IBM 6400-004, 6400-05P, 6400-04P, 6400-005, 6400-050 Maintenance Information Manual

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6400 Line Matrix Printers

Maintenance Information Manual

Cabinet and Pedestal Models

Form Number S246-0117-08

Maintenance Information Manual

Cabinet and Pedestal Models

6400 Line Matrix Printers

S246-0117-08

ENERGY STAR

NOTE: Before using the information and the product it works with, make sure

that you read the general information under “Notices” below. Ninth Edition (August 2000) This edition applies to the IBM 6400 Line Matrix Printer. The following paragraph does not apply to any other country where such

provisions are inconsistent with local law: INTERNATIONAL BUSINESS MACHINES CORPORATION PROVIDES

THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement may not apply to you. Requests for IBM publications should be made to your IBM representative or to the IBM branch office serving your locality. Publications are not stocked at the address given below.

You may send your comments by facsimile to 1-800-524-1519, by E-mail to print_pubs@vnet.ibm.com, or by mail to:

IBM Printing Systems Company Information Development Department H7FE, Building 003G P.O. Box 1900 Boulder, CO 80301-9191 USA

When you send information to IBM or IBM Printing Systems Company, you grant a nonexclusive right to use or distribute the information in any way IBM or IBM Printing Systems Company believes appropriate without incurring any obligation to you.

Note to U.S. Government Users - Documentation related to restricted rights Use, duplication or disclosure is subject to restrictions set forth in GSA ADP Schedule Contract with IBM Corp.

NERGY STAR

The EPA ENERGY STAR** Computers program is a partnership effort with manufacturers of data processing equipment to promote the introduction of energy-efficient personal computers, monitors, and printers, and to reduce air pollution caused by power generation.

IBM participates in this program by introducing printers that reduce power consumption when they are not being used. This feature can cut energy use by up to 50 percent.

Notices

Note: The ENERGY STAR emblem does not represent EPA endorsement of any product or service.

Notices

References in this publication to IBM products, programs, or services do not imply that IBM intends to make these available in all countries in which IBM operates. Any reference to an IBM licensed product, program, or service is

not intended to state or imply that only IBM’s product, program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any of IBM’s intellectual property rights may be used instead of the IBM product. Evaluation and verification of operation in conjunction with other products, except those expressly designated by IBM, is the user’s responsibility.

Any performance data contained in this document was obtained in a controlled environment based on the use of specific data. The results that may be obtained in other operating environments may vary significantly. Users of this document should verify the applicable data in their specific environment. Therefore, such data does not constitute a performance guarantee or warranty.

IBM may have patents or pending patent applications covering subject matter in this document. The furnishing of this document does not give you any license to th ese pa te nts. Yo u can se nd lic ens e inqu ir ies, in writ ing, to th e IBM Corporation, IBM Director of Licensing, 208 Harbor Drive, Stamford, Connecticut, United States, 06904.

Electrical Safety

This printer is inspected and listed by recognized national testing laboratories, such as Underwriters Laboratories, Inc. (UL**) in the U.S.A. and Canadian Standards Association (CSA**) in Canada. Listing of a product by a national testing laboratory indicates that the product is designed and manufactured in accordance with national requirements intended to minimize safety hazards. IBM equipment meets a very high standard of safety in design and manufacture. Remember, however, that this product operates under conditions of high electrical potentials and heat generation, both of which are functionally necessa r y.

Trademarks And Service Marks

The following terms, denoted by an asterisk (*) in this publication, are trademarks of IBM Corporation in the United States or other countries or both:

AS/400 IBM PC-DOS RISC System/6000 SCS Token-Ring

The following terms, denoted by a double asterisk (**) in this publication, are trademarks of other companies:

Acrobat Adobe Systems Incorporated Adobe Adobe Systems Incorporated AMD Advanced Micro Devices, Inc. Centronics Genicom Corporation Code V Quality Micro Systems CSA Canadian Standards Association Dataproducts Dataproducts Corporat ion ECOS ECOS Electronics Corp., Inc., Oak Park, Ill. EIA Electronic Industries Association Energy Star United States Environmental Protection Agency Epson Seiko Epson Corporation Ethernet Xerox Corporation Fluke John Fluke Manufacturing Co., Inc. FX Seiko Epson Corporation IEEE Institute of Electrical and Electronics Engineers, Inc. IGP Printronix, Inc. Motorola Motorola, Inc. MS-DOS Microsoft Corporation MTOS Industrial Programming, Inc. PrintNet Printronix, Inc. Printronix Printronix, Inc. QMS Quality Micro Systems, Inc. RibbonMinder Printronix, Inc. Siemens Fujitsu Siemens Corporation SureStak Printronix, Inc. Torx Camcar/Textron Inc. UL Underwriters Laboratories, Inc.

Table of Contents

ENERGY STAR ................................................................................4

Notices ..............................................................................................5

Electrical Safety ................................................................................5

Trademarks And Service Marks........................................................6

1 Maintenance Overview........................................13

About The Printer................ ............................................. ...... ................13

The IBM 6400 Series Printer Family......................................................13

Hanzi Printers..................................................................................14

Printer Evolution..............................................................................15

How To Identify The Printer.......................... ...... ....... ...... ....... .........15

Important Maintenance Notes.........................................................16

About This Manual.............. ...... ...... ....... ...... ....... ...... ....... ......................16

How To Use This Manual................................................................16

Notes And Notices ..........................................................................17

Printing Conventions In This Manual...............................................18

Related Documents.........................................................................18

Controls And Indicators .........................................................................20

Electrical Controls, Cabinet Models ................................................20

Electrical Controls, Pedestal Models...............................................22

Mechanical Controls, All Models.....................................................24

Tools, Test Equipment, And Supplies....................................................26

2 Installation ........................................................... 27

Installing And Configuring The IBM 6400 Printer...................................27

3 Preventive Maintenance............................ .......... 29

Cleaning The Printer................. ...... ....... ...... ....... ...... .............................29

Cleaning The Exterior ........................................ ....... ......................29

Cleaning The Interior............................. ....... ...... ....... ...... ....... ...... ... 3 0

Cleaning The Shuttle Frame Assembly...........................................31

Cleaning The Card Cage Fan Assembly.........................................33

4 Principles Of Operation ....................................... 35

Line Matrix Printing................................................................................35

Printing Rates ........................................................................................38

Table of Contents

Printing Mechanism ...............................................................................38

Shuttle Frame Assembly .................................................................39

Paper Transport System .................................................................41

Ribbon Transport System ...............................................................42

Logical Control Of The Printer...............................................................43

Printer Electronics...........................................................................43

Operator Panel ......................... ....... ...... ...... ....... ...... ....... ...... ....... ...... ...44

CMX Controller Board............................................................................45

Data Controller................................................................................47

Engine Controller ............................................................................49

Printer Interface.....................................................................................51

10Base2 And 10Base-T LEDs And DIP Switches ..........................52

10/100Base-T LEDs And DIP Switches..........................................54

Power Supply Board..............................................................................57

AC Power........................................................................................57

DC Power........................................................................................57

Graphics ................................................................................................58

5 Troubleshooting...................................................59

Introduction............................................................................................59

Troubleshooting Aids.............................................................................59

Start Of Call...........................................................................................60

Troubleshooting Display Messages.......................................................61

Message List...................................................................................62

Troubleshooting Other Symptoms.......................................................109

General Symptom List...................................................................110

Communications Failures ....................................................................131

Operator Print Tests .............................. ...... ....... ...... ...........................13 2

Selecting And Running Tests........................................................133

Customer Engineer (CE) Tests............................................................134

Boot Diagnostics Menu .................................................................137

Hex Code Printout ...............................................................................140

ASCII Character Set........... ...... ....... ...... ...... ....... ...... ....... ...... ..............142

Printer Information Menu .....................................................................143

Soft vs. Hard Reset..............................................................................145

Soft Reset .....................................................................................145

Hard Reset (“Cycle Power”)..........................................................145

The Power On Sequence ....................................................................146

CMX Controller Board Handshake Sequences.............................146

DC Software Initialization And Power Up......................................150

Table of Contents

6 Adjustment Procedures...................... ............... 151

Introduction..........................................................................................151

List Of Adjustments...... ...... ...... ....... ...... ....... ...... ...........................151

Preparing The Printer For Maintenance ..............................................152

Returning The Printer To Normal Operation........................................153

Belt, Paper Feed Timing, Adjustment..................................................154

Belt, Platen Open, Adjustment.............................................................156

Paper Drive Motor Pulley Alignment....................................................158

Paper Scale Alignment ........................................................................160

Platen Gap Adjustment........................................................................162

Platen Open Motor Pulley Alignment...................................................164

Ribbon Guide Alignment......................................................................166

Splined Shaft Skew Adjustment...........................................................168

Adjusting The End Of Forms Distance ................................................169

Hammer Phasing Adjustment..............................................................173

Downloading 6400 Microcode From The World Wide Web.................175

Loading Flash Memory ........................................................................176

Coil Temperature Adjustment..............................................................181

Set Shuttle Speed................................................................................182

Ethernet Initialization ...........................................................................183

7 Replacement Procedures

And Illustrated Parts Lists....................................... 185

Organization Of This Chapter..............................................................185

Section I: Replacement Procedures ....................................................186

List Of Procedures ............................................. ....... ....................186

Belt, Paper Feed Timing ...............................................................188

Belt, Platen Open......... ...... ...... ....... ...... ....... ...... ....... ...... ....... .......189

Circuit Board: Controller................................................................190

Circuit Board: Power Supply .........................................................192

Circuit Breaker ..............................................................................193

Coax/Twinax Multi-Platform Interface ...........................................194

Connector Shells...........................................................................195

Connector Stiffening Clips.............................................................198

Cover Assembly, Hammer Bank / Ribbon Mask ...........................200

Cover Assembly, Shuttle...............................................................203

Cover Assembly, Top, Pedestal Model.........................................204

Dashpot.........................................................................................205

Doors, Cabinet, Reversing ............................................................206

Ethernet Interface Assemblies ......................................................207

Fan Assembly, Cabinet Exhaust...................................................208

Fan Assembly, Card Cage ............................................................209

Table of Contents

Fan Assembly, Hammer Bank ......................................................210

Hammer Spring Assembly ............................................................211

IBM Coax/Twinax Expansi on Boa rd..............................................215

Magnetic Pick-up (MPU) Assembly...............................................216

Memory and Security Modules......................................................217

Motor Assembly, Paper Feed........................................................221

Motor Assembly, Platen Open ......................................................223

Motor Assembly, Ribbon Drive......................................................225

Network Print Server .....................................................................226

Operator Panel Assembly, Cabinet Model....................................227

Operator Panel Assembly, Pedestal Model ..................................228

Paper Guide Assembly .................................................................229

Paper Ironer ..................................................................................230

Platen............................................................................................231

Resistors, Terminating ..................................................................235

Ribbon Guide Assembly (L/R).......................................................237

Ribbon Hub ...................................................................................238

Shaft, Splined........ ....... ...... ....... ...... ...... ....... ................................. 23 9

Shaft, Support ................................. ...... ....... ...... ....... ....................241

Shuttle Frame Assembly ...............................................................242

Spring, Extension..........................................................................244

Switch Assembly, Cover Open......................................................245

Switch Assembly, Paper Detector.................................................246

Switch Assembly, Platen Interlock ................................................247

Tractor (L/R)..................................................................................248

Section II: Illustrated Parts Lists ..........................................................249

Illustrations Of Printer Components ..............................................249

A Wire Data ..........................................................287

Circuit Board And Cable Pinouts.........................................................287

B Printer Specifications.........................................327

Ribbon Specifications ..........................................................................327

Paper Specifications............................................................................328

Printer Dimensions ..............................................................................329

Environmental Characteristics.............................................................329

Electrical Characteristics .....................................................................330

Interfaces.............................................................................................336

Duty Cycle ...........................................................................................336

C Metric Conversion Tables ................................. 337

Length ...........................................................................................337

Torque and Force..........................................................................337

Table of Contents

Mass and Density..........................................................................338

Temperature..................................................................................338

Power............................................................................................338

D Torque Table.................................................... .339

E Safety Inspection Guide.................................... 341

Safety Inspections ...............................................................................341

Preparation..........................................................................................341

Prepare The Printer for Inspection.......................................................342

Inspect Mechanical Parts .... ...... ...... ....... ...... ....... ...... ....... ...... ..............342

Inspect Electrical Parts ............................................. ...........................343

F Abbreviations And Signal Mnemonics............... 347

G Cords And Adapters ......................................... 355

H Part Numbers.................................................... 357

I Noise Suppression Devices................................ 365

J SureStak Power Stacker.................................... 367

Contents ..............................................................................................367

Introduction..........................................................................................368

Stacker Operation................................................................................368

Removing The Power Stacker.............................................................375

Installing The Power Stacker....................... ....... ...... ....... ...... ..............380

Replacing The Constant Force Spring.................................................391

Replacing The Timing Belts.................................................................394

Illustrated Parts Breakdown.................................................................398

Table of Contents

1 Maintenance Overview

About The Printer

The entire system architecture of an IBM* 6400 line matrix printer is contained on one circuit board. The use of DRAM and flash memory on this board permits rapid access to stored printer emulations and fast processing of print data. A variable-speed shuttle and half-step paper control enables the printer to print a wide variety of high-volume jobs with minimum maintenance and maximum reliability.

Although technologically advanced, the printer is easy to use. The operator can select every printer function at the control panel or by sending printer control codes in the data stream from the host computer.

This is also an excellent graphics printer, with optional features that simplify the creation of dot images. The IGP** and Code V** Printronix** emulations are simple but versatile graphics programming languages that load into flash memory.

The IBM 6400 Series Printer Family

The IBM 6400 Line Matrix Printer family consists of pedestal mount and floor cabinet models that print at different speeds, as shown in Table 1. Some models are available in either floor cabinet or pedestal housings, while other models are available only in floor cabinets.

