Xerox Phaser 6200 Service Manual

PHASER® 6200 COLOR LASER PRINTER

Service Manual

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 the operating instructions, unless you are qualified to do so.

First Printing: March 2002 071-0784-00

Contents of this publication may not be reproduced in any form without permission of Xerox Corporation.

Xerox, and all product names and product numbers mentioned in this publication are trademarks.

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

MP RJ

ii Phaser 6200 Color Laser Printer - Service Manual

Service Terms

Manual Terms

Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger that might be present during a procedure or action. Be aware of all symbols and terms when they are used, and always read

CAUTION and WARNING messages.

NOTE,

Note: A NOTE may indicate an operating or maintenance

Caution A CAUTION indicates an operating or maintenance

Warning: A WARNING indicates an operating, or maintenance

PL: Correspondes to the FRU Parts List.

RRP: Correspondes to the FRU Dissassembly Removal and Replacement

Procedures.

Product Terms

Caution: A personal injury hazard exists that may not be apparent. For

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

procedure, practice or condition that is necessary to efficiently accomplish a task. A NOTE may also provide additional information related to a specific subject or add a comment on the results achieved through a previous action.

procedure, practice or condition that, if not strictly observed, could result in damage to, or destruction of, equipment.

procedure, practice or condition that, if not strictly observed, could result in injury or loss of life.

example, a panel may cover the hazardous area.

iii

Power Safety Precautions

Power source

For 110 VAC printers, do not apply more than 140 volts RMS between the supply conductors or between either supply conductor and ground. Use only the specified power cord and connector. For 220 VAC printers, do not apply more than 264 volts RMS between the supply conductors or between either supply conductor and ground. Use only the specified power cord. This manual assumes that the reader is a qualified service technician.

Warning: Plug the three-wire power cord (with grounding prong)

into a grounded AC outlet only. If necessary, contact a licensed electrician to install a properly grounded outlet. If the product loses its ground connection, contact with conductive parts may cause an electrical shock.

Disconnecting Power

Warning: Turning the power off using the On/Off switch does not

completely de-engergize the printer. You must also disconnect the printer power cord from the AC outlet. Position the power cord so that it is easily accessible during servicing so that you may power down the printer during an emergency.

Disconnect the power plug by pulling the plug, not the cord. Disconnect the power cord in the following cases:

■ if the power cord or plug is frayed or otherwise damaged,

■ if any liquid or foreign material is spilled into the case,

■ if the printer is exposed to any excess moisture,

■ if the printer is dropped or damaged,

■ if you suspect that the product needs servicing or repair,

■ whenever you clean the product.

iv Phaser 6200 Color Laser Printer - Service Manual

Electrostatic Discharge (ESD) Precautions

Some semiconductor components , and the respective sub-assemblies that contain them, are vulnerable to damage by Electrostatic discharge (ESD). These components include Integrated Circuits (ICs), Large-Scale Integrated circuits (LSIs), field-effect transistors and other semiconductor chip components. The following techniques will reduce the occurrence of component damage caused by static electricity.

Caution Be sure the power is off to the chassis or circuit board, and

observe all other safety precautions.

■ Immediately before handling any semiconductor components assemblies, drain the

electrostatic charge from your body. This can be accomplished by touching an earth ground source or by wearing a wrist strap device connected to an earth ground source. Wearing a wrist strap will also prevent accumulation of additional bodily static charges. (Be sure to remove the wrist strap before applying power to the unit under test to avoid potential shock.)

■ After removing a static sensitive assembly from its anti-static bag, place it on

a grounded conductive surface. If the anti-static bag is conductive, you may ground the bag and use it as a conductive surface.

■ Do not use freon-propelled chemicals. These can generate electrical charges

sufficient to damage some devices.

■ Do not remove a replacement component or electrical sub-assembly from its

protective package until you are ready to install it.

■ Immediately before removing the protective material from the leads of a

replacement device, touch the protective material to the chassis or circuit assembly into which the device will be installed.

■ Minimize body motions when handling unpackaged replacement devices.

