HP Color LaserJet Enterprise M651, Color LaserJet Enterprise MFP M680 Troubleshooting Manual. Repair Manual

Color LaserJet Enterprise M651 Color LaserJet Enterprise MFP M680

Troubleshooting Manual

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M651xhM651n

M680zM680fM680dn

HP Color LaserJet Enterprise M651 and MFP M680

Troubleshooting Manual

Reproduction, adaptation, or translation without prior written permission is prohibited, except as allowed under the copyright laws.

The information contained herein is subject to change without notice.

The only warranties for HP products and services are set forth in the express warranty statements accompanying such products and services. Nothing herein should be construed as constituting an additional warranty. HP shall not be liable for technical or editorial errors or omissions contained herein.

Edition 1, 4/2014

Conventions used in this guide

TIP: Helpful hints or shortcuts.

Reinstallation tip Reinstallation helpful hints, shortcuts, or considerations.

NOTE: Information that explains a concept or how to complete a task.

IMPORTANT: Information that help the user to avoid potential product error conditions.

CAUTION: Procedures that the user must follow to avoid losing data or damaging the product.

WARNING! Procedures that the user must follow to avoid personal injury, catastrophic loss of data, or

extensive damage to the product.

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Table of contents

1 Theory of operation ....................................................................................................................................... 1

Basic operation ...................................................................................................................................................... 2

Sequence of operation ........................................................................................................................ 4

Formatter-control system ..................................................................................................................................... 5

Formatter hardware ............................................................................................................................ 5

Sleep mode ....................................................................................................................... 6

Input/output ...................................................................................................................... 6

CPU .................................................................................................................................... 6

Memory ............................................................................................................................. 6

Firmware ........................................................................................................................... 6

Nonvolatile memory ......................................................................................................... 7

PJL overview ..................................................................................................................... 7

PML .................................................................................................................................... 7

Control panel ....................................................................................................................................... 7

Engine-control system .......................................................................................................................................... 8

DC controller ........................................................................................................................................ 9

Solenoids ......................................................................................................................... 10

Clutches ........................................................................................................................... 10

Switches .......................................................................................................................... 10

Sensors ............................................................................................................................ 11

Motors ............................................................................................................................. 12

Fans ................................................................................................................................. 13

High-voltage power supply ............................................................................................ 14

Low-voltage power supply ............................................................................................. 16

Over-current/over-voltage protection ........................................................ 17

Safety ............................................................................................................ 17

Function ........................................................................................................ 18

Voltage detection ......................................................................................... 18

Sleep (power save) mode ............................................................................. 18

Low-voltage power supply failure ............................................................... 19

Fuser control ................................................................................................................... 19

Fuser temperature control ........................................................................... 20

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Fuser sleeve temperature protection .......................................................... 20

Failure detection .......................................................................................... 21

Fuser unit identification ............................................................................... 22

Fuser unit life detection ............................................................................... 22

Laser/scanner system ......................................................................................................................................... 23

Laser/scanner failure ........................................................................................................................ 24

Protective-glass cleaners ................................................................................................................. 25

Image-formation system .................................................................................................................................... 26

Image formation process .................................................................................................................. 28

Step 1: Pre-exposure ...................................................................................................... 29

Step 2: Primary charging ................................................................................................ 29

Step 3: Laser-beam exposure ........................................................................................ 30

Step 4: Development ...................................................................................................... 30

Step 5: Primary transfer ................................................................................................. 31

Step 6: Secondary transfer ............................................................................................. 31

Step 7: Separation .......................................................................................................... 32

Step 8: Fusing .................................................................................................................. 32

Step 9: ITB cleaning ........................................................................................................ 33

Step 10: Drum cleaning .................................................................................................. 33

Toner cartridges ................................................................................................................................ 34

Memory tag ..................................................................................................................... 35

Developing unit engagement and disengagement control ........................................... 35

Intermediate transfer belt (ITB) unit ................................................................................................ 37

Primary transfer roller engagement and disengagement control ................................ 37

ITB cleaning mechanism ................................................................................................. 40

Calibration ......................................................................................................................................... 40

Color-misregistration control ........................................................................................ 41

Image stabilization control ............................................................................................. 42

Pickup, feed, and delivery system ...................................................................................................................... 43

Pickup-and-feed unit ........................................................................................................................ 48

Cassette pickup ............................................................................................................... 48

Cassette-presence detection ....................................................................... 49

Cassette lift operation and cassette paper-presence detection ................ 50

Cassette multiple-feed prevention .............................................................. 51

Multipurpose tray pickup ................................................................................................ 51

Paper feed ....................................................................................................................... 52

Skew-feed prevention .................................................................................. 54

Paper detection ............................................................................................ 55

Feed speed control ....................................................................................... 55

Fusing and delivery block ................................................................................................................. 56

Loop control .................................................................................................................... 57

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Pressure roller pressurization and depressurization control ....................................... 58

Duplex Block ...................................................................................................................................... 59

Duplex reverse and duplex feed control ........................................................................ 60

Duplex operation ............................................................................................................ 61

Jam detection .................................................................................................................................... 62

Optional paper feeders ........................................................................................................................................ 64

Motor control ..................................................................................................................................... 68

Paper-feeder pickup and feed operation ......................................................................................... 69

Paper-size detection and cassette-presence detection .................................................................. 71

Paper-feeder cassette lift operation ................................................................................................ 73

Paper feeder jam detection .............................................................................................................. 74

Scanning/image capture system (M680) ............................................................................................................ 77

Scanner .............................................................................................................................................. 77

Document feed system ..................................................................................................................... 77

Sensors in the automatic document feeder ................................................................... 77

Automatic document feeder paper path ........................................................................ 79

Automatic document feeder simplex operation ............................................................ 79

Automatic document feeder e-duplex operation .......................................................... 80

Front-side and back-side background selector ............................................................. 81

Deskew operation ........................................................................................................... 82

Automatic document feeder hinges ............................................................................... 83

Stapling mailbox (M680) ..................................................................................................................................... 85

Motor control ..................................................................................................................................... 87

Failure detection ............................................................................................................................... 87

Delivery operation ............................................................................................................................. 88

Staple operation ............................................................................................................. 90

Stapler ............................................................................................................................. 94

Output bin 3 lift operation .............................................................................................. 95

