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Optra R+

195-055 IBM 3116 PAGE PRINTER MODELS 001, 002, 003

Lexmark Optra R+
Lexmark FTP File Site
Printer Bi-directional Communication Support for  9.x, and NT 4.0
Search Lexmark Tech Library (not automated! real search engine!)
   Search for "Optra R Plus"
Optra R/R+ Engine Firmware ver. 43.94
MarkNet XL Firmware Flash
Optra 4049 Series Service Manual 

Internal Network Adapters (INAs)
installing/adding a network card option
Configure TCP/IP on MarkNet XL INA
   1402217 - Token Ring 16/4
   1402218 - 10baseT ethernet only
      1446702 - Combined ethernet 10base2/T  Use the same PCB
   13A0295 - IPDS
Installing a font card/font cartridge 1364915
installing the 100-Sheet Auxiliary Feeder or the Envelope+ Feeder
Toner Cartridge
   changing the toner cartridge and using the fuser cleaner bar (felt pad)
Duplex Unit
   installing the duplex unit
   Duplexor Sounds Like Machinegun!
W95 Drivers
Hard Disk
Using 4039 Cartridge
   Updating the engine code on the printer  (Flash ver 43.94)
    Update INA Adapter Flash
Calibration
Does Not Pick Up Paper

25 MHz AMD® 29030 32-bit RISC processor
      The only two differences between the Optra R and the R+ is that the R+ (as you noted) will print out at 16ppm whereas the R will do 12ppm. The other difference is that the R+ offers collating of multiple page print jobs on board the printer (not thru the software on the p.c which is common now).  The benefit is that it allows the user to regain control of the p.c. more quickly.  The toner cartridge is the same for all the Optra's (monochrome)and you can buy it in either 7,000 pages or 14,000 pages (which is more economical).  The add-on's (duplexing, 500 sheet 2nd drawers, flash memory ...)will fit the whole family of Optra machines range. The only exception is the dual paper feeder off the back of the machine and that is designed for the Plus models.

OZONE:  Ozone is an inherent by-product of many laser printing processes, including the older IBM 4019, 4029, and 4028 laser printers.  The 3116 does not create any measurable amount of ozone because the charge corona has been replaced with a charge roll.

The Optra Plus is the same engine and controller as the Optra, but with a different P-SIMM.  The Optra can be upgraded to a Plus by replacing the P-SIMM in a kit from Lexmark.

expandable to 64MB (4, 8, 16 and 32MB) using 72 pin 70 ns SIMMs, FPM and EDO supported.
RAMSmart intelligent memory management
100MB hard drive option

Flash Memory Option

Flash memory is useful for storing information like downloaded fonts and macros. Information stored in flash memory is retained when the printer is turned off and can be quickly retrieved by the printer.
   Use the Toolkit utility shipped with your printer to download fonts, symbol  sets, or macros to flash memory. Refer to the Technical Reference for  more details about using your Flash Memory Option.

Flash SIMMs

Flash Memory 2MB

Flash memory options of 1MB, 2MB and 4MB

How to format flash memory
From a Ready status message, press Menu> (right arrow) or <Menu (left arrow) until Tests Menu appears on the display.
Press Select to select the Tests Menu.
Press Menu> or <Menu until Format Flash appears.
Press Select to format the flash SIMM.

Warning! Any existing data stored on the flash SIMM will be erased when it is formatted
ROM SIMM (printer microcode)

J8 ROM SIMM (printer microcode)
1381840 R/Rt/L/Lx/Rx
1381872 Lx+/R+/Rt+

Regular memory (J9 and J10):
1364921 2MB DRAM SIMM
1364877 4MB DRAM SIMM
1364876 8MB DRAM SIMM
1364875 16MB DRAM SIMM
1364874 32MB DRAM SIMM

PRINT RESOLUTION/MEMORY REQUIREMENTS:
PCL5 and PostScript Level 2:  (On/Off refers to Page Protect)

Page   Simplex  Duplex  Simplex  Duplex  Simplex  Duplex
DPI      300     300     600       600     1200    1200
ON:      4MB     4MB     4MB       4MB     12MB    12MB
OFF:     4MB     4MB     4MB       4MB     12MB    12MB

       The standard 4MB of memory will allow some 1200 dpi print jobs to print successfully.  However, an additional 8MB of memory is recommended for complex print jobs and to increase the probability that most print jobs will print.

