HP Scitex FB500
HP Scitex FB700
AutoSet
AutoBidi
AutoJet
Auto Head X
Camera
Image Sensor
HP Scitex FB500/FB700 Printer - Auto Calibrations Fails or Cancel Without Completing
Environment
Questions/Symptoms
Auto calibration fails
AutoJet not successful
AutoBidi not successful
AutoSet not successful
Auto head X not successful
Cause
Poor jetting/too many nozzles out
Printhead Y-alignment incorrect
Media advance calibration incorrect
Media thickness inaccurately detected
Media thickness inaccurately entered manually
Image sensor focus height incorrect
Image sensor/camera hardware malfunction
Answer/Solution
The FB500 and FB700 printers use an on-carriage image sensor, commonly referred to as the camera, to perform certain routine calibrations of the printheads. These calibrations include:
• AutoJet: detects missing or misfiring jets and calculates replacements for them
• AutoBidi: ensures accurate drop placement in either direction of carriage travel
• Auto Head X: ensures accurate registration of the color planes in the X-axis (direction of carriage travel)
• Full AutoSet: performs AutoBidi, Auto Head Head X, and AutoJet in sequence.
When any one of the Auto Calibrations cancels or fails to complete successfully, it may be due to one or several of the following root causes:
1. Very poor jetting/too many nozzles out. If a given printhead has an excessive number of missing or misfiring jets (nozzles), there may not be enough of a calibration pattern printed to be read by the image sensor. If printhead #1 (black) in particular is severely misfiring, the key locator marks used by the image sensor to find the rest of the calibration pattern may not be printed adequately, and the calibration will cancel or fail.
Maintaining good jetting and resolving missing jets is outside the scope of this document. Consult the printer's user guide for information on cleaning and maintaining the printheads.
Click here to access the user guide.
2. Media feed calibration incorrect. During the Auto Calibrations, the media is moved forward and backward repeatedly to position the printed pattern to be read by the image sensor. If the media feed calibration is incorrect or has not been performed, the combined movements of the media will improperly position the pattern and the image sensor will be unable to find the key locator marks or the rest of the calibration pattern, and the calibration will cancel or fail.
To resolve, perform one of the media feed calibration routines found on the printer's control panel under "Printing | Calibrate | Manual Calibrations | Media Feed Calibration". The recommended methods for maximum accuracy are the "990 mm (or 39 inch), using image sensor" or the "900 mm (or 34 inch), using ruler" options. Consult the printer's User Guide for more details on these calibrations.
NOTE: that if there is a problem with the image sensor itself, the media feed calibrations that use the image sensor may not be successful either.
After the media feed calibration has been performed successfully, re-try the Auto calibration(s).
3. Media thickness inaccurately detected. Under most circumstances, the thickness of the media is detected automatically by the media thickness sensor during the media load process. If the media thickness is incorrectly sensed by the printer, the positioning of the rail and carriage relative to the media will also be incorrect. The resulting pattern printed for the Auto Calibrations may be distorted and unreadable due to the incorrect printing height, or the image sensor may be unable to achieve the correct focus height.
When loading media, check the control panel to verify that the displayed thickness of the media is within an expected range for the type being loaded, as shown in Figure 1.
Figure 1 Home Page with media loaded
1 - Displayed media dimension (width x length x thickness)
If the displayed thickness is incorrect, check that the media thickness sensor arm is moving freely and not binding, resulting in an incorrect thickness detection. Clean the sensor arm according to the instructions found in the printer's User Guide, chapter 9.
4. Media thickness inaccurately entered manually by the operator. In some circumstances, the media thickness is entered manually by the printer operator, such as when printing roll-fed material or when a rigid material has properties that prevent the automatic thickness detection from working properly. If the media thickness entered at the control panel is not correct for the actual media type, the same issues described in the preceding section may occur. Use the media manufacturer's information concerning the media thickness, or use a caliper to determine the actual thickness, and ensure that the correct unit of measurement (inches or centimeters) is selected on the control panel before entering the thickness manually.
5. Inaccurate printhead Y-alignment. The alignment of the printheads in the Y-axis (direction of media feed) is performed at the time of printer installation or when a printhead is removed/replaced. If jet health appears to be good, i.e., no or only a few nozzles missing in the Check Jet Health print, but the AutoJet calibration fails one or more heads indicating an extremely large number of jets are bad, then the Y-alignment of the affected printhead(s) may be questioned.
