Oki Data CONFIDENTIAL

IP6-777 Extra Ionizer Kit Maintenance Manual

U10000138001

This manual describes the maintenance procedures that differ from procedures with standard printers
when the IP6-777 extra ionizer kit is installed. For procedures not mentioned in this manual, refer to the
Maintenace Manual for the standard printers.

1. About maintenance parts

Parts of the extra ionizer kit are not designated as maintenance parts. If it becomes necessary to
replace a part due to a malfunction or another problem, use the required parts from available extra
ionizer kits.

2. Extra ionizers description

Power switch (always ON) Louver

LED

Description of LEDs
POWER: Lights up when the power is turned on.
H.V ALARM: Lights up when there is a problem with the power supply.
FAN ALARM: Lights up when there is a problem with the fan.

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3. Operating the extra ionizers from the ACTUATORS menu and the Actuator tab

3.1 MENU button

Used to display various information items and the system settings.
After installing the extra ionizers kit, EXTRA IONIZERS is displayed in the ACTUATORS menu as
shown with the blue frame in the table below.

Setting
System
Subscription code
Language
Date format
Time zone
Length unit
Temperature unit
Warning sound
PH uncapped
TUR open/timeout
Ink errors
Part replacement warning
Detect media width (before system firmware ver. 3.00 only)
Detect media (before system firmware ver. 3.00 only)
Jam detection sensitivity
Nozzle sweeping
Set all settings to default
Date setting
Time setting
Serial number
Initialize EEPROM
Save default settings
Load default settings
Save printer settings
Load printer settings
Number of colors (CIS model only)
Ink system status
Media heater settings
Print end heating
Standby time
Standby temperature
Actuators
Heaters
Media heaters
Print head heaters
Fans
Rear fans
Carriage fans

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Exhaust fan
Suction fan 1
Suction fan 2
Suction fan 3
Suction fan 4
Motors
Pump/Wipe motor
Cap motor
TUR unit motor
Ink supply motor 1
Ink supply motor 2
Ink supply motor 3
Ink supply motor 4
Ink supply motor 5
Ink supply motor 6
Ink supply motor 7
Solenoids
Air release solenoid 1
Air release solenoid 2
Air release solenoid 3
TUR electromagnetic clutch
LEDS
LED for red
LED for green
LED for blue
Ionizers
EXTRA IONIZERS
Printer power

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(3) ACTUATORS <maintenance mode>

This menu is used to operate the different actuators.

(h) EXTRA IONIZERS

This menu is used to operate the extra ionizers.

>>ACTUATORS
 EXTRA IONIZERS ◎

Select EXTRA IONIZERS with the Up and Down buttons, and then press the OK button.
Select a parameter with the Up and Down buttons, and then press the OK button.

>>>EXTRA IONIZERS
 YYY ◎

YYY: Setting after change

Parameter Description Remark

OFF Stop the extra ionizers

ON Activate the extra ionizers
* An error message is displayed if a problem occurs when the extra ionizers are turned on.
See Troubleshooting in this manual for details about the error messages.

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3.2 CP_Manager <maintenance mode>

The extra ionizers function (shown within the blue frame) has been added to the Actuator tab.

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4. Troubleshooting (General)

< Clogged nozzles cannot be cleared >

User inspection Assumed
Symptom User Solution Service Engineer Inspection
and check item Replacement Part
Clogged nozzles Damaged media If the media is damaged with some sections - Install the last firmware version. - Firmware version
cannot be cleared. edges coming out from the edge guards, it may - Check that ink is sucked when - CAPPING UNIT,MW
contact the heads nozzle surfaces and performing the FILL CAP or - INKJET HEAD,MW
cause nozzles to clog. PH.RECOVERY operation.
Cut any damaged sections with a pair of - Check that the air release solenoid
scissors or a cutter before installing the on the capping unit is not soiled
media. with ink.
Adhesive coming off Feed the media to beyond the risen area.
the vinyl causing the
media to rise
Media wrinkling and When using Nippon Carbide retro-reflective
rising sheeting for road signs, set the afterheater
temperature to 55°C, the printheater
temperature to 45°C, and the preheater
temperature to 50°C.
Set the suction fan level to HIGH.
Decrease the printheater temperature.
Media adhering to the Set the suction fan level to LOW or OFF to
platen make it advance again.
Setting media advance mode to BACK &
FWD LOW may also prevent the media
from adhering to the platen.
Daily maintenance Check that the daily maintenance has been
executed and that it is performed
periodically.