Font cards (bitmapped or scalable fonts)
1364915 Font Card Adapter

Adobe PDF Level Support
  I had been having a helluva time in getting my R+ to print the newer PDFs. A lot of "BUSY" with no output, documents failing within Print Monitor, and "PRINT BUFFER" . Lots of weak swearing and re-installation of drivers didn't fix it.

  Try using GhostScript / GhostGum to convert the file from PDF level 1.5 (Acrobat 6.x) to PDF level 1.2 (Acrobat 3.0). Once I did that, my R+ started to accept and print at 10PPM in duplex.

Internal Network Adapters (INAs) or Internal Option Port (IOP)

How to configure TCP/IP on the Marknet XL through the printer Operator Panel ID: ENUS286

1. Select Menus, More, Network Menu X (where X represents the slot in which the network adapter is installed).
2. Select More, and then IP Protocol.

• Use the buttons next to the '+' and '-' keys to assign each octet by moving upwards from 0 or decreasing from 255 to reach the correct number.
• Use the button next to the right arrow to tab to the next octet and then save the IP address when the correct number has been added to each octet.
  Repeat for the Netmask and Gateway.

1381050 - localtalk

1402217 Token Ring 16/4

1402218 10baseT ethernet only / 1446702 Combo 10baseT and 10base2

13A0294 - SCS (BNC or twinax, no cable adapter)

13A0295 - IPDS (BNC or twinax, no adapter)

    The parallel/serial cable port is the funky "beam" type used on the Server 500 backplane for the DASD Status cable header. Mine had a Smart SM532512LP-7 with four NEC 424260-70 chips, two front, two back. Pins 68 and 69 are grounded.
This card has IBM stickers all over. The actual manufacturer is idata a/s, Denmark
IPDS Memory:  4MB or 8MB option.  1 IPDS memory slot on IPDS cards.  2MB is standard.  The 2MB may be replaced with the 4MB or 8MB option.

   A change to the physical memory media type used on the IPDS feature was phased in around the Jan/96 time frame. New machine orders requiring additional IPDS memory should use Feature Code 4040 or 4050.  MES/Field upgrades requiring IPDS memory changes need to first determine what level IPDS feature card is installed to determine which style memory media type is required.  One or two techniques can be used to determine the IPDS feature card level:

    1) Open the side of the printer and physically measure the length of the IPDS/attachment card.  If the card is approximately 6" to 6.5" in length, then the new media style is required and feature codes 4040 or 4050 should be ordered.  If the card is approximately 8" in length, then the original memory features are installed and feature codes 4304 (4 MB ASCII Memory) or 4308 (8 MB ASCII Memory) should be ordered.

  2) By printing the IPDS PRINT MENUS, the micro-code level can be found and used to determine which IPDS memory media type is required (MENUS/NETWORK MENU 1/TEST MENU/PRINT MENUS).  The second page that prints out, is titled IPDS - MENU SETTINGS. Next to the "Firmware Version" you'll find some numbers that reference the exact micro-code level.  Find the first number that has 106.XXX.  If the .XXX is equal to or greater than 004, then the new media style is required and feature codes 4040 or 4050 should be ordered.  If the .XXX is less than 004, then the original memory features are installed and feature codes 4304 (4 MB ASCII Memory) or 4308 (8 MB ASCII Memory) should be ordered.

