HP LaserJet Enterprise Pro M570dn, LaserJet Enterprise Pro M570dw Troubleshooting Manual

LASERJET PRO 500 COLOR MFP

Troubleshooting Manual

M570

HP LaserJet Enterprise 500 color MFP M575 Printers

Troubleshooting Manual

Copyright and License

© 2012 Copyright Hewlett-Packard

Development Company, L.P.

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, 11/2012

Part number: CZ271-91021

Trademark Credits

Bluetooth is a trademark owned by its proprietor and used by Hewlett-Packard Company under license.

Microsoft®, Windows®, Windows® XP, and Windows Vista® are U.S. registered trademarks of Microsoft Corporation.

Conventions used in this guide

TIP: Tips provide helpful hints or shortcuts.

NOTE: Notes provide important information to explain a concept or to complete a task.

CAUTION: Cautions indicate procedures that you should follow to avoid losing data or damaging the product.

WARNING! Warnings alert you to specific procedures that you should follow to avoid personal injury, catastrophic loss of data, or extensive damage to the product.

ENWW

iii

Table of contents

1 Theory of operation ..........................................................................................................	1
Basic operation ........................................................................................................................	2
Sequence of operation ...............................................................................................	3
Formatter-control system ............................................................................................................	4
Sleep delay ..............................................................................................................	4
Input/output .............................................................................................................	4
CPU ........................................................................................................................	5
Memory ...................................................................................................................	5
Firmware ...................................................................................................	5
Nonvolatile memory ...................................................................................	5
PJL overview .............................................................................................................	5
PML .........................................................................................................................	5
Control panel ...........................................................................................................	6
USB flash drive .........................................................................................................	6
Engine-control system ................................................................................................................	7
DC controller ............................................................................................................	8
Solenoids ..................................................................................................	8
Clutches ....................................................................................................	9
Switches ...................................................................................................	9
Sensors ...................................................................................................	10
Motors and fans .......................................................................................	11
High-voltage power supply .......................................................................................	12
Low-voltage power supply ........................................................................................	14
Overcurrent/overvoltage protection ............................................................	15
Safety .....................................................................................................	16
Voltage detection .....................................................................................	16
Sleep (powersave) mode ...........................................................................	16
Power supply voltage detection ..................................................................	17
Low-voltage power supply failure ...............................................................	17
Power Off condition ................................................................................................	17
Auto on/Auto off mode ............................................................................................	17
Fuser (fixing) control ................................................................................................	19

ENWW

v

Fuser (fixing) temperature-control circuit ......................................................	20
Fuser (fixing) over-temperature protection ....................................................	20
Fuser (fixing)-failure detection ....................................................................	21
Laser/scanner system .............................................................................................................	23
Image formation system ..........................................................................................................	25
Image formation process ..........................................................................................	26
Step 1: Pre-exposure .................................................................................	27
Step 2: Primary charging ..........................................................................	27
Step 3: Laser-beam exposure .....................................................................	28
Step 4: Development ................................................................................	28
Step 5: Primary transfer ............................................................................	29
Step 6: Secondary transfer ........................................................................	29
Step 7: Separation ...................................................................................	30
Step 8: Fusing .........................................................................................	30
Step 9: ITB cleaning .................................................................................	31
Step 10: Drum cleaning ............................................................................	31
Toner cartridge .......................................................................................................	31
Developing roller engagement and disengagement .....................................................	33
Intermediate transfer belt (ITB) unit .............................................................................	35
Primary-transfer-roller engagement and disengagement .................................	36
ITB cleaning ............................................................................................	38
Calibration .............................................................................................................	39
Color misregistration control ......................................................................	39
Image stabilization control ........................................................................	40
Pickup, feed, and delivery system .............................................................................................	41
Pickup-and-feed unit ................................................................................................	44
Tray pickup .............................................................................................	45
Tray-presence detection ..............................................................	46
Tray lift operation ......................................................................	46
paper-presence detection ...........................................................	48
Multifeed prevention ..................................................................	48
Multipurpose tray pickup ...........................................................................	49
Paper feed ..............................................................................................	50
Skew-feed prevention .................................................................	51
OHT detection ..........................................................................	51
Fusing and delivery unit ...........................................................................................	52
Loop control ............................................................................................	52
Pressure-roller pressurization control ...........................................................	54
Duplexing unit ........................................................................................................	55
Duplexing reverse and feed control ............................................................	56
Duplex pickup operation ...........................................................................	56