Motion such as your clothes brushing together, or lifting a foot from a carpeted floor can generate enough static electricity to damage an electro-statically sensitive device

■ Handle IC’s and EPROM’s carefully to avoid bending pins.

■ Pay attention to the direction of parts when mounting or inserting them on

Printed Circuit Boards (PCB’s).

Service Safety Summary

General Guidelines

For qualified service personnel only: Refer also to the preceding Power Safety Precautions.

Avoid servicing alone: Do not perform internal service or adjustment of this product unless another person capable of rendering first aid or resuscitation is present.

Use care when servicing with power: 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 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 then 264 volts rms for a 220 volt AC outlet or 140 volts rms for a 110 volt AC outlet 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.

Warning Labels

Read and obey all posted warning labels. Throughout the printer, warning labels are displayed on potentially dangerous components. As you service the printer, check to make certain that all warning labels remain in place.

Safety Interlocks

Make sure covers and panel are in place and that all interlock switches are functioning correctly after you have completed a printer service call. If you bypass an interlock switch during a service call, use extreme caution when working on or around the printer.

CLASS 1 LASER PRODUCT

The Phaser® 6200 Color Laser Printer is certified to comply with Laser Product Performance Standards set by the U.S. Department of Health and Human Services as a Class 1 Laser Product. This means that this is a class of laser product that does not emit hazardous laser radiation; this is possible only because the laser beam is totally enclosed during all modes of customer operation. When servicing the printer or laser unit, follow the procedures specified in this manual and there will be no hazards from the laser.

vi Phaser 6200 Color Laser Printer - Service Manual

Servicing Electrical Components

Before starting any service procedure, switch off the printer power and unplug the power cord from the wall outlet. If you must service the printer with power applied,

be aware of the potential for electrical shock.

Warning: Turning the power off using the On/Off switch does not

completely de-energize the printer. You must also disconnect the printer power cord from the AC outlet. Position the power cord so that it is easily accessible during servicing so that you may power down the printer during an emergency.

Warning: Do not touch any electrical component unless you are

instructed to do so by a service procedure.

S7300-02

Servicing Mechanical Components

Manually rotate drive assemblies to inspect sprockets and gears.

Warning: Do not try to manually rotate or manually stop the drive

assemblies while any printer motor is running.

S7300-03

Servicing Fuser Components

Warning: This printer uses heat to fuse the toner image to a sheet of

paper. The Fuser Assembly is very hot. Turn the printer power off and wait at least 5 minutes for the Fuser to cool before you attempt to service the Fuser Assembly or adjacent components.

vii

Regulatory Specifications

Federal Communications Commission Compliance

The equipment described in this manual generates and uses radio frequency energy. If it is not installed properly in strict accordance with Xerox instructions, it may cause interference with radio and television reception or may not function properly due to interference from another device. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

■ Reorient or relocate the receiver (device being interfered with).

■ Increase the separation between the printer and the receiver.

■ Connect the printer into an outlet on a circuit different from that which the

receiver is connected.

■ Route the interface cables on the printer away from the receiver

■ Consult the dealer, Xerox service, or an experienced radio/television

technician for help.

Changes or modifications not expressly approved by Xerox can affect the emission and immunity compliance and could void the user's authority to operate this product. To ensure compliance, use shielded interface cables. A shielded parallel cable can be purchased directly from Xerox at www.xerox.com/officeprinting/6200supplies

Xerox has tested this product to internationally accepted electromagnetic emission and immunity standards. These standards are designed to mitigate interference caused or received by this product in a normal office environment. This product is also suitable for use in a residential environment based on the levels tested.

In the United States this product complies with the requirements of an unintentional radiator in part 15 of the FCC rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference; (2) this device must accept any interference received, including interference that may cause undesired operation.

This digital apparatus does not exceed the Class B limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications, ICES-003.

Le présent appareil numérique n'émet pas de bruits radioélectrique dépassant les limits applicables aux appareils numériques de la classe B prescrites dans le Réglement sur le brouillage radioélectrique édicté par le ministere des Communications du Canada, NMB-003.