Evaluating or correcting a Y-alignment problem is outside the scope of this document.
NOTE: Some hardware problems with the image sensor may also result in similar failure of both heads of one particular color, so continue with the rest of this document and then consult an authorized HP reseller or service provider or contact the HP regional Customer Care Center for further assistance if a Y-alignment issue is still suspected.
6. Image sensor focus height is incorrect. During printer installation and for some service events, the correct height for the image sensor must be calibrated and set. If this calibration has not been performed or was performed inaccurately, the carriage will move to a height that does not permit the image sensor to focus, and the calibration patterns will not be read successfully.
The current image sensor focus calibration may be checked and/or adjusted by loading an appropriate media such as paper-faced foam board, then selecting "System | Tools | User Diagnostics | Calibration". From the test menu, select Step 3: Image Sensor Height. Follow the on-screen prompts to view the current focus and make adjustments. A good focus height will allow the operator to see well-defined individual dots at the center of the image window. Outlying areas on the board may be less well-defined. See Figures 2 and 3 for comparisons of a good focus vs. poor focus.
Figure 2 Example of a good image sensor focus. The individual drops are clearly defined.
Figure 3 Example of poor image sensor focus. The image is blurry and individual drops poorly defined.
7. Image sensor hardware dirty or malfunctioning. In some cases the image sensor hardware is contaminated with ink or otherwise not working correctly. The image sensor consists of the sensor itself and an array of LEDs of various colors. When the image sensor is to read a particular color of ink, the appropriate color of LED is illuminated. If one or more LEDs is dirty or not working, or if the image sensor or lens itself is dirty or not working, the auto calibrations will fail or produce unexpected results.
For details on how to clean the image sensor, consult HP Support Article emr_na-c03467483, Click here to access the document HP Scitex FB700/FB900/FB500 Industrial/Designjet H35000/H45000 Commercial/ColorSpan Legacy Printer - Cleaning the Camera.
After cleaning the image sensor/camera, re-try the Auto calibration. If the calibration continues to fail, proceed with the following tests to identify an image sensor hardware issue.
1. Load an appropriate media such as paper-faced foam board.
2. Select "System | Tools | User Diagnostics | Calibration".
3. From the test menu, select Step 5: Run Image Sensor Tests.
4. From the test submenu, select "Visually Examine LEDs".
5. Follow the on-screen prompts and allow the carriage to move into position.
6. Use the On/Off buttons on the control panel to turn the image sensor LEDs on, and visually inspect to confirm that the LEDs of the selected color are on.
7. Press Proceed to end the test.
8. If any LEDs appeared not to illuminate, there may be a hardware problem. Otherwise, continue with the next steps.
9. From the test submenu, select "Take raw picture of dots". The printer will print a small square composed of individual dots of the various colors. After cooling the UV lamps, the carriage will move over this pattern and the image sensor will scan this pattern. The lamps will turn on again and the printer will print a 400% enlargement of the original pattern. When this 400% enlargement print is complete, remove the print from the printer and inspect the result. A typical, normal raw picture will have a slightly yellow or gray background (depending on media properties) and each individual ink color should be accounted for and discernible in the enlargement of the drops. If one or more colors of ink appear to be missing from the enlargement print, or if the overall image is significantly occluded or entirely black, then there is a hardware problem. Otherwise, continue with the next steps. An example of a typical raw picture result is shown in Figure 4.
Figure 4 Example of the Take Raw Picture of Dots pattern
1 - Initial small print of dots
2 - Subsequent 400% enlargement. The overall appearance is representative of a normal image sensor/camera
10. From the test submenu, select "Take enhanced picture of dots". The process is identical to the previous test, but after scanning the print with the image sensor, the image is cleaned and processed by the printer software, and this enhanced image is printed at a 400% enlargement. In comparison to the raw picture of dots, the enhanced picture should have a much whiter background and the individual dots should be well-defined and clear. If the actual print produced differs from this expectation, there is an issue with the image sensor hardware and/or software routines. An example of an enhanced picture result is shown in Figure 5.
Figure 5 Example of the Take Enhanced Picture of Dots pattern. This example shows evidence that a head rub by the carriage against the media occurred during printing, which is shown in the unusual blotches and halos in the enlargement print. This result should be discarded and the test repeated, although the general indication is that the imaging system is functioning normally.