vi

ENWW

Jam detection ........................................................................................................................	57
Optional paper feeder ............................................................................................................	59
Paper-feeder pickup and feed operation ....................................................................	61
Paper size detection and presence detection ..............................................................	62
Paper feeder lift operation ........................................................................................	64
Paper feeder presence detection ...............................................................................	65
Paper-feeder multiple feed prevention ........................................................................	65
Paper feeder jam detection .......................................................................................	67
Scanning/image capture system ..............................................................................................	68
Scanner power-on sequence of events .......................................................................	68
Copy or scan sequence of events ..............................................................................	69
Fax functions and operation ....................................................................................................	70
Computer and network security features .....................................................................	70
PSTN operation ......................................................................................................	70
Receive faxes when you hear fax tones ......................................................................	70
Distinctive ring function ............................................................................................	71
Use fax with voice over IP services ............................................................................	71
The fax subsystem ...................................................................................................	72
Fax card in the fax subsystem ...................................................................................	72
Safety isolation ........................................................................................	72
Safety-protection circuitry ..........................................................................	72
Data path ................................................................................................	73
Hook state ...............................................................................................	73
Downstream device detection ....................................................................	74
Hook switch control ..................................................................................	74
Ring detect ..............................................................................................	74
Line current control ...................................................................................	74
Billing- (metering-) tone filters .....................................................................	74
Fax page storage in flash memory ............................................................................	74
Stored fax pages ......................................................................................	75
Advantages of flash memory storage ..........................................................	75
2 Solve problems ...............................................................................................................	77
Solve problems checklist .........................................................................................................	78
Menu map ............................................................................................................................	80
Troubleshooting process ..........................................................................................................	81
Pre-troubleshooting checklist .....................................................................................	81
Determine the problem source ...................................................................................	83
Power subsystem .....................................................................................................	84
Power-on checks ......................................................................................	84
Control-panel checks ...............................................................................................	84

ENWW

vii

Tools for troubleshooting .........................................................................................................	86
Component diagnostics ............................................................................................	86
LED diagnostics ........................................................................................	86
Network LEDs ...........................................................................	86
Control panel LEDs ....................................................................	86
Engine diagnostics ...................................................................................	87
Engine test ................................................................................	87
Diagrams ...............................................................................................................	88
Block diagrams ........................................................................................	88
Plug/jack locations ...................................................................................	90
Location of connectors ..............................................................................	91
DC controller PCA .....................................................................	91
Locations of major components ..................................................................	93
Base product ............................................................................	93
1 x 500 paper feeder ................................................................	99
General timing chart ...............................................................................	100
General circuit diagrams .........................................................................	101
Use HP Device Toolbox (Windows) .........................................................................	103
Internal print-quality test pages ................................................................................	104
Clean the paper path .............................................................................	104
Print the configuration page .....................................................................	104
Print-quality troubleshooting tools ............................................................................	104
Repetitive image defect ruler ....................................................................	104
Control panel menus ..............................................................................................	106
Setup Menu ...........................................................................................	106
HP Web Services ....................................................................	106
Reports menu ..........................................................................	107
Self Diagnostics menu ..............................................................	108
Fax Setup menu ......................................................................	108
System Setup menu ..................................................................	111
Service menu ..........................................................................	115
Network Setup menu ...............................................................	117
Quick Forms menu ..................................................................	118
Function specific menus ...........................................................................	119
USB Flash Drive ......................................................................	119
Fax Menu ...............................................................................	119
Copy Menu ............................................................................	122
Scan Menu .............................................................................	123
Apps .....................................................................................	123
Interpret control-panel messages .............................................................................	124
Control panel message types ...................................................................	124

viii

ENWW

Control panel messages ..........................................................................	124
49 Error, Turn off then on .........................................................	124
50.x Fuser Error ......................................................................	124
51.XX Error ............................................................................	124
54.XX Error ............................................................................	125
55.X Error ..............................................................................	125
57 Fan Error, Turn off then on ...................................................	125
59.X Error ..............................................................................	126
79 Error Turn off then on ..........................................................	126
Black Cartridge Low ................................................................	126
Black Very Low .......................................................................	126
Cleaning ................................................................................	127
Communication error. ..............................................................	127
Device error, press OK ............................................................	127
Document feeder door is open. Canceled fax. ............................	128
Door open ..............................................................................	128
Fax is busy. Canceled send. .....................................................	128
Fax is busy. Redial pending. .....................................................	128
Fax receive error. ....................................................................	129
Fax Send error. .......................................................................	129
Fax storage is full. Canceling the fax receive. .............................	130
Fax storage is full. Canceling the fax receive. .............................	130
Fax storage is full. Canceling the fax send. .................................	130
Genuine HP supply installed .....................................................	130
Incompatible <color> ...............................................................	131
Install <color> cartridge ...........................................................	131
Invalid driver Press [OK] ..........................................................	131
Jam in Tray 1, Clear jam and then press OK ..............................	131
Load tray 1 Press [OK] for available media ................................	131
Load Tray 1 <TYPE> <SIZE>, Press OK to use available media .....	132
Load Tray 1, <PLAIN> <SIZE> / Cleaning mode, OK to start .......	132
Load Tray <X>: [Type], [Size] ...................................................	132
Manual Duplex Load Tray 1, Press OK ......................................	132
Manual feed <SIZE> <TYPE>, Press OK to use available media ....	132
Memory is low. Press OK. ........................................................	133
Misprint, Press OK ...................................................................	133
No dial tone. ..........................................................................	133
No fax answer. Canceled send. ................................................	134
No fax answer. Redial pending. ...............................................	134
No fax detected. .....................................................................	134
Print failure, press OK. If error repeats, turn off then on. ...............	135