Stacker mode .................................................................................................................................... 96

Mailbox/job separator mode ............................................................................................................ 97

Jam detection .................................................................................................................................... 98

Automatic delivery ............................................................................................................................ 99

2 Solve problems .......................................................................................................................................... 101

Solve problems checklist .................................................................................................................................. 102

Menu map .......................................................................................................................................................... 105

Current settings pages ...................................................................................................................................... 105

Event log ............................................................................................................................................................ 105

Pre-boot menu options ..................................................................................................................................... 107

Remote Admin ................................................................................................................................. 115

Required software and network connection ................................................................ 115

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Telnet client ................................................................................................ 116

Network connection ................................................................................... 117

Connect a remote connection ...................................................................................... 117

Disconnect a remote connection .................................................................................. 122

Troubleshooting process .................................................................................................................................. 124

Determine the problem source ....................................................................................................... 124

Troubleshooting flowchart .......................................................................................... 124

Power subsystem ............................................................................................................................ 125

Power-on checks .......................................................................................................... 125

Power-on troubleshooting overview ......................................................... 125

Scanning subsystem (M680) ........................................................................................................... 129

Control panel checks ....................................................................................................................... 129

Control panel diagnostic flowcharts ............................................................................ 133

Touchscreen black, white, or dim (no image) ............................................ 134

Touchscreen is slow to respond or requires multiple presses to

respond ....................................................................................................... 135

Touchscreen has an unresponsive zone .................................................... 136

No control panel sound .............................................................................. 137

Home button is unresponsive .................................................................... 138

Hardware integration pocket (HIP) is not functioning (control panel

functional) .................................................................................................. 139

Tools for troubleshooting ................................................................................................................................. 140

Individual component diagnostics .................................................................................................. 140

LED diagnostics ............................................................................................................. 140

Understand lights on the formatter .......................................................... 140

Engine diagnostics ........................................................................................................ 145

Defeating interlocks ................................................................................... 145

Disable cartridge check .............................................................................. 146

Engine test button ...................................................................................... 147

Paper path test ............................................................................................................. 148

Paper path sensors test ............................................................................................... 148

Manual sensor and tray/bin manual sensor tests ....................................................... 150

Manual sensor test ..................................................................................... 150

Tray/bin manual sensor test ...................................................................... 152

Print/stop test .............................................................................................................. 154

Component tests .......................................................................................................... 155

Component test (special-mode test) ......................................................... 155

Scanner tests (M680) .................................................................................................... 158

Scanner tests .............................................................................................. 158

Diagrams ......................................................................................................................................... 160

Block Diagrams ............................................................................................................. 160

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Sensors and switches ................................................................................. 160

Cross section diagrams .............................................................................. 165

Location of connectors ................................................................................................. 169

DC controller PCA ....................................................................................... 169

Intermediate paper transport unit (ITPU) driver PCA (M680) ................... 172

Accessories controller PCA ......................................................................... 173

3-bin stapling mailbox accessory (M680) ................................................. 174

Formatter connections ................................................................................................. 176

Location of major components .................................................................................... 178

Base product .............................................................................................. 178

1x500-sheet paper feeder ......................................................................... 181

1x500-sheet paper deck ............................................................................ 182

2,500-sheet high-capacity feeder (HCI) .................................................... 183

3-bin stapling mailbox accessory (M680) ................................................. 184

General timing chart ..................................................................................................... 185

Circuit diagrams ............................................................................................................ 186

Internal print-quality test pages .................................................................................................... 191

Print quality troubleshooting pages ............................................................................ 191

Print quality assessment page ..................................................................................... 194

Cleaning page ............................................................................................................... 196

Enable and configure auto cleaning .......................................................... 196

Print a configuration page ............................................................................................ 197

Configuration page ..................................................................................... 197

HP embedded Jetdirect page ..................................................................... 200

Finding important information on the configuration pages ..................... 202

Color band test ............................................................................................................. 202

Print quality troubleshooting tools ................................................................................................ 203

Print quality troubleshooting tools: repetitive defects ruler ...................................... 203

Calibrate the product to align the colors ..................................................................... 204

Control-panel menus ...................................................................................................................... 205

Administration menu .................................................................................................... 205

Reports menu ............................................................................................. 205

General Settings menu ............................................................................... 208

Copy Settings menu (M680 only) ............................................................... 222

Scan/Digital Send Settings menu (M680) .................................................. 229

Fax Settings menu (M680) ......................................................................... 240

General Print Settings menu ...................................................................... 253

Default Print Options menu ....................................................................... 256

Display Settings menu ............................................................................... 258

Manage Supplies menu .............................................................................. 260

Manage Trays menu ................................................................................... 266

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Network Settings menu ............................................................................. 268

Troubleshooting menu ............................................................................... 280

Device Maintenance menu ............................................................................................ 284

Backup/Restore menu ............................................................................... 284

Calibration/Cleaning menu (M680) ............................................................ 285

Calibration/Cleaning menu (M651) ............................................................ 288

USB Firmware Upgrade menu .................................................................... 289

Service menu .............................................................................................. 289

Print quality troubleshooting tools: interpret control-panel messages and event log entries . . . 290

Control-panel message types ...................................................................................... 290

Control-panel messages and event log entries ........................................................... 290

10.XX.YZ Error Messages ........................................................................... 290

11.XX.YZ Error Messages ........................................................................... 298

13.WX.YZ Error Messages .......................................................................... 298

20.XX.YY and 21.XX.YY .............................................................................. 318

30.XX.YZ Error Messages ........................................................................... 319

31.XX.YZ Error Messages ........................................................................... 326

32.08.XX Error Messages ........................................................................... 332

33.XX.YZ Error Messages ........................................................................... 337

41.XX.YZ Error Messages ........................................................................... 340

42.XX.YY Error Messages ........................................................................... 348

44.XX.XX Error Messages ........................................................................... 349

47.XX.XX Error Messages ........................................................................... 350

48.XX.YY Error Messages ........................................................................... 352

49.XX.YY Error Messages ........................................................................... 353

50.WX.YZ Error Messages .......................................................................... 354

51.XX.YZ, 52.XX.YZ Error Messages .......................................................... 360

54.XX.YZ Error Messages ........................................................................... 361

55.XX.YZ, 56.XX.YZ Error Messages .......................................................... 364

