Printronix P5214-SS, P52KA, P5214, P5215, P5210 User Manual

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Maintenance Manual

The Printronix P5000 series of Line Matrix Printers

Maintenance Manual

164253-001, Rev D

Trademark Acknowledgements

T rade mark Ack nowledgemen ts

ANSI is a registered trademark of American National Standards Institute, Inc. Centronics is a registered trademark of Genicom Corporation. Code V is a trademark of Quality Micro Systems. Chatillon is a trademark of John Chatillon & Sons, Inc. Dataproducts is a registered trademark of Dataproducts Corporation. EIA is a registered service mark of Electronic Industries Association.

ENERGY STAR® is a registered trademark of the United States

Environmental Protection Agency. As an Printronix has determined that this product meets the guidelines for energy efficiency. Ethernet is a trademark of Xerox Corporation. IBM is a registered trademark of International Business Machines Corporation. IEEE is a registered trademark of the Institute of Electrical and Electronics Engineers. IGP is a registered trademark of Printronix, Inc. Intelligent Printer Data Stream and IPDS are trademarks of International Business Machines Corporation. LinePrinter Plus is a registered trademark of Printronix, Inc. MS-DOS is a registered trademark of Microsoft Corporation. PC-DOS is a trademark of International Business Machines Corporation. PGL is a registered trademark of Printronix, Inc. PrintNet is a trademark of Printronix, Inc. Printronix is a registered trademark of Printronix, Inc. PSA is a trademark of Printronix, Inc. QMS is a registered trademark of Quality Micro Systems. RibbonMinder is a trademark of Printronix, Inc. SureStak is a trademark of Printronix, Inc. Torx is a registered trademark of Camcar/Textron Inc. Utica is a registered trademark of Cooper Power Tools.

ENERGY STAR® Partner,

ENERGY STAR®

War ranty and Copyrig ht Inform ation

Printronix, Inc. makes no representations or warranties of any kind regarding this material, including, but not limited to, implied warranties of merchantability and fitness for a particular purpose. Printronix, Inc. shall not be held responsible for errors contained herein or any omissions from this material or for any damages, whether direct, indirect, incidental or consequential, in connection with the furnishing, distribution, performance or use of this material. The information in this manual is subject to change without notice.

This document contains proprietary information protected by copyright. No part of this document may be reproduced, copied, translated or incorporated in any other material in any form or by any means, whether manual, graphic, electronic, mechanical or otherwise, without the prior written consent of Printronix, Inc.

COPYRIGHT © 1996, 1999, PRINTRONIX, INC.

Communication Notices

Federal Communications Commission (FCC) Statement: This equipment

has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case the user will be required to correct the interference at his own expense.

Properly shielded and grounded cables and connectors must be used in order to meet FCC emission limits. Printronix is not responsible for any radio or television interference caused by using other than recommended cables and connectors or by unauthorized changes or modifications to this equipment.

Unauthorized changes or modifications could void the user’s authority to operate the equipment.

Warranty and Copyright Information

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interferenc e that may cause unde si r ed operation.

Canadian Department of Communications Compliance Statement: This Class A digital apparatus meets all requirements of the Canadian

Interference-Causing Equipment Regulations. Avis de conformité aux normes du ministère des Communications du

Canada: Cet appareil numérique de la classe A respecte toutes les exigences du

Règlement sur le matériel brouilleur du Canada.

European Union (EC) Electromagnetic Compatibility Directives:

product is in conformity with the protection requirements of EC Council Directive 89/336/EEC on the approximation of the laws of the Member States relating to electromagnetic compatibility. Printronix cannot accept responsibility for any failure to satisfy the protection requirements resulting from a non-recommended modification of the product, including the fitting of non-Printronix option cards.

Dieses Gerät ist berechtigt in Übereinstimmung mit dem deutschen EMVG vom 9.Nov.92 das EG-Konformitätszeichen zu furhren.

Properly shielded and grounded cables and connectors must be used in order to reduce the potential for causing interference to radio and TV communication and to other electrical or electronic equipment.

This product has been tested and found to comply with limits for Class A Information Technology Equipment according to CISPR 22/European Standard EN 55022. The limits for Class A equipment were derived for commercial and industrial environments to provide reasonable protection against interference with licensed communication equipment.

This

Chapter Communication Notices

Warning: This is a Class A product. In a domestic environment this product

may cause radio interference in which case the user may be required to take adequate measures.

Dieses Gerät erfüllt die Bedingungen der EN 55022 Klasse A. Für diese Klasse von Geräten gilt folgende Bestimmung nach dem EMVG:

Geräte dürfen an Orten, für die sie nicht ausreichend entstört sind, nur mit besonderer Genehmigung des Bundesminesters für Post und Telekommunikation oder des Bundesamtes für Post und Telekommunikation betrieben werden. Die Genehmigung wird erteilt, wenn keine elektromagnetischen Störungen zu erwarten sind.

(Auszug aus dem EMVG vom 9.Nov.92, Para.3, Abs.4) Hinweis: Dieses Genehmigungsverfahren ist von der Deutschen Bundespost

noch nicht veröffentlict wor den .

Table of Contents

1 Maintenance Overview......................... 11

About the Printer....................... ...... ....... ...... ....................... 11

P5000 Printers.................................................................... 11

Kanji/Hanzi Printers...................................................... 11

Printer Evolution........................................................... 12

How to Identify the Printer............................................ 12

Important Maintenance Notes............................................. 15

About This Manual.............. ...... ...... ....... ...... ....... ...... ....... ... 15

How to Use This Manual .............................................. 16

Notes and Notices........................................................ 16

Printing Conventions in This Manual............................ 16

Safety Notices..................................................................... 17

Hinweise zur Sicherheit...................................................... 17

Controls and Indicators....................................................... 18

Tools, Test Equipment, and Supplies................................. 24

2 Preventive Maintenance....................... 25

Cleaning the Printer.................................................. ....... ... 25

Cleaning the Outside Surfaces................................. .......... 25

Cleaning the Shuttle Frame Assembly ............................ ... 27

Cleaning the Card Cage Fan Assembly ............................. 28

3 Troubleshooting ................................... 29

Introduction......................................................................... 29

Troubleshooting Aids.......................................................... 29

Start Here... ........................................................................ 30

Troubleshooting Display Messages.................................... 31

How to Clear LCD Messages....................................... 31

Troubleshooting Other Symptoms...................................... 36

Troubleshooting Procedures............................................... 38

How to Use the Troubleshooting Procedures............... 38

The Procedures............................................................ 39

Communications Failures ................................................... 88

Diagnostic Printer Tests...................................................... 89

Selecting and Running Diagnostic Printer Tests.......... 90

Boot Diagnostics Menu....................................................... 92

vii

Table of Contents

Hex Code Printout .............................................................. 95

How to Print a Hex Dump............................................. 96

ASCII Character Set.................................... ....... ...... ....... ... 97

Soft vs. Hard Reset............................................................. 98

The Power On Sequence ................................................... 99

CMX Controller Board Handshake Sequences............ 99

DC Software Initialization and Power Up ................... 103

4 Adjustment Procedures ..................... 105

Introduction....................................................................... 105

Preparing the Printer for Maintenance.............................. 106

Returning the Printer to Normal Operation....................... 107

Belt, Paper Feed Timing, Adjustment (Figure 10) ............ 108

Belt, Platen Open, Adjustment (Figure 11)....................... 110

Paper Drive Motor Pulley Alignment (Figure 12) .............. 112

Paper Scale Alignment (Figure 13)................................... 114

Platen Gap Adjustment (Figure 14).................................. 116

Platen Open Motor Pulley Alignment (Figure 15) ............. 118

Ribbon Guide Alignment (Figure 16)................................ 120

Splined Shaft Skew Adjustment (Figure 17)..................... 122

Paper Out Adjustment ...................................................... 124

Hammer Phasing Adjustment........................................... 128

Loading Flash Memory from One Diskette....................... 130

Loading Flash Memory from Multiple Diskettes................ 135

Set Shuttle Speed............................................................. 141

viii

5 Replacement Procedures

and Illustrated Parts Lists....................... 143

Organization of This Chapter............................................ 143

Section I: Replacement Procedures................................. 144

List of Removal/Installation Procedures..................... 144

Belt, Paper Feed Timing ............................................ 146

Belt, Platen Open......................................... ...... ....... . 147

Circuit Breaker ........................................................... 148

Connector Shells........................................................ 149

Connector Stiffening Clips.......................................... 151

Control Panel Assembly, Cabinet Models.................. 153

Control Panel Assembly, Pedestal Models................ 154

Controller Board (CMX).............................................. 155

Cover Assembly, Hammer Bank / Ribbon Mask........ 157

Cover Assembly, Shuttle............................................ 160

Cover Assembly, Top, Pedestal Models .................... 161

Table of Contents

Expansion-CT ............................................................ 162

Fan Assembly, Cabinet Exhaust................................ 163

Fan Assembly, Card Cage ......................................... 164

Fan Assembly, Hammer Bank.................................... 165

Hammer Spring Assembly.......................................... 166

Magnetic Pickup (MPU) Assembly............................. 170

Memory Modules and Security PAL........................... 171

Paper Feed Motor ...................................................... 174

Paper Ironer ............................................................... 176

Paper Path ................................................................. 177

Platen......................................................................... 178

Platen Open Motor ..................................................... 182

Power Supply Board .................................................. 184

PrintNet Ethernet Interface Assemblies ..................... 185

10Base2 and 10Base-T LEDs and DIP Switches ...... 186

10/100Base-T LEDs and Dipswitches........................ 188

Resistors, Terminating ............................................... 190

Ribbon Drive Motor .................................................... 192

Ribbon Guide Assembly (L/R).................................... 193

Ribbon Hub ................................................................ 194

Shaft, Splined.. ...... ....... ...... ...... ....... ...... ..................... 195

Shaft, Support . ...... ....... ...... ...... ....... ...... ..................... 197

Shuttle Frame Assembly ............................................ 198

Spring Assembly, Gas................................................ 200

Spring, Extension, Hammer Bank.............................. 201

Switch Assembly, Paper Detector.............................. 202

Switch Assembly, Platen Interlock ............................. 203

Tractor (L/R)............................................................... 204

Section II: Illustrated Parts Lists ....................................... 205

Illustrations of Printer Components............................ 205

6 Principles of Operation...................... 239

Line Matrix Printing........................................................... 239

Printing Rates ................................................................... 242

Printing Mechanism .......................................................... 242

Shuttle Frame Assembly ............................................ 243

Paper Transport System ............................................ 245

Ribbon Transport System........................................... 246

Logical Control of the Printer............................................ 247

Control Panel.................................................................... 248

CMX Controller Board....................................................... 249

Data Controller........................................................... 251

Table of Contents

Engine Controller ....................................................... 254

Power Supply Board......................................................... 255

AC Power................................................................... 255

DC Power................................................................... 256

Printer Interface................................................................ 256

Graphics ........................................................................... 257

A Wire Data............................................. 259

B Abbreviations &

Signal Mnemonics ................................... 299

C Metric Conversion Tables ................. 307

D Noise Suppression Devices.............. 309

E SureStak™ Power Stacker ....... .........311

Contents ........................................................................... 311

Introduction....................................................................... 311

Removing the Power Stacker........................................... 312

Installing the Power Stacker ............................................. 317

Replacing the Constant Force Spring............................... 328

Replacing the Timing Belts............................................... 331

Illustrated Parts Breakdown.............................................. 335

1 Maintenance Overview

About the Printer

Printronix P5000 series line matrix printers use PSA (Printronix System

Architecture), which puts all data control and printer control logic on one

circuit board. The use of 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 enable these printers to print a wide variety

of high-volume jobs with minimum maintenance and maximum reliability.

Although technologically advanced, the P5000 printer is easy to use. The

operator can select every printer function at the printer control panel or by

sending control codes in the data stream from the host computer to the

printer. For greater security and to protect special printer configurations, the

operator can program which key combination locks and unlocks the ENTER

key on the control panel.

This is also an excellent graphics printer, with optional features that simplify

the creation of images. The IGP and Code V Printronix emulations, for

example,

into flash memory.

are simple but versatile graphics programming languages that load

P5000 Printers

The P5000 family consists of machines that print at different speeds. (See

Table 1.) Many models are available in either a floor cabinet or pedestal

housing. P5XKA (Kanji/Hanzi) models are available in pedestal, cabinet, or

“table top” configuration. Despite its name, the table top P5XKA printer is not

intended for use on a table. It is really a pedestal model printer that has been

removed from the pedestal and packaged separately to facilitate shipping to

certain international markets. A “table top” printer is then installed on its

pedestal after it arrives at its destination.

Kanji/Hanzi Printers

P5XKA printers have shuttle assemblies, hammer springs, and software

modified to print the Kanji/Hanzi character sets used in Asia. These printers

support the GB Song and GB

Republic of China, Singapore, and Hong Kong, and the Big-5

set used in Hong Kong and Taiwan. P5XKA printers can mix ASCII and Kanji/

Hanzi characters on the same line, with ASCII characters occupying half the

width of Kanji/Hanzi character cells. Because of the density and complexity of

these character sets, these models print at lower speeds.

Kai character sets used in the People’s

Ming character

Chapter 1 P5000 Printers

Printer Evolution

The newest models in the family are the P5X05B, P5X10, and P5X15, which are available both in pedestal and floor cabinet housings. These models have a redesigned shuttle frame assembly, hammer bank, and ribbon guides. The new shuttle and hammer bank assemblies are not compatible with earlier P5000 printers, but the new ribbon guides can be used on any model P5000 printer.

The P5X05B, P5X10, and P5X15 models also use the CMX 040 controller board, which has a 40 MHz clock speed for the Data Controller unit. The CMX 040 can be used in any P5000 printer, but the P5X05B, P5X10, and P5X15 models cannot use earlier versions of the CMX board.

When you replace components, be careful to order the correct spares for the model you are servicing. The next section explains how to identify a P5000 series printer.

How to Identify the Printer

A P5000 printer is identified by its model number. The model number is a code that indicates the printer type, family, speed, and housing. Figure 1 shows how to interpret a model number.

Table 1 lists the models comprising the P5000 family. The speeds listed in Table 1 are the highest speeds attainable under controlled conditions. Actual printing speed is determined by the interaction of many variables. For more

information about printing speeds, refer to “Printing Rates” on page 242.

Optional 12 MIL (0.012 inch) hammer tips. Standard tips are 16 MIL (0.016 inch). This option does not apply to Kanji/ Hanzi printers, which have unique hammer spring assemblies.

Printronix Line Matrix Printer

Housing Code: 0 = Pedestal 1 = Table Top 2 = Floor Cabinet

P5005-12-QA

P5000 Printer

Speed Rating: 05 = 475 lpm 05A = 500 lpm 05B = 500 lpm (40 MHz CMX board) 08 = 800 lpm 09 = 900 lpm 10 = 1000 lpm 12 = 1200 lpm 14 = 1400 lpm 15 = 1500 lpm KA = Kanji/Hanzi printer

QA = Pedestal model with optional QuickAccess Cover

SS = Cabinet model with optional SureStak™ power paper stacker.

