Tektronix Phaser 540, Phaser 540 Plus Service manual

Service Manual

Phaser

540 and Phaser

Color Printers

540 Plus

Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in operating instructions unless you are qualified to do so.

This printing June 1995 070-9013-01

1995 by Tektronix, Inc., Wilsonville, Oregon. Printed in the United States of America. All rights

reserved. Contents of this publication may not be reproduced in any form without permission of Tektronix, Inc.

This instrument, in whole or in part, may be protected by one or more U.S. or foreign patents or patent applications. Information provided upon request from Tektronix, Inc., P.O. Box 1000, Wilsonville, Oregon 97070-1000.

If acquired subject to FAR or DFARS, the following shall apply:

Unpublished — rights reserved under the copyright laws of the United States.

■

Restricted Rights Legend — Use, duplication or disclosures by the government is subject to restrictions as set forth in subparagraph (c) (1)(ii) of the Rights in Technical Data and Computer Software at DFARS 252.227-7013, or in subparagraph (c) (2) of the Commercial Computer Software – Restricted Rights clause at FAR 52.227-19, as applicable. Tektronix, Inc., P.O. Box 1000, Wilsonville, Oregon 97070-1000.

Tektronix

is a registered trademark of Tektronix, Inc. TekColor™ and Photoﬁne™ are trademarks of Tektronix, Inc.

Phaser™ is a trademark of Tektronix, Inc. for color printers and related products.

Adobe™ and PostScript™ are trademarks of Adobe Systems, Incorporated which may be registered in certain jurisdictions.

EtherTalkg

is a registered trademark of Apple Computer, Incorporated.

Times™, Helvetica™, and Palatino™ are trademarks of Linotype-Hell AG and/or its subsidiaries.

Micronta

Microsoft

is a registered trademark of Radio Shack.

and Microsoft Windows® are registered trademarks of Microsoft Corporation.

Novell

OS/2

PANTONE

and NetWare

is a registered trademark of International Business Machine Corporation.

* Colors generated by the Phaser 540 and 540 Plus Color Printers are four-color process simulations and

are registered trademarks of Novell, Inc.

may not match PANTONE-identiﬁed solid color standards. Use current PANTONE Color Reference Manuals for accurate colors.

PANTONE Color simulations are only obtainable on these products when driven by qualiﬁed Pantone-licensed software packages. Contact Pantone, Inc. for a current list of qualiﬁed licensees. * Pantone, Inc.’s check-standard trademark for color reproduction and color reproduction materials. © Pantone. Inc., 1988.

TCP/IP is a trademark of FTP Software. Copyright (c) 1986, 1987, 1988, 1989 by FTP Software, Inc. All rights reserved. PC/TCP for DOS is based on a set of programs originally designed and developed by the Massachusetts Institute of Technology. FTP Software has made extensive modiﬁcations and enhancements to the M.I.T. programs.

TokenTalk® is a registered trademark of Apple Computer, Incorporated.

TORX™ is a trademark of TEKTRON.

The X Window System™ is a trademark of Massachusetts Institute of Technology.

Other marks are trademarks or registered trademarks of the companies with which they are associated.

TE/JG

Users safety summary

Terms in manual:

Power source:

conductor and ground. Use only the speciﬁed power cord and connector. Refer to a qualiﬁed service technician for changes to the cord or connector.

Operation of product:

product. Do not operate without the covers and panels properly installed. Do not operate in an atmosphere of explosive gases.

Safety instructions: Terms on product:

cover the hazardous area. Also applies to a hazard to property including the product itself.

DANGER A personal injury hazard exists in the area where you see the sign.

Care of product:

power cord or plug is frayed or otherwise damaged, if you spill anything into the case, if product is exposed to any excess moisture, if product is dropped or damaged, if you suspect that the product needs servicing or repair, and whenever you clean the product.

Ground the product:

necessary, contact a licensed electrician to install a properly grounded outlet.

Symbols as marked on product:

CAUTION Conditions that can result in damage to the product. WARNING Conditions that can result in personal injury or loss of life.

Does not apply more than 250 volts RMS between the supply conductors or between either supply

Avoid electric shock by contacting a qualiﬁed service technician to replace fuses inside the

Read all installation instructions carefully before you plug the product into a power source.

CAUTION A personal injury hazard exists that may not be apparent. For example, a panel may

Disconnect the power plug by pulling the plug, not the cord. Disconnect the power plug if the

Plug the three-wire power cord (with grounding prong) into grounded AC outlets only. If

DANGER high voltage:

Protective ground (earth) terminal:

Use caution. Refer to the manual(s) for information:

Laser use caution. Refer to the manual(s) for information:

WARNING:

cause an electrical shock. Electrical product may be hazardous if misused.

