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HP LaserJet Enterprise 500 Maintenance Manual - Page 229

Engine Controller

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Engine Controller Engine Controller The engine controller (EC) consists of four main elements: • 80C166 Microcontroller • 128KB 5.0V-only FLASH program memory, organized as 64K x 16 bits. This memory is not expandable. • MECA (Mechanism Engine Control ASIC) • Analog drive circuitry 80C166 Microprocessor The Siemens® SAB 80C166 is a high-integration microcontroller. It has many features that suit it extremely well to real-time control applications. This controller and the MECA ASIC provide the functionality of three separate processors used in earlier controller board architectures. In this manual, the 80C166 is referred to as either the EC or the 166. Bus Configuration The 166 bus is configured for 18-bit address, 16-bit data, non-multiplexed and segmented operation. The flash memory runs with zero wait states. An external PAL is used for address decoding. Power Reduction The 166 chip has two power reduction modes: idle and Energy Star. Idle mode is not used. In Energy Star® mode, +48V and all motors are deenergized, but the 166 operates as normal. EC Flash Memory The EC stores all boot code, program code, and tables in its own local flash memory. This flash is organized as 64Kx16 bits and uses the same technology as the DC flash: it is +5.0V-only and is rated for a minimum of 100,000 write/erase cycles. EC memory is fixed; it is soldered to the controller board. Its contents can be updated through the DC (through the serial or parallel ports). At run time, the EC also stores tables in shared DRAM, which is accessed through the Cajun bus. MECA ASIC The 166 uses numerous counters, PWM generators, and FIFOs in the MECA to control many printer motor functions. The MECA is a custom gate array, specifically designed to drive this system. Analog Drive Circuitry The analog drive circuits convert +48 volts and +8.5 volts into the power used to drive the motors and hammers in the printer. Sensors are used to monitor the operation and status of critical components within the printer. 229