Declaration of Conformity

Xerox Corporation, declares, under our sole responsibility that the printer to which this declaration relates, is in conformity with the following standards and other normative documents:

viii Phaser 6200 Color Laser Printer - Service Manual

In the European Union

following the provisions of the Low Voltage Directive 73/23/EEC and its amendments:

EN 60950 (IEC 950) "Safety of Information Technology Equipment including Electrical

Business Equipment"

following the provisions of the Electromagnetic Compatibility Directive 89/336/EEC and its amendments:

EN55022:1998

(CISPR 22)

EN61000-3-2:1995

+A1:1998+A2:1998.

(IEC61000-3-2)

EN61000-3-3:1995

(IEC61000-3-3)

EN55024:1998

(CISPR 24)

CISPR 24 Immunity Phenomena

Electrostatic Discharge IEC61000-4-2:1995 6kV Contact, 10kV Air

Radio-Frequency Electromagnetic Field (radiated)

Fast Burst Transients IEC61000-4-4:1995 5/50 Tr/Th ns, 5kHz Rep. Freq

Line Surge IEC61000-4-5:1995 Combination wave

Radio-Frequency Electromagnetic Field (Conducted)

Line voltage dips IEC61000-4-11:1994 >95% dip for ½ cycle @ 50 Hz

Line voltage drop-out IEC61000-4-11:1994 >95% dropout for 250 cycles @ 50 Hz

"Limits and Methods of measurement of radio interference characteristics of Information Technology Equipment." Class B.

“Part 3: Limits - Section 2: Limits for harmonic current emissions (equipment input current less than or equal to 16A per phase).”

“Part 3: Limits - Section 3: Limitation of voltage fluctuations and flicker in low-voltage supply systems for equipment with rated current less than or equal to 16A.”

"Information technology equipment - Immunity characteristics Limits and methods of measurement. "

Basic Standard Test Specification

IEC61000-4-3:1995 80-1000 MHz, 3V/m, 80% AM @

1KHz

0.5kV on Signal Lines

1kV on AC Mains

2.0kV Common mode

2.0kV Differential mode

IEC61000-4-6:1996 0.15 - 80 MHz, 3V, 80% AM @ 1kHz

30% dip for 25 cycles @ 50 Hz

This product, if used properly in accordance with the user's instructions is neither dangerous for the consumer nor for the environment. A signed copy of the Declaration of Conformity for this product can be obtained from Xerox.

Manual Organization

This Service Manual contains technical information for the Phaser 6200 Color Laser Printer, as well as complete Error Messages and Codes, Diagnostics, Disassembly/Reassembly (RRPs) procedures and a complete Field Replaceable Units (FRU) Parts List.

Frontis - Introductory, Safety and Regulatory Information

This is the section you are reading at this moment. It contains important safety information regarding technical components, regulatory agency requirements and information about the structure of this manual.

Chapter 1 - General Information

This chapter contains a general overview of the printer and basic information regarding printer specifications.

Chapter 2 - Error Messages and Codes

Information regarding front panel error codes and image processor diagnostics and fatal messages in tabular form.

Chapter 3 - Troubleshooting

This chapter discusses the most common troubleshooting problems encountered with: Printer Performance Problems, Image-Quality Problems and Electrical Problems.

Chapter 4 - Tests, Adjustments and NVRAM

This chapter provides information on how to use the service test prints, color registration, margin calibrations and resetting NVRAM to assist in analyzing and fine tuning printer performance.

Chapter 5 - Cleaning and Maintenance

A quick guide to routine cleaning and maintenance for the printer.

Chapter 6 - FRU Disassembly Removal and Replacement Procedures (RRPs)

This large chapter provides many procedures and illustrations for removing and replacing key Field Replaceable Units (FRUs) within the print engine.

