Welcome to bratlady.com --- DMP-160 Series Plotters Operation Manual --- Chapter 5

Cleaning

The plotter's routine media-handling operations can cause paper dust to accumulate around media-handling mechanisms. Clean these areas periodically with a soft damp cloth.

For ink stains, use a soft cloth slightly dampened with a concentrated solution of soap or a mild detergent and water, or isopropyl alcohol.

Use a lint-free cloth dampened with isopropyl alcohol to clean the pen pads in the pen changer stalls.

CAUTION: Unplug the plotter's power cord before cleaning the plotter with dampened cloths. Be careful to prevent any liquids from dripping into plotter enclosures, as that could cause electrical malfunction.

CAUTION: Do not use aerosol cleaners or cleaners containing strong solvents on the plotter, as they may damage the plotter's internal parts or plastic case. Do not use abrasive cleaners or pads. Do not use alcohol or other solvents to clean the pen carriage rail---use only a clean, soft, dry cloth to avoid contaminating the pen carriage nearings.

Paper Sensor

The plotter uses an optical sensor to detect whether media is loaded, and to determine the length of cut sheets. Normal operation can cause dust and debris to accumulate and block the paper sensor. Use compressed air or a soft brush to clean the sensor periodically. The sensor is recessed in an opening in the top-right side of the rear platen.

Drum

The friction area of the drum can become clogged with accululated residue from the media. This can cause slippage of the media between the drum and the pinch rollers, resulting in inaccurate plots (tracking errors). The following steps explain how to clean the drum when necessary. Note that the special cleaning strips (part number DMP-40-303) are available from your dealer.

Power on the plotter and remove the media.

Press the Online key.

Remove the protective liner from the cleaning strip.

Open the right pinch roller arm.

Place the cleaning strip between the pinch roller and the drum, with the tacky side of the cleaning strip toward the drum. Close the right pinch roller arm.

Using the up arrow and down arrow keys, slew the cleaning strip back and forth several times until all residue is removed from the drum.

Open the right pinch roller arm and remove the cleaning strip.

Repeat Steps 5 through 7 for the left pinch roller at each media size setting.

Remove the strip. Press the Online key.

Residue can be removed from the cleaning strip by washing it in cold water. Thoroughly dry the cleaning strip and replace it in its protective lining.

Pen Changer Pad Replacement

The pen pad in the bottom of the pen changer stalls help protect and seal pen tips. If the pen pad becomes worn or damaged, replacement pads (listed in "Appendix A") are available from your dealer. To replace a pen pad:

Remove and discard the used pad from the bottom of the pen stall. Clean the pad area using a lint-free cloth dampened with isopropyl alcohol.

Avoid touching the adhesive side of the new pad as you remove the backing. Place the new pad, adhesive side down, into the bottom of the pen stall.

Firmly press the pad with your finger to seat it. Wait at least 24 hours to allow the adhesive to set before using the pen stall.

Sending Files from the Operating System

When you use plotting software on the host computer, the plotting software is responsible for the details of sending plots to the plotter, and is usually in charge of configuring the host computer's interface port. If you want to send plot files directly to the plotter from your host computer using its operating system, though, you may first need to configure the computer's serial interface port from its operating system.

Be sure to configure the computer's serial port to match the values set for the plotter's BAUD RATE, PARITY, and RTS/DTR Configuration Menu parameters (see "Chapter 4" for setting plotter parameters and refer to your operating system manual for setting your computer's serial port).

When you are sending files directly from the computer's operating system to the plotter, the host computer may report time-out errors. This is most likely to occur when you are copying large or multiple files to the plotter---after the plotter's data input buffer is full, the plotter signals that it is not ready to receive more data and the operating system refuses to wait to send the remaining data. If your operating system reports a time-out error when sending files to the plotter, consult your operating system manual on increasing the retry setting or time-out period for the serial interface port you are using.

On PC-compatible computers running DOS, you can set the serial port to continuous retry using the MODE command (actually a utility program included with DOS; to use it, make sure that the DOS programs are either in the current directory or on the directory path).