If the product loses the ground connection, usage of knobs and controls (and other conductive parts) can

Service safety summary

For qualiﬁed service personnel only: Do not service alone:

Do not perform internal service or adjustment of this product unless another person capable of

Refer also to the preceding Users Safety Summary.

rendering ﬁrst aid or resuscitation is present.

Use care when servicing with power on:

Dangerous voltages may exist at several points in this product. To avoid

personal injury, do not touch exposed connections and components while power is on.

Disconnect power before removing the power supply shield, soldering, or replacing components.

Do not wear jewelry:

Remove jewelry prior to servicing. Rings, necklaces, and other metallic objects could come into

contact with dangerous voltages and currents.

Power source:

This product is intended to operate from a power source that will not apply more than 250 volts rms between the supply conductors or between either supply conductor and ground. A protective ground connection by way of the grounding conductor in the power cord is essential for safe operation.

This product is certiﬁed under IEC 825 as a Class 1 Laser Product.

DANGER:

Invisible laser radiation when open and interlock defeated. AVOID DIRECT EXPOSURE TO BEAM.

PELIGRO:

Cuando se abre y se invalida el bloqueo, se producen radiaciones invisibles de láser. EVITESE LA

EXPOSICION DIRECTA A TALES RAYOS.

CAUTION:

Invisible laser radiation when open and interlocks defeated. AVOID DIRECT EXPOSURE TO BEAM.

VARNING:

Osynlig laser- strálning när denna del är öppnad och spärrar är urkopplade. STRÅLEN ÄR FARLIG.

VORSICHT:

Unsichtbare Laserstrahlung, wenn Abdeckung geöffnet und Sicherheitsverriegelung überbrückt. NICH DEM STRAHL AUSSETZEN.

VAROI:

Näkymätön avattaessa ja suojalukitus ohitettaessa olet alttiina lasersäteilylle. ÄLÄ KATSO SÄTEESEN.

ATTENTION:

Rayonnement laser invisible dangereux en cas d'ouverture et lorsque la sécurité est neutralisée. EXPOSITION DANGEREUSE AU FAISCEAU.

VARNING:

Osynlig laserstrálning när denna del är öppnad och spärrar är urkopplade. BETRAKTA EJ STRÅLEN.

ADVARSEL:

Usynlig laserstràling ved abning når sikkerhedsafbrydere er ude af funktion. UNDGÅ UD ÆTTELSE FOR STRÅLING.

Class 3B

ADVARSEL:

Usynlig laserstraling nar deksel åpnes og sikkerhedslas brytes. UNNGÅ EKSPONERING FOR STRÅLEN.

PJQT4521ZA

9008-78

Contents

1 General Information

The Phaser 540 Color Printers 1-2

RAM and printer capabilities 1-2 Print engine assemblies 1-3 Front panel 1-6 Rear panel 1-8

Network card LEDs 1-9

Test print button 1-9

Health LED 1-10

Media tray type sensing 1-10 Specifications 1-12

Regulatory specifications 1-15

2 Installing the Printer and Drivers

Pre-install questions for customers 2-2 Unpacking 2-5

Printer inventory 2-5

Accessory box 2-5 Setting up the printer 2-7

Installing SIMM memory 2-7

Installing a network card 2-7 Cabling the printer 2-8

Connecting the printer to a Macintosh 2-8

LocalTalk connection to a Macintosh 2-8 Ethernet connection to a Macintosh 2-8

Connecting the printer to a PC 2-9

Direct connection to a PC 2-9 Networked connection using the Ethernet port 2-9 Networked connection using the Token ring port 2-9

Connecting the printer to a workstation 2-10

Direct connection to the workstation 2-10 Networked connection to a workstation 2-10

Networked connection using the Token Ring port 2-10 Connecting an optional SCSI hard disk drive to the printer 2-11 Connecting the optional CopyStation to the printer 2-12

Turning on the printer 2-13

The startup page 2-13 The configuration page 2-14

Service Manual

Driver and communication set up 2-20

Loading the Macintosh driver 2-20 Installing the Tektronix driver for Windows 3.1 2-21

If you have other Tektronix printer drivers already installed 2-21

Configuring the Tektronix Windows printer driver 2-22 Updating the standard Microsoft Windows PostScript driver 2-24 Installing the printer driver for OS/2 Version 2 2-25 Configuring the printer's serial port for a PC 2-27 Using printcap to configure a workstation for the printer's serial port 2-29 Configuring a Novell NetWare server for the printer 2-30 Configuring TCP/IP on a UNIX host 2-31