Section	Page
TRADEMARKS AND SERVICE MARKS	2
1 Maintenance Overview 9	3
2 Installation 23	3
3 Preventive Maintenance 25	3
4 Troubleshooting 31	3
5 Adjustment Procedures 99	4
6 Replacement Procedures and Illustrated Parts Lists 125	4
7 Principles of Operation 215	5
A Wire Data 233	5
B Printer Specifications and Regulatory Information 269	6
C Abbreviations & Signal Mnemonics 277	6
D Firmware Download Procedure 285	6
E Host Configurations and Drivers 293	6
F Paper Specifications and Forms Design 297	6
G Noise Suppression Devices 309	6
H Power Stacker 311	6
1 Maintenance Overview	9
About the Printer	9
Table 1 . LineJet Printers	9
Important Maintenance Notes	10
About This Manual	11
1. Locate the procedure or information you need. (Refer to the Table of Contents or the Index.)	11
2. Read the entire procedure before you do it.	11
3. Gather the parts and tools you will need.	11
4. Make sure you understand all notes and notices before you start a task. Notes and notices are ...	11
Notes and Notices	11
Printing Conventions in This Manual	12
Related Documents	13
Safety Notices	14
Hinweise zur Sicherheit	15
Controls and Indicators	16
Figure 1 . Electrical Controls, Cabinet Models	17
Figure 2 . Electrical Controls, Pedestal Models	19
1) Tractor Lock	21
2) Horizontal Adjustment Knob	21
3) Left Tractor	21
4) Paper Supports	21
5) Right Tractor	21
6) Vertical Position Knob	21
7) Forms Thickness Lever	21
8) Forms Thickness Pointer	21
9) Ribbon Loading Diagrams	21
Figure 3 . Mechanical Controls and Indicators, All Models	21
Tools, Test Equipment, and Supplies	22
2 Installation	23
Installation	23
3 Preventive Maintenance	25
Cleaning the Printer	25
Cleaning the Outside Surfaces	26
1. Power off the printer.	26
2. Disconnect the AC power cord from the printer or the power source.	26
3. Remove paper and the ribbon.	26
4. Dampen a clean, lint-free cloth with water and a mild detergent or with window cleaning soluti...	26
5. Dry the outside surfaces with a clean, lint-free cloth.	26
6. Open the printer cover.	26
7. Using a soft-bristled, non-metallic brush (such as a toothbrush), brush paper dust and ribbon ...	26
8. Wipe the splined shaft with a soft cloth.	26
9. Using a cloth dampened (not wet) with alcohol, clean the ribbon guides.	26
10. Vacuum up dust and residue from the lower cabinet.	26
11. Wipe the interior of the lower cabinet with a clean, lint-free cloth dampened with water and ...	26
12. Dry the cabinet interior with a clean, lint-free cloth.	26
13. Clean the shuttle frame assembly, as described in the next section.	26
1) Base Casting	27
2) Shuttle Cover Assembly	27
3) Splined Shaft	27
4) Tractors	27
5) Forms Thickness Lever	27
6) Ribbon Guide (2)	27
Figure 4 . Cleaning Inside the Cabinet or Top Cover	27
Cleaning the Shuttle Frame Assembly	28
1. Remove the shuttle cover assembly (page 141).	28
2. Remove the shuttle frame assembly (page 177).	28
3. Remove the paper ironer (page 160).	28
4. Moisten a clean, soft cloth with alcohol. Wipe the paper ironer to remove lint, ink, and paper...	28
5. Install the paper ironer (page 160).	28
6. Remove the hammer bank / ribbon mask cover assembly (page 139).	28
7. Moisten a clean, soft cloth with alcohol. Wipe the hammer bank cover and ribbon mask to remove...	28
8. Using a stiff, non-metallic brush (such as a toothbrush), gently brush the hammer tips to remo...	28
1) Hammer Tip	29
Figure 5 . Cleaning the Hammer Tips	29
9. Install the hammer bank / ribbon mask cover assembly (page 139).	29
10. Install the shuttle frame assembly (page 177).	29
11. Install the shuttle cover assembly (page 141).	29
12. Clean the card cage fan assembly, as described in the next section.	29
Cleaning the Card Cage Fan Assembly	30
1. Cabinet Models: Remove the paper path (page 161). Pedestal Models: Remove the top cover assemb...	30
2. Vacuum the card cage fan assembly and surrounding areas to remove paper particles, dust, and l...	30
3. Cabinet Models: Install the paper path (page 161) Pedestal Models: Install the top cover assem...	30
4. Return the printer to normal operation (page 101).	30
1) Card Cage Fan Assembly	30
Figure 6 . Cleaning the Card Cage Fan Assembly	30
4 Troubleshooting	31
Introduction	31
Troubleshooting Aids	31
Start Here ...	32
Troubleshooting Display Messages	33
List of Messages	33
Table 2 . Message List	34
1. Cycle power. If the message appears, replace the power supply board.	34
2. Power on the printer. If the message appears, replace the CMX controller board. Record the mes...	34
3. Power on the printer. If the message appears, replace the shuttle frame assembly.	34
1. Cycle Power. Run the print job again. If the message appears, remove the hammer bank logic cab...	34
2. Cycle Power. Run the print job again. If the message appears, download the emulation software ...	34
3. Cycle power. Run the print job again. If the message appears, replace the flash memory.	34
4. Power on the printer. Run the print job again. If the message appears, replace the CMX control...	34
5. Check the resistance of connectors P106/LRIB M and P107/RRIB M. (Refer to the Main Wire Harnes...	34
6. Power on the printer. Run the print job again. If the message appears, replace the power suppl...	34
7. Power on the printer. If the message appears, replace the shuttle frame assembly.	34
1. Cycle Power. Run the print job again. If the message appears, download the emulation software ...	35
2. Cycle power. Run the print job again. If the message appears, replace the flash memory.	35
3. Power on the printer. Run the print job again. If the message appears, replace the CMX control...	35
4. Power on the printer. Run the print job again. If the message appears, replace the power suppl...	35
5. Power on the printer. If the message appears, replace the shuttle frame assembly.	35
1. Power off the printer. Remove the paper path or pedestal top cover. Check that power supply co...	35
2. Power on the printer. If the message appears, replace the hammer bank logic cable assembly (P1...	35
3. Power on the printer. If the message appears, replace the power supply board.	35
4. Power on the printer. If the message appears, replace the CMX controller board. Record the mes...	35
5. Power on the printer. If the message appears, replace shuttle frame assembly.	35
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	35
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	35
1. Verify that the printer matches the host serial interface configuration settings for Data Prot...	36
2. Send a print job to the printer. If the message appears, go to Communications Failures, page 83.	36
1. Inspect the paper path for jams. Clear jams. Load paper.	36
2. Press PAPER ADVANCE several times and check that forms feed without erratic motion, noise, or ...	36
3. Press VIEW once and check that forms move up. Make sure the forms thickness lever is not set t...	36