Figure 1. How to Interpret Model Numbers

Table 1. P5000 Printers

How to Identify the Printer

Model Number

Speed

Enclosure Hammer Bank

P50KA 585 lpm Pedestal 91 Hammers

Data

Controller

Clock Speed

25 MHz

Kanji / Hanzi P5005 475 lpm Pedestal 28 Hammers 25 MHz P5005-QA 475 lpm Pedestal w/Quick-

28 Hammers 25 MHz

Access Cover

P5005-12 475 lpm Pedestal 28 Hammers,

25 MHz

12 MIL tips

P5005-12-QA 475 lpm Pedestal w/Quick-

Access Cover

P51KA 585 lpm Table Top 91 Hammers

28 Hammers,

12 MIL tips

25 MHz

Kanji / Hanzi P5205 475 lpm Cabinet 28 Hammers 25 MHz P5205-12 475 lpm Cabinet 28 Hammers,

25 MHz

12 MIL tips

P5005A 500 lpm Pedestal 28 Hammers 25 MHz

P5005A-QA 500 lpm Pedestal w/Quick-

28 Hammers 25 MHz

Access Cover

P5005A-12 500 lpm Pedestal 28 Hammers,

25 MHz

12 MIL tips

P5005A-12-QA 500 lpm Pedestal w/Quick-

Access Cover

28 Hammers,

12 MIL tips

25 MHz

P5205A 500 lpm Cabinet 28 Hammers 25 MHz P5205A-12 500 lpm Cabinet 28 Hammers,

25 MHz

12 MIL tips P5005B 500 lpm Pedestal 28 Hammers 40 MHz P5005B-QA 500 lpm Pedestal w/Quick-

28 Hammers 40 MHz

Access Cover

P5005B-12 500 lpm Pedestal 28 Hammers,

40 MHz

12 MIL tips P5005B-12-QA 500 lpm Pedestal w/Quick-

Access Cover

28 Hammers,

12 MIL tips

40 MHz

P5205B 500 lpm Cabinet 28 Hammers 40 MHz

Chapter 1 P5000 Printers

Table 1. P5000 Printers

Model Number

Speed

Enclosure Hammer Bank

P5205B-12 500 lpm Cabinet 49 Hammers,

Data

Controller

Clock Speed

40 MHz

12 MIL tips P5008 800 lpm Pedestal 49 Hammers 25 MHz P5008-QA 800 lpm Pedestal w/Quick-

49 Hammers 25 MHz

Access Cover P5208 800 lpm Cabinet 49 Hammers 25 MHz P500 900 lpm Pedestal 49 Hammers 25 MHz P5009-QA 900 lpm Pedestal w/Quick-

49 Hammers 25 MHz

Access Cover P5209 900 lpm Cabinet 49 Hammers 25 MHz P5010 1000 lpm Pedestal 60 Hammers 40 MHz P5010-QA 1000 lpm Pedestal w/Quick-

60 Hammers 40 MHz

Access Cover P5210 1000 lpm Cabinet 60 Hammers 40 MHz

P5212 1200 lpm Cabinet 91 Hammers 25 MHz P5214 1400 lpm Cabinet 91 Hammers 40 MHz P5214-SS 1400 lpm Cabinet

91 Hammers 40 MHz

w/SureStak

Paper Stacker P5015 1500 lpm Pedestal 102 Hammers 40 MHz P5015-QA 1500 lpm Pedestal w/Quick-

102 Hammers 40 MHz

Access Cover P5215 1500 lpm Cabinet 102 Hammers 40 MHz P5215-SS 1500 lpm Cabinet

102 Hammers 40 MHz

w/SureStak

Paper Stacker

P52KA 585 lpm Cabinet 91 Hammers

40 MHz

Kanji / Hanzi

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 these printers, used as indicated in Table 1. The 40 MHz controller board, however, is compatible with all models that use the 25 MHz board and should be used if the CMX board is replaced.

Important Maintenance Notes

To ensure the best performance of the printer, remember these maintenance principles whenever you service the printer.

How to Identify the Printer

CAUTION

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

• Do not

1) the original shuttle frame assembly or platen has been replaced with a new or rebuilt unit, or

2) you are instructed to do so in a troubleshooting procedure.

• Never bend or tweak hammer springs. Always handle hammer springs by

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

• Use only

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 locate maintenance information quickly.

This manual does not explain how to install, operate, or configure the printer. That information is in the

adjust the platen gap unless

the ribbons specified in Appendix B. Use of incorrect ribbons

User’s Manual.

This manual does not explain how to program application software for operation with the printer. Programming information for the protocols used by

the printer is in the appropriate programmer’s reference manual:

•

LinePrinter Plus

Defines host control codes for the LinePrinter Plus emulations.

•

Character Sets Reference Manual

Information about and examples of the character sets available in Printronix line matrix printers.

•

Network User’s Manual

Information about network protocols, configuration, and network operation.

•

Coax/Twinax Programmer’s Reference Manual

Defines host control codes and character sets for the optional coax/twinax emulations.

•

ANSI Programmer’s Reference Manual

Defines host control codes and character sets for the ANSI emulation.

•

IPDS Twinax Emulation Programmer’s Reference Manual

An overview of Intelligent Printer Data Stream™ (IPDS) features, commands, and diagnostics.



Programmer’s Reference Manual

Chapter 1 About This Manual

•

IGP/PGL Programmer’s Reference Manual

Describes the optional IGP Printronix emulation. 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.

•

IGP/VGL Programmer’s Manual

Describes the optional Code V Printronix emulation. 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.

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 work on the printer.

3. Gather the parts and tools you will need.

4. Make sure you understand all safety notices before you start a task. (See below.)

WARNING

CAUTION

IMPORTANT

Notes and Notices

For your safety and to protect valuable equipment, read and comply with all information highlighted under notes and notices. The heading of a notice indicates the kind of information it contains:

Conditions that could hurt you and damage equipment. Conditions that could damage equipment. Information vital to proper operation and maintenance of the printer.

NOTE: Notes contain tips for efficient operation, maintenance, and

troubleshooting.

The Safety Notices on page 17 apply at all times when you are working on the printer. Please read them now.

Printing Conventions in This Manual

Control panel keys and indicators are highlighted in UPPERCASE BOLD PRINT. Example: Press the CANCEL key, then press the ON LINE key.

LCD (Liquid Crystal Display) messages are set off by quotation marks (“ “). Example: Press the ON LINE key. “OFF LINE” appears on the LCD.

Control panel key combinations are indicated by the + (plus) symbol. Example: Press means Press the

= + >.

=(UP) key and the >(DOWN) key at the same time.

Safety Notices

Printing Conventions in This Manual

WARNING

WARNING WARNING

WARNING

Always disconnect the AC power cord from the printer or power source before performing any maintenance procedure. Failure to remove power could result in injury to persons or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure.

Always disconnect the AC power cord before cleaning the printer. To prevent injury from electric shock, wait at least one minute after

shutting off power before removing the power supply circuit board. Wear a properly grounded static wrist strap when handling the power supply board. Handle the board by the sides. Do not touch components or flex the board during removal/installation.

Over time, the upper edge of the paper ironer can become sharp. To avoid cutting yourself, handle the paper ironer on the sides.

Hold the printer cover securely while disengaging the gas spring assembly.

Hinweise zur Sicherheit

Bevor Sie anfällige Wartungsarbeiten durchführen, müssen Sie zuerst immer das Netzkabel aus der Steckdose ziehen. Wird das Netzkabel nicht herausgezogen, können Verletzungen oder Geräteschäden entstehen. Falls die Wartungsarbeit Stromzufuhr erfordert, wird im Wartungsablauf darauf hingewiesen.

VORSICHT

Ziehen Sie das Netzkabel aus der Steckdose, bevor Sie den Drucker reinigen.

VORSICHT

Um Verletzungen durch Elektroschocks zu vermeiden, warten Sie mindestens eine Minute nach Stromausschaltung, bevor Sie die elektrische Schaltkarte entfernen. Bitte immer einen geerdeten, statischen Handgelenkriemen tragen, wenn Sie die elektrische Schaltkarte handhaben. Halten Sie die Karte nur an den seitlichen Auswurfshebeln. Während des Herausnehmens/Installierens dürfen die Komponenten der Karte nicht berührt oder gebogen werden.

VORSICHT

Die obere Kante der Papierschiene wird mit der Zeit scharf. Halten Sie die Schiene deshalb an den Seiten, damit Sie sich nicht schneiden.

VORSICHT

Behalten Sie die Druckerabdeckung sicher im Griff, wenn Sie das Gasfederpaket entfernen.

Chapter 1 Controls and Indicators

Controls and Indicators

Electrical Controls and Indicators, Cabinet Models (Figure 2)

Switch or

Indicator

Power Switch Turns printer on and off: 1 = on, 0 = off. This switch is also a circuit breaker.

Status

Indicator

LCD Liquid Crystal Display. Displays pri nter status messages, fault messages, and

ON LINE/

CLEAR PAPER

ADVANCE

VIEW / EJECT

CANCEL Clears all data from the print buffer (if enabled in the MAINT/MISC menu).

= (UP)

On when the print er is on -lin e, o f f w h en th e printer is off-line. Flashes to indicate a fault or warning.

menus which permit user to set various configurations. Toggles the printer on-line and off-line. Clears the printer after a fault is corrected

and returns the printer to off-line state. Prints any data in the buffer then moves paper up one line at the currently active

line spacing. If pressed longer than 1/2 second, moves paper to the next Top Of Form as defined by the currently active form length.

Moves the current print position to the tractor area for viewing. When paper is in

VIEW position, “Printer in View” displays and microstep adjustment feature is active. (See UP and DOWN keys.) Holding key down for more than 1/2 second invokes EJECT and paper is advanced two pages. (EJECT can be disabled via the menus.) Pressing key a second time moves paper back to the print position from either VIEW or EJECT position.

Displays next higher level of a configuration menu. In VIEW mode, moves paper up 1/72 inch. (See VIEW / EJECT key.)

Function

Active

On-line

Active

Off-line

ää

> (DOWN)

< (NEXT)

; (PREV)

SET TOF Moves paper downward from TOF alignment mark to the print station and sets this

PRT CONFIG Prints the current printer configuration. JOB SELECT Allows fast selection of any stored configuration. Repeated pressing scrolls

ENTER Enters an option disp layed on th e LCD into p rinter no n-volatile memory. Starts and

;+<

Displays next lower level of a configuration menu. In VIEW mode, moves paper down 1/72 inch. (See VIEW / EJECT key.)

Displays the next option in a configuration menu. Displays the previous option in a configuration menu.

as the first line of print on a page, independent of forms length. If there are data in the buffers, the printer slews to the page position where printing left off and prints the data.

through all saved configurations. Press ENTER to select the displayed configuration. (ENTER does not have to be unlocked for this function.)

stops printer tests, sets a value, or prints the configuration. This key is locked and unlocked by a user-selectable key combination. (Refer to the

Resets the printer by reloading the power-up configuration and resetting the internal state.

User’s Manual

ää

Printing Conventions in This Manual

(Off) (On)

Raise printer cover to use these keys.

DOWN

SET TOF

PRT CONFIG

JOB SELECT

ENTER

LCD

Power Switch

Status Indicator

ON LINE

CLEAR EJECT

PAPER

ADVANCE

VIEW

CANCEL

Figure 2. Electrical Controls, Cabinet Models

Chapter 1 Controls and Indicators

Electrical Controls and Indicators, Pedestal Models (Figure 3)

Switch or

Indicator

Power Switch Turns printer on and off: 1 = on, 0 = off. This switch is also a circuit breaker.

Status

Indicator

LCD Liquid Crystal Display. Displays pri nter status messages, fault messages, and

ON-LINE

CLEAR PAPER

ADVANCE

VIEW

EJECT

CANCEL Clears all data from the print buffer (if enabled in the MAINT/MISC menu).

↑

On when the printer is on -lin e, o f f w h en th e p rinte r is off-line. Flashes to indicate a fault or warning.

menus which permit user to set various configurations. Toggles the printer on-line and off-line. Clears the printer after a fault is corrected

and returns the printer to off-line state. Prints any data in the buffer then moves paper up one line at the currently active

line spacing. If pressed longer than 1/2 second, moves paper to the next Top Of Form as defined by the currently active form length.

Moves the current print position to the tractor area for viewing. When paper is in

Displays next higher level of a configuration menu. In VIEW mode, moves paper up 1/72 inch. (See VIEW / EJECT key.)

Function

Active

On-line

Active

Off-line

ää

↓

DOWN

→

←

SET

TOF

PRT

CONFIG

JOB

SELECT

ENTER Enters an option disp layed on th e LCD into p rinter non -volatile memory. Starts and

← + → Resets the printer by reloading the power-up configuration and resetting the

Displays next lower level of a configuration menu. In VIEW mode, moves paper down 1/72 inch. (See VIEW / EJECT key.)

Displays the next option in a configuration menu.

Displays the previous option in a configuration menu.

Moves paper downward from TO F ali gnment m ark to the p rint s tation and s ets this as the first line of print on a page, independent of forms length. If there are data in the buffers, the printer slews to the page position where printing left off and prints the data.

Prints the current printer configuration.

Allows fast selection of any stored configuration. Repeated pressing scrolls through all saved configurations. Press ENTER to select the displayed configuration. (ENTER does not have to be unlocked for this function.)

stops printer tests, sets a value, or prints the configuration. This key is locked and unlocked by a user-selectable key combination. (Refer to the

internal state.

User’s Manual

ää

Printing Conventions in This Manual

(Off) (On)

LCD

Power Switch

JOB

PRT

SET

DOWNUPNEXTPREV

TOF

SET

PRT

UP DOWN

TOF

CONFIG

Status Indicator

CONFIG

JOB

SELECT

ENTER

SELECT

ON-LINE

ENTER

CLEAR

PAPER

ADVANCE

ON-LINE PAPER VIEW CANCEL

CLEAR ADVANCE EJECT

VIEW

EJECT

CANCEL

Figure 3. Electrical Controls, Pedestal Models

Chapter 1 Controls and Indicators

Mechanical Controls and Indicators, All Models (Figure 6)

Control or

Indicator

Forms Thickness Lever

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

Function

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 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 Vertical Position

Knob

Allows fine positioning of left print margin. Moves

paper and tractors left or right.

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.)

1 inch

110 20

0.1 inch

Column Number

Left Tractor

Printing Conventions in This Manual

Paper Supports

Tractor Lock

Horizontal Adjustment Knob

Ribbon Loading Path Diagrams

Right Tractor

Tractor Lock

Vertical Position Knob

Forms Thickness Lever and Scale

Forms Thickness Pointer

Figure 4. Mechanical Controls and Indicators, All Models

Chapter 1 Tools, Test Equipment, and Supplies

Tools, Test Equipment, and Supp lies

For field level maintenance of the printer, you will need these tools:

Adapter, 1/4 in. hex to 1/4 in. square, Utica Alcohol, anhydrous Allen Wrench, 1/16 inch Allen Wrench, 3/32 inch Allen Wrench, 7/64 inch Allen Wrench, 5/64 inch ESD Wrist Strap Feeler Gauge, .010 inch Feeler Gauge, .011 inch Feeler Gauge, .040 inch Force Gauge, (Chatillon NY, Gauge-r, 0-20 lb., CAT 719-20)

HW-18

Hex bit, 3/16 in., torque screwdriver Hex bit, 3/32 in., torque screwdriver Hex bit, 5/32 in., torque screwdriver Hex bit, 5/64 in., torque screwdriver Lubricant, Bearing (Printronix P/N 101805-001) Nut Driver, 1/4 inch Nut Driver, 5/16 inch Nut Driver or Open End Wrench, 7/32 inch Open End Wrench, 5/16 inch Pliers, Grip Ring, External Screwdriver, flat tip Screwdriver, Phillips, #1 Screwdriver, Phillips, #2 Screwdriver, Torque, Utica TS-35 Tie Wraps, 4 inch Torx

T-10 Driver

2 Preventive Maintenance

Cleaning the Printer

The printer is designed to require very little maintenance. Aside from normal replenishment of paper and ribbons, the only preventive maintenance required is periodic cleaning.

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

Since there is no guarantee that the user will clean the printer regularly, you should clean the printer whenever you are called to service it. The cleaning procedures in this chapter pertain to all models.

WARNING

CAUTION

Always disconnect the AC power cord before cleaning the printer. 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 the circuit boards.

Cleaning the Outside Surfaces

1. Power off the printer.

CAUTION

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

3. Remove paper and the ribbon.

4. Dampen a clean, lint-free cloth with water and a mild detergent or with window cleaning solution. The cloth must be damp, not wet. Wipe down the outside surfaces of the printer.

5. Dry the outside surfaces with a clean, lint-free cloth.

6. Open the printer cover.

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

8. Wipe the splined shaft with a soft cloth.

To avoid corrosion damage, use only alcohol when cleaning printer mechanical elements, and make sure the cleaning solution contains no water.