57.XX.YZ Error Messages ........................................................................... 365

58.XX.YY & 59.XX.YZ Error Messages ........................................................ 367

60.00.0Y, 62.00.00 Error Messages .......................................................... 371

65.X0.AZ Error Messages ........................................................................... 373

70.XX.YY Error Messages ........................................................................... 374

80.XX.YY, 82.XX.YY Error Messages .......................................................... 374

98.0X.0Y Error Messages ........................................................................... 375

99.XX.YY Error Messages ........................................................................... 376

Alpha Error Messages ................................................................................. 384

Print quality troubleshooting tools: event log messages ............................................................. 430

Print or view an event log ............................................................................................. 431

Clear the event log ........................................................................................................ 431

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Clear jams .......................................................................................................................................................... 432

Auto-navigation for clearing jams .................................................................................................. 432

Experiencing frequent or recurring paper jams? ............................................................................ 432

Jam sensor locations ...................................................................................................................... 433

Paper path sensor locations ......................................................................................... 433

Jam locations (M680) ...................................................................................................................... 438

Jam locations (M651) ...................................................................................................................... 439

Clear jams in Tray 1 ......................................................................................................................... 440

Clear jams in Tray 2 and the 500-sheet trays ................................................................................ 442

Clear jams in the 1,500-sheet high-capacity input tray and the lower-right door ....................... 447

Clear jams in the lower-right door .................................................................................................. 451

Clear jams in the right door and the fuser area .............................................................................. 452

Clear jams from under the top cover (M680) ................................................................................. 455

Clear jams in the document feeder (M680) .................................................................................... 456

Clear jams in the output bin (M680) ............................................................................................... 460

Clear jams in the output bin (M651) ............................................................................................... 460

Clear jams in the stapling mailbox accessory (M680) .................................................................... 461

Clear staple jams in the stapling mailbox accessory (M680) ......................................................... 463

Change jam recovery ....................................................................................................................... 466

Paper feeds incorrectly or becomes jammed ................................................................................................... 467

The product does not pick up paper ............................................................................................... 467

The product picks up multiple sheets of paper .............................................................................. 467

The document feeder jams, skews, or picks up multiple sheets of paper (M880) ........................ 468

Prevent paper jams ......................................................................................................................... 468

Use manual print modes ................................................................................................................................... 469

Solve image quality problems .......................................................................................................................... 473

Image defects table ........................................................................................................................ 473

Clean the product .............................................................................................................................................. 491

Print a cleaning page ...................................................................................................................... 491

Check the scanner glass for dirt or smudges (M680) ..................................................................... 492

Clean the pickup rollers and separation pad in the document feeder (M680) .............................. 494

Clean the pickup, feed, and separation rollers in the 1x500-sheet paper-feeder and 1x500-

sheet paper-feeder with storage cabinet ...................................................................................... 496

Clean the pickup, feed, and separation rollers in the 2,500-sheet high-capacity feeder (HCI) .... 497

Solve performance problems ............................................................................................................................ 498

Solve connectivity problems ............................................................................................................................. 499

Solve USB connection problems ..................................................................................................... 499

Solve wired network problems ....................................................................................................... 499

Poor physical connection ............................................................................................. 499

The computer is using the incorrect IP address for the product ................................. 499

The computer is unable to communicate with the product ........................................ 500

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The product is using incorrect link and duplex settings for the network ................... 500

New software programs might be causing compatibility problems ........................... 500

The computer or workstation might be set up incorrectly .......................................... 500

The product is disabled, or other network settings are incorrect ............................... 500

Service mode functions ..................................................................................................................................... 501

Service menu ................................................................................................................................... 501

Product resets ................................................................................................................................. 506

Restore factory-set defaults ........................................................................................ 506

Restore the service ID ................................................................................................... 507

Product cold reset ........................................................................................................ 507

Format Disk and Partial Clean functions ........................................................................................ 508

Active and repository firmware locations .................................................................... 508

Partial Clean .................................................................................................................. 508

Execute a Partial Clean ............................................................................... 509

Format Disk ................................................................................................................... 509

Execute a Format Disk ................................................................................ 510

Solve fax problems (M680) ............................................................................................................................... 511

Checklist for solving fax problems ................................................................................................. 511

What type of phone line are you using? ....................................................................... 511

Are you using a surge-protection device? .................................................................... 511

Are you using a phone company voice-messaging service or an answering

machine? ....................................................................................................................... 511

Does your phone line have a call-waiting feature? ..................................................... 511

Check fax accessory status .......................................................................................... 512

General fax problems ...................................................................................................................... 513

The fax failed to send ................................................................................................... 513

An Out of Memory status message displays on the product control panel ................ 513

Print quality of a photo is poor or prints as a gray box ............................................... 513

You touched the Stop button to cancel a fax, but the fax was still sent ..................... 513

No fax address book button displays ........................................................................... 513

Not able to locate the Fax settings in HP Web Jetadmin ............................................. 513

The header is appended to the top of the page when the overlay option is enabled 513

A mix of names and numbers is in the recipients box ................................................. 513

A one-page fax prints as two pages ............................................................................. 514

A document stops in the document feeder in the middle of faxing ............................ 514

The volume for sounds coming from the fax accessory is too high or too low .......... 514

Use Fax over VoIP networks ........................................................................................................... 515

Problems with receiving faxes ........................................................................................................ 516

Problems with sending faxes ......................................................................................................... 518

Fax error messages on the product control panel ......................................................................... 519

Send-fax messages ...................................................................................................... 520

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Receive-fax messages .................................................................................................. 521

Service settings ............................................................................................................................... 522

Settings in the Troubleshooting menu ........................................................................ 522

Firmware upgrades ........................................................................................................................................... 523

Determine the installed revision of firmware ................................................................................ 523

Perform a firmware upgrade .......................................................................................................... 523

HP Embedded Web Server ............................................................................................ 523

USB flash drive (Pre-boot menu) ................................................................................. 524

USB flash drive (control-panel menu) .......................................................................... 525

Appendix A Product specifications ................................................................................................................. 527

Product dimensions ........................................................................................................................................... 528

Product space requirements ............................................................................................................................. 529

Power consumption, electrical specifications, and acoustic emissions .......................................................... 530

Environmental specifications ............................................................................................................................ 530