ENWW

ix

Remove shipping lock from <color> cartridge .............................	135
Replace [color] .......................................................................	135
Unexpected size in tray 1 Load <size> Press [OK] ......................	135
Unsupported <color> Press [OK] to continue ...............................	136
Used <color> cartridge is installed Press [OK] to continue ............	136
Event-log messages ...............................................................................................	137
Print the event log ...................................................................................	137
Show an event log .................................................................................	137
Event log messages ................................................................................	137
Clear jams ..........................................................................................................................	140
Jam locations ........................................................................................................	140
Clear jams in the document feeder ..........................................................................	141
Clear jams in the output bin area ............................................................................	143
Clear jams in Tray 1 ..............................................................................................	144
Clear jams in Tray 2 ..............................................................................................	146
Clear jams in the right door ....................................................................................	147
Clear jams in optional Tray 3 .................................................................................	151
Clear jams in the lower right door (Tray 3) ...............................................................	152
Paper feeds incorrectly or becomes jammed ............................................................................	153
The product does not pick up paper ........................................................................	153
The product picks up multiple sheets of paper ...........................................................	153
The document feeder jams, skews, or picks up multiple sheets of paper .......................	154
Prevent paper jams from the paper trays ..................................................................	154
Solve image quality problems ................................................................................................	155
Image defects table ...............................................................................................	155
Clean the product ................................................................................................................	161
Clean the pickup and separation rollers ...................................................................	161
Clean the paper path ............................................................................................	161
Clean the scanner glass strip and platen ..................................................................	161
Clean the document feeder pickup rollers and separation pad ....................................	162
Clean the touchscreen ...........................................................................................	163
Solve performance problems .................................................................................................	164
Factors affecting print performance .........................................................................	164
Print speeds ...........................................................................................	165
The product does not print or it prints slowly .............................................................	165
The product does not print .......................................................................	165
The product prints slowly .........................................................................	166
Solve connectivity problems ...................................................................................................	167
Solve direct-connect problems .................................................................................	167
Solve network problems .........................................................................................	167
Poor physical connection .........................................................................	167

x

ENWW

The computer is using the incorrect IP address for the product ......................	167
The computer is unable to communicate with the product ............................	168
The product is using incorrect link and duplex settings for the network ..........	168
New software programs might be causing compatibility problems ................	168
The computer or workstation might be set up incorrectly ..............................	168
The product is disabled, or other network settings are incorrect ....................	168
Solve wireless network problems .............................................................................	169
Wireless connectivity checklist .................................................................	169
The control panel displays the message: The wireless feature on this product
has been turned off ................................................................................	170
The product does not print after the wireless configuration completes ............	170
The product does not print, and the computer has a third-party firewall
installed ................................................................................................	170
The wireless connection does not work after moving the wireless router or
product .................................................................................................	170
Cannot connect more computers to the wireless product ..............................	170
The wireless product loses communication when connected to a VPN ...........	171
The network does not appear in the wireless networks list ...........................	171
The wireless network is not functioning ......................................................	171
Service mode functions .........................................................................................................	172
Service menu ........................................................................................................	172
Service menu settings ..............................................................................	172
Restore the factory-set defaults .................................................................	172
Secondary service menu ........................................................................................	173
Open the secondary service menu ............................................................	173
Secondary service menu structure .............................................................	173
Product resets .......................................................................................................	174
NVRAM initialization ..............................................................................	174
Super NVRAM initialization .....................................................................	175
Solve fax problems ...............................................................................................................	176
Checklist for solving fax problems ...........................................................................	176
Perform a fax diagnostic test ...................................................................................	177
Fax trace report ....................................................................................................	178
Fax error report printing .........................................................................................	178
Print all fax reports .................................................................................	178
Print individual fax reports .......................................................................	178
Set the fax error report ............................................................................	179
Set the fax-error-correction mode .............................................................................	179
Change the fax speed ...........................................................................................	179
Solve problems sending faxes .................................................................................	180
An error message displays on the control panel .........................................	180