The print speeds listed in Table 1 are the maximum speeds attainable under controlled conditions. Actual print speed is determined by the interaction of many variables. For more information, refer to the discussion of Printing Rates on page 38.

Chapter 1 The IBM 6400 Series Printer Family

Hanzi Printers

IBM 6400-C05 and 6400-C5P printers have shuttle assemblies, hammer springs, and software specially designed to print the GB character set and

Song typeface used in the People’s Republic of China. These printers can mix ASCII and Hanzi characters on the same line, with ASCII characters occupying half the width of Hanzi character cells. Because of the density and

Table 1. The IBM 6400 Series Printer Family

Model

Number

Speed

Enclosure

Hammer

Bank

Data

Controller

Clock

6400-004 475 lpm Cabinet 28 Hammers 25 MHz 6400-04P 475 lpm Pedestal 28 Hammers 25 MHz 6400-005 500 lpm Cabinet 28 Hammers 25 MHz 6400-05P 500 lpm Pedestal 28 Hammers 25 MHz 6400-050 500 lpm Cabinet 28 Hammers 40 MHz 6400-P50 500 lpm Pedestal 28 Hammers 40 MHz 6400-008 800 lpm Cabinet 49 Hammers 25 MHz 6400-08P 800 lpm Pedestal 49 Hammers 25 MHz 6400-009 900 lpm Cabinet 49 Hammers 25 MHz 6400-09P 900 lpm Pedestal 49 Hammers 25 MHz 6400-010 1000 lpm Cabinet 60 Hammers 40 MHz 6400-P10 1000 lpm Pedestal 60 Hammers 40 MHz 6400-012 1200 lpm Cabinet 91 Hammers 25 MHz 6400-014 1400 lpm Cabinet 91 Hammers 40 MHz

6400-015 1500 lpm Cabinet 102 Hammers 40 MHz 6400-C05 585 lpm Cabinet 91 Hammers 40 MHz 6400-C5P 585 lpm Pedestal 91 Hammers 40 MHz

The microprocessor of the Data Controller unit on the CMX controller

board runs at 25 MHz or 40 MHz, depending on printer model. This means there are two kinds of CMX controller board for IBM 6400 printers, used as shown in this table. The 40 MHz controller board, however, is backwards compatible in all models that use the 25 MHz board.

Printer Evolution

complexity of Hanzi characters, the highest rated speed for these models is 585 lpm.

Printer Evolution

IBM 6400-050, -P50, -010, -P10, and -015 printers use a redesigned shuttle frame assembly, hammer bank, and ribbon guides. These models use the CMX 040 controller board, which has a 40 MHz clock speed on the Data Controller unit. These models use standard hammer springs, which have 16 MIL (0.016 inch) tips.

IBM 6400-C05 and -C5P printers use a shuttle frame assembly, hammer spring assemblies, and software specially designed to print complex Hanzi characters. The hammer springs have 10.5 MIL (0.0105 inch) tips and are unique to these printers. The 6400-C05 and -C5P printers also use the CMX 040 controller board, which has a 40 MHz clock speed on the Data Controller unit.

Except for the CMX 040 controller board and ribbon guides, which are backwards compatible with all 6400 printers, the redesigned components of these newer models are not compatible with earlier models.

When replacing components, be careful to order the correct spares for the model you are servicing. The next section explains how to identify an IBM 6400 printer.

How To Identi fy T he Prin ter

The model number of the printer indicates the printer family, speed, and type of enclosure. (See Figure 1.)

Figure 1. How to Interpret Model Numbers

IBM 6400 Printer Family

* Uses hammer springs with 10.5 MIL (0.0105 inch) tips. Standard hammer tips are 16 MIL (0.016 inch).

6400-04P

Enclosure Code: P = Pedestal Model No Code = Cabinet Model

Maximum Speed Rating: 004 = 475 lpm 005 = 500 lpm (25 MHz controller) 050 = 500 lpm (40 MHz controller) C05 = 585 lpm Hanzi* 008 = 800 lpm 009 = 900 lpm 010 = 1000 lpm 012 = 1200 lpm 014 = 1400 lpm 015 = 1500 lpm

Chapter 1 About This Manual

Important Maint enance Notes

To ensure the best performance of the printer, remember these important maintenance concepts when you service the printer.

ATTENTION

Failure to observe the guidelines below can result in damage to the equipment.

• Do not adjust the platen gap unless the original shuttle frame assembly or

platen has been replaced with a new or rebuilt unit, or unless instructed to do so in the troubleshooting chapter.

• Never bend or “tweak” hammer springs. Always handle the hammer

springs by the thick mounting base. The hammer springs and hammer tips are delicate and precisely aligned.

• Use only the ribbons specified in Appendix B. Use of incorrect ribbons

can lead to ink migration problems, degraded print quality, and expensive damage to the printer.

• Do not close the forms thickness lever too tightly. Closing the forms

thickness lever too tightly can lead to smearing, degraded print quality, paper jams, and damage to the platen and shuttle assembly.

About This Manual

This is a field service maintenance manual. It is designed so that you can quickly locate maintenance information.

How To Use This Manual

1. Find the procedure or information you need in the Table of Contents or the Index.

2. Read the entire procedure before you do it.

3. Gather the parts and tools you will need.

4. Make sure you understand all safety notices before you start a task. Notes and notices are defined below.

Notes And Notices

For your safety and to protect valuable equipment, it is very important that you read and comply with all information highlighted under notes and notices:

ATTENTION

The word Attention indicates the possibility of damage to a program, device, system, or data.

<#> The word Danger next to the lightning slash indicates the

presence of a hazard that could cause death or serious personal injury. Danger and Caution notices are numbered to help you find the translated versions in the

IBM 4400

Safety Notices

booklet.

<#> The word Caution next to the exclamation point (!) indicates

the presence of a hazard that could cause moderate or minor personal injury.

<#> The word Caution next to this symbol indicates a heavy

assembly that requires two or more persons to lift or hold.

<#> The word Caution next to this symbol indicates a part or

assembly that is sharp enough to cut you.

DANGER

CAUTION

Chapter 1 About This Manual

IMPORTANT

The word Important indicates information vital to proper operation of the printer.

NOTE: A note gives you helpful tips about printer operation and

maintenance.

Printing Conventions In This Manual

Operator panel keys and LCD messages are set off from regular text in this manual:

• Operator panel keys and indicators are printed boldface.

Example: Press the Cancel key, then press the Start key.

• Liquid Crystal Display (LCD) messages are printed in capital letters inside

quotation marks ( “ ” ). Example: Press the Stop key. “NOT READY” appears on the LCD.

• Key combinations are denoted by the + (plus) symbol.

Example: Press Scroll↑ + Scroll↓ means

Press the Scroll↑ key and the Scroll↓ key at the same time.

Related Documents

•

IBM 6400 Code V User’s Manual:

Form No. S544-5638 Provides information used with the optional Code V Printronix emulation enhancement feature. The Code V Printronix emulation allows the user to create and store forms, generate logos, bar codes, and expanded characters, create other graphics, and merge graphics with alphanumeric data as a document is printed.

•

IBM 6400 IGP User’s Manual:

Form No. S544-5639 Provides information used with the optional IGP Printronix emulation enhancement feature. The IGP Printronix emulation allows the user to create and store forms, generate logos, bar codes, and expanded characters, create other graphics, and merge graphics with alphanumeric data as a document is printed.

Installation, configuration, and troubleshooting of the Network Print Server and internal Network Interface Card (NIC) are covered in the following documents:

•

Print Server User’s Guide,

Part No. 30H4056

•

Ethernet** Interface User’s Manual

, Form No.S246-0153

(10Base2 and 10Base-T cards

)

•

Ethernet Interface User’s Manual

, Form No. S246-0154

(10/100Base-T card

)

Chapter 1 Controls And Indicators

Controls And Indicators

Electrical Controls, Cabinet Models

Key or Indicator Function

Power Indi cator Lit when the printer is on. Ready Indicator Lit when the printer is in READY mode (on-line), no errors are pending, and the printer is

ready to process data. Off when the printer is in NOT READY mode (off-line).

Processing Indicator Flashes when the printer is receivi ng data from the host.

Attention Indicator Flashes when an error occurs. After correcting the error, press Stop to turn off this LED.

Power Switch Applies AC power to the printer: (1 = on, 0 = off.) This switch is also a circuit breaker.

LCD The LCD (Liquid Crystal Display) displays printer status messages. Start Puts the printer in the READY (on-line) mode. This key also clears fault conditions, exits

program mode me nus , m ov es paper back to print position a fter View is pressed, and rest ore s print position after an eject.

Stop Puts the printer in the NOT READY (off-line) mode. This key also silences the audible alarm,

stops a Printer Test, and restores after an eject. Stop + Enter resets the printer.

Form Feed Advances paper to next Top-Of-Form, as defined by the current page length.

Set Top Of Form Sets TOF and moves paper d ownwa rd fro m t he tractor alignment notches to the print pos ition.

Line Feed Moves paper up one line, as determined by current line spacing.

View Press to move the current print position up to the tractor area for viewing. Press again to

return paper to original print position.

Cancel Cancels a print job.

Eject / Restore Moves paper for viewing or tear-off. This key is configurable: refer to the

Operator’s Guide.

Menu If in the NOT READY mode, this key puts the printer in the PROGRAM mode. If the

configuration menus are locked, the LCD indicates the operator panel is locked.

Enter Selects the option displayed on the LCD. This action either sets a value, moves to the next

lower level of configuration, or starts a self-test. Stop + Enter resets the printer.

Return Returns to the next higher level of a configuration menu.

Micro

↑

In the NOT READY mode, moves the paper upward 1/72 inch (“micro-step” function).

Micro

↓

In the NOT READY mode, moves the paper downward 1/72 inch (“micro-step” function).

Scroll

↑

In the PROGRAM mode, this key moves to the next menu (“Scroll” function).

Scroll

↓

In the PROGRAM mode, this key moves to the previous menu (“Scroll” function).

Printer Configuration Prints the current configuration.

Stop + Enter Soft reset: load power on configuration in memory. Printer must be in NOT READY mode.

Scroll ↑ + Scroll ↓

Toggles the lock on the configuration menus.

Electrical Controls, Cabinet Models

Figure 2. Electrical Controls, Cabinet Models

Ready

Power

Cancel

Processing

Start

Stop

Form Feed

Set Top Of Form

Line Feed

Enter

Return

Scroll

View

Attention

Scroll

Micro

Printer Configuration

Eject/ Restore

LCD

Power Switch

(Off) (On)

Chapter 1 Controls And Indicators

Electrical Contro ls , Pede stal Models

Key or Indicator Function

Power Indicator Lit when the printer is on. Ready Indicator Lit when the printer is in READY mode (on-line), no errors are pending, and the printer is

ready to process data. Off when the printer is in NOT READY mode (off-line).

Processing

Indicator

Flashes when the printer is receiving data from the host.

Attention Indicator Flashes when an error occurs. After correcting the error, press Stop to turn off this LED.

Power Switch Applies AC power to the printer: (1 = on, 0 = off.) This switch is also a circuit breaker.

LCD The LCD (Liquid Crystal Display) displays printer status messages. Start Puts the printer in the READY (on-line) mode. This key also clears fault conditions, exits

program mode menus, moves paper back to print position after View is pressed, and restores print position after an eject.

Stop Puts the printer in the NOT READY (of f-li ne) mod e. This key al so silen ces th e audib le alarm,

stops a Printer Test, and restores after an eject. Stop + Enter resets the printer.

Form Feed Advances paper to next Top-Of-Form, as defined by the current page length.

Set Top Of Form Sets TOF and moves paper dow nward from the tractor alignment notches to the print

position.

Line Feed Moves paper up one line, as determined by current line spacing.

View Press to move the current print position up to the tractor area for viewing. Press again to

return paper to original print position.

Cancel Cancels a print job.

Eject / Restore Moves paper for viewing or tear-off. This key is configurable: refer to the

Operator’s Guide.

Menu If in the NOT READY mode, this key puts the printer in the PROGRAM mode. If the

configuration menus are locked, the LCD indicates the operator panel is locked.

Enter Selects the option displayed on the LCD. This action either sets a value, moves to the next

lower level of configuration, or starts a self-test . Stop + Enter resets the printer.

Return Returns to the next higher level of a configuration menu.

Micro

↑

In the NOT READY mode, moves the paper upward 1/72 inch (“micro-step” functi on).

Micro

↓

In the NOT READY mode, moves the paper downward 1/72 inch (“mic ro-step” function).

Scroll

↑

In the PROGRAM mode, this key moves to the next menu (“Scroll” function).

Scroll

↓

In the PROGRAM mode, this key moves to the previous menu (“Scroll” function).

Printer

Configuration

Prints the current configuration.

Stop + Enter Soft reset: load power on configuration in memory. Printer must be in NOT READY mode.

Scroll

↑ + Scroll ↓

Toggles the lock on the configuration menus.

Electrical Controls, Pedestal Models

Figure 3. Electrical Controls, Pedestal Models

Ready

Power

Cancel

Processing

Start

Stop

Form Feed

Set Top Of Form

Line Feed

Enter

Return

Scroll

View

Attention

Scroll

Micro

Printer Configuration

Eject/ Restore

LCD

Power Switch

(Off) (On)

Chapter 1 Controls And Indicators

Mechanical Controls, All Models

Control or

Indicator

Function

Forms Thickness Lever

Sets the platen for paper and forms of different thicknesses. Lever must be fully opened (raised) to load or unload paper.

Paper Supports Help prevent paper jams by supporting inner sections of paper. They are

positioned manually by sliding them along the tractor shafts.

Forms Thickness Pointer and Scale

Indicates relative thickness of forms and paper. Set this lever at A for thin (single-part) forms, B for thicker forms, and so on.