Certificate of Volatility ...................................................................................................................................... 531

Index ........................................................................................................................................................... 535

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List of tables

Table 1-1 Sequence of operation ......................................................................................................................................... 4

Table 1-2 Formatter hardware components ....................................................................................................................... 5

Table 1-3 Solenoids ............................................................................................................................................................ 10

Table 1-4 Clutches .............................................................................................................................................................. 10

Table 1-5 Switches ............................................................................................................................................................. 10

Table 1-6 Sensors ............................................................................................................................................................... 11

Table 1-7 Motors ................................................................................................................................................................ 12

Table 1-8 Fans .................................................................................................................................................................... 13

Table 1-9 High-voltage power supply circuits ................................................................................................................... 14

Table 1-10 Converted DC voltages ..................................................................................................................................... 17

Table 1-11 Low-voltage power supply functions .............................................................................................................. 18

Table 1-12 Fuser components ........................................................................................................................................... 19

Table 1-13 Image formation process ................................................................................................................................. 28

Table 1-14 Primary-transfer roller engagement states ................................................................................................... 38

Table 1-15 Image-stabilization controls ........................................................................................................................... 42

Table 1-16 Switches and sensors for the pickup, feed, and delivery system ................................................................... 45

Table 1-17 Motors and solenoids for the pickup, feed, and delivery system ................................................................... 46

Table 1-18 Cassette-presence detection ........................................................................................................................... 49

Table 1-19 Print mode and feed speed .............................................................................................................................. 55

Table 1-20 Paper sizes ....................................................................................................................................................... 61

Table 1-21 Jams that the product detects ......................................................................................................................... 63

Table 1-22 Electrical components for the paper feeder ................................................................................................... 65

Table 1-23 Electrical components for the 2,500-sheet paper feeder HCI ........................................................................ 67

Table 1-24 Motor control (1x500-sheet paper feeder) ..................................................................................................... 68

Table 1-25 Motor control (2,500-sheet paper feeder HCI) ................................................................................................ 68

Table 1-26 Pickup feed components (1x500-sheet paper feeder) ................................................................................... 69

Table 1-27 Pickup feed components (2,500-sheet paper feeder HCI) .............................................................................. 70

Table 1-28 Paper-size detection and cassette-presence detection (1 x 500 paper feeder) ............................................ 71

Table 1-29 Paper-size detection and cassette-presence detection (2,500-sheet paper feeder HCI) ............................. 72

Table 1-30 Automatic document feeder sensors .............................................................................................................. 78

Table 1-31 Automatic document feeder paper path ......................................................................................................... 79

Table 1-32 Automatic document feeder deskew features ................................................................................................ 82

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Table 1-33 Electrical components for the stapling mailbox ............................................................................................. 86

Table 1-34 Motor control (stapling mailbox) ..................................................................................................................... 87

Table 1-35 Delivery components (stapling mailbox) ........................................................................................................ 88

Table 2-1 Pre-boot menu options (1 of 7) ....................................................................................................................... 107

Table 2-2 Pre-boot menu options (2 of 7) ....................................................................................................................... 109

Table 2-3 Pre-boot menu options (3 of 7) ....................................................................................................................... 110

Table 2-4 Pre-boot menu options (4 of 7) ....................................................................................................................... 111

Table 2-5 Pre-boot menu options (5 of 7) ....................................................................................................................... 111

Table 2-6 Pre-boot menu options (6 of 7) ....................................................................................................................... 113

Table 2-7 Pre-boot menu options (7 of 7) ....................................................................................................................... 114

Table 2-8 Troubleshooting flowchart .............................................................................................................................. 124

Table 2-9 Control panel diagnostic functions .................................................................................................................. 130

Table 2-10 Connectivity LED, product initialization ........................................................................................................ 141

Table 2-11 Connectivity LED, product operational .......................................................................................................... 143

Table 2-12 Paper-path sensors diagnostic tests ............................................................................................................ 148

Table 2-13 Manual sensor diagnostic tests ..................................................................................................................... 150

Table 2-14 Tray/bin manual sensors ............................................................................................................................... 152

Table 2-15 Component test details ................................................................................................................................. 155

Table 2-16 Sensors and switches (product; M651) ......................................................................................................... 160

Table 2-17 Sensors and switches (product; M680) ......................................................................................................... 161

Table 2-18 1x500-sheet paper-feeder and 1x500-sheet paper-feeder with storage cabinet sensors and switches .. 162

Table 2-19 2,500-sheet paper deck (HCI) sensors and switches .................................................................................... 163

Table 2-20 3-bin stapling mailbox accessory sensors and switches (M680) ................................................................. 164

Table 2-21 Product base .................................................................................................................................................. 165

Table 2-22 1x500-sheet paper-feeder and 1x500-sheet paper-feeder with storage cabinet

.................................... 166

Table 2-23 2,500-sheet high-capacity feeder (HCI) sensors and switches .................................................................... 167

Table 2-24 3-bin stapling mailbox accessory (M680) ..................................................................................................... 168

Table 2-25 DC controller connectors ............................................................................................................................... 169

Table 2-26 Intermediate paper transport unit (ITPU) driver PCA (M680) ....................................................................... 172

Table 2-27 Accessories controller PCA ............................................................................................................................ 173

Table 2-28 3-bin stapling mailbox accessory (M680) ..................................................................................................... 174

Table 2-29 Formatter connections (M651) ...................................................................................................................... 176

Table 2-30 Formatter connections (M680) ...................................................................................................................... 176

Table 2-31 M680 product integrated scanner assembly (ISA) ........................................................................................ 178

Table 2-32 Base product external view M651 ................................................................................................................. 179

Table 2-33 Base product external view M680 ................................................................................................................. 180

Table 2-34 1x500-sheet paper feeder ............................................................................................................................. 181

Table 2-35 1x500-sheet paper deck ................................................................................................................................ 182

Table 2-36 2,500-sheet high-capacity feeder (HCI) ........................................................................................................ 183

Table 2-37 3-bin stapling mailbox accessory (M680) ..................................................................................................... 184

Table 2-38 Configuration page ........................................................................................................................................ 198

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Table 2-39 HP embedded Jetdirect page ......................................................................................................................... 200

Table 2-40 Important information on the configuration pages ...................................................................................... 202