3 Verifying the Printer and Host Connections

Macintosh verification 3-1

Selecting the printer via the Chooser 3-1

Printing the directory from a Macintosh 3-3 Verifying that an application communicates to the printer 3-4 Using the Error Handler utility 3-4

PC verification 3-5

DOS connection verification 3-5 Windows 3.1 driver verification 3-5 OS/2 connection verification 3-6 Novell NetWare verification 3-7

Send a print file to the printer 3-7 Using the Error Handler utility 3-8

Workstation verification 3-9

Verifying connection and printing using TCP/IP protocols 3-9 Using the Error Handler utility 3-10

xvi

Phaser 540 Color Printer

4 Key Operator Training

Overview 4-1 Printer controls and indicators 4-2 Loading media 4-3 Customer-replaceable consumables 4-4

Imaging unit 4-4 Toner cartridges 4-4 Transfer roller 4-4

Fuser 4-4 Clearing paper jams 4-5 Cleaning 4-5 Warranty information 4-6 Service support 4-6 Supplies ordering 4-7 If you need help 4-7

Using the automated fax systems 4-7

Tektronix Color Printer Information Server 4-9

Customer Support Hotline 4-10

Service support 4-10

Electronic bulletin board service 4-10

5 Theory of Operation

Overview 5-1 Functional block diagram 5-2 Laser imaging 5-4

Overview 5-4

Pre-exposure 5-6

Electrostatic charging 5-7

Laser exposure 5-8

The laser scanner 5-9

Toner pickup (development) 5-10

Toner transfer to the accumulator belt 5-11

Paper picking 5-12

Toner transfer to paper 5-13

Fusing and exiting 5-14

Print modes 5-15

Automatic color correction 5-16 Power supply 5-17 Image processor 5-18

Image rendering technology 5-18

Service Manual

xvii

6 Troubleshooting

System power-up sequence 6-1 Print engine troubleshooting 6-2

Testing the print engine 6-2 Verifying printer operation by using its self-test print 6-3 Verifying power supply operation 6-3

Measuring power supply voltages 6-3 Inspecting the power supply fuses 6-5 Safety interlocks 6-5

Testing for a shorted motor 6-6 Testing motor resistances 6-7 Media jams and the paper path 6-8

Media-based problems 6-8 Media problems 6-8

Multiple-sheet pick 6-8

The printer is not distinguishing between paper and transparency film 6-9

The media skews passing through the paper path 6-9

Paper tray indicates empty when it is not 6-10

No paper feeder installed 6-10

No imaging unit installed 6-10 Jams 6-11

Paper mis-picks at the paper tray 6-11

Paper jams midway in the paper feeder 6-11

Paper jams at the second bias transfer roller 6-12

Fuser jams 6-13

Eject jams 6-13

Manual feed jams 6-14 Other problems 6-15

Waste tray for the photoconductive belt cleaner shows full when it is not 6-15

Transfer roller waste tray indicates not full when it is 6-15

No toner cartridge installed when it is 6-15

No pre-transfer charger installed when it is 6-16

No fuser installed when it is 6-16

Front door open when it is closed 6-16

Left-side door open when it is not 6-17

High temperature error 6-17

Low temperature error 6-17

High voltage error 6-18

Thermistor open error 6-18

Power supply fan does not run 6-18

xviii

Phaser 540 Color Printer

Error messages 6-19 Print engine error codes 6-19 Printing and print quality problems 6-24

Blank print 6-24 All-black print 6-24 Missing primary color 6-24 Light print 6-25 Dark vertical line in print 6-25 Wavy light vertical lines in print 6-25 White horizontal line or band in all the colors of a print 6-25 White vertical lines in the print 6-26 Dirty background 6-26 Mis-transfer, missing portions of toner 6-26 Partial black dots 6-26 Dark, irregular steaks in all colors 6-26 Ghosting 6-27 Unfused or partially fused printing 6-27 Image is skewed on the paper 6-27 Stains on the back of the print 6-27 No printing on edge of print 6-28 Image is not centered on the print when it should be 6-28 The print is wrinkled 6-28

Macintosh printing problems 6-29

Image never prints 6-29 Image prints in black-and-white 6-29 Image is rotated 90 degrees 6-29 Printer isn’t in the Chooser 6-30

PC DOS printing problems 6-30

Image never prints 6-30

Windows printing problems 6-32

Image never prints 6-32 Blue color on the screen is printing too purple 6-32 Windows message “Problem writing device LPT1: Cancel or Retry” 6-32

Workstation printing problems 6-33

Image never prints 6-33

Service Manual

xix

7 Cleaning and Maintenance

Service preventive maintenance procedure 7-1 Recommended tools 7-1 Cleaning 7-2 Lubrication 7-2