< The media is curled or wrinkled >

Assumed
Symptom User Solution Service Engineer Inspection
Replacement Part
Outside the (1) Use the printer within the operating temperature/humidity range. - Check that the pinch roller is not PINCH ROLLER, MW
operating * Note that some media may wrinkles even within the operating damaged.
temperature/humidit temperature and humidity range. - Check that the pinch roller spring is
y range (2) Use proven media. not missing.
The media storage If there is a difference between the media storage conditions and the
conditions are not printer operating conditions, leave the media for a while in the new
the same as the environment before printing.
printer operating * The time depends on the media type and the storage conditions.
conditions.
The media was not Check that the media was installed properly in the conditions below.
installed properly. - The media is installed parallel to the printer.
- The operation panel shows the media type correctly.
- The media winding mode is optimal for the installed media.
- Check that the leading edge of the media output from the printer is
installed straight to the TUR unit paper tube.
The media wrinkled (1) If the media wrinkles while the printer is warmed by the heaters,
because of the install the media only after the printer is warmed up by the
heater temperatures heaters.
(2) Change the heater temperature. Decrease all three heaters in
increment of 5°C.*1
(3) Use proven media.
(4) If the media is still wrinkled, feed the media until you reach a
portion without wrinkles.
(5) If the media wrinkles between each print job, change the media
advance mode.
(6) When using Nippon Carbide retro-reflective sheeting for road
signs, set the afterheater temperature to 55°C, the printheater
temperature to 45°C, and the preheater temperature to 50°C.
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* When the heaters temperatures are changed, adjust the media
advance adjustment value again.
The media is curled. (1) Do not use media curled in the vertical direction (vertical to the
media).
(2) Do not use media curled in the horizontal direction (from the right
edge to left edge) if it is so curled that the media edge guards and
the suction fan cannot flat the media.
(3) Use proven media.
The suction fan Set the suction fan parameter of the preset to a stronger setting.
parameter of the
preset is LOW.
Wrinkles caused by (1) Remove the media and install it again.
media advance (2) Use proven media.

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5. Troubleshooting (Engine Section and USB Controller Section)

<Missing dots are found at the beginning of printing.>

Assumed
Cause User Solution Service Engineer Inspection
Replacement Part
Outside the Use the printer within the operating temperature/humidity range. - Install the last firmware version. - Firmware version
operating - Check that the nozzles eject ink - PRINT HAED
temperature/ correctly. - CAP, MW
humidity range. - Check the cap position. - WIPING UNIT,MW
Obstructions in the Check the platen, the media edge guards, the capping unit, the wiper - Check that ink is sucked when
nozzle surface. blade, the pressure roller, and the head guards, and remove any performing the FILL CAP or
foreign matter. PH.RECOVERY operation.
Lint or paper fibers coming from a damaged media may touch the - Check the wiping unit operation.
print heads, which may cause missing dots. Replace the media with - Check the wiping position.
a media with no lint or paper fibers. - Fill the system with ink again.
The media entered Perform normal cleaning.
into contact with the If the problem persists, perform the action.
nozzle surfaces.
Cleaning did not Perform the daily maintenance.
finish normally. Clean the caps.
Ionizer setting When using Nippon Carbide retro-reflective sheeting for road signs, - Check that the ionizer setting is set - Firmware version
set the ionizer setting to EXTRA IONIZERS ON. to EXTRA IONIZERS ON. - Extra ionizer
- Install the last firmware version. - HCB1N
Decrease in extra Perform extra ionizers maintenance. - Check that the extra ionizers
ionizer performance maintenance has been performed.
The extra ionizers Connect the extra ionizers harnesses if they are disconnected. - Check that the ionizer setting is set
do not operate. Turn the extra ionizers power switches on if they are turned off. to EXTRA IONIZERS ON.
- Install the last firmware version.
- Check the extra ionizer connection
harnesses are correctly connected.