Table 2-41 Reports menu ................................................................................................................................................. 206

Table 2-42 General Settings menu .................................................................................................................................. 208

Table 2-43 Copy Settings menu (M680) .......................................................................................................................... 222

Table 2-44 Scan/Digital Send Settings menu (M680) ..................................................................................................... 229

Table 2-45 Fax Settings menu (M680) ............................................................................................................................. 240

Table 2-46 General Print Settings menu ......................................................................................................................... 253

Table 2-47 Default Print Options menu ........................................................................................................................... 256

Table 2-48 Display Settings menu ................................................................................................................................... 258

Table 2-49 Manage Supplies menu .................................................................................................................................. 260

Table 2-50 Manage Trays menu ....................................................................................................................................... 266

Table 2-51 Network Settings menu ................................................................................................................................. 268

Table 2-52 Jetdirect Menu ................................................................................................................................................ 268

Table 2-53 Troubleshooting menu .................................................................................................................................. 280

Table 2-54 Backup/Restore menu ................................................................................................................................... 284

Table 2-55 Calibration/Cleaning menu (M680) ............................................................................................................... 285

Table 2-56 Calibration/Cleaning menu (M651) ............................................................................................................... 288

Table 2-57 Sensors and switches (product; M651) ......................................................................................................... 433

Table 2-58 Sensors and switches (product; M680) ......................................................................................................... 434

Table 2-59 1x500-sheet paper-feeder and 1x500-sheet paper-feeder with storage cabinet sensors and

switches ............................................................................................................................................................................... 435

Table 2-60 2,500-sheet paper deck (HCI) sensors and switches .................................................................................... 436

Table 2-61 3-bin stapling mailbox accessory sensors and switches (M680) ................................................................. 437

Table 2-62 Print modes

under the Adjust Paper Types submenu ................................................................................. 470

Table 2-63 Print modes under the Optimize submenu ................................................................................................... 471

Table 2-64 Image defects table ....................................................................................................................................... 473

Table 2-65 Solve performance problems ........................................................................................................................ 498

Table 2-66 Service menu (M651 and M680) .................................................................................................................... 501

Table 2-67 Service menu (M680 only) ............................................................................................................................. 505

Table 2-68 Send-fax messages ....................................................................................................................................... 520

Table 2-69 Receive-fax messages ................................................................................................................................... 521

Table A-1 Physical specifications, with toner cartridges (M680) .................................................................................... 528

Table A-2 Physical specifications, with toner cartridge (M651) ...................................................................................... 528

Table A-3 Product dimensions with all doors, trays, and document feeder fully opened (M680) ................................. 528

Table A-4 Product dimensions with all doors and trays fully opened (M651) ................................................................ 528

Table A-5 Accessory dimensions ...................................................................................................................................... 528

Table A-6 Product space requirements ........................................................................................................................... 529

Table A-7 Operating-environment specifications ........................................................................................................... 530

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List of figures

Figure 1-1 Relationship between the main product systems .............................................................................................. 2

Figure 1-2 System block diagram ........................................................................................................................................ 3

Figure 1-3 Engine-control system ........................................................................................................................................ 8

Figure 1-4 DC controller block diagram ............................................................................................................................... 9

Figure 1-5 High-voltage power supply circuits .................................................................................................................. 14

Figure 1-6 Low-voltage power-supply circuit ................................................................................................................... 16

Figure 1-7 Fuser components ............................................................................................................................................ 19

Figure 1-8 Fuser temperature-control circuit .................................................................................................................... 20

Figure 1-9 Laser/scanner system ...................................................................................................................................... 23

Figure 1-10 Protective-glass cleaners (PGCs) ................................................................................................................... 25

Figure 1-11 Image-formation system ............................................................................................................................... 26

Figure 1-12 Image-formation drive system ...................................................................................................................... 27

Figure 1-13 Image-formation process ............................................................................................................................... 28

Figure 1-14 Pre-exposure .................................................................................................................................................. 29

Figure 1-15 Primary charging ............................................................................................................................................ 29

Figure 1-16 Laser-beam exposure ..................................................................................................................................... 30

Figure 1-17 Development .................................................................................................................................................. 30

Figure 1-18 Primary transfer ............................................................................................................................................. 31

Figure 1-19 Secondary transfer ......................................................................................................................................... 31

Figure 1-20 Separation ....................................................................................................................................................... 32

Figure 1-21 Fusing .............................................................................................................................................................. 32

Figure 1-22 ITB cleaning ..................................................................................................................................................... 33

Figure 1-23 Drum cleaning ................................................................................................................................................. 33

Figure 1-24 Toner cartridge system .................................................................................................................................. 34

Figure 1-25 Developing-roller engagement and disengagement control ........................................................................ 35

Figure 1-26 ITB unit ............................................................................................................................................................ 37

Figure 1-27 Three states of primary-transfer roller engagement and disengagement .................................................. 39

Figure 1-28 ITB cleaning process ....................................................................................................................................... 40

Figure 1-29 Toner patterns for calibration ........................................................................................................................ 41

Figure 1-30 Paper path ....................................................................................................................................................... 43

Figure 1-31 Switches and sensors for the pickup, feed, and delivery system (M651 only) ............................................. 44

Figure 1-32 Switches and sensors for the pickup, feed, and delivery system (M680 only) ............................................. 44

ENWW xix

Figure 1-33 Motors and solenoids for the pickup, feed, and delivery system .................................................................. 46

Figure 1-34 Three main units of the pickup, feed, and delivery system ........................................................................... 47

Figure 1-35 Pickup-and-feed unit ...................................................................................................................................... 48

Figure 1-36 Cassette-pickup mechanism .......................................................................................................................... 49

Figure 1-37 Cassette lift mechanism ................................................................................................................................. 50

Figure 1-38 Multiple-feed prevention ................................................................................................................................ 51

Figure 1-39 Multipurpose tray pickup mechanism ............................................................................................................ 52

Figure 1-40 Paper-feed mechanism .................................................................................................................................. 53

Figure 1-41 Skew-feed prevention .................................................................................................................................... 54

Figure 1-42 Fuser and delivery unit ................................................................................................................................... 56

Figure 1-43 Loop-control mechanism ............................................................................................................................... 57

Figure 1-44 Pressure-roller pressurization control .......................................................................................................... 58