Tractors (2) Hold and feed paper. Used to set side margin and position paper

horizontally. Tractor Locks (2) Lock tractors in position. Horizontal

Adjustment Knob

Allows fine positioning of left print margin. Moves paper and tractors left or

right. Vertical Position

Knob

Used to set top of form or first line to be printed. Rotate this knob to move

paper vertically. Works when forms thickness lever is open. Ribbon Loading

Path Diagrams

Instructions showing how to load the ribbon correctly. One diagram is cast

in relief on the shuttle cover, and another is printed on the paper scale. Paper Scale A horizontal scale graduated in tenths of an inch, useful for setting paper

margins counting text columns. (See below.)

110 20

1 inch

0.1 inch

Column Number

Mechanical Controls, All Models

Figure 4. Mechanical Controls, All Models

Horizontal Adjustment Knob

Tractor Lock

Left Tractor

Right Tractor

Vertical Position Knob

Forms Thickness Lever and Scale

Forms Thickness Pointer

Tractor Lock

Paper Supports

Ribbon Loading Path Diagrams

Chapter 1 Tools, Test Equipment, And Supplies

Tools, Test Equipment, And Supplies

The tools and equipment required for field level maintenance of the printer are listed below.

Item Part No.

6400 Line Matrix Printer Configuration Utility Disk 63H7379 1-30 Inch-pound Torque Screwdriver 16F1661 ESD Wrist Strap 6405959 Feeler Gauge, .010 inch Feeler Gauge, .011 inch Feeler Gauge, .040 inch Force Gauge, 20 lb. 25F9687 Grip Ring Pliers 9900317 Lubricant, Bearing, IBM #20 117397 DIP Module Extracting Tool 9900764 Nut Driver, 1/4 inch Nut Driver, 5/16 inch Open End Wrench, 7/32 inch 1650843 Open End Wrench, 5/16 inch 9900005 PLCC Module Pick Extraction Tool 73G5523 PLCC Module Plier Extraction Tool 10G3902 Screwdriver, Phillips, #1 73G5362 Screwdriver, Phillips, #2 73G5363 Spring Hook, Heavy Duty Tie Wraps 75X5972 Torque Screwdriver Adapter 39F8449 Torque Screwdriver Hex Adapter 3/32 inch 39F8451 Torque Screwdriver Hex Adapter 5/32 inch 39F8450 Torque Screwdriver Hex Adapter 3/16 inch 39F8455 Torque Screwdriver Hex Adapter 5/64 inch 16F1663 Torx** T-10 Bit 83F2834

2 Installation

Installing And Configuring The IBM 6400 Printer

Installation and configuration of the printer are covered in the

6400 Line Matrix Printer Set-Up Guide

, Form No. S544-5640

Installation, operation, and replacement parts for the optional coax/twinax interface are covered in the

Coax/Twinax Multi-Platform Interface Option

Installation and Operation Guide

, Form No. S246-0149

Installation, configuration, and troubleshooting of the Network Print Server are covered in the following documents:

•

IBM Network Print Server Ethernet Administrator’s Guide,

Form No. S246-0111

•

IBM Network Print Server Token-Ring Administrator’s Guide,

Form No. S246-0112

• The

Network Print Server Technical Reference Manual

is included on a

diskette that comes with the Network Print Server. This “softcopy” document is in Adobe** Acrobat** Reader format.

Installation, configuration, and troubleshooting of the internal Network Interface Card are covered in two manuals:

• 10Base2 and 10Base-T cards

: Ethernet Interface User’s Manual

Form No.S246-0153

• 10/100Base-T card

: Ethernet Interface User’s Manual

Form No. S246-0154

Chapter 2 Installing And Configuring The IBM 6400 Printer

3 Preventive Maintenance

Cleaning The Printer

Aside from normal replenishment of paper and ribbons, the only preventive maintenance required for the printer is periodic cleaning.

Because operating conditions vary widely, the user must determine how often to clean the printer.

There is no guarantee that the user will clean the printer regularly, however, so you should clean the printer whenever you are called to service it.

ATTENTION

Do not use abrasive cleaners, particularly on the window. Do not drip water into the printer. Damage to the equipment will result. Do not spray directly onto the printer when using spray solutions (spray the cloth, then apply the dampened cloth to the printer). Do not vacuum circuit boards.

Cleaning The Exterior

1. Power off the printer.

2. Disconnect the AC power cord from the power source.

3. Wipe the outside of the enclosure with a clean, lint-free cloth dampened (not wet) with water and a mild detergent or window cleaning solution.

4. Dry the enclosure with a clean, lint-free cloth.

5. Clean the inside of the printer, as described below.

<2> Switch off printer power and unplug the printer power cord

before cleaning the printer.

DANGER

Chapter 3 Cleaning The Printer

Cleaning The Interior

1. Power off the printer.

2. Disconnect the AC power cord from the power source.

3. Open the printer cover.

4. Remove paper from the printer.

5. Remove the ribbon.

6. Using a soft-bristled, non-metallic brush, wipe paper dust and ribbon lint off the tractors, shuttle cover assembly, base casting, and ribbon guides. Vacuum up the residue. (See Figure 5.)

7. Wipe the splined shaft and the ribbon guides with a soft cloth.

8. Vacuum up dust or residue that has accumulated inside the lower cabinet.

9. Wipe the interior of the lower cabinet with a clean, lint-free cloth dampened with water and a mild detergent or window cleaning solution.

10. Dry the cabinet interior with a clean, lint-free cloth.

11. Clean the shuttle frame assembly, as described below.

Figure 5. Cleaning Inside the Cabinet or Top Cover

Splined Shaft

Shuttle Cover Assembly

Base Casting

NOTE: Cabinet model shown. Procedure is the same for pedestal model.

Ribbon Guide (2)

Forms Thickness Lever

Tractors

Cleaning The Shuttle Frame Assembly

1. Remove the shuttle cover assembly (page 203).

2. Remove the shuttle frame assembly (page 242).

3. Remove the paper ironer (page 230).

4. Wipe the paper ironer with a soft cloth to remove lint, ink, and paper residue.

5. Install the paper ironer (page 230).

6. Remove the hammer bank / ribbon mask cover assembly (page 200).

ATTENTION

The thin plate (ribbon mask) of the hammer bank cover assembly is fragile. Be careful not to over-bend or kink the ribbon mask when handling and cleaning the hammer bank cover assembly.

7. Using a clean soft cloth, wipe the hammer bank cover and ribbon mask to remove lint, ink, and paper residue. Clean the holes in the cover strips. Carefully wipe between the hammer bank cover and the ribbon mask (early models).

ATTENTION

Do not use solvents or liquids to clean the hammer tips. Clean the hammer tips gently; too much pressure can chip hammer tips.

8. Using a stiff, non-metallic brush (such as a toothbrush), gently brush the hammer tips to remove lint and ink accumulations. (See Figure 6.) Vacuum up any residue.

<2> Over time the upper edge of the paper ironer can become

sharp. To avoid cutting yourself handle the paper ironer on the sides.

CAUTION

Chapter 3 Cleaning The Printer

Figure 6. Cleaning the Hammer Tips

ATTENTION

The hammer bank contains a strong magnet. To prevent damage to the hammer tips, do not let the hammer bank cover assembly snap into place as the hammer bank magnet attracts it. Any impact of the cover against the hammer bank can break hammer tips.

9. Install the hammer bank / ribbon mask cover assembly (page 200).

10. Install the shuttle frame assembly (page 242).

11. Install the shuttle cover assembly (page 203).

12. Clean the card cage fan assembly, as described on the next page.

NOTE: 6400-004 hammer bank is shown. Procedure is the same for all hammer banks.

Hammer Tip

Cleaning The Card Cage Fan Assembly

1. Cabinet Models: Remove the paper guide assembly (page 229). Pedestal Model: Remove the top cover assembly (page 204).

2. Vacuum the card cage fan assembly and surrounding areas to remove paper particles, dust, and lint. (See Figure 7.)

3. Cabinet Models: Install the paper guide assembly (page 229). Pedestal Model: Install the top cover assembly (page 204).

4. Close the printer cover.

5. Connect the AC power cord to the power source.

Figure 7. Cleaning the Card Cage Fan Assembly

NOTE: Cabinet model shown.

Procedure is the same for pedestal model.

Chapter 3 Cleaning The Printer

4 Principles Of Operation

Line Matrix Printing

The printer creates characters and graphics by printing patterns of ink dots on paper, an entire line at a time. This technique is called line matrix printing.

Every text character is stored in printer memory as a pattern of dots on a logical grid called the dot matrix. (See Figure 8.) The ink dots are made by a row of small hammers mounted on a shuttle that sweeps rapidly back and forth. Printer logic circuits divide every line of incoming data into horizontal dot rows. The hammers put dots at the required positions for the entire

line by

striking an inked ribbon and the paper.

Figure 8. A Dot Matrix

112Column No.

0.01389 inch

0.02 inch

First row and column of next character column (at 10 cpi)

Lowest descender dot line

First row and column of next character line (at 6 LPI)

0.00835 inch

0.10 inch

Chapter 4 Line Matrix Printing

When the shuttle reaches the end of a sweep, it reverses direction, the paper is advanced one dot row, and the hammers print the next row of dots as the shuttle sweeps in the opposite direction. After a line of characters is printed, hammer action stops and the paper advances to the first dot row of the next print line. The number of dot rows allowed for line separation depends on the vertical line spacing the user selects.

The dot matrix patterns of text characters vary according to the font the user selects. For example, in the data processing (DP) font at a line spacing of six lines per inch (lpi), a dot matrix contains 12 dot rows from the top of one character line to the top of the next. (See Figure 8 and Figure 9.) At eight lpi there are nine dot rows per character line, at nine lpi eight dot rows per character line, and so on.

Each individual hammer spring forms more than one character as the shuttle moves horizontally. This principle is illustrated in Figure 10.

Figure 9. Standard Character Formation

1 2 3 4 5 6 7 8

9 10 11

n 1 2

* **

One Text Line

Paper Feed Direction

Number of rows determined by line spacing

Direction of Shuttle Movement

* This row is used only for lowercase descenders ** This row is used for underlining and lowercase descenders

Dot

Row

Start

Figure 10. Action of One Hammer Spring in Text Printing

= Hammer Released and Dot Printed

******

1 13 135 1 357 1357 9

1 2 3 4 5 6 7

1 2 3 4 5 6

1 2 3 4 5

1 2 3

1 2

1 2 3

NOTE:

Even column dot centers within the printed character area and character space hammer positions are not illustrated in this diagram.

= Hammer Not Released; No Dot Printed

Succesive Hammer Strokes Per Scan

Shuttle

Scan

Dot

Row

Chapter 4 Printing Rates

Printing Rates

Because a line matrix printer prints entire lines sequentially, it is faster than a moving-printhead printer, which prints single characters sequentially. The printing speed of text is measured in lines per minute (lpm) rather than characters per minute (cpm).

Many variables affect printing speed, the main ones being the selected font and the vertical dot density. Lines containing attributes such as bold or emphasized print, superscripts, subscripts, or elongated characters also reduce print speed to never less than half the rates of lines without such attributes. The actual print rate of lines containing these attributes depends on the specific print job, but software maximizes the throughput by dynamically determining which dot rows contain adjacent dots and must be printed in two strokes. Printing speed is not affected by the number of characters in a character set.

The printing speed of graphics (“plot mode”) is expressed in inches per minute (ipm).

The ability of the printer to feed paper downwards as well as upwards allows the printing of multiple densities on a single line. This is useful for printing forms and text together or for mixing fonts on the same print line. Use of multiple densities and reverse paper feed also affects throughput.

Printing Mechanism

While the principles of line matrix printing are easy to state, the act of printing dots accurately from a rapidly oscillating shuttle onto a piece of paper moving vertically requires complex timing and coordination between printer logic and the printing mechanism.

The printing mechanism consists of three integrated subassemblies:

• Shuttle Frame Assembly

• Ribbon Transport System

• Paper Transport System.

Shuttle Frame Assembly

The central element of the printing mechanism is the shuttle frame assembly, which houses the hammer bank assembly and the shuttle drive motor. (See Figure 11.)

Figure 11. Shuttle Frame Assembly

Hammer Bank Assembly

The hammer springs are grouped in comb-like assemblies mounted on a solid hammer bank. (See Figure 12.) Both the number of hammer springs per hammer assembly and the number of hammer spring assemblies on the hammer bank vary according to printer model:

• 6400-004/-04P/-005/-05P/-050/-P50: seven 4-hammer assemblies, for a

total of 28 hammer springs

• 6400-008/-08P/-009/-09P: seven 7-hammer assemblies, for a total of 49

hammer springs

• 6400-010 and -10P: six 10-hammer assemblies, for a total of 60 hammer

springs

• 6400-012/-014/-C05/-C5P: seven 13-hammer assemblies, for a total of 91

hammer springs

• 6400-015: six 17-hammer assemblies, for a total of 102 hammer springs

Shuttle Drive Motor

The shuttle drive motor is built into the shuttle assembly casting and drives two connecting rods on a crankshaft. (See Figure 11.) The small end of one connecting rod attaches to the hammer bank; the small end of the other

Shuttle Frame Assembly

Hammer Bank Assembly

Counterweight Assembly

Connecting Rod

Guide Shaft

Shuttle Motor

Chapter 4 Printing Mechanism

connecting rod attaches to a counterweight frame surrounding the hammer bank. (The hammer bank and the counterweight constitute the shuttle assembly.) The rotary motion of the shuttle drive motor converts to linear and opposing motion of the hammer bank assembly and the counterweight, in an arrangement similar to that of a horizontally-opposed gasoline engine. Mechanically, this design achieves the same benefits as this type of engine: perfect primary balance, low vibration, and durability.

Each hammer spring is a stiff leaf spring with a cylindrical tungsten carbide tip on the free end. (See Figure 12.) A permanent magnet is imbedded along the length of the hammer bank and acts on the hammer springs through individual pole pieces. The pole pieces magnetically attract and hold the free end of the hammer spring under tension. This is called the retracted state.

Figure 12. Hammer Springs and Hammer Bank (Detail)

Two electromagnetic coils are mounted behind each hammer and wound around each pole piece. The coils are normally de-energized. When hammer driver logic determines that the hammer must print a dot, a current pulse energizes the coils. The polarity of the resulting magnetic field opposes the field of the permanent magnet, canceling its effect and releasing the hammer. The hammer springs forward, strikes the ribbon and paper, and leaves a dot impression of the hammer tip on the paper.