4. Press VIEW again and check that the forms thickness lever rotates and the paper moves down. If...	36
5. Check the paper tension between the tractors. Adjust the right tractor so that it does not pul...	36
6. Inspect the ribbon mask for bends or deformation. Replace if damaged.	36
7. Check anddjust the platen open belt. Replace the belt if it is damaged.	36
8. Bottom out the platen open motor pulley on the motor shaft and torque the 1/16 inch set screw ...	37
9. Inspect the tractors and tractor door springs for damage or excessive wear. If either tractor ...	37
10. Check the condition and tension of the paper feed belt. Adjust the paper feed belt. Replace t...	37
11. Check and adjust the platen gap.	37
12. Clean the paper motion detector with a cotton swab and alcohol. At the control panel, set the...	37
1. Load paper. Close the forms thickness lever.	38
2. Power off the printer. Remove the paper path or pedestal top cover. Disconnect connector P107 ...	38
3. Tighten the screws securing the platen interlock switch	38
4. Check and adjust the platen open belt. Replace the belt if it is damaged.	38
5. Bottom out the platen open motor pulley on the motor shaft and torque the 1/16 inch set screw ...	38
6. Disconnect connector P106 from the CMX controller board. Check the resistance of connector P10...	38
7. Run a print test. If the message appears, replace the CMX controller board. Record the message...	38
1. Advise the user to move the printer to cooler, cleaner location.	39
2. Check the kinds of print jobs the user is running: look for very dense graphics and layouts. A...	39
3. Power off the printer. Remove the paper path or pedestal top cover. Check all fan cable connec...	39
4. Power on the printer. Verify that all fans operate. Replace any fan that does not operate.	39
5. Inspect vents and fan airways for obstructions. Look underneath cabinet models for items block...	39
6. Install the paper path or pedestal top cover. Load paper. Run the “All E’s” print test for 5 t...	39
7. Run the “All E’s” print test for 5 to 10 minutes. If the message appears, replace the CMX cont...	39
1. Cycle Power. Run the print job again. If the message appears, download the emulation software ...	40
2. Cycle power. Run the print job again. If the message appears, replace the flash memory.	40
3. Power on the printer. Run the print job again. If the message appears, replace the CMX control...	40
4. Power on the printer. Run the print job again. If the message appears, replace the power suppl...	40
5. Power on the printer. If the message appears, replace the shuttle frame assembly.	40
1. Cycle power. If the message appears, press CLEAR.	40
2. Power off the printer. Remove the shuttle cover. At the shuttle frame assembly, disconnect the...	40
1. Replace the DRAM.	40
2. Power on the printer. If the message appears, replace the CMX controller board. Record the mes...	40
1. Download the program again (page 129). If the message occurs again, replace all flash memory S...	41
2. Power on the printer. Download the emulation. If the message appears, replace the CMX controll...	41
1. Power off the printer. Remove all flash memory and DRAM SIMMs. Inspect the SIMM sockets on the...	41
2. Install the flash and DRAM SIMMs, making sure they are fully and correctly seated. Power on th...	41
3. Power on the printer. Download the emulation. If the message appears, replace the DRAM SIMM(s).	41
4. Power on the printer. Download the emulation. If the message appears, replace the CMX controll...	41
1. Check the security PAL at location U54 on the CMX controller board. If the PAL is absent, inst...	42
2. Power on the printer. If the message appears, replace the CMX controller board. Record the mes...	42
1. Power off the printer. Download the program again from the beginning. If the messages appears,...	42
2. Download the program using a new software diskette. If the messages appears, replace the flash...	42
3. Download the program. If the messages appears, replace the CMX controller board. Record the me...	42
1. Cycle power. If the message appears, press CLEAR.	43
2. Check that the exhaust fan is connected to exhaust fan cable connector J307. Connect the fan c...	43
3. Power off the printer. Remove the paper path. Disconnect connector P107 from the CMX controlle...	43
4. Make sure connector P107/EHF has a good connection at J107 on the CMX controller board.	43
5. Inspect for obstructions of airways and vents. Check for items beneath the printer blocking ca...	43
6. Power on the printer. Check for fan operation. If the message appears or the fan doesn’t work,...	43
7. Power on the printer. If the message appears, replace the CMX controller board. Record the mes...	43
1. Cycle power. Run the print job. If the message appears, download the emulation software again ...	44
2. Cycle power. Run the print job again. If the message appears, replace the flash memory.	44
3. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	44
4. Power on the printer. Run the print job again. If the message still appears, there is an appli...	44
1. Make a configuration printout. Set printer serial interface parameters to match host configura...	44
2. Send a print job to the printer. If the message appears, go to Communications Failures, page 83.	44
1. Release stuck keys. Determine and correct what made the key(s) stick.	44
2. Cycle power: power off the printer, wait 15 seconds, power on the printer. If the message appe...	44
1. Power off the printer. Hold any control panel key down and power on the printer. Hold the key ...	44
2. If the message reappears after doing step 1, replace the CMX controller board. Record the mess...	44
1. Cycle power. If the message appears, replace the shuttle frame assembly.	45
2. Power on the printer. Run a print test. If the message appears, replace the CMX controller boa...	45
1. Cycle power. If the message appears, replace the shuttle frame assembly. Record the message an...	45
2. Power on the printer. If the message appears, replace CMX controller board. Record the message...	45
1. Install the shuttle frame assembly.	45
2. Remove the paper path or pedestal top cover. Verify that the hammer bank logic cable is connec...	45
3. Power on the printer. If the message appears, replace the hammer bank logic cable.	45
4. Power on the printer. If the message appears, replace the shuttle frame assembly.	45
5. Power on the printer. If the message appears, replace the CMX controller board. Record the mes...	45
1. Cycle power. If the message appears, press CLEAR. If the message does not clear, go to step 2.	46
2. Power off the printer. Remove the paper path or pedestal top cover. Disconnect connector P107 ...	46
3. Make sure P107/HBF has a good connection at J107 on the CMX controller board.	46
4. Inspect for obstructions of airways and vents. Remove obstructions.	46