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<White stripes appear on the print.>

[Symptom A]
Reference
Service Engineer Assumed to Check/
Cause User Solution
Inspection Replacement Part Replace
Parts
Media feed is not Adjust the media advance adjustment value. - Install the last firmware - Firmware version
adjusted properly. * The media advance adjustment value differs depending on the version. - PRINT HAED
winding mode, loose or tension. - Check that the nozzles - CAP, MW
- Be sure to adjust the media advance adjustment value again after eject ink correctly. - WIPING UNIT,MW
changing the winding mode (loose or tension). - Check the cap position.
- Be sure to adjust the media advance adjustment value again after - Check that ink is sucked
changing the pressure roller lever position. when performing the FILL
- Be sure to adjust the media advance adjustment value again after CAP or PH.RECOVERY
changing the suction fan setting of the media preset. operation.
The media advance (1) Check that the media was installed properly in the conditions - Check the wiping unit
accuracy is poor, or below. operation.
is not stable. - The installed media is installed parallel to the printer. - Check the wiping position.
- The operation panel shows the media type correctly.
- The media winding mode is optimal for the installed media.
- If the media is curled or wrinkled, see the description on the
problem, The media is curled or wrinkled.
(2) Adjust the pressure on the media with the pressure roller lever. *1
(3) Change the print mode to be slower. *1 *2
(4) Check that the media is correctly stretched between the paper roll
and the pressure roller.
* If the media is loose when performing the media advance
adjustment, the value will be incorrect.
*1 Adjust the media advance adjustment value again.
*2 Note that the print speed differs depending on the mode selected.

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[Symptom B]
Reference
Service Engineer Assumed to Check/
Cause User Solution
Inspection Replacement Part Replace
Parts
Print head nozzles (1) Perform a nozzle print, and set nozzle map for the clogged - Install the last firmware - Firmware version
are clogged. nozzles. version. - PRINT HAED
(2) Check for obstructions such as media lint or ink clot in the nozzle - Check that the nozzles - CAP, MW
scanning path including the platen surface, and remove them. eject ink correctly. - WIPING UNIT,MW
(3) If the media is curled or wrinkled, solve the problem by referring - Check the cap position.
to the description on the problem, The media is curled or - Check that ink is sucked
wrinkled. when performing the FILL
(4) Perform the daily maintenance. CAP or PH.RECOVERY
* Do not forget to clean the head guard and media edge guards. operation.
* Be sure to perform the print head cleaning. - Check the wiping unit
(5) Clean the print heads surfaces with print sheet mount cleaning. operation.
(6) When using Nippon Carbide retro-reflective sheeting for road - Check the wiping position.
signs, set the ionizer setting to EXTRA IONIZERS ON. - Check the extra ionizers
operation.
Printing with a color stripe bar is effective to prevent missing dots.
Print head nozzles (1) Print a nozzle print pattern, and set nozzle map for the inclined
inclination. nozzles.
(2) Printing with a color stripe bar is effective to prevent missing dots.

[Symptom C]
Reference
Service Engineer Assumed to Check/
Cause User Solution
Inspection Replacement Part Replace
Parts
The ink does not (1) Decrease the temperature of all three heaters by 5°C. *1 - Install the last firmware - Firmware version
match the media. * Before starting the print, ensure that the heater temperatures have version. - PRINT HAED
(Media with low dot been decreased to the target temperature. - Check that the nozzles - CAP, MW
spread rate) * With some media, the increasing the heater temperatures may be eject ink correctly. - WIPING UNIT,MW
effective. - Check the cap position.
(2) Change the print mode to be slower. *1 *2 - Check that ink is sucked
(3) Use proven media. when performing the FILL
(4) Print in high density. CAP or PH.RECOVERY
operation.
- Check the wiping unit
operation.
- Check the wiping position.
*1 Adjust the media advance adjustment value again.
*2 Note that the print speed differs depending on the mode selected.