Chapter 7- FRU Parts List

This is the parts list for the Field Replaceable Units. This chapter contains exploded views of the FRUs as well as part numbers for items available as FRUs.

x Phaser 6200 Color Laser Printer - Service Manual

Chapter 8 - Theory of Operation

This chapter covers the detailed processes for the printer’s major assemblies: switches and sensors, drives and gears, and the paper path.

Chapter 9 - Plug/Jack Locator Maps

This chapter contains detailed Plug/Jack locator maps for all wiring harnesses within the printer.

Chapter 10 - Wiring Diagram

The Master Wiring Diagram is contained in this chapter.

Power Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Electrostatic Discharge (ESD) Precautions . . . . . . . . . . . . . . . . . v

Service Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

Servicing Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . vii

Regulatory Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .viii

Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

General Information 1

Phaser 6200 Color Laser Printer Overview . . . . . . . . . . . . . . . . . . . . 2

Printer Memory and RAM Capabilities. . . . . . . . . . . . . . . . . . . . . 3

Parts of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CRC Life Counter Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Front Panel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Printer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Functional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Environmental Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Media and Tray Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . .14

Error Messages and Codes 17

Service Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Using the Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . .21

Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Service Diagnostics Tests and Functions Table . . . . . . . . . . . . . 24

Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Troubleshooting 81

System Boot Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Power On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

POST Diagnostics Test Descriptions. . . . . . . . . . . . . . . . . . . . . . 85

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Front Panel and Printer Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . 87

Table of Contents xiii

Engine Power-Up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

AC Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 88

DC Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 88

Media Jams and the Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

Operating System and Application Problems . . . . . . . . . . . . . . . . . . . 92

Macintosh printing problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Windows printing problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Network Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Print-Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Test Prints, Adjustments and NVRAM 109

Service Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Analyizing the CMYK Sample Page . . . . . . . . . . . . . . . . . . . . . 110

Analyizing the RGB Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Analyizing the Test Pattern Sample. . . . . . . . . . . . . . . . . . . . . . 111

Analyizing the 600 x 600 Service Test Print . . . . . . . . . . . . . . . 112

Color Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Color Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Margin Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Resetting NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

PostScript NVRAM Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Service Diagnostics PostScript NVRAM Resets . . . . . . . . . . . . 116

Cleaning and Maintenance 117

FRU Disassembly

Removal and Replacement Procedures 119

Orientation of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

General Notes on Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 124

FRU Parts List 253

xiv Phaser 6200 Color Laser Printer - Service Manual

Theory of Operation 301

Summary of the Printing Process. . . . . . . . . . . . . . . . . . . . . . . . . . . 302

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

Print Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

Printer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

Control of Paper Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

Laser Quantity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

Bias Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

Toner Density Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

Color Registration Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

Transfer Roller Assembly Control . . . . . . . . . . . . . . . . . . . . . . . 311

Toner Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

Fuser Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

Paper Path of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

Paper Path Route. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

Major Assemblies and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

Plug/Jack Locator Maps 341

Print Engine Plug/Jack Locator Table . . . . . . . . . . . . . . . . . . . . . . . 341

High-Capacity Feeder Plug/Jack Locator Table. . . . . . . . . . . . . . . . 349

Wiring Diagrams 351

Main Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

Paper Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354

Drive Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

Developer Section 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356

Developer 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357

Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

Laser Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359

Xerographics 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

Xerographics 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

Image Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

High-Capacity Feeder Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . 364

Drive Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365

Paper Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

Paper Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367

Table of Contents xv

General Information

The Xerox Phaser® 6200 Color Laser Printer Service Manual is the primary document used for repairing, maintaining and troubleshooting the printer.

To ensure complete understanding of the product, participation in Xerox Phaser 6200 Service Training is recommended.

S6200-001

Phaser 6200 Color Laser Printer shown with the optional High-Capacity Feeder

General Information 1

Phaser 6200 Color Laser Printer Overview

The Phaser 6200 Color Laser Printer combines a single-pass, tandem color laser design with an image processor supporting PostScript 3 and PCL5c. The Phaser 6200 is a high performance, A4, 16 ppm desktop color laser printer with a resolution up to 2400 x 600 dpi.

The Phaser 6200 has four configurations. The main difference is optional networking, standard memory, optional High-Capacity Feeder (HCF), duplexing and optional internal hard drive.

