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Maintenance Manual
Approved Final
May 19, 2011
6600 Series Printers
Page 2
Page 3
6600 Series Printers
Maintenance Manual
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T rade mark Ack nowledgem ent s
ANSI is a registered trademark of American National Standards Institute, Inc.
Belkin is a registered trademark of Belkin Corporation.
Centronics is a registered trademark of Genicom Corporation.
Chatillon is a trademark of John Chatillon & Sons, Inc.
Code V is a trademark of Quality Micro Systems.
Dataproducts is a registered trademark of Dataproducts Corporation.
EIA is a registered service mark of Electronic Industries Association.
E
NERGY 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.
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.
E
NERGY STAR® Partner,
E
NERGY STAR®
Java is a trademark of Sun Microsystems.
LinePrinter Plus is a registered trademark of Printronix, Inc.
Linux is a registered trademark assigned to Linus Torvalds.
MS-DOS and Microsoft Windows (3.1x, 95, 98, Me, NT, 2000, and XP) are
trademarks of Microsoft Corporation.
PC-DOS is a trademark of International Business Machines Corporation.
PGL is a registered trademark of Printronix, Inc.
Primelogic is a trademark of PTC Group, Inc.
PrintNet is a registered trademark of Printronix, Inc.
Printronix is a registered trademark of Printronix, Inc.
PSA and PSA3 are trademarks of Printronix, Inc.
QMS is a registered trademark of Quality Micro Systems.
SureStak is a trademark of Printronix, Inc.
TallyGenicom brand is owned by Printronix, Inc.
Torx is a registered trademark of Camcar/Textron Inc.
UNIX is a registered trademark of The Open Group.
Utica is a registered trademark of Cooper Power Tools.
Page 5
War ranty And Cop yright Information
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.
All rights reserved.
© 2011, Prin tron i x, Inc.
E
NERGY STAR
The Environmental Protection Agency E
a partnership effort with manufacturers of data processing equipment to
promote the introduction of energy-efficient personal computers, monitors,
printers, fax machines, and copiers to help reduce air pollution and global
warming caused by electricity generation.
Printronix, Inc. participates in this program by introducing printers that reduce
power consumption when they are not being used. As an E
Partner, Printronix has determined that this product meets the E
guidelines for energy efficiency.
NOTE: The E
NERGY STAR
any product or service.
® emblem does not represent EPA endorsement of
NERGY STAR
® Computers program is
NERGY STAR
NERGY STAR
®
®
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Communication Notices
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.
WARNING
Federal Communications Com m ission (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 Fules. 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 instructions, 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.
This device complies with Part 15 of the FCC Fules. 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 interference that may cause undesired operation.
European Union (EU) Co nformity Statement
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 option cards not authorized by Printronix.
This product has been tested and found to comply with the limits for Class A
Information Technology Equipment according to 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 devices.
Page 7
Properly shielded and grounded cables and connectors must be used in order
to reduce the potential for causing interference to radio and TV
communications and to other electrical or electronic equipment. Such cables
and connectors are available from Printronix authorized dealers. Printronix
cannot accept responsibility for any interference caused by using other than
recommended cables and connectors.
Industry Canada Compliance St atem ent
This Class A digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la classe A conform á la norme NMB-003 du
Canada.
Statement of CISPR 22 Compliance
Attention: 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.
Japanese VCCI Class A
Taiwan
Warning: This is a Class A product. In a domestic environment this product
may cause radio interference in which case the user will be required to take
adequate measures.
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Australia/New Zealand
Attention: This is a Class A Product. In a domestic enviroment this product
may cause radio interference in which case the user may be required to take
adequate measures.
China
Declaration: This is a Case A Product. In a domestic environment this
product may cause radio interference, in which case the user may be required
to take practical actions.
German Conformity St ateme nt
Zulassungsbescheinigung Gesetz über die elektromagnetische
Verträglichkeit von Geraten (EMVG) vom 30. August 1995
Dieses Gerät ist berechtigt in Übereinstimmung mit dem deutschen das EGKonformitätszelchen - CE - zu führen.
Der Außteller der Konformitätserklärung ist die Printronix......(1)
Informationen in Hinsicht EMVG Paragraph 3 Abs. (2) 2:
Das Gerät erfüllt die Schutzanforderungen nach EN 55022 und
EN 55024 Klasse A.
EN 55022 Klasse A Geräte bedürfen folgender Hinweise:
Nach dem EMVG: “Geräte dürfen an Orten, für die sie nicht asreichend
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, Paragraph 3, Abs. 4) Dieses Genehmigungsverfahren ist nach
Paragraph 9 EMVG in Verbindung mit der entsprechenden Kostenverordnung
(Amtsblatt 14/93) kostenpflichtig.
EN 55022: Dieses ist eine Kategorie A Vorrichtung. Betrieb in den
Wohnbereichen kann elektrische Störung verursachen. Es ist die
Verantwortlichkeit des Benutzers, passende Gegenmaßnahmen zu ergreifen.
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EN 55024: Begrenzung Werte für Gebrauch in bevölkerten Bereiche,
kommerziellen und Industriegebieten sind innen Übereinstimmung mit den
spezifizierten Anforderungen Hinsichtlich Störfreiheit.
Anmerkung: Um die Einhaltung des EMVG sicherzustellen sind die Geräte,
wie in den Handbüchern angegeben, zu installieren und zu betreiben.
European Union (EC) Electromagnetic Compatibility
Directives
This product conforms to 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 nonrecommended modification of the product, including the fitting of option cards
not authorized by Printronix.
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 to
reduce the potential for causing interference to radio and TV communication
and to other electrical or electronic equipment. Printronix cannot be
responsible for any interference caused by using other than recommended
cables and connectors.
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.
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 worden.
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Page 11
Table of Contents
1 Maintenance Overview......................................... 17
TallyGenicom® 6600 Cartridge Ribbon Printer (CRP) Series ................ 17
Order the Correct Spares ................................................................. 18
How to Identify a 6600 Cartridge Ribbon Printer..............................19
Zero Tear Pedestal (ZTP) Printers................................................... 19
Printer Configuration Code...............................................................20
Forms Handling ................................................................................ 20
Important Maintenance Notes................................................................. 21
Notices ............................................................................................. 21
About this Manual ...................................................................................22
How to Use this Manual ................................................................... 22
Printing Conventions in this Manual .................................................23
Safety Notices.........................................................................................23
Hinweise zur Sicherheit ..........................................................................24
Controls and Indicators ........................................................................... 25
Electrical Controls ............................................................................25
Mechanical Controls.........................................................................28
Tools and Test Equipment......................................................................30
Plugging in the Printer ............................................................................31
TallyGenicom Customer Support Center................................................32
TallyGenicom Supplies Department .......................................................32
Corporate Offices.................................................................................... 33
Maintenance Training for TallyGenicom Products..................................33
2 Preventive Maintenance....................................... 35
Cleaning the Printer ................................................................................35
Cleaning the Exterior........................................................................35
Cleaning the Interior ......................................................................... 36
Cleaning the Shuttle Frame Assembly ...................................................38
Cleaning the Card Cage Fan Assembly .................................................41
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Table of Contents
3 Troubleshooting ....................................................43
Introduction .............................................................................................43
Troubleshooting Aids ..............................................................................43
Start Here... ............................................................................................44
Troubleshooting Display Messages........................................................45
List of Messages ..............................................................................46
Troubleshooting Other Symptoms........................................................111
General Symptom List....................................................................112
Communications Failures .....................................................................134
Diagnostic Printer Tests........................................................................ 136
Selecting And Running Diagnostic Printer Tests ........................... 137
Boot Diagnostics Menu......................................................................... 141
Factory Menu........................................................................................144
Exception Menu ....................................................................................146
Firmware Diagnostic Port .....................................................................147
Diagnostic Cable ............................................................................147
Capturing Information.....................................................................148
Hex Code Printout ................................................................................149
How To Print A Hex Dump ............................................................. 149
ASCII Character Set ............................................................................. 151
Hard Reset (Cycle Power) ....................................................................152
4 Adjustments and Tests ....................................... 153
Introduction ...........................................................................................153
Adjustments and Tests...................................................................153
Preparing the Printer for Maintenance.................................................. 154
Returning the Printer to Normal Operation ........................................... 155
Belt, Paper Feed Timing, Adjustment...................................................156
Belt, Platen Open, Adjustment.............................................................. 158
Paper Scale Alignment .........................................................................160
Platen Gap Adjustment......................................................................... 162
Paper Out Adjustment ..........................................................................164
Hammer Phasing Adjustment...............................................................167
Loading Flash Memory .........................................................................169
Loading Software with the Firmware Download Utility ...................170
Loading through Parallel Port using DOS ...................................... 171
Loading Software if Flash Contains Only Boot Code .....................173
Loading Software through the NIC................................................. 174
Reprogramming the Security Key......................................................... 176
How to Reprogram the Security Key.............................................. 176
Coil Temperature Adjustment ...............................................................178
Dynamic Paper Tension Adjustment ....................................................179
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Table of Contents
Tractor Belt Tension Adjustment ..........................................................181
Shuttle Electrical Short Check ..............................................................182
Hammer Bank Power Cable Shorts Test..............................................183
Cable Shorts Test .................................................................................184
Main Wire Harness Test Diagnostic .....................................................186
Power Supply Operational Check......................................................... 187
5 Replacement Procedures ................................... 191
Organization of this Chapter .................................................................191
Replacement Procedures .....................................................................191
List of Removal / Installation Procedures .......................................191
Belt, Paper Feed Timing ................................................................193
Belt, Platen Open ...........................................................................194
Cartridge Interface Board (CIB)......................................................195
Circuit Breaker ...............................................................................196
Connector Coupling Shrouds ......................................................... 197
Control Panel Assembly .................................................................199
Controller Board ............................................................................. 200
Cover Assembly, Hammer Bank / Ribbon Mask ............................202
Cover Assembly, Shuttle ................................................................ 203
Cover Assembly, Top, Pedestal Models ........................................ 204
Dashpot.......................................................................................... 205
Fan Assembly, Cabinet Exhaust ....................................................206
Fan Assembly, Card Cage .............................................................207
Fan Assembly, Hammer Bank........................................................208
Hammer Spring Assembly, Version 1 ............................................ 209
Hammer Spring Assembly, Version 2 ............................................ 211
Magnetic Pickup (MPU) Assembly.................................................217
Memory (Flash, Expansion) ........................................................... 218
Motor Bracket Assembly ................................................................ 219
Paper Feed Motor .......................................................................... 220
Paper Ironer ................................................................................... 221
Paper Guide Assembly ..................................................................222
Platen ............................................................................................. 223
Platen Open Motor .........................................................................227
Platen Stop Assembly ....................................................................229
Power Supply Board ......................................................................230
Resistors, Terminating, V6 Controller Board..................................231
Ribbon Drive Motor ........................................................................ 233
Security Key ................................................................................... 234
Shaft, Splined................................................................................. 236
Shaft, Support ................................................................................238
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Table of Contents
Shuttle Frame Assembly ................................................................ 239
Spring, Extension, Hammer Bank .................................................. 241
Switch Assembly, Paper Detector.................................................. 242
Switch Assembly, Platen Interlock ................................................. 243
Tractor (L/R)................................................................................... 244
Weld Sensor...................................................................................244
6 Illustrated Parts Breakdown................................ 245
Organization of this Chapter .................................................................245
Illustrations of Printer Components ................................................ 245
7 Principles Of Operation....................................... 279
Line Matrix Printing ...............................................................................279
Printing Rates .......................................................................................282
Printing Mechanism ..............................................................................282
Shuttle Frame Assembly....................................................................... 283