8 FRU Disassembly/Assembly

Required tools 8-1 The printer cabinet 8-2

Upper rear cover 8-2 Lower rear cover 8-2 Top cover 8-2 Left door (for paper feeder access) 8-2 Left side cover 8-2

Manual feed tray 8-2 Front door 8-4 Upper and lower front covers 8-4 Bottom front cover 8-4 Front panel board 8-4 Toner level sensor board 8-4 Right side covers (front, rear and lower) 8-5

Paper feeder 8-6 Paper tray sensor board 8-6 Cartridge selector/eject unit (right door) 8-8 Laser scanner 8-9 Laser modulation board 8-10 Power supply 8-11 Fuser installed switch 8-11

Power supply fuse 8-13

Printer rear assemblies 8-14

Engine control board 8-14 Engine driver board 8-14 Charger sensor board 8-15 Main motor 8-16 Paper feed motor 8-16 Cleaning board 8-16 Toner cartridge drive unit 8-18 Home position sensor assembly and the left door opened switch 8-18

High-voltage board 8-20 Pre-exposure lamp 8-21 Pre-transfer lamp 8-21

Phaser 540 Color Printer

Toner auto-density sensor 8-21 Image processor board 8-23 Installing RAM SIMMs 8-24 Installing a network card 8-26

Enabling TCP/IP with the authorization code 8-27

Replacing the code ROM SIMM 8-28

9 Checks and Adjustments

Required tools 9-1 Front panel menu 9-2 Printing test prints 9-4

Print service test prints 9-4 Printing the configuration page 9-4 Printing the demonstration pages 9-4

Printing the print engine’s test print 9-4 Image processor normal indicators 9-5 Image processor hard and soft error indicators 9-5 Printer self-diagnostics 9-6 Resetting NVRAM 9-9 Print engine calibration 9-10 Checking print registration 9-10

A Field Replaceable Units List

B Test Patterns

C Wiring Diagram

D Test Pattern Generator

Index

Service Manual

xxi

Figures

Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 1-5 Figure 1-6 Figure 1-7

Figure 2-1 Figure 2-2 Figure 2-3

Figure 5-1 Figure 5-2 Figure 5-3 Figure 5-4 Figure 5-5 Figure 5-6 Figure 5-7 Figure 5-8 Figure 5-9 Figure 5-10 Figure 5-11 Figure 5-12 Figure 5-13 Figure 5-14

The Phaser 540 Color Printer 1-1 Print engine major components 1-3 Print engine components (continued) 1-4 Print engine sensor, switch and solenoid locations 1-5 The front panel and its functions 1-7 The Phaser 540 rear panel 1-8 Tray switch sensors and actuators 1-11

The Phaser 540 and its packaging 2-6 Connecting a SCSI hard disk drive to the Phaser 540 2-11 Connecting a CopyStation to the Phaser 540 2-12

Block diagram of the printer 5-2 Laser printing process overview 5-5 Pre-exposing the photoconductive belt 5-6 Electrostatic charging of the photoconductive belt 5-7 Laser exposure of the photoconductive belt 5-8 The laser scanner 5-9 Toner pickup 5-10 Toner transfer to the accumulator belt 5-11 Paper picking 5-12 Transferring toner to the paper 5-13 Fusing the toner to the paper 5-14 Print modes and printing dots 5-15 The power supply 5-17 The image processor graphics pipeline 5-19

Figure 6-1 Figure 6-2

xxii

Measuring the DC voltages (test points) 6-4 Door safety interlock switches 6-6

Phaser 540 Color Printer

Figure 8-1 Figure 8-2 Figure 8-3 Figure 8-4 Figure 8-5 Figure 8-6 Figure 8-7 Figure 8-8 Figure 8-9 Figure 8-10 Figure 8-11

Figure 8-12 Figure 8-13 Figure 8-14 Figure 8-15 Figure 8-16 Figure 8-17

Removing cabinet covers 8-3

Removing cabinet covers 8-5

Removing the paper feeder and the paper tray sensor board 8-7

Removing the cartridge selector/eject unit 8-8

Removing the laser scanner 8-9

Removing the laser modulation board 8-10

Removing the power supply and the fuser installed switch 8-12

Replacing the power supply fuse 8-13

Removing the engine control, engine driver and charger sensor boards 8-15

Removing the main motor, paper-feed motor and cleaning board 8-17

Removing the toner cartridge drive unit, home position sensor and

the left door interlock switch 8-19

Removing the high-voltage board 8-20

Removing the pre-exposure lamp, pre-transfer lamp and toner auto-density sensor 8-22

