS > SERVICE PRINTER > SERVICE CALIBRATIONS ...........................................186 Menu: Invalidate calibration ........................................................................................................... 186 TOOLS > SERVICE PRINTER > RESET HOME POSITIONS..........................................187 Menu: Reset carriage home position................................................................................................ 187 Menu: Reset rail home position ....................................................................................................... 187 Menu: Home service station ........................................................................................................... 187 Menu: Home UV shutters................................................................................................................ 187 Menu: Home input roller ................................................................................................................ 188 Menu: Home output roller .............................................................................................................. 188 Menu: Home alignment bar............................................................................................................ 188 TOOLS > SERVICE PRINTER ..................................................................................189 Menu: Measure media width .......................................................................................................... 189 Menu: Replace printhead ............................................................................................................... 189 Menu: Fill replaced printhead ......................................................................................................... 189 Menu: Set head vacuum ................................................................................................................ 189

Part No. CQ114-90035 Rev B HP Scitex FB500 / FB700 Service Manual Page 6 of 510 Menu: Reset image sensor.............................................................................................................. 190 Menu: Prep for shipping ................................................................................................................ 190 Menu: Install shipping restraint ....................................................................................................... 190 Menu: Set clock ............................................................................................................................ 190 Menu: Raise rail, bar, and rollers .................................................................................................... 191 Menu: Restore hard drive to defaults ............................................................................................... 191 Menu: Support roll fed: yes ............................................................................................................ 191 Menu: Roll fed media control: method a .......................................................................................... 191 Menu: Configure warming attns ...................................................................................................... 191 Menu: Carriage control ................................................................................................................. 191 Menu: Show autoH2H Y calibration ................................................................................................ 192 Menu: UV current sense method...................................................................................................... 192 Menu: Auto printhead service ......................................................................................................... 192 Error codes, warnings and actions ......................................................................193 Menu: ERRORS ............................................................................................................................. 193 Menu: ACTIONS .......................................................................................................................... 194 Menu: WARNINGS ...................................................................................................................... 195 Cleaning and Maintenance.................................................................... 196 Schedule of tasks normally completed by printer’s operator ...............................196 Schedule of cleaning and maintenance performed by service provider ................197 Replacing UV lamp filters ............................................................................................................... 199 Cleaning the printheads ................................................................................................................. 199 Clean the electronics box fan filters ................................................................................................. 202 Clean and grease the service station wiper slide rails ........................................................................ 203 Replace the service station wipers ................................................................................................... 205 Clean service station wiper ............................................................................................................ 206 Clean and oil rail carriage-wheel strips............................................................................................ 206 Clean the rail encoder strip ............................................................................................................ 208 Clean carriage wheels................................................................................................................... 208 Clean bottom of carriage ............................................................................................................... 210 Clean ionizer tips with brush .......................................................................................................... 211 Service station empty / close .......................................................................................................... 212 Waste-ink jug’s open and closed positions ....................................................................................... 212 Clean media thickness sensor roller ................................................................................................. 213 Clean the carriage home sensor ..................................................................................................... 213 Cleaning the high-resolution encoder hub ........................................................................................ 214 Replacement of field replaceable modules (FRMs) ................................. 216 Managing Power Off Scenarios ..........................................................................216 Enclosures ..........................................................................................................217 Remove the user-end and service-end enclosures ............................................................................... 217 Installing the user and service-end enclosure ..................................................................................... 217 Removing the output-side, user-end belt enclosure.............................................................................. 218 Removing the input-side, user-end belt enclosure ............................................................................... 218 Removing the light-blocking tray...................................................................................................... 218 Installing the light-blocking tray ....................................................................................................... 219 Disconnecting the OHS Cabinet ...................................................................................................... 219 Removing the output-side top door .................................................................................................. 220 Installing the output-side top door .................................................................................................... 222 Removing a fan from the output-side door ........................................................................................ 222 Installing a fan in the output-door .................................................................................................... 223 Carriage FRM Assemblies ...................................................................................224 Carriage assembly cover ............................................................................................................... 224 Removing printheads ..................................................................................................................... 224 Releasing the service station latch ................................................................................................... 225 Installing Printheads....................................................................................................................... 226 Install the flex cables ..................................................................................................................... 229 Post printhead-replacement calibrations ........................................................................................... 230 Removing the carriage headboard .................................................................................................. 230 Disconnecting the carriage pressure sensor tube ............................................................................... 230 Removing the headboard (with mounting plate) ................................................................................ 231 Installing the carriage headboard (with mounting plate) ..................................................................... 231 Headboard cable connection chart ................................................................................................. 232 Removing the carriage camera board.............................................................................................. 233 Installing the carriage camera board ............................................................................................... 234 Removing a thermistor set .............................................................................................................. 235 Power off printer and unplug power cords ....................................................................................... 235 Removing the printhead reservoir cover ........................................................................................... 235