A replaceable “Configuration Upgrade Chip” holds configuration information that enables or disables built-in features as described below.

Phaser 6200B The Phaser 6200B is a base configuration, entry-level, single pass

color laser printer. The printer comes standard with 64 Mbytes of memory, resolution of 600 x 600 dpi, USB and Parallel support, a built in Multi-Purpose Tray and a 500-sheet universal paper tray.

Phaser 6200N The Phaser 6200N is the networking configuration. This

configuration includes all the features of the 6200B, but comes with 128 Mbytes of memory, built-in 10/100 Ethernet networking capabilities, job pipelining, enhanced print mode and a resolution up to 2400 x 600 dpi.

Phaser 6200DP The Phaser 6200DP is the plus configuration. The printer includes

all the features of the 6200N, but comes standard with 128 Mbytes of memory, builtin auto-duplexing, PDF and Photo Mode support.

Phaser 6200DX The Phaser 6200DX is the marketing configuration. The printer

includes all the features of the 6200DP, but comes standard with 256 Mbytes of memory, a 1000-sheet High-Capacity Feeder Assembly with wheels and an internal 10+ Gbyte hard drive.

Page Description Languages (PDL)

■ PCL5c (not available on the Phaser 6200B)

■ Adobe PostScript 3

■ PDF (not available on the Phaser 6200B, requires internal hard drive)

Resident Fonts

■ 136 PostScript Type 1

■ 115 Central European PostScript Type 1

■ 46 PCL fonts (more fonts are available with the optional internal hard drive)

2 Phaser 6200 Color Laser Printer - Service Manual

Proof Jobs. A proof job is a specific case of a multiple-copy job. With a proof job, the

customer assigns a password and copy count at the client workstation before printing. The first set of prints are printed immediately. The original number of requested sets are printed after the customer enters the matching password on the printer’s control panel. The customer has the option of printing the original number of requested sets or deleting the job. Since more than one job may be associated with the same password, the customer can print all the jobs, delete all the jobs, or select or delete individual jobs. A proof job that has not been printed is retained on the optional internal hard drive through power cycles.

Secure Jobs. Secure printing allows the customer to defer printing of a job until a

matching password is entered from the control panel. The customer assigns the password at the client workstation before printing. The job is stored, and printing is delayed until the password is entered on the printer’s control panel. Since more than one job can have the same password, all secure jobs with the same password are printed. A secure job that has not been printed or released is retained on the internal hard drive through power cycles.

Saved Jobs. Saved print allows the user to save print jobs to the internal hard drive of

the printer. The print job is not deleted after printing, it is stored on the hard drive for print on demand. This function requires an internal hard drive.

Printer Memory and RAM Capabilities

The printer features two slots which accept 64, 128 and 256 Mbyte of SDRAM. All combinations are allowed for 64, 128, 192, 256, 320, 384 and 512 Mbytes.

■ PC133 DRAM Standard

■ 144 Pin SODIMM

■ Serial Presence Detect

■ 3.3 Volt

The Startup Page and the Configuration Page list the amount of RAM installed in the printer.

If the memory does not meet the above specifications, it will be ignored by the printer.

General Information 3

Parts of the Printer

S6200-005

No. Description

1 Top Cover (Output Tray)

2 Control Panel (Front Panel)

3 Front Cover

4 Multi-Purpose Tray

5 Universal Paper Tray 1

6 High-Capacity Feeder with Tray 2 and Tray 3

7 Door Latch B

8 Door Latch A

9 Power On/Off Switch

4 Phaser 6200 Color Laser Printer - Service Manual

S6200-006

No. Description

1 Top Cover

2 Toner Cartridge

3 AC Power Cord Plug

4 Image Processor Board

5 Paper Tray Rear Cover

General Information 5

1 23

S6200-008a

S6200-008b

No. Description

1 Transfer Roller

2 Imaging Unit

3 Door C

4 Fuser Assembly

6 Phaser 6200 Color Laser Printer - Service Manual

CRC Life Counter Behavior

Internal counters track Customer-Replaceable Consumables (CRCs) life usage and store the values in NVRAM. The image processor board monitors these counters in order to display the near end-of-life and end-of-use messages.