ENWW

xi

The Communication error. message appears ..............................	180
No dial tone. ..........................................................................	181
The Fax is busy. message appears ............................................	181
The No fax answer. message appears .......................................	182
Document feeder paper jam .....................................................	182
The Fax storage is full. message appears ...................................	183
Scanner error .........................................................................	183
The control panel displays a Ready message with no attempt to send the fax . 183
The control panel displays the message "Storing page 1" and does not
progress beyond that message .................................................................	184
Faxes can be received, but not sent ..........................................................	184
Product is password protected .................................................................	184
Unable to use fax functions from the control panel ......................................	184
Unable to use speed dials .......................................................................	185
Unable to use group dials .......................................................................	185
Receive a recorded error message from the phone company when trying to
send a fax .............................................................................................	185
Unable to send a fax when a phone is connected to the product ..................	186
Solve problems receiving faxes ...............................................................................	186
The fax does not respond ........................................................................	186
The fax has a dedicated phone line ...........................................	186
An answering machine is connected to the product .....................	187
The Answer Mode setting is set to the Manual setting ...................	187
Voice mail is available on the fax line ........................................	188
The product is connected to a DSL phone service ........................	188
The product uses a fax over IP or VoIP phone service ...................	188
An error message displays on the control panel .........................................	189
The No fax detected. message displays .....................................	189
The Communication error. message appears ..............................	189
The Fax storage is full. message appears ...................................	190
The Fax is busy. message appears ............................................	190
A fax is received but does not print ..........................................................	191
The Private Receive feature is on ...............................................	191
Sender receives a busy signal ..................................................................	191
A handset is connected to the product ........................................	191
A phone line splitter is being used .............................................	191
No dial tone ..........................................................................................	191
Cannot send or receive a fax on a PBX line ...............................................	191
Solve general fax problems ....................................................................................	192
Faxes are sending slowly ........................................................................	192
Fax quality is poor .................................................................................	193

xii

ENWW

Fax cuts off or prints on two pages ...........................................................	193
Solve email problems ...........................................................................................................	195
Cannot connect to the email server ..........................................................................	195
The email failed ....................................................................................................	195
Unable to scan .....................................................................................................	195
Product upgrades .................................................................................................................	196
Manually upgrade the firmware ..............................................................................	196
Set the product to automatically upgrade the firmware ...............................................	196
Appendix A Service and support .....................................................................................	197
Hewlett-Packard limited warranty statement .............................................................................	198
HP's Premium Protection Warranty: LaserJet toner cartridge limited warranty statement .................	200
HP policy on non-HP supplies ................................................................................................	201
HP anticounterfeit Web site ...................................................................................................	202
Data stored on the toner cartridge ..........................................................................................	203
End User License Agreement ..................................................................................................	204
OpenSSL .............................................................................................................................	207
Customer self-repair warranty service .....................................................................................	208
Customer support .................................................................................................................	209
Repack the product ..............................................................................................................	210
Prepare the product for shipping .............................................................................	210
Repack the product ...............................................................................................	214
Appendix B Product specifications ...................................................................................	215
Physical specifications ..........................................................................................................	216
Power consumption, electrical specifications, and acoustic emissions ..........................................	216
Environmental specifications ..................................................................................................	216
Appendix C Regulatory information .................................................................................	217
FCC regulations ...................................................................................................................	218
Environmental product stewardship program ...........................................................................	219
Protecting the environment ......................................................................................	219
Ozone production .................................................................................................	219
Power consumption ...............................................................................................	219
Toner consumption ................................................................................................	219
Paper use .............................................................................................................	219
Plastics .................................................................................................................	219
HP LaserJet print supplies .......................................................................................	220
Return and recycling instructions .............................................................................	220
United States and Puerto Rico ..................................................................	220