Chapter 2 Cleaning the Outside Surfaces

9. Using a cloth dampened (not wet) with alcohol, clean the ribbon guides.

10. Vacuum up dust and residue from the lower cabinet.

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

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

13. Clean the shuttle frame assembly, as described in the next section.

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

Legend:

1) Base Casting

2) Shuttle Cover Assembly

3) Splined Shaft

4) Tractors

5) Forms Thickness Lever

6) Ribbon Guide

Figure 5. Cleaning Inside the Cabinet or Top Cover

Cleaning the Shuttle Frame Assembly

1. Remove the shuttle cover assembly (page 160).

2. Remove the shuttle frame assembly (page 198).

3. Remove the paper ironer (page 176).

WARNING

CAUTION

Over time, the upper edge of the paper ironer can become sharp. To avoid cutting yourself, handle the paper ironer on the sides.

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

5. Install the paper ironer (page 176).

6. Remove the hammer bank / ribbon mask cover assembly (page 157).

The ribbon mask is thin and easily bent. Be careful not to crease or kink the ribbon mask when handling and cleaning it.

7. Moisten a clean, soft cloth with alcohol. 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).

Do not use any solvents or liquids to clean the hammer tips. Clean the

hammer tips gently—too much pressure can chip them.

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.

NOTE: P5005 hammer bank is shown. Procedure is the same

for all hammer banks.

CAUTION

Legend:

1) Hammer Tip

Figure 6. Cleaning the Hammer Tips

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 157).

10. Install the shuttle frame assembly (page 198).

Chapter 2 Cleaning the Card Cage Fan Assembly

11. Install the shuttle cover assembly (page 160).

12. Clean the card cage fan assembly, as described in the next section.

Cleaning the Card Cage Fan Assembly

1. Cabinet Models: Remove the paper path (page 177). Pedestal Models: Remove the top cover assembly (page 161).

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 path (page 177) Pedestal Models: Install the top cover assembly (page 161).

4. Return the printer to normal operation (page 107).

NOTE: Cabinet model show n. Procedure is the same for pedestal model.

Legend:

1) Card Cage Fan Assemb.y

Figure 7. Cleaning the Card Cage Fan Assembly

3 Troubleshooting

Introduction

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

Always have the 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 Here” Logic Tree page 30

• Troubleshooting Display Messages page 31

• Message List page 31

• Troubleshooting Other Symptoms page 36

• General Symptom List page 36

• Troubleshooting Procedures page 38

• Diagnostic Printer Tests page 92

• Hex Code Printout page 95

User’s Manual

handy when you troubleshoot because this

• ASCII Character Set page 97

• The Power On Sequence page 99

• Appendix A: Wire Data page 259

Chapter 3 Start Here...

Start Here...

Are you here because of an error message?

Power on the printer and observe the control panel for the following sequence of events (retry as required):

1. All blac k squares appear on the display.

2. Display goes blank.

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

Did the fans come on after 10 seconds?

YES

Go to Troubleshooting Display Messages, page 31.

Did the status indicator lamp

After about 10 seconds did the fans come on?

Press ON LINE. Press PRT CONFIG. Press ENTER. Does machine configuration print?

YES

come on and ONLINE appear on the display? (If default is OFFLINE, status indicator will not come on.)

Go to Printer

does not initialize, page 71.

YES

Go to the Control Panel section of Table 3: page 36

Printer initialized successfully. Other symptoms are listed in Table 3: page

36.

Did ANY of steps 1 thru 3 occur?

Go to No power, and

control panel is blank, and card cage fan is not running, page 62.

YES

The Control Panel is not functioning (Table 3: page 36)

—OR—

Printer does not initialize, page 71.

Are there black squares on the control panel?

Go to Printer does not initialize, page 71.

YES

Go to Black squares

on control panel display, page 44.

T roubleshooting Display Messages

How to Clear LCD Messages

WARNING

Always disconnect the AC power cord from the printer before doing a maintenance procedure. Failure to remove power could result in injury to you or damage to equipment. If you must apply power during maintenance, you will be instructed to do so in the maintenance procedure.

Three kinds of messages appear on the Liquid Crystal Display (LCD):

• Status messages

• Configuration menus and menu options

• Fault messages

NOTE: Most fault messages are cleared from the LCD by correcting the fault

condition and then pressing the CLEAR key. Fault messages that can only be cleared by shutting down and restarting the printer are indicated by an asterisk (*) appended to the message.

If printer logic detects a fault condition, three things happen:

• The status indicator on the control panel flashes on and off.

• The audible alarm beeps if it is enabled. Press CLEAR to silence the

alarm.

• The control panel LCD displays a fault message.

How to Clear LCD Messages

Find the message in the Message List below, go to the troubleshooting procedure, and follow the numbered instructions. After correcting an error, press the CLEAR key to clear the message and place the printer in the offline state.

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 2: Message List

Symptom

06 HOST REQUEST page 39 08 HOLD PRINT

TIMEOUT

8.5V POWER FAIL * page 39 15 COMM CHECK page 39 15V CTL FAIL* page 40 22 INVALID ADDR page 40

23.5V CTL FAIL* page 40

Troubleshooting

Procedure

page 39

Chapter 3 Troubleshooting Display Messages

Table 2: Message List

Symptom

31 PAPER OUT TIMEOUT

32 PAPER JAM TIMEOUT

33 PLATEN OPEN TIMEOUT

34 RIBBON STALL TIMEOUT

48V PWR FAIL* page 43 ACCESS NULL PTR* page 43 ACTIVATE LOST page 44 A TO D OVERRUN* page 44 BUFFER OVERRUN page 45 CLEAR PAPER JAM page 46 CLEARING PROGRAM

FROM FLASH

Troubleshooting

Procedure

page 41

page 42

page 49

CLOSE PLATEN page 49 COIL HOT page 49 CTL VOLT FAIL* page 51 DIAGNOSTIC

PASSED DRVR CIR BAD* page 52 ERROR: DC PROGRAM

NOT VALID ERROR: DRAM AT

ADDRESS XXXXXXXX ERROR: EC PROGRAM

NOT VALID ERROR: EC STOPPED

AT STATE XXXX ERROR: FLASH

DID NOT PROGRAM ERROR: FLASH

NOT DETECTED ERROR: NO DRAM

DETECTED

page 51

page 52

page 53

page 54

How to Clear LCD Messages

Table 2: Message List

ERROR: NVRAM FAILURE

ERROR: PROGRAM NEEDS MORE DRAM

ERROR: PROGRAM NEEDS MORE FLASH

ERROR: PROGRAM NOT COMPATIBLE

ERROR: PROGRAM NOT VALID

ERROR: SECURITY PAL NOT DETECTED

ERROR: SHORT AT ADDRESS XXXX

ERROR: WRITING TO FLASH

ERROR: WRONG CHECKSUM

Symptom

Troubleshooting

Procedure

page 54

page 55

EXHAUST FAN FLT page 56 FIRMWARE ERROR page 56 FM HEADER ERROR page 57 FRAMING ERROR page 57 GRF CHK ERROR

PRESS STOP HAM. COIL OPEN* page 57 HAMMER COIL BAD

#, #, #, #, ... etc. HB NOT INSTALLD* page 58 HMR BANK FAN FLT page 58 ILL EXT BUS ACC* page 59 ILL INST ACCSS* page 60 ILLGL OPR ACCSS* page 60 INTAKE FAN FAULT page 60 INVALID ACTIVATE page 60 INVALID COMMAND page 61

page 57

page 58

Chapter 3 Troubleshooting Display Messages

Table 2: Message List

Symptom

LO DRV. SHORT* page 61 LOAD PAPER page 62 LOADING PROGRAM

FROM PORT XX% ONLINE

28 CU NOT ENAB ONLINE

8344 FAIL ED ONLINE

CU TIMED OUT PAP BAD TABLE* page 63 PAP BSY TOO LNG* page 64 PAP FIFO OVERFL* page 64 PAP FIFO UNDRFL* page 64 PAP ILLGL ST* page 65 PAP INCMPL ENER* page 65

Troubleshooting

Procedure

page 62

page 63

PAP INVLD CMD* page 65 PAP INVLD PARM* page 65 PAP NOT SCHED* page 66 PAP NT AT SPEED* page 66 PAP UNEXP INT* page 66 PARAMETER ERROR page 66 PARITY ERROR page 67 PLAT INV CMD* page 67 PLAT INV PARM* page 67 PLAT INV STATE* page 67 PLEASE WAIT...

RESET IN PROGRESS POWER SAVER MODE page 69 POWER SUPPLY HOT page 69 PRINTER HOT page 72 PROTECTED INSTR* page 73

page 68

How to Clear LCD Messages

Table 2: Message List

Symptom

PWR SUPP VOLT* page 73 QUEUE OVERRUN page 73 RESTORING

BOOT CODE RIB INVLD CMD* page 75 RIB INVLD STATE* page 75 RIBBON DRIVE page 75 RIBBON INK OUT

CHANGE RIBBON SCS COMMAND ERROR page 76 SECURITY CODE VIOLATION page 77 SECURITY PAL NOT DETECTED page 76 SENDING PROGRAM

TO EC PROCESSOR SF ERROR page 77

Troubleshooting

Procedure

page 73

page 76

page 77

SHUTL INV CMD* page 78 SHUTL INV PARM* page 78 SHUTTLE JAM page 79 SOFTWARE ERROR*

CYCLE POWER STACK OVERFLOW* page 80 STACK UNDERFLOW* page 80 STACKER FAULT page 82 STACKER FULL page 83 STACKER JAM page 83 TABLE MISMATCH

DOWNLOAD AGAIN TCB CORRUPTED* page 85 UNDEF INTERRUPT* page 86 UNDFNED OPCODE* page 86 UP DRV. SHORT* page 86

page 80

page 85

Chapter 3 Troubleshooting Other Symptoms

T roubleshooting Other Symptoms

WARNING

Use standard fault isolation techniques to troubleshoot malfunctions not indicated by display messages. These techniques are summarized below:

1. Ask the operator to describe the problem.

2. Verify the fault by running a diagnostic printer test or by replicating conditions reported by the user.

3. Look for a match in the General Symptom List below. If you find a match, go to the troubleshooting procedure and follow the numbered instructions.

4. If you cannot find the symptom in the General Symptom List, use the Half-Split Method to find the malfunction:

a. Start at a general level and work down to details. b. Isolate faults to half the remaining system at a time, until the final half

is a field-replaceable part or assembly. (Troubleshooting aids are listed on page 29.)

5. Replace the defective part or assembly. Do not attempt field repairs of electronic components or assemblies. Most electronic problems are corrected by replacing the printed circuit board assembly, sensor, or cable that causes the fault indication. The same is true of failures traced to the hammer bank: replace the entire shuttle frame assembly. It is not field repairable.

6. Test printer operation after every corrective action.

7. Reinstall any parts you replaced earlier that did not solve the problem.

8. Stop troubleshooting and return the printer to normal operation when the reported symptoms disappear.

Table 3: General Symptom List

Symptom

Communications Failures page 88

Jams

CLEAR P APER JAM message ins tead of LOAD PAPER when printer is out of paper

CLEAR PAPER JAM message will not clear and paper does not move

CLEAR PAPER JAM message will not clear but paper moves page 48

Troubleshooting

Procedure

page 47

How to Clear LCD Messages

Table 3: General Symptom List

Symptom

Control Panel

Black squares on control panel page 44 Control panel blank page 50 Control panel keys do not work page 51 Control panel display shows garbled, broken characters page 51

Power Failures

No power, and control panel blank, and card cage fan not running

Printer does not initialize page 71

Power Stacker

Printer does not detect presence of power stacker page 70

Stacker “chatters” at upper or lower limit page 80 Stacker does not stack properly page 81 Stacker elevator does not move page 81

Troubleshooting

Procedure

page 62

Stacker elevator moves by itself page 82 Stacker limit switch check page 83 Stacker motor check page 84 Stacker not operating page 70

Print Quality

Characters or dots are mis sing, smeared, too light, or too d ark page 45 Horizontal misalignment of characters (Dots or characters

move left or right from dot row to dot row or line to line) page 59 Randomly misplaced dots page 74 Vertical misalignment of characters:

1. Dots or characters move up or down from dot row to dot row or line to line

2. Incorrect spacing from dot row to dot row or line to line

3. Characters randomly compressed and/or enlarged

Printer Operation

Downloads consistently fail page 52 Flash SIMM won’t copy page 57

page 86

Paper feeds poorly page 68

Chapter 3 Troubleshooting Procedures

Table 3: General Symptom List

Symptom

Power on “hang” condition page 69 Printer does not print from the host page 71 Printer does not print self tests page 72 Reverse paper feed: platen does not open page 73 TOF is lost repeatedly page 85

Ribbon folding or feed problems page 75

Shuttle does not move page 77 Shuttle is noisy page 78

T roubleshooting Procedures

Troubleshooting procedures are listed in this section. Every troubleshooting procedure has three parts:

Troubleshooting

Procedure

Ribbon

Shuttle

MESSAGE / MALFUNCTION — The LCD message or a description of

the malfunction

1. TEST / INSPECTION / EXPLANATION — Numbered steps that provide information and tell you what to test or inspect

CORRECTIVE ACTION — Actions to take as a result of tests or inspections

How to Use the Troubleshooting Procedu res

1. Find the message or symptom you want to troubleshoot in the Message List (page 31) or the General Symptom List (page 36). The lists tell you

which page the troubleshooting procedure is on. Go to that page.

2. Start at step 1 of the troubleshooting procedure. Each step has corrective action(s) indented below it.

3. Test the printer after every step and corrective action.

4. Work sequentially down the steps until the problem is solved. STOP troubleshooting as soon as the problem is solved.

5. Reinstall any original parts you replaced earlier that did NOT solve the problem.

6. Reassemble the printer and give it a final test.

The Procedures

06 HOST REQUEST Message

1. Status message: in CT emulation, the host computer or printer controller requires attention.

Not a printer problem.

08 HOLD PRINT TIMEOUT Message

1. Status message: in CT emulation, the printer was off-line more than 10

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

Press ON LINE.

8.5V PWR F A IL* M essage

1. 8.5 Volt Power Failed. Internal power failure.

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 defective CMX board.

3. Power on the printer.

If the message appears, replace the shuttle frame assembly.

15 COMM CHECK Message

1. Communication Check: a message that appe ar s in the CT emu lat ion meaning the line is not active on a twinax interface. Power off 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 in the Main Wire Harness Test Tables in Appendix A.

If resistances are not correct, replace the twinax auto-termination cable.

3. 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

Chapter 3 Troubleshooting Procedures

message still appears, replace the expansion-CT board. Record the message and return it with defective board.

15V CTL FAIL* Message

1. Controller Voltage Failure. Cycle Power. Run the print job again. If the message appears,

download the emulation software again (page 130).

2. Cycle power. Run the print job again. If the message appears, replace the flash memory.

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 Harness Test Tables in Appendix A.) 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.

22 INVALID AD DR Message

1. Invalid Address: poll time-out on the twinax interface indicating the unit

address is not recognized by printer.

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

23.5V CTL FAIL* Message

1. 23.5 Volt Controller Failed: a voltage failure on the CMX controller board. Cycle Power. Run the print job again. If the message appears,

download the emulation software again (page 130).

2. Cycle power. Run the print job again. If the message appears, replace the flash memory.

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.

The Procedures

31 PAPER OUT TIMEOUT Message

1. In the CT emulation with a coax interface, a time-out message is sent to

the host if paper is not loaded within 10 minutes after CLEAR was pressed to clear a paper out fault. Load paper. Run a print test.

If the message appears, replace the paper detector switch assembly.

2. Run a print test.

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

32 PAPER JAM TIMEOUT Message

1. In the CT emulation with a coax interface, a time-out message is sent to

the host if paper motion has not occurred for 10 minutes after CLEAR was pressed to clear a paper jam fault.