1. Initial small print of dots
2. Subsequent 400% enlargement
3. Head rub evidence
If any of these test results are unexpected or inconclusive, and/or the original Auto Calibration failure problem persists, consult an authorized HP reseller or service provider or contact the HP regional Customer Care Center for further assistance.
• AutoJet: detects missing or misfiring jets and calculates replacements for them
• AutoBidi: ensures accurate drop placement in either direction of carriage travel
• Auto Head X: ensures accurate registration of the color planes in the X-axis (direction of carriage travel)
• Full AutoSet: performs AutoBidi, Auto Head Head X, and AutoJet in sequence.
When any one of the Auto Calibrations cancels or fails to complete successfully, it may be due to one or several of the following root causes:
1. Very poor jetting/too many nozzles out. If a given printhead has an excessive number of missing or misfiring jets (nozzles), there may not be enough of a calibration pattern printed to be read by the image sensor. If printhead #1 (black) in particular is severely misfiring, the key locator marks used by the image sensor to find the rest of the calibration pattern may not be printed adequately, and the calibration will cancel or fail.
Maintaining good jetting and resolving missing jets is outside the scope of this document. Consult the printer's user guide for information on cleaning and maintaining the printheads.
Click here to access the user guide.
2. Media feed calibration incorrect. During the Auto Calibrations, the media is moved forward and backward repeatedly to position the printed pattern to be read by the image sensor. If the media feed calibration is incorrect or has not been performed, the combined movements of the media will improperly position the pattern and the image sensor will be unable to find the key locator marks or the rest of the calibration pattern, and the calibration will cancel or fail.
To resolve, perform one of the media feed calibration routines found on the printer's control panel under "Printing | Calibrate | Manual Calibrations | Media Feed Calibration". The recommended methods for maximum accuracy are the "990 mm (or 39 inch), using image sensor" or the "900 mm (or 34 inch), using ruler" options. Consult the printer's User Guide for more details on these calibrations.
NOTE: that if there is a problem with the image sensor itself, the media feed calibrations that use the image sensor may not be successful either.
After the media feed calibration has been performed successfully, re-try the Auto calibration(s).
3. Media thickness inaccurately detected. Under most circumstances, the thickness of the media is detected automatically by the media thickness sensor during the media load process. If the media thickness is incorrectly sensed by the printer, the positioning of the rail and carriage relative to the media will also be incorrect. The resulting pattern printed for the Auto Calibrations may be distorted and unreadable due to the incorrect printing height, or the image sensor may be unable to achieve the correct focus height.
When loading media, check the control panel to verify that the displayed thickness of the media is within an expected range for the type being loaded, as shown in Figure 1.
Figure 1 Home Page with media loaded
1 - Displayed media dimension (width x length x thickness)
If the displayed thickness is incorrect, check that the media thickness sensor arm is moving freely and not binding, resulting in an incorrect thickness detection. Clean the sensor arm according to the instructions found in the printer's User Guide, chapter 9.
4. Media thickness inaccurately entered manually by the operator. In some circumstances, the media thickness is entered manually by the printer operator, such as when printing roll-fed material or when a rigid material has properties that prevent the automatic thickness detection from working properly. If the media thickness entered at the control panel is not correct for the actual media type, the same issues described in the preceding section may occur. Use the media manufacturer's information concerning the media thickness, or use a caliper to determine the actual thickness, and ensure that the correct unit of measurement (inches or centimeters) is selected on the control panel before entering the thickness manually.
5. Inaccurate printhead Y-alignment. The alignment of the printheads in the Y-axis (direction of media feed) is performed at the time of printer installation or when a printhead is removed/replaced. If jet health appears to be good, i.e., no or only a few nozzles missing in the Check Jet Health print, but the AutoJet calibration fails one or more heads indicating an extremely large number of jets are bad, then the Y-alignment of the affected printhead(s) may be questioned.
Evaluating or correcting a Y-alignment problem is outside the scope of this document.
NOTE: Some hardware problems with the image sensor may also result in similar failure of both heads of one particular color, so continue with the rest of this document and then consult an authorized HP reseller or service provider or contact the HP regional Customer Care Center for further assistance if a Y-alignment issue is still suspected.