Part No. CQ114-90035 Rev B HP Scitex FB500 / FB700 Service Manual Page 7 of 510 Clamp vacuum tubes to service printhead components....................................................................... 236 Installing a thermistor set ................................................................................................................ 237 Removing the carriage air manifold................................................................................................. 238 Removing the pressure and vacuum tube.......................................................................................... 239 Installing the carriage air manifold .................................................................................................. 240 Removing the carriage encoder reader ............................................................................................ 240 Installing the carriage encoder reader ............................................................................................. 242 Removing the carriage from the rail ................................................................................................. 242 Disconnecting the lamp power cables .............................................................................................. 243 Disconnecting the ink tube from the ink reservoir ............................................................................... 243 Remove the trolley attachment bracket ............................................................................................. 244 Installing the carriage on the rail ..................................................................................................... 244 Reconnecting tubes using tube joiner (tube mender)........................................................................... 245 Removing the upper trolley plate ..................................................................................................... 246 Installing the upper trolley plate ...................................................................................................... 248 Removing the home sensor ............................................................................................................. 249 Installing the home sensor .............................................................................................................. 249 Removing the home sensor flag....................................................................................................... 250 Installing the home sensor flag ........................................................................................................ 250 Carriage Lamp Assemblies..................................................................................251 Remove the user-end lamp cover ..................................................................................................... 251 Installing the user-end lamp cover.................................................................................................... 252 Remove the service-end lamp cover ................................................................................................. 252 Install the service-end lamp cover .................................................................................................... 252 Removing the UV Lamp Bulb........................................................................................................... 253 Installing the UV Lamp Bulb ............................................................................................................ 254 Removing the Lamp Glass .............................................................................................................. 255 Installing the lamp glass ................................................................................................................. 256 Removing the lamp fan assembly .................................................................................................... 256 Installing the lamp fan ................................................................................................................... 257 Removing a single lamp fan ........................................................................................................... 257 Installing a single lamp fan............................................................................................................. 258 Carriage-drive assemblies ..................................................................................259 Releasing the carriage-drive belt tension .......................................................................................... 259 Removing the carriage-drive idler .................................................................................................... 259 Installing the carriage-drive idler ..................................................................................................... 259 Removing the carriage-drive belt ..................................................................................................... 260 Installing the carriage-drive belt ...................................................................................................... 260 Remove the carriage-drive motor ..................................................................................................... 261 Remove the carriage-drive timing belt .............................................................................................. 262 Install the carriage-drive motor ........................................................................................................ 262 Remove the carriage-drive shaft ...................................................................................................... 262 Remove the carriage-drive assembly housing .................................................................................... 263 Remove the rail encoder strip .............................................................................264 Installing the rail encoder strip ........................................................................................................ 264 Removing rail wheel strips .............................................................................................................. 266 Installing a rail wheel strip ............................................................................................................. 267 Media-drive media-drive assemblies ..................................................................270 Removing the high-resolution encoder .............................................................................................. 270 Installing the high-resolution encoder ............................................................................................... 273 Set the high-resolution encoder’s readhead spacing .......................................................................... 274 Aligning the high-resolution encoder................................................................................................ 275 Turning off AGC (Automatic Gain Control) ....................................................................................... 276 Align readhead with AGC turned off ............................................................................................... 277 High-resolution encoder incremental signal calibration....................................................................... 278 Activate high-resolution encoder calibration mode............................................................................. 279 Set the reference mark for the high-resolution encoder ....................................................................... 279 Turning AGC on for the high-resolution encoder interface .................................................................. 279 Removing the media-drive motor ..................................................................................................... 280 Loosening the media-drive belt tension ............................................................................................. 280 Removing the media-drive motor ..................................................................................................... 283 Installing the media-drive motor ...................................................................................................... 284 Torque conversion......................................................................................................................... 287 Tensioning the media-drive belt ....................................................................................................... 288 Removing the media-drive motor’s encoder ...................................................................................... 288 Installing the media-drive motor’s encoder ........................................................................................ 290 Remove an input roller actuator assembly......................................................................................... 291 Install an input actuator assembly .................................................................................................... 293 Calibrate the input roller assembly .................................................................................................. 293 Remove an alignment bar actuator assembly .................................................................................... 294

