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Troubleshooting
HP DesignJet 430, 450C and 455CA Printers
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Introduction
This chapter will guide you through the relevant steps to take when troubleshooting the printer. Is the Printer Using the Latest Firmware Revision? Before spending time troubleshooting the problem by doing the various tests or replacing parts (which may not need replacing), check which firmware revision the printer is using. To check which firmware revision the printer is using, Print the Service Configuration Plot ' page 4 29. Some problems which occurred in earlier firmware releases may have been solved in later revisions. So if there is a new firmware revision then replace the Firmware SIMM before replacing any parts. Important Information The Printer firmware is contained either on a flash ROM SIMM at the back of the Printer or on a masked ROM inside the electronics module. The firmware revision level, for example A.01.03, is printed by the Printer on the setup sheet and on the service configuration plot. The revision level is also printed on a label on any flash ROM SIMM. Do not open the electronics module. Important: When replacing the electronics module, always remember to check the firmware revision level of the new electronics module. The revision level will be printed on the top surface of the module. Also, check the firmware revision level of the ROM SIMM installed in the old electronics module. With this information you must do the following: 1. If the firmware revision level of the ROM SIMM in the old electronics module is lower than the firmware revision level of the new electronics module, then you must not install the ROM SIMM into the module. 2. If the firmware revision level of the ROM SIMM in the old electronics module is higher than the firmware revision level of the new electronics module, then you must install the ROM SIMM into the module. Example 1: The ROM SIMM firmware revision level is A.01.03 and the firmware revision level of the electronics module is A.01.04. You would use the electronics module without the ROM SIMM installed. Example 2: The ROM SIMM firmware revision level is A.01.05 and the firmware revision level of the electronics module is A.01.04. You would use the electronics module with the ROM SIMM installed.
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HP DesignJet 430, 450C and 455CA Printers
Troubleshooting
What Can I do when a System Error Code Appears on the Front Panel Display? Chapter 2 contains a list of system error codes and their respective descriptions and recommended corrective actions. Only try one recommended action at a time and check if the error code has disappeared. If you have an error code which is not documented in this Service Manual or you have an error which you cannot resolve, then report the error to the HP Response Center or the nearest HP Support Office. When reporting the error, have the following information ready:
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Model and Serial Number of the printer. Which firmware revision the printer is using. The complete error code. The Service Configuration Plot. The Current configuration sheet. Which software application the customer is using (name, version, etc.). Is the problem reproducible by you? Additional comments about the usage, the setting, etc..
Have you performed a Service Test on the Failed Component/Assembly? If possible, always perform a Service Test on the component/assembly that you are about to replace, just to make sure that is the component/assembly that has failed. If the test on that component/assembly passes, you should NOT replace it. For information on the Service Tests and how to use them ' Chapter 4. Have you Performed the Accuracy Calibration? Is the printer calibrated correctly after replacing a component? Refer to Chapter 5 to check when the Accuracy Calibration is required. What can I do to Solve Print Quality Problems? Whenever an Print Quality problem appears, it is advisable to print the Print Quality Plot to help diagnose the problem. The Print Quality Print will help you differentiate between possible Cartridge errors and other problems such as incorrect front panel selection, driver or RIP configuration or mechanical problems. For information on solving Print Quality problems ' Chapter 6.
Troubleshooting
HP DesignJet 430, 450C and 455CA Printers
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What can I do if the Line Sensor has Problems Detecting Media? 1 Excessive ink deposits on the drive roller surface can fool the sensor by reflecting the light. Clean the drive roller ' Chapter 9. 2 Line sensor incorrectly calibrated: The accuracy calibration includes calibration of the line sensor on the carriage. You must use HP Matte film when performing the accuracy calibration (Details ' Chapter 5). Otherwise the line sensor will have problems loading some types of media. 3 The Line Sensor is faulty. Replace the Carriage Assembly ' page 8 37. What can I do if the Carriage is Noisy? 1 Dirty Carriage bushings. Remove dust particles from the Carriage bushings and from the slider rod along which the Carriage moves. If necessary, apply lubricant to the slider rod. 2 Make sure that the belt is correctly positioned on the Y axis motor. 3 Remove dust particles from the Back Beam and, if necessary, apply grease. 4 Check for a faulty Carriage. Perform the Carriage Axis Test ' page 4 10. What can I do if the Cover Sensor isn't Working? The cover sensor is part of the front panel assembly. 1 Before troubleshooting, make sure that you are not in Service Mode 1 because the Cover sensor is disabled and Printer will think that the cover is always closed. Power OFF the Printer and switch it back ON again and check if the Cover sensor works. 2 Check if the cable for the front panel assembly is connected correctly to the electronics module. 3 Replace the front panel assembly ' page 8 12. What can I do if the Carriage Assembly has problems parking in the Service Station? 1 Mispositioned trailing cable: The trailing cable may be preventing the carriage from reaching the left hand stop. Make sure that the trailing cable is positioned under the plastic tabs at the back of the carriage cover, and not above them. 2 The Carriage is not at the correct height. Check and, if necessary, adjust the Carriage height (Details ' chapter 5). 3 The Belt is not correctly positioned over the idler pulley. 4 Check for a faulty bail lever mechanism because the Carriage may have trouble passing over it.