While the hammer is in flight the coil is de-energized and its field collapses. After striking the ribbon and paper, the hammer rebounds and the permanent magnet recaptures it. When the shuttle reaches the end of a sweep, it reverses direction, the paper is moved up one dot row, and the hammer springs print the next row of dots as the shuttle sweeps in the opposite direction.

NOTE: 6400-004 hammer bank shown.

Hammer Bank Assembly: Coils, Magnet, Pole Pieces, Hammer Spring Assemblies

Alignment Pin

Hammer Spring Assembly

Tungsten Carbide Hammer Tip

Paper Transport System

Paper T ra nsport Syst em

Figure 13. Paper Transport System

A two-phase DC stepper motor, directed by the EC on the controller board, drives two tractor sprockets by means of a toothed belt and splined shaft pulley arrangement. The stepper motor permits extremely accurate incremental vertical paper movement. This drive configuration is designed for continuous, fan-folded paper three to 17 inches wide and one to six sheets thick. For reverse paper feeding, the platen open motor opens and closes the platen via a toothed belt. Opening the platen prevents paper jams when paper

direction is reversed—that is, paper is moved downwards—in order to view the print area, set top of form, or allow applications to overprint forms.

Paper is positioned horizontally using the tractors and the horizontal adjustment knob. Each tractor engages paper perforations with six sprocket pins and locks in place with a friction lock. The horizontal adjustment knob allows vernier positioning of the left print margin.

Paper can be positioned vertically by hand with the vertical adjustment knob.

Paper Supports

Shuttle Cover Assembly

Tractor Support Shaft

Horizontal Adjustment Knob

Tractors

Paper Path

Splined Shaft

Vertical Adjustment Knob and Splined Shaft Pulley

Paper Feed Timing Belt (under the cover)

Chapter 4 Printing Mechanism

Ribbon T ransp ort System

Figure 14. Ribbon Transport System

An inked ribbon winds and unwinds continuously on a pair of spools latched to hubs that are driven by the ribbon motors. The hubs and spools are offset vertically to equalize ribbon wear and prolong ribbon life. The ribbon motors operate only when the shuttle assembly is moving. Ribbon motion reverses when a metal strip at either end of the ribbon crosses the left or right ribbon guide, completing a circuit that causes both motors to reverse direction.

Constant ribbon tension is maintained by controlling each motor with a drive or drag circuit. While the shuttle assembly is in motion, one motor acts as a drive motor, pulling the ribbon against the resistance exerted by the other

motor—the drag motor. This system maintains a constant motor speed and ribbon tension.

Right Ribbon Guide

Ribbon

Ribbon Motors

Ribbon Spool

Hub Locking Latch

Left Ribbon Guide (Not Shown)

Ribbon Hub

Printer Electronics

Logical Control Of The Printer

The printer is divided into four functional elements: the operator panel, the CMX controller board, the power supply, and the print mechanism.

Printer Electronics

The functional elements of the printer are diagrammed in Figure 15.

Figure 15. Functional Elements of the Printer

Line 2 / Neutral

Flex Circuits:

ON/OFF SWITCH

Power Supply

Board

Line 1

CHASSIS

GND

Cabinet

Paper Feed

Motor

Platen Open

Switch

Right Ribbon

Guide

Right Ribbon

Motor

Platen Motor

Paper Motion

Detector

Paper Out

Detector

Left Ribbon

Motor

Card Cage

Fan

Left Ribbon

Guide

Hammer Bank

Fan

Shuttle Motor

Hammer Bank Board

Terminator Board

MPU

Shuttle

Assy

CMX Controller Board

Circuit

Breaker

Shuttle Assembly

Exhaust

Fan

Input

Operator

Panel

Print Mechanism

POWER

EIA-232-E

Serial I/O

(Cabinet

models

+5 V Remote

Power

Shield

GND

Parallel

I/O

only)

Chapter 4 Operator Panel

Operator Panel

The operator communicates with the printer by pressing keys on the operator panel. The keys are momentary contact switches. The operator panel processes and sends key closure information to the controller board and displays information from the controller on the LCD. A status indicator next to the LCD also conveys printer status information to the user.

The LCD, status indicator, and keys are mounted on a printed circuit board assembly enclosed in a protective housing.

Figure 16. Operator Panel Functional Overview

J110

Operator Panel

CMX Controller Board

• Data

• Control

• Key (Switch) Closures

Printer Electronics

CMX Controller Board

The heart of the printer is the CMX controller board, which monitors and directs all printer functions. The controller board receives and processes all data from the host computer, builds the printable images, controls all motors, and drives the hammer springs. Except for the power supply and final hammer drive circuits, all logic and drive circuitry for the printer are contained on the controller board.

The CMX controller board consists of two functional units: the Data Controller (DC) and the Engine Controller (EC).

The DC is responsible for:

• Host I/O

• Operator I/O

• Security Interface

• Print Image Generation

• Overall High Level (Logical) Control

The EC is responsible for:

• Print Mechanism Operation

• Print Mechanism Fault Monitoring

• Power Shutdown/Power Saving Modes

The EC and DC communicate through semaphore registers. The DC receives host and operator input and returns dot images and LCD messages to buffers in memory. Image data are passed to the EC upon request, are processed, then sent to the hammer bank. The EC synchronizes paper, ribbon, platen, and shuttle motion as it feeds dot data to the hammer drivers. Figure 17 summarizes this architecture.

Chapter 4 CMX Controller Board

Figure 17. CMX Controller Board Block Diagram

Expansion

Port

RS-232/422

IEEE-1284

(Parallel)

Fault

Sensors

Paper

Feed

Ribbon

Shuttle

Platen

Hammer

Drive

TTL

Diagnostic

Port

Control

Panel

RS-232

Diagnostic

Port

25 or 40 MHz

Data Controller

The data controller (DC) consists of the following elements:

• 68EC030 microprocessor

• Two flash SIMM sockets, used for up to 30MB of program memory

• Two DRAM SIMM sockets, used for up to 32MB of data memory

• 8K x 8 Non-Volatile Battery-Backed static RAM (NVRAM) for storage of

configuration and system statistical data

• VX ASIC (Application-Specific Integrated Circuit)

• Host I/O Drivers/Termination

68EC030 Microprocessor

A Motorola** 68EC030 microprocessor serves as the processor of the DC unit. This processor runs at 25 MHz on all models except the 6400-050, -P50,

-010, -P10, -015, -C05, and -C5P. On 6400-050, -P50, -010, -P10, -015, -C05, and -C5P printers the 68EC030

processor runs at 40 MHz and the controller board on these models is called

the “CMX 040.” The CMX 040 controller is backward compatible with any 6400 Series printer, but must be used in 6400-050, -P50, -010, -P10, -015, C05, and -C5P printers.

Although this chapter refers to the DC microprocessor as simply the “030,” remember that two different clock speeds are available.

Flash Memory

The DC stores program and emulation code in flash memory. Flash memory is erasable, non-volatile, and significantly faster than a disk drive.

The DC uses AMD** 5.0V-only flash memory, which does not require higher programming and erasing voltages on the board (it has an internal charge pump to make these voltages itself). This memory supports at least 100,000 write/erase cycles. The flash memory is 32 bits wide. It is byte, word, and double word readable, but is always written as double words.

Two 80-pin SIMM sockets are provided for flash memory. Up to 30MB of flash (total), organized as up to four banks, may be installed in the two sockets on the controller board. The boot code for the 68EC030 processor must reside in bank 0.

Programs stored in flash memory are changed through the parallel or serial port.

DRAM

System DRAM is used for program variables, image buffers, and input buffers. All DRAM supports page mode operation and is addressable by individual byte.

Two standard 72-pin DRAM SIMMs are used for expansion memory. The DC, through the VX ASIC, may address up to 32MB of DRAM in four banks.

Chapter 4 CMX Controller Board

NVRAM

A 8K x 8 bit Non-Volatile battery-backed static RAM (NVRAM) device provides for the storage of configuration and system statistical data.

VX ASIC

The VX is a multifunction custom gate array ASIC containing all the logic for the DC that is not contained in the 68EC030 processor. The VX provides the following services:

• Memory Access Cont roller

• DRAM Controller

• Flash Controller

• Two DMA Channels

• Operator Panel Interface

• “Dot Plucking” and Adjacent Dot Checking

• “Cajun” Bus Interface

• Host I/O and Diagnostic Port

Memory Access Controller All 030 addresses go through the VX ASIC. The VX handles all address decoding, chip selects, DTACKs, and so on.

DRAM Controller

The VX supports up to four banks of page mode DRAM.

FLASH Controller

The VX supports up to four banks of flash memory.

DMA Channels

The VX provides two channels for direct memory access. These channels move data from the host interface or expansion bus to the DRAM and vice versa. One address is an I/O address, the other is a memory address with auto-increment.

Operator Panel Interface

The VX operator panel interface consists of five lines: serial clock, serial data, and three select lines. It is the VX that handles all parallel-to-serial (and vice versa) conversion to and from the panel, as well as any special timing needed when toggling select lines, etc.

“Dot Plucking” And Adjacent Dot Checking

“Dot Plucking” is a specialized DMA function that removes dot data from a dot image buffer in DRAM in a programmable manner, serializes it, and sends it to the hammer bank. This function is actually controlled by the EC (see page

49), which has access to the VX through the “Cajun” Bus Interface.

Engine Controller

“Cajun” Bus Interface

The “Cajun” bus interfaces the DC, the EC, and the expansion port. The EC uses this bus to access DC resources, including the semaphore registers. (The semaphore registers are the primary communications path between the EC and DC.)

Ports

The VX ASIC controls the following I/O functions:

• Interface to an IEEE** 1284 Level 2 host

• Interface to RS-232E serial host

• Interface to RS-422 serial host

All the circuitry required for these host types is provided on the CMX board, except for the drivers themselves, ESD protection, and terminations.

Host I/O Drivers And Term ination

Beyond the 030 processor and VX ASIC, additional support circuitry completes the serial and parallel interfaces. These circuits include:

• RS-232 drivers and receivers. These circuits use internal charge pumps

to eliminate the need for ±12V power.

• RS-422 differential drivers and receivers

• Parallel port pull up and pull down terminating resistors are DIP-socketed

for easy removal and installation.

All interface ICs and terminations have the following characteristics:

• Provide ESD protection to 15KV for all inputs.

• Less than 0.05V common mode ripple, measured at the power and

ground of the interface ICs.

• Less than 0.02V common mode ripple, measured between chassis

ground and the ground pins of the interface ICs.

• Greater than 200V/µs slew rate for all outputs.

Engine Controller

The engine controller (EC) consists of four main elements:

• 80C166 Microcontroller

• 128KB 5.0V-only FLASH program memory, organized as 64K x 16 bits.

This memory is not expandable.

• MECA (Mechanism Engine Contro l ASI C)

• Analog drive circuitry

80C166 Microprocessor

The Siemens** SAB 80C166 is a high-integration microcontroller. It has many features that suit it extremely well to real-time control applications. This

Chapter 4 CMX Controller Board

controller and the MECA ASIC provide the functionality of three separate processors used in earlier controller board architectures. In this manual, the 80C166 is referred to as either the EC or the 166.

The 166 used on the CMX board runs at 20MHz and is housed in a 100-pin metric rectangular flat pack.

Bus Configuration

The 166 bus is configured for 18-bit address, 16-bit data, non-multiplexed and segmented operation. The flash memory runs with zero wait states. An external PAL is used for address decoding.

Power Reduction

The 166 chip has two power reduction modes: idle and Energy Star. Idle mode is not used. In Energy Star mode, +48V and all motors are deenergized, but the 166 operates as normal.

EC Flash Memory

The EC stores all boot code, program code, and tables in its own local flash memory. This flash is organized as 64K x16 bits and uses the same technology as the DC flash: it is +5.0V-only and is rated for a minimum of 100,000 write/erase cycles. EC memory is fixed; it is soldered to the controller board. Its contents can be updated through the DC (through the serial or parallel ports). At run time, the EC also stores tables in shared DRAM, which is accessed through the Cajun bus.

MECA ASIC

The 166 uses numerous counters, PWM generators, and FIFOs in the MECA to control many printer motor functions. The MECA is a custom gate array, specifically designed to drive this system.

Analog Drive Circuitry

The analog drive functions convert 48 and 8.5 volts into the power used to drive the motors and hammers in the printer. Sensors are used to monitor the operation and status of critical components within the printer.

The printer uses five motors: two ribbon drive, one paper feed, one platen open, and one shuttle motor. The shuttle motor is a brushless DC motor driven by current control. The MPU encoder is used as feedback for motor commutations, hammer fire timing, and motor stall detection. The paper feed motor is a DC stepping motor driven by current control. The paper feed motor may be driven in full, half, or microsteps, depending on print requirements. The ribbon system uses two DC stepping motors that alternate drive and drag roles when the ribbon reaches turnaround. The drive ribbon motor is microstepped in voltage mode, while the drag motor is loaded and monitored to maintain correct linear speed and tension. The platen motor is driven in current mode and can be full or half stepped. The overall current level may be reduced for standby modes.

Engine Controller

The paper feed, ribbon drive, and shuttle motors are driven in control loops containing power MOSFETs, vo lta ge and curr ent sens ors, the MEC A ASI C, and the EC processor. The platen open motor is driven by a stepping motor controller IC and the EC processor.

Control of the hammer drive is split between the controller board and the hammer bank. Common circuits are located on the controller board, while hammer specific circuitry is contained on the hammer bank. The EC uses the MECA ASIC on the controller board to set timing and upper drive profiles for hammer fire events. The controller also contains diagnostic circuitry for the hammer system. The hammer bank contains HBA ASICs that interpret fire commands and data from the MECA and VX ASICs. The HBAs control lower drive MOSFETs on the hammer bank. These determine which hammers will

participate in a fire event generated by the controller’s upper drive.