ENWW

xiii

Multiple returns (more than one cartridge) ..................................	220
Single returns ..........................................................................	220
Shipping ................................................................................	220
Non-U.S. returns ....................................................................................	221
Paper ..................................................................................................................	221
Material restrictions ...............................................................................................	221
Disposal of waste equipment by users ......................................................................	222
Electronic hardware recycling .................................................................................	222
Chemical substances .............................................................................................	222
Material Safety Data Sheet (MSDS) .........................................................................	222
For more information .............................................................................................	222
Declaration of conformity ......................................................................................................	224
Declaration of conformity (wireless models) .............................................................................	226
Certificate of Volatility ..........................................................................................................	228
Safety statements .................................................................................................................	230
Laser safety ..........................................................................................................	230
Canadian DOC regulations ....................................................................................	230
VCCI statement (Japan) ..........................................................................................	230
Power cord instructions ..........................................................................................	230
Power cord statement (Japan) .................................................................................	230
EMC statement (China) ..........................................................................................	231
EMC statement (Korea) ..........................................................................................	231
EMI statement (Taiwan) ..........................................................................................	231
Laser statement for Finland .....................................................................................	231
GS statement (Germany) ........................................................................................	233
Substances Table (China) .......................................................................................	233
Restriction on Hazardous Substances statement (Turkey) .............................................	233
Restriction on Hazardous Substances statement (Ukraine) ...........................................	233
Additional statements for telecom (fax) products .......................................................................	234
EU Statement for Telecom Operation .......................................................................	234
New Zealand Telecom Statements ...........................................................................	234
Additional FCC statement for telecom products (US) ..................................................	234
Telephone Consumer Protection Act (US) ..................................................................	235
Industry Canada CS-03 requirements ......................................................................	235
Vietnam Telecom wired/wireless marking for ICTQC Type approved products .............	236
Additional statements for wireless products ..............................................................................	237
FCC compliance statement—United States ................................................................	237
Australia statement ................................................................................................	237
Brazil ANATEL statement ........................................................................................	237
Canadian statements .............................................................................................	237
Products with 5 GHz Operation Industry of Canada ..................................................	238

xiv

ENWW

Exposure to Radio Frequency Radiation (Canada) .....................................................	238
European Union regulatory notice ...........................................................................	238
Notice for use in France .........................................................................................	238
Notice for use in Russia .........................................................................................	238
Mexico statement ..................................................................................................	239
Taiwan statement ..................................................................................................	239
Korean statement ..................................................................................................	239
Vietnam Telecom wired/wireless marking for ICTQC Type approved products .............	239
Index ...............................................................................................................................	241

ENWW

xv

List of tables

Table 1-1 Sequence of operation ............................................................................................................	3
Table 1-2 Solenoids ..............................................................................................................................	8
Table 1-3 Switches ................................................................................................................................	9
Table 1-4 Sensors ...............................................................................................................................	10
Table 1-5 Motors ................................................................................................................................	11
Table 1-6 Fans ...................................................................................................................................	12
Table 1-7 High-voltage power supply circuits .........................................................................................	13
Table 1-8 Converted DC voltages .........................................................................................................	15
Table 1-9 Fuser (fixing) components ......................................................................................................	19
Table 1-10 Image formation process .....................................................................................................	26
Table 1-11 Primary-transfer-roller engagement states ...............................................................................	36
Table 1-12 Image-stabilization controls ..................................................................................................	40
Table 1-13 Switches and sensors for the pickup, feed, and delivery system ................................................	41
Table 1-14 Motors and solenoids for the pickup, feed, and delivery system ...............................................	42
Table 1-15 Jams that the product detects ...............................................................................................	57
Table 1-16 Electrical components for the paper feeder ............................................................................	60
Table 1-17 Paper size detection ...........................................................................................................	63
Table 2-1 Control-panel 2ndary Service test access buttons ......................................................................	85
Table 2-2 Plug/jack locations ...............................................................................................................	90
Table 2-3 DC controller connectors .......................................................................................................	91
Table 2-4 Component locations ............................................................................................................	97
Table 2-5 Component locations (1 x 500-sheet paper feeder) ..................................................................	99
Table 2-6 Repetitive defects ................................................................................................................	105
Table 2-7 Event-log messages .............................................................................................................	137
Table 2-8 Event-log-only messages ......................................................................................................	138
Table 2-9 Image defects table ............................................................................................................	155
Table 2-10 Control-panel 2ndary Service test access buttons ..................................................................	173
Table 2-11 Secondary Service menu ...................................................................................................	173
Table B-1 Physical specifications .........................................................................................................	216
Table B-2 Operating-environment specifications ....................................................................................	216