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HP DesignJet 430, 450C and 455CA Printers
Troubleshooting
What can I do if the Printer continuously rejects Cartridges? If you are in Service Mode 1, the cover sensor is disabled. In order to test a new Cartridge set, the Printer must be powered OF and and ON again. 1 Remove tape and align cartridges: One frequent cause of cartridge problems is that the user has forgotten to remove the tape from new cartridges. Remove the tape. 2 Dirty pads: The connection between the carriage PCA and the cartridge flex connector is made by means of a gold bubble on the flex connector that touches a gold pad on the PCA. The Carriage Test (details ' page 4 12) includes a test of this connection. When nozzle failures occur, clean the flex contacts on the cartridge and in the Carriage. 3 Continuity Problem: Remove all the cartridges from the Carriage and try installing just the rejected cartridge. If the cartridge is still rejected then replace the cartridge with a new one. If the new cartridge is not rejected then check, one by one, if the other cartridges are rejected or not. 4 Faulty cartridge: Some black cartridges (51640A) with USE BEFORE dates of April '96 and earlier may have thin film damage. This means that the material used for channeling ink behind the nozzles can crack with aging. When this happens, ink seepage may cause many nozzles to fail (eight or more). Replace the black cartridge with one with USE BEFORE date of May '96 or later. 5 If the Cartridges are not inserted correctly into the Carriage, the Cartridges will be rejected. Make sure that the springs that hold the Cartridges in the Carriage are not broken or misplaced. 6 Perform the Carriage Test ' page 4 12. 7 Replace the Trailing Cable ' page 8 8. 8 Replace the Carriage Assembly ' page 8 37.
Troubleshooting
HP DesignJet 430, 450C and 455CA Printers
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What can I do if the Media continuously crashes? 1 Check if the media loaded is HP approved. If the media is not HP approved, advise the customer to use HP media and check to see if the problem is now solved. 2 Anti static brush: If this brush (located under the entry platen) is damaged or removed, static charge can build up on the media. A charge can cause the media to stick to itself and jam the Printer. 3 The Carriage is at the incorrect height in relation to the Drive Roller. Check and if necessary adjust the carriage to media distance ' page 5 5 and try to load the media again. 4 The Drive Roller is installed incorrectly. Remove the Drive Roller and install in the correct position ' page 8 44 and try to load the media again. 5 The overdrive wheels turn free in both directions, creating bubbles in the media. Make sure that the Clutch assembly is installed correctly and is not faulty. 6 Missing or damaged starwheels. Make sure that all the starwheels on the bail assembly are correctly installed and turn properly. 7 Missing Media Deflectors. Make sure that all the Media deflectors are installed on the Printer, otherwise there could be media crashes. What can I do if the Printer does not Power ON? 1 Check that the power cord is connected correctly. 2 Check that the ROM SIMM (firmware) is installed correctly in the correct slot (the slot furthest from you) at the back of the Printer. 3 Try to disconnect all the cables, apart from the Front Panel Cable, from the Electronics Module and then try to power ON the Printer again. If nothing appears on the front panel display, then replace the Electronics Module ' page 8 13. If the Printer does Power On with the cables disconnected, then the problem must be with another component of the Printer. To find the faulty component, power OFF the Printer and connect one of the cables and power ON again. Once the faulty component is connected, it will not allow the Printer to power ON. This component should then be replaced.