Hammer Bank Assembly................................................................ 283
Shuttle Drive Motor ........................................................................284
Paper Transport System....................................................................... 285
Ribbon Transport System .....................................................................286
Integrated Print Management System .................................................. 287
Operation .......................................................................................287
Logical Control of the Printer ................................................................290
Control Panel ........................................................................................291
Controller Board.................................................................................... 292
Data Controller ............................................................................... 294
Engine Controller ...........................................................................296
Power Supply Board .............................................................................298
AC Power ....................................................................................... 298
DC Power....................................................................................... 298
Printer Interface ....................................................................................299
A Wire Data ........................................................... 301
B Abbreviations...................................................... 343
C Metric Conversion Tables .................................. 351
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Table of Contents
D SureStak™ Power Stacker ................................ 353
Contents ...............................................................................................353
Introduction ...........................................................................................354
Stacker Operation.................................................................................354
Stacker Problems .................................................................................359
Stacker First Inspection..................................................................359
Stacker Confidence Check.............................................................360
Stacker Motor Check......................................................................361
Removing the Power Stacker ...............................................................364
Installing the Power Stacker .................................................................370
Replacing the Constant Force Spring...................................................382
Replacing the Timing Belts ...................................................................384
Replacing the Roller Drive Shaft...........................................................387
Illustrated Parts Breakdown.................................................................. 390
List of Illustrations ..........................................................................390
E Zero Tear Pedestal (ZTP) Printer....................... 403
Contents ...............................................................................................403
Overview...............................................................................................404
Operation ..............................................................................................405
Load Paper and Set Up the Tractors .............................................405
Remove Paper ............................................................................... 406
Adjust The Paper Guides ...............................................................407
Position the Paper Out Sensor.......................................................409
Set the Tear Bar Distance .............................................................. 410
Set the Top Of Form ......................................................................411
Control Panel Menus ............................................................................412
Performance Limitations .......................................................................413
Adjustments and Tests .........................................................................415
List of Adjustments and Tests Procedures.....................................415
Preparing the ZTP Printer for Maintenance.................................... 416
Returning the Printer to Normal Operation.....................................416
Barrier Panel .................................................................................. 417
Belt, Paper Feed Timing, Adjustment.............................................418
Paper Guide Leaf, Front, Center, Outer......................................... 420
Paper Out Sensor, Adjustment ......................................................420
Paper Tension, Horizontal..............................................................420
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Table of Contents
Replacement Procedures .....................................................................421
List of Removal / Installation Procedures ....................................... 421
Belt, Paper Feed Timing ................................................................422
Control Panel Assembly ................................................................. 423
Cover Assembly, Top, Pedestal Models ........................................ 423
Paper Feed Motor .......................................................................... 424
Paper Guide Leaf, Center .............................................................. 425
Paper Guide Leaf, Front.................................................................425
Paper Guide Leaf, Outer................................................................425
Paper Out Sensor ..........................................................................426
Shaft, Splined................................................................................. 428
Shaft, Support ................................................................................431
Tractor (L/R)................................................................................... 432
Tractor Assembly Support Gate..................................................... 433
Illustrated Parts Lists ............................................................................435
Illustrations of ZTP Components.................................................... 435
F Paper Specifications And Forms Design ............ 449
Introduction ...........................................................................................449
General Paper Specifications ...............................................................450
Paper Guidelines ..................................................................................451
Terms and Definitions .................................................................... 451
Environmental Considerations ....................................................... 453
Form Types ....................................................................................453
Form Weight...................................................................................453
Form Thickness.............................................................................. 453
Form Evenness ..............................................................................453
Tractor Pin Engagement ................................................................ 453
Methods of Forms Attachment ....................................................... 454
Chaff Content .................................................................................455
Form Design Checklist.......................................................................... 456
Summary ..............................................................................................459
Storage and Handling ....................................................................459
G Customer Support.............................................. 461
TallyGenicom Customer Support Center..............................................461
TallyGenicom Supplies Department ..................................................... 462
Corporate Offices.................................................................................. 462
Page 17
1
Maintenance Overview
TallyGenicom® 6600 Cartridge Ribbon Printer (CRP) Series
TallyGenicom® has been the global leader in industrial printing solutions for
over 30 years, earning a reputation for designing and manufacturing leading
edge products and delivering them to market with unsurpassed service and
support.
The TallyGenicom 6600™ Line Matrix Printing Platform extends the series of
technology innovations that cement TallyGenicom’s leadership position. Line
matrix printing is TallyGenicom’s flagship technology, and it remains the
workhorse solution for supply-chain and back-office printing applications
because of its reliability, lower cost of ownership and flexibility of printing
applications.
•
Most reliable printer ever – provides more up time and lower operating
costs
•
Ultra capacity ribbons – deliver darker image, last longer, and costs less
to operate than other print technologies
•
Integrated print management system – provides precise control over print
quality, print costs, and job planning
•
Cabinet or Pedestal styles – best user access and forms handling
flexibility
•
Unsurpassed ease of use – simplifies operation and enhances
productivity
There are four printer configurations:
Enclosed Cabinet
•
The enclosed cabinet models provide for near silent operation, making
these printers perfectly suitable for use in the quietest of office
environments.
•
Provides the best paper handling for large print runs. All paper input and
output is contained inside the cabinet and protected from bumping and
contamination.
•
Highly effective combination of moveable fences and chains allows for
precise stacking all the way up to a full box of paper.
•
For tougher forms that tend not to refold well, a SureStak power stacker
option is available for the enclosed cabinet models.
•
Available in four print speeds – 500 line per minute (lpm), 1000 lpm,
1500 lpm, and 2000 lpm models.
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Chapter 1
TallyGenicom® 6600 Cartridge Ribbon Printer (CRP) Series
Pedestal
•
The pedestal model has a clamshell design that allows easy access to all
controls, providing faster ribbon replacements and easier paper loading.
•
Oversized casters are standard making movement easy.
•
Versatility to configure the paper path for either top or rear exit.
•
Using the top paper exit, this printer is ideal for short print runs and easy
access to output.
•
Available in three print speeds – 500 line per minute (lpm), 1000 lpm, and
1500 lpm models.
Quiet Pedestal
•
This printer configuration is the same as the above Pedestal configuration
but with an enclosed input paper area with a front door, side panels, and
bottom panel to seal the input paper path.
•
Provides a reduction in acoustic noise.
Zero Tear Pedestal
•
Special push tractor configuration enables printing from the very first to
the very last line of a form and then tear-off with no forms lost.
•
The elimination of wasted forms between jobs can yield significant
savings.
•
An ideal solution for supply-chain and back-office applications.
•
Available in three print speeds – 500 line per minute (lpm), 1000 lpm, and
1500 lpm models.
Order the Correct S p are s
When you replace worn or damaged printer components, make sure you
order the correct spares for the model you are servicing. The next section
shows you how to identify a 6600 Cartridge Ribbon Printer.
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How to Identify a 6600 Cartridge Ribbon Printer
6600 CRP Printer
6605QZ
Housing Code:
Without Q = Pedestal
Q = Floor Cabinet
Speed Rating:
05 = 500 lines per minute (lpm)
10 = 1000 lpm
15 = 1500 lpm
20 = 2000 lpm
Z = Zero Tear printer
How to Identify a 6600 Cartridge Ribbon Printe r
A 6600 printer has a model number logo and ribbon cartridge logo on the
printer front cover. The model number is an alphanumeric code that identifies
the printer type, its housing, and its maximum rated print speed. The serial
number “C” indicates that this is a cartridge equipped printer. The model
number and serial number of the printer are on the identification label next to
the input/output ports at the rear of the printer.
interpret a model number.
Figure 1 shows how to
The speed of printing for “real world” print jobs is affected by the interaction of
many variables and varies from print job to print job. For more information,
see “Printing Rates” on
Zero Tear Pedestal (ZTP) Printers
Zero Tear Pedestal (ZTP) printers are models equipped with special
hardware and software that permits them to print small jobs or single sheets
without losing a sheet between print jobs. A ZTP printer automatically
presents the current print line to a tear bar when it finishes printing and
presents the perforation of the last form printed to the tear bar. When it
receives more data from the host computer, the printer pulls the form down to
the print station and resumes printing.
ZTP printers are covered in Appendix E (page 403).
Figure 1. How to Interpret a Model Number
page 282.
19
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Chapter 1
FH06AA
Cabinet Type:
F = Floor Cabinet
P = Pedestal Model
Controller Board Revision Level.
H = PSA3 board
V8 ASIC Revision Level
MECA ASIC
Revision Level
TallyGenicom® 6600 Cartridge Ribbon Printer (CRP) Series
Printer Configuration Code
Every printer has a configuration code which specifies the printer’s cabinet
type, controller board revision level, V8 ASIC revision level, and MECA ASIC
revision level. The configuration code is included in the configuration printout.
Figure 2 shows how to interpret the printer’s configuration code.
Figure 2. How to Interpret the Printer’s Configuration Code
Forms Handling
Pedestal Models
Pedestal models provide access to printed forms from the top cover with a
tear-at-perforation edge for ejected forms or a paper exit at the rear of the top
cover. Pedestal printers also have a wireform paper tray attached to the front
of the pedestal and a wireform catch basket attached either to the back of the
pedestal or to the back of the printer top cover.
Cabinet Models
Cabinet models can be equipped with four kinds of paper stacking devices:
•
The fixed paper fence is a wireform divider that separates the source
paper stack from the printed output stack, and is used in combination with
hanging chains that guide printed forms downward.
•
For improved performance at higher print speeds, the chains are used
with a moveable fence called the “passive paper stacker,” which can be
positioned to match the form’s length.
•
The front access paper stacker consists of a shelf that holds the input
paper and a sliding tray that receives the printed forms. The sliding tray
pulls forward, permitting the user to both load and unload paper from the
front of the printer. This option is helpful in locations where access to the
rear of the printer is limited or impossible.
•
For more demanding applications, an optional power stacker is available.
(The power stacker is covered in Appendix D on
page 353.)
These devices are summarized in Table 1.
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Table 1. Paper Stackers Used On Cabinet Models
Notices
Printer
6605Q Standard Option Option Option
6610Q Not Used Standard Option Option
6615Q Not Used Standard Option Option
6620Q Not Used Standard Option Option
Fixed Paper
Fence
Important Maintenance Notes
To ensure the best performance of the printer, remember these maintenance
principles when you service it. Failure to observe these guidelines can result
in damage to the equipment:
•
Do not adjust the platen gap unless
1) the original shuttle 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 try to adjust (“tweak”) the hammer springs. The
hammer springs are precisely aligned and the hammer tips are delicate.
Always handle hammer springs by the thick mounting base.
•
Use only the ribbon cartridges specified in the User’s Manual. Using
ribbon cartridges not made by TallyGenicom can lead to degraded print
quality, expensive damage to the printer, and can void the owner’s
warranty.
Passive
Paper
Stacker
Front
Access
Stacker
Power
Paper
Stacker
WARNING
CAUTION
IMPORTANT
•
Never close the forms thickness lever (platen lever) too tightly.
Closing the forms thickness lever too tightly can lead to smeared print,
degraded print quality, paper jams, and damage to the platen and shuttle
assembly.
Notices
For your safety and to protect valuable equipment, always read and comply
with all information highlighted under notices.
The heading of a notice indicates the kind of information it contains, as
explained below:
Describes a condition that could hur t you.
Describes a condition that coul d damage equipment or data.
Information vital to proper operation and maintenance of the printer.
NOTE: Tips for efficient operation, maintenance, and troubleshooting.
21
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Chapter 1
About this Manual
About this Manual
This is a field service maintenance manual, intended for use by trained
service personnel. It is designed so that you can quickly locate the
maintenance information you need to restore the printer to operation.
This manual does not explain how to install, operate, or configure the printer.
For that information, refer to the Quick Reference Guide and the User’s
Manual.
This manual does not explain how to program application software for
operation with the printer. Programming information for the printer languages
used by the printer is in the appropriate programmer’s reference manual:
•
Integrated Network Interface Card User’s Manual
Information about network protocols, configuration, and network
operation.
•
6600 Series Printers Emulations Applications Manual, Volume 1
Defines printer emulations.
•
6600 Series Printers Fonts and Character Sets Applications Manual,
Volume 3
Defines printer fonts and character sets.
•
6600 Series Printers Graphics Languages Applications Manual, Volume 4
Defines Code V, PGL, and MT660 IG printer graphics languages.
