Trying to restore a rev A z3200 44"

[JonDuncan]

Hello,

I'm new to the forum. I picked up a z3200 44" rev A printer a few days ago that a man had sitting in his garage from April to Oct 2020. I'd like to try and restore it.

When I purchased the machine, it would only produce a blank screen and beep three times.

I purchased a new battery for the formatter board. However, I grabbed them at the dollar store, and I suspect they may be crap.

After leaving the printer plugged in for a few hours, I flicked the switch at the back off and on, and it initialized.

From there, I printed a test page, which only showed two colors printed - grey and magenta. I initialized a printer head replacement, and removed and cleaned the heads. 4/6 showed full colour lines when blotting onto paper. Two heads seemed FUBAR in one of their colours (Light cyan dead in one, Yellow dead in another). I then returned the heads to the machine.

The printer goes through a 30+ minute process and then says "Printhead replacement incomplete... restart" I've repeated this a few times now, cleaning off the contacts, shaking the ink and cartridges, and each time it will tell me a head needs replaced. Initially, that head was Yellow/Magenta, then Blue/Green (flowing well), then light magenta/light cyan.

I suspect I need at least three new printheads, but I'm cautious about how deep of a rabbit hole this can be. Part of me wonders if I should just get the cheap ones, so I can continue trying to see what problems there are. It won't let me print anything at the moment, even in service mode.

One thing I was able to do was run diagnostics. Doing a scan axis check, it failed during the check PSU portion and gave me a 03:10 error. I'm not sure if the other tests check the PSU, but checks on things like paper loading, spectrophotometer, carriage, service station, all went fine. (For whatever they're worth.)

Now I'm looking at purchasing a PSU/Main PCA assembly, or assembling them myself. I've seen Main PCA-only boards online that say "rev C", but say they are compatible as Q6719-67005 (the Main PCA part for my model according to HP). Usually, they say Q6719-80005 on the board itself.

Does anyone have any experience with these types of parts, will they work in my machine? Also, I understand rev A was discontinued first. How many parts would need to be swapped to turn my machine into a rev B? Is it worth it? How terrible are refurbished heads?

[Mark Lindquist]

So Jon,
Looks like you’ve opened a can of worms.
Reading what you’ve done, I think all was working fine, but you should have just got an entire new print head set.

I think you can still do this. Pull the plug, get all your printheads and carts out, and go to town cleaning everything you can, but do it all carefully.

Get all new printheads and buy them direct from HP. If you buy direct from HP they have to support your ink purchase when you call for support.

You need to have at least 1/2 to 60% full cartridges as well.

Go through start up and initialization just as if the printer was new. Everything out, start putting carts in first, then follow the screen prompts to put in printheads. Have at least a 2’ wide sheet or roll of gloss paper ready.

Good luck,

Mark

[deanwork]

What I found out after letting my Z3100 sit for nearly a year with a broken belt before I restored it was  -  the ink lines are sealed off so they do not dry out and clog. That surprised me. New heads and it started right up.

So, as Mark just said, buy a new set of print heads and a good battery in the formatter board and I bet you will be in business. I’m a big believer in these machines and use them just about everyday. Someone  just offered me another Z3200 yesterday to trade for printing a show. The owner passed away, and despite my full studio space I’m  going to go pick it up. I don’t think it has been used much and having three of these could keep me going for a long time.

John

So Jon,
Looks like you’ve opened a can of worms.
Reading what you’ve done, I think all was working fine, but you should have just got an entire new print head set.

I think you can still do this. Pull the plug, get all your printheads and carts out, and go to town cleaning everything you can, but do it all carefully.

Get all new printheads and buy them direct from HP. If you buy direct from HP they have to support your ink purchase when you call for support.

You need to have at least 1/2 to 60% full cartridges as well.

Go through start up and initialization just as if the printer was new. Everything out, start putting carts in first, then follow the screen prompts to put in printheads. Have at least a 2’ wide sheet or roll of gloss paper ready.

Good luck,

Mark

[JonDuncan]

So Jon,
Looks like you’ve opened a can of worms.
Reading what you’ve done, I think all was working fine, but you should have just got an entire new print head set.

I think you can still do this. Pull the plug, get all your printheads and carts out, and go to town cleaning everything you can, but do it all carefully.

Get all new printheads and buy them direct from HP. If you buy direct from HP they have to support your ink purchase when you call for support.

You need to have at least 1/2 to 60% full cartridges as well.

Go through start up and initialization just as if the printer was new. Everything out, start putting carts in first, then follow the screen prompts to put in printheads. Have at least a 2’ wide sheet or roll of gloss paper ready.

Good luck,

Mark

Hey Mark,

You have a great website, thanks for getting back to me.

That's a good tip about ordering direct from HP. The printheads are expensive at $115 CAD a pop, but a service call to them is probably going to be invaluable to me; I'm just starting out in the world of printer repair.