Printer Interface

The printer interface is the point where the data line from the host computer plugs into the printer. The printer interface processes all signals and data to and from the host computer.

The printer supports supports a number of standard and optional interfaces to the host:

• Centronics** parallel (standard)

• IEEE 1284 parallel (standard)

• EIA**-232-E serial (standard)

• EIA-422-B serial (standard)

• Coaxial/twinaxial “Expansion-CT” (optional)

• Ethernet 10Base2, 10Base-T, or 10/100Base-T adapter (optional)

Selection of the input/output interface is controlled by configuration menus accessed at the operator panel. It is possible to physically connect more than one interface, but only one interface at a time can be used electrically.

Chapter 4 Printer Interface

10Base2 And 10Bas e-T LEDs And DIP Swi tches

10Base2 and 10Base-T PrintNet Ethernet interfaces have three LEDs and three DIP switches, as shown below. The indicators and switches are adjacent to the data line connectors. LED patterns are defined in the table below the illustration.

Status Indicator LEDs And DIP Switches

The PrintNet Ethernet assembly has a self test and two internally controlled modes:

Power-on Self Test: A seven stage power-on self test performs diagnostics on the Ethernet Interface processor, RAM, ROM, EEPROM, parallel port, and network interface. The STAT, ERR, and NET LEDs indicate which test is currently in progress.

Table 2. LED Pattern Indications

STAT

(System

Status)

ERR

(System

Error)

NET

(Data to

Network)

Mode

ON OFF ON RAM Test ON OFF OFF ROM Test

ON ON OFF EEPROM Test OFF ON ON Network Interface Test OFF OFF ON PRN1 Test

FLASH OFF FLASH Run Mode FLASH ON FLASH Auto Reset Mode FLASH FLASH OFF Firmwar e Pan ic

ON FLASH ON Hardware Exception

123

OFF

Grn Red Grn

STAT ERR NET

Status

Indicators

DIP

Switches

(Default is all switches OFF, as shown.)

10Base2 And 10Base-T LEDs And DIP Switches

Run Mode and Auto Reset Mode: Run Mode is the normal operating state of the Ethernet Interface. Auto Reset mode is entered when the watchdog timer is triggered and the Print Server resets itself. In either mode, the STAT LED flashes differently, depending on whether the unit IP address is configured:

IMPORTANT

Setting both DIP Switch 1 and DIP Switch 2 to the ON (down) position will clear ALL passwords, specifically passwords in the html webpage.

DIP Switch 1 = EEPROM Enable: Default position is OFF (up). Setting this

switch to the ON (down) position and powering the printer off then on resets the Ethernet Interface to the factory default settings. This also erases any previously configured IP address. Before reconfiguring the unit, DIP switch 1 must be set back to the OFF (up) position, otherwise it will lose its configuration through another power on/off cycle.

DIP Switch 2 = Default IP: Default position is OFF (up). Setting this switch to the ON (down) position and powering the printer off then on resets a previously configured IP address to the factory default setting (no IP address). However, this does not cause the unit to lose its other stored configuration settings, as happens with DIP switch 1. Before reconfiguring the unit with an IP address, DIP switch 2 must be set back to the OFF (up) position, otherwise it will lose its IP address through another power on/off cycle.

DIP Switch 3 = Link Integrity Disable: Default position is OFF (up), which means link integrity is enabled. This DIP switch determines whether link integrity is turned on or off in the Ethernet interface. It may be necessary to turn link integrity off if the unit is connected to an older hub, etc. Link integrity only applies to the 10Base-T interface option.

For more information . . .

For more information about the 10Base2 or 10Base-T Ethernet interface, refer to

Ethernet Interface User’s Manual

, Form No.S246-0153.

STAT Rate Indicates

Flashes On once per second Normal Mode, IP address

configured

Flashes On 2.5 times per second Monitor Mode, IP address not

configured

Flashes Off 2.5 times per second Monitor Mode or Download

Mode, IP address not configured

Flashes Off once per 2 seconds Download Mode, IP address

configured

Chapter 4 Printer Interface

10/100Base-T LEDs And DIP Switches

The 10/100Base-T Ethernet interface has two indicator lights and two DIP switches, as shown below.

Inspect the two LEDs on the 10/100Base-T Ethernet interface:

1. When an IP address is configured into the printer via the control panel, the bottom LED should be blinking on and off at the same rate.

2. When a working network cable is installed, the top LED should be on steadily and will blink off for 1/3 second when data are received.

When these two conditions are met, you should be able to

ping

the printer

from a network host. You can test by starting a telnet session (

telnet

IP address

) and sending

start fox prn

stop prn

This command sequence sends consecutively numbered lines of text from the

interface to the printer. The “fox” test is resident in the network interface and verifies that it can receive commands and can transfer data successfully to the printer.

If no network cable is connected or the cable is defective and the IP address is configured from the control panel, the top LED will be off and the bottom LED will blink on/off.

STAT (System

Status)

NET (Data to

Network)

DIP Switches

Shown in OFF (default) position

10/100Base-T LEDs And DIP Switches

STAT (Status) Indicator In Run And Auto Reset Modes

Run Mode is the normal operating state of this interface. Auto Reset mode is entered when the watchdog timer is triggered and the print server resets itself. In either mode, the STAT LED flashes at a varying rate, depending on whether the unit IP address is configured:

NET (Network) Indicator

The NET LED displays the status of the network link:

DIP Switches

On the back of the 10/100Base-T interface inside the printer, there are two DIP switches labeled 1 and 2. The functions of the DIP switches are explained in Table 3.

STAT Rate Indication

OFF Flashes ON

once per second

Normal Mode, IP address configured

OFF Flashes ON 2

times per seco nd

IP address not configured

ON Flashes OFF

once per second

Download (MOS)

ON Flashes OFF

twice per second

Error

NET Rate Indication

ON Constantly Indicates link integrity ON Flashes OFF 1/3

second

Flashes off 1/3 second every time a data packet is transmitted

OFF Constantly Network connection has been severed

Chapter 4 Printer Interface

For More Information . . .

For more information about the 10/100Base-T Ethernet interface, refer to

Ethernet Interface User’s Manual

, Form No.S246-0154.

Table 3. 10/100Base-T DIP Switch Settings

DIP Switch

Description

OFF OFF Normal operation. With both DIP switches in the “OFF”

position, the interface boots up using the settings in flash memory rather than the default settings.

ON OFF Factory default settings. With the DIP switches in this

configuration, the interface boots up and all settings stored in flash memory are erased except the Ethernet address and key value.

OFF ON Default IP. With the DIP switches in this configuration,

the interface boots up with factory default settings, but the stored settings in flash memory remain intact. Setting DIP switch 2 to “ON” does not clear any settings stored in flash memory, it boots the unit in a different state with the settings in flash memory temporarily ignored.

ON ON If the interface is connected to a network with link

integrity and then reset to MOS, a download will be forced. If the unit is not connected to a network, it will print a test page.

AC Power

Power Supply Board

The printer power supply is contained on a printed circuit board mounted in the card cage. The power supply automatically senses and adjusts to any commercial electrical system that provides AC mains potential in 50 or 60 Hertz systems. In other words, the printer is fully operational from available commercial power anywhere in the world.

The power supply converts alternating current (AC) to direct current (DC) at three voltage levels and sends the DC voltages to the controller board. The controller board distributes all DC power to the logic and electromechanical circuits.

AC Power

The power supply operates on AC voltages ranging from 88 to 270 V. It can tolerate variations in frequency of 47 to 63 Hz. The power supply is designed to withstand an AC input overvoltage of 300 VAC for one second with no degradation of DC output voltage or damage to printer circuits.

DC Power

The power supply board contains two DC power supply systems for the printer. The first is a +5 V bus for logic. The second consists of +48 V and +8.5 V buses for the hammer bank and all motors.

The +5 V supply has an isolated return line that connects to the +48 V return at the printer load. Both returns are tied together in a single-point ground. The +5 V power supply has its own inverter, separate from the +48 V and +8.5 V outputs.

There is an opto-isolated input on the power supply that will shut down and latch off the +48 V and +8.5 V supplies unless it is pulled up to 5V with a 1K Ω resistor. This resistor is mounted on the controller board and may be pulled down or disconnected by software or internal cable interlocks. The +5 V output will remain stable for reporting and latching the fault condition. The return for this signal is the +5 V return. In addition, this shutdown circuit discharges and latches the +48 V down to a level lower than 15 V in less than 200 milliseconds and requires recycling of the circuit breaker (On/Off switch) to reset the latch.

Loss of +48 V is seen by the EC and reported as a fault.

Chapter 4 Graphics

Graphics

The Code V programming language (a QMS** graphics emulation) and the IGP programming language (a Printronix IGP emulation) are options that install in flash memory on the CMX controller board.

These programming languages simplify the job of creating forms, bar codes, logos, expanded characters, and other graphics. These languages enable the printer to print sideways, upside down, and to make forms combining

graphics, alphanumeric data, and bar codes—all in a single pass. Documents explaining configuration, operation, and programming are included with each option.

5 Troubleshooting

Introduction

This chapter lists fault messages and symptoms, and provides procedures for troubleshooting printer malfunctions.

Always have the

Operator’s Guide

and the

Setup Guide

handy when you troubleshoot because this manual does not cover printer operation or configuration. You must operate the printer to check its performance, and sometimes you may have to reconfigure it.

T roubleshooting Aids

Troubleshooting is faster and more effective if you understand the equipment and make use of all available tools.

This manual provides a number of troubleshooting aids to help you isolate printer malfunctions:

• Start of Call................................................................................. page 60

• Troubleshooting Display Messages............................................ page 61

• Message List............................................................................... page 62

• Troubleshooting Other Symptoms............................................ page 109

• General Symptom List .............................................................. page 110

• Communications Failures ......................................................... page 131

• Operator Print Tests ................................................................. page 132

• Customer Engineer (CE) Tests................................................. page 134

• Hex Code Printout .................................................................... page 140

• ASCII Character Set ................................................................. page 142

• The Power On Sequence ......................................................... page 146

• Appendix A: Wire Data ............................................................. page 287

Chapter 5 Start Of Call

St art Of Call

Are you here because of an error message?

YES

Go to Troubleshooting Display Messages, page 61.

Power on the printer and observe the operator panel for the following seque nce of events (retry as required):

1. All LEDs on and black squares on the display.

2. All LEDs off and display blank.

3. TESTING HARDWARE PLEASE WAIT appears on display. Did steps 1, 2, and 3 occur?

Did the fans come on after 10 seconds?

YES

After about 10 seconds did the fans come on ?

YES

Did Power and Ready LEDs come after 10 seconds?

YES

IML was successful. Other symptoms are listed in Table 5, page 110.

Go to Printer does not complete IML, page 115.

Did ANY of steps 1 thru 3 occur?

Press Stop. Press Print Configuration. Press Start. Does machine configuration print?

YES

Go to the Operator Panel section of Table 5, page 110

The Operator Panel is not functioning (Table 5 page 110)

—OR—

Printer does not complete IML, page

115.

Go to No power, and

operator panel is blank, and card cage fan is not running, page 114.

YES

Are there black squares on the operator panel?

Go to Printer does not complete IML, page 115.

YES

Go to Black squares on operator panel display, page 112.

T roubleshooting Display Messages

If a fault condition occurs in the printer, four things happen:

• The Attention indicator on the operator panel flashes on and off.

• If enabled, the audible alarm sounds. (Press Stop to silence the alarm.)

• A message describing the fault condition appears on the LCD.

• Certain

Unit Check

conditions (see below) are automatically recorded in the error log. The error log is a buffer in NVRAM that stores up to 50 messages as a list. The most recent message is stored at the top of the list, the oldest message at the bottom of the list. If more than 50 messages occur before the log is cleared, the oldest messages are deleted, so the log never contains more than 50 messages. You can print the error log and clear it. (See page 135.)

The LCD displays two kinds of printer conditions:

• An

Attention

condition halts printing until the operator replenishes supplies, clears paper jams, corrects a problem of communication between the printer and host computer, etc.

• A

Unit Check

condition is a failure detected by self-test and fault circuitry.

Unit check conditions are either

recoverable

unrecoverable

Recoverable

unit check conditions are errors detected in the electromechanical print mechanism that may be temporary and correctable by cycling power. The printer tries a number of times to correct the condition before posting the message to the operator panel. The first thing to do in such cases is to power the printer off, wait 15 seconds, then power the printer back on. If the message reappears, classify the check condition unrecoverable.

Unrecoverable

unit check conditions are “hard” failures such as overcurrent, component failure, or microcode failures that prevent printing until the conditions are corrected. Unrecoverable conditions require that

<3> Hazardous voltages are present in the printer with the

power cord connected to the power source. Switch off printer power and unplug the printer power cord before proceeding.

<4> Do not connect or disconnect any communication port,

teleport, attachment connector , or power cord during an electrical storm.

<5> Power off the printer and disconnect the power cord before

connecting or disconnecting any communication port, teleport, or attachment cable connector.

DANGER

Chapter 5 Troubleshooting Display Messages

the printer be powered off and the condition corrected before powering the printer back on.

Message List

Find the message in the Message List below and follow the suggested procedure. After correcting an error, press the Start key to clear the message.

If an error is not cleared, the printer will try to print again but will display the error message until the error is cleared.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

001 END OF FORMS LOAD FORMS

Attention message: the printer is out of paper.

1. Load paper. Press Stop. If message does not clear, go to the next step.

2. Check forms for dark backs or holes/ perforations large enough to cause false End Of Forms messages. Consider ordering the black back paper detector switch assembly.

3. Power off the printer. Remove the paper guide assembly or pedestal top cover. Remove the barrier shield (cabinet model) or the barrier shield and paper guide (pedestal model, see Figure 45, page 260). Make sure the sensors are securely snapped into the bracket, the mounting screws hold the paper detector switch assembly securely, and clean the sensors if they are dirty.