How to Use this Manual
Taking a systematic approach to maintenance tasks will help you restore the
printer to operation as quickly as possible:
1. Locate the procedure or information you need in the Table of Contents or
Index.
2. Read the entire procedure before you do it.
3. Gather the parts and tools you will need.
4. Make sure you understand all notices before you start a task. (Notices are
defined on
page 21.)
22
Page 23
Printing Conventions in this Manual
Printing Conventions in this Manual
Control panel keys and indicators are highlighted in UPPERCASE BOLD
PRINT.
Example: Press the CLEAR key, then press the ONLINE key.
Messages that appear on the LCD (Liquid Crystal Display) are set off by
quotation marks (“ ”).
Example: Press the ONLINE key. “OFFLINE” appears on the LCD.
Control panel key combinations are indicated by the + (plus) symbol.
Example: Press U + V.
means press the key and the key at the same time.
IMPORTANT
The Safety Notices on page 23 apply at all times when you are working
on the printer. Please read them now.
Safety Notices
WARNING
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 dashpot.
23
Page 24
Chapter 1
Hinweise zur Sicherheit
Hinweise zur Sicherheit
VORSICHT
VORSICHT
VORSICHT
VORSICHT
VORSICHT
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.
Ziehen Sie das Netzkabel aus der Steckdose, bevor Sie den Drucker
reinigen.
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.
Die obere Kante der Papierschiene wird mit der Zeit scharf. Halten Sie
die Schiene deshalb an den Seiten, damit Sie sich nicht schneiden.
Behalten Sie die Druckerabdeckung sicher im Griff, wenn Sie das
Gasfederpaket entfernen .
24
Page 25
Controls and Indicators
Electrical Contro ls
Electrical Controls
Switch or
Indicator
Power Switch Turns printer on and off: 1 = on, 0 = off. This switch is also a circuit
breaker.
Status Indicator On when the printer is online, off when the printer is offline. Flashes to
indicate a fault or warning.
LCD Liquid Crystal Display. Displays printer status messages, fault messages,
and menus which permit user to set various configurations.
ONLINE Toggles the printer online and offline. Clears the printer after a fault is
corrected and returns the printer to offline state. Pressing CLEAR silences
the audible alarm (if enabled).
LF Performs a line feed (LF - line feed). A single press of the LF key causes a
line advance.
FF Performs a form feed paper advance (FF - form feed) . A single press of
the FF key causes a form advance to the top of the next form.
CLEAR In a fault state this key attempts to clear the fault. When the fault is cleared
the printer returns to the offline mode.
When the printer is in offline mode and no fault is present, this key allows
entry into the Clear menu..
TOF Moves paper downward from TOF (Top Of Form) alignment mark to the
print station and sets 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.
Function
Active
Online
9 9
9 9
9 9
9 9
9 9
Active
Offline
9
9
VIEW When the printer is online or offline, pressing this key executes the view or
eject function. A short press of the View key performs the view function. If
the key is held down for more than one second, the key eject function is
performed.
If online with data in the printer buffer, the data prints and the key functions
as described below.
For cabinet models, pressing the VIEW key moves the last data printed to
the tractor area for viewing. While in the view state, the message "Printer
in View" displays, and pressing the UP or DOWN arrow keys moves the
paper up or down in 1/72 inch increments. Pressing VIEW a second time
moves the paper back to the adjusted print position.
If in a fault state, this key will be ignored.
CONFIG In offline mode, this key allows for fast selection of any of the previously
stored configurations. Pressing this key causes the printer to cycle through
the following messages: Load Config., Factory Config, Load Config 1,
Load Config 2, Load Config 3,...,Load Config 8.
9 9
9
25
Page 26
Chapter 1
Controls and Indicators
Switch or
Indicator
MENU/ENTER While in offline mode, this key allows entry into the configuration menus.
When navigating the configuration menus, MENU/ENTER selects the
currently displayed option value as the active value. An asterisk (*)
appears next to the active value on the display. MENU/ENTER is also
used for starting and stopping printer tests and generating a configuration
printout.
Moves up between levels in the configuration menus. When in offline
mode, makes vertical forms adjust.
In VIEW mode, moves paper up 1/72 inch. (See VIEW key.)
Moves down between levels in the configuration menus. When in offline
mode, makes vertical forms adjust.
In VIEW mode, moves paper down 1/72 inch. (See VIEW key.)
Moves between the options on the current level of configuration.
Moves between the options on the current level of configuraiton.
+
Press up and down arrow keys together unlocks or locks the MENU/
ENTER key.
Function
Active
Online
Active
Offline
9
9
9
9
9
9
26
Page 27
Electrical Controls
184071b
184071 REV B
(Off) (On)
A
A
Rotated 180 Degrees
B
C
Power Switch
C
A
184136b
FF
LF
ONLINE
TOF
VIEW
CONFIG
MENU/ENTER
CLEAR
TOF
VIEW
CONFIG
MENU/ENTER
ONLINE
LF
FF
CLEAR
Circular Pad
ONLINE
Message
Display
Status
Indicator
B
C
B
Figure 3. Electrical Controls
27
Page 28
Chapter 1
110 20
1 inch
0.1 inch
Column
Number
Controls and Indicators
Mechanical Controls
Control or Indicator Function
Paper Supports Help prevent paper jams by supporting inner sections of paper. They
are positioned manually by sliding them along the tractor shafts.
Forms Thickness Lever Sets the platen for paper and forms of different thicknesses. This
lever must be fully opened (raised) to load paper, unload paper, and
move paper with the vertical position knob.
Forms Thickness
Pointer and Scale
Forms Thickness Lever
and Platen Stop
Assembly
Indicates the relative thickness of forms and paper. Align pointer with
A for thin (single-part) forms, B for thicker forms, and so on.
The forms thickness lever closes the platen to the relative thickness
of the paper. The platen stop assembly returns the platen to the lever
adjustment made by the user.
Tractors (2) Hold and feed paper. Used to set side margins and position the paper
horizontally.
Tractor Locks (2) Lock tractors in position.
Vertical Position Knob Used to set top of form or the first line to be printed. Open the forms
thickness lever and rotate this knob to move paper vertically.
Paper Scale A horizontal scale graduated in tenths of an inch, useful for setting
paper margins and counting text columns. (See below.)
28
Page 29
Mechanical Controls
TOF
TOF
TOF
T
OF
183871 REV A
183871a
Ribbon
Ribbon
Cartridge
Ribbon
Tension Knob
Air Shroud
Assembly
Tab (2)
Tab
Slot (2)
Blue Tractor
Lock (2)
Paper
Support (2)
Tractor (2)
Vertical
Position Knob
Platen Lever
Splined Shaft
Platen Stop
Hammer Bank
Cover and
Ribbon Mask
Ribbon Cartridge
Interface
Figure 4. Mechanical Controls
29
Page 30
Chapter 1
Tools and Test Equipment
Tools and Test Equipment
For field level maintenance of the printer, you will need these tools:
Adapter, 1/4 in. hex to 1/4 in. square, Utica® HW-18
Alcohol, anhydrous
Allen Wrench, 1/16 inch
Allen Wrench, 3/32 inch
Allen Wrench, 5/32 inch
Allen Wrench, 7/64 inch
Allen Wrench, 5/64 inch
ESD Wrist Strap
Feeler Gauge, Flat, 0.010 inch
Feeler Gauge, Flat, 0.011 inch
Feeler Gauge, Flat, 0.012 inch
Feeler Gauge, Flat, 0.013 inch
Feeler Gauge, Flat, 0.040 inch
Field Kit, Tester, P5 Power Supplies, Generic, (P/N 178083-001)
Force Gauge, (Chatillon™ NY, Gauge-r, 0-20 lb., CAT 719-20)
Force Gauge, “Fish Scale” type, 0-16 oz.
Hardware Kit, P5XXX Mech, ZTP (P/N 178573-001)
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 (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
Shuttle Stabilizer Tool (P/N 255447-001)
Tie Wraps, 4 inch and 8 inch
Torx® T-10, T-15 Driver
30
Page 31
Plugging in the Printer
Power Cord Requirements
In compliance with international safety standards, a 6600 printer is equipped
with a three-pronged electrical plug on the power cord. When this power cord
is plugged into a correctly wired AC power outlet, the ground conductor
ensures that the printer chassis is at ground (earth) electrical potential.
Mechanical Controls
WARNING
Failure to properly ground the printer can result in electrical shock to
the operator.
Never use adapter plugs that have no grounding prong. Never remove
the grounding prong from the power cable plug. If an extension cord is
required, make sure it is a three-wire cable with a properly grounded
plug.
Interface Cable Requirement s
To comply with Electromagnetic Compatibility (EMC) regulatory requirements
all interface cables must be of a minimal quality level, be the correct length,
and be properly installed.
RS-232 port and parallel port cables must meet the following specifications:
•
The cable design must be double shielded with a copper braid over an
aluminum mylar foil and not just a conductive foil spiral wrapped around a
drain wire.
•
The shield must terminate coaxially (360 degrees) to a metal connector
housing and not be terminated by just a simple wire lead.
•
Cable length, including connectors, must be three meters or less.
•
The cable connector anchor screws must be securely seated in the
printer receptor hardware.
For reference purposes only, two Centronics parallel port cables that have
been tested and found to comply with these requirements are a Belkin® P/N
F2A046-10 and a Primelogic P/N PLU 2823224. Other electrically equivalent
cables are acceptable.
31
Page 32
Chapter 1
TallyGenicom Customer Support Center
TallyGenicom Customer Support Center
The TallyGenicom Customer Support Center offers technical support with:
•
Installation
•
Configuration and setup
•
Loading supplies and operating the printer
•
Specifications of the proper ribbons, forms, and paper
•
Answers to post-sale service support questions
IMPORTANT
Please have the following information available before you call the
TallyGenicom Customer Support Center:
•
Model number of the printer
•
Serial number (located on the back of the printer)
•
Installed options (i.e., interface and host type if applicable to the problem)
•
Help Menu printout (While offline press the MENU/ENTER key on the
control panel to enter the menu. Press the Left Arrow key until the Help
Menu displays. Press the MENU/ENTER key).
•
Is the problem with a new installation or an existing printer?
•
Description of the problem (be specific)
•
Good and bad samples that clearly show the problem (faxing or emailing
these samples may be required)
Americas (714) 368-2686
Europe, Middle East, and Africa (31) 24 6489 410
Asia Pacific (65) 6548 4114
China (86) 800-999-6836
http://www.tallygenicom.com/service/default.aspx
TallyGenicom Supplies Department
Contact the TallyGenicom Supplies Department for genuine TallyGenicom
supplies.
Americas (800) 733-1900
Europe, Middle East, and Africa 33 (0) 1 46 25 19 07
Asia Pacific (65) 6548 4116
China (86) 400-886-5598
http://www.tallygenicom.com/supplies/default.aspx
32
or (65) 6548 4182
Page 33
Corporate Offices
Printronix, Inc.
14600 Myford Road
P.O. Box 19559
Irvine, CA 92623-9559
Phone: (714) 368-2300
Fax: (714) 368-2600
Printronix, Inc.
Nederland BV
P.O. Box 163, Nieuweweg 283
NL-6600 Ad Wijchen
The Netherlands
Phone: (31) 24 6489489
Fax: (31) 24 6489499
Printronix Schweiz GmbH
42 Changi South Street 1
Changi South Industrial Estate
Singapore 486763
Phone: (65) 6542 0110
Fax: (65) 6546 1588
Mechanical Controls
Printronix Commercial (Shanghai) Co. Ltd
22F, Eton Building East
No.555, Pudong Av.
Shanghai City, 200120, P R China
Phone: (86) 400 886 5598
Fax: (86-21) 5138 0564
Visit the web site at www.tallygenicom.com
Maintenance T raining for TallyGenicom Product s
Upon request TallyGenicom offers Product Maintenance Training Classes
designed to enhance the knowledge of service personnel. Taught by
experienced professional instructors, these classes include:
•
Theory of operation
•
Hands-on work with the products
•
Diagnosis of equipment failures
•
Preventive and corrective maintenance requirements and procedures
Customized classes designed to meet specific needs are also available upon
request. Call Customer Training at (714) 368-2595 or visit the TallyGenicom
web page at www.tallygenicom.com.