ENWW

xvii

List of figures

Figure 1-1 Relationship between the main product systems .........................................................................	2
Figure 1-2 Engine-control system .............................................................................................................	7
Figure 1-3 DC controller block diagram ...................................................................................................	8
Figure 1-4 High-voltage power supply circuits ........................................................................................	13
Figure 1-5 Low-voltage power-supply circuit ...........................................................................................	14
Figure 1-6 Fuser (fixing) components .....................................................................................................	19
Figure 1-7 Fuser temperature-control circuit ............................................................................................	20
Figure 1-8 Laser/scanner system ...........................................................................................................	23
Figure 1-9 Image formation system ........................................................................................................	25
Figure 1-10 Image formation process ....................................................................................................	26
Figure 1-11 Pre-exposure .....................................................................................................................	27
Figure 1-12 Primary charging ...............................................................................................................	27
Figure 1-13 Laser-beam exposure .........................................................................................................	28
Figure 1-14 Development .....................................................................................................................	28
Figure 1-15 Primary transfer .................................................................................................................	29
Figure 1-16 Secondary transfer ............................................................................................................	29
Figure 1-17 Separation .......................................................................................................................	30
Figure 1-18 Fusing ..............................................................................................................................	30
Figure 1-19 ITB cleaning ......................................................................................................................	31
Figure 1-20 Drum cleaning ..................................................................................................................	31
Figure 1-21 Toner-cartridge system .......................................................................................................	32
Figure 1-22 Developing-roller engagement and disengagement control .....................................................	33
Figure 1-23 ITB unit .............................................................................................................................	35
Figure 1-24 Three states of primary-transfer-roller engagement and disengagement .....................................	36
Figure 1-25 ITB cleaning process ..........................................................................................................	38
Figure 1-26 Toner patterns for calibration ..............................................................................................	39
Figure 1-27 Switches and sensors for the pickup, feed, and delivery system ...............................................	41
Figure 1-28 Motors and solenoids for the pickup, feed, and delivery system ..............................................	42
Figure 1-29 Three main units of the pickup, feed, and delivery system .......................................................	43
Figure 1-30 Pickup-and-feed unit ...........................................................................................................	44
Figure 1-31 Tray-pickup mechanism ......................................................................................................	45
Figure 1-32 Tray presence sensor .........................................................................................................	46

ENWW

xix

Figure 1-33 Tray lift mechanism ............................................................................................................	47
Figure 1-34 Paper-level-detection mechanism ..........................................................................................	48
Figure 1-35 Multifeed prevention ..........................................................................................................	48
Figure 1-36 Multipurpose tray pickup mechanism ...................................................................................	49
Figure 1-37 Paper-feed mechanism .......................................................................................................	50
Figure 1-38 Skew-feed prevention .........................................................................................................	51
Figure 1-39 Fuser and delivery unit .......................................................................................................	52
Figure 1-40 Loop-control mechanism .....................................................................................................	53
Figure 1-41 Pressure-roller pressurization control ....................................................................................	54
Figure 1-42 Duplexing unit ...................................................................................................................	55
Figure 1-43 Jam detection sensors ........................................................................................................	57
Figure 1-44 Optional paper feeder .......................................................................................................	59
Figure 1-45 Signals for the paper feeder ...............................................................................................	60
Figure 1-46 Paper-feeder pickup and feed operation ...............................................................................	61
Figure 1-47 Paper size detection ..........................................................................................................	62
Figure 1-48 Paper-feeder lift .................................................................................................................	64
Figure 1-49 Paper-feeder multiple feed prevention ..................................................................................	65
Figure 1-50 Jam detection ....................................................................................................................	67
Figure 2-1 Control-panel 2ndary Service test access buttons .....................................................................	85
Figure 2-2 Engine test button access ......................................................................................................	87
Figure 2-3 Block diagram (product base) ...............................................................................................	88
Figure 2-4 DC controller PCA ...............................................................................................................	91
Figure 2-5 Component locations (1 of 5) ................................................................................................	93
Figure 2-6 Component locations (2 of 5) ................................................................................................	94
Figure 2-7 Component locations (3 of 5) ................................................................................................	95
Figure 2-8 Component locations (4 of 5) ................................................................................................	96
Figure 2-9 Component locations (5 of 5) ................................................................................................	97
Figure 2-10 1 x 500-sheet paper feeder ................................................................................................	99
Figure 2-11 Timing diagram ...............................................................................................................	100
Figure 2-12 Circuit diagram — product base (1 of 2) ............................................................................	101
Figure 2-13 Circuit diagram — product base (2 of 2) ............................................................................	102
Figure 2-14 Control-panel 2ndary Service test access buttons .................................................................	173
Figure A-1 Prepare the product for shipping (1 of 3) .............................................................................	211
Figure A-2 Prepare the product for shipping (2 of 3) .............................................................................	212
Figure A-3 Prepare the product for shipping (3 of 3) .............................................................................	213
Figure C-1 Certificate of Volatility (1 of 2) ............................................................................................	228
Figure C-2 Certificate of Volatility (2 of 2) ............................................................................................	229

xx

ENWW

1 Theory of operation

●Basic operation

●Formatter-control system

●Engine-control system

●Laser/scanner system

●Image formation system

●Pickup, feed, and delivery system

●Jam detection

●Optional paper feeder

●Scanning/image capture system

●Fax functions and operation

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

2

Chapter 1 Theory of operation

ENWW

Sequence of operation

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

NOTE: The terms fusing and fixing are synonymous.