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6. Error Messages
Operator Call Error Messages
Operator call errors are errors that can be handled by operators.
The description (causes) of these errors and the solutions that can be performed are shown below.
Table of errors
<Extra ionizers errors>
Panel Message Error Description
The extra ionizers
CHECK EXTRA IONIZERS
connector to the board
CONNECTION TO BOARD ◎ is not connected
properly.
The connector of the
CHECK RIGHT EXTRA
extra ionizer on the
IONIZER CONNECTION ◎ right side is not
connected properly.
The connector of the
CHECK LEFT EXTRA
extra ionizer on the left
IONIZER CONNECTION ◎ side is not connected
properly.
The connectors of the
CHECK R & L EXTRA extra ionizers on both
IONIZERS CONNECTION ◎ sides are not
connected properly.
A problem has been
CHECK RIGHT EXTRA
detected with the extra
IONIZER ◎ ionizer on the right
side.
A problem has been
CHECK LEFT EXTRA
detected with the extra
IONIZER ◎ ionizer on the left side.
User Solution
- Press any key to clear the
error.
- Contact your service
representative.
- Press any key to clear the
error.
- Check the connector of the
extra ionizer on the right
side, and connect it if it is
not connected.
- Press any key to clear the
error.
- Check the connector of the
extra ionizer on the left side,
and connect it if it is not
connected.
- Press any key to clear the
error.
- Check the connectors of the
extra ionizers on both sides, - Check that the connector to
and connect them if they are
not connected.
- Press any key to clear the
error.
- Check the power switch of
the extra ionizer on the right
side, and turn it on if it is
turned off.
- If this error occurs
regardless of the power
switch being turned on,
contact your service
representative.
- Press any key to clear the
error.
- Check the power switch of
the extra ionizer on the left
side, and turn it on if it is
turned off.
- If this error occurs
regardless of the power
switch being turned on,
contact your service
representative.
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Oki Data CONFIDENTIAL
Service Engineer Inspection
(For inspection criteria, see Assumed
Reference to Check/Replace Replacement Part
Parts.)
- Check that the connector to - PCB-ASSY-HCB1N
the HCB1N board is correctly - Extra ionizers
connected. connection harnesses
- Check that the extra ionizers
connection harnesses are not
broken.
- Check that the connector of - PCB-ASSY-HCB1N
the extra ionizer on the right - Extra ionizer
side is correctly connected. connection harness
- Check that the connector to - Extra ionizer
the HCB1N board is correctly
connected.
- Check that the extra ionizer
connection harness is not
broken.
- Check that the connector of - PCB-ASSY-HCB1N
the extra ionizer on the left - Extra ionizer
side is correctly connected. connection harness
- Check that the connector to - Extra ionizer
the HCB1N board is correctly
connected.
- Check that the extra ionizer
connection harness is not
broken.
- Check that the connectors of - PCB-ASSY-HCB1N
the extra ionizers on both - Extra ionizer
sides are correctly connected. connection harnesses
- Extra ionizer
the HCB1N board is correctly
connected.
- Check that the extra ionizers
connection harnesses are not
broken.
- Check the power switch of the - PCB-ASSY-HCB1N
extra ionizer on the right side. - Extra ionizer
- Check the alarm LEDs of the connection harness
extra ionizer on the right side. - Extra ionizer
- Check that the extra ionizer
connection harness is not
broken.
- Check the power switch of the - PCB-ASSY-HCB1N
extra ionizer on the left side. - Extra ionizer
- Check the alarm LEDs of the connection harness
extra ionizer on the left side. - Extra ionizer
- Check that the extra ionizer
connection harness is not
broken.
 Oki Data CONFIDENTIAL

Service Engineer Inspection

(For inspection criteria, see Assumed
Panel Message Error Description User Solution
Reference to Check/Replace Replacement Part
Parts.)

A problem has been - Press any key to clear the - Check the power switches of - PCB-ASSY-HCB1N
CHECK R & L EXTRA
detected with both error. both extra ionizers. - Extra ionizer
IONIZER ◎ extra ionizers. - Check the power switches of - Check the alarm LEDs of both connection harnesses
both extra ionizers, and turn extra ionizers. - Extra ionizer
them on if they are turned - Check that the extra ionizers
off. connection harnesses are not
- If this error occurs broken.
regardless of the power
switches being turned on,
contact your service
representative.

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Errors details
Extra ionizers errors

CHECK EXTRA IONIZERS

CONNECTION TO BOARD ◎

<Description>
The extra ionizers connector to the board is not connected properly.

<Action>
Check the Items to be Checked on the table below, and perform the actions starting from the top until
the problem is solved.

No Items to be Checked Action

1 Check that the connector to the
HCB1N board is correctly connected.
2 Check that the extra ionizers
connection harnesses are not broken.
3 PCB-ASSY-HCB1N
Check that the connectors of the extra ionizers connection
harnesses are correctly connected to the connectors on
the HCB1N board.
Check that the extra ionizers connection harnesses are
not damaged or broken.
Replace the board.