Life ratings are based on 5% coverage. Imaging Unit average 4 page job length.

Customer-Replaceable Consumable (CRC) Print Life

Toner Cartridges*

*(Black Toner Cartridge Standard Capacity is 4,000)

Imaging Unit

Fuser Assembly

Transfer Roller and Waste Box

Customer-Replaceable Unit (CRU)

Feed Roller Kit

High-Capacity 8,000 (B50) Standard-Capacity 3,000

30,000 (B50)

60,000 (B10)

15,000 (B50)

up to 100,000

General Information 7

Front Panel Configuration

The Front Panel consists of one tricolor LED, a display window and six functional keys. These keys navigate the menu system, perform functions and select modes of operation for the printer.

LED indicators:

■ Green = Ready to Print or Printing

■ Flashing Green = Receiving, Processing Data, Printing or Power Saver Mode

■ Flashing Yellow = Warning

■ Flashing Red = Error

Phaser 6200

12345678

S6200-004

Phaser 6200 Front Panel Configuration

Front Panel Key Descriptions

LED (Power/Status)

Graphic front panel display

Cancel Key

Back Key

Up Arrow Key - scrolls up the menu

system

Down Arrow Key - scrolls down the

menu system

OK (select) Key

Information Key - for additional

explanation or help

Front Panel Shortcuts

Mode Press this selection at Power On

Skip execution of POST diagnostics OK

Print Service Diagnostics Map INFO

Reset PostScript NVRAM BACK+OK

Password Bypass UP+DOWN

Enter Service Diagnostics BACK+INFO

8 Phaser 6200 Color Laser Printer - Service Manual

Image Processor Board

The following components need to be transferred from the old board when installing a new Image Processor Board in the printer. See RRP 12.8 for information on replacing the Image Processor Board.

pin 1

1 2 3 4

Top View

No. Description

1 Hard Drive (optional)

2 Configuration Upgrade Chip (“i” Button)

3 NVRAM

4 Memory (RAM) DIMM 1 and DIMM 2

S6200-270

Rear Panel Configuration Interfaces

■ IEEE 1284 Parallel

■ Ethernet 10BaseT and 100BaseTx

■ USB

General Information 9

Printer Specifications

Physical Dimensions - Printer

Dimensions Value

Height: 445 mm (17.52 in.)

Width: 439 cm (17.28 in.)

Depth: 638 mm (25.12 in.)

Weight: Approximately 36.5 kg (80.5 lb.) Print engine

Approximately 56.5 kg (124.5 lb.) with Paper Tray(s) installed

Physical Dimensions - Optional High-Capacity Feeder

Dimensions Value

Height: 336 mm (13.23 in.) Optional Paper Tray Assembly

Width: 439 cm (17.28 in.)

Depth: 563 cm (22.17 in.)

Weight: Approximately 15 kg (33 lb.) no Paper Tray(s) installed

Approximately 20 kg (44 lb.) with Paper Tray(s) installed

Printer Clearances

Clearances Value

Top: 350 mm (13.78 in.)

Left: 100 mm (3.94 in.)

Right: 150 mm (5.91 in.)

Front: 600 mm (23.62 in.)

Rear: 200 mm (7.87 in.)

Mounting surface level tolerance:

Within 3 degrees of horizontal with all four feet in contact with the surface.

10 Phaser 6200 Color Laser Printer - Service Manual

Functional Specifications

Characteristic Specification

Printing process Imaging System - 4-tandem drums, electro-photographic system

Color medium Cyan, Magenta, Yellow and Black Toner Cartridges

Resolution / Addressability

Operating Modes Running Mode: Print Engine capable of making prints immediately.

Continuuous Operating Printing Speed

ppm = pages per minute ipm = image per minute

using intermediate drum transfer rolls (IDTs).