Removing the image processor board 8-23

Installing RAM SIMMs 8-25

Installing a network card in the printer 8-26

Installing the code ROM SIMM 8-28

Figure 9-1 Figure 9-2 Figure 9-3

Figure A-1 Figure A-2 Figure A-3

Figure C-1

Menu map 9-2

Menu map 9-3

Checking the registration of the toner layers 9-10

Cabinet FRUs A-2

Cabinet FRUs A-3

The internal printer A-5

Wiring diagram C-1

Service Manual

xxiii

Tables

Table 1-1 Table 1-2 Table 1-3 Table 1-4 Table 1-5 Table 1-6

Table 2-1 Table 2-2

Table 6-1 Table 6-2

Table A-1 Table A-2 Table A-3 Table A-4

Tray switch sensor combinations 1-10 Physical dimensions 1-12 Printer clearances 1-12 Functional specifications 1-13 Electrical specifications 1-13 Environmental specifications 1-14

Configuration page settings for the Phaser 540 2-14 Values for modifying the DEVPARAMS.PS file 2-28

Motor and solenoid resistances 6-7 Print engine service error codes 6-19

FRU parts list of the printer cabinet A-2 FRU part list of the printer cabinet A-3 FRU parts list of the exploded printer A-4 Supplies and accessories A-6

Table D-1

Test Pattern Generator DIP Switch settings for Phaser 540 D-4

xxiv

Phaser 540 Color Printer

Chapter

General Information

This service manual contains information useful for troubleshooting, repairing, adjusting, and maintaining a Tektronix Phaser Printers. This manual includes troubleshooting guides, adjustment procedures, a ﬁeld replaceable units (FRU) list and assembly/disassembly procedures for selected FRUs. To ensure complete understanding of the product, we recommend participation in Phaser 540 service training.

540 and Phaser

540 Plus Color

Figure 1-1 The Phaser 540 Color Printer

9013-01

Service Manual

1-1

General Information

The Phaser 540 Color Printers

The Phaser 540 and Phaser 540 Plus Color Printers both combines a color laser, continuous-tone print engine with an image processor supporting Adobe’s PostScript Level 2 page description language (version 2015). The image processor features a bi-directional parallel interface for host communication. Optional network adapter cards to the image processor allow the printer to communicate on networks using LocalTalk, serial, Ethernet or Token Ring protocols. The Ethernet network card supports EtherTalk, Novell and TCP/IP. With the Token Ring network card, the Phaser 540 Plus supports Toten Ring protocols. The network cards are sometimes referred to as “smart cards” because each houses its own processor for executing speciﬁc on-board protocols; only data is transferred from the installed smart card to the printer’s image processor board.

The printers each comes standard with 20 Mbytes of RAM which can be supplemented with one or two additional 16-Mbyte RAM SIMMs. The printer contains 39 standard, built-in fonts. The printer features a SCSI-compatible interface to connect to an external hard disk drive for additional font storage. An orderable option, the Phaser CopyStation can also be connected to the printer’s SCSI port to give the printer the ability to optically copy color images.

The printer supports printing on A- and A4-sized paper and transparency ﬁlm from an A or A4-size tray. An optional two-tray second feeder (called the Lower Tray Assembly) is available. The printer also supports manual feeding. The Phaser 540 Plus also supports Legal-size paper in its Legal-size tray.

The printer prints at a user-selectable resolution of 300 dots-per-inch or 600 dots-per-inch. Color printing is at either 4 or 16 levels of color depending on the amount of memory installed in the printer. After being idle for one hour the printer switches into its Energy Star mode where it consumes less than 45 watts of power. It “awakens” upon receiving data at any of its ports. The printer also features a closed-loop image density sensor system that allows it to auto-calibrate its color imaging so printing output remains consistent over the life of the print engine and its consumable supplies.

RAM and printer capabilities

With additional RAM memory the printer’s capabilities increase:

■

With standard 20 Mbytes of RAM, the printer has a frame buffer of 16 Mbytes, an I/O buffer of 100 kbytes, an image pipeline color cache of 500 kbytes, and PostScript virtual memory of 3.6 Mbytes. With standard 20 Mbytes of RAM, the printer can print 300 dpi continuous-tone and 600 dpi bi-level images.

1-2

Phaser 540 Color Printer

With 36 Mbytes of RAM, the printer has a frame buffer of 32 Mbytes,

■

an I/O buffer of 100 kbytes, an image pipeline color cache of 500 kbytes, and PostScript virtual memory of 3.6 Mbytes. With 36 Mbytes of RAM the printer can print 300 or 600 dpi continuous-tone images and has faster data throughput. With the additional RAM in the Phaser 540 Plus, the scan-to-print start time of the Phaser CopyStation is reduced to about 65 seconds.