Clear the paper jam. Press CLEAR.

2. Press PAPER ADVANCE 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 68. 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.

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 73.

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.

6. 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.

7. Check the condition and tension of the platen open belt.

Adjust the platen open belt. Replace the belt if it is damaged.

8. 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 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.

± 2 inch-pounds (1.02 ± 0.23

Chapter 3 Troubleshooting Procedures

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 the condition and tension of the paper feed belt. Adjust the paper feed belt. Replace the belt if it is damaged.

11. Check the platen gap. 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 defective CMX board. If the message does not appear, replace the paper detector switch assembly and set the paper motion detector (PMD) to ENABLE.

33 PLATEN OPEN TIMEOUT Message

1. In the CT emulation with a coax interface, the forms thickness lever has

been open for at least one minute. Load paper.

Close the forms thickness lever. Press CLEAR.

2. Run a print test. If a platen open or close platen message appears, power

off the printer. Remove the paper path 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.

3. 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 defective CMX board.

34 RIBBON STALL TIMEOUT Message

1. In the CT emulation with a coax interface, the ribbon has not moved for 10

minutes after CLEAR was pressed to clear the ribbon drive fault. 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.

The Procedures

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 path or pedestal top cover.

Disconnect P106 and P107 from the CMX controller board. Check the resistance of LRIB M in P106 and RRIB M in P107. (Refer to the Main Wire Harness Test Tables in Appendix A.)

If ribbon motor resistance is not correct, replace the motor. If the resistance is correct, disconnect the ribbon motor cables from the motors and check continuity . Repl ac e a cable if it fails the co ntin ui ty test.

6. Power on the printer. Run a diagnostic print test.

If the RIBBON STALL message appears, replace the CMX controller board. Record the message and return it with the defective board.

48V PWR F A IL* M essage

1. 48 Volt Power Failed: an internal power failure. Power off the printer.

Remove the paper path or pedestal top cover. Check that power supply connector P101 is fully seated in connector J101 on the CMX controller board.

Connect power supply connector P101 to J101 on the CMX controller board.

2. If the printer has the expansion-CT board, check the adapter connection

to the CMX controller board.

Make sure the 60-pin expansion adapter is correctly seated in the CMX controller board and the CT 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. NOTE: 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 defective CMX board.

6. Power on the printer.

If the message appears, replace shuttle frame assembly.

ACCESS NULL PTR* Message

1. Access Null Pointer. The processor tried to access a pointer that contains

nothing (null).

Chapter 3 Troubleshooting Procedures

Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130).

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.

ACTIV ATE LOST Message

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

error. 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 expansion-CT board.

Reseat the twinax host data cable connection and the twinax I/O cable connection at the expansion-CT board.

2. Disconnect the twinax auto-termination cable from the printer. Test the

cable for the resistances shown in the Main Wire Harness Test Tables in Appendix A.

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 88.

A TO D OVERRUN* Message

1. Analog to Digital Overrun. The analog-to-digital converter overflowed. 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.

Black squares on control panel display

1. Power off the printer. Remove the paper path or pedestal top cover.

Disconnect the control panel cable from the panel and from J110 on the CMX controller board. Check continuity of the cable. (See Appendix A.)

Replace the control panel cable if it fails continuity test. Connect the cable. Power on the printer. If the symptom appears, replace the control panel.

2. If the printer has the expansion-CT board, check the adapter connection

to the CMX controller board.

Make sure the 60-pin expansion adapter is correctly seated in the CMX controller board connector J111 and the expansion-CT board.

3. Power off the printer. Make sure the flash memory is seated properly in

J10 and J11 on the CMX controller board. Regardless of memory configuration, J11 must be used.

The Procedures

Reseat flash memory.

4. Power on the printer.

If black squares appear on the LCD, the flash memory could be blank. Replace the flas h S I MM in J1 1 wi t h a ne w f la sh SI M M with the boot program installed.

5. Power on the printer.

If black squares appear on the LCD, replace the CMX controller board. Record the message and return it with defective CMX board. If the LCD displays characters correctly, download the emulation software again (page 130).

BUFFER OVERRUN Message

1. The print buffer has overflowed on a serial interface. The printed output

may contain random * (asterisk) characters. 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.

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 88.

Characters or dots are missing, smeared, too light, or too dark

1. Check the forms thickness lever: if it is set too loose or too tightly print

quality can be affected.

Set the forms thickness lever to match the thickness of the paper being used.

2. 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.

3. Inspect the shuttle frame assembly for print chaff, debris, or ink residue

that could be causing the problem.

Clean the shuttle frame assembly.

4. Check the ribbon for folds or tears. Check that the ribbon guides are tight

and the ribbon tracks straight across them.

Rewind or install new ribbon. If the ribbon does not track straight across the ribbon guides, adjust the ribbon guides. If the ribbon guides are loose, tighten them. If the ribbon guides are damaged, replace them.

5. Power off the printer. Remove the shuttle cover. Remove the shuttle

frame assembly. Inspect the ribbon mask for bends or deformation that adversely affect paper feeding. Make sure the hammer bank cover assembly is correctly installed on its mounting pegs. Check the shuttle

Chapter 3 Troubleshooting Procedures

frame assembly for broken hammer springs, hammer tips, or contaminations.

Replace any damaged hammer spring assemblies. Replace the hammer bank cover assembly if it is deformed or damaged.

6. Check the platen gap. Adjust the platen gap.

7. Remove the paper guide assembly or pedestal top cover. Make sure

Connectors P105 and P108 have good connections on the CMX controller board. Make sure connectors P04 and P05 have good connections at the shuttle frame assembly.

Reseat connectors P04, P05, P105, and P108.

8. Power on the printer. If the problem still occurs, replace the shuttle frame assembly.

9. Power on the printer. If the problem still occurs, replace the power supply board.

10. Power on the printer. If the problem still occurs, replace the CMX controller board.

CLEAR PAPER JAM Message

1. Inspect the paper path for jams. Clear jams. Load paper.

2. Press PAPER ADVANCE 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 68. 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.

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 73.

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.

6. 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.

7. Check the condition and tension of the platen open belt. Adjust the platen open belt. Replace the belt if it is damaged.

The Procedures

8. 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

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 the condition and tension of the paper feed belt.

Adjust the paper feed belt. Replace the belt if it is damaged.

11. Check the platen gap.

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.

± 2 inch-pounds (1.02 ± 0.23

CLEAR PAPER JAM message inst ead of LOA D PAPER when printer is out of paper

1. Power off the printer. Remove the paper path 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.

Install the paper detector switch assembly.

2. Check that connector P106/PMD is fully seated in connector J106 on the

CMX controller board.

Connect P106/PMD to J106 on the CMX controller board.

3. Load paper. Power on the printer.

Replace the paper detector switch assembly if either message appears.

4. Load paper. Power on the printer.

Replace the CMX controller board if either message appears. Record the message and return it with defective CMX board.

CLEAR PAPER JAM message will not clear and paper does not move

1. Remove the paper path or pedestal top cover. Make sure connector

P107/PAPR M is fully seated in connector J107 on the CMX controller board.

Chapter 3 Troubleshooting Procedures

Connect P107/PAPR M to J107 on the CMX controller board.

2. Check the paper feed motor pulley for looseness. Hold the collar snug against the motor pulley and torque the 7/64 inch

setscrew to 25

3. Check the condition and tension of the paper feed timing belt. Adjust the paper feed timing belt. Replace the belt if it is damaged.

4. Load paper. Power on the printer. Press PAPER ADVANCE and VIEW

several times and check that paper moves correctly in both directions.

Replace the paper feed motor if the message appears or the paper moves erratically.

5. Power on the printer. Press PAPER ADVANCE and VIEW several times

and check that paper moves correctly in both directions.

Replace the CMX controller board if the message appears or the paper moves erratically. Record the message and return it with defective CMX board.

± 2 inch-pounds (2.82 ± 0.23 N•m).

CLEAR PAPER JAM message will not clear but paper moves

1. Power off the printer. Remove the paper path or pedestal top cover.

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

Connect P106/PMD to J106 on the CMX controller board.

2. 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.

Install the paper detector switch assembly.

3. Check that the paper detector switch assembly is securely mounted to the

mechanism base.

Tighten the two screws securing the paper detector switch assembly to the mechanism base.

4. Check that the motion detector wheel rotates. Replace the paper detector switch assembly if the wheel does not

rotate.

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

6. Load paper. Power on the printer.

Replace the CMX controller board if the message appears. Record the message and return it with defective CMX board.

The Procedures

CLEARING PROGRAM FROM FLASH Message

1. 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.

CLOSE PLATEN Message

1. The forms thickness lever is open.

Load paper. Close the forms thickness lever.

2. Power off the printer. Remove the paper path or pedestal top cover.

Disconnect connector P107 from the CMX controller board. Check continuity of the platen interlock switch 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.

Tighten the screws securing the platen interlock switch

4. Check the condition and tension of the platen open belt.

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

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.

6. Disconnect connector P106 from the CMX controller board. Check the

resistance of connector P106/PLAT M. (Refer to the Main Wire Harness Test Tables in Appendix A.)

Replace the platen open motor if it fails the resistance test.

7. Run a print test.

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

± 2 inch-pounds (1.02 ± 0.23

COIL HOT Message

NOTE: 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 sent 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 extremely dense print jobs, such as “All Black” plot. If the printer often prints at half speed, it may be operating in a severe environment. A severe environment is one with an ambient

Chapter 3 Troubleshooting Procedures

temperature at or 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.

1. One or more hammer coils are overheating. Inspect printer environment

for severity. (See NOTE above.)

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 path or pedestal top cover.

Check all fan cable connections.

Connect fan cables.

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 path 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.

7. 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 defective CMX board.

Control panel blank

1. Power off the printer. Remove the paper path or pedestal top cover.

Check all cabl e conn ectio ns into t he CMX co ntroll er boar d; mak e sure t he control panel cable is seated in connector J110 on the controller board.

Connect all cables.

2. If the printer has the expansion-CT board, check the CT cable

connections and the adapter connection to the CMX controller board.

Connect all cables. Make sure the 60-pin expansion adapter is correctly seated in the CMX controller board and the CT board.

3. Power on the printer. Inspect the control panel display and cooling fans.

If the control panel is blank and the cooling fans come on, replace the control panel cable assembly and/or the control panel, as required.

4. Power on the printer. If the control panel is blank and the fans do not come on, replace the

CMX controller board.

The Procedures

Control panel keys do not work

1. Power on the printer. Check the operation of the control panel keys.

Replace the control panel assembly.

2. Power on the printer. Check the operation of the control panel keys.

Replace the control panel cable assembly.

3. Power on the printer. Check the operation of the control panel keys.

Replace the CMX controller board.

Control panel display shows garbled, broken characters

1. Remove the paper path or pedestal top cover. Check cable connections

into the CMX controller board. Make sure the control panel cable is seated in connector J110 on the controller board.

Connect all cables.

2. Make sure the DRAM SIMM(s) is/are seated properly in J15/J16.

Reseat DRAM SIMM(s).

3. Power on the printer. Inspect the control panel display.

If the control panel shows broken characters, replace the DRAM.

CTL VOL T FAIL* Message

1. Controller Voltage Failure. 15 V failure on the CMX controller board.

Cycle Power. Run the print job again. If the message appears, download the emulation software again (page 130).

2. Cycle power. Run the print job again.

If the message appears, replace the flash memory.

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.

DIAGNOSTIC PASSED Message

1. Status message: the printer passed its memory and hardware

initialization tests.

No action required.

Chapter 3 Troubleshooting Procedures

Downloads consistently fail

NOTE: Most download problems are detected by software during the

procedure and communicated by LCD messages. (See Table 5: on page 132.) If downloads fail consistently with no messages or with erratic messages, suspect a hardware failure.

1. Power off the printer. Remove the paper path or pedestal top cover.

Check the I/O cable connections from the host to the printer. Check the parallel cable connection at J112 on the CMX controller board. Inspect all cables for damaged, bent, broken, or burnt pins.

Replace any damaged cables. Reconnect all I/O cables; make sure all connections are clean and tight.

2. Remove the flash SIMMs. Inspect the flash SIMM sockets on the CMX

controller board.

If any socket pins are bent or damaged, replace the CMX controller board.

3. Check that customer has the right size SIMMs for the emulation. (See

page 171)

Install SIMMs that support the emulation software.

4. Power up the printer. Download the emulation (page 130). If the download fails, activate the Boot Diagnostics Menu (page 92)

and run MISC UTILITIES / RUN MEMORY TESTS. If memory fails test, replace the DRAM. If memory tests OK, replace the flash SIMM(s).

5. Power up the printer. Download the emulation (page 130). If the download fails, replace the CMX controller board.

DRVR CIR BAD* Message

1. Driver Circuit Bad: the hammer coil count test failed. Cycle power. If the message appears, press CLEAR.

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.

ERROR: DC PROGRAM NOT VALID Message

1. The printer cannot find the data controller program or the validation

checksum is corrupt.

Download the program again (page 130). If the message appears, replace all flash memory SIMMs.

The Procedures

ERROR: DRAM AT ADDRESS XXXXXXXX Message

1. The printer found a defective memory location.

Replace the DRAM.

2. Power on the printer.

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

ERROR: EC PROGRAM NOT VALID Message

1. The printer cannot find the engine controller program or the validation

checksum is corrupt.

Download the program again (page 130). If the message occurs again, replace all flash memory SIMMs.

2. Power on the printer. Download the emulation.

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

ERROR: EC STOPPED AT STATE XXXX Message

NOTE: If the EC stops at state 0000 at power-up, replace the CMX controller

board. Record the message and return it with the defective board.

1. Where XXXX is a number from 0000 to 0010. The Engine Controller has

stopped and is in the state identified by the number displayed. 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 (page

130). If the message appears, replace the flash SIMM(s).

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 defective CMX board.

ERROR: FLASH DID NOT PROGRAM Message

1. The printer encountered an error trying to program flash memory.

Chapter 3 Troubleshooting Procedures

Download the program again (page 130). If the message occurs again, replace the flash memory.

ERROR: FLASH NOT DETECTED Message

1. The printer could not find flash memory. Check flash memory on the CMX controller board. If present, reseat

the flash SIMMs; if missing, install flash SIMMs.

ERROR: NO DRAM DETECTED Message

1. The printer could not find any DRAM. Check DRAM on the CMX controller board. If present, reseat DRAM;

if missing, install DRAM.

ERROR: NVRAM FAILURE Message

1. The non-volatile memory has failed. Replace the CMX controller board. (Do NOT attempt to replace

NVRAM.) Record the message and return it with defective CMX board.

ERROR: PROGRAM NEEDS MORE DRAM Message

1. The printer requires more DRAM memory in order to run the downloaded

program.

Add DRAM or use a smaller emulation program.

ERROR: PROGRAM NEEDS MORE FLASH Message

1. The printer requires more flash memory in order to run the downloaded

program.

Add flash memory or use a smaller emulation program.

ERROR: PROGRAM NOT COMP ATIBLE Message

1. The printer is not compatible with the downloaded program. Use the correct emulation software option(s) for this model printer.

ERROR: PROGRAM NOT VALID Message

1. The printer does not see a program in flash memory.

There is no program in printer memory. Download the emulation (page 130).

ERROR: SECURITY PAL NOT DETECTED Message

1. The security PAL is no t present or has failed.

Check the security PAL at location U54 on the CMX controller board. If the PAL is absent, install the correct PAL. If a security PAL is present, replace it.

2. Power on the printer.

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

The Procedures

ERROR: SHORT AT ADDRESS XXXX Message

1. Hardware failure in DRAM or CMX controller circuitry.

Download the program again (page 130). If the message occurs again, replace the DRAM. If message occurs with new memory, replace the CMX controller board. Record the message and return it with defective CMX board.

ERROR: WRITING TO FLASH Message

1. Hardware or software fault in flash memory.

Replace flash memory. If message occurs with new memory, replace the CMX controller board. Record the message and return it with defective CMX board.