5. Power on the printer. If the message appears, replace the CMX controller board. Record the mes...	46
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	46
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	46
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	46
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	46
1. Illegal Operand Accessed. Firmware error on the CMX controller board.	46
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	46
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	46
1. Cycle power. If the message appears, press CLEAR. If the message does not clear, go to step 2.	47
2. Power off the printer. Remove the paper path or pedestal top cover. Disconnect connector P106 ...	47
3. Make sure P106/CCF has a good connection at J106 on the CMX controller board.	47
4. Inspect for obstructions of airways and vents. Remove obstructions.	47
5. Power on the printer. If the message appears, replace the CMX controller board. Record the mes...	47
1. Cycle power. If this message occurred once and never again, you can ignore it. If the message ...	47
2. Power on the printer. Cycle power. If the message appears, suspect an application software err...	47
1. Cycle power. If the message appears, press CLEAR. If message does not clear, replace the hamme...	47
2. Power on the printer. If the message appears, replace the shuttle frame assembly.	47
3. Power on the printer. If the message appears, replace the CMX controller board. Record the mes...	47
1. Load paper. Press CLEAR. If message does not clear, go to step 2.	48
2. Power off the printer. Remove the paper path or pedestal top cover. Remove the barrier shield ...	48
3. Check that connector P106/PMD is fully seated in connector J106 on the CMX controller board.	48
4. Load paper. Power on the printer. Replace the paper detector switch assembly if message appears.	48
5. Load paper. Power on the printer. Replace the CMX controller board if message appears. Record ...	48
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	48
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	48
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	49
2. Run the print job again. If the message appears, power off the printer. Remove the paper path ...	49
3. Power on the printer. Run the print job again. If the message appears, replace the shuttle fra...	49
4. Power on the printer. Run the print job again. If the message appears, replace the CMX control...	49
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	49
2. Power on the printer. Run the print job again. If the message appears, replace the CMX control...	49
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	50
2. Run the print job again. If the message appears, power off the printer. Remove the paper path ...	50
3. Check hammer phasing. Try using a lower phasing value; sometimes this message indicates too hi...	50
4. Power on the printer. Run the print job again. If the message appears, replace the shuttle fra...	50
5. Power on the printer. Run the print job again. If the message appears, replace the power suppl...	50
6. Power on the printer. Run the print job again. If the message appears, replace the CMX control...	50
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	50
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	50
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	50
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	50
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	51
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	51
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	51
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	51
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	51
2. Cycle power. Run the print job again. If the message appears, replace the MPU cable assembly.	51
3. Power on the printer. Run the print job again. If the message appears, replace the power suppl...	51
4. Power on the printer. Run the print job again. If the message appears, replace the shuttle fra...	51
5. Power on the printer. Run the print job again. If the message appears, replace the CMX control...	51
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	51
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	51
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	52
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	52
1. Press CLEAR then press ON LINE.	52
2. Run the print job that generated the error message. If the message appears, check the host dat...	52
3. Ask the system operator to verify that the printer’s Device ID is set to the correct emulation...	52
4. Run the print job that generated the error message. If the message appears, go to Communicatio...	52
1. Verify that the printer matches host serial configuration settings for Data Protocol, Baud Rat...	52
2. Send a print job to the printer. If the message appears, replace the serial data cable.	52
3. Send a print job to the printer. If the message appears, go to Communications Failures, page 83.	52
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	52
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	52
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	53
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	53
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	53
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	53
1. Inspect printer environment for severity. Advise the user to move the printer to cooler, clean...	54
2. Check the kinds of print jobs the user is running: look for very dense graphics and layouts. A...	54
3. Power off the printer. Remove the paper path or pedestal top cover. Check that the power suppl...	54
4. Check that all fan cables are connected.	54
5. Inspect vents and fan airways for obstructions. Look underneath cabinet models for items block...	54
6. Install paper path or pedestal top cover. Load paper. Power on the printer. Run the “All E’s” ...	54
1. CMX controller board sensors report high temperatures on the board. Inspect printer environmen...	55
2. Power off the printer. Remove the paper path or pedestal top cover. Check that all fan cables ...	55
3. Inspect vents and fan airways for obstructions. Look underneath cabinet models for items block...	55
4. Install paper path or pedestal top cover. Load paper. Power on the printer. Run the “All Black...	55
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	55
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	55
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	55
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	55
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	56
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	56
1. Cycle power. If the message appears, power off the printer. Remove the paper path or pedestal ...	56
2. Power on the printer. Using a screwdriver, short across the ribbon guide screws to reverse rib...	56