4. Check that connector P106/PMD is fully seated in connector J106 on the CMX controller board.

5. Power on the printer. Load paper. Replace the paper detector switch assembly if the message appears.

6. Power on the printer. Load paper. Replace the CMX controller board if the message appears. Record the message and return it with the defective board.

Message List

002 FORMS JAMMED CLEAR JAM AND RELOAD FORMS

Attention message: the printer cannot detect paper motion. Inspect the paper path for jams.

1. Clear jams. Load paper.

2. Press Form Feed several times and check that forms feed without erratic motion, noise, or pin-hole damage. If forms do not feed, go to Paper feeds poorly, page 125. If forms feed, go to the next step.

3. Press View once and check that forms move up. Make sure the forms thickness lever is not set too tightly.

4. Press View again and check that the forms thickness lever rotates and the paper moves down. If the forms thickness lever does not rotate and/or the paper does not move down, refer to Reverse paper feed: platen does not open, page

126.

5. Check the paper tension between the tractors. Adjust the right tractor so that it does not pull paper too tightly or leave it too loose. The right tractor should hold

the paper under “slight” tension.

Inspect the ribbon mask for bends or deformation that block the paper path or prevent paper from exiting the pedestal top cover. Replace a damaged hammer bank cover assembly.

Check and adjust the platen open belt. Replace the belt if it is damaged.

Check the platen open pulley and the platen pulley for looseness. Bottom out the platen open motor pulley on the motor shaft and torque the 1/16 inch set screw to 9 ± 2 inch-pounds (1.02 ± 0.23 N•m). Tighten the 7/64 inch setscrew in the platen shaft pulley, then open and close the forms thickness lever and check that the platen pulley setscrew does not hit the left ribbon guide.

9. Inspect the tractors and tractor door springs for damage or excessive wear. If either tractor is worn or damaged, replace both tractor assemblies.

10. Check and adjust the paper feed belt. Replace the belt if it is damaged.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Chapter 5 Troubleshooting Display Messages

002 FORMS JAMMED CLEAR JAM AND RELOAD FORMS (continued)

11. Check and adjust the platen gap.

12. Clean the paper motion detector with a cotton swab and alcohol. At the control panel, set the paper motion detector (PMD) fault setting to DISABLE. Load paper. Run a print test and observe how the paper feeds. If the message appears, replace the CMX controller board. Record the message and return it with the defective board. If the message does not appear, replace the paper detector switch assembly and set the paper motion detector (PMD) to ENABLE.

003 FORMS EJECTED PRESS EJECT/ RESTORE

Non-error status message.

Press Eject/Restore key to return paper to print position.

004 VIEW FORMS PRESS VIEW KEY0

Non-error status message.

Press View key to return paper to print position.

006 HOST SYSTEM REQUEST ATTENTION

Host attention message: the host computer or printer controller requires attention.

Not a printer problem.

007 FM HEADER ERROR

Applications software has violated header format parameters.

Not a printer problem. Have the system administrator correct applications data or configuration.

008 HOLD PRINT TIMEOUT PRESS START

Status message: the printer was offline more than 1 0 minutes

and the “Intervention Required” parameter is set to “Send to Host.”

Press Start to put the printer in the READY state.

009 INVALID KEY PRESS

Attention message informing the operator that the wrong key was pressed.

No action required.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Message List

010 PARAMETER ERROR

The printer received an illegal parameter value in the command code.

1. Press Stop to clear fault. Press Start to go on-line.

2. Run the print job that generated the error message. If the message appears, check the host data for invalid characters.

3. Ask the system operator to verify that the

printer’s Device ID is set to the correct emulation with respect to the host configuration.

Run the print job that generated the error message. If the message appears, go to Communications Failures, page 131.

011 SCS COMMAND ERROR

The printer received an undefined control character (hex 40) through the coax/ twinax interface.

The printer clears the error.

Run the print job that generated the error message. If the message appears, verify that there are no invalid control codes in the host data.

Ask the system operator to verify that the printer’s Device ID is set to the correct emulation with respect to the host configuration.

Run the print job that generated the error message. If the message appears, go to Communications Failures, page 131.

012 STRUCTURED FIELD ERROR

Application software has violated structured data field parameters.

Not a printer problem. Have the system administrator correct applications data or configuration.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Chapter 5 Troubleshooting Display Messages

013 ACTIVATE LOST

The printer detects a twinax protocol communication error and reports the error.

1. Power off the printer. Disconnect the AC power cord from the printer. Check the twinax host data cable and twinax I/O cable connection at the CT board. Reseat the twinax host data cable connection and the twinax I/O cable connection at the CT board.

2. Disconnect the twinax auto-termination cable from the printer. Test the cable for the resistances shown on page 306. If resistances are not correct, replace the twinax auto-termination cable.

3. Connect the power cord to the printer. Power on the printer. Send a print job to the printer. If the message appears, replace the twinax cable.

4. Send a print job to the printer. If the message appears, go to Communications Failures, page 131.

014 IN VALID ACTIVATE

The printer detects a twinax protocol communications error and reports the error.

2. Disconnect the twinax auto-termination cable from the printer or from the last device on this twinax port. Test the cable for the resistances shown on page 306. If resistances are not correct, replace the twinax auto-termination cable.

3. Connect the power cord to the printer. Power on the printer. Send a print job to the printer. If the message appears, replace the twinax cable.

4. Send a print job to the printer. If the message appears, go to

Communications Failures, page 131.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Message List

015 COMMUNICA TIONS CHECK CHECK CABLE

The line is not active on a twinax interface.

1. Power off the printer. Disconnect the AC power cord from the printer. Check the twinax host data cable connection and twinax I/O cable connection at the CT board. Reseat the twinax host data cable connection and the twinax I/O cable connection at the CT board.

2. Disconnect the twinax auto-termination cable from the printer. Test the cable for the resistances shown on page 306. If resistances are not correct, replace the twinax auto-termination cable.

3. Connect the AC power cable to the printer. Power on the printer. Send a print job to the printer. Verify that all other devices on the twinax line are working properly. (Refer to line problem determination procedures, as recommended by the host system.) If the message is gone, the host has reestablished communication with the printer. If all other twinax devices work properly and the message still appears, replace the coax/twinax expansion board. Record the message and return it with defective board.

016 INVALID COMMAND

The printer detects a twinax protocol communications error and reports the error.

2. Disconnect the twinax auto-termination cable from the printer. Test the cable for the resistances shown on page 306. If resistances are not correct, replace the twinax auto-termination cable.

3. Connect the power cord to the printer. Power on the printer. Send a print job to the printer. If the message appears, replace the twinax cable.

4. Send a print job to the printer. If the message appears, go to

Communications Failures, page 131.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Chapter 5 Troubleshooting Display Messages

017 STACKER JAM CHECK STACKER

This message is triggered if there is paper inside the throat of the stacker elevator, but the elevator is not moving.

1. Open the cabinet rear door and check for obstructions preventing elevator movement. Remove any obstructions.

2. Check that the wheel of the stacker paper motion detector rests against the rear brace of the paper throat. Also make sure the wheel rotates freely. If necessary, gently bend the brace toward the paper motion detector wheel until the wheel contacts the brace. Clean the stacker paper motion detector.

3. Power on the printer. Operate the power stacker and check that: a) all motors are operating, b) the paddles are rotating, c) the elevator moves smoothly and without obstruction, d) the timing belts are undamaged and the belt pulleys are not slipping, e) extension springs are attached and not bent or stretched), f) drive rollers are not damaged. Tighten setscrews and replace damaged components as necessary.

4. Power off the printer. Remove the paper path. Disconnect stacker cables from the CMX controller board, stacker assembly, and stacker control panel. Check cables for cuts, breaks, or damaged pins. Check continuity of cables. (See Appendix A.) Replace any cable that is damaged or fails continuity test.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Message List

018 STACKER FULL CHECK STACKER

Status message: the power paper stacke r is full.

1. Unload the stacker.

2. Check the stacker limit switches. (See page 119.) If the limit switches are OK, go to the next step.

3. Power off the printer. Remove the paper guide assembly. Disconnect stacker cables from the CMX controller board, stacker assembly, and the stacker control panel (see Figure 68, page 376). Check cables for cuts, breaks, or damaged pins. Check continuity of cables. (See Appendix A.) Replace any cable that is damaged or fails continuity test. Reconnect all stacker cables to the CMX controller board, stacker, and stacker control panel.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Chapter 5 Troubleshooting Display Messages

019 STACKER FAULT CHECK STACKER

Two situations can trigger this message:

1. The stacker elevator is obstructed while attempting to move up or down. The message will always occur if the user presses the ELEVATOR UP key on the stacker control panel to move the elevator and the elevator is blocked so that it cann ot mo ve t o the top of its travel.

2. Controller hardware tells firmware that an overcurrent condition exists. This will only occur if the controller board or the stacker motors are bad.

1. Open the cabinet rear door and check for obstructions preventing elevator movement. Remove any obstructions.

2. Power on the printer. Operate the power stacker and check that: a) all motors are operating, b) the paddles are rotating, c) the elevator moves smoothly and without obstruction, d) the timing belts are undamaged and the belt pulleys are not slipping, e) the extension springs are attached and undamaged (not bent or stretched), f) the drive rollers are not damaged, g) the constant force springs are tightly mounted and undamaged. Tighten pulley setscrews and/or replace damaged components as necessary.

3. Adjust the stacker rails if they are not vertical and parallel.

4. Check the stacker limit switches. (See page 119.) If the limit switches are OK, go to the next step.

5. Disable the power stacker unit under the Printer Control menu. (Refer to the

User’s

Guide.)

If the message occurs, replace the CMX controller board and download new function code.

6. Power off the printer. Remove the paper path. Disconnect stacker cables from the CMX controller board, stacker assembly, and the stacker control panel (see Figure 70, page 348). Check cables for cuts, breaks, or damaged pins. Check continuity of cables. (See Appendix A.) Replace any cable that is damaged or fails continuity test. If the cables are okay, replace the stacker motors.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Message List

021 RECEIVE BUFFER OVERRUN VERIFY CONFIGURATION

The print buffer has overflowed on a serial interface. The printed output may contain random * (asterisk) characters.

1. Make a configuration printout. Verify that the printer matches the host serial interface configuration settings for Data Protocol, Baud Rate, Data Bits, Stop Bits, Parity, Data Terminal Ready, and Request to Send.

2. Set printer serial interface parameters to match those of the host.

3. Send a print job to the printer. If the message appears, go to Communications Failures, page 131.

022 UNIT ADDRESS NOT RECEIVED CHECK PRINTER ADDRESS

Poll timeout on the twinax interface indicating the unit address is not recognized by the printer.

Have the system administrator make sure the printer address is correct.

024 SERIAL LINE PARITY ERROR VERIFY CONFIGURATION

The printed output may contain random ? (question mark) characters.

1. Make a configuration printout. Verify that the printer matches host serial configuration settings for Data Protocol, Baud Rate, Data Bits, Stop Bits, Parity, Data Terminal Ready, and Request to Send. Set printer serial interface parameters to match those of the host.

2. Send a print job to the printer. If the message appears, replace the serial data cable.

3. Send a print job to the printer. If the message appears, go to Communications Failures, page 131.

4. If the printer is in a twinax environment, check the error log for 024 errors and

inspect the customer’s cable hook-ups. Connect all communications cables correctly.

5. Send a print job to the printer. If the message appears, replace the twinax auto-termination cable (“T” connector).

6. Send a print job to the printer. If the message appears, replace the coax/ twinax multi-platform interface. (Refer to the

Coax/Twinax Multi-Platform Interface

Feature Installation and Operation Guide

Form Number S246-0149.)

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Chapter 5 Troubleshooting Display Messages

025 SERIAL FRAMING ERROR VERIFY CONFIGURATION

The printed output may contain random ! (exclamation point) characters.

1. Make a configuration printout. Verify that the printer matches host configuration settings for Data Protocol, Baud Rate, Data Bits, Stop Bits, Parity, Data Terminal Ready, and Request to Send. Set printer serial interface parameters to match those of the host.

2. Send a print job to the printer. If the message appears, go to Communications Failures, page 131.

026 HEX DUMP MODE

Printer attach status message.

No action required.

027 COMMUNICATIONS CHECK CALL SYSTEM OPERATOR

Enable poll timeout. The printer was not enabled for one minute over a coax interface

Power off the printer. Disconnect the AC power cord from the printer. Check data cable connection and host system. (Refer to line problem determination procedures, as recommended by the host system.)

028 COMMUNICATIONS CHECK CALL SYSTEM OPERATOR

Poll timeout error. The printer was not polled for one minute over a coax interface.

Power off the printer. Disconnect the AC power cord from the printer. Check data cable connection and host system. (Refer to line problem determination procedures, as recommended by the host system.)

029 8344 DIAGNOSTIC TEST FAILED

Link-level code test detects a hardware failure on the coax/ twinax expansion board. This message can also occu r if the software in flash memory is corrupted.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the coax/ twinax expansion board. Record the message and return it with defective board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Message List

031 END OF FORMS TIMEOUT LOAD FORMS

On a coax interface, a timeout message is sent to the host if paper is not loaded within 10 minutes after Stop was pressed to clear an end of forms fault.

1. Load paper. Press Stop. If message does not clear, go to the next step.

2. Power off the printer. Remove the paper guide assembly or pedestal top cover. Remove the barrier shield (cabinet model) or the barrier shield and paper guide (pedestal model). Check that the paper detector switch assembly is securely mounted in its bracket.

3. Check that connector P106/PMD is fully seated in connector J106 on the CMX controller board.

4. Power on the printer. Load paper. Replace the paper detector switch assembly if the message appears.

5. Power on the printer. Load paper. Replace the CMX controller board if the message appears. Record the message and return it with the defective board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Chapter 5 Troubleshooting Display Messages

032 FORMS JAMMED TIMEOUT CLEAR JAM AND RELOAD FORMS

On a coax interface, a timeout message is sent to the host if paper motion has not occurred for 10 minutes after Stop was pressed to clear a paper jam fault.