33
Page 34
Chapter 1
Maintenance Training for TallyGenicom Products
34
Page 35
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
necessary is periodic cleaning. Clean the printer every six months or after
every 1000 hours of operation, whichever occurs first. If the printer is located
in a dusty area or is used for heavy duty printing, clean it more often. Periodic
cleaning, especially of the ribbon path, contributes to increased printer life and
reliability, and helps sustain superior print quality.
Because operating conditions vary so widely, the user must determine how
often to clean the printer. But, since there is no guarantee that the user will
clean the printer regularly, you should clean the printer every time you are
called to service it.
NOTE: A cabinet model printer is illustrated in this chapter, but the cleaning
procedures presented here 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
a cloth, then apply the dampened cloth to the printer.
Do not vacuum circuit boards.
Cleaning the Exterior
1. Power off the printer.
2. Disconnect the AC power cord from the power source.
3. Wipe the outside of the enclosure with a clean, lint-free cloth dampened
(not wet) with water and a mild detergent or window cleaning solution.
4. Dry the enclosure with a clean, lint-free cloth.
5. Clean the inside of the printer, as described on page 36.
35
Page 36
Chapter 2
Cleaning the Printer
Cleaning the Interior
1. Power off the printer and unplug the printer power cord.
2. Open the printer cover.
3. Fully raise the platen lever.
4. Unload the paper.
5. Remove the ribbon cartridge.
6. Lift the ribbon out of the ribbon path.
7. Brush the paper dust and ribbon lint off the tractors, shuttle cover
assembly, and base casting with a soft-bristled, non-metallic brush (such
as a toothbrush). Vacuum up the residue. (See
Figure 5.)
CAUTION
CAUTION
Vacuum carefully around the hammer bank and surrounding area to
avoid damage. To avoid corrosion damage, us e only alcohol when
cleaning the printer mechanical elements. Solutions used to clean
mechanical elements must contain no water.
8. Wipe the splined shaft with a soft cloth.
9. Check the ribbon mask and hammer bank cover for bits of torn paper or
ribbon lint.
10. Remove dust and ink from the platen using a soft cloth lightly moistened
with anhydrous alcohol
hammer bank cover that rotates when the platen is rotated).
When cleaning the platen, be very careful not to get any alcohol in the
hammer bank, because alcohol will cause severe damage to the
hammer bank. Only a trained service technician should clean the shuttle
assembly.
11. For cabinet models:
a. Brush and vacuum the accumulated dust or residue inside the lower
cabinet.
b. Wipe the lower cabinet interior with a clean, lint-free cloth dampened
(not wet) with water and mild detergent or window cleaning solution.
Dry the lower cabinet interior by wiping it down with a clean, lint-free
cloth.
1
. (The platen is the thick silver bar behind the
12. Install the ribbon, load paper, and set the top–of–form. Refer to the Quick
Reference Guide.
13. Clean the shuttle frame assembly (page 38).
1
Due to water content in most isopropyl alcohol products, 99% alcohol is required.
A lower percentage of alcohol will cause internal components to rust. We recommend
MG Chemical Isopropyl Wipes, Product #824-W. Refer to www.mgchemicals.com for
product details.
36
Page 37
Cleaning the Interior
TOF
T
O
F
TOF
T
OF
183871 REV A
183871a
Ribbon
Ribbon
Cartridge
Ribbon
Tension Knob
Tab (2)
Tab
Slot (2)
Blue Tractor
Lock (2)
Paper
Support (2)
Tractor (2)
Vertical
Position Knob
Platen Lever
Splined Shaft
Platen Stop
Hammer Bank
Cover and
Ribbon Mask
Ribbon Cartridge
Interface
Ribbon Turn
Direction Arrow
Base
Casting
Shuttle Cover
Assembly
(Air Shroud)
Figure 5. Printer Interior Components
37
Page 38
Chapter 2
Cleaning the Shuttle Frame Assembly
Cleaning the Shuttle Frame Assembly
NOTE: To help steady the shuttle, be sure to obtain a shuttle stabilizer tool,
P/N 255447-001 (see
1. Prepare the printer for maintenance (page 154).
2. Remove the ribbon cartridge and paper. (Refer to the User’s Manual.)
3. Unlock and slide the tractors outward as far as they will go on the tractor
support shaft. Leave the tractor doors open.
4. Remove the air shroud to expose the shuttle assembly.
5. Disconnect the shuttle logic, data, power, and MPU connectors.
6. Loosen and disengage the left and right shuttle retaining clamps.
7. Loosen the rear shuttle mounting screw and carefully lift the shuttle free of
the printer, and set it on the shuttle stabilizer tool (P/N 255447-001), on a
clean, level work surface.
NOTE: Since the paper ironer is now accessible, it can be cleaned with the
following three steps.
Figure 37 on page 239).
WARNING
CAUTION
WARNING
IMPORTANT
Over time, the upper edge of the paper ironer can become sharp. To
avoid cutting yourself, handle the paper ironer on the sides.
8. Remove the paper ironer (page 221).
9. Wipe the paper ironer with a soft cloth to remove lint, ink, and paper
residue.
10. Install the paper ironer (page 221).
The thin plate (ribbon mask) of the hammer bank cover assembly is
fragile. Do not over-bend or kink the ribbon mask when handling and
cleaning the hammer bank cover assembly.
Do not rub the edges of the mask and cover as they can be sharp.
11. Remove the hammer bank / ribbon mask cover assembly (page 202).
Do not bend the ribbon mask when cleaning between the cover and
mask.
12. Using a clean soft cloth, wipe the hammer bank cover and ribbon mask to
remove lint, ink, and paper residue. Clean the holes in the cover strips.
Carefully wipe between the hammer bank cover and the ribbon mask.
NOTE: Due to evaporation, do not open alcohol packets until they are
required for cleaning.
13. Use the brush provided to clear any debris from the outside of the ribbon
mask and cover plate. Use one or more of the alcohol pads to clean all
surfaces of the hammerbank cover assembly, removing ink residue and
debris.
14. Set the clean hammerbank cover assembly aside for later reassembly.
CAUTION
38
Do not use solvents or liquids to clean the hammer tips. Clean the
hammer tips gently; too much pressure can chip them.
Page 39
Cleaning the Interior
184072a
Hammer Tip
15. Place the shuttle so that the base sits flat on the work surface. Use the
brush provided to remove as much debris as possible from the hammer
tips, brushing in a downward direction (
Figure 6.). Rotate the shuttle 90°
away from you and repeat the brushing this time working from the center
of the shuttle outward towards both ends.
NOTE: Only remove the frets if contamination is affecting print quality. Study
the procedure first to understand how you will align and re-install the
frets. Tools are available to aid this process for certain frets.
CAUTION
Figure 6. Cleaning the Hammer Tips
Do not use liquid cleaners of any kind or metal tools of any kind when
removing or cleaning the frets. Due to water content in most isopropyl
alcohol products, 99% alcohol or higher is required. Do not use alcohol
with high water content as the water could later cause corrosion.
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.
16. Use tape or a nonabrasive marker or pencil to mark the location of each
fret in relation to the counter balance.
17. Remove the fret mounting hardware and set aside for later reassembly.
18. Remove the frets from the shuttle and set aside for later reassembly.
19. Use the brush to remove any remaining debris from the spring mounting
surface and pole pin areas of the shuttle.
20. Use an alcohol pad to remove any remaining debris from these areas of
the shuttle.
21. Before reinstalling the frets, brush the back side of the tines in the
direction of the tines with the brush provided to remove any debris
clinging to the tines.
39
Page 40
Chapter 2
Cleaning the Shuttle Frame Assembly
22. For a 6600 nonflat product, reinstall the frets in the appropriate locations
using a wood or plastic tool to seat them against the locating pins.
For 6600 flat shuttles use the appropriate alignment tool from Table A to
align the frets in the appropriate location and torque in place using a 14
inch pound driver and #10 Torx bit.
Table 2. Hammer Tip Alignment Tool Kits
Part Number Description
253648-901 Hammer Tip Alignment Field kit 6605
253649-901 Hammer Tip Alignment Field kit 6610
253650-901 Hammer Tip Alignment Field kit 6615
253651-901 Hammer Tip Alignment Field kit 6620
23. Reinstall the hammerbank cover assembly (page 202) insuring that it is
properly seated over the mounting pins.
24. Reinstall the shuttle into the printer using a 25 inch pound driver and
5/32 hex bit.
25. Install the shuttle cover assembly (page 203).
26. Return the printer to normal operation (see page 155).
27. Set the platen gap as appropriate.
28. Run a test print to verify that the print quality is acceptable.
40
Page 41
Cleaning the Card Cage Fan Assembly
183925a
Card Cage Fan
NOTE: A cabinet model is
shown here, but the
procedure is the same for
pedestal models.
1. Cabinet Models: Remove the paper path (page 222).
Pedestal Models: Remove the top cover assembly (page 204).
2. Vacuum the card cage fan assembly and surrounding areas to remove
paper particles, dust, and lint. (
3. Install the ribbon.
4. Cabinet Models: Install the paper path (page 222)
Pedestal Models: Install the top cover assembly (page 204).
5. Return the printer to normal operation (page 155).
Figure 7.)
Cleaning the Interior
Figure 7. Cleaning the Card Cage Fan Assembly
41
Page 42
Chapter 2
Cleaning the Card Cage Fan Assembly
42
Page 43
3
Troubleshooting
Introduction
This chapter lists fault messages and general symptoms, and provides
procedures for troubleshooting printer malfunctions.
NOTE: Because you must operate the printer to check its performance and
sometimes you may have to reconfigure it, always have the User’s
Manual handy when you troubleshoot. This manual does not cover
printer operation or configuration.
T roubleshooting Aids
Troubleshooting is faster and more effective if you understand the equipment
and make use of all available tools.
This manual has a number of troubleshooting aids to help you isolate printer
malfunctions:
•
“Start Here” Logic Tree ............................................................... page 44
•
Troubleshooting Display Messages............................................ page 45
•
Message List............................................................................... page 46
•
Troubleshooting Other Symptoms............................................ page 111
•
General Symptom List .............................................................. page 112
•
Communications Failures ......................................................... page 134
•
Diagnostic Printer Tests............................................................ page 136
•
Boot Diagnostics Menu ............................................................. page 141
•
Factory Menu............................................................................ page 144
•
Exception Menu ........................................................................ page 146
•
Hex Code Printout .................................................................... page 149
•
ASCII Character Set ................................................................. page 151
•
Appendix A: Wire Data ............................................................. page 301
43
Page 44
Chapter 3
Are you here because of an
error message? YES
NO
Go to Troubleshooting Display
Messages, page 45.
Power on the printer and
observe the control panel for
the following sequence of
events (retry as required):
1. All black squares appear on
the display.
2. Display goes blank.
3. The following messages
appear on the display, in this
order:
B00 STATUS: SDRAM
DETECTION 33MHZ
B01 STATUS: 8245
SDRAM TEST 32MB
B51 STATUS: XX%
LOADING
B30: STATUS INITIALIZING...
Power on the printer.
Did steps 1, 2, and 3 occur?
NO
Did the fans come on after
10 seconds?
YES
After about 10
seconds did
the fans come
on?
YES
YES
NO
Did the status
indicator lamp
come on and
ONLINE appear
on the display? (If
default is
OFFLINE, status
indicator will not
come on.)
NO
YES
Printer initialized
successfully.
Other symptoms
are listed in
Table 4 page
112.
Go to Printer
does not
initialize, page
117.
Did ANY of steps 1 thru 3
occur?
NO
Press ONLINE.
Go to Help menu.
Press ENTER.
Does machine
configuration
print?
YES
NO
Go to the Control
Panel section of
Table 4 page 112.
The Control Panel
is not functioning
(Table 4 page 112)
—OR—
Printer does not
initialize, page 117.