ERROR: WRONG CHECKSUM Message

1. The printer received the complete program but the checksum did not

match. The data may have been corrupted during download.

Power off the printer. Download the program again from the beginning (page 130). If the messages appears, replace the DRAM.

2. Download the program using a new software diskette.

If the messages appears, replace the flash memory.

3. Download the program.

Chapter 3 Troubleshooting Procedures

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

EXHAUST FAN FLT Message

1. Exhaust Fan Fault. Sensors cannot detect current in the fan circuit. Cycle power. If the message appears, press CLEAR.

2. Check that the exhaust fan is connected to exhaust fan cable connector

J307.

Connect the fan cable connector.

3. Power off the printer. Remove the paper path. Disconnect connector

P107 from the CMX controller board. Test connector P107/EHF for shorts or opens. (Refer to the Main Wire Harness Test Tables in Appendix A.)

Replace components that fail test.

4. Make sure connector P107/EHF has a good connection at J107 on the

CMX controller board.

Connect P107 to the CMX controller board.

5. Inspect for obstructions of airways and vents. Check for items beneath

the printer blocking cabinet vents.

Remove obstructions. Make sure cabinet exhaust fan vents are not blocked.

6. Power on the printer. Check for fan operation.

If the message appears or the fan doesn’t work, replace the exhaust fan.

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

the message and return it with defective CMX board.

FIRMWARE ERROR Message

1. 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.)

Cycle power. Run the print job. If the message appears, download the emulation software again (page 130).

2. Cycle power. Run the print job again. If the message appears, replace the flash memory.

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.

The Procedures

Flash SIMM won’t copy

1. Power off the printer. Remove the flash SIMMs. Inspect the flash SIMM

sockets on the CMX controller board.

If any SIMM socket pins are bent or damaged, replace the CMX controller board.

2. Make sure the blank SIMM is the same size as the SIMM to be copied.

Install the SIMMs, making sure they are fully and correctly seated. Power on the printer. From the Boot Diagnostics menu, select and run MISC UTILITIES / COPY FLASH SIMMS. (See page 92.)

If the DESTINATION NOT DETECTED message appears, the blank SIMM is not a type supported by the boot code on the original SIMM. If SOURCE LARGER THAN DESTINATION appears, the blank SIMM is not large enough to contain the code on the original SIMM. If the SIMM does not copy or the ERROR WRITING TO FLASH message appears, replace the blank SIMM.

3. Power on the printer. From the Boot Diagnostics menu, select and run

MISC UTILITIES / COPY FLASH SIMMS.

If the new SIMM does not copy, replace the CMX controller board.

FM HEADER ERROR Message

1. Frame Header Error. Application software has violated header

parameters.

Not a printer problem. The system administrator should correct applications data or configuration.

FRAMING ERROR Message

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

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 88.

GRF CHK ERROR PRESS STOP Message

1. Graphic Check Error: in the CT emulation over a twinax interface, the

printer received a non-printable character.

Press CLEAR then press ON LINE.

HAM. COIL OPEN* Message

1. Hammer Coil Open. Electrical malfunction of one or more hammer coils.

Chapter 3 Troubleshooting Procedures

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 defective CMX board.

HAMMER COIL BAD #, #, #, #, ... etc. Message

1. Hammer coil(s) number #, #, etc. failed the current test at power-up.

Check that the hammer bank cables are connected.

Cycle power. If the message appears, replace the shuttle frame assembly. Record the message and return it with the defective assembly.

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

message and return it with the defective assembly.

HB NOT INST ALLD* Message

1. Hammer Bank Not Installed. Self-test routines do not detect hammer coils

at printer start-up. Power off the printer. Verify that the shuttle frame assembly is installed.

Install the shuttle frame assembly.

2. Remove the paper path or pedestal top cover. Verify that the hammer

bank logic cable is connected to connector J108 on the CMX controller board and to the shuttle frame assembly.

Connect the hammer bank logic cable to connector J108 on the CMX controller board and to the shuttle frame assembly.

3. Power on the printer. If the message appears, replace the hammer bank logic cable.

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

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

the message and return it with defective CMX board.

HMR BANK FAN FLT Message

1. Hammer Bank Fan Fault. Sensors cannot detect current in the fan circuit. Cycle power. If the message appears, press CLEAR. If the message

does not clear, go to step 2.

2. Power off the printer. Remove the paper path or pedestal top cover.

Disconnect connector P107 from the CMX controller board. Test

The Procedures

connector P107/HBF for shorts or opens. (Refer to the Main Wire Harness Test Tables in Appendix A.)

Replace components that fail test.

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

controller board.

Connect P107 to the CMX controller board.

4. Inspect for obstructions of airways and vents.

Remove obstructions.

5. Power on the printer.

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

Horizontal misalignment of characters (Dots or characters move left or right from dot row to dot row or line to line

1. If dots between alternate dot rows are misaligned, check the hammer

phasing.

Adjust hammer phasing.

2. If the printer is a P5X05 model (i.e., a 475 or 500 lpm model), check the

shuttle speed setting.

Set the shuttle speed (page 135).

3. Inspect the shuttle frame assembly area for ink residue, paper chaff, or

debris.

Clean the shuttle frame assembly.

4. Check the MPU gap.

Using a feeler gauge, adjust the gap between the MPU assembly and the flywheel to 0.010 16 inch MPU clamp screw to 18

5. Power up the printer. Run a print test.

If the symptom is not gone, replace the MPU.

6. Power up the printer. Run a print test.

If the symptom is not gone, replace the CMX controller board.

7. Power up the printer. Run a print test.

If the symptom is not gone, replace the shuttle frame assembly.

± .001 inch (0.254 ± 0.025 mm). Torque the 7/

± 1 inch-pounds (2.03 ± 0.11 N•m).

ILL EXT BUS ACC* Message

1. Illegal External Bus Access. Firmware error on the CMX controller board.

Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130).

2. Cycle power. Run the print job again.

Chapter 3 Troubleshooting Procedures

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

ILL INST ACCSS* Message

1. Illegal Instruction Accessed. Firmware error on the CMX controller board. Cycle power. Run the print job again. If the message appears,

download the emulation software again (page 130).

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.

ILLGL OPR ACCSS* Message

1. Illegal Operand Accessed. Firmware error on the CMX controller board. Cycle power. Run the print job again. If the message appears,

download the emulation software again (page 130).

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.

INTAKE FAN FAULT Message

1. Sensors cannot detect current in the card cage fan circuit. Cycle power. If the message appears, press CLEAR. If the message

does not clear, go to step 2.

2. Power off the printer. Remove the paper path 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 in Appendix A.)

Replace components that fail test.

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

controller board.

Connect P106 to the CMX controller board.

4. Inspect for obstructions of airways and vents. Remove obstructions.

5. Power on the printer.

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

INVALID ACTIVATE Message

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

the error. 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 expansion-CT board.

The Procedures

Reseat the twinax host data cable connection and the twinax I/O cable connection at the expansion-CT board.

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 in the Main Wire Harness Test Tables in Appendix A.

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 88.

INVALID COMMAND Message

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

the error. 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 expansion-CT board.

Reseat the twinax host data cable connection and the twinax I/O cable connection at the expansion-CT board.

2. Disconnect the twinax auto-termination cable from the printer. Test the

cable for the resistances shown in the Main Wire Harness Test Tables in Appendix A.

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 88.

LO DRV. SHORT* Message

1. Lower Driver Short. Circuit(s) on the hammer bank or in the hammer bank

power cable are shorted to ground.

Cycle power. If the message appears, press CLEAR. If message does 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 defective CMX board.

Chapter 3 Troubleshooting Procedures

LOAD PAPER Message

1. Printer is out of paper. Load paper. Press CLEAR. If message does not clear, go to step 2.

2. Power off the printer. Remove the paper path 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.

Install the paper detector switch assembly.

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

CMX controller board.

Connect P106/PMD to J106 on the CMX controller board.

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

5. Load paper. Power on the printer. Replace the CMX controller board if message appears. Record the

message and return it with defective CMX board.

LOADING PROGRAM FROM PORT XX% Message

1. Status message: the new emulation program is loading into printer RAM.

XX% indicates how much of the program has loaded.

No action required.

No power, and cont rol panel blank, and card cage fan not running

1. Check that the AC power outlet has power. Restore AC power.

2. Unplug the printer AC power cord from the printer (leave it plugged into

the power outlet) and check for AC power at the printer end of the cord.

If there is no power through the AC power cord, replace it. Plug the AC power cord into the printer and power outlet.

3. Remove the paper path or pedestal top cover. Verify that the AC-in power

cable and the AC power input cables are connected to the on/off switchcircuit breaker. (See Figure 42, page 232.)

Connect the AC-in power supply cable and AC power input cables to the on/off switch-circuit breaker. Make sure all ground connections are clean and tight.

4. Check that AC-in power cable connector P1 is connected to J1 on the

power supply board.

Connect AC-in power cable connector P1 to J1.

The Procedures

5. Check that power supply cable connector P101 is connected to J101 on

the CMX controller board.

Connect power supply connector P101 to J101 on the CMX controller board.

6. Check all cable connections on the CMX controller board.

Connect all cables.

7. If the printer has the expansion-CT board, check the CT cable

connections and the adapter connection to the CMX controller board.

Connect all cables. Make sure the 60-pin expansion adapter is correctly seated in the CMX controller board and the CT board.

8. Disconnect AC-in power supply cable connector P1. Set the circuit

breaker to 1 (on). Measure AC voltage at pins 1 and 2 of connector P1.

If no voltage, replace the circuit breaker. If there is voltage, replace the power supply board.

ONLINE 28 CU NOT ENAB Message

1. Controller Unit Not Enabled. Poll time-out error. The printer was not

polled for one minute across a coax interface.

Check cable connection and host system. (Refer to line problem determination procedures, as recommended by the host system.)

ONLINE 8344 FAILED Message

1. Link-level code test detects a hardware failure on the expansion-CT

board.

Replace the expansion-CT board. Record the message and return it with defective board.

ONLINE CU TIMED OUT Message

1. Controller Unit Timed Out: the printer was not enabled for one minute or

PAP BAD TABLE* Message

NOTE: 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. Record the message and return it with defective CMX board.

Chapter 3 Troubleshooting Procedures

1. Paper Bad Table. The paper feed process on the CMX controller board

has a corrupted table.

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.

PAP BSY TOO LNG* Message

1. Paper Busy Too Long. Firmware error on the CMX controller board. Cycle power. Run the print job again. If the message appears,

download the emulation software again (page 130).

2. Run the print job again. If the message appears, power off the printer. Remove the paper path

or pedestal top cover. Make sure connectors P106 and P107 are fully seated on the CMX controller board. 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.)

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, replace the CMX controller board. Record

the message and return it with defective CMX board.

PAP FIFO OVERFL* Message

1. Paper First In First Out Overflow. Firmware error on the CMX controller

board.

Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130).

2. 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.

PAP FIFO UNDRFL* Message

1. Paper First In First Out Underflow. Cycle power. Run the print job again. If the message appears,

download the emulation software again (page 130).

2. Run the print job again. If the message appears, power off the printer. Remove the paper path

or pedestal top cover. Make sure connectors P106 and P107 are fully seated on the CMX controller board. Make sure the MPU cable, the hammer bank logic cable, and the hammer bank power cable are

The Procedures

undamaged and have good connections. Replace as necessary. (Refer to Appendix A.)

3. Check hammer phasing.

Try using a lower phasing value; sometimes this message indicates too high a hammer phase value.

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 power supply board.

6. 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.

PAP ILLGL ST* Message

1. Paper Illegal State. Firmware error on the CMX controller board.

Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130).

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.

PAP INCMPL ENER* Message

1. Paper Incompletely Energized. Firmware error on the CMX controller

board.

Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130).

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.

PAP INVLD CMD* Message

1. Paper Invalid Command. Firmware error on the CMX controller board.

Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130).

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.

PAP INVLD PARM* Message

1. Paper Invalid Parameter. Firmware error on the CMX controller board.

Chapter 3 Troubleshooting Procedures

Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130).

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.

PAP NOT SCHED* Message

1. Paper Not Scheduled. The paper feed process is not scheduling on the

CMX controller board, and the printer cannot feed paper.

Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130).

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.

PAP NT AT SPEED* Message

1. Paper Not At Speed. Firmware error on the CMX controller board. Cycle power. Run the print job again. If the message appears,

download the emulation software again (page 130).

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.

PAP UNEXP INT* Message

1. Paper Unexpected Interrupt. Firmware error on the CMX controller board. Cycle power. Run the print job again. If the message appears,

download the emulation software again (page 130).

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.

PARAMETER ERROR Message

1. Illegal parameter value received in a command code over a coax/twinax

interface.

Press CLEAR then press ON LINE.

The Procedures

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.

Set printer Device ID to the correct emulation with respect to the host configuration.

4. Run the print job that generated the error message.

If the message appears, go to Communications Failures, page 88.

PARITY ERROR Message

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

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 88.

PLAT INV CMD* Message

1. Platen Invalid Command. Firmware error on the CMX controller board.

Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130).

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.

PLAT INV PARM* Message

1. Platen Invalid Parameter. Firmware error on the CMX controller board.

Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130).

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.

PLAT INV STATE* Message

1. Platen Invalid State. Firmware error on the CMX controller board.

Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130).

2. Cycle power. Run the print job again.

Chapter 3 Troubleshooting Procedures

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

PLEASE W AIT... RESET IN PROGRESS Message

1. Status message: the printer finished loading the program into flash

memory and is automatically resetting itself.

No action required.

Paper feeds poorly

1. Check the forms thickness lever: if it is set too tightly paper feeding can

be affected.

Set the forms thickness lever to match the thickness of the paper being used.

2. Power off the printer. Remove paper. Inspect the paper feed path for

obstructions that could snag paper.

Clear paper feed path of any obstructions.

3. Inspect the tractors and tractor door springs for damage or excessive

wear.

If either tractor is damaged or excessively worn, replace both tractor assemblies.

4. Check the paper feed motor pulley for looseness. Hold the collar snug against the motor pulley and torque the 7/64 inch

setscrew to 25

5. Check the condition and tension of the paper feed timing belt. Adjust the paper feed timing belt. Replace the belt if it is damaged.

6. Check the platen gap. Adjust the platen gap.

7. Remove the paper path or pedestal top cover. Make sure connector

P107/PAPR M is fully seated in connector J107 on the CMX controller board.

Connect P107/PAPR M to J107 on the CMX controller board.

8. Load paper. Power on the printer. Press PAPER ADVANCE and VIEW

several times and check that paper moves in both directions.

Replace the paper feed motor if paper does not move in both directions.

± 2 inch-pounds (2.82 ± 0.23 N•m).

9. Power on the printer. Press PAPER ADVANCE and VIEW several times

and check that paper moves in both directions.

Replace the CMX controller board if paper does not move in both directions.

The Procedures

Power on “hang” condition

1. Remove the paper path or pedestal top cover. Check all cable

connections to the CMX controller board and the power supply board.

Connect cables.

2. Power up the printer.

If the printer “hangs,” replace the CMX controller board.

3. Power up the printer.

If the printer “hangs,” replace the power supply board.

POWER SAVER MODE Message

1. This is a status message. The printer is in low–energy idle state, all fans

and higher voltages are off, only +5Vdc logic circuits are active.

No action required, but you can press the PAPER ADVANCE key to revive the printer from power saver mode.

POWER SUPPLY HOT Message

NOTE: 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 CLEAR key resumes the print task. Check the operating environment. A severe environment is one with an ambient temperature at or 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. (See NOTE above.)

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 path or pedestal top cover.

Check that the power supply guard/air deflector is correctly positioned over the power supply board. WARNING: POWER SUPPLY, but hold your hand close enough to check for heat radiating off the power supply board.

DO NOT TOUCH THE

If the power supply is noticeably hot, replace it.

4. Check that all fan cables are connected.

Connect all fan cables.

Chapter 3 Troubleshooting Procedures

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 paper path or pedestal top cover. Load paper. Power on the printer.