Figure 1-45 Duplexing unit ................................................................................................................................................. 59

Figure 1-46 Duplex reverse and feed control .................................................................................................................... 60

Figure 1-47 Jam detection sensors .................................................................................................................................... 62

Figure 1-48 1 x 500 optional paper feeder ........................................................................................................................ 64

Figure 1-49 Signals for the paper feeder ........................................................................................................................... 65

Figure 1-50 2,500-sheet paper feeder HCI ........................................................................................................................ 66

Figure 1-51 Signals for 2,500-sheet paper feeder HCI ...................................................................................................... 67

Figure 1-52 Paper-feeder pickup and feed operation (1x500-sheet paper feeder) ........................................................ 69

Figure 1-53 Paper-feeder pickup and feed operation (2,500-sheet paper feeder HCI) ................................................... 70

Figure 1-54 Paper-feeder cassette lift .............................................................................................................................. 73

Figure 1-55 Jam detection (1x500-sheet paper feeder) ................................................................................................... 74

Figure 1-56 2,500-sheet paper feeder HCI media feed sensors ....................................................................................... 75

Figure 1-57 Automatic document feeder sensors ............................................................................................................. 78

Figure 1-58 Automatic document feeder paper path ........................................................................................................ 79

Figure 1-59 Automatic document feeder deskew features .............................................................................................. 82

Figure 1-60 Automatic document feeder open (book mode) ............................................................................................ 83

Figure 1-61 Automatic document feeder open (60º to 80º) .............................................................................................. 84

Figure 1-62 Stapling mailbox ............................................................................................................................................. 85

Figure 1-63 Signals for the stapling mailbox ..................................................................................................................... 85

Figure 1-64 Stapling mailbox delivery operation .............................................................................................................. 88

Figure 1-65 Stapling mailbox stapler operation (1 of 4) ................................................................................................... 90

Figure 1-66 Stapling mailbox stapler operation (2 of 4) ................................................................................................... 91

Figure 1-67 Stapling mailbox stapler operation (3 of 4) ................................................................................................... 92

Figure 1-68 Stapling mailbox stapler operation (4 of 4) ................................................................................................... 93

Figure 1-69 Stapling mailbox sensors for the stapler ....................................................................................................... 94

Figure 1-70 Stapling mailbox sensors for output bin 3 lift operation .............................................................................. 95

Figure 1-71 Stapling mailbox sensors for stacker mode .................................................................................................. 96

Figure 1-72 Stapling mailbox sensors for mail

Figure 1-73 Stapling mailbox sensors for jam detection .................................................................................................. 98

box/jam separation ................................................................................. 97

xx ENWW

Figure 2-1 Open the Control Panel ................................................................................................................................... 116

Figure 2-2 Turn Windows features on or off .................................................................................................................... 116

Figure 2-3 Enable the telnet client feature ..................................................................................................................... 117

Figure 2-4 Select the +3:Administrator item ................................................................................................................... 118

Figure 2-5 Select the +A:Remote Admin item ................................................................................................................. 118

Figure 2-6 Select the 1:Start Telnet item ........................................................................................................................ 118

Figure 2-7 Telnet connecting message ............................................................................................................................ 118

Figure 2-8 Telnet error message ..................................................................................................................................... 119

Figure 2-9 Telnet server function initialized ................................................................................................................... 119

Figure 2-10 Open a command window ............................................................................................................................ 120

Figure 2-11 Start a telnet session .................................................................................................................................... 120

Figure 2-12 Establish a telnet connection ....................................................................................................................... 120

Figure 2-13 Enter the PIN ................................................................................................................................................. 121

Figure 2-14 Remote Admin window ................................................................................................................................. 121

Figure 2-15 Access the administrator menu ................................................................................................................... 122

Figure 2-16 Access the remote admin menu ................................................................................................................... 122

Figure 2-17 Terminate the telnet connection ................................................................................................................. 123

Figure 2-18 M650 control-panel test button location .................................................................................................... 130

Figure 2-19 Touchscreen blank, white, or dim (no image) .............................................................................................. 134

Figure 2-20 Touchscreen is slow to respond or requires multiple presses to respond ................................................. 135

Figure 2-21 Touchscreen has an unresponsive zone ...................................................................................................... 136

Figure 2-22 No control panel sound ................................................................................................................................ 137

Figure 2-23 Home button is unresponsive ...................................................................................................................... 138

Figure 2-24 Hardware integration pocket (HIP) is not functioning (control panel functional) ...................................... 139

Figure 2-25 Defeating interlocks (1 of 2) ......................................................................................................................... 145

Figure 2-26 Defeating interlocks (2 of 2) ......................................................................................................................... 146

Figure 2-27 Engine test button ........................................................................................................................................ 147

Figure 2-28 Sensors and switches (paper path; M651) ................................................................................................... 160

Figure 2-29 Sensors and switches (paper path; M680) ................................................................................................... 161

Figure 2-30 1x500-sheet paper-feeder and 1x500-sheet paper-feeder with storage cabinet sensors and

switches ............................................................................................................................................................................... 162

Figure 2-31 2,500-sheet high-capacity feeder (HCI) sensors and switches ................................................................... 163

Figure 2-32 3-bin stapling mailbox accessory sensors and switches (M680) ................................................................ 164

Figure 2-33 Product base ................................................................................................................................................. 165

Figure 2-34 1x500-sheet paper-feeder and 1x500-sheet paper-feeder with storage cabinet .................................... 166

Figure 2-35 2,500-sheet high-capacity feeder (HCI) sensors and switches ................................................................... 167

Figure 2-36 3-bin stapling mailbox accessory (M680) .................................................................................................... 168

Figure 2-37 DC controller PCA .......................................................................................................................................... 169

Figure 2-38 Intermediate paper transport unit (ITPU) driver PCA (M680) ...................................................................... 172

Figure 2-39 Accessories controller PCA ........................................................................................................................... 173

Figure 2-40 3-bin stapling mailbox accessory (M680) .................................................................................................... 174

ENWW xxi

Figure 2-41 Formatter connections (M651) .................................................................................................................... 176

Figure 2-42 Formatter connections (M680) .................................................................................................................... 176

Figure 2-43 M680 product integrated scanner assembly (ISA) ....................................................................................... 178

Figure 2-44 Base product external view M651 ................................................................................................................ 179