Exposure System - Semiconductor laser, simultaneous scanning by 4 beams.

Development System - Dry type 2-component developer.

Fusing System - Heat fusing, free nip-belt system.

Standard & Draft 600 x 600 dpi

Enhanced 2400 x 600 dpi* (Factory Default)

Photo 1200 x 1200 dpi**

* Not available on the Phaser 6200B. ** Not Available on the Phaser 6200B or Phaser 6200N.

Ready Mode: 20 seconds from completion of a print.

Sleep/ Low Power/ Power Saver Mode: entered after a specified

period of Print Engine inactivity since completion of the last print.

Mode Paper Size / wt g/m

600 dpi Letter / A4

65 -105 16 ppm 10 ipm 100-159 8 ppm N/A 160-216 8 ppm N/A

1200/2400 dpi Letter / A4

65 -105 8 ppm 5 ipm 100-159 8 ppm N/A 160-216 8 ppm N/A

Simplex Duplex

Cleaning Cycle interval for continuous printing

600/1200 dpi Envelope/Postcard

Mode OHP

600 dpi Letter / A4 8 ppm N/A 1200 dpi Letter / A4 8 ppm N/A

Print speed will be reduced if the print job is larger than the cleaning cycle interval.

IU Print Volume Standard/Draft Enhanced/Photo

0 - 5 K Pages 48 24 5 - 10 K Pages 32 16 10 - 15 K Pages 32 16 15 - 20 K Pages 32 16 20 - 25 K Pages 20 10 25 - 30 K Pages 16 8

160-216 8 ppm N/A

pages pages

General Information 11

Functional Specifications (cont'd.)

Characteristic Specification

First Print-Out (in seconds)

(Letter/A4)

Warm-up time 30 seconds from cold start (power off condition)

Mode Tray 1 Tray 2 Tray 3 MPT

Simplex, 600 dpi 15 16.5 18 14.5 Duplex, 600 dpi 23.5 25 26.5 23 Simplex, 1200 dpi 24.5 27.5 30.5 23.5 Duplex, 1200 dpi 39.5 42.5 45.5 38.5

Electrical Specifications

Electrical specifications

Characteristic Specification

Primary line voltages 100-120 V Printer - (97 - 132 V) 13 amp circuit

220-240 V Printer - (198 - 264 V) 7-8 amp circuit

Primary line voltage frequency range

Power consumption Mode Condition 100/115 VAC 240 VAC

100-120 V Printer - 50/60 Hz + 2 Hz

220-240 V Printer - 50/60 Hz + 2 Hz

Print Mode Max. 850 W or less 850 W or less

Ready Mode Fuser On 180 W or less 180 W or less

Sleep Mode Fuser Off 45 W or less 45 W or less

12 Phaser 6200 Color Laser Printer - Service Manual

Environmental Specifications

Characteristic Specification

Temperature:

Operating

Transportation

Storage

24 month maximum

1 month maximum

Humidity

Operating

Transportation

Storage

Altitude

Operating

Transportation

Acoustic Noise

Idle

Printing

Optimal print-quality range: 62o to 80o F (17o to 26o C)

10o C to 32o C (50o F to 90o F)

-30o C to +50o C (-22o F to 122o F)

Normal: 0o C to 35o C (32o F to 95o F)

Severe: -20o C to 40o C (-4o F to 104o F)

Optimal print-quality range: 35% to 70%

10% - 85%

30% - 85%

5% - 95%

0 - 2,500 meters (8,000 ft.)

0 - 6,092 meters (20,000 ft.)

35.0db or less

53.0db or less (Full Speed) (5.3 B)

70.0db or less (Half Speed) (7.0 B)

General Information 13

Media and Tray Specifications

Specification Trays

Printable Area

Usable paper sizes

Supported paper types and weights

Supported envelopes

Specialty Media

Minimum margins = 5 mm (0.2 in.) on all sides

Maximum paper size = 215.9 mm x 355.6 mm (8.5 in. x 14 in.)