13A0296, 0297, 0298 SCS or IPDS adapters for DE9 to twinax, BNC or DE9 setup.

BTW, the rear envelope feeder that fits the 4039's in yukky green/olive are the same thing as the pretty beige and blue ones sold for the 4049 Optras, just different pigment in the plastic.

The envelope feeder will have a picture of an envelope on the feeder.
 The 100 Sheet feeder will have a picture of a piece of paper. 
 1408893 Envelope+ Feeder
 1364895 100-Sheet Auxiliary Feeder

 Once you get a 10baseT card get the MarkVision software, setup a network address, and then let the software auto-detect the options in the printer. Less crap to deal with and you can tell hpw the print server is responding with the printer.

Toner Cartridges

There are two toner cartridges for the Optra series.  P/N 1382100 is a 7000 page cartridge (at 5% coverage).  P/N 1382150 is a 14000 page cartridge (at 5% coverage). This single unit contains the drum and toner supply.  No other items are required. (Ed. I have seen a Lexmark box with PN 1382650, listing the Rx/+, Lx/+ etc. Replaces Part numbers 1380950 and 1382150. These cartriges are/were 1380950's which are taken back by Lexmark and totally reconditioned/ remanufactured)
   These cartridges work with the Lexmark Optra R+, Optra Rn+, Optra Rt+, Optra Lx+, Optra Lxi+, Optra Lxn+, 4039 10plus, 3112 and 3116 printers.

   The R+ comes standard with collating on board so if you are printing multiple copies of a duplexed report the Optra can handle it.  Operating cost;  if you use the 7,000 page toner cartridge the cost per page is about .03 cents.  If you use the 14,000 page toner cartridge the cost per page goes down to about .02 cents (that includes paper0  you need not worry about additional parts that need to be replaced  because when the toner cartridge is replaced about 70% of the print process is also replaced - thus assuring the user of consistently clear, crisp output.

Duplex Unit

You MUST have both the duplex unit (part # 1408904) and the tray, or it WON'T work!

Duplex Feed Unit P/N 1408904

   The duplexor is very easy to remove/reinstall. The printer software does "Plug 'n Play" on it. You have the duplexor itself and a duplexor tray. Pull the standard tray out, put the duplexor tray in. Remove the front exit cover, open the top cover, pop the two small plastic guards that cover the guides where you hang the duplexor, "hang" the duplexor on the printer. The biggest trick would be not losing the front exit cover or the two small plastic covers while you are duplexing.

  You really need the 500 sheet lower tray if you are serious about big duplex jobs. The duplex tray can only hold 75 sheets. What I do is store a different type of paper in the duplexor, and the plain paper in the 500 sheet lower tray.

Duplexor Sounds Like Machinegun!

  I was preparing to massacre another ream of paper when my duplexor started to make noises like a gear was jumping. Puzzled, I unhooked the motor unit, worked the gears, and didn't find a problem. Reinstalled the duplex motor unit and tried to print. It rattled for about 15 (very long) seconds before it set Error 23 and stopped.

  Flipped open the top cover on the duplex tray assembly, and I saw the roller had ripped apart and the chunk had jammed in the roller opening in the top cover. The gear is well designed, where it is held in place by spring tension, so if it's jammed for whatever reason, it can bounce against a spring instead of grinding teeth. Good job, Lexmark!

  When I find out the part number or source for replacement rollers, I'll post it.

Envelope Feeder

All you do is remove the rear manual tray and slip this in it's place, then plug the little cable into the Env/AUX connector and the driver should auto-magically recognize it. If not cycle the  power and it should then.