Run the “All E’s” print test for 5-10 minutes.

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

Printer does not detect presence of power stacker

—or—

Stacker not operating

1. Check that the power stacker is enabled under the Printer Control menu.

(Refer to the

Enable the power stacker under the Printer Control menu. If the power stacker enable/disable option does not appear in the menu, go to the next step.

2. Open the rear cabinet door. Check that the ON/OFF indicator lamp is lit.

Setup Guide.)

If the ON/OFF indicator is not lit, go to step 3. If the ON/OFF indicator is lit, press the ON LINE key and check that

the ON LINE indicator lights. If the ON LINE indicator comes on, the stacker is detected by the printer. If the ON LINE indicator does not come on, go to step 4.

3. a) Power off the printer.

b) Unfasten the cable clamp holding the stacker control panel cables. c) Disconnect the stacker power cable from the back of the stacker control panel. (See Figure 59, page 313.) d) Locate pin 1 of connector P106. (See the cable assembly drawing in Appendix A.) e) Power on the printer. f) At connector P106 check for +48 volts DC between pins 1 and 2 and +5 volts DC between pins 3 and 4.

If the voltages are correct, replace the stacker control panel. If the voltages are not correct, power off the printer, remove the paper path, and disconnect the stacker power cable from the CMX controller board. (See Figure 64, page 318.) Check the continuity of the stacker power cable between P105 and P106. If the cable fails the continuity test, replace it. If the cable is OK, replace the CMX controller board.

4. 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 59, page 313). 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.

5. Power on the printer. Check that the ON LINE indicator lights on the

stacker control panel.

The Procedures

If the ON LINE indicator does not light, replace the stacker control panel.

6. Power on the printer. Check that the ON LINE indicator lights on the

stacker control panel.

If the ON LINE indicator does not light, replace the CMX controller board.

Printer does not initialize

NOTE: Power-on initialization is explained on page 99.

1. Power off the printer. Remove the paper guide or pedestal top cover.

Check that all cables are connected to the CMX controller board.

Reseat all cable connectors on the CMX controller board, especially connectors P106 and P107.

2. If the printer has the expansion-CT board, verify that the user is running

CT emulation software. If the printer does not have the expansion-CT board, go to step 6.

Download CT emulation software.

3. If the printer has the expansion-CT board, check that the user has enough

flash memory installed to handle the emulation software. (See Figure 24 on page 173, and the Boot Diagnostics Menu on page 92.)

Install flash memory and download emul ati on sof twar e.

4. If the printer has the expansion-CT board, check the adapter connection

to the CMX controller board.

Connect all cables. Make sure the 60-pin expansion adapter is correctly seated in both the CMX controller board and the CT board.

5. Power up the printer.

If the fans run but the printer does not initialize, replace the expansion-CT board.

6. Power up the printer.

If the fans run but the printer does not initialize, replace the power supply board.

7. Power up the printer.

If the fans run but the printer does not initialize, replace the CMX controller board.

Printer does not print from the host

1. Check the host data cable connection at the rear of the printer.

Attach the data cable to the printer interface.

2. Make a configuration printout. Verify that the printer matches host

interface settings.

Set printer interface parameters to match those of the host.

3. Power up the printer. Send a print job from the host.

Chapter 3 Troubleshooting Procedures

If printer does not print and the interface is RS-232, interchange the wires to pins 2 and 3. (This is the most common cause of an inoperative RS-232 cable.) Verify that the host and printer have the same baud rate, number of data bits, number of stop bits, and parity. Configure the host for XON/XOFF if possible, since this requires the least complex cable.

4. Power up the printer. Send a print job from the host. If the printer does not print from the host, replace the data and

interface cable assemblies.

5. Remove the paper path or pedestal top cover. Check all cable

connections on the CMX controller board.

Reseat all cable connectors on the CMX controller board.

6. Power up the printer. Send a print job from the host. If the printer still does not print from the host, replace the CMX

controller board.

Printer does not print self tests

1. Power off the printer. Remove the paper path or pedestal top cover.

Disconnect the control panel cable from connector J110 on the CMX controller board. Disconnect the control panel cable from the control panel. Check continuity of the control panel cable assembly.

Replace the control panel cable assembly if it fails continuity test.

2. Connect the control panel cable assembly to J110 on the CMX controller

board and to the control panel. Load paper. Power on the printer. Run a self test.

If the self test does not run, replace the control panel assembly.

3. Power on the printer. Run a self test. If the self test does not run, replace the CMX controller board.

PRINTER HOT Message

NOTE: This message indicates internal temperatures over 60° Celsius (140°

Fahrenheit). Print jobs will not create such temperatures, so immediately determine that th e 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 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° Celsiu s (10 4 ° Fahrenheit). If the printer is located in such an environment, relocate it to a cooler, cleaner area.

1. CMX controller board sensors report high temperatures on the board.

Inspect printer environment for severity. (See NOTE above.)

Advise the user to move the printer to cooler, cleaner location.

The Procedures

2. Power off the printer. Remove the paper path or pedestal top cover.

Check that all fan cables are connected.

Connect all fan cables.

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 paper path or pedestal top cover. Load paper. Power on the printer.

Run the “All Black” print test for 1/4 page.

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

PROTECTED INSTR* Message

1. Protected Instruction. Firmware error on the CMX controller board.

Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130).

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.

PWR SUPP VOLT* Message

1. Power Supply Voltage. The power supply has failed.

Replace the power supply board.

QUEUE OVERRUN Message

1. In the CT twinax emulation, the print buffer has overflowed. Send a print

job to the printer.

If the message appears, replace the expansion-CT board. Record the message and return it with defective board.

2. Send a print job to the printer.

If the message appears, replace the twinax data cable and the twinax auto-termination cable assembly (“Smart T”).

RESTORING BOOT CODE Message

1. Normal download initialization message.

No action required.

Reverse paper feed: platen does not open

1. Raise the forms thickness lever and check that the platen opens.

If the platen opens with difficulty, inspect for and remove jams or obstructions.

Chapter 3 Troubleshooting Procedures

2. 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

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.

3. Check the condition and tension of the platen open belt. Adjust the platen open belt. Replace the belt if it is damaged.

4. Check the platen gap. Adjust the platen gap.

5. Power off the printer. Remove the paper guide assembly. Disconnect

connector P106 from the CMX controller board. Check the resistance of connector P106/PLAT M. (Refer to the Main Wire Harness Test Tables in Appendix A.)

Replace the platen open motor if it fails the resistance test.

6. Power on the printer. Press PAPER ADVANCE and VIEW several tim es

and check that paper moves in both directions.

± 2 inch-pounds (1.02 ± 0.23

Replace the CMX controller board if the platen does not open during paper reverse.

Randomly misplaced dots

1. Power off the printer. Check the platen gap. Adjust the platen gap.

2. Remove the paper guide assembly or pedestal top cover. On the left rear

wall of the card cage, make sure the nut which secures the line filter ground line and the AC In Power Supply cable lead to the ground stud is tight. (See Figure 42, page 232.)

Tighten the nut on the ground stud.

3. Disconnect the AC power cord and check the ground leads for continuity. Replace the AC power cord if it fails continuity test.

4. Make sure the printer is plugged in to a grounded power outlet. Power up

the printer. Run a print test.

If the problem occurs, replace the hammer bank logic cable.

5. Power up the printer. Run a print test. If the problem occurs, replace the flash memory and DRAM.

Download the emulation software again (page 130).

6. Power up the printer. Run a print test. If the problem occurs, replace the CMX controller board.

7. Power up the printer. Run a print test. If the problem occurs, replace the power supply board.

8. Power up the printer. Run a print test. If the problem occurs, replace the shuttle frame assembly.

The Procedures

RIB INVLD CMD* Message

1. Ribbon Invalid Command. Firmware error on the CMX controller board.

Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130).

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.

RIB INVLD STATE* Message

1. Ribbon Invalid State. Firmware error on the CMX controller board.

Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130).

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.

RIBBON DRIVE Message

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

Cycle power. If the message appears, power off the printer. Remove the paper path 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 defective CMX board.

Ribbon folding or feed problems

1. Check that both ribbon spools are fully seated on the ribbon hubs and the

ribbon runs between the ribbon mask and hammer bank cover.

Install the ribbon correctly.

2. Check that the ribbon spools are not rubbing against the shuttle cover

assembly.

Install the shuttle cover assembly correctly, so that the ribbon spools do not rub against it.

3. Inspect the paper print path for paper chaff, ink residue, and debris.

Clean the shuttle frame assembly.

4. Power on the printer. Run a print test and observe ribbon movement

across the left and right ribbon guides.

Adjust the right and left ribbon guides.

Chapter 3 Troubleshooting Procedures

5. Observe ribbon movement at both left and right ribbon posts as the metal

end strip crosses each ribbon post.

If the metal strip moves past either post without reversing the direction of the ribbon, power down the printer. Remove the paper path or pedestal top cover. Reseat connectors P106/LRP and P107/ RRP on the CMX controller board.

6. While shorting across each ribbon post with the ribbon metal strip or a

screwdriver, check for continuity in connector P106/LRP pins 10 and 12, and connector P107/RRP pins 14 and 16. (Refer to the Main Wire Harness Test Tables in Appendix A.)

Replace a ribbon post that fails the continuity test.

7. Check the platen gap. Adjust the platen gap.

RIBBON INK OUT CHANGE RIBBON Message

1. RibbonMinder software has determined that the ribbon is out of ink. Install a new ribbon and set ribbon life to 100%.

SCS COMMAND ERROR Message

1. In the CT emulation, the printer received undefined control character (hex

40). The printer clears the error.

2. 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.

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.

Set the printer Device ID to the correct emulation with respect to the host configuration.

4. Run the print job that generated the error message. If the message appears, go to Communications Failures, page 88.

SECURITY PAL NOT DETECTED Message

1. The security PAL is missing or has failed. Power off the printer. Remove

the paper path or pedestal top cover.

Check the security PAL at location U54 on the CMX controller board. If the PAL is absent, install the correct PAL. If security PAL is present, replace the CMX controller board. Record the message and return it with defective CMX board.

The Procedures

SECURITY CODE VIOLATION Message

1. Security code of the PAL on the CMX controller board does not match the

code of the firmware on the CMX controller board. Remove the paper path or pedestal top cover. Check that the security PAL is correctly installed.

Install correct PAL for the customer’s emulations with the notched end facing toward the flash and DRAM SIMM sockets.

2. Run a print test.

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

SENDING PROGRAM TO EC PROCESSOR Message

1. Status message: the printer is loading the engine controller program into

the engine controller.

No action required.

SF ERROR Message

1. Structured Field Error. Application software has violated structured data

field parameters.

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

Shuttle does not move

1. Power down the printer. Remove the shuttle cover. Check the MPU gap.

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

2. Check that the MPU cable is connected to J03 on the mechanism base.

Check that the shuttle motor cable is connected to J02 on the mechanism base.

Connect the MPU and the shuttle motor cables.

3. Remove the paper path or pedestal top cover. Check that the shuttle

motor drive cable is connected to J116 on the CMX controller board.

Connect the shuttle motor drive cable.

4. Check the platen gap.

Adjust the platen gap.

± 1 inch-pounds (2.03 ± 0.11 N•m).

5. 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.

Reinstall the hammer bank cover assembly. Replace a damaged or deformed hammer bank cover assembly.

Chapter 3 Troubleshooting Procedures

6. Check continuity of the shuttle motor drive cable assembly. Replace shuttle motor drive cable assembly if it fails continuity test.

7. Power up the printer. Run a Shuttle Slow or Shuttle Fast test. If the shuttle does not move, replace the shuttle frame assembly.

8. Power up the printer. Run a Shuttle Slow or Shuttle Fast test. If the shuttle does not move, replace the power supply board.

9. Power up the printer. Run a Shuttle Slow or Shuttle Fast test. If the shuttle does not move, replace the CMX controller board.

SHUTL INV CMD* Message

1. Shuttle Invalid Command. Firmware error on the CMX controller board. Cycle power. Run the print job again. If the message appears,

download the emulation software again (page 130).

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.

SHUTL INV P ARM * Message

1. Shuttle Invalid Parameter. Firmware error on the CMX controller board. Cycle power. Run the print job again. If the message appears,

download the emulation software again (page 130).

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.

Shuttle is noisy

1. Check the bolts securing the mechanism base to the base pan. Tighten the mechanism base mounting bolts if they are loose enough

to permit movement of the mechanism base.

2. Remove the shuttle cover. Check the shuttle frame assembly mounting/

clamp screws for looseness.

Torque the 5/32 inch socket head clamp screws to 20 pounds (2.26

socket head screw to 20

± 0.23 N•m). Torque the center captive 5/32 inch

± 2 inch-pounds (2.26 ± 0.23 N•m).

± 2 inch-

3. Inspect the shuttle area for loose hardware. Tighten loose hardware.

4. Check that the hammer bank cover assembly is correctly installed, that it

has not slipped off the mounting pegs. Check that the ribbon mask has not partially separated from the hammer bank cover. Check for debris trapped between the ribbon mask, hammer bank cover, and hammer bank.

The Procedures

Clean the shuttle frame assembly and hammer bank cover assembly if you find debris. Replace the hammer bank cover assembly if you find any damage to the ribbon mask or hammer bank cover.

5. Power up the printer. Run a shuttle test.

Replace the shuttle frame assembly if it is noisy or rattles.

SHUTTLE JAM Message

1. The shuttle is not moving or is moving at the wrong speed. 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 the platen gap.

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.

Reinstall the hammer bank cover assembly. Replace a damaged or deformed hammer bank cover assembly.

4. Run a print test.

If the message appears, power off the printer.

5. Remove the shuttle cover. Remove the paper path 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 the Interconnection Diagrams in Appendix A.)

Remove obstructions and reseat all cables. Check the resistance of the MPU at connector P107. (Refer to the Main Wire Harness Test Tables in Appendix A.) 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 Torque the 7/16 inch MPU clamp screw to 18

± .001 inch (0.254 ± 0.025 mm).

± 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 defective CMX board.

9. Run a print test.

If the message appears, replace the power supply board.

10. Run a print test.

Chapter 3 Troubleshooting Procedures

If the message appears, replace the shuttle frame assembly.

SOFTWARE ERROR* Cycle power Message

1. Application software tried to perform an illegal printer function or

damaged logic circuits were detected on the CMX controller board.

Cycle power. If the message appears, power off the printer.

2. Disconnect the input data line from the host computer. Power on the

printer.

If the message appears, download the emulation software again (page 130).

3. Cycle power. Run the print job again. If the message appears, replace the CMX controller board. If the

message is gone, there is an application software error. Request assistance from your local support group.

STACK OVERFLOW* Message

1. Firmware error on the CMX controller board. Cycle power. Run the print job again. If the message appears,

download the emulation software again (page 130).

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.

STACK UNDERFLOW* Message

1. Firmware error on the CMX controller board. Cycle power. Run the print job again. If the message appears,

download the emulation software again (page 130).

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.

Stacker “chatters” at upper or lower limit

1. Power off the printer. Unload paper. Open the rear cabinet door and

check that stacker motion is not obstructed by the control panel cable or other obstruction.

Remove obstruction or reroute the stacker control panel cable as necessary.

2. Verify that the stacker rails are vertical and parallel. Adjust the stacker rails if necessary: they must be vertical and

parallel.

The Procedures

3. Move the elevator up and down by hand and check that the limit switches

are being tripped at the highest and lowest limits of elevator travel.

Adjust the limit switches, if necessary, by gently bending the contact arms. Replace switches that cannot be adjusted.

4. Power on the printer. Operate the power stacker. (Refer to the

.) While the stacker is operating, check that:

Guide

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.

Stacker does not stack properly

—or—

Stacker elevator does not move

1. Check for obstructions preventing elevator movement.

Remove obstructions.

2. Check for misaligned stacker rails

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

Operator’s

3. Power on the printer. Operate the power stacker. (Refer to the

.) While the stacker is operating, check that:

Guide

Tighten pulley setscrews and/or replace damaged components as necessary.