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HP DesignJet 430, 450C and 455CA Printers
Troubleshooting
What can I do if the Printer has problems with Media Loading? 1 Check that the Media Sensor is installed correctly. 2 Check if the cable for the Media Sensor is connected correctly. 3 Check if the Pincharms are down (the Pincharm lever should be up). 4 If the media is continuously rejected during the media edge check, then make sure that the Line Sensor is installed correctly. If necessary, perform the Carriage Test ' page 4 12. 5 Make sure the line sensor is calibrated. Perform the Accuracy Calibration ' page 5 2. 6 Replace the Media Sensor (part of the overdrive assembly) ' page 8 50. 7 Replace the Carriage Assembly ' page 8 37. Only replace one component at a time and check if the problem has been solved before replacing another component. Using this procedure you will be able to determine exactly which component failed. What can I do if the Printer has problems with the Cutter? 1 If the Carriage Assembly has problems picking up the Cutter:
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Check that the cable for the Front Panel Assembly is is not loose and is routed correctly in the cover clips. A loose cable can be trapped by the Cutter, preventing the Cutter from moving. Make sure that the Spittoon Assembly is correctly installed and is aligned with the Overdrive Assembly. If the Spittoon is loose or mispositioned, the cutter will have problems parking in the right cover. Make sure that there is no media trapped inside the Cutter mechanism. Remove the Cutter to inspect it correctly. Remove the Cutter and make sure that both rotary blades are touching each other by the flat sides and not the sloping sides. If the rotary blades are touching each other by the sloping sides, you must reseat them. If the Printer is placed on a table, it must be placed as close to the edge as possible to make sure that the media that is coming out falls correctly. If the Printer is in the middle of the table, the media that is coming out will be lifted up causing the cutter to crash into it.
2 If the media crashes when moving the Cutter:
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Troubleshooting
HP DesignJet 430, 450C and 455CA Printers
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What can I do if the Bail Mechanism Fails? 1 Obstructions: Check that there are no obstructions in the way of the Bail Assembly. 2 Wearing of parts: The cam gear and engaging gear may not make correct contact with the left drive roller gear even though the carriage is actuating the engaging lever. This can happen due to excessive wearing of parts. Another problem may be that the bail cable has broken. 3 Carriage motor control: The carriage may not properly locate the engagement lever, preventing the gears from engaging. Any problems with the carriage motor control system (for example, the encoder strip) or associated mechanics could cause this problem. Also, if the carriage cannot find the true left stop during initialization (caused by interference), the engaging lever cannot be located. 4 Bail cam: The bail may fall from the up position. This can happen if the cam is over or under rotated. The notch on the cam, used to engage the left bail bracket, is not properly located for the bail up" condition, and the bail falls abruptly. Perform a bail cycle test. 5 Adjust carriage: If the carriage moves over the engaging lever without raising it, you may need to adjust the carriage angle on the slider rod. (Details ' page 5 5.) However, be careful not to jeopardize the print quality, which is very sensitive to the carriage angle.
EEROM Errors
What is an EEROM error? An EEROM error means that some of the internal tests that the firmware performs have detected that, when re reading information from the EEROM, it doesn't correspond to the information that had previously been written there, or that the checksum of all the information is incorrect. This failure has five possible causes:
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Faulty electronics module. Contact problems with the trailing cable connections. Faulty trailing cable. Faulty carriage. The Printer was turned off while a test was writing to the EEROM, thus leaving corrupt information (or a communication cable was disconnected while sending information to the EEROM using software diagnostic tools).
It is generally not easy to discover the cause, due to the intermittent character of the failure modes.
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HP DesignJet 430, 450C and 455CA Printers
Troubleshooting
If you are sure that the failure occurred just after an electricity power cut, or after turning off the Printer during the bench run or other service tests, then the Printer is not faulty. You just need to reset the EEROM. In other cases, you need to find the cause: There is always an EEROM error when you switch on the Printer: D If it is easy to reproduce a Steady EKL error, then try one or all of the following steps for a possible solution: 1 Configure the EEROM with the correct model ID (instructions ' page 4 27).
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2 If you cannot configure the EEROM with the correct model ID after several attempts and you continue getting the same error code, replace the electronics module ' page 8 13. There is sometimes an EEROM error when you switch on the Printer (normally shows up as a Steady EK error): 1 Switch on the Printer, allow it to initialize until it has completed the power on LED sequence, and switch off the Printer. (You are now sure that the EEROM has not been corrupted. If a Steady EK error appeared, it also corrects the EEROM contents, and the next time you switch the Printer ON, the error should not occur in good units.)
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2 Leave the unit off for 15 minutes to detect if the EEROM is losing its information. Then turn it on again and allow it to initialize. If a Steady EK error appears during the initialization sequence, and the carriage does not begin to move, then the EEROM is probably faulty. Replace the electronics module.
Troubleshooting
HP DesignJet 430, 450C and 455CA Printers
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