Jeffrey M. Wells wrote:
   I'm not certain if this pertains to the LJ5L, but I just bought a Lexmark Optra R+, a bad-ass machine to be sure.  After a week or so, I tried an envelope in the manual feeder, letting it exit out the front tray.  This printer began making a loud clicking noise, as if someone were inside with a tackhammer, very periodic, about five clicks per envelope.  These clicks were strong enough to rattle my desk.  I called Lexmark and they told me that this was a FEATURE, called "Envelope Enhance".  The fuser rollers exert about 25lbs of pressure during a print cycle and air bubbles can build up in envelopes causing wrinkling - but the "Envelope Enhance" feature fires a solenoid which releases the fuser bar for a split- second four or five times per envelope to make sure no air build-up occurs.  Envelopes printed on my LaserJet III do invariably wrinkle in one corner, but the Lexmark prints them perfectly so it seems to work, but it sounds like the thing is about to croak!  It turns out that if I feed a regular sheet of paper in the manual tray before telling the printer it is a normal sheet (through software) and not an envelope, it will assume that it is an envelope (just to be safe, I guess) and begin its clicking - so if I did a lot of manual feeding, I would hear it often.

Envelope steady state print rate is slightly reduced because of the heavier demand toward keeping the fuser hot. After a certain number of envelopes are processed the print speed reduces by about 50%. An envelope does not pass across the full width of the machine's fuser, therefore the portion of the fuser that is not cooled by passing the envelope will continue to heat.

Win95 Drivers

Gary R. Webster wrote:
   Windows 95 does not support 32-bit printer drivers.  Lexmark does, however, have two packages on our bulletin board, ftp site, and web site which contain 16-bit PostScript printer driver files, written specifically for Windows 95.  The package names are MPWN95AE.EXE and MPLX952E.EXE.  These packages are different from the previous 16-bit packages that worked in Windows 3.1x.

MPWN95AE.EXE contains the .SPD files for use with Microsoft's PostScript driver (PSCRIPT.DRV) which ships with the operating system.  There is also a readme.1st file which describes how to install the printer driver for your printer.

MPLX952E.EXE contains Lexmark's custom PostScript Level 2 printer driver (LEXPS). This package will contain all of the files necessary to install that driver.  There is a file in the package called readme.1st which contains a list of all of the files that will be installed for this driver.  This file also contains information on how to install.

Hard Disk Option 1381856 100MB, (40MB Drive No Longer Available)

Supports up to 1,023KB on the Optra, Optra Plus (firmware level up through 52.29).

I found my Hard Disk option on ebay, popped it in, and was hit by Error 64 Defective Disk. I  tried reseating it in the carrier, but it refused to clear. I then swapped it out and installed a 100MB Type II PCMCIA drive (originally for a 730 TE), and powered back up. Then it displayed Error 63 Unformatted Disk, I cycled to Test Menu, then to Format Disk, hit the button, and now it works.

Error 64 Defective Disk

The printer has determined that the hard disk is defective.

• Power the printer off and reseat the disk.
  If the message is displayed again when the printer is powered on, replace the hard disk.

To use the disk:

1. Format the disk (see below).
2. Send the data again.

The Format Disk menu item only appears when the printer detects that a Disk Option is installed. Formatting deletes all resources stored on the disk and prepares the disk to receive new resources. The Format Disk option can be found in the printer's Test Menu.

Warning! If you select Format Disk and then Continue, any data stored in the disk is lost. Do not turn off the printer while the disk is formatting.

Optra Printer Using a 4039 Cartridge

Beginning with engine code level 43.74, 4039 cartridges will now print in Optra machines.
      *The 4039 cartridge is generally not recommended for use in Optra, especially not for 1200 dpi applications. For heavy graphics use, continue to use the Optra toner cartridge for the best print quality.
   *The 4039 cartridge may be used for some special applications, such as label or cardstock printing. Also, it is important to use the 4039 fuser wiper that comes packaged with the 4039 cartridge.
   *Machines that have earlier code levels may have the new code flashed to upgrade them.
   Use a 4039 print cartridge (part number 1380850 or 1380950) in Optra and Optra plus laser printers that are dedicated to printing labels. Machine engine code level 43.74 or higher is required to use the 4039 cartridges in your Optra and Optra plus printer. Print the menus page from the Tests Menu to determine the level of engine code installed in your printer.