I have/had low expectations for the machine, but I guess if I'm going to do it, I just have to do it.

I've watched a few teardown videos, and went through the machine checking connections too. I was surprised. Everything looks good inside, not much crud at all. Belt looks new also; however, I noticed the moistener (?) was dry. Any tips on products I can use for that?

I also cleaned the service station off, which had some gunk on it. The waste bin wasn't too full, but maybe I should check that too.

I'll take your advice. Going to stop dicking with it and order the heads.

[JonDuncan]

What I found out after letting my Z3100 sit for nearly a year with a broken belt before I restored it was  -  the ink lines are sealed off so they do not dry out and clog. That surprised me. New heads and it started right up.

So, as Mark just said, buy a new set of print heads and a good battery in the formatter board and I bet you will be in business. I’m a big believer in these machines and use them just about everyday. Someone  just offered me another Z3200 yesterday to trade for printing a show. The owner passed away, and despite my full studio space I’m  going to go pick it up. I don’t think it has been used much and having three of these could keep me going for a long time.

John

Thanks John,

I'm going to do as you and Mark suggested. New battery in the board, and new print heads. Your confidence inspires me.

If I sink $1000 into it, I'll still be out on top.

I've been photographing for 10 years now, and owning a wide-format printer has been a dream for a while. Just to be able to make mistakes and have no one else see them maybe, lol.

I'll let you know how this goes.

Best,
Jon

[JonDuncan]

Well things were hunky dory for a little while.  After getting the new printheads my revA 44" z3200 ran like a top for a few months.

Now I'm back to the initial problem: when I flick the power switch on at the back the machine beeps three times and the screen stays blank. The led on the front power button blinks endlessly.

Does anyone have any idea what the problem is? Trying to reinitialize does nothing. I used to be able to get it to come back if I just left it blinking and blank for awhile, then flicked the power. Now. Nothing works.

Is there a definitive answer to this problem after 14+ years?

[Lessbones]

No experience with that particular printer, but just from an electronics standpoint, it sounds like bad capacitors in the power supply--

[Mark Lindquist]

Well things were hunky dory for a little while.  After getting the new printheads my revA 44" z3200 ran like a top for a few months.

Now I'm back to the initial problem: when I flick the power switch on at the back the machine beeps three times and the screen stays blank. The led on the front power button blinks endlessly.

Does anyone have any idea what the problem is? Trying to reinitialize does nothing. I used to be able to get it to come back if I just left it blinking and blank for awhile, then flicked the power. Now. Nothing works.

Is there a definitive answer to this problem after 14+ years?

Just go back to the beginning. Start from scratch.

Turn off the printer and unplug.
Wait a good several hours.
Open the cover and roll up a piece of paper to stick in the right upper corner to defeat the limit or cover safety switch.
Plug the printer back in and wait for the carriage to come out of the home position, then unplug the printer again.
Pull All print heads and cartridges.
Carefully clean all print heads and PH receptacles.
Check expiration dates and replace any long expired and/or iffy print heads, especially those that won't pass the ink blot test with flying colors.
Plug printer back in, start from scratch, add carts only when called for, then print heads as called for.
Pay attention to the beeps when printheads are seated.
See if it initializes.

Seems extreme, but this process is in itself a diagnostic tool. If you can't get past this process, then begin trouble shooting.
Try it - you may get another month or two out of the printer until something else goes wrong.   

Best -
Mark

[neil snape]

There is someone on Ebay selling a Z3100 for almost nothing. Same problem more or less. It could be the PSU or even LCD screen. Technicians can bypass the LCD on boot up. Yet ti is in the start up checks, so if it fails it or is not present it will not boot.  Although if it was working before it is likely not that.
As you bought new print heads could you still call for support?

You can find rebuilt PSU or formatter boards if needed. Make sure the battery is a real one those Chinese copy batteries are really any good.

[JonDuncan]

Just go back to the beginning. Start from scratch.

Turn off the printer and unplug.
Wait a good several hours.
Open the cover and roll up a piece of paper to stick in the right upper corner to defeat the limit or cover safety switch.
Plug the printer back in and wait for the carriage to come out of the home position, then unplug the printer again.
Pull All print heads and cartridges.
Carefully clean all print heads and PH receptacles.
Check expiration dates and replace any long expired and/or iffy print heads, especially those that won't pass the ink blot test with flying colors.
Plug printer back in, start from scratch, add carts only when called for, then print heads as called for.
Pay attention to the beeps when printheads are seated.
See if it initializes.

Seems extreme, but this process is in itself a diagnostic tool. If you can't get past this process, then begin trouble shooting.
Try it - you may get another month or two out of the printer until something else goes wrong.   