If you are using the COM2 serial port, for example, you might enter the following command at the DOS prompt to configure COM2:

MODE COM2: 9600,N,8,1,P

The "P" (or "RETRY=B" for DOS 4) at the end of the command sets the port to continuous retry.

Note: If you are using the plotter on a network, check with the person who manages the network before reconfiguring interface (input/output) ports.

On PC-compatible computers running DOS, the COPY command can be used at the DOS command prompt to send plot files directly to the plotter. HP-GL/2 plot files are in binary (non-ASCII) form, so you must add a "/B" to the Copy command when sending them. For example:

COPY /B C:\PLOTS\HPGL2.PLT COM2

Note: Command names and syntax vary by operating system type and version. Refer to your operating system manual for detailed information.

Problems and Solutions

The tables below list problems and suggest corrective action. When more than one action is suggested, try each in turn until the problem is solved.

GENERAL PROBLEMS

Problem Corrective Action

Plotter will not power on. Check the AC source power outlet, power cord, fuse or fuses.
Check the plotter power entry module voltage setting (the required values are listed in Appendix D).

Cut sheet ejects during load. Check that both pinch rollers are down.
Clean paper sensor.

Sheets skews left or right. Ensure that both pinch rollers are down.
Clean drum.

LCD is unreadable. Adjust LCD contrast (see "Chapter 4").

Plotter powers on and loads media, but fails to respond properly to host computer. Check the data interface cable.
Make sure that plotter is ONLINE and SELECTED by the plotting software.
For HP-GL or HP-GL/2, try setting LINE STATUS to STANDALONE.
Check the plotter's LANGUAGE parameter and make sure that it matches your software's plotter configuration or device driver.
Check the plotter's BAUD RATE, PARITY, and RTS/DTR parameters (see "Configuration Menu" in "Chapter 4") and the corresponding settings for the plotting software.

Plotter starts then stops before completion of plot. Make sure that PEN PAUSE was not inadvertently enabled
(see "Chapter 4").
Note: Pauses are normal when plotting with a clip window.

PLOT QUALITY PROBLEMS

Problem Corrective Action

Pen skips. Check pen and media compatibility in "Chapter 3."
Test pen by hand on scrap media. If pen works, try lower PEN VELOCITY settings and set VEL OVERRIDE to IGNORE HOST (see "Chapter 4").

Ink bleeds onto media. Check pen and media compatibility in "Chapter 3." If bleeding occurs only at the beginning of lines, try setting a shorter DOWN DELAY (see "Service Mode" later in this chapter).

Short stray lines on plot. Check that sheet is flat, without wrinkles, creases, or curls.
Try lower PEN VELOCITY settings and set VEL OVERRIDE to IGNORE HOST (see "Chapter 4").
Try setting a longer UP DELAY (see "Service Mode").

Random spikes on plot. Check the serial interface cable.
Check the plotter's BAUD RATE, PARITY, and RTS/DTR Configuration Menu parameters (see "Configuration Menu" in "Chapter 4").

Error Messages

The following tables describe error messages that might be displayed on the plotter's LCD. Corrective actions are suggested for these errors.

POWER-ON ERROR MESSAGES

Error Message Cause/Corrective Action

LOW LINE VOLTAGE
TURN POWER OFF Line voltage too low for safe operation. For a new installation, check plotter's voltage setting and outlet voltage.

HIGH LINE VOLTAGE
TURN POWER OFF Line voltage too high for safe operation. For a new installation, check plotter's voltage setting and outlet voltage.

SYSTEM DATA HAS BEEN RECONSTRUCTED DUE TO ROM CHANGE
1=CONTINUE This message appears the first time the plotter is powered on after its ROM chips have been changed (upgraded). Press "1" to continue. No other action is required.

USER NVRAM CHECKSUM FAILURE
1=CONTINUE Error detected in user data stored in NVRAM (semi-permanent memory). Configuration menu variables for failed user number are temporarily set to default values after "continue" is selected, but NVRAM is not updated, so this error may persist until you edit menu variables for failed user number.

SYSTEM NVRAM CHECKSUM FAILURE
1=CONTINUE Check the data interface cable.
Error detected in system data stored in semi-permanent memory. System variables are set to default values after "continue" is selected, and factory calibration is lost --- service is recommended.