Part No. CQ114-90035 Rev B HP Scitex FB500 / FB700 Service Manual Page 8 of 510 Install an alignment bar actuator assembly ....................................................................................... 295 Calibrate the alignment bar............................................................................................................ 295 Replace an output-roller actuator assembly ....................................................................................... 296 Remove the output roller................................................................................................................. 296 Install an output-roller actuator assembly .......................................................................................... 297 Calibrate the output-roller ............................................................................................................... 297 Rail exploded views ...................................................................................................................... 297 Remove a rail actuator................................................................................................................... 298 Install a rail actuator assembly ........................................................................................................ 301 Removing the optional foot switch ......................................................................302 Installing the replacement foot switch ............................................................................................... 302 Media-drive fan arrays ......................................................................................303 Fan array exploded views .............................................................................................................. 303 Removing the output-side vacuum fan array ...................................................................................... 304 Installing the output-side vacuum fan array ....................................................................................... 305 Removing the middle vacuum fan array ........................................................................................... 305 Installing the middle vacuum fan array............................................................................................. 306 Removing the input-side fan array ................................................................................................... 307 Installing the input-side fan array..................................................................................................... 308 Replacing a fan-array fan .............................................................................................................. 309 Media-drive belt, Removal .............................................................................................................. 311 Installing the media-drive belt ......................................................................................................... 318 Center the media rollers ................................................................................................................. 320 Center the driver roller ................................................................................................................... 320 Begin idler roller centering ............................................................................................................. 321 Checking media-drive belt tension ................................................................................................... 321 Belt tension specification ................................................................................................................ 323 Make sure media rollers are parallel ............................................................................................... 324 Check belt tracking ....................................................................................................................... 324 Measure roller tracking with a dial indicator .................................................................................... 325 Move the belt using the velocity test................................................................................................. 325 Lap the belt .................................................................................................................................. 326 Media Sensors ....................................................................................................327 Remove the media thickness sensor ................................................................................................. 327 Install the media thickness sensor .................................................................................................... 327 Calibrate the Media Thickness Sensor ............................................................................................. 328 Remove the media detection sensor ................................................................................................. 328 Install the media detection sensor .................................................................................................... 328 Roll-to-roll assemblies ........................................................................................329 Fasteners for roll-to-roll assemblies ................................................................................................... 329 Optional roll-to-roll box contents...................................................................................................... 330 Installation of optional roll-to-roll kit ..................................................................331 Required tools .............................................................................................................................. 331 Configure printer for roll-to-roll ........................................................................................................ 331 Level the printer ............................................................................................................................ 331 Install the roll-to-roll supply arms ...................................................................................................... 332 Roll-to-roll alignment tool configurations ............................................................334 Assemble tool for supply and/or takeup spools................................................................................. 334 Roll-to-roll alignment tool configurations for supply and/or takeup ....................................................... 335 Roll-to-roll alignment tool configuration for foam rollers ...................................................................... 335 Roll-to-roll alignment tool configurations for foam roller tool configuration............................................. 335 Align the roll-to-roll supply spool........................................................................336 Align the service-end supply spool position....................................................................................... 337 Tighten the supply arm turnbuckle bolts ............................................................................................ 341 Align the foam roller racks ............................................................................................................. 342 Center the foam rollers between the foam roller collars ...................................................................... 345 Roll-to-roll Takeup ..............................................................................................348 Remove the output roller................................................................................................................. 348 Set the takeup roller position .......................................................................................................... 348 Tighten the takeup arm’s turnbuckle bolts ......................................................................................... 350 Install the roll-to-roll moveable dancer bar ........................................................................................ 352 Install the fixed bar into the dancer rack .......................................................................................... 354 Takeup motor power ..................................................................................................................... 355 Verify movement of dancer bar ....................................................................................................... 356 Verify takeup motor turn-off trigger point .......................................................................................... 356 Verify takeup motor’s turn-on trigger point ........................................................................................ 357 Adjusting takeup switch positions .................................................................................................... 358 Install the output roller.................................................................................................................... 359 Loading roll-to-roll media ...................................................................................360