4. Check the stacker limit switches. (See page 83.)

If the limit switches are OK, go to the next step.

5. Check the stacker motors. (See page 84.)

If the stacker motors are OK, go to the next step.

6. Remove the paper path. Disconnect stacker cables from the CMX

controller board, stacker assembly, and the stacker control panel (see Figure 59, page 313). Check cables for cuts, breaks, or damaged pins. Check continuity of cables. (See Appendix A.)

Operator’s

Chapter 3 Troubleshooting Procedures

Replace any cable that is damaged or fails continuity test. Reconnect all stacker cables to the CMX controller board, stacker, and stacker control panel.

Stacker elevator moves by itself

1. Power off the printer. Inspect all stacker LEDs for dust, chaff, or dirt. (See

Figure 81 through Figure 83, page 338 through page 342.)

Clean the stacker LEDs and the sight tubes in the LED mounts.

2. Power on the printer. If the stacker elevator moves by itself, replace the stacker LEDs. (See

Figure 81 through Figure 83, page 338 through page 342.)

STACKER FAULT Message

NOTE: This message is triggered when the elevator cannot reach either the

top or bottom position switch before timing out.

1. Power on the printer. Operate the power stacker. (Refer to the

Check for obstructions preventing elevator movement.

Guide.

Remove obstructions.

2. Operate the power stacker. While the stacker is operating, check that:

Tighten pulley setscrews and/or replace damaged components as necessary.

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

4. Check the stacker limit switches. (See page 83.)

If the limit switches are OK, go to the next step.

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

Setup Guide.)

the

If the message occurs, replace the CMX controller board.

Operator’s

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 59, page 313). 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.

The Procedures

STACKER FULL Message

1. Status message: the power paper stacker is full.

Unload the stacker.

2. Check the stacker limit switches. (See page 83.)

If the limit switches are OK, go to the next step.

3. 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 59, page 313). 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.

STACKER JAM Message

1. Paper is bunching above the elevator or the paper motion detector is not

working properly.

Remove the paper jam.

2. Power off the printer. 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 on its axle.

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. (Refer to the

Guide.)

4. 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 59, page 313). Check cables for cuts, breaks, or damaged pins. Check continuity of cables. (See Appendix A.)

While the stacker is operating, check that:

Tighten pulley setscrews and/or replace damaged components as necessary.

Operator’s

Replace any cable that is damaged or fails continuity test. Reconnect all stacker cables to the CMX controller board, stacker, and stacker control panel.

Stacker limit switch check

NOTE: This procedure tests the motion limit switches at the top and bottom

of the vertical rails. You will usually be referred to this procedure from

Chapter 3 Troubleshooting Procedures

other troubleshooting procedures. When you have completed this procedure, return to the procedure that sent you here.

1. Power off the printer. Open the rear cabinet door. Unload the power

stacker. Move the elevator up and down by hand, checking that it moves smoothly and without chattering or shuddering.

Eliminate causes of chattering or shuddering. (E.g., loose, damaged, or broken constant force springs, bent or misaligned rails, obstructions, etc.)

NOTE: If the elevator assembly or the rails are bent or damaged, you must

replace the entire power stacker assembly.

2. Move the elevator up and down by hand. Check that the limit switches are

physically tripped when elevator reaches top and bottom of travel.

If necessary, gently bend the contact arms to adjust limit switches. If you cannot adjust a switch that requires adjustment, replace it.

3. a) Unfasten the cable clamp holding the stacker control panel cables.

b) Disconnect stacker rail cable connector P107 from connector J3 on the back of the stacker control panel. (See Figure 59, page 313.) c) Locate pin 1 of connector P107. (See the cable assembly drawing in Appendix A, page 263.) d) Check the stacker rail cable and limit switches for continuity and shorts. Check continuity of the switch when open and closed. (See the power stacker control panel PCBA pinout drawing on in Appendix A, page 270. STK FULL is the upper limit switch, STK LIMIT is the bottom switch.)

Replace the stacker rail cable if it is damaged or fails continuity test. Replace any switch that fails continuity test.

Stacker motor check

NOTE: This proced ure test s the four stacke r motors and their cables . You wil l

usually be referred to this procedure from other troubleshooting procedures. When you have completed this procedure, return to the procedure that sent you here.

1. a) Power off the printer.

b) Open the rear cabinet door. c) Unfasten the cable clamp holding the stacker control panel cables. d) Disconnect stacker rail cable connector P107 from connector J3 on the back of the stacker control panel. (See Figure 59, page 313.) e) Disconnect stacker frame cable connector P102 from connector J4 on the rear of the stacker control panel. (See Figure 59, page 313.) f) Locate pin 1 of connector P102 and connector P107. (See the cable assembly drawings in Appendix A, page 291 and page 294.) g) Check both cables for pin damage, continuity, and shorts. Check all motors for 15.2 control panel PCBA pinout drawing on page 270.)

Replace any cable that is damaged or fails continuity test. Replace any motor that fails the resistance test.

± 1.5 Ohms on both phases. (Refer to the power stacker

The Procedures

TABLE MISMATCH DOWNLOAD AGAIN Message

1. This message indicates that an EC software update is in process.

Power off the printer. Download the program again from the beginning (page 130).

TCB CORRUPTED* Message

1. Task Control Block Corrupted. Firmware error on the CMX controller

board.

Cycle power. Run the print job again. If the message appears, download the emulation software again (page 130).

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.

TOF is lost repeatedly

1. Check that the customer is setting the forms length to match the size

paper used.

Set the forms length to match the length of paper being used.

2. If the customer is using multi-part forms, check that the forms thickness

lever is not being set too tightly.

Set the forms thickness lever to match the thickness of paper and provide satisfactory print quality, but not too tightly.

3. Check the paper feed motor pulley for looseness. Make sure the correct

pulley is being used: it should have 25 teeth.

Hold the collar snug against the motor pulley and torque the 7/64 inch setscrew to 25

paper feed pulley if it does not have 25 teeth.

4. Check the condition and tension of the paper feed timing belt.

Adjust the paper feed timing belt. Replace the belt if it is damaged.

5. Remove the paper path or pedestal top cover. Make sure connector

P107/PAPR M is fully seated in connector J107 on the CMX controller board.

Connect P107/PAPR M to J107 on the CMX controller board.

6. Power on the printer. Load paper and set TOF. Press PAPER ADVANCE

and VIEW several times and check that paper returns to TOF.

± 2 inch-pounds (2.82 ± 0.23 N•m). Replace the

Replace the paper feed motor if paper does not return to TOF.

7. Power on the printer. Press PAPER ADVANCE and VIEW several times

and check that paper returns to TOF.

Replace the CMX controller board if paper does not return to TOF.

Chapter 3 Troubleshooting Procedures

UNDEF INTERRUPT* Message

1. Undefined Interrupt. Firmware error on the CMX controller board. Cycle power. Run the print job again. If the message appears,

download the emulation software again (page 130).

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.

UNDFNED OPCODE* Message

1. Undefined Opcode. Firmware error on the CMX controller board. Cycle power. Run the print job again. If the message appears,

download the emulation software again (page 130).

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.

UP DRV. SHORT* Message

1. Upper Driver Short. Hammer driver circuits on the CMX controller board

are shorted to ground.

Cycle power. If the message appears, press CLEAR. If the message does not clear, replace the hammer bank logic cable and the hammer bank power cable assemblie s.

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

the message and return it with defective CMX board.

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

V ertical misalignment of characte rs:

- Dots or characters move up or down from dot row to dot

row or line to line

- Incorrect spacing from dot row to dot row or line to line

- Characters randomly compressed and/or enlarged

1. Load paper. Press PAP ER ADVA NCE and check that paper feeds

smoothly. Press VIEW to verify that paper moves in both directions. Check the forms thickness lever: if it is set too loose or too tightly print quality can be affected.

Set the forms thickness lever to match the thickness of the paper being used.

2. Check the paper feed motor pulley for looseness.

The Procedures

Hold the collar snug against the motor pulley and torque the 7/64 inch setscrew to 25

3. Check the condition and tension of the paper feed timing belt.

Adjust the paper feed timing belt. Replace the belt if it is damaged.

4. Check the platen gap.

Adjust the platen gap.

5. Inspect the tractors and tractor door springs for damage or excessive

wear.

If either tractor is damaged or excessively worn, replace both tractor assemblies.

6. Remove the paper guide assembly or pedestal top cover. Make sure

connector P107/PAPR M is fully seated in connector J107 on the CMX controller board.

Connect P107/PAPR M to J107 on the CMX controller board.

7. Load paper. Power on the printer. Run a print test.

If the problem occurs, replace the paper feed motor.

± 2 inch-pounds (2.82 ± 0.23 N•m).

8. Run a print test.

If the problem occurs, replace the CMX controller board.

9. Run a print test.

If the problem occurs, replace the power supply board.

Chapter 3 Communications Failures

Communications Failures

Many host-printer communications problems are complex. With the exception of a defective interface cable, most communications problems are not a result of a hardware failure. They usually result from an incompatible configuration of the host computer system, network (LAN, print server, controller, multiplexer, etc.), or the printer. Sometimes the print application program itself is at fault.

If you have limited communications experience, and the cause of the problem is not readily apparent, do the following:

1. Print out the printer configuration.

2. Obtain a copy of the Device Host Configuration if possible.

3. Call your support group for assistance in probl em anal y sis.

If you cannot obtain support, or you have experience solving host-printer communications problems, the following additional information is provided.

You can quickly check the ASCII portion of the printer logic by sending a plain text file from a PC to the printer via the parallel or serial port. For a description of each of the ASCII interfaces, refer to the

User’s Manual.

Table 4: Common Communications Problems

Problems Interface Common Causes

Fails to print from host

-orPrints incorrect characters

-orPrints extra characters

-orDrops characters

parallel - Interface cable defective

- Host/Network configuration

- Printer logic

- Terminating Resistors

serial - Host/Printer interface cable

pinouts incompatible

- Host/Printer/Network configuration

- Set DTR and RTS both True

- Interface cable defective

- Printer logic

twinax - Interface cable defective

- Host-Printer definition

- Controller/Network configuration

- Printer logic

coax - Interface cable defective

- Controller/Network configuration

- Printer logic

Diagnostic Printer T ests

A set of printer tests is included in the configuration menu structure for use as diagnostic tools. Use these printer tests to check the print quality and basic operation of the printer. You will also use some of the tests in some adjustment procedures. The diagnostic printer tests are summarized below:

• Shift Recycle — A “sliding” alphanumeric pattern useful for identifying

missing or malformed characters, improper vertical alignment, or vertical compression.

• All E’s — A pattern of all uppercase letter E’s useful for identifying

missing characters, misplaced dots, smeared characters, improper phasing, or light/dark character variations.

• E’s + TOF — A pattern of all E’s repeated for ten lines and followed by a

form feed to the top of the next page. This test is useful for identifying paper motion or paper feed problems.

• All H’s — A pattern of all uppercase letter H’s useful for detecting missing

characters or dots, smeared characters, or improper phasing.

The Procedures

• Underline Only — An underline pattern useful for identifying hammer

bank misalignment.

• All Black — Prints all dot positions, creating a solid black band.

Exercises the shuttle and hammer bank at maximum capacity.

• Shuttle Slow — Exercises the shuttle and ribbon mechanisms at low

speed. You can also use this test to check ribbon tracking and reversing.

• Shuttle Fast — Exercises the shuttle and ribbon mechanisms at high

speed. You can also use this test to check ribbon tracking and reversing.

• Shuttle Only — Runs the shuttle mechanism with no ribbon movement.

• Phase Printer — A hammer timing test that permits you to adjust the

hammer phase value. The hammer phase value is a timing parameter that controls the vertical alignment of dots in character printing. The numerical units are relative, they do not represent a physical measurement or value. There is no “correct” value or range. The factory prints the initial phase value on the casting of the shuttle assembly, next to the motor housing. Use this value as your starting point when adjusting hammer phasing.

• Paperout Adj. — Prints a vertical comb pattern. You use this pattern

when you do the end of forms (paper out) adjustment procedure. The comb pattern lets you measure the number of dot rows from the completion of a paper out fault to the end of the paper.

• Burnin Test — Do not use. This test is used by the printer manufacturer

to burn in the printer prior to shipment and has no value as a maintenance tool.

Chapter 3 Diagnostic Printer Tests

Selecting and Running Diagnostic Printer Tests

NOTE: You must set TOF after running any diagnostic test.

Step Press LCD Result Notes

1. Make sure the printer is on. Raise the printer cover.

2. Load paper.

3. Set TOF. (Refer to the

4. OFFLINE

ON LINE

User’s Manual

CONFIG. CONTROL

5. ENTER SWITCH

UNLOCKED

OFFLINE

CONFIG. CONTROL

6. OFFLINE

UNTIL

DIAGNOSTICS

7. DIAGNOSTICS Printer Tests

8. DIAGNOSTICS

UNTIL

Test Width

9. Test Width Full Width*

10. Test Width

The printer must be offline to run a print test.

Unlocks ENTER key and control panel.

Cycle through choi ces. X = Full Width or X = 80 columns.

11. Test Width

ENTER

12. DIAGNOSTICS Test Width

13. DIAGNOSTICS

UNTIL

Printer Tests

14. Printer Tests Shift Recycle*

15. Printer Tests

All E’s

Test width is selected.

Cycle through the choices.

Selecting and Running Diagnostic Printer Tests

Step Press LCD Re sult Notes

16. Printer Tests

ENTER

Starts test.

All E’s*

17. Printer Tests

ENTER

Stops test.

All E’s*

18. ENTER SWITCH

19. ONLINE

ON LINE

LOCKED

LinePrinter+

Locks the ENTER key and control panel.

Places the printer in on-line mode.

20. Examine print quality. Characters should be fully formed and of uniform density.

21.

Set TOF. (Refer to the

User’s Manual

Chapter 3 Boot Diagnostics Menu

Boot Diagnostics Menu

Printer boot-up software contains a “Boot Diagnostics” menu that you can access by holding down two keys while powering on the printer. This menu is not intended for the end user, but provides useful information for manufacturing and maintenance personnel.

The boot diagnostics menu is a multi-level menu that operates the same way as the user menus. The menu structure is shown in Figure 8 on page 93.

Activating the Boot Diagnostics Menu

1. Set the printer power switch to O (off).

2. On cabinet models, raise the printer cover.

3. On the control panel, press and hold down

4. While holding (on).

5. When “BOOT DIAGNOSTICS / PRESS ENTER” appears on the LCD, release the

6. Press the ENTER key. Menu options are shown in Figure 8.

; (PREV) + > (DOWN), set the printer power switch to 1

; (PREV) + > (DOWN) keys.

; (PREV) + > (DOWN).

Exiting the Boot Diagnostics Menu

Method 1: Resetting the printer from the Boot Diagnostics Menu

1. Using the directional keys, move to the MISC UTILITIES / RESET PRINTER menu option. (Refer to the menu map on page 93.)

2. Press the ENTER key.

Method 2: Cycling power

1. Power off the printer.

2. Wait 15 seconds.

3. Power on the printer.

Selecting and Running Diagnostic Printer Tests

BOOT DIAGNOSTICS PRESS ENTER

ENTER

NOTE:

To exit this menu, cycle power.