■

With a maximum 52 Mbytes of RAM, the printer has a frame buffer of 32 Mbytes, an I/O buffer of 1 Mbytes, and image pipeline color cache of 2 Mbytes, and PostScript virtual memory of 16.8 Mbytes.

Print engine assemblies

Toner level sensor board

General Information

Pre-exposure lamp

Imaging unit

Paper feeder

Black toner cartridge

Yelllow toner cartridge

Magentatoner cartridge

Cyan toner cartridge

Pre-transfer lamp



Ozone filter



Fuser

Laser scanner

Toner cartridge selector/paper exit unit

Paper tray

9013-02

Figure 1-2 Print engine major components

Service Manual

1-3

General Information

Toner cartridge drive unit

Power supply fan

Power supply unit

Engine control board

Fuser fan

Charger sensor board

Cleaning board

Toner  cartridge motor

Ozone fan

Laser driver board

Image processor board

High voltage board

Main motor

Paper feed motor

Engine driver board

Figure 1-3 Print engine components (continued)

9013-03

1-4

Phaser 540 Color Printer

Manual feed sensor

Registration sensor

Transparency sensor (transmitter)

Transparency sensor (receiver)

Toner level sensors (transmitters)

Accumulator belt home position sensor

Image density sensor

Scorotron charger sensor

Pre-transfer charger sensor

General Information

Toner level sensors (receivers) are mounted inside the toner cartridge driver unit

Front right door opened switch

Transfer waste bin sensor

Transfer roller position sensor

Fuser-installed switch

Left door opened switch

Paper low sensor*

Paper tray type sensors

Paper jam sensor

*Unused by image processor

Power switch

Figure 1-4 Print engine sensor, switch and solenoid locations

These sensors are not illustrated:

■

The photoconductive belt position sensor. This optical sensor marks the home position of the photoconductive belt. It is mounted inside the customer-replaceable imaging unit.

The photoconductive belt toner disposal bin full sensor. It is mounted

■

inside the customer-replaceable imaging unit. This ultrasonic sensor determines if one of the imaging unit’s two waste toner bins is full which, if true, would impair print quality. Under ordinary circumstances, neither waste toner bin should ﬁll up before the imaging unit’s life is expired.

Paper-exit sensor

Fuser-exit sensor

Paper-empty sensor

9013-04

The logic state of paper low sensor is not monitored or used by the image processor.

Service Manual

1-5

General Information

Front panel

These front panel features are found on the printer:

■

A two-line, 24-character LCD and two LEDs

Four push buttons

■

LCD

The LCD serves two purposes: displaying current controller and print engine status information and displaying an interactive menu. Status information includes controller status such as

Printing . Print engine status includes messages such as Out of paper , Paper Jam , and Out of toner . The interactive menu can only be entered

while the print engine and controller are idle. The interactive menu allows the user to review and change certain NVRAM, I/O ports and peripheral parameters. Using the front panel to review and change parameters is discussed in Chapter 9, “Checks and Adjustments.”

Ready , Receiving data and

Buttons

cancel an operation while in the interactive menu. The functions of Buttons 2, 3 and 4 are deﬁned by the particular menu or function being displayed on the LCD display. The bottom row of the LCD labels the current function of each button.

In addition, pressing the buttons as you turn on the printer enables certain diagnostic modes:

■

The Chapter 9 topic, “Resetting NVRAM” on page 9-9 explains how to use the front panel buttons to reset the NVRAM to its factory default values.

Button 1, the left-most button, is labeled the Exit key and is used to

Pressing and holding Button 1, as you turn on the printer, skips power-up diagnostics (except for a brief kernel test) and proceeds to PostScript startup.

Pressing and holding Button 2, as you turn on the printer, executes extended diagnostics.

Pressing and holding Button 3, as you turn on the printer, executes interactive service tests. These are described in “Printer self-diagnostics” on page 9-6.

1-6

Phaser 540 Color Printer

General Information

LEDs

The Power LED indicates the printer has +5 VDC available for its logic

control boards.

The

Error LED has three indications:

■

Off indicates that no errors have been detected.

■

indicates a warning to the user. An explanatory message, such as

Low Paper , is displayed on the LCD.

Blinking indicates an error has been detected. An error message, such

■

Paper Jam at Output , is displayed on the LCD. Error codes

as, are listed and explained in the Section 6 topic, “Error messages” on page 6-19.

Exit

Button 1

Button 2

Button 3

Button 4

Figure 1-5 The front panel and its functions

Power Error

9013-06

Service Manual

1-7

General Information

Rear panel

Connectors

The rear panel of the Phaser 540 printer features the host interface connectors to the printer. It includes the following connectors:

Standard parallel (high-density connector).

■

SCSI high-density connector (font hard disk drive or Phaser CopyStation only).

With the addition of a network card, the printer can feature either of these groups of connectors:.