6. Image sensor focus height is incorrect. During printer installation and for some service events, the correct height for the image sensor must be calibrated and set. If this calibration has not been performed or was performed inaccurately, the carriage will move to a height that does not permit the image sensor to focus, and the calibration patterns will not be read successfully.
The current image sensor focus calibration may be checked and/or adjusted by loading an appropriate media such as paper-faced foam board, then selecting "System | Tools | User Diagnostics | Calibration". From the test menu, select Step 3: Image Sensor Height. Follow the on-screen prompts to view the current focus and make adjustments. A good focus height will allow the operator to see well-defined individual dots at the center of the image window. Outlying areas on the board may be less well-defined. See Figures 2 and 3 for comparisons of a good focus vs. poor focus.
Figure 2 Example of a good image sensor focus. The individual drops are clearly defined.
Figure 3 Example of poor image sensor focus. The image is blurry and individual drops poorly defined.
7. Image sensor hardware dirty or malfunctioning. In some cases the image sensor hardware is contaminated with ink or otherwise not working correctly. The image sensor consists of the sensor itself and an array of LEDs of various colors. When the image sensor is to read a particular color of ink, the appropriate color of LED is illuminated. If one or more LEDs is dirty or not working, or if the image sensor or lens itself is dirty or not working, the auto calibrations will fail or produce unexpected results.
For details on how to clean the image sensor, consult HP Support Article emr_na-c03467483, Click here to access the document HP Scitex FB700/FB900/FB500 Industrial/Designjet H35000/H45000 Commercial/ColorSpan Legacy Printer - Cleaning the Camera.
After cleaning the image sensor/camera, re-try the Auto calibration. If the calibration continues to fail, proceed with the following tests to identify an image sensor hardware issue.
1. Load an appropriate media such as paper-faced foam board.
2. Select "System | Tools | User Diagnostics | Calibration".
3. From the test menu, select Step 5: Run Image Sensor Tests.
4. From the test submenu, select "Visually Examine LEDs".
5. Follow the on-screen prompts and allow the carriage to move into position.
6. Use the On/Off buttons on the control panel to turn the image sensor LEDs on, and visually inspect to confirm that the LEDs of the selected color are on.
7. Press Proceed to end the test.
8. If any LEDs appeared not to illuminate, there may be a hardware problem. Otherwise, continue with the next steps.
9. From the test submenu, select "Take raw picture of dots". The printer will print a small square composed of individual dots of the various colors. After cooling the UV lamps, the carriage will move over this pattern and the image sensor will scan this pattern. The lamps will turn on again and the printer will print a 400% enlargement of the original pattern. When this 400% enlargement print is complete, remove the print from the printer and inspect the result. A typical, normal raw picture will have a slightly yellow or gray background (depending on media properties) and each individual ink color should be accounted for and discernible in the enlargement of the drops. If one or more colors of ink appear to be missing from the enlargement print, or if the overall image is significantly occluded or entirely black, then there is a hardware problem. Otherwise, continue with the next steps. An example of a typical raw picture result is shown in Figure 4.
Figure 4 Example of the Take Raw Picture of Dots pattern
1 - Initial small print of dots
2 - Subsequent 400% enlargement. The overall appearance is representative of a normal image sensor/camera
10. From the test submenu, select "Take enhanced picture of dots". The process is identical to the previous test, but after scanning the print with the image sensor, the image is cleaned and processed by the printer software, and this enhanced image is printed at a 400% enlargement. In comparison to the raw picture of dots, the enhanced picture should have a much whiter background and the individual dots should be well-defined and clear. If the actual print produced differs from this expectation, there is an issue with the image sensor hardware and/or software routines. An example of an enhanced picture result is shown in Figure 5.
Figure 5 Example of the Take Enhanced Picture of Dots pattern. This example shows evidence that a head rub by the carriage against the media occurred during printing, which is shown in the unusual blotches and halos in the enlargement print. This result should be discarded and the test repeated, although the general indication is that the imaging system is functioning normally.
1. Initial small print of dots
2. Subsequent 400% enlargement
3. Head rub evidence
If any of these test results are unexpected or inconclusive, and/or the original Auto Calibration failure problem persists, consult an authorized HP reseller or service provider or contact the HP regional Customer Care Center for further assistance.
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