>= DOWN key <= NEXT key

VERSION CHECK BOOT VERSION

ENTER ENTER

BOOT/CMX V100H 12Sep95 #154669

BOOT DIAGNOSTICS FILE UTILITIES

VERSION CHECK SOFTWARE VERSION

09/08/95 11:41:08

VERSION CHECK P.C. BOARD VERSION

ENTER

P.C. BOARD VERSION

3.5

BOOT DIAGNOSTICS VERSION CHECK

VERSION CHECK SECURITY PART #

SECURITY PART # 154140-017

VERSION CHECK EC VERSION

EC V1.00H 07Sep95 #154643

ENTER

VERSION CHECK PROCESSOR SPEED

PROCESSOR SPEED 68E030 AT 25 MHZ

VERSION CHECK ASIC VERSIONS

ENTER

VX VERSION=F MECA VERSION=F

ENTER

Continued on next page

FILE UTILITIES VIEW FILES

VIEW FILES

VERSION

FLASHDISK STATUS FREE = 0012473

ENTER

FLASHDIS K STATUS # ERASES = 000073

FILE UTILITIES FILE SYSTEM STATUS

VIEW FILES

FILENAME

FLASHDISK STATUS # OF FILES = 000

FLASHDISK STATUS USED = 0002048

Figure 8. Boot Diagnostics Menu

FILE UTILITIES OPTIMIZE FILES

OPTIMIZING FLASH FILES

ENTER

FLASHDISK STATUS DELETED = 0000000

Chapter 3 Boot Diagnostics Menu

BOOT DIAGNOSTICS

From previous page

MISC UTILITIES

NOTE:

To exit this menu, cycle power.

>= DOWN key <= NEXT key

MISC UTILITIES DISPLAY MEMORY

ENTER ENTER

FLASH = 2 MBYTES DRAM = 2 MBYTES

MISC UTILITIES ERASE ALL FLASH

ENTER

ERASE ALL FLASH COMPLETED

SELECT DOWNLOAD PORT = CENTRONIC

ENTER

WAITING DOWNLOAD PORT = CENTRONIC

MISC UTILITIES RESET PRINTER

RESETTING... PLEASE WAIT

MISC UTILITIES RUN MEMORY TESTS

TESTING FOR ADDRESS SHORTS

SELECT DOWNLOAD PORT = RS232-9600

ENTER

WAITING DOWNLOAD PORT = RS232-9600

MISC UTILITIES COPY FLASH SIMMS

LOADING PROGRAM INTO FLASH

ENTER

SELECT DOWNLOAD PORT = RS232-19.2K

WAITING DOWNLOAD PORT = RS232-19.2K

ENTER

MISC UTILITIES FILE DOWNLOAD

SELECT DOWNLOAD PORT = RS232-38.4K

ENTER

WAITING DOWNLOAD PORT = RS232-38.4K

MISC UTILITIES COPY BOOT SIMMS

LOADING PROGRAM INTO FLASH

MISC UTILITIES CLEAR NVRAM

CLEAR NVRAM COMPLETED

ENTER

SELECT DOWNLOAD PORT = RS232-115K

ENTER

WAITING DOWNLOAD PORT = RS232-115K

SELECT DOWNLOAD PORT = RS422-9600

ENTER

WAITING DOWNLOAD PORT = RS422-9600

SELECT DOWNLOAD PORT = RS422-19.2K

ENTER

WAITING DO WNLOAD PORT = RS422-19.2K

SELECT DOWNLOAD PORT = RS422-38.4K

ENTER

WAITING DOWNLOAD PORT = RS422-38.4K

SELECT DOWNLOAD PORT = RS422-115K

ENTER

WAITING DOWNLOAD PORT = RS422-115K

SELECT DOWNLOAD PORT =

WAITING DOWNLOAD PORT =

Figure 10. Boot Diagnostics Menu (continued)

DATAPRODUCT

ENTER

DATAPRODUCT

Hex Code Printout

A hex code printout (or “hex dump”) prints every ASCII data character received from the host computer, and lists its corresponding two-digit hexadecimal code. (See Figure 9 below.) You can use hex dumps as an aid in troubleshooting data reception problems.

In a hex dump every printable character is printed both as its assigned symbol and as its hex equivalent. Every unprintable (ASCII control) character is printed out as a period (.) and its hex equivalent. If the printer is using a parallel interface, the letter “p” before a hex code indicates an active Paper Instruction (PI) line, and a blank space before a hex code indicates an inactive PI line.

To convert an ASCII character to its corresponding hex code, or vice versa, refer to the ASCII code chart on page 97. To make a hex code printout, refer to the procedure on page 96.

Selecting and Running Diagnostic Printer Tests

Figure 9. Sample Hex Dump

Chapter 3 Hex Code Printout

How to Print a Hex Dump

Step Press LCD Result Notes

1. Make sure the printer is on. Raise the printer cover.

2. OFFLINE

ON LINE

CONFIG. CONTROL

3. ENTER SWITCH

UNLOCKED

OFFLINE

CONFIG. CONTROL

4. OFFLINE

UNTIL

MAINT / MISC

5. MAINT / MISC Hex Dump Mode

6. Hex Dump Mode Disable*

7. Hex Dump Mode

8. Hex Dump Mode

ENTER

Enable

Enable*

Unlocks ENTER key and control panel.

Default

Cycle through choices.

Asterisk (*) indicates choice is act ive.

9. ENTER SWITCH

10. ONLINE

ON LINE

LOCKED

LinePrinter+

Locks the ENTER key and control panel.

Places the printer in on-line mode.

11. Send a file from the host computer. the printer outputs a hex dump. Refer to the ASCII chart on page 97.

12. When the hex du mp is complet e, take the print er of f-line and cha nge the Hex Dump Mode back to Disable. Follow the steps outlined above and select Disable.

ASCII Character Set

How to Print a Hex Dump

ESC

33 27

OCTAL equivalent DECIMAL equivalent HEX equivalent

KEY

BITS

B4 B2B3 B1

10 1 1

ASCII Character Name

B70000111 1

BITS

B4 B2B3 B1

0000

00 10

001 0

001 1

010 0

010 1

011 0

011 1

1000

100 1

101 0

101 1

110 0

110 1

111 0

111 1

B6 0

B5 0

COLUMN

ROW

NUL

SOH

STX

ETX

EOT

ENQ

ACK

BEL

01234567

0 0 0

1 1 1

2 2 2

3 3 3

4 4 4

5 5 5

6 6 6

7 7 7

8 8

9 9

12 10

0 A

13 11

0 B

14 12

0 C

15 13

0 D

16 14

0 E

17 15

0 F

DLE DC1

(XON)

DC2

DC3

(XOFF)

DC4

NAK

SYN

ETB

CAN

SUB

ESC

20 16 10

21 17 11

22 18 12

23 19 13

24 20 14

25 21 15

26 22 16

27 23 17

30 24 18

31 25 19

32 26 1A

33 27

1B 34

28 1C

35 29 1D

36 30 1E

37 31 1F

’

(

)

40 32 20

41 33 21

42 34 22

43 35 23

44 36 24

45 37 25

46 38 26

47 39 27

50 40 28

51 41 29

52 42 2A

53 43

2B 54

44 2C

55 45 2D

56 46 2E

57 47 2F

48 30

49 31

62 50

32 63

33 64

52 34

53 35

66 54

36 67

55 37

70 56

38 71

39 72

58 3A

;

59 3B

76 62

3E 77

100

64 40

101

65 41

102

66 42

103

67 43

104

68 44

105

69 45

106

70 46

107

71 47

110

72 48

111

112

74 4A

113

75 4B

114

76 4C

115

77 4D

116

78 4E

117

79 4F

120

80 50

121

81 51

122

82 52

123

83 53

124

84 54

125

85 55

126

86 56

127

87 57

130

88 58

131

89 59

132

90 5A

133

[

91 5B

134

92 5C

135

]

93 5D

136

94 5E

137

95 5F

140

96 60

141

97 61

142

143

144

100

145

101

146 102

147

103

150 104

151 105

152

106

153

107

154

108

155 109

156 110

157 111

{

}

DEL

160 112

161 113

162 114

163 115

164 116

165 117

166 118

167 119

170 120

171 121

172 122

173 123

174 124

175 125

176 126

177 127

Chapter 3 Soft vs. Hard Reset

Soft vs. Hard Reset

Soft Reset

A soft(ware) reset clears printer memory then loads the power-up configuration set by the user. (If no power-up configuration has been set by the user, the factory default configuration is loaded.) It is called a soft reset because no hardware is tested. All diagnostic and initialization tests are bypassed and memory is simply refreshed with the power-up printer configuration.

The printer must be off-line to do a soft reset:

1. Press the ON LINE key to put the printer in the off-line state.

2. Press the

The LCD will display “Standby / Soft Reset” while the printer loads the powerup configuration.

Hard Reset (“Cycle Power”)

; (PREV) + < (NEXT) keys simultaneously.

A hard(ware) reset is a power shutdown and restart that runs all initialization

and diagnostic routines. This is also called “cycling power.”

1. Set the printer power switch to O (off).

2. Wait 15 seconds.

3. Set the printer power switch to 1 (on). NOTE: A hard printer reset causes the +48V power supply (fans, motors,

etc.) to shut down in 1 to 5 seconds, depending on the amount of memory installed on the controller board.

The Power On Sequence

This section describes the normal sequence of events from the time the power switch is set to 1 until ONLINE (or OFFLINE, if so configured by the user) appears on the LCD.

Use this sequence as a reference baseline to help you isolate problems that occur before the printer completes its boot and initialization routines.

The power on sequence consists of two sets of routines:

1. CMX controller board handshake sequences (DC hardware initialization)

2. DC software initialization and power up The routines are listed below, in order of occurrence.

CMX Controller Board Handshake Sequ ences

• Processor Alive — The green LED marked CR1 on the CMX controller

board is turned on to indicate that the processor received a valid reset vector and the first instructions to the processor are correct. This LED is used to report all DC errors and states.

CMX Controller Board Handshake Sequences

• Test VX Data Bus — A walking zero and one test verifies that all 32 data

lines from the VX bus to the processor are connected. If a bad line is detected, a 4-1-1-XX blink code is sent to the LED on the CMX controller, where XX is the data line plus 1. (For example, a bad data line 8 would blink as 4-1-1-9.)

• Initialize VX ASIC — The boot code detects the processor type and sets

up the internal registers of the VX ASIC.

• Initialize Debug Serial Port — The boot code checks the validity of the

debug serial parameters in NVRAM; if they are valid, it sets the baud rate, data type, and which messages should be sent out the debug port. If the values in NVRAM are not valid, boot code initializes NVRAM to 9600 baud, 8 data bits, one stop, bit, no parity bit, and standard messages.

• Turn On Instruction Cache — The instruction cache is turned on to help

speed up memory tests and the entire boot process.

• Enable DRAM Controller — A DRAM controller is built into the VX ASIC.

DRAM must be refreshed a few times to operate correctly. To speed the boot process, the refresh rate is temporarily increased. The message “TESTING HARDWARE PLEASE WAIT” is sent to the LCD, during which time the refreshes run and finish. At this point, the fans start. After sending the message, the refresh rate is set to the proper rate and DRAM is ready to be tested.

• Test I/O Clock — The VX ASIC has two clocks for internal timing, a

processor clock and an I/O clock. The processor clock cannot be checked because the processor will not run without it, but the I/O clock can be checked. The I/O clock is used for sending data to the control panel and to get the time for DRAM refreshes. If the boot code detects a problem with the I/O clock, the error blink code 4-3-4 is sent to the diagnostic LED on the CMX board.

Chapter 3 The Power On Sequence

• Read Control Panel Keys — The control panel keys are read to

determine if the user is requesting that the printer be placed in download mode, diagnostic mode, or debug SIMM disabled. If ON LINE and PAPER ADVANCE are pressed during start-up, the printer is placed in download mode. If the printer is placed in diagnostic mode. If any other combination of keys are pressed, the debug SIMM is disabled. Key states are put in an internal register in the VX ASIC.

; (PREV) and > (DOWN) are pressed during start-up,

• Detect DRAM — The VX ASIC supports up to four banks of DRAM

totalling up to 32 Megabytes. Boot code detects how much DRAM is located in each bank, and relocates the banks to create one contiguous block of DRAM. The size and location of each bank is then displayed on the debug terminal through the debug serial port.

• Test DRAM — DRAM is tested by writing a pseudo–random number

sequence to all the DRAM, then reading the pattern back to verify it against what was originally written. If an error is detected, the message “ERROR: DRAM AT ADDRESS XXXXXXXX” is displayed on the LCD. When finished, the DRAM test sets all memory to zero.

• Inform the EC Processor — The first 8 Kilobytes of DRAM are reserved

for the EC processor, which must be notified when DRAM is ready to be used. This is done by putting the message “DCS1” in the ECDC communications register in the VX ASIC.

• Detect Ethernet Adapter — An Ethernet adapter must be detected early

in the power up sequence so the printer can tell the adapter it has been detected and continue with its own power up sequence. An Ethernet adapter takes a long time to complete its internal diagnostic tests, so the boot code allows the adapter to power up in parallel with the printer to reduce its effect on overall boot time.

• Load Boot Messages — The boot code scans flash memory for OEM

boot messages and loads them into DRAM. The manufacturer’s boot code is the same for all OEMs, and contains a set of default messages. Boot messages for specific OEMs are stored in the DC code, not the boot code.

• Load Boot Code into DRAM — Flash memory cannot be accessed

while flash is being detected, cleared, or programmed. This prevents boot code from running in flash because the opcodes cannot be fetched. This is solved by copying the program into DRAM and executing the program out of DRAM. The boot code is position-independent in order for the program to operate at a different address. The interrupt vector table is also move to DRAM and the vectors are changed to reflect the new address.

• Detect Flash — The boot code supports many different kinds of flash

memory, permitting any mixture of flash in the four memory banks. The only requirement is that flash must exist in bank 0 and have boot code programmed on it. The boot code displays flash configuration, manufacturer’s part number, size, and start address out the debug serial port.

100

• Display VX Registers — The boot code displays the values of the VX

registers out of the debug serial port.

Printronix P5214-SS, P52KA, P5214, P5215, P5210 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Trademark Acknowledgements

War ranty and Copyrig ht Inform ation

COPYRIGHT © 1996, 1999, PRINTRONIX, INC.

Communication Notices

1 Maintenance Overview

About the Printer

P5000 Printers

Kanji/Hanzi Printers

Printer Evolution

How to Identify the Printer

Figure 1. How to Interpret Model Numbers

Table 1. P5000 Printers

Important Maintenance Notes

CAUTION

About This Manual

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 work on the printer.

3. Gather the parts and tools you will need.

4. Make sure you understand all safety notices before you start a task. (See below.)

WARNING

CAUTION

IMPORTANT

IMPORTANT

Notes and Notices

Printing Conventions in This Manual

Safety Notices

WARNING

WARNING

WARNING

Hinweise zur Sicherheit

Controls and Indicators

Figure 2. Electrical Controls, Cabinet Models

Figure 3. Electrical Controls, Pedestal Models

Figure 4. Mechanical Controls and Indicators, All Models

Tools, Test Equipment, and Supp lies

2 Preventive Maintenance

Cleaning the Printer

WARNING

CAUTION

Cleaning the Outside Surfaces

1. Power off the printer.

CAUTION

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

3. Remove paper and the ribbon.

5. Dry the outside surfaces with a clean, lint-free cloth.

6. Open the printer cover.

8. Wipe the splined shaft with a soft cloth.

9. Using a cloth dampened (not wet) with alcohol, clean the ribbon guides.

10. Vacuum up dust and residue from the lower cabinet.

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

13. Clean the shuttle frame assembly, as described in the next section.

1) Base Casting

2) Shuttle Cover Assembly

3) Splined Shaft

4) Tractors

5) Forms Thickness Lever

6) Ribbon Guide

Figure 5. Cleaning Inside the Cabinet or Top Cover

Cleaning the Shuttle Frame Assembly

1. Remove the shuttle cover assembly (page 160).

2. Remove the shuttle frame assembly (page 198).

3. Remove the paper ironer (page 176).

WARNING

CAUTION

CAUTION

5. Install the paper ironer (page 176).

6. Remove the hammer bank / ribbon mask cover assembly (page 157).

CAUTION

1) Hammer Tip

Figure 6. Cleaning the Hammer Tips

9. Install the hammer bank / ribbon mask cover assembly (page 157).

10. Install the shuttle frame assembly (page 198).

11. Install the shuttle cover assembly (page 160).

12. Clean the card cage fan assembly, as described in the next section.

Cleaning the Card Cage Fan Assembly