1. Clear the paper jam. Press Stop.

2. Press Form Feed several times and check that forms feed without erratic motion, noise, or pin-hole damage. If forms do not feed, go to Paper feeds poorly, page 125. If forms feed, go to step 3.

3. Press View once and check that forms move up. Make sure the forms thickness lever is not set too tightly.

126.

5. Check the paper tension between the tractors. Adjust the right tractor so that it does not pull paper too tightly or leave it too loose. The right tractor should hold

the paper under “slight” tension.

Inspect the ribbon mask for bends or deformation that block the paper path or prevent paper from exiting the pedestal top cover. Replace a damaged hammer bank cover assembly.

Check and adjust the platen open belt. Replace the belt if it is damaged.

9. Inspect the tractors and tractor door springs for damage or excessive wear. If either tractor is worn or damaged, replace both

tractors.

10. Check and adjust the paper feed belt. Replace the belt if it is damaged.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Message List

032 FORMS JAMMED TIMEOUT CLEAR JAM AND RELOAD FORMS (continued)

11. Check and adjust the platen gap.

041 BUFFER OVERFLOW

The print buffer has overflowed on a serial interface. The printed output may contain random * (asterisk) characters.

2. Send a print job to the printer. If the message appears, go to Communications Failures, page 131.

042 CUSTOM SET DOES NOT EXIST SAVE FIRST

Printer configuration: the custom configuration set does not exist.

Save the custom configuration set.

043 CUSTOM SET ALREADY EXISTS DELETE EXISTING SET FIRST

Printer configuration: custom set is writeprotected.

Delete the existing custom configuration set, then save the new set.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Chapter 5 Troubleshooting Display Messages

044 EC FIRMWARE/ HARDWARE ERROR

Application software tried to perform an illegal printer function or damaged memory is detected on the CMX controller board. (If the message appears at power-up, replace the CMX controller board. Record the message and return it with defective CMX board.)

1. Cycle power. Run the print job. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the flash memory with pre-written flash memory. (See Table 8 and Table 9 on page 219 and Figure 35 on page 220.)

3. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

4. Power on the printer. Run the print job again. If the message still appears, there is an application software error. Use your local support procedure to request assistance.

046 EC STOPPED AT STATE <state>

Where <state> is a number from 0000 to

0010. The Engine Controller processor has stopped and is in the state identified by the number displayed. (If the EC stops at state 0000 at powerup, replace the CMX controller board. Record the message and return it with the defective board.)

1. Power off the printer. Remove all flash memory and DRAM SIMMs. Inspect the SIMM sockets on the CMX controller board. If any socket pins are bent or damaged, replace the CMX controller board.

2. Install the flash and DRAM SIMMs, making sure they are fully and correctly seated. Power on the printer. Download the emulation. If the message appears, replace the flash memory with pre-written flash. (See Table 8 and Table 9 on page 219 and Figure 35 on page 220.)

3. Power on the printer. Download the emulation. If the message appears, replace the DRAM SIMM(s).

4. Power on the printer. Download the emulation. If the message appears, replace the CMX controller board. Record the message and return it with the defective board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Message List

057 CLOSE PLATEN

The forms thickness lever is open.

1. Load paper. Close the forms thickness lever. If message does not clear, go to the next step.

2. Power off the printer. Remove the paper guide assembly or pedestal top cover. Disconnect connector P107 from the CMX controller board. Check continuity of the platen interlock switch cable from P107/PLO to the switch. Replace the platen interlock switch assembly if it fails the continuity test. (Refer to Appendix A, Switch Assembly, Platen Interlock.)

3. Check that the platen interlock switch is not loose.

4. Check and adjust the platen open belt. Replace the belt if it is damaged.

5. Check the platen open pulley and the platen pulley for looseness. Bottom out the platen open motor pulley on the motor shaft and torque the 1/16 inch set screw to 9 ± 2 inch-pounds (1.02 ± 0.23 N•m).

Tighten the 7/64 inch setscrew in the platen shaft pulley, then open and close the forms thickness lever and check that the platen pulley setscrew does not hit the left ribbon guide.

Disconnect connector P106 from the CMX controller board. Check the resistance of connector P106/PLAT M. (Refer to the Main Wire Harness Test Tables on page 306.) Replace the platen open motor if it fails the resistance test.

Run a print test. If the message appears, replace the CMX controller board. Record the message and return it with the defective board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Chapter 5 Troubleshooting Display Messages

058 SHUTTLE JAM

SEE USER’S GUIDE

The shuttle is not moving or is moving at the wrong speed.

1. Check the forms thickness lever: if it is set too tightly, it can slow the shuttle enough to trigger the fault message. Set the forms thickness lever to match the thickness of paper and provide satisfactory print quality, but not too tightly.

2. Check and adjust the platen gap.

3. Inspect the ribbon mask for bends or deformation that snag and interfere with shuttle movement. Make sure the hammer bank cover assembly is correctly installed on its mounting pegs.

4. Run a print test. If the message appears, power off the printer.

5. Remove the shuttle cover. Remove the paper guide assembly or the pedestal top cover. Inspect the shuttle mechanism for obstructions. Check that all cables are attached at the shuttle and the CMX controller board. Make sure the MPU cable is not pinched. (Refer to Appendix A, Interconnection Diagram, page 289.) Remove obs tructions and reseat all cables. Check the resistance of MPU in P107. (Refer to the Main Wire Harness Test Tables, page 289.) Replace the MPU if it fails the test.

6. Run a shuttle test and observe shuttle movement. If the shuttle oscillates too slowly, adjust the gap between the MPU assembly and the flywheel to 0.010

.001 inch (0.254 ± 0.025 mm). Torque the 7/16 inch MPU clamp screw to 18 ± 1 inch-pounds (2.03 ± 0.11 N•m).

7. Run a print test. If the message appears,

replace the MPU and the MPU cable assembly.

8. Run a print test. If the message appears, replace the CMX controller board. Record the message and return it with the defective board.

9. Run a print test. If the message appears, replace the power supply board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Message List

058 SHUTTLE JAM

SEE USER’S GUIDE (continued)

10. Run a print test. If the message appears, replace the shuttle frame assembly.

059 CANCEL PRINT ACTIVE

Non-error status message.

No action required.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Chapter 5 Troubleshooting Display Messages

060 PRINTER HOT

CMX controller board sensors report high temperatures on the board. This message indicates internal temperatures over 60° Celsius (140° Fahrenheit). Print jobs do not create such temperatures, so immediately determine that the fans are operating and that all air vents are unobstructed. It is crucial that the exhaust vents on the floor of the cabinet remain unblocked, since hot air from inside the printer is vented through the cabinet floor. Nothing must be stored under the printer. Then check the operating environment. A severe environment is one with an ambient temperature at or above above 40° Celsius (104° Fahrenheit) or is dirty enough to create blockage of the cabinet fan vents. The printer must never be run at ambient temperatures greater than 40° Celsius (104° Fahrenheit). If the printer is located in such an environment, relocate it to a cooler, cleaner area.

1. Inspect printer environment for severity. Advise the user to move the printer to cooler, cleaner location.

2. Power off the printer. Remove the paper guide assembly or pedestal top cover. Check that all fan cables are connected.

3. Inspect vents and fan airways for obstructions. Look underneath cabinet models for items blocking the cabinet exhaust vents. Remove any obstructions from vents and airways.

4. Install the paper guide assembly or pedestal top cover. Power on the printer. Load paper. Run the Plot Test for 1/4 page. If the message appears, replace the CMX controller board. Record the message and return it with the defective board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Message List

062 EXHAUST FAN FAULT

Sensors cannot detect current in the fan circuit.

1. Cycle power. If the message appears, press Stop.

2. If the message occurs on a pedestal model, check that the correct operator panel is installed. The operator panel for a pedestal model has resistors R18 and R19 next to the operator panel cable connector.

3. Check that the exhaust fan is connected to exhaust fan cable connector J307.

4. Power off the printer. Remove the paper guide assembly. Disconnect connector P107 from the CMX controller board. Test connector P107/EHF for shorts or opens. (Refer to the Main Wire Harness Test Tables on page 291.) Replace components that fail test.

5. Make sure connector P107/EHF has a good connection at J107 on the CMX controller board.

6. Inspect for obstructions of airways and vents. Check for items beneath the printer blocking cabinet vents. Make sure cabinet exhaust fan vents are not blocked.

7. Power on the printer. Check for fan operation. If the message appears or the

fan doesn’t work, replace the exhaust fan.

Power on the printer. If the message appears, replace the CMX controller board. Record the message and return it with the defective board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Chapter 5 Troubleshooting Display Messages

065 HAMMER BANK FAN FAULT

Hammer Bank Fan Fault. Sensors cannot detect current in the fan circuit.

1. Cycle power. If the message appears, press Stop.

2. Power off the printer. Remove the paper guide assembly or pedestal top cover. Disconnect connector P107 from the CMX controller board. Test connector P107/HBF for shorts or opens. (Refer to the Main Wire Harness Test Tables on page 291.) Replace components that fail test.

3. Make sure P107/HBF has a good connection at J107 on the CMX controller board.

4. Inspect airways and vents for obstructions.

5. Power on the printer. If the message appears, replace the CMX controller board. Record the message and return it with the defective board.

069 DATA CLEARED

This message appears when data are cleared out of printer after Cancel key has been pressed.

No action required.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Message List

080 POWER SUPPL Y HOT

The printer has sensor circuits that sample the operating temperature of key components of the power supply. When higher than normal temperatures are sensed, print speed is automatically reduced. If the printer runs at reduced speed for an extended period of time, the POWER SUPPLY HOT message is sent to the LCD and printing stops, allowing printer components to cool down. Pressing the Start key resumes the print task. Check the operating environment. A severe environment is one with an ambient temperature at or above above 40° Celsius (104° Fahrenheit) or is dirty enough to create blockage of the cabinet fan vents. The printer must never be run at ambient temperatures greater than 40° Celsius (104° Fahrenheit). If the printer is located in such an environment, relocate it to a cooler, cleaner area.

1. Inspect printer environment for severity. Advise the user to move the printer to cooler, cleaner location.

2. Check the kinds of print jobs the user is running: look for very dense graphics and layouts. Advise the user to run jobs in smaller batches.

3. Power off the printer. Remove the paper guide assembly or pedestal top cover. Check that the power supply guard/air deflector is correctly positioned over the power supply board. CAUTION: DO NOT TOUCH THE POWER SUPPLY, but hold your hand close enough to check for heat radiating off the power supply board. If the power supply is noticeably hot, replace it.

4. Check that all fan cables are connected.

5. Inspect vents and fan airways for obstructions. Look underneath cabinet models for items blocking the cabinet exhaust vents.

6. Install paper guide assembly or pedestal top cover. Power on the printer. Load

paper. Run the “All E’s” print test for 5 to 10 minutes. If the message appears, replace the CMX controller board. Record the message and return it with the defective board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Chapter 5 Troubleshooting Display Messages

081 POWER SUPPLY VOL TAGE FAILURE

The power supply has failed.

1. Replace the power supply board.

2. Power on the printer. If the message appears, replace the CMX controller board.

082 POWER SUPPLY

8.5V FAILED

8.5 V olt Power Failed . Internal power failure.

1. Cycle power. If the message appears, replace the power supply board.

2. Power on the printer. If the message appears, replace the CMX controller board. Record the message and return it with the defective board.

3. Power on the printer. If the message appears, replace the shuttle frame assembly.

083 INTAKE FAN FAULT

Sensors cannot detect current in the card cage fan circuit.

1. Cycle power. If the message appears, press Stop.

2. Power off the printer. Remove the paper guide assembly or pedestal top cover. Disconnect connector P106 from the CMX controller board. Test connector P106/CCF for shorts or opens. (Refer to the Main Wire Harness Test Tables on page 291.) Replace components that fail test.

3. Make sure P106/CCF has a good connection at J106 on the CMX controller board.

4. Inspect for obstructions of airways and vents.

5. Power on the printer. If the message appears, replace the CMX controller board. Record the message and return it with the defective board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Message List

084 POWER SUPPL Y 48V FAILED

48 Volt Power Failed. Internal power failure.

1. Power off the printer. Remove the paper guide assembly or pedestal top cover. Check that power supply connector P101 is fully seated in connector J101 on the CMX controller board.

2. If the printer has the coax/twinax expansion board, check the adapter connection to the CMX controller board. Make sure the 60-pin expansion adapter is correctly seated between the CMX controller board and the coax/twinax expansion board.

3. Power on the printer. If the message appears, replace the hammer bank logic cable assembly (P108) and the power cable assembly (P105). (Refer to Appendix A.)

4. Power on the printer. If the message appears, replace the power supply board.

5. Power on the printer. If the message appears, replace the CMX controller board. Record the message and return it with the defective board.

6. Power on the printer. If the message appears, replace shuttle frame assembly.

085 CONTROLLER VOLTAGE

Controller Voltage Failure.

1. Cycle Power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the flash memory with pre-written flash. (See Table 8 and Table 9 on page 219 and Figure 35 on page 220.)

3. Power on the printer. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

4. Power on the printer. Run the print job again. If the message appears, replace the power supply board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Chapter 5 Troubleshooting Display Messages

086 CONTROLLER 15V

Controller Voltage Failure.

1. Cycle Power. Run the print job again. If the message appears, remove the hammer bank logic cable, inspect it for damage, and test it for continuity. (See Appendix A.) Replace the hammer bank logic cable if it is damaged or fails continuity test.

2. Cycle power. Run the print job again. If the message appears, replace the flash memory with pre-written flash. (See Table 8 and Table 9 on page 219 and Figure 35 on page 220.)

3. Power on the printer. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board. Also check the resistance of connectors P106/LRIB M and P107/RRIB M. (Refer to the Main Wire Test Tables, page 291.) If ribbon motor resistance is not correct, replace the motor and/or the intermediate cable, if installed.

4. Power on the printer. Run the print job again. If the message appears, replace the power supply board.

5. Power on the printer. If the message appears, replace the shuttle frame assembly.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Message List

087 PLATEN OPEN TIMEOUT CLOSE PLATEN

On a coax interface, the forms thickness lever has been open for at least one minute. Load paper.