Miscellaneous errors that prevent plotter from beginning operation "Fatal" errors that prevent the plotter from operating, and cannot be corrected by the user, are rare. If one does occur, power down the plotter for at least 5 seconds, then turn it back on. If error persists, note the error message and call Tech Support.

OPERATIONAL ERROR MESSAGES

Error Message Cause/Corrective Action

PAPER OUT INDICATED BY SENSOR
1=CONTINUE The paper sensor indicates that it is uncovered when media should be covering it. Press "1" to abort current plot or load operation. Clean sensor and retry. If using preprinted form, adjust paper sensor sensitivity (see "Service Mode" later in this chapter).

PEN CHANGER POSITION CHANGED;
RESTORE ORIGINAL POSITION TO RETRY OR MOVE ALL PENS INTO CHANGER TO ABORT
1=RETRY   2=ABORT The pen changer was raised or lowered while the plotter was on-line. Restore the original position and press "1" to continue operation, or press "2" to abort the current plot and restart with the pen changer in its new position (if using pen changer, put all pens in pen changer before restarting).

PEN CHANGER FAILURE;
MOVE ALL PENS INTO CHANGER
1=RETRY   2=ABORT Usually caused by an obstruction in the pen changing path, or the addition of a pen to a changer stall reserved for the current pen. Remove the obstruction or extra pen, put all pens in their stalls, then press "1" to retry the pen changing operation or press "2" to abort the plot.

PEN CHANGER FAILURE;
COULD NOT MOVE CHANGER OUT
TURN POWER OFF Usually caused by an obstruction in the pen changing path. Switch off the plotter, remove the obstruction and start the plot over.

PEN CHANGER REPEATEDLY FAILED;
CLEAR OBSTRUCTIONS AND CHECK ALIGNMENT
TURN POWER OFF The pen changer has failed on more than five consecutive pen changes. Unless an obstruction in the pen changing path can be found and removed, the pen changer requires adjustment.

UNKNOWN INTERNAL ERROR
TURN POWER OFF Usually caused by unintelligible commands sent to the plotter. Check the data interface cable.
Check the plotter's LANGUAGE parameter and make sure that it matches your software's plotter configuration or device driver.
Check the plotter's BAUD RATE, PARITY, and RTS/DTR parameters (see "Configuration Menu" in "Chapter 4") and the corresponding settings for the plotting software.

ERROR IN X AXIS POSITION
TURN POWER OFF Media fails to move properly in plotter, usually due to jammed media. Reload media and retry.

ERROR IN Y AXIS POSITION
TURN POWER OFF Pen fails to move properly, usually due to pen carriage obstruction. Turn plotter off and verify that pen carriage is free to move.
Clean pen carriage rail with soft dry cloth.

ILLEGAL CLIP & SCALE SETTINGS
1=CONTINUE Invalid clip, or scale corners were entered in Clip & Scale Menu. Press "1" to reset corners to full media area (default).

SHEET EXCEEDS MAXIMUM LENGTH ALLOWED;
MAXIMUM LENGTH CAN BE USED
1=ACCEPT   2=ABORT Sheet longer than 240 inches (6096 mm) detected during load. Press "1" to use up to 240 inches (6096 mm) of the sheet, or "2" to abort the load.

INTERNAL SOFTWARE ERROR---

An internal software error occurred. Write down error
and call Tech Support.
Power down/up and retry.

SYSTEM NVRAM WOULD NOT ACCEPT VALUE WRITTEN TO IT
1=CONTINUE An error occurred during an attempt to store new system data in NVRAM. No action required unless error persists.

DM/PL Mode Errors

When LANGUAGE=DM/PL and DM/PL ERRORS=REPORTED in the Configuration Menu for current user number, the error messages in the following table can appear on the LCD.

Note: If your plotting software uses automatic baud rate selection and DM/PL ERRORS is set to REPORTED, error messages will be displayed as the software attempts to match baud rate with the plotter.