Figure 2-45 Base product external view M680 ................................................................................................................ 180

Figure 2-46 1x500-sheet paper feeder ........................................................................................................................... 181

Figure 2-47 1x500-sheet paper deck .............................................................................................................................. 182

Figure 2-48 2,500-sheet high-capacity feeder (HCI) ....................................................................................................... 183

Figure 2-49 3-bin stapling mailbox accessory (M680) .................................................................................................... 184

Figure 2-50 General timing chart ..................................................................................................................................... 185

Figure 2-51 General circuit diagram (M651) .................................................................................................................... 186

Figure 2-52 General circuit diagram (M680; 1 of 2) ......................................................................................................... 187

Figure 2-53 General circuit diagram (M680; 2 of 2) ......................................................................................................... 188

Figure 2-54 1x500-sheet paper feeder, 1x500-sheet paper deck, and 2,500-sheet high-capacity feeder (HCI) ......... 189

Figure 2-55 3-bin stapling mailbox accessory (M680) .................................................................................................... 190

Figure 2-56 Print-quality troubleshooting procedure .................................................................................................... 191

Figure 2-57 Yellow print-quality troubleshooting page ................................................................................................. 192

Figure 2-58 Yellow comparison page .............................................................................................................................. 192

Figure 2-59 Black print-quality troubleshooting page .................................................................................................... 193

Figure 2-60 Configuration page ....................................................................................................................................... 198

Figure 2-61 Configuration page ....................................................................................................................................... 200

Figure 2-62 Repetitive defects ruler ................................................................................................................................ 203

Figure 2-63 Sample event log .......................................................................................................................................... 430

Figure 2-64 Sensors and switches (paper path; M651) ................................................................................................... 433

Figure 2-65 Sensors and switches (paper path; M680) ................................................................................................... 434

Figure 2-66 1x500-sheet paper-feeder and 1x500-sheet paper-feeder with storage cabinet sensors and

switches ............................................................................................................................................................................... 435

Figure 2-67 2,500-sheet high-capacity feeder (HCI) sensors and switches ................................................................... 436

Figure 2-68 3-bin stapling mailbox accessory sensors and switches (M680) ................................................................ 437

Figure A-1 Product space requirements .......................................................................................................................... 529

Figure A-2 Certificate of Volatility (M680; 1 of 2) ............................................................................................................ 531

Figure A-3 Certificate of Volatility (M680; 2 of 2) ............................................................................................................ 532

Figure A-4 Certificate of Volatility (M651; 1 of 2) ............................................................................................................ 533

Figure A-5 Certificate of Volatility (M651; 2 of 2) ............................................................................................................ 534

xxii ENWW

1 Theory of operation

●

Basic operation

●

Formatter-control system

●

Engine-control system

●

Laser/scanner system

●

Image-formation system

●

Pickup, feed, and delivery system

●

Optional paper feeders

●

Scanning/image capture system (M680)

●

Stapling mailbox (M680)

ENWW 1

Basic operation

The product routes all high-level processes through the formatter, which stores font information, processes the print image, and communicates with the host computer.

The basic product operation comprises the following systems:

●

The engine-control system, which includes the power supply and the DC controller printed circuit assembly (PCA)

●

The laser/scanner system, which forms the latent image on the photosensitive drum

●

The image-formation system, which transfers a toner image onto the paper

●

The media feed system, which uses a system of rollers and belts to transport the paper through the product

●

Option (optional paper feeder)

Figure 1-1 Relationship between the main product systems

Laser/scanner system

Image-formation system

Engine control system

Media-feed system

Option

The interconnect board (ICB) provides connections from the formatter to the following components:

●

DC controller (DCC)

●

Scan control board (SCB)

●

Control panel, USB walk-up port, USB hardware integration pocket through a USB cable

The formatter receives +12 volts from the low-voltage power supply (LVPS).

The automatic document feeder/scanner receives 24 volts from the scanner power supply, which is powered by an AC line from the LVPS.

The intermediate paper transport unit (IPTU) receives +24 volts and 3.3 volts from the DCC.

2 Chapter 1 Theory of operation ENWW

The stapling mailbox receives +24 volts and the JetLink control lines for communications from the DCC.

Figure 1-2 System block diagram

ENWW Basic operation 3

Sequence of operation

The DC controller PCA controls the operating sequence, as described in the following table.

Table 1-1 Sequence of operation

Period Duration Description

Waiting From the time the power is turned on, the door is

closed, or when the product exits Sleep mode until the product is ready for printing

Standby From the end of the waiting sequence, the last

rotation until the formatter receives a print command, or until the product is turned off

Initial rotation From the time the formatter receives a print

command until the paper enters the paper path

Printing From the time the first sheet of paper enters the

paper path until the last sheet has passed through the fuser

●

Heats the fuser sleeve in the fuser

●

Pressurizes the pressure roller in the fuser

●

Detects the toner cartridges

●

Moves the ITB and developing unit to the home position

●

Cleans the ITB and secondary transfer roller

●

The product is in the Ready state

●

The product enters Sleep mode if the sleep command is received from the formatter

●

The product calibrates if it is time for an automatic calibration

●

Activates the high-voltage power supply

●

Prepares each laser/scanner unit

●

Warms the fuser to the correct temperature

●

Forms the image on the photosensitive drums

●

Transfers the toner to the paper

●

Fuses the toner image onto the paper

Last rotation From the time the last sheet of paper exits the fuser

until the motors stop rotating

●

Moves the last printed sheet into the output bin

●

Stops the high-voltage power supply

●

Stops each laser/scanner unit

●

If another print command is received, the product enters the initial rotation period when the last rotation is complete.

4 Chapter 1 Theory of operation ENWW

Formatter-control system

The formatter performs the following functions:

●

Controlling sleep mode

●

Receiving and processing print data from the various product interfaces

●

Monitoring control panel functions and relaying product status information (through the control panel and the network or bi-directional interface)

●

Developing and coordinating data placement and timing with the DC controller PCA

●

Storing font information

●

Communicating with the host computer through the network or the bidirectional interface

The formatter receives a print job from the network or bidirectional interface and separates it into image information and instructions that control the printing process. The DC controller PCA synchronizes the image formation system with the paper input and output systems, and then signals the formatter to send the print image data.

Formatter hardware

The formatter system includes the following components.