1. Close the forms thickness lever. Press

Stop.

2. Run a print test. If a platen open or close platen message appears, power off the printer. Remove the paper guide assembly or pedestal top cover. Disconnect connector P107 from the CMX controller board. Check continuity of the platen interlock switch cable from P107 to the switch. Replace the platen interlock switch assembly if it fails continuity test. (Refer to Appendix A, Switch Assembly, Platen Interlock.)

3. Check that the platen interlock switch is not loose.

4. Check and adjust the platen open belt. Replace the belt if it is damaged.

5. Check the platen open pulley and the platen pulley for looseness. Bottom out the platen open motor pulley on the motor shaft and torque the 1/16 inch set screw to 9 ±

2 inch-pounds (1.02 ± 0.23 N•m).

Tighten the 7/64 inch setscrew in the platen shaft pulley, then open and close the forms thickness lever and check that the platen pulley setscrew does not hit the left ribbon guide.

Disconnect connector P106 from the CMX controller board. Check the resistance of connector P106/PLAT M. (Refer to the Main Wire Harness Test Tables on page 291.) Replace the platen open motor if it fails the resistance test.

Run a print test. If a platen open or close platen message appears, replace the CMX controller board. Record the message and return it with the defective board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Chapter 5 Troubleshooting Display Messages

088 CONTROLLER

23.5V

Controller Voltage Failure.

1. Cycle Power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the flash memory with pre-written flash. (See Table 8 and Table 9 on page 219 and Figure 35 on page 220.)

3. Power on the printer. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

4. Power on the printer. Run the print job again. If the message appears, replace the power supply board.

5. Power on the printer. If the message appears, replace the shuttle frame assembly.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Message List

089 RIBBON STALL

This message occurs when the ribbon fails to move while printing.

1. Check the forms thickness lever: if it is set too tightly it can inhibit ribbon movement. Set the forms thickness lever to match the thickness of the paper being used, but not too tightly.

2. Inspect the ribbon guides for ink buildup, which can inhibit ribbon movement. Clean the printer.

3. Inspect the hammer bank cover/ribbon mask for bending or damage, which can inhibit ribbon movement. Replace the hammer bank cover assembly if it is bent or damaged.

4. Check the platen gap. If the gap is too small, it can inhibit ribbon movement. Adjust the platen gap.

5. Power off the printer. Remove the paper guide assembly or pedestal top cover. Check the resistance of connectors P106/LRIB M and P107/RRIB M. (Refer to the Main Wire Harness Test Tables, page 291.) If ribbon motor resistance is not correct, replace the motor and/or the intermediate cable, if installed.

6. Power on the printer. Run an Operator Print Test. (See page 132.) If the 089 RIBBON STALL message appears, replace the CMX controller board. Record the message and return it with the defective board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Chapter 5 Troubleshooting Display Messages

090 SHUTTLE COVER OPEN CLOSE SHUTTLE COVER

The shuttle cover is missing, damaged, or not correctly installed.

1. Inspect shuttle cover for warping, damage, or missing magnet. (The magnet covers the sensor housing when the cover is installed.) If the shuttle cover is warped, damaged, or the magnet is missing, replace the shuttle cover assembly.

2. Check shuttle cover installation. Make sure the cover lies flat and the two captive screws are fully seated.

3. Power on the printer. If the message appears, power off the printer. Remove the paper guide assembly or pedestal top cover. Disconnect P107 on the CMX controller board and check the CVO switch by testing for continuity across pins 18 and 20. (Refer to the Main Wire Harness Test Tables, page 291.) Replace the cover open switch assembly, as required.

4. Power on the printer. If the message appears, replace the CMX controller board. Record the message and return it with the defective board.

092 RIBBON DRIVER CIRCUIT

The CMX controller board does not detect a ribbon drive motor.

1. Cycle power. If the message appears, power off the printer. Remove the paper guide assembly or pedestal top cover. Reseat the cable connections of both ribbon drive motors.

2. Power on the printer. Using a screwdriver, short across the ribbon guide screws to reverse ribbon hub motion. Check for a ribbon drive motor that will not wind the ribbon. If the ribbon will not wind in one or both directions, replace the defective ribbon drive motor(s). If the ribbon winds in both directions, replace the CMX controller board. Record the message and return it with the defective board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Message List

101 UPPER DRIVER SHORT

Hammer driver circuits on the CMX controller board are shorted to ground.

1. Cycle power. If the message appears, press Stop. If the message does not clear, replace the hammer bank logic cable and the hammer bank power cable assemblies.

2. Power on the printer. If the message appears, replace the CMX controller board. Record the message and return it with the defective board.

3. Power on the printer. If the message appears, replace the shuttle frame assembly.

102 LOWER DRIVER SHORT

Circuit(s) on the hammer bank or in the hammer bank power cable are shorted to ground.

1. Cycle power. If the message appears, press Stop. If the message doe s not clear, replace the hammer bank logic cable and the hammer bank power cable.

2. Power on the printer. If the message appears, replace the shuttle frame assembly.

3. Power on the printer. If the message appears, replace the CMX controller board. Record the message and return it with the defective board.

105 HAMMER COIL <number> OPEN

Electrical malfunction of one or more hammer coils.

1. Cycle power. If the message appears, replace the shuttle frame assembly.

2. Power on the printer. Run a print test. If the message appears, replace the CMX controller board. Record the message and return it with the defective board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Chapter 5 Troubleshooting Display Messages

107 HAMMER COIL <number> HOT

One or more hammer coils are overheating. The printer has sensor circuits that sample the operating temperature of key components of the print mechanism. When higher than normal temperatures are sensed, print speed is automatically reduced by 50% and a COIL HOT message is s ent to the LCD to inform the operator. When the coil(s) cool down, print speed automatically returns to 100% and the message clears from the LCD. This message is normal for extremel y dense print jobs, such as the Plot Test. If the printer often prints at half speed, it may be operating in a severe environment. A severe environment is one with an ambient temperatu re at or above above 40° Celsius (104° Fahrenheit) or that is dirty enough to create blockage of the cabinet fan vents. The printer must never be run at ambient temperatures greater than 40° Celsius (104° Fahrenheit). If the printer is located in such an environment, relocate it to a cooler, cleaner area or reduce the size and duration of the print jobs.

1. Inspect the printer environment for severity. Advise the user to move the printer to cooler, cleaner location.

2. Check the kinds of print jobs the user is running: look for very dense graphics and layouts. Advise the user to run jobs in smaller batches.

3. Power off the printer. Remove the paper guide assembly or pedestal top cover. Check all fan cable connections.

4. Power on the printer. Verify that all fans operate. Replace any fan that does not operate.

5. Inspect vents and fan airways for obstructions. Look underneath cabinet models for items blocking the cabinet exhaust vents. Remove any obstructions from vents and airways.

6. Install the paper guide assembly or pedestal top cover. Load paper. Run the

“All E’s” print test for 5 to 10 minutes. If the message appears, replace the shuttle frame assembly.

Run the “All E’s” print test for 5 to 10 minutes. If the message appears, replace the CMX controller board. Record the message and return it with the defective board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Message List

11 0 STACK OVERFLOW

SEE USER’S GUIDE

System stack has run out of room and overflowed into other memory.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

1 11 STACK UNDERFLOW SEE USER’S GUIDE

Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

112 UNDEFINED OPCODE SEE USER’S GUIDE

Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

113 PROTECTED INSTRUCTION SEE USER’S GUIDE

Protected In st ru ct i on. Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

114 ILLEGAL OPERAND ACCESS SEE USER’S GUIDE

Illegal Operand Accessed. Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

115 ILLEGAL INSTRUCTION ACCESS SEE USER’S GUIDE

Illegal Instruction Accessed. Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Chapter 5 Troubleshooting Display Messages

116 ILLEGAL EXTERNAL BUS ACCESS

SEE USER’S GUIDE

Illegal External Bus Accessed. Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

117 A TO D OVERRUN SEE USER’S GUIDE

The analog-to-digital converter on the CMX controller board has overflowed.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

118 UNDEFINED INTERRUPT SEE USER’S GUIDE

Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

119 TCB CORRUPTED SEE USER’S GUIDE

T ask Control Block on the CMX controller board has been corrupted.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

120 ACCESS NULL POINTER SEE USER’S GUIDE

The proces sor tried t o access a pointer that contains nothing (null).

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

121 PAPER NOT AT SPEED SEE USER’S GUIDE

Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Message List

122 PAPER NOT SCHEDULED

SEE USER’S GUIDE

The paper feed process is not scheduling on the CMX controller board, and the printer cannot advance paper.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the MPU cable assembly.

3. Power on the printer. Run the print job again. If the message appears, replace the power supply board.

4. Power on the printer. Run the print job again. If the message appears, replace the shuttle frame assembly.

5. Power on the printer. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

123 PAPER BUSY TOO LONG SEE USER’S GUIDE

Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Run the print job again. If the message appears, power off the printer. Remove the paper guide assembly or pedestal top cover. Make sure connectors P106 and P107 are fully seated on the CMX controller board.

3. Power on the printer. Run the print job again. If the message appears, replace the shuttle frame assembly.

4. Power on the printer. Run the print job again. If the message appears, power off the printer . Make sure the MPU cable, the hammer bank logic cable, and the hammer bank power cable are undamaged and have good connections. Replace as necessary. (Refer to Appendix A.)

5. Power on the printer. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Chapter 5 Troubleshooting Display Messages

124 PAPER FIFO OVERFLOW

SEE USER’S GUIDE

Paper First In First Out Overflow. Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

125 PAPER FIFO UNDERFLOW SEE USER’S GUIDE

Paper First In First Out Underflow.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

3. Check hammer phasing. Try using a lower phasing value; sometimes this message indicates too high a hammer phase value.

5. Power on the printer. Run the print job again. If the message appears, replace the shuttle frame assembly.

6. Power on the printer. Run the print job again. If the message appears, replace the power supply board.

7. Power on the printer. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Message List

126 PAPER FEED BAD TABLE

SEE USER’S GUIDE

The paper feed process on the CMX controller board has a corrupted table. If this message appears during a software download, do the download again. If the message appears on the second try, replace the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

127 PAPER FEED ILLEGAL STATE SEE USER’S GUIDE

Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

128 PAPER FEED INV ALID COMMAND SEE USER’S GUIDE

Paper Invalid Command. Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

129 PAPER FEED INV ALID PARAMETER SEE USER’S GUIDE

Paper Invalid Parameter. Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

130 PAPER FEED PARTLY ENERGIZED SEE USER’S GUIDE

Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Chapter 5 Troubleshooting Display Messages

131 PAPER FEED INTERRUPT

SEE USER’S GUIDE

Unexpected interrupt in the paper feed process on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

132 RIBBON INVALID COMMAND SEE USER’S GUIDE

Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

133 RIBBON INVALID STATE SEE USER’S GUIDE

Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

134 PLATEN INVALID COMMAND SEE USER’S GUIDE

Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

135 PLATEN INVALID STATE SEE USER’S GUIDE

Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

136 PLATEN INVALID PARAMETER SEE USER’S GUIDE

Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

Message List

137 SHUTTLE INVALID COMMAND

SEE USER’S GUIDE

Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

138 SHUTTLE INVALID PARAMETER SEE USER’S GUIDE

Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

139 SHUTTLE OVERSPEED SEE USER’S GUIDE

Firmware error on the CMX controller board.

1. Cycle power. Run the print job again. If the message appears, download the emulation software again.

2. Remove the shuttle cover. Remove the paper guide assembly or the pedestal top cover. Make sure the MPU cable (P/N 14H5329) is not pinched. Check both the section of MPU cable coming from the sensor and the intermediate cable extension that runs to the controller board. (Refer to Appendix A, Interconnection Diagram, page 289.) Check the resistance of the MPU at connector P107. (Refer to the Main Wire Harness Test Tables, page 291.) Replace the MPU if it fails the test.

3. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. Record the message and return it with defective CMX board.

990 MACHINE CHECK

Host status message. No action required.

998 NON-VOLATILE MEMORY FAILED

The non-volatile memory has failed.

Replace the CMX controller board. (Do NOT attempt to replace NVRAM.)

A97 GRAPHIC CHECK ERROR PRESS STOP THEN START

The printer received a non-printable character over a twinax interface.

Press Stop then Start.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

100

Chapter 5 Troubleshooting Display Messages

BOOT DIAGNOSTICS

Non-error status message.

No action required.

CLEARING PROGRAM FROM FLASH

Status message: emulation software successfully loaded into printer RAM and the checksum matched. The old program is now being deleted from flash memory.

No action required.

DRIVER CIRCUIT BAD

The hammer coil count test failed.

1. Cycle power. If the message appears, press Stop.

2. Power off the printer. Remove the shuttle cover. At the shuttle frame assembly, disconnect the hammer bank logic and power cables. Power on the printer. If

“HB NOT INSTALLD” appears on the LCD, replace the shuttle frame assembly. If “HB NOT INSTALLD” does not appear on the LCD, replace the CMX controller board.

ENERGY SAVER MODE ACTIVE

Status message: the printer is in lowenergy idle state, all fans and higher voltages are off, only +5Vdc logic circuits are active.

No action required.

ERROR: DRAM AT ADDRESS <hex>

The printer found a defective memory location.

Replace the DRAM.

Power on the printer. If the message appears, replace the CMX controller board. Record the message and return it with the defective board.

ERROR: DRAM NOT DETECTED

DRAM is defective or missing.

1. Check DRAM on the CMX controller board. If present, reseat DRAM; if missing, install DRAM.

2. Power on the printer. If the message appears, replace the DRAM.

3. Power on the printer. If the message appears, replace the CMX controller board. Record the message and return it with the defective board.

Table 4. Message List

Operator Panel

Message

Explanation Corrective Action

IBM 6400-004, 6400-05P, 6400-04P, 6400-005, 6400-050 Maintenance Information Manual

Specifications and Main Features

Frequently Asked Questions

User Manual