Go to No power, and
control panel is blank,
and card cage fan is not
running, page 117.
YES
NO
Are there black
squares on the
control panel?
NO
Go to Printer does not
initialize, page 117.
YES
Go to Black squares
on control panel
display, page 115.
Start Here...
Start Here...
44
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T roubleshooting Display Messages
WARNING
Always disconnect the AC power cord from the printer before doing a
maintenance procedure. Failure to do so 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 with associated options
•
Fault messages
Most fault messages are cleared from the LCD by correcting the fault
condition then pressing the CLEAR key.
Some fault messages can only be cleared by shutting down and restarting the
printer. These fault messages are indicated by an asterisk (*) after the
message.
If printer logic circuits detect 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.
45
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Chapter 3
Troubleshooting Display Messages
List of Messag es
Find the message in the Message List below and follow the suggested
procedure. 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 3. 6600 Error Messages List
Displayed Message Explanation Solution
8.5V POWER FAIL * 8.5 Volt Power Failed.
Internal power failure.
1. Cycle power. If the message
appears, do the power supply
operational check (
the power supply fails the check,
replace it. If it passes the check,
go to the next step.
2. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
3. Power on the printer. If the
message appears, replace the
shuttle frame assembly.
page 187). If
46
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List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
15V CTL FAIL* Controller Voltage Failure. 1. Cycle Power. Run the print job
again. If the message appears,
remove the hammer bank logic
cable, inspect it for damage, and
test it for continuity. (See
Appendix A.) Replace the
hammer bank logic cable if it is
damaged or fails the continuity
test.
2. Cycle Power. Run the print job
again. If the message appears,
download the emulation software
again (
page 169).
3. Cycle power. Run the print job
again. If the message appears,
replace the flash memory.
4. Power on the printer. Run the
print job again. If the message
appears, replace the controller
board. Record the message and
return it with the defective board.
5. Power on the printer. Run the
print job again. If the message
appears, do the power supply
operational check (
page 187). If
the power supply fails the check,
replace it. If it passes the check,
go to the next step.
6. Power on the printer. If the
message appears, replace the
shuttle frame assembly.
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Chapter 3
Displayed Message Explanation Solution
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
23.5V CTL FAIL* 23.5 Volt Controller Failed: a
voltage failure on the
controller board.
48V CIRCUIT*
See User Manual
Either the power supply is
not generating a proper 48
Volts or the controller board
is not detecting a 48 Volt
output from the power
supply board.
1. Cycle Power. Run the print job
again. If the message appears,
download the emulation software
again (
2. Cycle power. Run the print job
again. If the message appears,
replace the flash memory.
3. Power on the printer. Run the
print job again. If the message
appears, replace the controller
board. Record the message and
return it with the defective board.
4. Power on the printer. Run the
print job again. If the message
appears, do the power supply
operational check (
the power supply fails the check,
replace it. If it passes the check,
go to the next step.
5. Power on the printer. If the
message appears, replace the
shuttle frame assembly.
1. Make sure the power supply
board is correctly connected to
the controller board.
2. Power on the printer. If the
message appears, do the power
supply operational check
(page 187). If the power supply
fails the check, replace it. If it
passes the check, go to the next
step.
3. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
page 169).
page 187). If
48
Page 49
List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
48V CHECK* 48 Volt Power Failed: an
internal power failure.
1. 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 controller
board.
2. 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.)
3. Power on the printer. If the
message appears, do the power
supply operational check
(page 187). If the power supply
fails the check, replace it. If it
passes the check, go to the next
step.
4. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
5. Power on the printer. If the
message appears, replace
shuttle frame assembly.
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Chapter 3
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
48V PWR FAIL*
48 Volt Power Failed: an
internal power failure.
1. 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 controller
board.
2. 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.)
3. Power on the printer. If the
message appears, do the power
supply operational check
(page 187). If the power supply
fails the check, replace it. If it
passes the check, go to the next
step.
4. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
5. Power on the printer. If the
message appears, replace
shuttle frame assembly.
A TO D OVERRUN* Analog to Digital Overrun.
The analog-to-digital
converter overflowed.
ACCESS NULL PTR* Access Null Pointer: The
processor tried to access a
pointer that contains nothing
(null).
B00 STATUS: SDRAM
DETECTION 166MHZ
Status message: the printer
has begun its boot-up
routines and is checking for
the presence of SDRAM.
50
Cycle power. Run the print job again.
If the message appears, replace the
controller board. Record the message
and return it with the defective board.
1. Cycle power. Run the print job
again. If the message appears,
download the emulation software
again (
page 169).
2. Cycle power. Run the print job
again. If the message appears,
replace the controller board.
Record the message and return it
with the defective board.
No action required.
Page 51
List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
B01 STATUS: 8245
SDRAM TEST 32MB
B02 STATUS:
SDRAM PASSED
B10 ERROR:
NO DRAM
DETECTED*
B11 ERROR:
RAM TEST FAILED*
Status message: printer
boot-up routines are testing
SDRAM.
Status message informing
the operator that the printer
finished testing SDRAM.
Boot-up routines did not
detect the presence of the
SDRAM DIMM.
SDRAM failed the boot
initialization test.
No action required.
No action required.
1. Cycle power. If the message
appears again, power down and
check that there is an SDRAM
DIMM installed on the controller
board. If not, install the SDRAM.
If so, reseat the SDRAM DIMM.
2. Power up the printer. If the
message appears, replace the
SDRAM DIMM.
3. Power up the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
1. Cycle power. If the message
appears again, reseat the
SDRAM DIMM.
B12 ERROR:
PROGRAM MISSING*
B13 ERROR:
NOT COMPATIBLE*
B19 ERROR:
DC RETURNED*
The printer does not see a
program in flash memory.
The printer is not compatible
with the downloaded
program.
This message indicates an
incorrectly assembled and
tested machine.
2. Power up the printer. If the
message appears, replace the
SDRAM DIMM.
3. Power up the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
There is no program in printer
memory. Download an emulation.
Load the correct emulation software
option(s) for this printer.
Cycle power. If the message appears
again contact the printer
manufacturer and report this
message.
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Chapter 3
Displayed Message Explanation Solution
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
B20 STATUS: 00%
DOWNLOAD MODE
B21 STATUS:
PRINTER RESET
B22 ERROR:
DECOMPRESS SIZE*
Status message informing
the operator that software is
being downloaded through
the printer’s parallel port
using the three-key
download activation
(page 173). The percentage
indicates the approximate
amount loaded into the
printer.
Status message informing
the operator that the printer
is undergoing a system
reset.
Flash memory has not
passed boot initialization
tests.
No action required.
No action required.
1. Cycle power. If the message
appears again, reseat the flash
SIMM.
2. Power on the printer. If the
message appears, replace the
flash SIMM.
3. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
B23 ERROR:
DECOMPRESS
CKSUM*
B30 STATUS:
INITIALIZING...
52
Flash memory has not
passed boot initialization
tests.
Status message: the printer
is running its initialization
routines after startup and
successful memory tests.
1. Cycle power. If the message
appears again, reseat the flash
SIMM.
2. Power on the printer. If the
message appears, replace the
flash SIMM.
3. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
No action required.
Page 53
List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
B35 STATUS:
WAITING FOR EC
STATUS
B40 ERROR: SDRAM
EEPROM CKSUM
BAD*
B41 ERROR: DIMM
MEMORY NOT
SDRAM*
Status message: the DC on
the controller board is
waiting for communication
with the EC. If this message
does not clear within a few
seconds there is an
electrical or electronic
problem on the controller
board.
Flash memory has not
passed boot initialization
tests.
The DRAM DIMM installed
on the controller board is not
Synchronous DRAM
(SDRAM).
Cycle power. If the message appears
again, replace the controller board.
Record the message and return it
with the defective board.
1. Cycle power. If the message
appears again, reseat the flash
SIMM.
2. Power on the printer. If the
message appears, replace the
flash SIMM.
3. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
1. Cycle power. If the message
appears again, reseat the
SDRAM DIMM.
2. Power on the printer. If the
message appears, install a new
SDRAM DIMM of the correct type
and size.
B42 ERROR: SDRAM
ROWS NOT
ALLOWED*
Printer boot initialization
tests detect incorrect
SDRAM.
3. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
1. Cycle power. If the message
appears again, reseat the
SDRAM DIMM.
2. Power on the printer. If the
message appears, install a new
SDRAM DIMM of the correct type
and size.
3. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
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Chapter 3
Displayed Message Explanation Solution
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
B43 ERROR: SDRAM
TOO MANY BANKS*
B44 ERROR: SDRAM
NOT 64 BITS WIDE*
Printer boot initialization
tests detect incorrect
SDRAM.
Printer boot initialization
tests detect incorrect
SDRAM.
1. Cycle power. If the message
appears again, reseat the
SDRAM DIMM.
2. Power on the printer. If the
message appears, install a new
SDRAM DIMM of the correct type
and size.
3. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
1. Cycle power. If the message
appears again, reseat the
SDRAM DIMM.
2. Power on the printer. If the
message appears, install a new
SDRAM DIMM of the correct type
and size.
3. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
B45 ERROR: SDRAM
IS WRONG
VOLTAGE*
Printer boot initialization
tests detect incorrect
SDRAM.
1. Cycle power. If the message
appears again, reseat the
SDRAM DIMM.
2. Power on the printer. If the
message appears, install a new
SDRAM DIMM of the correct type
and size.
3. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
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List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
B46 ERROR: SDRAM
HAS MIXED SIZES*
B47 ERROR: SDRAM
LARGER THAN 256M*
Printer boot initialization
tests detect incorrect
SDRAM.
Printer boot initialization
tests detect incorrect
SDRAM.
1. Cycle power. If the message
appears again, reseat the
SDRAM DIMM.
2. Power on the printer. If the
message appears, install a new
SDRAM DIMM of the correct type
and size.
3. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
1. Cycle power. If the message
appears again, reseat the
SDRAM DIMM.
2. Power on the printer. If the
message appears, install a new
SDRAM DIMM of the correct type
and size.
3. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
B49 ERROR: SDRAM
# LOGICAL BANKS*
Printer boot initialization
tests detect incorrect
SDRAM.
1. Cycle power. If the message
appears again, reseat the
SDRAM DIMM.
2. Power on the printer. If the
message appears, install a new
SDRAM DIMM of the correct type
and size.
3. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
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Chapter 3
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
B50 ERROR: SDRAM
LOGIC COMB
BANKS*
B51 STATUS: XX%
LOADING
B52 ERROR:
I2C DID NOT
COMPLETE
Printer boot initialization
tests detect incorrect
SDRAM.
Status message: printer
boot-up routines are loading
printer system software into
flash memory and SDRAM.
There is a problem on the
I2C bus which allows the
SDRAM DIMM to
communicate with the GPIO.
1. Cycle power. If the message
appears again, reseat the
SDRAM DIMM.
2. Power on the printer. If the
message appears, install a new
SDRAM DIMM of the correct type
and size.
3. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
No action required.
1. Cycle power. If the message
appears again, replace the GPIO,
in installed.
2. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
B53 ERROR: I2C NO
ARBITRATION
There is a problem on the
I2C bus which allows the
SDRAM DIMM to
communicate with the GPIO.
1. Cycle power. If the message
appears again, replace the GPIO,
in installed.
2. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
56
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List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
B54 ERROR: SDA
LINE STUCK LOW
BAD VFU CHANNEL
BC SENSOR ERR
See User Manual
The SDRAM or a PCI card is
shorting out the serial data
bus on the controller board.
Bad vertical forms unit
channel given in host file.
The printer does not detect
the presence of the ribbon
cartridge sensor.
NOTE: On a cartridge
printer this will
display if the
security key is from
a spool printer.
1. Cycle power. If the message
appears again, reseat the
SDRAM DIMM.
2. Power on the printer. If the
message appears, install a new
SDRAM DIMM of the correct type
and size.
3. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
Correct host file.
Replace the security key with a CRP
security key.