CHECK RIGHT EXTRA

IONIZER CONNECTION ◎

<Description>
The connector of the extra ionizer on the right side is not connected properly.

<Action>
Check the Items to be Checked on the table below, and perform the actions starting from the top until
the problem is solved.

No Items to be Checked Action

1 Check that the connector of the extra
ionizer on the right side is correctly
connected.
2 Check that the connector to the
HCB1N board is correctly connected.
3 Check that the extra ionizer
connection harness is not broken.
4 Extra ionizer
Check that the connector of the extra ionizer connection
harness is correctly connected to the connector on the
extra ionizer.
Check that the connector of the extra ionizer connection
harness is correctly connected to the connector on the
HCB1N board.
Check that the extra ionizer connection harness is not
damaged or broken.
Replace the extra ionizer.

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CHECK LEFT EXTRA

IONIZER CONNECTION ◎

<Description>
The connector of the extra ionizer on the left side is not connected properly.

<Action>
Check the Items to be Checked on the table below, and perform the actions starting from the top until
the problem is solved.

No Items to be Checked Action

1 Check that the connector of the extra
ionizer on the left side is correctly
connected.
2 Check that the connector to the
HCB1N board is correctly connected.
3 Check that the extra ionizer
connection harness is not broken.
4 Extra ionizer
Check that the connector of the extra ionizer connection
harness is correctly connected to the connector on the
extra ionizer.
Check that the connector of the extra ionizer connection
harness is correctly connected to the connector on the
HCB1N board.
Check that the extra ionizer connection harness is not
damaged or broken.
Replace the extra ionizer.

CHECK R & L EXTRA

IONIZERS CONNECTION ◎

<Description>
The connectors of the extra ionizers on both sides are not connected properly.

<Action>
Check the Items to be Checked on the table below, and perform the actions starting from the top until
the problem is solved.

No Items to be Checked Action

1 Check that the connectors of the extra
ionizers on both sides are correctly
connected.
2 Check that the connector to the
HCB1N board is correctly connected.
3 Check that the extra ionizers
connection harnesses are not broken.
4 Extra ionizers
Check that the connectors of the extra ionizers connection
harnesses are correctly connected to the connectors on
the extra ionizers.
Check that the connectors of the extra ionizers connection
harnesses are correctly connected to the connectors on
the HCB1N board.
Check that the extra ionizers connection harnesses are
not damaged or broken.
Replace the extra ionizers.

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CHECK RIGHT EXTRA

IONIZER ◎

<Description>
A problem has been detected with the extra ionizer on the right side.

<Action>
Check the Items to be Checked on the table below, and perform the actions starting from the top until
the problem is solved.

No Items to be Checked Action

1 Check the power switch of the extra
ionizer on the right side.
2 Check the alarm LEDs of the extra
ionizer on the right side.
3 Check that the extra ionizer
connection harness is not broken.
Turn the power switch on if it is turned off.
If the alarm LEDs of the extra ionizer are lit, replace the
extra ionizer.
Check that the extra ionizer connection harness is not
damaged or broken.

CHECK LEFT EXTRA

IONIZER ◎

<Description>
A problem has been detected with the extra ionizer on the left side.

<Action>
Check the Items to be Checked on the table below, and perform the actions starting from the top until
the problem is solved.

No Items to be Checked Action

1 Check the power switch of the extra
ionizer on the left side.
2 Check the alarm LEDs of the extra
ionizer on the left side.
3 Check that the extra ionizer
connection harness is not broken.
Turn the power switch on if it is turned off.
If the alarm LEDs of the extra ionizer are lit, replace the
extra ionizer.
Check that the extra ionizer connection harness is not
damaged or broken.

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CHECK R & L EXTRA

IONIZERS ◎

<Description>
A problem has been detected with both extra ionizers.

<Action>
Check the Items to be Checked on the table below, and perform the actions starting from the top until
the problem is solved.

No Items to be Checked Action

1 Check the power switches of both
extra ionizers.
2 Check the alarm LEDs of both extra
ionizers.
3 Check that the extra ionizers
connection harnesses are not broken.
Turn the power switches on if they are turned off.
If the alarm LEDs of the extra ionizers are lit, replace the
extra ionizers.
Check that the extra ionizers connection harnesses are
not damaged or broken.

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