Table 1-1 Sequence of operation

Period	Duration	Description
Waiting	From the time the power is turned on,	●	Heats the fuser sleeve
	the door is closed, or when the product	●	Pressurizes the fuser pressure roller
	exits Sleep mode until the product has
	fully initialized and is ready for printing	●	Detects the toner cartridges
		●	Detects the home position for the
			primary transfer roller and the
			developing unit
		●	Cleans the secondary transfer roller
Standby	From the end of the waiting sequence or	●	Is fully initialized and is ready to
	the last rotation until the formatter		print.
	receives a print command or until the	●	Enters Sleep mode after the
	product is turned off
			specified length of time
		●	Calibrates if it is time for an
			automatic calibration
Initial rotation	From the time the formatter receives a	●	Activates the high-voltage power
	print command until the paper enters the		supply
	paper path	●	Prepares each laser/scanner unit
		●	Warms the fuser to the correct
			temperature
Printing	From the time the first sheet of paper	●	Forms the image on the
	enters the paper path until the last sheet		photosensitive drums
	has passed through the fuser	●	Transfers the toner to the paper
		●	Fuses the toner image onto the
			paper
		●	Performs calibration after a
			specified number of pages
Last rotation	From the time the last sheet of paper	●	Moves the last printed sheet into
	exits the fuser until the motors stop		the output bin
	rotating	●	Stops each laser/scanner unit
		●	Discharges the bias from the high-
			voltage power supply

ENWW

Basic operation

3

Formatter-control system

The formatter is responsible for the following procedures:

●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 bidirectional 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.

The formatter also provides the electrical interface and mounting locations for an additional DIMM.

Sleep delay

This feature conserves power after the product has been idle for an adjustable period of time. When the product is in Sleep Delay, the control panel backlight is turned off, but the product retains all settings, downloaded fonts, and macros. The default setting is for Sleep Delay to be enabled, and the product enters Sleep Delay after a 15-minute idle time.

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

●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

NOTE: Product error messages override the sleep function. The product enters Sleep Delay at the appropriate time, but the error message continues to appear.

Input/output

The product has three I/O interfaces:

●Hi-Speed USB 2.0

●10/100/1000 Ethernet LAN connection

●Easy-access USB printing (no computer required)

4

Chapter 1 Theory of operation

ENWW

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 appears on the control panel display.

Firmware

The firmware is contained on the formatter. A remote firmware upgrade process is used to overwrite and upgrade the firmware on the formatter.

Nonvolatile memory

The product uses nonvolatile random access memory (NVRAM) to store device 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 which 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.

ENWW

Formatter-control system

5

Control panel

The control panel is a capacitive touchscreen and adjustable viewing angle.

The control panel has a diagnostic mode to allow testing of the touchscreen. The control panel does not require calibration.

USB flash drive

The product features printing from a USB flash drive. The product prints the following file types from the USB flash drive.

●PDF

●RGB JPEG

When a USB flash drive is inserted into the front of the product, the control panel will display the USB Flash Drive menu. The files on the USB flash drive can be accessed from the control panel using the touchscreen. Any RGB JPEG or PDF files on the USB flash drive can be printed directly from the product control panel.

6

Chapter 1 Theory of operation

ENWW

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

●High-voltage power supply

●Low-voltage power supply

Figure 1-2 Engine-control system

AC input
			DC controller
Fuse
Noise filter
	Fusing control			Power switch
Fuse	circuit
Noise filter		PSTYP100		PWRSWON
Zero crossing		/ZEROX
circuit		24VRMT
		+24VB
Switch	+24V	+24VA
Rectifying	generation
circuit
	circuit	SW3
Rectifying		+24VB	+5VD
circuit	Protection circuit			SW1
			Switch	+5VC
Protection circuit
				SW2
		+5VA
		PWRSAVE	+3.3VC
+5V	+3.3V	+3.3VA
generation	generation		Switch
circuit	circuit
Switch		VC5VOFF
Low-voltage power supply
		VC3VOFF
	ICB		+3.3VB
		Switch
				Formatter
			+3.3VA
	+5VB		+5VB

ENWW

Engine-control system

7

DC controller

The DC controller controls the operational sequence of the printer.