BUFFER OVERRUN The print buffer has
overflowed on a serial
interface. The printed output
may contain random *
(asterisk) characters. Make
a configuration printout.
CRTG COMM ERR
See User Manual
The hardware cannot
communicate properly with
the cartridge.
1. 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 134.
1. Make sure the ribbon cartridge is
seated properly.
2.
Remove and replace the ribbon
cartridge if necessary.
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Chapter 3
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
CRTG INCOMPAT
Use correct RBN
CRTG MISMATCH
Use correct RBN
CRTG MISSING
Install new RBN
The cartridge board being
used is not compatible with
the software in the printer.
The cartridge board being
used is not compatible with
the software in the printer.
The ribbon cartridge is
missing or installed
improperly.
1. Press the CLEAR key, open the
platen, or cycle power to change
and clear the error.
2. If necessary, replace the ribbon
with an authorized cartridge that
matches the printer’s firmware
level.
1. Press the CLEAR key, open the
platen, or cycle power to change
and clear the error.
2. If necessary, replace the ribbon
with an authorized cartridge that
matches the printer’s firmware
level.
1. Make sure a ribbon cartridge is
installed in the printer.
2.
Make sure the ribbon cartridge is
seated properly.
3.
Remove and replace the cartridge if
necessary.
4.
Check the cable connection from the
cartridge interface board to the
controller.
5.
Replace the cartridge interface board
if necessary.
CRTG NOT SETx
Re-install RBN
58
The ribbon cartridge is not
properly positioned.
1. Make sure a ribbon cartridge is
installed in the printer.
2.
Make sure the ribbon cartridge is
seated properly.
3.
Remove and replace the cartridge if
necessary.
Page 59
List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
CLEAR PAPER JAM Paper jam. 1. Inspect the paper path for jams.
Clear jams. Load paper.
2. Press FF 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
128. 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 130.
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. Check the dynamic paper
tension.
7. Inspect the ribbon mask for
bends or deformation. Replace if
damaged.
8. Check and adjust the platen open
belt. Replace the belt if it is
damaged.
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Chapter 3
Displayed Message Explanation Solution
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
CLEAR PAPER JAM
(continued)
9. Inspect the tractors and tractor
door springs for damage,
excessive wear, and equal door
closing tension. If either tractor is
worn, damaged, or exhibits
uneven door closing tension,
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 and adjust the platen gap.
12. Clean the paper motion detector
with a cotton swab and alcohol.
At the control panel, set the paper
motion detector (PMD) fault
setting to DISABLE. Load paper.
Run a print test and observe how
the paper feeds. If the message
appears, replace the controller
board. Record the message and
return it with the defective board.
If the message does not appear,
replace the paper detector switch
assembly and set the paper
motion detector (PMD) to
ENABLE.
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Page 61
List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
CLOSE PLATEN The forms thickness lever is
open.
1. 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 controller board. Check
continuity of the platen interlock
switch from P107/PLO to the
switch. Replace the switch
assembly if it fails the continuity
test. (Refer to Appendix A, Switch
Assembly, Platen Interlock.)
3. With the forms thickness lever
closed (position A), hold a 0.011
inch (0.028 cm) feeler gauge
between the switch and the body
of the forms thickness lever,
gently press down on the switch,
and tighten the two screws.
4. Check and adjust the platen open
belt. Replace the belt if it is
damaged.
5. Disconnect connector P106 from
the controller board. Check the
resistance of connector P106/
PLAT M. (See the Main Wire
Harness Test Tables in Appendix
A.) Replace the platen open
motor if it fails the resistance test.
6. Run a print test. If the message
appears, replace the controller
board. Record the message and
return it with the defective board.
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Chapter 3
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
CTL VOLT FAIL* Controller Voltage Failure.
15 V failure on the controller
board.
D50 Status %XX
Clearing Flash
Status message: The printer
is clearing its flash memory,
where %XX represents the
percentage completed.
1. Cycle Power. Run the print job
again. If the message appears,
download the emulation software
again (
page 169).
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 controller
board. Record the message and
return it with the defective board.
4. Power on the printer. Run the
print job again. If the message
appears, do the power supply
operational check (
page 187). If
the power supply fails the check,
replace it. If it passes the check,
go to the next step.
5. Power on the printer. If the
message appears, replace the
shuttle frame assembly.
No action required.
D51 Status %XX
Programming...
D55 Status: Send
Program to EC
DIAGNOSTIC
PASSED
DO NOT POWER OFF
62
Status message: The printer
is loading firmware, where
%XX represents the
percentage completed.
Status message: The printer
is loading the engine
controller program into the
engine controller (EC).
Status message: the printer
passed its memory and
hardware initialization tests.
Status message: the printer
is performing an operation
that must be completed
before you can cycle power.
No action required.
No action required.
No action required.
No action required, but do not power
the printer off until the operation is
completed.
Page 63
List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
DP FIFO Busy* There is a timing problem in
the Engine Controller
firmware.
DRVR CIR BAD* Driver Circuit Bad: the
hammer coil count test
failed.
1. Cycle Power. Run the print job
again. If the message appears,
download the emulation software
again (
page 169).
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 controller
board. Record the message and
return it with the defective board.
1. 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 controller
board.
E00 EXE @ ADDR0
See User Manual
E01A TYPE 0x40
See User Manual
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
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Chapter 3
Displayed Message Explanation Solution
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
E01B TYPE 0x60
See User Manual
E02 MACHINE CHK
See User Manual
E03A DSI HASH L
See User Manual
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
E03B DSI HASH S
See User Manual
64
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
Page 65
List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
E03C DSI BAT PL
See User Manual
E03D DSI BAT PS
See User Manual
E03E DSI CXIWX
See User Manual
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
E03F DSI CXOWX
See User Manual
An illegal or unsupported
instruction was attempted in
the application programn.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
65
Page 66
Chapter 3
Displayed Message Explanation Solution
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
E03G DSI ECXIWX
See User Manual
E03H DSI ECXOWX
See User Manual
E04A ISI NO TRA
See User Manual
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
E04B ISI DIRECT
See User Manual
66
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
Page 67
List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
E04C ISI PROTEC
See User Manual
E06 NOT ALIGNED
See User Manual
E07 ILLEGAL INS
See User Manual
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
E08 FLOATINGPNT
See User Manual
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
67
Page 68
Chapter 3
Displayed Message Explanation Solution
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
E12 SYSTEM CALL
See User Manual
E13 TRACE INT
See User Manual
E16 ITRANS MISS
See User Manual
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
E17 DLOAD MISS
See User Manual
68
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
Page 69
List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
E18 DSTORE MISS
See User Manual
E19 BREAKPOINT
See User Manual
E20 SYS MANAGE
See User Manual
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
E30 DEBUGGER
See User Manual
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
69
Page 70
Chapter 3
Displayed Message Explanation Solution
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
E31A EVENT O BP
See User Manual
E31B EVENT 1 BP
See User Manual
E31C EVENT 2 BP
See User Manual
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
E31D EVENT 3 BP
See User Manual
70
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
Page 71
List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
E31E EVENT 4 BP
See User Manual
E31F EVENT 5 BP
See User Manual
E31G EVENT 6 BP
See User Manual
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
E31H EVENT 7 BP
See User Manual
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
71
Page 72
Chapter 3
Displayed Message Explanation Solution
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
E32A CND 0 BP
See User Manual
E32B CND 1 BP
See User Manual
E32C CND 2 BP
See User Manual
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
E32D CND 3 BP
See User Manual
72
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
Page 73
List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
E32E CND 4 BP
See User Manual
E32F CND 5 BP
See User Manual
E32G CND 6 BP
See User Manual
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
E32H CND 7 BP
See User Manual
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
73
Page 74
Chapter 3
Displayed Message Explanation Solution
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
E33 WRITE BP
See User Manual
E34 TRACE CMPLT
See User Manual
E99 UNKNOWN INT
See User Manual
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
An illegal or unsupported
instruction was attempted in
the application program.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
1. Cycle Power. Run the print job. If
the message appears again,
access the exception menu and
record the displayed messages
(
page 146).
2. Power off the printer. Provide this
fault message and the messages
you recorded from the exception
menu to your next higher support
facility.
E Net Test Unavailable The ethernet PCBA did not
initialize correctly.
ERROR OCCURRED
FLUSHING QUEUES *
74
An interim message that
displays while the printer
discards host data it cannot
use because a fault
condition exists. While this
message displays, the
asterisk (*) rotates.
Cycle power. Wait for “E Net Ready”
to display, then retry operation. If it
still fails, replace the ethernet PCBA.
Wait. When the asterisk (*) stops
rotating, a different fault message will
appear: troubleshoot the final
message.
Page 75
List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
ERROR: CPLD NOT
PROGRAMMED
ERROR: DC
PROGRAM
NOT VALID
ERROR: DRAM AT
ADDRESS
XXXXXXXX
ERROR: EC
PROGRAM
NOT VALID
The Complex Programmable
Logic Device (CPLD) on the
controller board is not
programmed. The EC
cannot read the version bits
in the CPLD which tell the
EC which configuration
version is installed.
The printer cannot find the
data controller program or
the validation checksum is
corrupt.
The printer found a defective
memory location.
The printer cannot find the
engine controller program or
the validation checksum is
corrupt.
Cycle power. If the message appears
again, replace the controller board.
Record the message and return it
with the defective board.
1. Download the program again
(
page 169).
2. If the message appears, replace
the flash memory SIMM.
1. Replace the DRAM DIMM.
2. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
1. Download the program again
(
page 169). If the message
occurs again, replace all flash
memory SIMMs.
2. Power on the printer. Download
the emulation. If the message
appears, replace the controller
board. Record the message and
return it with the defective board.
75
Page 76
Chapter 3
Displayed Message Explanation Solution
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
ERROR: EC
STOPPED
AT STATE XXXX
Where XXXX is a number
from 0000 to 0010. The
Engine Controller has
stopped and is in the state
identified by the number
displayed. If the EC stops at
state 0000 at power-up,
replace the controller board.
Record the message and
return it with the defective
board.
1. Power off the printer. Remove the
flash memory SIMM and SDRAM
DIMM. Inspect the SIMM and
DIMM sockets on the controller
board. If any socket pins are bent
or damaged, replace the
controller board.
2. Install the flash SIMM and
SDRAM DIMM, making sure they
are fully and correctly seated.
Power on the printer. Download
the emulation (
message appears, replace the
flash SIMM.
3. Power on the printer. Download
the emulation. If the message
appears, replace the SDRAM
DIMM.
4. Power on the printer. Download
the emulation. If the message
appears, replace the controller
board. Record the message and
return it with the defective board.
page 169). If the
ERROR: FLASH
DID NOT PROGRAM
ERROR: FLASH
NOT DETECTED
The printer encountered an
error trying to program flash
memory.
The printer could not find
flash memory.
Download the program again
(page 169). If the message occurs
again, replace the flash memory.
Check flash memory on the controller
board. If present, reseat the flash
SIMM; if missing, install flash SIMM.
76
Page 77
List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
ERROR: LOCKED
SN=
nnnnnnnnnnnnnnnn
ERROR: NO DRAM
DETECTED
Where nnnnnnnnnnnnnnnn
is the serial number of the
printer’s security key. The
SPX gets “locked” to the
printer as the first part of the
security key reprogramming
process. The “lock” consists
of copying the printer’s
security key serial number
into the flash memory of the
SPX, which prevents the
SPX from being used on
other printers. It also
enables the customer to
retry upgrading the same
printer if the SPX was
removed before
reprogramming is complete.
The printer could not find
any DRAM.
1. Remove the SPX from the Debug
Port.
2. Cycle printer power.
1. Check SDRAM on the controller
board. If present, reseat SDRAM
DIMM; if missing, install SDRAM.
2. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
ERROR: NVRAM
FAILURE
ERROR: PROGRAM
NEEDS MORE DRAM
ERROR: PROGRAM
NEEDS MORE FLASH
ERROR: PROGRAM
NOT COMPATIBLE
ERROR: PROGRAM
NOT VALID
The non-volatile SRAM on
the controller board has
failed.