DM/PL ERROR MESSAGES

Error Message Cause/Corrective Action

ILLEGAL PLOT COMMAND
1=RETRY 2=ABORT Illegal command(s) encountered in plot data, but an attempt can be made to continue plot. Press "1" to continue plot, or press "2" to abort the current plot.

ILLEGAL PLOT COMMAND
1=CONTINUE Illegal command(s) encountered in plot data that prevent completion. Press "1" to abort plot. Check interface (as below) and resend plot.

RS232 DATA ERROR DETECTED Serial interface received an invalid character or the input buffer overflowed. Check the data interface cable. Check the plotter's BAUD RATE, PARITY, and RTS/DTR parameters (see "Configuration Menu" in "Chapter 4") and the corresponding settings for the plotting software.

HP-GL or HP-GL/2 Mode Errors

When the plotter is in the HP-GL or HP-GL/2 mode, one of the following error messages can appear on the LCD:

SYNTAX ERROR nn
or
DEVICE ERROR

where nn is an error number. Errors 1 through 14 and 18 result from a problem in the plot data sent to the plotter. See the plotting language reference sources listed in "Appendix B" for more information on these errors.

Errors 15, 16, and 17 indicate communications problems between the plotter and the host computer. If you receive one of these errors, check the serial interface cable and verify that the host computer is using the same values for communication parameters as the plotter (BAUD RATE, PARITY, and RTS/DTR in the Configuration menu, covered in "Chapter 4.")

SYNTAX ERRORS

1 Instruction not recognized.

2 Wrong number of parameters.

3 Illegal character or out-of-range parameter.

4 Not used.

5 Unknown character set.

6 Positive overflow.

7 Polygon buffer overflow.

8 Page advance command (AF, AH, FR, PG) received while in cut-sheet mode.

10 An output instruction was received while another output instruction was still executing.

11 An invalid byte was received after the ESC. characters in a device control instruction.

12 An invalid byte was received while parsing a device control instruction. The parameter containing the invalid byte and all following parameters are defaulted.

13 A parameter is out-of-range.

14 Too many parameters were received. Excess parameters are ignored. Parsing of the instructions ends when a colon (normal exit) or the first byte of another instruction is received (abnormal exit).

15 Communications error. A framing, parity, or overrun error has been detected.

16 An input buffer overflow has occurred. One or more bytes of data have been lost --- a syntax or plot error will likely result.

17 Baud rate mismatch with host computer, or full-duplex communications error.

18 Indeterminate I/O error.

Service Mode

The plotter's service mode adds tests and functions to the control panel menus that are useful for service technicians but are not needed for normal operation. The service mode parameters added to the Configuration Menu are described under "Additional Configuration Menu Parameters" later in this chapter. The functions described below can be accessed from an additional menu, the Service Mode Menu, that appears in the list of menus when the plotter is in its service mode. Refer to the service manual for this plotter for more information on service mode tests and functions.

To put the plotter in service mode and access the Service Mode Menu:

If the plotter is on, switch it off.

Switch on the plotter. Put your fingers over the Online and Reset/Load keys. After the memory (RAM) test finishes, the plotter will beep.

When the plotter beeps, press and hold down the Online and Reset/Load keys simultaneously until the plotter beeps again (about two seconds). When the plotter is in the service mode, it will display an "S" in the upper right corner of the LCD.

Load media and pens.

Press the Menu key repeatedly until SERVICE MODE is displayed, then press the Enter key.

Use the left and right arrow keys to display the desired function, then press the Enter key to select it.

SERVICE PLOT

With media loaded in the plotter, select SERVICE PLOT to plot information about the plotter, including its ROM revision and current configuration.

PAPER SENSOR
1 ... 3 ... 25

The sensitivity of the paper sensor can be changed with this parameter if the plotter has problems loading a specific type of media. Use the left and right arrow keys to display the setting desired function, then press the Enter key to select it.

MP-80 INSTALL

This routine is used by service personnel to test the pen changer alignment, optical sensors, and pen change capability.

PEN-PEN TEST

This routine is used by service personnel to test the pen-to-pen plotting repeatablilty of the pen changer.