■

ThinNet (10base2) and Twisted Pair (10baseT) Ethernet connectors. This is Option P1 and P2.

■

RS-232 serial and LocalTalk connectors. This is Option P2

Unshielded Twisted Pair (10baseT) and shielded Twisted Pair (DB-9)

■

Token Ring connectors. This is Option P4.

The ﬁgure below illustrates the rear panel.

Parallel

Smart card slot for network card

Phaser™ Share

Ethernet Card

10Base2

Link

RX

10Base-T

LocalTalk/Serial Card

Phaser™ Share

Serial LocalTalk®

RS-232 serial

LocalTalk

1-8

Figure 1-6 The Phaser 540 rear panel

Phaser 540 Color Printer

SCSI

Option P1 P2

Option P3

9013-05

Network card LEDs

The Ethernet network card has two LED indicators:

■

Note

General Information

TX indicator (yellow); blinks while data is transmitted to the host. The LED is off while no data is being sent.

Twisted Pair (10baseT). RX indicator (green); blinks while the

network card is receiving data. The LED is being received. If the LED is hardware) has occurred at the network hub.

ThinNet (10base2). RX indicator (green); blinks while the network

card is receiving data. The LED is received. If the LED is has occurred at the network hub.

Do not use both Ethernet connectors at the same time. If both are used the 10base2 line is ignored.

on steady , then a problem (probably hardware)

off steady , then a problem (probably

off stead y while no data is being

on steady while no data is

Test print button

The Token Ring network card has two LED indicators:

■

Connection (yellow); off when the printer is not inserted into the Token

blinks while the printer is attemping to insert itself into the Token

Ring, Ring,

Ring Speed (green); off when the card is set for 4 megabits per second

■

(MBPS),

When both LEDs blink, a network card failure has occured.

■

In the center of the rear cabinet panel is the test print button. Pressing this button while the printer is idle causes the print engine to print a built-in test print. The print is made independently of the image processor board.

when the printer is properly inserted in the ring.

when the card is set for 16 MBPS.

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1-9

General Information

Health LED

A health LED indicates the status of the image processor board. The health LED is mounted on the image processor board and is viewable through the grill behind the manual feed tray. (The grill is the removable RAM SIMM options cover.) Once the PostScript code is loaded into memory and the image processor is initialized and running, the image processor blinks the LED at a one-second rate.

Blinking (at a steady rate): The printer is operating normally. The LED

■

blinks irregularly during power-up self-diagnostics.

If a soft error occurs, the image processor board operates, but in a reduced capacity. Soft failures include failure of expansion memory SIMMs or any of the interface ports. When a soft error occurs, the printer automatically prints a startup page listing the error.

■

or Off : A hard error condition has occurred that would keep the

image processor board from operating.

Media tray type sensing

The combinations of the three tray sensors “tell” the print engine what type of paper tray is installed. The tray sensors are located on the left-side interior of the paper tray slot. Sensor actuators are attached to the bottom end of the tray to close the appropriate sensor. There are four tray types:

■

Letter (A-size) paper

Letter (A-size) transparency ﬁlm

■

Metric Letter (A4-size) paper

■ Metric Letter (A4-size) transparency ﬁlm

■ Legal-size paper (Phaser 540 Plus)

Table 1-1 Tray switch sensor combinations

Left switch Middle switch Right switch Tray type

Closed Open Open Letter (A-size) paper

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Closed Closed Open Letter (A-size) transparency ﬁlm Open Open Closed Metric Letter (A4-size) paper Closed Open Closed Metric Letter (A4-size) transparency ﬁlm Open Closed Open Legal-size paper

Phaser 540 Color Printer

General Information

Sensor actuators

Middle

Left

Right

Tray sensors

Figure 1-7 Tray switch sensors and actuators

9013-40

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General Information

Speciﬁcations

Table 1-2 Physical dimensions

Dimensions Speciﬁcation

Height: Width: 48.3 cm (19 in.) With output tray: 69.6 cm (27.4 in.) Depth: 48.3 cm (19.5 in.)

45.7 cm (18 in.) With Lower Tray Assembly: 68.6 cm (27 in.)

Weight: Approximately 53.3 kgs (117 lbs.) with Lower Tray Assembly

and consumables installed. Approximately 39.1 kgs (86.2 lbs.) without Lower Tray Assembly.

Table 1-3 Printer clearances

Clearances Speciﬁcation

Top: 7.6 cm (3 in.) Left: 7.6 cm (3 in.) Right: 10.2 cm (4 in.) for handling the output tray Front: Unlimited for removal of consumable Rear: 15.3 cm (6 in.) for connecting computer cable and pow er cord Bottom: No obstruction under printer that could block its cooling vents. Mounting surface

ﬂatness:

Within 2 degrees of horizontal with all four feet in contact with the table surface.