1. Remove the paper path or pedestal top cover. Check that the security PAL is correctly installed.	56
2. Install correct PAL for the customer’s emulations with the notched end facing toward the flash...	56
3. Run a print test. If the message appears, replace the CMX controller board. Record the message...	56
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	57
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	57
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	57
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	57
1. Set the forms thickness lever to match the thickness of paper, but not too tightly.	58
2. Check/adjust the platen gap.	58
3. Inspect the ribbon mask for deformation that snags and interferes with shuttle movement. Corre...	58
4. Run a print test. If the message appears, power off the printer.	58
5. Remove the shuttle cover and paper path or the pedestal top cover. Inspect the shuttle mechani...	58
6. Run a print test. If the message appears, replace the power supply board.	58
7. Run a shuttle test and observe shuttle movement. If the shuttle oscillates too slowly, adjust ...	58
8. Run a print test. If the message appears, replace the MPU and the MPU cable assembly.	58
9. Run a print test. If the message appears, replace the CMX controller board. Record the message...	58
10. Run a print test. If the message appears, replace the shuttle frame assembly.	58
1. Cycle power. If the message appears, power off the printer.	59
2. Disconnect the input data line from the host computer. Power on the printer. If the message ap...	59
3. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	59
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	59
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	59
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	59
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	59
1. Power on the printer. Operate the power stacker. Check for obstructions preventing elevator mo...	60
2. Operate the power stacker, and check that: a) all motors are operating, b) the paddles are rot...	60
3. Adjust the stacker rails if they are not vertical and parallel.	60
4. Check the stacker limit switches. (See page 71.) If the limit switches are OK, go to the next ...	60
5. Disable the power stacker unit under the Printer Control menu. (Refer to the Setup Guide.) If ...	60
6. Power off the printer. Remove the paper path. Disconnect stacker cables from the CMX controlle...	60
1. Unload the stacker.	61
2. Check the stacker limit switches. (See page 71.) If the limit switches are OK, go to the next ...	61
3. Power off the printer. Remove the paper path. Disconnect stacker cables from the CMX controlle...	61
1. Remove the paper jam.	61
2. Power off the printer. Check that the wheel of the stacker paper motion detector rests against...	61
3. Power on the printer. Operate the power stacker and check that: a) all motors are operating, b...	61
4. Power off the printer. Remove the paper path. Disconnect stacker cables from the CMX controlle...	61
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	62
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	62
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	62
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	62
1. Cycle power. Run the print job again. If the message appears, download the emulation software ...	62
2. Cycle power. Run the print job again. If the message appears, replace the CMX controller board...	62
1. Cycle power. If the message appears, press CLEAR. If the message does not clear, replace the h...	62
2. Power on the printer. If the message appears, replace the CMX controller board. Record the mes...	62
3. Power on the printer. If the message appears, replace the shuttle frame assembly.	62
Troubleshooting Other Symptoms	64
1. Ask the operator to describe the problem.	64
2. Verify the fault by running a diagnostic printer test or by replicating conditions reported by...	64
3. Look for a match in the General Symptom List below. If you find a match, go to the troubleshoo...	64
4. If you cannot find the symptom in the General Symptom List, use the Half-Split Method to find ...	64
a. Start at a general level and work down to details.	64
b. Isolate faults to half the remaining system at a time, until the final half is a field-replace...	64
5. Replace the defective part or assembly. Do not attempt field repairs of electronic components ...	64
6. Test printer operation after every corrective action.	64
7. Reinstall any parts you replaced earlier that did not solve the problem.	64
8. Stop troubleshooting and return the printer to normal operation when the reported symptoms dis...	64
General Symptom List	65
Table 3 . General Symptom List	65
1. On 475 lpm and 500 lpm printers, check the shuttle speed (page 136). Adjust the shuttle speed ...	65
2. Power off the printer. Remove the paper path or pedestal top cover. Remove the barrier shield ...	65
3. Check that connector P106/PMD is fully seated in connector J106 on the CMX controller board.	65
4. Load paper. Power on the printer. Replace the paper detector switch assembly if either message...	65
5. Inspect the paper ironer. If the paper ironer has slipped up into the print line, reposition t...	65
6. Load paper. Power on the printer. Replace the CMX controller board if either message appears. ...	65
1. Remove the paper path or pedestal top cover. Make sure connector P107/PAPR M is fully seated i...	65
2. Check the paper feed motor pulley for looseness. Hold the collar snug against the motor pulley...	65
3. Check the condition and tension of the paper feed timing belt. Adjust the paper feed timing be...	65
4. Load paper. Power on the printer. Press PAPER ADVANCE and VIEW several times and check that pa...	65
5. Power on the printer. Press PAPER ADVANCE and VIEW several times and check that paper moves co...	65
1. Power off the printer. Remove the paper path or pedestal top cover. Check that connector P106/...	66
2. Remove the barrier shield (cabinet model) or the barrier shield and paper guide (pedestal mode...	66
3. Check that the paper detector switch assembly is securely mounted to the mechanism base. Tight...	66
4. Check that the motion detector wheel rotates. Replace the paper detector switch assembly if th...	66
5. Load paper. Power on the printer. Replace the paper detector switch assembly if the message ap...	66
6. Load paper. Power on the printer. Replace the CMX controller board if the message appears. Rec...	66
1. Power off the printer. Remove the paper path or pedestal top cover. Disconnect the control pan...	66
2. Power off the printer. Make sure the flash memory is seated properly in J10 and J11 on the CMX...	66
3. Power on the printer. If black squares appear on the LCD, the flash memory could be blank. Rep...	66