Figure 1-3 DC controller block diagram

Fuser

Laser/scanner

Solenoids

Table 1-2 Solenoids

Component abbreviation	Component name
SL1	Primary transfer roller disengagement solenoid
SL2	Duplex reverse solenoid
SL3	Multipurpose-tray pickup solenoid
SL4	Tray pickup solenoid

8

Chapter 1 Theory of operation

ENWW

Clutches

Component abbreviation	Component name
CL1	Duplex re-pickup clutch

Switches

Table 1-3 Switches

Component abbreviation Component name

SW1, SW2	5V interlock switch
SW3	24V interlock switch
SW4	Power switch
SW100	Test print switch

ENWW

Engine-control system

9

Sensors

Table 1-4 Sensors

Component abbreviation	Component name
SR1	Drum home position sensor 1
SR2	Drum home position sensor 2
SR3	Drum home position sensor 3
SR5	Fuser (fixing) delivery sensor
SR6	Delivery tray media full sensor
SR7	Fuser (fixing) pressure release sensor
SR8	TOP (top of page) sensor
SR9	Tray-media-stack surface sensor
SR11	Developing home position sensor
SR13	Tray presence sensor
SR14	Loop sensor 1
SR15	Loop sensor 2
SR17	Primary-transfer-roller disengagement sensor
SR20	Tray-media presence sensor
SR21	MP-tray-media-presence sensor
SR22	Duplex re-pickup sensor
	OHT sensor (in)
	OHT sensor (out)
	RD sensor (front)
	RD sensor (rear)
	Environmental sensor (temperature and humidity)
	Yellow toner-level sensor
	Magenta toner-level sensor
	Cyan toner-level sensor
	Black toner-level sensor
	Toner collection-box-full sensor
	Fuser (fixing) home-position sensor

10 Chapter 1 Theory of operation

ENWW

Motors and fans

The product has 11 motors and three fans. The motors drive the components in the paper-feed and image-formation systems. The fan motors cool the inside of the product.

Table 1-5 Motors

Abbreviation	Name	Purpose	Type	Failure detection
M2	Fuser (fixing) motor	Drives the fuser (fixing)	DC motor	Yes
		roller, the delivery
		roller, and the fuser
		(fixing) pressure roller
M3	Drum motor 1	Drives the	DC motor	Yes
		photosensitive drum
		(yellow/magenta),
		developing unit
		(yellow), and primary
		charging roller
		(yellow/magenta)
M4	Drum motor 2	Drives the	DC motor	Yes
		photosensitive drum
		(cyan), developing unit
		(magenta/cyan), and
		primary charging roller
		(cyan)
M5	Drum motor 3	Drives the	DC motor	Yes
		photosensitive drum
		(black), developing unit
		(black), and ITB drive
		roller, and secondary
		transfer roller
M7	Lifter motor	Drives the lifter for the	DC motor	Yes
		tray
M8	Cyan/black scanner	Drives the scanner	DC motor	Yes
	motor	mirror in the cyan/
		black laser scanner
M9	Yellow/magenta	Drives the scanner	DC motor	Yes
	scanner motor	mirror in the yellow/
		magenta laser scanner
M10	Developing	Drives the developing	Stepping motor	No
	disengagement motor	unit disengagement
M11	Duplex reverse motor	Drives the duplex	Stepping motor	No
		reverse roller and
		duplex feed roller

ENWW	Engine-control system 11

Table 1-5 Motors (continued)

Abbreviation	Name	Purpose	Type	Failure detection
M12	Residual toner-feed	Drives the residual	DC motor	Yes
	motor	toner feed screw
M13	Pickup motor	Drives the tray pickup	Stepping motor	No
		roller, MP tray pickup
		roller, feed roller,

registration roller, and re-pickup roller

Table 1-6 Fans

Abbreviation	Name	Cooling area	Type	Speed
FM1	Power supply fan	Around the power	Intake	Full/half
		supply unit
FM2	Cartridge fan	Around the cartridges	Intake	Full/half
FM3	Delivery fan	Around the delivery	Intake	Full/half
		unit

High-voltage power supply

The high-voltage power supply delivers the high-voltage biases to the following components used to transfer toner during the image-formation process:

●Primary-charging roller (in the cartridge)

●Developing roller (in the cartridge)

12 Chapter 1 Theory of operation

ENWW