The printer requires more
DRAM in order to run the
downloaded program.
The printer requires more
flash memory in order to run
the downloaded program.
The printer is not compatible
with the downloaded
program.
The printer does not see a
program in flash memory.
Replace the controller board. (Do
NOT attempt to replace NVRAM.)
Record the message and return it
with the controller board.
Add DRAM or use a smaller
emulation program.
Add flash memory or use a smaller
emulation program.
Use the correct emulation software
option(s) for this model printer.
There is no program in printer
memory. Download the emulation.
77
Page 78
Chapter 3
Displayed Message Explanation Solution
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
ERROR: SECURITY
KEY NOT DETECTED
ERROR: SHORT AT
ADDRESS XXXX
ERROR: WRITING
TO FLASH
ERROR: WRONG
CHECKSUM
The security key is not
present or has failed.
Hardware failure in SDRAM
or controller circuitry.
Hardware or software fault in
flash memory.
The printer received the
complete program but the
checksum did not match.
The data may have been
corrupted during download.
1. Check the security key at
connector J9 on the controller
board. If the key is absent, install
the correct key. If a security key is
present, replace it.
2. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
1. Download the program again.
2. If the message occurs again,
replace the controller board.
Record the message and return it
with the defective board.
1. Replace flash memory.
2. If message occurs with new
memory, replace the controller
board. Record the message and
return it with the defective board.
1. Power off the printer. Download
the program again from the
beginning. If the message
appears, replace the DRAM.
2. Download the program using a
new software diskette. If the
message appears, replace the
flash memory.
3. Download the program. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
ERROR: WRONG
OEM OR PRINTER
TYPE
ERROR: xxxx User defined fault using
Ethernet Adapter
Being Initialized
78
The SPX inserted in the
debug port is not intended
for this OEM.
PNE.
Status message indicating
that the ethernet interface is
running its boot-up
procedure.
1. Remove the SPX from the Debug
Port.
2. Cycle printer power.
User defined.
No action required.
Page 79
List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
ETHERNET
DETECTED
ETHERNET
INITIALIZING
EXCESS RIBBON WEAR
Install New RBN
Status message indicating
that the PrintNet ethernet
interface has established
communication.
Status message that
indicates that the internal
Network Interface Card is
processing the boot
procedure. (May occur with
older versions of
microcode.)
Status message that
displays when ribbon
reaches the end of its
service life, whether the
Integrated Print
Management System is
enabled or not.
No action required.
No action required.
Install a new ribbon.
79
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Chapter 3
Displayed Message Explanation Solution
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
EXHAUST FAN FLT Exhaust Fan Fault. Sensors
cannot detect current in the
fan circuit.
NOTE: For cabinet models
only.
1. 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 controller board.
Test connector P107/EHF for
shorts or opens. (See 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 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 does not work,
replace the exhaust fan.
7. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
80
Page 81
List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
FIRMWARE ERROR Application software tried to
perform an illegal printer
function or damaged
memory is detected on the
controller board. If the
message appears at powerup, replace the controller
board. Record the message
and return it with the
defective board.
FRAMING ERROR The printed output may
contain random !
(exclamation point)
characters.
1. Cycle power. Run the print job. If
the message appears, download
the emulation software again
(
page 169).
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 controller board.
Record the message and return it
with the defective 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.
1. Make a configuration printout. Set
printer serial interface parameters
to match host configuration
settings for Data Protocol, Baud
Rate, Data Bits, Stop Bits, Parity,
Data Terminal Ready, and
Request to Send.
2. Send a print job to the printer. If
the message appears, go to
Communications Failures,
page 134.
H00: PCI SLOT ?
See User Manual
The controller board is not
communicating with a PCI
card. This could indicate a
bad PCI card, poor
connection, or problem in
the PCI bus.
1. Cycle power. If the message
appears, power down and reseat
the PCI card.
2. Power on the printer. If the
message appears, move the PCI
card to the other PCI slot.
3. Power on the printer. If the
message appears, replace the
PCI card.
4. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
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Troubleshooting Display Messages
Table 3. 6600 Error Messages List
H01: PCI J12
See User Manual
H02: PCI J13
See User Manual
The controller board is not
communicating with the PCI
card in PCI slot J12. This
could indicate a bad PCI
card, poor connection, or
problem in the PCI bus.
The controller board is not
communicating with the PCI
card in PCI slot J13. This
could indicate a bad PCI
card, poor connection, or
problem in the PCI bus.
1. Cycle power. If the message
appears, power down and reseat
the PCI card.
2. Power on the printer. If the
message appears, move the PCI
card to PCI slot J13.
3. Power on the printer. If the
message appears, replace the
PCI card.
4. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
1. Cycle power. If the message
appears, power down and reseat
the PCI card.
2. Power on the printer. If the
message appears, move the PCI
card to PCI slot J12.
3. Power on the printer. If the
message appears, replace the
PCI card.
4. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
82
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List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
<Online, etc. ... .>
Half Speed Mode
This is a status message,
not an operational state. The
controller samples the
operating temperature of key
components of the print
mechanism. When higher
than normal temperatures
are sensed, the print speed
is automatically reduced by
50% and the message sent
to the LCD. When the
components cool down, the
print speed returns to 100%
and the message clears.
Periodic appearance of this
message is normal for
extremely dense print jobs,
such as “All Black” plot. If
this message often appears,
the printer may be operating
in a severe environment. A
severe environment has an
ambient temperature at or
above 40° Celsius (104°
Fahrenheit) or is dirty
enough to clog air vents. The
printer must never be run at
ambient temperatures
greater than 40° Celsius
(104° Fahrenheit). Inspect
the printer environment for
severity, and if the printer is
located in such an
environment relocate it to a
cooler, cleaner area.
1. 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.
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 controller
board. Record the message and
return it with the defective board.
8. If the printer is a 6620 or 6620Q,
set the coil temperature (
page
178).
HAM. COIL OPEN* Hammer Coil Open.
Electrical malfunction of one
or more hammer coils.
1. Cycle power. If the message
appears, replace the shuttle
frame assembly.
2. Power on the printer. Run a print
test. If the message appears,
replace the controller board.
Record the message and return it
with the defective board.
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Displayed Message Explanation Solution
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
HAMMER COIL BAD
#, #, #, #, ... etc.
HAMMER SHORT *
See User Manual
HB NOT INSTALLD* Hammer Bank Not Installed.
Hammer coil(s) number #, #,
etc. failed the current test at
power-up. Check that the
hammer bank cables are
connected.
Electrical malfunction of one
or more hammer coils.
Self-test routines do not
detect hammer coils at
printer start-up. Power off
the printer. Verify that the
shuttle frame assembly is
installed.
1. 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
controller board. Record the
message and return it with the
defective assembly.
1. Cycle power. If the message
appears, replace the shuttle
frame assembly.
2. Power on the printer. Run a print
test. If the message appears,
replace the controller board.
Record the message and return it
with the defective board.
1. 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 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
controller board. Record the
message and return it with the
defective board.
84
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List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
HMR BANK FAN FLT Hammer Bank Fan Fault.
Sensors cannot detect
current in the fan circuit.
1. 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 controller board. Test
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
controller board.
4. Inspect for obstructions of
airways and vents. Remove
obstructions.
5. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
ILL EXT BUS ACC* Illegal External Bus Access.
Firmware error on the
controller board.
ILL INST ACCSS* Illegal Instruction Accessed.
Firmware error on the
controller board.
1. Cycle power. Run the print job
again. If the message appears,
download the emulation software
again (
page 169).
2. Cycle power. Run the print job
again. If the message appears,
replace the controller board.
Record the message and return it
with the defective board.
1. Cycle power. Run the print job
again. If the message appears,
download the emulation software
again (
page 169).
2. Cycle power. Run the print job
again. If the message appears,
replace the controller board.
Record the message and return it
with the defective board.
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Displayed Message Explanation Solution
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
ILLGL OPR ACCSS* Illegal Operand Accessed.
Firmware error on the
controller board.
INCOMPAT E-NET
Remove NIC
INCOMPAT WLAN
Remove NIC
INTAKE FAN FAULT Sensors cannot detect
The ethernet NIC for a
thermal printer has been
installed in this printer.
The wireless NIC for a
thermal printer has been
installed in this printer.
current in the card cage fan
circuit.
1. Cycle power. Run the print job
again. If the message appears,
download the emulation software
again (
2. Cycle power. Run the print job
again. If the message appears,
replace the controller board.
Record the message and return it
with the defective board.
Remove the installed NIC and
replace it with the correct card for this
printer.
Remove the installed NIC and
replace it with the correct NIC for this
printer.
1. Cycle power. If the message
appears, press CLEAR. If the
message does not clear, go to
step
2. Power off the printer. Remove the
paper path or pedestal top cover.
Disconnect connector P106 from
the 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
controller board.
4. Inspect for obstructions of
airways and vents. Remove
obstructions.
5. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
page 169).
2.
86
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List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
INTERRUPT UNUSED
VECTOR 00
This message is generated
when the controller board
gets an interrupt it does not
understand. The problem
can be created by electrical
noise, by a software
problem, or by a hardware
problem.
LO DRV. SHORT* Lower Driver Short.
Circuit(s) on the hammer
bank or in the hammer bank
power cable are shorted to
ground.
1. Cycle power. If this message
occurred once and never again,
you can ignore it. If the message
reappears or appears
consistently check the grounding
of the printer. If the machine is
correctly grounded, replace the
controller board.
2. Power on the printer. Cycle
power. If the message appears,
suspect an application software
error. Request assistance from
your local support group. Install
the original controller board.
1. 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
controller board. Record the
message and return it with the
defective board.
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Displayed Message Explanation Solution
LOAD PAPER The printer is out of paper. 1. Load paper. Press CLEAR. If
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
message does not clear, go to
the next step.
2. Check for black or colored
backing on the paper being used
in printer. The paper out detector
is optical and may not detect
paper with a black or dark
backing facing the detector. Try
paper with a white or light back. If
paper with white/light back works
and black/dark paper does not,
replace the paper detector switch
with the optional black back forms
switch assembly.
(See page 242.)
3. 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.
4. Check that connector P106/PMD
is fully seated in connector J106
on the controller board.
5. Load paper. Power on the printer.
Replace the paper detector
switch assembly if message
appears.
6. Load paper. Power on the printer.
Replace the controller board if
message appears. Record the
message and return it with the
defective board.
LOADING PROGRAM
FROM PORT XX%
88
Status message: the new
emulation program is
loading into printer RAM.
XX% indicates how much of
the program has loaded.
No action required.
Page 89
List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
LOADING PROGRAM
INTO FLASH
NEW SPX DETECTED
PRESS ENTER
NON VOLATILE
MEMORY FAILED
The printer has deleted the
previous program from flash
memory and is loading the
new program into flash
memory.
The printer detects an SPX
in its debug port and the
SPX is valid for this printer.
Large emulations reduce the
amount of space available
for saving configurations,
which means that
sometimes fewer than 8
configurations can be saved.
If this message appears
when saving a configuration,
it means the printer is out of
memory. Previously saved
configurations will still be
available, but the one that
was “saved” when the
message appeared is not in
memory. If this message
appears at power-up, it
means the flash memory is
defective.
No action required.
Press the ENTER key. The following
actions occur:
1. The SPX copies the printer’s
security key serial number into its
flash memory.
2. The printer reprograms its
security key with the information
stored in the SPX.
3. The printer verifies that the key
was programmed as intended.
4. The SPX overwrites itself so that
it cannot be used again.
1. If the message appears at powerup, replace the flash memory.
2. If the message appears while
saving a configuration, the printer
is out of memory and will not save
that or subsequent
configurations. (Previously saved
configurations are still okay.)
3. If the message appears after
replacing/increasing memory,
replace the controller board. (Do
NOT attempt to replace NVRAM.)
NOVRAM ERROR n Processor Halted message.
This error is most likely
associated with the V6 PSA3
Logic card. Follow the
corrective action steps to
resolve it.
Replace the controller board. (Do
NOT attempt to replace NVRAM.)