Minimum paper size = 88.9 mm x 139.7 mm (3.5 in. x 5.5 in.)

Paper Type Size

Letter 8.5 x 11 in. Legal 8.5 x 14 in. Executive 7.25 x 10.5 in. Statement 5.5 x 8.5 in. US Folio 8.5 x 13 in. A4 210 x 297 mm A5 148 x 210 mm A6 105 x 148 mm B5 JIS 182 x 257 mm ISO B5 176 x 250 mm Custom Size

Type Weight

Plain Paper 64 - 90 g/m2 (17 - 24 lb. Bond) Heavy Plain Paper 85 - 105 g/m Phaser 6200 Transparency ONLY Thin Card Stock 100 - 163 g/m Thick Card Stock 160 - 216 g/m Labels N/A Letterhead 85 - 105 g/m Glossy Coated Paper 120 - 163 g/m Business and Greeting Card N/A CD/DVD Labels and Inserts N/A Digital Photo Paper 120 - 163 g/m

Envelopes Weight 20 - 24 lb. Bond

Commercial #10 4.12 x 9.5 in Monarch Envelope 3.87 x 7.5 in A7 Envelope 5.25 x 7.25 in Custom DL Envelope 110 x 220 mm C5 Envelope 162 x 229 mm C6 Envelope 114 x 162 mm B5 Envelope 176 x 250 mm

Envelopes with hot melt type glue are not supported in this printer.

Premium Phaser 6200 Transparencies

Letter 216 x 279 mm 8.5 x 11 in.

A4 210 x 297 mm 8.27 x 11.69 in.

Other sizes will be handled through the Multi-Purpose Tray with use of the custom size option.

(22 - 28 lb. Bond)

(26 - 60 lb. Cover)

(59 - 80 lb. Cover)

(22 - 28 lb. Bond)

(81 - 110 lb. Book

(81 - 110 lb.)

All Trays

All Trays All Trays All Trays MPT Only All Trays All Trays MPT Only MPT Only All Trays MPT Only MPT Only

All Trays All Trays MPT & Tray 1 MPT Only MPT Only MPT Only All Trays MPT Only MPT Only MPT Only MPT Only

MPT Only

MPT and Tray 1 Only

14 Phaser 6200 Color Laser Printer - Service Manual

Media and Tray Specifications (cont'd.)

Specification Trays

Tray Capacity

Standard Paper 500 Sheets 100 Sheets

Transparency* 100 Sheets* 50 Sheets

Envelopes N/A 10 each

Universal Tray MPT

*Tray 1 / MPT only

General Information 15

Error Messages and Codes

This section covers troubleshooting procedures for the Phaser 6200 Color Laser Printer’s front panel error messages and codes. Only jams and fatal errors will produce an associated numeric code. Error messages and codes are generally specific, making it important that service personnel and users record errors exactly when reporting problems with the printer. Any code associated with an error message or jam can be viewed by pressing the INFO key and scrolling to the bottom of the help text displayed on the front panel.

Some procedures require running service diagnostic test functions to verify a specific printer part is operating correctly. For information on Service Diagnostics and all internal printer test functions, see the table "Service Diagnostics" on page 23

To troubleshoot problems, such as start up and power on, media, paper path, print-quality or image problems, and electrical failures not associated with a front panel message or code, refer to the section "Troubleshooting" on page 81.

If an error message or code is not visible on the front panel, the usage profile report and fault history list errors reported by the printer.

When an error first occurs, record the error message and code then cycle power to the printer to see if the error recurs. These can be accessed one of three ways:

Accessing Fault History

1. Print (if possible) the Usage Profile Report Log from the printer’s front panel

Support Menu. The fault history will be detailed in this report log.

2. View the printer’s fault history on the front panel. a. Go to Support Menu --> Service Tools --> Fault History.

3. If the printer is connected to a network and has a TCP/IP address, view the

printer’s web page using a web browser.

a. Open a web browser.

b. Enter the printer’s IP address as the URL. c. Select the Troubleshoot link and the fault history will be displayed.

Error Messages and Codes 17

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