4. Power on the printer. If black squares appear on the LCD, replace the CMX controller board. Re...	66
1. Power off the printer. Remove the paper path or pedestal top cover. Check all cable connection...	66
2. Power on the printer. Inspect the control panel display and cooling fans. If the control panel...	66
3. Power on the printer. If the control panel is blank and the fans do not come on, replace the C...	66
1. Power on the printer. Check the operation of the control panel keys. Replace the control panel...	67
2. Power on the printer. Check the operation of the control panel keys. Replace the control panel...	67
3. Power on the printer. Check the operation of the control panel keys. Replace the CMX controlle...	67
1. Remove the paper path or pedestal top cover. Check cable connections into the CMX controller b...	67
2. Make sure the DRAM SIMM(s) is/are seated properly in J15/J16. Reseat DRAM SIMM(s).	67
3. Power on the printer. Inspect the control panel display. If the control panel shows broken cha...	67
1. Check that the AC power outlet has power. Restore AC power if necessary.	67
2. Unplug the printer AC power cord from the printer (leave it plugged into the power outlet) and...	67
3. Remove the paper path or pedestal top cover. Verify that the AC- In power cable and the AC pow...	67
4. Check that AC-in power cable connector P1 is connected to J1 on the power supply board. Reseat...	67
5. Check that power supply cable connector P101 is connected to J101 on the CMX controller board....	67
6. Check all cable connections on the CMX controller board.	67
7. Disconnect AC-in power supply cable connector P1. Set the circuit breaker to 1 (on). Measure A...	67
1. Power off the printer. Remove the paper guide or pedestal top cover. Reseat all cable connecto...	67
2. Power up the printer. If the fans run but the printer does not initialize, replace the power s...	67
3. Power up the printer. If the fans run but the printer does not initialize, replace the CMX con...	67
1. Check that the power stacker is enabled under the Printer Control menu. (Refer to the Setup Gu...	68
2. Open the rear cabinet door. Check that the ON/OFF indicator lamp is lit. If the ON/OFF indicat...	68
3. a) Power off the printer. b) Unfasten the cable clamp holding the stacker control panel cables...	68
4. Power off the printer. Remove the paper path. Disconnect stacker cables from the CMX controlle...	68
5. Power on the printer. Check that the ON LINE indicator lights on the stacker control panel. If...	68
6. Power on the printer. Check that the ON LINE indicator lights on the stacker control panel. If...	68
1. Power off the printer. Unload paper. Open the rear cabinet door and check that stacker motion ...	69
2. Verify that the stacker rails are vertical and parallel. Adjust the stacker rails if necessary...	69
3. Move the elevator up and down by hand and check that the limit switches are being tripped at t...	69
4. Power on the printer. Operate the power stacker. (Refer to the User’s Guide.) While the stacke...	69
1. Check for and removeobstructions preventing elevator movement.	70
2. Check for misaligned stacker rails Adjust the stacker rails if they are not vertical and paral...	70
3. Power on the printer. Operate the power stacker. (Refer to the User’s Guide.) While the stacke...	70
4. Check the stacker limit switches. (See page 71.) If the limit switches are OK, go to the next ...	70
5. Check the stacker motors. (See page 72.) If the stacker motors are OK, go to the next step.	70
6. Remove the paper path. Disconnect stacker cables from the CMX controller board, stacker assemb...	70
1. Power off the printer. Inspect all stacker LEDs for dust, chaff, or dirt. (See Figure 81 throu...	70
2. Power on the printer. If the stacker elevator moves by itself, replace the stacker LEDs. (See ...	70
1. Power off the printer. Open the rear cabinet door. Unload the power stacker. Move the elevator...	71
2. Move the elevator up and down by hand. Check that the limit switches are physically tripped wh...	71
3. a) Unfasten the cable clamp holding the stacker control panel cables. b) Disconnect stacker ra...	71
1. a) Power off the printer. b) Open the rear cabinet door. c) Unfasten the cable clamp holding t...	72
1. Check the forms thickness lever: if it is set too loose or too tightly print quality can be af...	73
2. Check the paper tension between the tractors. Adjust the right tractor so that it does not pul...	73
3. Inspect the shuttle frame assembly for print chaff, debris, or ink residue that could be causi...	73
4. Check the ribbon for folds or tears. Check that the ribbon guides are tight and the ribbon tra...	73
5. Power off the printer. Remove the shuttle cover. Remove the shuttle frame assembly. Inspect th...	73
6. Check the platen gap. Adjust the platen gap if necessary.	73
7. Remove the paper guide assembly or pedestal top cover. Make sure Connectors P105 and P108 have...	73
8. Power on the printer. If the problem still occurs, replace the hammer bank logic cable and the...	73
9. Power on the printer. If the problem still occurs, replace the shuttle frame assembly.	73
10. Power on the printer. If the problem still occurs, replace the power supply board.	73
11. Power on the printer. If the problem still occurs, replace the CMX controller board.	73
1. Take the printer offline and print a test pattern of All H’s. If characters shift left or righ...	74
2. Check the hammer phasing. Adjust hammer phasing if necessary.	74
3. If the printer is a a 500 lpm model, check the shuttle speed setting. Set the shuttle speed (p...	74
4. Inspect the shuttle frame assembly area for ink residue, paper chaff, or debris. Clean the shu...	74
5. Check the MPU gap. Using a feeler gauge, adjust the gap between the MPU assembly and the flywh...	74
6. Power up the printer. Run a print test. If the symptom is not gone, replace the MPU.	74
7. Power up the printer. Run a print test. If the symptom is not gone, replace the CMX controller...	74
8. Power up the printer. Run a print test. If the symptom is not gone, replace the shuttle frame ...	74
1. Power off the printer. Check the platen gap. Adjust the platen gap if necessary.	74
2. Remove the paper guide assembly or pedestal top cover. On the left rear wall of the card cage,...	74
3. Disconnect the AC power cord and check the ground leads for continuity. Replace the AC power c...	74
4. Make sure the printer is plugged in to a grounded power outlet. Power up the printer. Run a pr...	74
5. Power up the printer. Run a print test. If the problem occurs, replace the flash memory and DR...	74
6. Power up the printer. Run a print test. If the problem occurs, replace the CMX controller board.	74
7. Power up the printer. Run a print test. If the problem occurs, replace the power supply board.	74
8. Power up the printer. Run a print test. If the problem occurs, replace the shuttle frame assem...	74