Best -
Mark

Thanks again Mark,

The printer carriage won't come out of the docking station at all. The only thing the printer will do is beep at me three times and sit there with a blank screen.

Print heads are all new from HP - inks are between 50-100 % (several new from HP).

When I pull the formatter board and flick the switch the only thing that changes is the machine does not beep three times. I've tried replacing the HDD, as recommended to me by Tim at LPS, but that had no impact. I've also tried 3-4 different watch batteries, the deluxe Energizer ones.

The fan on the unit was seized - maybe since I got it. Since I never knew what it sounded like I assumed the noise I was hearing was the PSU fan - now I think it was just the service station fan the whole time, and the PSU fan never actually worked.

I replaced the fan in the PSU, and I can hear that now when I start the machine (thanks for the tutorial on this one, Mark) - but the z3200 still just beeps at me and does nothing when turned on.

Already replaced the encoder strip and carriage bushing.

I ordered a PSU. I'm hoping that something on there got fried when the fan wasn't running.

I guess next I'll try to replace the formatter board, and then the PCA board.

Mark, I noticed in another thread you said never to replace just the HDD. However, LPS sells an "upgraded" HDD. I take that to mean that it is possible to switch the HDD. Any thoughts on this?

[JonDuncan]

No experience with that particular printer, but just from an electronics standpoint, it sounds like bad capacitors in the power supply--

Thanks Less,

PSU is at the top of my list. I'll let you know if that's the ticket.

[JonDuncan]

There is someone on Ebay selling a Z3100 for almost nothing. Same problem more or less. It could be the PSU or even LCD screen. Technicians can bypass the LCD on boot up. Yet ti is in the start up checks, so if it fails it or is not present it will not boot.  Although if it was working before it is likely not that.
As you bought new print heads could you still call for support?

You can find rebuilt PSU or formatter boards if needed. Make sure the battery is a real one those Chinese copy batteries are really any good.

Thanks Neil,

You're right about the HP support. I should give them a ring and see if they'll put me through.

This just seems like it has specific symptoms, so there should be a specific solution. Appreciate the feedback.

[Mark Lindquist]

Thanks again Mark,

The printer carriage won't come out of the docking station at all. The only thing the printer will do is beep at me three times and sit there with a blank screen.

Print heads are all new from HP - inks are between 50-100 % (several new from HP).

When I pull the formatter board and flick the switch the only thing that changes is the machine does not beep three times. I've tried replacing the HDD, as recommended to me by Tim at LPS, but that had no impact. I've also tried 3-4 different watch batteries, the deluxe Energizer ones.

The fan on the unit was seized - maybe since I got it. Since I never knew what it sounded like I assumed the noise I was hearing was the PSU fan - now I think it was just the service station fan the whole time, and the PSU fan never actually worked.

I replaced the fan in the PSU, and I can hear that now when I start the machine (thanks for the tutorial on this one, Mark) - but the z3200 still just beeps at me and does nothing when turned on.

Already replaced the encoder strip and carriage bushing.

I ordered a PSU. I'm hoping that something on there got fried when the fan wasn't running.

I guess next I'll try to replace the formatter board, and then the PCA board.

Mark, I noticed in another thread you said never to replace just the HDD. However, LPS sells an "upgraded" HDD. I take that to mean that it is possible to switch the HDD. Any thoughts on this?

Yeah, the HDD and formatter board must be matched or paired together. No bueno to just install HD.
You will need to get a matched set. If you’re getting a new PSU it should come with a board that the formatter card plugs into. The only other problem could be the print mech board.

Beware, however, that rear carriage bushing could be broken, and or cable from the print mech board to the main pca board could be kinked or shorted. Like I said earlier, you’re in no man’s land now. This means you’ll need to burn the midnight oil studying the repair manual, search, search, search again for answers.

I have pulled the machine back apart at this stage, started recleaning, and checking cables, etc., for breaks or sockets with TMI (too many insertions) and just started over methodically making sure all parts are correct. Body-off restoration kind of thing.

You can try calling HP support where you are in the process now, but since it’s not under warranty and you’ve had it apart, they may decline. Serious feet stomping may be required, although as nicely as possible.

Tim at LPS might hook you up with a matched HD and formatter board. He’s very knowledgeable - might be worth a try. He’ll stand behind his sales as well.

Best,

Mark

PS, if you study the manual, learn the machine’s requirements and persist until you beat it and succeed, you can help others. We need more sources here with knowledge to help the Z3100-Z3200 community. Kers has come a very long way and has gained insights. Ernst is a master, and John knows a great deal. Neal is a long time original Z3100 user, and their are many here who have knowledge but not the time.

I wish I could help you more but without being able to put my hands on and in the printer, it’s very much a crap shoot. I would encourage you to keep at it and win. There’s nothing like winning and making the printer print again.

Best,

Mark