Record the message and return it
with the controller board.
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Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
OLD RIBBON
Install New RBN
The sensor detects a ribbon
that was previously declared
to be at the end of its service
life.
PAP BSY TOO LNG* Paper Busy Too Long.
Firmware error on the
controller board.
Install a new ribbon.
1. Cycle power. Run the print job
again. If the message appears,
download the emulation software
again (
page 169).
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 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 controller
board. Record the message and
return it with the defective board.
PAP FD DRVR CIR*
See Manual
Paper Feed Driver Circuit.
The paper feed driver circuit
on the controller board is
drawing too much current.
90
1. Cycle power. If the message
appears, replace the controller
board. Record the message and
return it with the defective board.
2. Power on the printer. If the
message appears, replace the
paper feed motor.
Page 91
List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
PAP FIFO OVERFL* Paper First In First Out
Overflow. Firmware error on
the controller board.
1. Cycle power. Run the print job
again. If the message appears,
download the emulation software
again.
2. Power on the printer. Run the
print job again. If the message
appears, replace the controller
board. Record the message and
return it with the defective board.
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Chapter 3
Displayed Message Explanation Solution
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
PAP FIFO UNDRFL* Paper First In First Out
Underflow. Firmware error
on the controller board.
1. Cycle power. Run the print job
again. If the message appears,
download the emulation software
again.
2. Run the print job again. If the
message appears, power off the
printer. Remove the paper path or
pedestal top cover. Make sure
connectors P106 and P107 are
fully seated on the 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. 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, do the power supply
operational check (
the power supply fails the check,
replace it. If it passes the check,
go to the next step.
6. Power on the printer. Run the
print job again. If the message
appears, replace the controller
board. Record the message and
return it with the defective board.
page 187). If
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List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
PAP ILLGL ST* Paper Illegal State. Firmware
error on the controller board.
PAP INCMPL ENER* Paper Incompletely
Energized. Firmware error
on the controller board.
PAP INVLD CMD* Paper Invalid Command.
Firmware error on the
controller board.
1. Cycle power. Run the print job
again. If the message appears,
download the emulation software
again.
2. Cycle power. Run the print job
again. If the message appears,
replace the controller board.
Record the message and return it
with the defective board.
1. Cycle power. Run the print job
again. If the message appears,
download the emulation software
again.
2. Cycle power. Run the print job
again. If the message appears,
replace the controller board.
Record the message and return it
with the defective board.
1. Cycle power. Run the print job
again. If the message appears,
download the emulation software
again.
2. Cycle power. Run the print job
again. If the message appears,
replace the controller board.
Record the message and return it
with the defective board.
PAP INVLD PARM* Paper Invalid Parameter.
Firmware error on the
controller board.
1. Cycle power. Run the print job
again. If the message appears,
download the emulation software
again.
2. Cycle power. Run the print job
again. If the message appears,
replace the controller board.
Record the message and return it
with the defective board.
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Chapter 3
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Troubleshooting Display Messages
Table 3. 6600 Error Messages List
PAP NOT SCHED* Paper Not Scheduled. The
paper feed process is not
scheduling on the controller
board, and the printer cannot
feed paper.
1. Cycle power. Run the print job
again. If the message appears,
download the emulation software
again.
2. Cycle power. Run the print job
again. If the message appears,
replace the MPU cable assembly.
3. Power on the printer. Run the
print job again. If the message
appears, do the power supply
operational check (
the power supply fails the check,
replace it. If it passes the check,
go to the next step.
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 controller
board. Record the message and
return it with the defective board.
page 187). If
PAP NT AT SPEED* Paper Not At Speed.
Firmware error on the
controller board.
PAP UNEXP INT* Paper Unexpected Interrupt.
Firmware error on the
controller board.
1. Cycle power. Run the print job
again. If the message appears,
download the emulation software
again.
2. Cycle power. Run the print job
again. If the message appears,
replace the controller board.
Record the message and return it
with the defective board.
1. Cycle power. Run the print job
again. If the message appears,
download the emulation software
again.
2. Cycle power. Run the print job
again. If the message appears,
replace the controller board.
Record the message and return it
with the defective board.
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List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
PARITY ERROR The printed output may
contain random ? (question
mark) characters. Make a
configuration printout.
PLAT INV CMD* Platen Invalid Command.
Firmware error on the
controller board.
1. 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.
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 134.
4. Inspect the customer’s cable
hook-ups. Connect all
communications cables correctly.
1. Cycle power. Run the print job
again. If the message appears,
download the emulation software
again.
2. Cycle power. Run the print job
again. If the message appears,
replace the controller board.
Record the message and return it
with the defective board.
PLAT INV PARM* Platen Invalid Parameter.
Firmware error on the
controller board.
PLAT INV STATE* Platen Invalid State.
Firmware error on the
controller board.
1. Cycle power. Run the print job
again. If the message appears,
download the emulation software
again.
2. Cycle power. Run the print job
again. If the message appears,
replace the controller board.
Record the message and return it
with the defective board.
1. Cycle power. Run the print job
again. If the message appears,
download the emulation software
again.
2. Cycle power. Run the print job
again. If the message appears,
replace the controller board.
Record the message and return it
with the defective board.
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Displayed Message Explanation Solution
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
PLEASE WAIT...
RESET IN
PROGRESS
POWER SAVER
MODE
POWER SUPPLY HOT The printer has sensor
Status message: the printer
finished loading the program
into flash memory and is
automatically resetting itself.
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.
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.
No action required.
No action required. (To revive the
printer from power saver mode press
the FF key.)
1. Inspect printer environment for
severity. Advise the user to move
the printer to cooler, cleaner
location.
2. Check the kinds of print jobs the
user is running: look for very
dense graphics and layouts.
Advise the user to run jobs in
smaller batches.
3. Power off the printer. Remove the
paper path or pedestal top cover.
Check that the plastic power
supply guard/air deflector is
correctly positioned over the
power supply board.
DO NOT TOUCH THE POWER
SUPPLY, but hold your hand
close enough to check for heat
radiating off the power supply
board. If the power supply is
noticeably hot, let it cool down,
then replace it.
4. Check that all fan cables are
connected.
5. Inspect vents and fan airways for
obstructions. Look underneath
cabinet models for items blocking
the cabinet exhaust vents.
6. Install paper 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 controller
board. Record the message and
return it with the defective board.
WARNING:
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List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
PRINTER HOT This message indicates
internal temperatures over
60° Celsius (140°
Fahrenheit). Print jobs will
not create such
temperatures, so
immediately determine that
the fans are operating and
that all air vents are
unobstructed. It is crucial
that the exhaust vents on the
floor of the cabinet remain
unblocked, since hot air from
inside the printer is vented
through the cabinet floor.
Nothing must be stored
under the printer. Then
check the operating
environment. A severe
environment is one with an
ambient temperature at or
above 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. Controller board sensors report
high temperatures on the board.
Inspect printer environment for
severity. Advise the user to move
the printer to cooler, cleaner
location.
2. Power off the printer. Remove the
paper path or pedestal top cover.
Check that all fan cables are
connected.
3. Inspect vents and fan airways for
obstructions. Look underneath
cabinet models for items blocking
the cabinet exhaust vents.
Remove any obstructions from
vents and airways.
4. Install 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 controller
board. Record the message and
return it with the defective board.
PRINTER UNDER
REMOTE CONTROL
PROTECTED INSTR* Protected Instruction.
Status message: The printer
is under the control of the
PrintNet Enterprise (PNE)
remote printer management
software.
Firmware error on the
controller board.
No action required.
1. Cycle power. Run the print job
again. If the message appears,
download the emulation software
again.
2. Cycle power. Run the print job
again. If the message appears,
replace the controller board.
Record the message and return it
with the defective board.
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Chapter 3
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
PWR SUPP VOLT* Power Supply Voltage. The
power supply has failed.
RIBBON AT END
POINT
Change Ribbon
Integrated Print
Management System
software has determined
that the ribbon is out of ink.
RBN DRVR CIR*
See Manual
The ribbon motor driver
circuit on the controller
board is drawing too much
current.
REGIONx MISMATCH
Use Correct RBN
The incorrect cartridge type
is being used for the printer.
“X” indicates the region of
the printer.
REMOVE USED SPX
THEN PRESS ENTER
Status message: An SPX is
depleted because it has
successfully reprogrammed
the security key on the
controller board.
Replace the power supply board.
Install a new ribbon.
1. Cycle power. If the message
appears, replace the controller
board (
page 200). Record the
message and return it with the
defective board.
2. Power on the printer. If the
message appears replace the
ribbon motor.
Install Region X ribbon cartridge in
the printer.
NOTE: Specify the region of the printer
when ordering ribbons.
1. Remove the SPX from the Debug
Port.
2. Press the ENTER key. The
printer will reboot itself.
RESTORING
BOOT CODE
RIB INVLD CMD*
See User Manual
Normal download
initialization message.
Ribbon Invalid Command.
Firmware error on the
controller board.
No action required.
1. Cycle power. Run the print job
again. If the message appears,
download the emulation software
again.
2. Cycle power. Run the print job
again. If the message appears,
replace the controller board.
Record the message and return it
with the defective board.
98
Page 99
List of Messages
Table 3. 6600 Error Messages List
Displayed Message Explanation Solution
RIBBON STALL The controller board does
not detect ribbon movement.
1. Cycle power. If the message
appears, power off the printer.
2. Check that the ribbon cartridge is
properly set. Make sure ribbon
motion is free by turning the
ribbon tension knob clockwise.
Replace cartridge if ribbon does
not move freely.
3. Inspect the ribbon mask for
excessive ink build-up or a torn/
bunched ribbon. Clean the ribbon
mask and replace the ribbon as
required to insure unobstructed
movement of the ribbon between
the ribbon mask and hammer
bank cover.
4. Check the platen gap and adjust
if required. If the gap is too
narrow, it can restrict ribbon
movement through the ribbon
mask.
5. Remove the paper path or
pedestal top cover. Reseat the
ribbon drive motor cable
connection.
6. Power on the printer. Check that
the ribbon drive motor winds the
ribbon. If the ribbon will not wind,
replace the defective ribbon drive
motor.
7. If the ribbon continues not to wind
replace the controller board and
download new function code.
Record the message and return it
with defective board.
RIBBON UNDER 2%
Change RBN Soon
RWP DOWNLOAD
Please Wait
Status message indicating
the Integrated Print
Management System is
enabled and the ribbon ink
level is 2%.
Status message indicating
the software in the cartridge
is being updated. The user
must wait for the update to
complete.
Install a new ribbon.
No action is required unless the
message displays for more than 2 to
3 minutes. In this case, replace the
weld sensor.
99
Page 100
Chapter 3
Displayed Message Explanation Solution
Troubleshooting Display Messages
Table 3. 6600 Error Messages List
SECURITY
VIOLATION
SECURITY KEY NOT
DETECTED
SHTL MISMATCH
Use Correct RBN
Security code of the security
key at J9 on the controller
board does not match the
code of the firmware on the
controller board.
The security key is not
present or has failed.
This message displays when
an Extended Life Ribbon is
mounted on a 500 lpm
printer.
1. Remove the paper path or
pedestal top cover. Check that
the security key is correctly
installed.
2. Install correct key for the
customer’s emulations.
3. Run a print test. If the message
appears, replace the controller
board. Record the message and
return it with the defective board.
1. Check the security key at
connector J9 on the controller
board. The security key is a 3-pin
jumper connector. If it is absent,
install the correct key. If a key is
present, replace it.
2. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
Install Standard Life Ribbon.
SHUT DRVR CIR*
See User Manual
100
The shuttle driver circuit on
the controller board is
drawing too much current.
1. Power down the printer. Remove
the paper path or top cover to
gain access to the card cage.
Make sure the shuttle data and
power cables are undamaged
and have good connections at the
shuttle and the controller board.
2. Power on the printer. If the
message appears, replace the
controller board. Record the
message and return it with the
defective board.
3. Power on the printer. If the
message appears, replace the
shuttle frame assembly.
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