1. Load paper. Press PAPER ADVANCE and check that paper feeds smoothly. Press VIEW to verify that...	75
2. Check the paper feed motor pulley for looseness. Hold the collar snug against the motor pulley...	75
3. Check the condition and tension of the paper feed timing belt. Adjust the paper feed timing be...	75
4. Check the platen gap. Adjust the platen gap.	75
5. Inspect the tractors and tractor door springs for damage or excessive wear. If either tractor ...	75
6. Remove the paper guide assembly or pedestal top cover. Make sure connector P107/PAPR M is full...	75
7. Load paper. Power on the printer. Run a print test. If the problem occurs, replace the paper f...	75
8. Run a print test. If the problem occurs, replace the CMX controller board.	75
9. Run a print test. If the problem occurs, replace the power supply board.	75
1. Power off the printer. Remove the paper path or pedestal top cover. Check the I/O cable connec...	76
2. Remove the flash SIMMs. Inspect the flash SIMM sockets on the CMX controller board. If any soc...	76
3. Check that customer has the right size SIMMs for the emulation. (See page 166) Install SIMMs t...	76
4. Power up the printer. Download the emulation (page 129). If the download fails, activate the B...	76
5. Power up the printer. Download the emulation (page 129). If the download fails, replace the CM...	76
1. Power off the printer. Remove the flash SIMMs. Inspect the flash SIMM sockets on the CMX contr...	76
2. Make sure the blank SIMM is the same size as the SIMM to be copied. Install the SIMMs, making ...	76
3. Power on the printer. From the Boot Diagnostics menu, select and run MISC UTILITIES / COPY FLA...	76
1. Check the forms thickness lever: if it is set too tightly paper feeding can be affected. Set t...	77
2. Power off the printer. Remove paper. Inspect the paper feed path for obstructions that could s...	77
3. Inspect the tractors and tractor door springs for damage or excessive wear. If either tractor ...	77
4. Check the paper feed motor pulley for looseness. Hold the collar snug against the motor pulley...	77
5. Check the condition and tension of the paper feed timing belt. Adjust the paper feed timing be...	77
6. Check the platen gap. Adjust the platen gap.	77
7. Remove the paper path or pedestal top cover. Make sure connector P107/PAPR M is fully seated i...	77
8. Load paper. Power on the printer. Press PAPER ADVANCE and VIEW several times and check that pa...	77
9. Power on the printer. Press PAPER ADVANCE and VIEW several times and check that paper moves in...	77
1. Remove the paper path or pedestal top cover. Reseat all cable connections to the CMX controlle...	77
2. Power up the printer. If the printer “hangs,” replace the CMX controller board.	77
3. Power up the printer. If the printer “hangs,” replace the power supply board.	77
1. Check the host data cable connection at the rear of the printer. Attach the data cable to the ...	78
2. Make a configuration printout. Verify that the printer matches host interface settings. Set pr...	78
3. Power up the printer. Send a print job from the host. If printer does not print and the interf...	78
4. Power up the printer. Send a print job from the host. If the printer does not print from the h...	78
5. Remove the paper path or pedestal top cover. Check all cable connections on the CMX controller...	78
6. Power up the printer. Send a print job from the host. If the printer still does not print from...	78
1. Power off the printer. Remove the paper path or pedestal top cover. Disconnect the control pan...	78
2. Connect the control panel cable assembly to J110 on the CMX controller board and to the contro...	78
3. Power on the printer. Run a self test. If the self test does not run, replace the CMX controll...	78
1. Raise the forms thickness lever and check that the platen opens. If the platen opens with diff...	79
2. Check the platen open pulley and the platen pulley for looseness. Bottom out the platen open m...	79
3. Check the condition and tension of the platen open belt. Adjust the platen open belt. Replace ...	79
4. Check the platen gap. Adjust the platen gap.	79
5. Power off the printer. Remove the paper guide assembly. Disconnect connector P106 from the CMX...	79
6. Power on the printer. Press PAPER ADVANCE and VIEW several times and check that paper moves in...	79
1. Check that the customer is setting the forms length to match the size paper used. Set the form...	79
2. If the customer is using multi-part forms, check that the forms thickness lever is not being s...	79
3. Check the paper feed motor pulley for looseness. Make sure the correct pulley is being used: i...	79
4. Check the condition and tension of the paper feed timing belt. Adjust the paper feed timing be...	79
5. Remove the paper path or pedestal top cover. Make sure connector P107/PAPR M is fully seated i...	79
6. Power on the printer. Load paper and set TOF. Press PAPER ADVANCE and VIEW several times and c...	79
7. Power on the printer. Press PAPER ADVANCE and VIEW several times and check that paper returns ...	79
1. Check that both ribbon spools are fully seated on the ribbon hubs and the ribbon runs between ...	80
2. Check that the ribbon spools are not rubbing against the shuttle cover assembly. Install the s...	80
3. Inspect the paper print path for paper chaff, ink residue, and debris. Clean the shuttle frame...	80
4. Power on the printer. Run a print test and observe ribbon movement across the left and right r...	80
5. Observe ribbon movement at both left and right ribbon posts as the metal end strip crosses eac...	80
6. While shorting across each ribbon post with the ribbon metal strip or a screwdriver, check for...	80
7. Check the platen gap. Adjust the platen gap.	80
1. Power down the printer. Remove the shuttle cover. Check the MPU gap. Adjust the gap between th...	81
2. Check that the MPU cable is connected to J03 on the mechanism base. Check that the shuttle mot...	81
3. Remove the paper path or pedestal top cover. Check that the shuttle motor drive cable is conne...	81
4. Check the platen gap. Adjust the platen gap.	81
5. Inspect the ribbon mask for bends or deformation that snag and interfere with shuttle movement...	81
6. Check continuity of the shuttle motor drive cable assembly. Replace shuttle motor drive cable ...	81
7. Power up the printer. Run a Shuttle Slow or Shuttle Fast test. If the shuttle does not move, r...	81
8. Power up the printer. Run a Shuttle Slow or Shuttle Fast test. If the shuttle does not move, r...	81
9. Power up the printer. Run a Shuttle Slow or Shuttle Fast test. If the shuttle does not move, r...	81
1. Check the bolts securing the mechanism base to the base pan. Tighten the mechanism base mounti...	82
2. Remove the shuttle cover. Check the shuttle frame assembly mounting/clamp screws for looseness...	82