Calibration

Timo Autiokari
   The Optra R+ (and most of the Lexmark new PS printers) *can* be calibrated. It is easy, one only needs to send the calibration data as a PostScript file to the printer, there after the printer is calibrated until it is powered off. If the printer has a flash memory card or a hard disk the calibration can be written in either and it will be persistent until it is changed.

Howard C. Cochran
   I would like to point out that Lexmark laser printers are designed to provide a nearly linear gray curve, so long as one of the printer's builtin halftone screens is used.
   In Mr. Autiokari's case, he configured the driver for a higher screen frequency of 130 lpi.  Such user-defined screens are uncalibrated, so they can appear dark due to dot gain.  If you stick to the printer's built-in screen, calibration is generally unnecessary.

Update Engine Code on Optra R+

If something has happened to the engine code stored on the printer engine board, or if you have an older code level on your printer, it is possible to send new code to the printer without having it serviced. In order to be able to send new engine code to the printer, you will need the following:

• a direct parallel connection using a PC with command prompt access.
• a network connection to the printer

Downloading the Code

1. Download optengn.zip.
2. Save optengn.zip to a directory of your choice.
3. Extract the zipped file to an easily accessed directory.
4. Read the Readme file for full instructions on how to flash the file over to the printer.
   

Downloaded Files

P4394-12.PJL - This is the engine code for the Optra R and L only (the 12 page per minute printers).
P4394-16.PJL  - This is the engine code for the Optra Rx, Lx, Lxi, R+, Rt+, Rn+, Lx+, Lxn+, and Lxi+ only (the 16 page per minute printers).
README.1ST -  This is a text file explaining installation from diskette.

Installing the Engine Code

The installation directions in the engine code file are as follows:

1. Go to a DOS prompt.
2. Change directory to the one containing the engine code files.
3. Turn the printer on and make sure it is connected and in the Ready state. Note: Make sure you are using a high quality (IEEE 1284) 6 foot cable or Lexmark's 10 foot cable.
4. Type the following command, depending on which OPTRA you are updating:
   
   OPTRA R or L: Copy P4394-12.PJL /B LPTx
   OPTRA Rx,Lx,Lxi,R+,Rt+,Rn+,Lx+,Lxn+ or Lxi+: Copy P4394-16.PJL /B LPTx
   
   Note: The  in the above commands represents the port to which you are copying; this port can be physical, redirected, or captured.
   
5. The printer display panel should read Programming Engine Code. Note: Do not power off the printer or touch any menus during this operation. If the printer does not return to Ready after 15 minutes, it is safe to turn the printer off and back on.
6. When the printer returns to the Ready state, print the menu settings page. To print the menu settings page: 
1. Press the button next to Menus.
2. If you do not see Test Menus, press More until you find it. Now select Test Menus.
3. Press the More button until you find Print Menus. Select Print Menus.
7. The appropriate updated engine code should be displayed in the bottom right corner of the menu settings page.  Make sure the engine code on this printer has been updated - that is, an engine code level of 43.94 should be displayed. 

Using a TCP/IP or network connection

You can also attempt this upgrade using a TCP/IP or network connection, provided you know the TCP/IP address of the printer. Note: Lexmark recommend upgrading the engine code using a direct parallel connection whenever possible. To perform the engine code upgrade using a TCP/IP or network connection:

1. Go to Start, Programs, MSDos Prompt. 
2. Change to the directory that contains the engine code file. 
3. Type ftp (address) and then press ENTER twice.
   For example: ftp 157.184.29.127 
4. Type bin and press ENTER.  
5. Type put (depending on which OPTRA you are updating) and press ENTER.
   