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Phaser 540 Color Printer

General Information

Table 1-4 Functional specifications

Characteristic Speciﬁcation

Printing process Electro-photographic, four color (CMYK) transfer printing

Color medium Four toner cartridges each contain one of four colors: cyan,

Addressability Standard mode: 300 x 300 dots-per-inch text and graphics

Printing speed Time from paper-load to paper-eject:

Minimum printing margins

Usable paper A-size (letter) and A4-size (Metric letter) and Legal-size of a

Paper tray capacity 250 sheets using 20-lb. paper. 100 sheets of transparency

magenta, yellow or black. The toner is a nonmagnetic, monocomponent contact medium.

Enhanced mode: 600 x 600 dpi text and graphics

Four-color 3.5 pages per minute at 300 dpi paper: 1.75 pages per minute at 600 dpi Monochrome: 14 pages per minute at 300 dpi 7 pages per minute at 600 dpi Four-color transparency: 1.3 pages per minute at 300 dpi

Print times do not include image processing time, which can vary depending on image complexity.

All sides, 5 mm (0.2 ins.).

good quality, or premium laser printer or copier paper.

ﬁlm. The optional Lower Tray Assembly also uses trays with the same capacity.

Table 1-5 Electrical specifications

Characteristic Speciﬁcation

Primary line voltages 87 to 128 VAC (115 VAC or 100 VAC nominal); 174 to 260

Primary voltage frequency range

Power consumption 60 watts (fuser off), 850 watts (fuser on) during Ready state,

Primary voltage fusing 110 VAC conﬁguration – 10 amp

Secondary DC voltages Image processor:

RF emissions Both 110 and 220 VAC-conﬁgured instruments pass these

VAC (220 VAC nominal) 47 to 63 Hz

950 watts during Warm-up state, 45 watts during Energy Star state

220 VAC conﬁguration – 6.3 amp

+ 5 VDC ± 0.25 (1A minimum, 6 A maximum) ± 12 VDC ± 0.6 (100 mA max)

Print engine: + 5V ± .25 (2.2 A max) + 12V ± .25 (0.4 A max)

- 12V ± .25 (0.1 A max) + 24V ± .25 (3.0 A max)

standards: FCC Part 15 Class B VDE Class B EN55022 (CISPR 22) Class B VCCI (CISPR 22) Class B

Service Manual

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General Information

Table 1-6 Environmental specifications

Characteristic Speciﬁcation

Temperature Operating Non-operating Storage

Humidity Operating Non-operating

10o to 32.5o C (50oto 91oF)

to 40o C (32o to 104o F)

-20

to 60o C (-4

to 140o F)

Media should be acclimated 24 hours before using in the printer.

10 to 80% relative humidity, non-condensing 10 to 90% relative humidity, non-condensing

Media should be acclimated 24 hours before using in the printer.

Altitude Operating Non-operating

Vibration/shock Operating

Non-Operating (vibration)

Non-operating (shock) Acoustic Noise

(operating)

0 to 2500 m (8,000 ft.) at 25

0 to 15000 m (50,000 ft.) (Fuser maximum 4000 m (13,300 ft.)

May drop any side or corner 50 mm (2 in.) without impairment of subsequent operation. On ﬁve mutually perpendicular axes: 0.5 g, 25-minute sweep, 5 to 200 to 5 Hz, 100 to 200 sec./sweep cycle. No resonant frequencies below 50 Hz. 30 g, trapezoidal ﬂared pulse, 20 msec each axis.

Aver age sound le vel (LEQ) is less than 53 dbA. Peak noise in standby mode is 47 dbA.

1-14

Phaser 540 Color Printer

Regulatory speciﬁcations

The printer is a recognized component in conformance with the following regulatory standards:

■ The packaged product meets ASTM D4169-86 and ASTM D4728-87

Transportation Standards.

■ Listed UL 1950 Information Processing and Business Equipment.

■ Certiﬁed CSA C22.2 No. 950 Safety of Information Technology

Equipment, Including electrical Business Equipment.

■ GS licensed IEC 950 (1991) Second Edition; EN60950 Information

Processing and Business Equipment.

■ VDE 0871/6.78 (Class B) Regulation for the Radio Frequency Interface

Suppression of High Frequency Apparatus and Installations.

■ VDE 0875, Regulation for RFI Suppression of Electrical Equipment

and Installations

General Information

■ EN55022 (CISPR 22) Class B

VCCI (CISPR 22) Class B

■ FCC Class B (for 115 VAC equipment) pursuant to Sub-part J

of Part 15.

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