Match case Limit results 1 per page

Engine Controller

229

Engine Controller

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

•

80C166 Microcontroller

•

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

This memory is not expandable.

•

MECA (Mechanism Engine Control ASIC)

•

Analog drive circuitry

80C166 Microprocessor

The Siemens® SAB 80C166 is a high-integration microcontroller. It has many

features that suit it extremely well to real-time control applications. This

controller and the MECA ASIC provide the functionality of three separate

processors used in earlier controller board architectures. In this manual, the

80C166 is referred to as either the EC or the 166.

Bus Configuration

The 166 bus is configured for 18-bit address, 16-bit data, non-multiplexed and

segmented operation. The flash memory runs with zero wait states. An

external PAL is used for address decoding.

Power Reduction

The 166 chip has two power reduction modes: idle and Energy Star. Idle

mode is not used. In Energy Star® mode, +48V and all motors are de-

energized, but the 166 operates as normal.

EC Flash Memory

The EC stores all boot code, program code, and tables in its own local flash

memory. This flash is organized as 64Kx16 bits and uses the same

technology as the DC flash: it is +5.0V-only and is rated for a minimum of

100,000 write/erase cycles. EC memory is fixed; it is soldered to the controller

board. Its contents can be updated through the DC (through the serial or

parallel ports). At run time, the EC also stores tables in shared DRAM, which

is accessed through the Cajun bus.

MECA ASIC

The 166 uses numerous counters, PWM generators, and FIFOs in the MECA

to control many printer motor functions. The MECA is a custom gate array,

specifically designed to drive this system.

Analog Drive Circuitry

The analog drive circuits convert +48 volts and +8.5 volts into the power used

to drive the motors and hammers in the printer. Sensors are used to monitor

the operation and status of critical components within the printer.