   For the OPTRA R or L, type:  put P4394-12.PJL
   For the OPTRA Rx,Lx,Lxi,R+,Rt+,Rn+,Lx+,Lxn+ or Lxi+, type:  put P4394-16.PJL
   
   The printer should now read Upgrading Engine Code.

Update INA Firmware to 79.135

INA_XL.EXE INA firmware version 79.135

This document assumes the firmware revision has already been downloaded and expanded on the local hard drive. For a list of which firmware extensions go with which adapter, refer to the list at the end of this document.

Flash memory is a type of ROM (read-only memory) that can be electronically erased and reprogrammed. The flash memory in the network adapter contains the firmware that operates it. This firmware communicates with the network, the printer, and the network utility.  When the firmware is updated, the flash memory on the network adapter is reprogrammed.  This procedure overwrites old firmware and replaces it with the upgraded version.  Although many adapters can accept each firmware file, there are some intermediate levels that must be reached before the adapter can accept the current level, as explained below.

• The MarkNet S adapter must be flashed to 1.9.14 before it can accept any higher level of firmware. 
• The MarkNet Pro adapters must also be flashed to 2.9.14 before it can be set to the current level. 
• When a PJL file is flashed, the intermediate level is not necessary.
• The MarkNet XL must be flashed to 15.84 before it can be flashed to 79.* levels. 

Warning! While the code is being updated, be careful not to turn the adapter (or printer) off!

After reprogramming, all of the network adapter's settings should be saved; however, this is not always the case.  Be sure to print a network settings page before starting the procedure in order to compare it with network settings after the firmware update.

From Windows

From most Windows operating systems as well as OS/2,  MarkVision Classic and MarkVision Professional can be used to update the print server firmware. Firmware can also be sent using a TFTP session from Windows NT, 2000 and XP. For the MarkNet S series, N series, Pro series, and X series adapters, the internal web interface is another option for updating firmware.  Some adapters also accept PJL files which can be sent via FTP and over a parallel port.

• This document outlines MarkVision update procedures.
• This document provides information on the TFTP procedures.
• This document provides information on the web interface update procedure.
• This document provides information on updating with a parallel connection.

Via FTP

For adapters that support PJL files, an FTP session can be used to update print server firmware. First download and expand the PJL file to a local directory on the hard drive.  This file is usually available for download from our FTP site as *pjl.exe under the firmware directory for each adapter. It is useful to start the FTP session from within the directory where the PJL file has been saved.  For example, if you were upgrading a MarkNet Pro adapter to 1.10.17 code, and the 1_10_17.pjl flash file was in the C:\inaflash directory, you would perform the following steps from a command prompt:

1. From the C:\inaflash directory, type ftp <ip address> replacing the words in brackets with the IP address of the adapter. 
2. Press ENTER.  A Connected status message should appear, prompting for a login ID.
3. Press ENTER to log in as an anonymous user.
4. Type bin to set up a binary transfer.
5. Type put <filename.pjl> where <filename> is the PJL file from the Lexmark site. Press ENTER.
6. When the transfer is complete, type bye to exit the FTP session.

Important! These commands should be implemented quickly as the FTP session may time out. A connection closed by remote host error indicates that the session has timed out and must be initiated again.

Paper Does Not Pick Up from Tray

If you are experiencing the problem that the paper does not pick up from the paper tray, you probably need to replace the rubber band-like part that grabs the paper. You can fix it yourself. Just order part 69G5480 for the built-in paper tray, or part 1039540 for the optional extra tray. You will get extra parts with the 69G part, but that's the only way to order it.

Transparencies

Lexmark has a new transparency that is exclusively for Optra 4049 printer cartridges. It is made by 3M Company with the Lexmark name and part number -- 1402810 (8.5 X 11), and 1402809 (A4).

This particular foil will NOT be recommended for 4019, 4029 or 4039 printers. It has been thoroughly tested and approved by 3M and Product Assurance and shown to provide high quality for the demands of our Optra customers, even with 1200 dpi.