PEN LIFT SETUP

This routine is used by service personnel to adjust pen lift.
TRACKING TEST

This plot tests media tracking, It requires pen 1 in the pen changer and media in the plotter.

FRICTION PLOT

This plot is used by service personnel to diagnose plotter problems.

RS232 TEST

This routine is used to test the plotter's RS-232C interface with a loop-back test cable.
DRAM TEST

Select this option to run a test on the plotter's dynamic RAM. This test is more thorough than the power-on memory test amd takes several minutes to complete. Upon successful completion of this test, the LCD will show "RAM ERRORS 00000000." Power the plotter off, then on, after this test.

INSTALL MENU

Pressing the Enter key while INSTALL MENU is displayed returns all four sets of user select configuration parameters to their factory-selected (default) values.

Additional Configuration Menu Parameters

The following additional parameters appear on the Configuration Menu, shown below, only when the plotter is in the service mode. the default settings for these parameters are usually correct for normal operation, and you should not change them if you are uncertain about the need for changing them. To access the Configuration Menu in the service mode, press the Menu key repeatedly until "CONFIGURATION" is displayed and press the Enter key.

Configuration Menu --- Parameters in Service Mode

MEDIA ACCELERATION
1.0 <--> 2.0 <--> 3.0 <--> 4.0 g

This setting limits the maximum media acceleration.

CARRIAGE VELOCITY
1 <--> 2 <--> 4 <--> 6 <--> 8 <--> 10 <--> 12 <--> 14 <--> 16 <--> 18 <--> 20 <--> 22 <--> 24 <--> 28 <--> 32IPS <--> 30 <--> 50 <--> 100 <--> 150 <--> 200 <--> 250 <--> 300 <--> 350 <--> 400 450 <--> 500 <--> 550 <--> 600 <--> 700 <--> 800 MM/S

This setting limits the maximum pen carriage velocity.

CARRIAGE ACCELERATION
1.0 <--> 2.0 3.0 <--> 4.0g

This setting limits the maximum pen carriage acceleration.

UP DELAY
25 <--> 30 <--> 35 <--> 40 <--> 45 <--> 50 <--> 55 <--> 60 <--> 65 <--> 70 <--> 75 <--> 80 MS
This parameter sets the time in milliseconds that the plotter waits after lowering the pen before it starts moving.

DOWN DELAY
25 <--> 30 <--> 35 <--> 40 <--> 45 <--> 50 <--> 55 <--> 60 <--> 65 <--> 70 <--> 75 <--> 80 MS
This parameter sets the time in milliseconds that the plotter waits after lowering the pen before it starts moving.

CHART COMMANDS DMP-160 EH/EF <--> DMP-60 EH/EF

For DM/PL, only, this parameter selects the plotter's response to DM/PL Full Chart EF and Half Chart EH commands. When set to DMP-160 EH/EF, the plotter ignores EH and EF commands. When set to DMP-60 EH/EF, an EH command sets the origin to the left front of the sheet, an EF command sets the origin to the right front of the sheet, and the ORIENTATION parameter is overridden.

Voltage Conversion and Fuse Replacement

DMP-160 Series plotters are equipped with a voltage selection panel that lists 100V, 120V, 220V, and 240V (AC only). Each voltage listed on the panel has a hole next to it. The hole next to the plotter's present voltage setting has a pin in it. If the plotter's present voltage setting does not match the voltage of your electrical outlet, change the plotter's operating voltage as instructed below.

Switch off the plotter and unplug its power cord from both the outlet and the back of the plotter.

Pry the cover off the fuse cavity with a small flat blade screwdriver.

Replace the fuse with the type listed in "Appendix D" for your outlet voltage.

To change the plotter's operating voltage, pull out the voltage select board. The board has four voltage selection labels printed on it. Move the voltage indicator pin to the opposite side of the board from the desired voltage label, making sure that the pin is seated in a notch on the board's edge. Replace the voltage select board, turning it so that the voltage select pin will fit in one of the holes on the fuse cover.

Snap the fuse cover back into place. Verify that the voltage select pin is now in the hole next to the voltage listed on the cover that matches your outlet voltage before plugging in the plotter's power cord.

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