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m680mfp
Troubleshooting Manual
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Service Manual
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HP m651, m680mfp Troubleshooting Manual

Color LaserJet Enterprise M651 Color LaserJet Enterprise MFP M680
Troubleshooting Manual
M651dn
M651xhM651n
M680zM680fM680dn
www.hp.com/support/colorljM651
www.hp.com/support/colorljMFPM680
Troubleshooting Manual
Copyright and License
© 2014 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, 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.
ENWW iii
iv Conventions used in this guide ENWW
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
ENWW v
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
vi ENWW
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
ENWW vii
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
viii ENWW
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
ENWW ix
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
x ENWW
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
ENWW xi
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
xii ENWW
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
ENWW xiii
xiv ENWW
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
ENWW xv
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
1
.................................... 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
xvi ENWW
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
1
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
ENWW xvii
xviii ENWW
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

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Basic operation
●
Formatter-control system
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Engine-control system
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Laser/scanner system
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Image-formation system
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Pickup, feed, and delivery system
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Optional paper feeders
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Scanning/image capture system (M680)
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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:
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The engine-control system, which includes the power supply and the DC controller printed circuit assembly (PCA)
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The laser/scanner system, which forms the latent image on the photosensitive drum
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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
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Detects the toner cartridges
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Moves the ITB and developing unit to the home position
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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
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Activates the high-voltage power supply
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Prepares each laser/scanner unit
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Warms the fuser to the correct temperature
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Forms the image on the photosensitive drums
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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:
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Controlling sleep mode
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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
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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
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