Table 1-2 Formatter hardware components

Component Function

Microprocessor Stores fonts and microprocessor control programs.

RAM Stores printing and font information and temporarily stores print-image data before it sent to the

print engine. RAM data is lost when the product is turned off.

NVRAM Stores configuration information. NVRAM is saved when the product is turned off.

USB Sends and receives data through USB type B interface connector (connected to the host computer).

Hard disk drive (HDD)

Solid state module (SSM)

Real time clock This clock is used for the Wake-up time feature. It includes a battery to supply power when the

HP Jetdirect Inside (JDI) JDI is an Ethernet interface that is part of the formatter.

The firmware is contained in the HDD or SSD. A remote firmware upgrade process is used to overwrite and upgrade the firmware on the HDD or SSM.

product is turned off.

ENWW Formatter-control system 5

Sleep mode

NOTE: In the General Settings menu (a submenu of the Administration menu), this item is termed Sleep

Timer Settings.

This feature conserves power after the product has been idle for an adjustable period of time. When the product is in Sleep Mode, the control panel backlight is turned off, but the product retains all settings, downloaded fonts, and macros. The default setting is for Sleep Mode to be enabled, and the product enters Sleep Mode after a 30-minute idle time.

The product exits Sleep Mode and enters the warm-up cycle when any of the following events occur:

●

NOTE: Product error messages override the Sleep message. The product enters Sleep Mode at the

appropriate time, but the error message continues to appear.

TIP: When the product is in Sleep Mode, the sub power supply is off and the low-voltage power supply is

on. The scanner can not be used when the product is in Sleep Mode.

A print job, valid data, or a PML or PJL command is received

A control panel button is pressed

A cover is opened

A paper tray is opened

The engine-test switch is pressed

Input/output

The product has three I/O interfaces:

●

CPU

The formatter incorporates an 800 MHz processor.

Memory

The random access memory (RAM) on the formatter printed circuit assembly (PCA) contains the page, I/O buffers, and the font storage area. It stores printing and font information received from the host system, and can also serve to temporarily store a full page of print-image data before the data is sent to the print engine.

NOTE: If the product encounters a problem when managing available memory, a clearable warning

message displays on the control panel display.

Firmware

The hard disk drive (HDD) or solid state module (SSM) store the firmware. A remote firmware upgrade process is used to overwrite and upgrade the firmware on the HDD or SSM.

Hi-Speed USB 2.0

10/100/1000 Ethernet LAN connection with IPv4 and IPv6

Easy-access USB printing (no computer required)

6 Chapter 1 Theory of operation ENWW

Nonvolatile memory

The product uses nonvolatile random access memory (NVRAM) to store product and user configuration settings. The contents of NVRAM are retained when the product is turned off or disconnected.

PJL overview

The printer job language (PJL) is an integral part of configuration, in addition to the standard printer command language (PCL). With standard cabling, the product can use PJL to perform a variety of functions:

●

Two-way communication with the host computer through a network connection or a USB connection. The product can inform the host about the control panel settings that can be changed from the host.

●

Dynamic I/O switching. The product uses this switching to be configured with a host on each I/O. The product can receive data from more than one I/O simultaneously, until the I/O buffer is full. This can occur even when the product is offline.

●

Context-sensitive switching. The product can automatically recognize the personality (PS or PCL) of each job and configure itself to serve that personality.

●

Isolation of print environment settings from one print job to the next. For example, if a print job is sent to the product in landscape mode, the subsequent print jobs print in landscape mode only if they are formatted for landscape printing.

PML

The printer management language (PML) allows remote configuration and status read-back through the I/O ports.

Control panel

The control panel is an 20.3 cm (8 in) full-color SVGA (M680 model) or 10.9 cm (4.3 in) full-color SVGA (M651 model) with capacitive touchscreen and adjustable viewing angle. It includes an easy-access USB port for walk-up printing and a hardware integration pocket for third-party USB devices such as card readers.

The control panel has a diagnostic mode to allow testing of the touchscreen, Home button, and speaker. The control panel does not require calibration.

The M680z model has a QWERTY retractable keyboard beneath the control panel. The keys are mapped to a specific language in the same way the virtual keyboard on the product control panel is mapped. Selecting a different keyboard layout for the virtual keyboard remaps the keys on the physical keyboard to match the new settings.

ENWW Formatter-control system 7

Engine-control system

The engine-control system receives commands from the formatter and interacts with the other main systems to coordinate all product functions. The engine-control system consists of the following components:

●

DC controller

●

Low-voltage power supply

●

High-voltage power supply

●

Fuser control

Figure 1-3 Engine-control system

Formatter

ENGINE CONTROL SYSTEM

DC controller

Low-voltage power supply

High-voltage power supply

Fuser control

LASER SCANNER SYSTEM

IMAGE-FORMATION SYSTEM

MEDIA FEED SYSTEM

OPTION

8 Chapter 1 Theory of operation ENWW

DC controller

The DC controller controls the operational sequence of the product.

Figure 1-4 DC controller block diagram

Motor

Solenoid

ITB ass’y

Cartridge

(Y/M/C/K)

Motor

Fan

Sensor

T2 roller

AC input

High-voltage

power supply-T

High-voltage

power supply-D

Fuser

Low-voltage

power supply

DC controller

Only for M651

Control panel

Fan

Motor

Clutch

Solenoid

Switch

Photointerrupter

Sensor

LED

HIP

Accessory

Image scanner (only for M680)

Laser scanner ass’y

Only for M680

Photointerrupter

IPTU driver

ICB

NVRAM

Formatter

Motor

Fan

ENWW Engine-control system 9

Solenoids

Clutches

Switches

Table 1-3 Solenoids

Component abbreviation Component name

SL1 T1 alienation solenoid

SL2 Duplex switch back solenoid

SL3 Multipurpose-tray pickup solenoid

SL4 Cassette pickup solenoid

Table 1-4 Clutches

Component abbreviation Component name

CL1 Duplex re-pickup clutch

Table 1-5 Switches

Component abbreviation Component name

SW1 5V interlock switch

SW2 24V interlock switch

SW3 Power switch

SW4 Cassette media size switch

SW5 Front door open detection switch

SW6 Right door open detection switch

Test print switch

10 Chapter 1 Theory of operation ENWW

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