Part No. CQ114-90035 Rev B HP Scitex FB500 / FB700 Service Manual Page 9 of 510 Media loading overview ................................................................................................................ 360 Prepare the printer ........................................................................................................................ 361 Center the media on the supply spool .............................................................................................. 361 Initiate LOAD MEDIA from printer’s menu......................................................................................... 363 Mid-spool support for heavy media rolls .......................................................................................... 366 Electronic assembly FRMs ...................................................................................367 Removing the fan’s air filter ............................................................................................................ 367 Installing the fan filter cover ............................................................................................................ 367 Removing the electronics box covers................................................................................................ 368 Installing the electronics box covers ................................................................................................. 368 Removing the motor control board .................................................................................................. 368 Installing the motor control board .................................................................................................... 370 Removing the FB 500 ebox UV power output cables ......................................................................... 370 Installing the FB 500 ebox UV power output cables ........................................................................... 372 Removing the ebox ionizer power-out cable ..................................................................................... 372 Installing the ebox ionizer power-out cable....................................................................................... 374 Removing the ebox ShopVac power-out cable .................................................................................. 374 Installing the ebox ShopVac power-out cable.................................................................................... 376 Removing the ebox main input-power cable ..................................................................................... 376 Installing the ebox main input-power cable ....................................................................................... 378 Removing the AC distribution board ................................................................................................ 378 Installing the AC distribution board ................................................................................................. 379 Removing the FB500 UV power supply ............................................................................................ 379 Installing the FB500 UV power supply ............................................................................................. 380 Removing the FB700 UV power supply ............................................................................................ 380 Installing the FB700 UV power supply ............................................................................................. 382 Removing an AC relay................................................................................................................... 382 Installing an AC relay .................................................................................................................... 383 Removing the IO controller board ................................................................................................... 383 Installing the IO controller board ..................................................................................................... 385 Removing the ebox motherboard .................................................................................................... 385 Installing the ebox motherboard ...................................................................................................... 387 Motherboard BIOS configuration .................................................................................................... 388 Removing the ebox hard disk ......................................................................................................... 390 Installing the ebox hard disk ........................................................................................................... 390 Removing the ATX power supply ..................................................................................................... 390 Installing the ATX power supply ...................................................................................................... 391 Removing an electronics box fan..................................................................................................... 392 Installing an electronics box inlet fan ............................................................................................... 392 Maintenance assemblies .....................................................................................393 Removing the service station ........................................................................................................... 393 Service station cables .................................................................................................................... 393 Service station bolts....................................................................................................................... 394 Installing the service station ............................................................................................................ 394 Disconnecting the service station drain hose ..................................................................................... 394 Install the service station drain hose................................................................................................. 395 Installing complete drain hose kit .................................................................................................... 395 Remove the service station actuator ................................................................................................. 398 Install the service station actuator .................................................................................................... 398 Remove the service station wiper motor............................................................................................ 399 Install the service station wiper motor............................................................................................... 399 OHS assemblies..................................................................................................400 Tube joiners and plugs .................................................................................................................. 400 Removing a permanent ink filter ...................................................................................................... 401 Cutting the ink tube for removal ...................................................................................................... 401 Installing the permanent ink filter ..................................................................................................... 402 Removing the OHS controller board ................................................................................................ 402 Installing the OHS controller board ................................................................................................. 402 Adjusting vacuum level .................................................................................................................. 403 Track assemblies ................................................................................................405 Replacing the complete track assembly ............................................................................................ 405 Overview ..................................................................................................................................... 405 Things to do first for track replacement ..............................................................406 Print a prime bar pattern ................................................................................................................ 406 Access the password protected service menu.................................................................................... 406 Empty the carriage of ink ............................................................................................................... 406 Remove both endcap enclosures ..................................................................................................... 406 Included fasteners, plugs and joiners ..................................................................407 Included tube joiners and plugs for track replacement........................................................................ 407 Included fasteners for track replacement .......................................................................................... 407

HP Scitex FB500 / FB700 Service Repair Manual

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